This application note describes implementation universal input Flyback

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This application note describes implementation universal input Flyback

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AND8124/D Universal Input, Single Stage, Converter
This application note describes implementation universal input Flyback Power-Factor-Correction (PFC) converter using Semiconductor's NCP1651 controller. NCP1651 enables cost single-stage (with voltage isolated output) converter demonstrated this application circuit, which designed Vdc, output current. NCP1651 designed operate fixed frequency, continuous mode (CCM), discontinuous (DCM) mode operation, Flyback converter topology. converter described this application note following valuable features:
Features
Wide Input Voltage Range Vac) Galvanic Isolation Primary Side Cycle-by-Cycle Average Current Secondary Side Power Limiting High Voltage Start-up Circuit
Detailed Circuit Description
Limit
Operational description design equations contained NCP1651 Data Sheet. This application note addresses specific design issues related this converter design. Please refer Figure component reference designators.
Voltage Regulation Loop
With Flyback topology, output isolated from input power transformer. Output voltage regulation accomplished ways. first, simplest method sensing primary side voltage auxiliary winding. This eliminates feedback isolation circuitry, expense accuracy voltage regulation current sensing. second method sense secondary side voltage which more complex, provides better voltage regulation transient response.
NCP1651 demo board uses quad operational amplifier secondary perform multiple functions. section amplifier used error amplifier. voltage divider comprised R23, R24, senses output voltage divides down This signal applied negative input error amplifier; reference applied non-inverting input error amplifier. output error amplifier provides current sink that drives optocoupler. primary side optocoupler circuit sinks current from This varies voltage into Voltage-to-Current converter that feeds reference multiplier. loop operation follows: output voltage less than nominal value, voltage output voltage divider (inverting input error amplifier) will less than reference signal non-inverting error amplifier input. This will cause output error amplifier increase. increase output error amplifier will cause optocoupler conduct less current, which turn will reduce current optocoupler photo-transistor. This will increase voltage chip, turn increase output reference multiplier, causing increase NCP1651 duty cycle. current shaping network comprised error amplifier, buffer current sense amplifier. This network will force average input current maintain scaled replica current reference increase reference voltage will cause current shaping network draw more input current, which translates into increase output current passes through transformer. increase current will increase output power therefore, output voltage. calculate loop stability, recommended that Semiconductor spread sheet used. This easy convenient check gain phase control loop.
Semiconductor Components Industries, LLC, 2003
December, 2003 Rev.
Publication Order Number: AND8124/D
1N4006
1N4006
1N4006 1500
AZ23C18
BAS19LT1
Shutdown MUR160
Input
1N4006
1N4006 1.5kE25CA
1500 R34B R34A
1.5kE68CA
MUR1620CT 40.2 Vref littr
Output
FB/SD ACin ACref Ramp Lavg 8.66 .001 Start-up
2N2222A BAS19LT1
BAS19LT1
AND8124/D
Figure Applications Circuit Schematic
NCP1651
MC3303
MC3303 1000 BAS19LT1 MC3303 .047
.022
.022
TL431
MC3303
AND8124/D
Overshoot/Undershoot Circuit sections quad amplifier used comparators. these monitors output overvoltage condition other undervoltage condition. voltage divider requires four resistors (R33, R23, R24, R25) order make various ratios available comparators well error amplifier. undervoltage comparator provides drive opto-coupler. output normally saturated high state, which allows flow current into opto-coupler determined error amplifier overvoltage comparator. undervoltage condition occurs, output comparator goes low, which reduces drive current opto-coupler LED. This causes NCP1651 into high duty cycle state, will increase flow current into output until output voltage above limit. over-voltage comparator's output OR'ed with output error amplifier. During overvoltage event (e.g. transient load dump), output this comparator will ground, cause maximum current flow opto-coupler LED. This will pull reduce duty cycle zero until output voltage below limit. should noted that purpose resistor (R8) series with opto-coupler photo transistor, there keep voltage above threshold during such events. This keeps control chip operational will allow immediate operation when output voltage again normal operating range. Without this resistor, voltage would drop below causing NCP1651 enter power shutdown mode operation.
Current/Power Limit Circuit
regulation inverting input voltage typically This causes error amplifier signal low, sinking more current through opto-coupler. This turn drives more current opto-coupler transistor collector, pulling reducing duty cycle, folding back output voltage.
Output Voltage Ripple
output voltage ripple secondary transformer components, traditional high frequency ripple associated with flyback converter, frequency ripple associated with line frequency Hz). this application goal have output ripple nominal output voltage, pk-pk. High Frequency Ripple Calculated
DVcap2 DVesr2 DVcap irms
(eq. (eq.
current peak sinewave (phase angle 90°).
irms (toff (toff (((Ipk2 (Ipk Iped) Iped2) (Ipk Iped )2))
(eq.
irms ((3.85
(((13.382 13.38 10.27
(eq.
10.272) 3.85 (13.38 10.27)2) 5.78
meet capacitors ripple current requirements lower equivalent esr, 1500 capacitors were used parallel.
DVcap (5.78 3.85 3000 0.00742
(eq.
fourth section amplifier biased differential amplifier. This section senses output current, provides signal that diode OR'ed into feedback divider. demo board overload current limit 125% full load, 2.375 resistors used series limit their maximum power dissipation) sense output current (R31 R32). set-the current sense amplifier gain. Where gain amplifier
(R29 R30) 3000 2.375 0.14 0.33 0.33 3.63
(eq.
Where: Iped
=Transformer Turns Ratio (3.89) =Peak Current Secondary (13.38) =Pedestal Current Secondary (10.27) =Output Capacitance (1500 each) =Output Capacitor Equivalent Series Resistance (0.03 Each) =Switching Interval
(eq. (eq. (eq.
DVesr Ipksec DVesr 13.38 0.015 0.20 0.007422 0.22 0.200
voltage input differential amplifier
(eq.
output voltage from differential amplifier
(eq.
Frequency Portion Ripple:
IAVG IAVG 0.637
(eq. (eq. (eq.
When output load current increases, output current sense amplifier will also increase. When amplifiers output voltage, minus diode drop (D11), increases above pulls feedback signal inverting input error amplifier when loop
0.637 (48)(0.637) 2.95
(eq.
AND8124/D
divided output ripple into increments over cycle (180°) sinusoidal ripple voltage with respect phase angle
0.637 sin(q) fline
(eq.
Cycle Line 16.67ms (60Hz) Vmax Vmin Pout
16.67 (482 362) 3000
(eq.
Figure frequency output voltage ripple plotted with respect phase angle.
1.50 1.00 RIPPLE 0.50 0.00
coincidence that output capacitor calculated voltage ripple hold-up time same value.
MOSFET Turn-off Snubber
MOSFET design rating peak voltage across device turn-off (including leakage inductance spike)
VpkTotal Vinmax 1.414 ((VO Vf)n) Vspike
(eq.
-0.50 -1.00 -1.50
DEGREES
Figure Calculated Output Ripple
=265 Vrms =the Output Voltage =the Transformer Turns Ratio =Voltage Spike Transformer Leakage Inductance provide safe operating voltage MOSFET have selected Vspike Vpeak, when MOSFET turns off, maximum Drain Source voltage
1.414 48(4)
(eq.
Where: Vinmax Vspike
Figure Measured Output Voltage Ripple
minimize effect leakage inductance spike, coupling between primary secondary transformer needs tight possible. This accomplished, your transformer requires primary with multiple layers, interleaving primary secondary windings. application transformer primary turns, secondary turns. manufacture transformer, TDK, wound layer primary with turns, then turn secondary, remaining turns primary. results were leakage inductance approximately compare this transformer where entire turns were wound, layers, then turn secondary, leakage inductance increased energy stored transformer leakage:
Ipk2
(eq.
seen from calculations, scope waveform that long capacitor with used, that output voltage ripple dominated frequency (120 ripple.
Hold-Up time
user would like select Hold-Up time versus, voltage ripple:
Pout
(eq.
Where: Leakage Inductance Measured) Peak Primary Current Second Relationship
(eq.
Rearranging equation:
Pout
(eq.
Where: Snubber Capacitor Voltage Across MOSFET
AND8124/D
Combining Equations:
Ipk2 ((VO Vf)n Vspike)2 (eq. ((VO Vf)n Vpk)2 Csnubber 3.82 ((192 130)2 (eq. (192 375)2
During MOSFET turn-off, capacitor charge through Diode Prior next switching cycle capacitor must fully discharged, Rsnubber selected
Rsnubber ((VO Vf)n Vinmax 1.414 Vspike) 0.63 (Vspike Csnubber) (eq. ((192 130)0.63(6.5 (130
(eq.
power snubber
(0.5)790 pF(1302) 0.68
(eq.
Figure output voltage drops Vdc, recovers less than Figure input voltage increased Vac, load switched from 100% load. output voltage drops only Vdc, recovers approximately significant improvement transient response performance attributed increase gain loop bandwidth high line. input line voltage increases control loop gain (Refer www.onsemi.com copy excel design spreadsheet details) increases from control loop bandwidth increases from result that high line, there improvement transient response, because there less attenuation output ripple, results increase input Total Harmonic Distortion (THD). system designers will need trade their overall system performance THD, Power Factor, transient response optimize control loop meet their requirements.
After installing snubber NCP1651 Demo Board, measuring voltage spike, snubber components where adjusted maximum performance, increased 1000 changed difference between measured calculated value attributed board layout, other parasitic components.
Evaluation Board Test Results
results from NCP1651 Demo Board show that using flyback topology converter provide input Total Harmonic Distortion (THD), high input power factor, excellent steady state output voltage regulation. NCP1651 achieved input full load 3.12% with 0.998. input 6.8% with 0.971. steady state output voltage regulation from Vac, load full load less than 0.02%, with output voltage ripple meeting design goal Vpk-pk, measured pk-pk.
Transient Response
Figure
Figures through show output transient response converter. test conditions each Figure listed below:
Table Test Conditions
Figure Figure Figure Figure 0.19 1.92 1.92 0.19 0.19 1.92 1.92 0.19
Figure
AND8124/D
Power Dissipation Estimates
NCP1651 Demo Board power dissipation (measured) Vrms, full load, (106.27 47.95 14.21 Following table provides calculated estimated power loss spread among different power train components.
Components D1-D4 Input Rectifier MOSFET Output rectifier Flyback transformer Snubber resistor Transient suppressor miscellaneous Total average 1.65 (estimate) 0.84 0.41 14.20
Figure
Demo Board Operating Instructions
Connect source, Vac, input terminals Connect load output terminals market positive output, return. Turn source, NCP1651 will automatically start, providing load.
Shutdown Circuit
Figure
shutdown circuit will inhibit operation power converter NCP1651 into power shutdown mode. activate this circuit, apply test point, with black jack being "ground". aware that black jack actually connected output input bridge rectifiers. isolated supply should used. this circuit being used, left open there enough resistance built circuit keep transistor (Q2) it's state.
Table Performance Data Regulation
Line/Load Vrms Vrms Vrms Load 47.94 47.94 47.94 47.94 47.95 47.95 47.95 47.94 47.95 47.95 47.95 47.95
AND8124/D
Table Harmonics Distortion
harmon 11th 13th 15th 17th 19th THD(A) Ifund 0.143 0.203 0.13 0.08 0.04 0.08 0.16 0.28 0.05 harm. 0.156 1.94 0.28 0.19 0.29 0.32 0.41 0.41 0.29 0.998 3.12 0.918 harm 0.08 0.25 0.12 0.07 0.09 0.08 0.06 0.14 0.28 0.12 harm% 4.74 2.88 0.22 0.76 0.27 0.33 0.68 0.95 0.971 0.468
Table Efficiency
Vrms Load Efficiency 109.42 47.95 1.92 0.841 Vrms 1.52 106.27 47.95 1.92 0.866 Vrms 1.51 105.35 47.95 1.92 0.874 Vrms 1.59 105.25 47.95 1.92 0.875
Table Vendor Contact List
Vendor Semiconductor Vishay Bussman (Cooper Ind.) Coiltronics (Cooper Ind.) Fairchild Panasonic Weidmuller Keystone Smith Aavid Thermalloy Phone Internet 1-800-282-9855 www.onsemi.com/ 1-847-803-6100 www.component.tdk.com/ www.vishay.com/ 1-888-414-2645 www.cooperet.com/ 1-888-414-2645 www.cooperet.com/ www.fairchildsemi.com/ www.eddieray.com/panasonic/ www.weidmuller.com/ 1-800-221-5510 www.keyelco.com/ 1-888-847-6484 www.hhsmith.com/ www.aavid.com/
AND8124/D
Table NCP1651 Application Circuit Parts List (Specifications:, Input Range, Output)
C10, C12, C22, Description Cap, Ceramic, Chip, 1000 Cap, Ceramic, Chip, Cap, Ceramic, Chip, Cap, Ceramic, Chip, Cap, Ceramic, Chip, .022 Cap, Ceramic, Chip, 0.022 Cap, Ceramic, chip, 0.001 Cap, Ceramic, Chip, alum elect, (0.394dia 0.492H) (.394dia .492H) Cap, Ceramic, Chip, Cap, Ceramic, Chip, .047 Cap, Ceramic, Chip, Cap, Ceramic, Chip, alum elect, 1800 alum elect, (2.2A min) 1500 alum elect, Cap, Ceramic, Chip, Cap,Ceramic, .001 vac, Cap, polypropylene, Cap, Ceramic, Chip, Diode, Rectifier, Diode, Ultrafast, Diode, Ultrafast, Diode, Rectifier, Diode, Switching, SOT-23 TVS, Zener Diode, Zener Diode, Fuse, sat, inductor, diff mode sat, inductor, diff mode FET, N-channel Bipolar, npn, SOT-23 Resistor, SMT1206, Resistor, Axial Lead, 180k, Resistor, Axial Lead, 180k, Resistor, SMT1206, Resistor, SMT, 0.12 Resistor, SMT1206, 8.66 Resistor, SMT1206, Part Number VJ0603Y102KXAAT VJ0603Y471JXAAT VJ0603Y471JXAAT VJ0603Y471JXAAT VJ0603Y223KXXAT VJ0603Y223KXXAT VJ0603Y102KXAAT VJ0606Y104KXXAT ECA-2WHG2R2 EKA00DC122P00 C3225X5R0J226MT VJ0603Y473KXXAT VJ0603Y103KXAAT C3216X7R1E105KT ECA1EM331 EEU-FC1J182 EKB00JL415J00 VJ0603Y103KXAAT ECK-03A102KBP F1778-512K2KCT0 MKP1841-468-405 VJ1206V105ZXXAT 1N4006 MUR1620CT MUR160 1N4006 BAS19LT1 1.5KE250A AZ23C18 1.5kE68CA 1025TD2A TSL1315-101K2R5 TSL1315-101K2R5 SPA11N80C3 MMBT2222ALT1 CRCW1206100JRE4 CMF-55-180K00FKRE CMF-55-180K00FKRE CRCW120635KOJNTA WSL2512 .12W CRCW12068661F CRCW12066800F VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY Panasonic (Digi P5873) Vishay Sprague (20) VISHAY VJ0603Y103KXAAT Panasonic Panasonic (Digi P11283) Vishay Sprague (20) VISHAY Panasonic VISHAY Vishey Sprague VISHAY Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor VISHAY Semiconductor Bussman Infineon Semiconductor Vishey Vishey Vishey Vishey Vishey Dale Vishey Vishey Manufacturer
AND8124/D
Table NCP1651 Application Circuit Parts List (Specifications:, Input Range, Output)
Description Resistor, axial lead, 3.6k, Resistor, SMT1206, 1.2k Resistor, SMT1206, 2.0k Resistor, SMT1206, 2.0k Resistor, SMT1206, Resistor, SMT1206, 210, Resistor, SMT1206, 174, Resistor, SMT1206, 2.05k, Resistor, SMT1206, 3.3k Resistor, SMT1206, 7.5k Resistor, SMT1206, 3.3k Resistor, SMT1206, 3.01k, Resistor, SMT1206, 301, resistor resistor Resistor, SMT1206, 40.2k, Resistor, axial lead, 20k, Resistor, SMT1206, 4.7k Resistor, SMT1206, Resistor, SMT1206, 100k Transformer, Flyback Controller programmable ref, SOIC Quad Optocoupler, CTR, CRCW12064K70NTA CRCW120612K0JNTA CRCR1206100K0JNTA SRW42EC-U04H14 NCP1651 TL431ACD MC3303D SFH615AA-X007 Vishey Vishey Vishey Semiconductor Semiconductor Semiconductor Vishay Part Number CMF-55-3K600FKBF CRC12061K20JNTA CRC12062K00JNTA CRC12062K00JNTA CRC12052K10JNTA CRCW12062100F CRCW12061740F CRCW12062051F CRC12063K30JNTA CRC12067K50JNTA CRC12063K30JNTA CRCW12063011F CRCW12063010F WSL251R0700FTB WSL251R0700FTB CRCW120640022F Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Vishey Manufacturer
Hardware
Printed Circuit Board Connector Connector Standoff, 4-40, alum, hex, .500 inches Standoff, 4-40, alum, hex, .500 inches Standoff, 4-40, alum, hex, .500 inches Standoff, 4-40, alum, hex, .500 inches Heatsink, TO-220 Heatsink, TO-220 Test point, Test point, black Shoulder Washer Insulator 171602 171602 8403 8403 8403 8403 590302B03600 590302B03600 5005 5006 3049K-ND 4672 Weidmuller (Digi 281-1435-ND) Weidmuller (Digi 281-1435-ND) Smith (Newark 67F4111) Smith (Newark 67F4111) Smith (Newark 67F4111) Smith (Newark 67F4111) Aavid Thermalloy Aavid Thermalloy Keystone (Digi 5005K-ND) Keystone (Digi 5006K-ND) Digi-Key Keystone
AND8124/D
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AND8124/D

This application note describes implementation universal input Flyback

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