AND8461JP - NCP1237 PWMコントローラを活用した65 Wアダプタの設計

Transcription

1 ENERGY STAR EPS 2.0 ( ) (MOSFET ) MOSFET 1 NCP1237/38PWM 65 WAC Output Power 65 W Output Voltage Output Current Minimum Input Voltage Maximum Input Voltage Average Efficiency (as per ENERGY STAR 2.0 guidelines) No-load Input Power 19 V dc 3.42 A 88 V 265 V > 85% < 150 mw CCM (Continuous Conduction Mode)DCM APPLICATION NOTE (Discontinuous Conduction Mode) CCM DCM 65 khz NCP1237 ACSOIC 7 Figure 1 EMI AC EMIEMI L1 L2CX1CX4 R12 NTC (Negative Temperature Coefficient ) R11 RD1 RD2RD3 X HVAC NDF06N60ZG MOSFET TR1 2 MBRF20H150 2RC 2 Semiconductor Components Industries, LLC, 2014 October, 2014 Rev. 1 1 Publication Order Number: AND8461JP/D

2 TL431 TL431 NCP1237B65 khz 1 COUT1COUT2L3COUT3 2 AND8461/D NCP1237/38/87/88 NCP1237/38/87/88PWM 1 (DSS) IC DSSIC IC V CC V CC V CC 0.6 V 500 V OVP () HVV HV 112V( V HV(start) )V CC HV V HV(stop) ( )V HV(OV1) (HV) DRV HV (250 s) HV 61 ms () Figure 1. Electrical Schematic of the Adapter with the NCP1237B65 2

3 2 NCP1237/87(2 ) (156 ms) CS 0.5 V () 2 NCP1237/87 NCP1237/38/87/88 (78 ms) CS0.7 V () 150% 1 MOSFET 1 HV CS R OPP V sense D 50%CCM LATCH OVPOTP() 0.8 V2.5 V( 1.2 V) OTPNTC 0.8 V OTP C1 OTP C1 I NTC(SSTART) C1 325 nf OTP Figure 2 Figure 2. Power Stage Schematic P in P out (eq. 1) V bulk,avg,min I in,avg V bulk,avg,min (V peak ) V bulk,avg,min V bulk,avg,min I in,avg P in V bulk,avg,min (eq. 2) C bulk 1 C bulk 1 I in,avg 1 V 2 line V bulk1 bulk cos 1 1 V peak (eq. 3) 3

4 V bulk V peak V min (eq. 4) Figure 3 V bulk (t) V peak V min I ACin (t) 0 I ACin,MAX 0 Rectified input voltage without bulk capacitor T Vbulk,avg,min t 1 t 2 T/2 Rectified input voltage with bulk capacitor NO sinusoidal input current Figure 3. Bulk Capacitor Ripple and Rectifier Input Current V peak V min V bulk,min Figure 4 V ds(t) V DSmax VDS,peak t leak Vleak Vclamp t rec Vr Vr t off T sw Figure 4. Drain Voltage Waveform of Q1 Q1 0V Q1Q1 V DS,peak V DS,peak V bulk V r V leak Vbulk t on V bulk t t t V DS,peak V bulk V clamp ( 20 V) V clamp > V r k C V clamp k C (eq. 5) V r k C V clamp k C ( V DSmax 0.85 ) k C Vout V,diode N (eq. 6) 0.85 V DSmax 20 V V bulk,max N N N sec N prim (eq. 7) V r ()D max (CCM9 DCM10) V out V,diode V r N (eq. 8) V r D max (CCM) (eq. 9) V r V bulk,min D max (DCM) V 2 L out prim F sw V bulk,min (eq. 10) R load,min DCMCCM CCM AC DCM 1 2 DCM CCM DCM 4

5 I prim(t) I prim,rms D max I 2 peak I peak I I2 3 (eq. 18) I L,avg I I IN,avg t on Ipeak T sw Figure 5. Primary Current Flowing Though Q1 and Transformer Primary Winding Figure 5CCM 1(Q1) I L,avg 1 t off I in,avg I L,avg (eq. 11) D max 1I r 1I r I r t on Ivalley I I L,avg (eq. 12) CCMI r I1 I peak 1I valley I I r I L,avg (eq. 13) I I peak I valley (eq. 14) I peak I L,avg 1 I r 2 (eq. 15) I valley I L,avg 1 I r 2 (eq. 16) 1I17 1L prim V bulk,min D max L prim (eq. 17) F sw I 1L prim 1 1rmsI prim,rms 2 I sec,peak 2 I sec 2rmsI sec,rms t I sec,rms I peak I sec,peak N I sec I N (eq. 19) (eq. 20) 1 Dmax I sec,peak 2 Isec,peak I sec I sec 2 3 (eq. 21) 12 k k L v sec (t) k sec v prim (t) (eq. 22) L prim k12 12 L prim,leak 1 k 2 Lprim (eq. 23) L sec,leak 1 k 2 Lsec (eq. 24) 1 L prim,leak () (TVS)RCD P loss(prim,leak) 1 2 L prim,leak I peak 2 F sw (eq. 25) L prim,leak Q1 2.5% 5

6 P out R DS(on) 40 I 2 prim,rms (eq. 26) Q1 1I peak V DSmax t on t off P loss(switching) 1 2 C DRAIN V DRAIN(turnon) 2 F sw (eq. 27) 2 C DRAIN I peak V ILIM (0.7 V) 1 L prim 10% R sense V ILIM 1.1 I peak (eq. 28) P sense I prim,rms 2 R sense (eq. 29) 2 PIV V bulk,max N V out (eq. 30) DC I out EMI 2I sec,peak 2 (ESR )1 ESR V out,ripple ESR (eq. 31) I sec,peak ESRESR rms I Cout,rms I Cout,rms I 2 sec,rms I 2 (eq. 32) out C out I out D max V out,ripple F sw (eq. 33) Figure 6 Figure 6. Simplified Schematic of Application NCP %CCM 3 I peak,max V ILIMIT t PROP 2 V bulk I peak,max V ILIMIT t PROP V R bulk (eq. 34) sense L P NCP1237/38/87/88 1 V bulk 6

7 2 HVCS g OPP V off HV V off R OPP R OPP V sense CS HV 1 V ILIMIT R OPP I peak,max g OPP R sense R sense V bulk t PROP L P (eq. 35) R OPP V off g OPP R sense V bulk 0 R OPP t PROP R sense L p g OPP (eq. 36) DCM P out I peak P out 1 2 L prim F sw I peak 2 (eq. 37) CCMI valley I peak I valley P out 1 2 L prim F sw Ipeak 2 I valley 2 (eq. 38) CCM 2 ROPP V CStran R I tran Vbulk V R off OPP gopp (eq. 39) sense R sense 2 CCM Ivalley VCS(tran) 2 Web BACK DWS.XLS.ZIP (TVS) Q1 V clamp TVS P clamp TVS EMI P clamp E clamp F sw 1 2 L leak I peak 2 F sw V clamp (eq. 40) V clamp V r RCD RCD RCD 2 V r V leak k C 1.5 (k C ) 3 TVS V clamp 7

8 R clamp 2 V leak V clamp L leak I peak 2 F sw (eq. 41) RCDC clamp V clamp = 115 V TVS V DS,peak = 485 V RCD 440 V C clamp V clamp V ripple R clamp F sw (eq. 42) V 2 clamp P clamp (eq. 43) R clamp RCD 1N4007 CCM1N4007 1N40071N4007 RCDR clamp C clamp V clamp R clamp TVS1N4007 RCD (EMI) Figure 7Figure 8 2 TVS 226 V RCD 106 V 110 MHzEMI TVS TVS TVS 160 V TVSP6KE160ARLGRCD Figure 7. Ringing at Drain Node when the Drain Voltage is Clamped by TVS at Full Load (3.5 A) and 230 V/50 Hz Input Figure 8. Ringing at Drain Node when the Drain Voltage is Clamped by RCD Clamp at Full Load (3.5 A) and 230 V/50 Hz Input 2RC 2 C d 2 L sec,leak C d EMI 8

9 RC R snubber L sec,leak R snubber (eq. 44) RC C snubber 34 C d C snubber 3 4 C d (eq. 45) 2C d 65 WDC I out I out P out A (eq. 46) V out 19 (85%) P in P out W (eq. 47) V bulk,avg,min 90 V I in,avg P in V bulk,avg,min A (eq. 48) C bulk 1 I in,avg 1 2 line V bulk1 cos 1 1 C bulk cos C bulk F V bulk V peak (eq. 49) 100 V 47 F/450 V N 1.5 (19 0.6) (eq. 50) V out V,diode V r V (eq. 51) N V clamp k c V r V (eq. 52) V CC V,VCC N aux (eq. 53) V r V D max V r V r V bulk,min (eq. 54) I in,avg I L,avg 0.85 D max A (eq. 55) I r = 0.62 I I r I L,avg A (eq. 56) I peak I L,avg 1 I r A (eq. 57) I valley I L,avg 1 I r A (eq. 58) 2 V bulk,min D max L prim F sw I H (eq. 59) 90V 90 V (PFC) PFC 9

10 V bulk I prim,rms I prim,rms A I peak I sec,peak N (eq. 60) A (eq. 61) I sec I 1.15 N A (eq. 62) I sec,rms (1 0.46) I sec,rms 5.38 A (eq. 63) (HA3776 AL)Coilcraft 1560 H H2 210 nh R DS(on) R DS(on) 1.01 P out 40 I prim,rms (eq. 64) MOSFETNDF06N60ZV DSmax = 600 VR DS(on) = 0.98 R sense V ILIM 1.1 I peak m (eq. 65) A 235 m MBRF20H V PIV V bulk,max N V out PIV 115 V (eq. 66) V out,ripple ESR m (eq. 67) I sec,peak mv ESR20 m I Cout,rms A (eq. 68) C out 121 F (eq. 69) KOSHIN 1,000 F/35 V KZH(KZH 35V102MI6) 100 khz18 m 100 khz2.77 A 2 R OPP 36 R OPP t PROP R sense L p g OPP (eq. 70) DCMCCM 67 Figure 9 I peak 2 I tran V in I peak,max (A), I tran (A) I peak,max and I tran vs. Line Input Voltage I peak,max I tran V in (V) Figure 9. The Primary Peak Current is Independent on the Bulk Voltage using the Resistor 67 CCM I valley 38 Figure 10 P max (W), P tran (W) P max and P tran vs. Line Input Voltage P max P tran V in (V) Figure 10. The Maximum Output Power is Rising if there is Used the Resistor 67 10

11 I peak 680 I peak,max 2 ItranVin I peak,max (A), I tran (A) P max (W), P tran (W) I peak,max and I tran vs. Line Input Voltage I peak,max I tran V in (V) Figure 11. The Primary Peak Current is Decreasing with the Bulk Voltage Increase using the Resistor P max and P tran vs. Line Input Voltage P tran P max V in (V) Figure 12. The Maximum Output Power is Quite Well Compensated in CCM Mode in Range 150 V to 375 V V CS(tran) 2 RCD 2 V leak V clamp 2 ( ) 115 R clamp L leak I 2 peak F sw R clamp 4543 C clamp C clamp 101 nf V clamp V ripple R clamp F sw (eq. 71) (eq. 72) RCD 1N4007 R clamp = 165 kc clamp = 5.6 nf V clamp L sec,leak R snubber C d (eq. 73) 10 V1 MHz550 pf RC1.2 nf15 65 W YOKOGAWA WT210 EMC (AC 5 8 VAR) 50%100% AC DCDC 2 X RD1RD2RD3 115 VDC V230 V V DC 11

12 Table 1. EFFICIENCY VERSUS OUTPUT POWER AND INPUT LINE VOLTAGE V in = 115 Vac / 60 Hz Notebook adapter load regulation P out /P outmax (%) P out (W) P in (W) Efficiency (%) V in = 230 Vac / 50 Hz P out /P outmax (%) P out (W) P in (W) Efficiency (%) Table 2. AVERAGE EFFICIENCY AND NO LOAD INPUT POWER Efficiency Input Line 115 Vac / 60 Hz 230 Vac / 50 Hz Average Efficiency (%) No Load Input Power (W) % 90.0% 85.0% 80.0% 75.0% 70.0% 65.0% 60.0% Notebook adapter efficiency 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0% Pout/Poutmax 115V/60Hz 230V/50Hz Figure 13. Efficiency vs Output Power and Input Line Voltage V out (V) V/60Hz 230V/50Hz I out (A) Figure 14. Load Regulation for Low and High Input line Vout [V] Notebook adapter line regulation VinAC [V] Vout Iout Iout 3.0 A Iout Iout 2.5 A Vout Figure 15. Line Regulation for High Output Loads. The Output Voltage Drops for Low Input Line Voltage due the Activation of 2 nd Level Overcurrent Protection. See Figure 12. 5%40% DCM CCMDCM CCM 115 V230 V 12

13 Figure 16. CCM Operation at Full Load (3.5 A) and 115 V/60 Hz Figure 17. Ripple at Bulk Capacitor at Full Load (3.5 A) and 115 V/60 Hz Figure 18. No Subharmonic Oscillations Appear under Full Load (3.5 A) and CCM Operation, with D > 50%, 110 V/45 Hz Figure 19. The DCM Mode Starts at 1.5 A of Load Current at 115 V/60 Hz Input Figure 20. The Frequency Foldback Mode Starts at 1.3 A of Load Current at 115 V/60 Hz Input Figure 21. The Lowest Frequency at 0.25 A of Load Current at 115 V/60 Hz Input Frequency Foldback is Finished 13

14 Figure 22. The Skip Mode at 0.23 ma of Load Current at 115 V/60 Hz Input Figure 23. CCM Operation at Full Load (3.5 A) and 230 V/50 Hz Input Figure 24. The DCM Mode Starts at 2.3 A of Load Current at 230 V/50 Hz Input Figure 25. The Frequency Foldback Mode Starts at 1.3 A of Load Current at 230 V/50 Hz Input Figure 26. The Lowest Frequency at 0.23 A of Load Current at 230 V/50 Hz Input Frequency Foldback is Finished Figure 27. The Load Transient Step from 20% of Load to 100% of Load at 115 V/60 Hz Input 14

15 Figure 28. The Load Transient Step from 100% of Load to 20% of Load at 115 V/60 Hz Input Figure 29. The Overcurrent Protection Timer Duration is 83 ms when the Adapter was Overloaded to 5.5 A at 115 V/60 Hz Input Figure 30. The Transient Protection Timer Duration is 161 ms when the Adapter was Overloaded to 4.0 A at 115 V/60 Hz Input Figure 31. Adapter Start Up at 115 V/60 Hz Input and 1 A Output Current Load Figure 32. Brown Out Protection Reaction when the rms ac Input Voltage Steps Down from 80 V to 74 V under 1 A Output Current Loading Figure 33. The Soft Start at 115 V/60 Hz Input with 3.5 A Output Current Loading 15

16 Figure 34. Frequency Deviation of the Frequency Jittering Figure 35. Ripple at Bulk Capacitor at 88 V/50 Hz Input and 3 A Continuous Output Loading Current. See the Full Duty Cycle Operation and Lower Peak current NCP1237/38/87/ mw 1.3 A (34%) (230 V/ 50 Hz)0.23 A(6%) (115 V/60 Hz)0.25 A (230 V/50 Hz) 0.21 A (115 V/60 Hz)0.18 A 5.5% 1.5%70% (115 V/60 Hz)85.9% (230 V/50 Hz)85.2% 2Q1 COILCRAFT EMI EPCOS Figure 36. Detail of the Output Voltage Ripple and Voltage across Secondary Winding of Transformer at 115 V/60 Hz Input with 3.5 A Output Current Loading (the ringing is caused by the secondary diode reverse recovery) 16

17 Figure 37. Photograph of the Designed Prototype (Real Dimensions are 143 x 57.6 mm) L1 Czech Design Center Pb NCP1238B65NBGEVB Figure 38. Component Placement on the Top Side (Top View) 17

18 R14 R17 C8 C3 R25 D10 R6 R5 R3 C11 R24 R4 D12 D6 R2 IC1 C2 R26 R1 C4 C9 C1 R15 D7 R23 D9 RD3 RD2 RD1 Figure 39. Component Placement on the Bottom Side (Bottom View) Figure 40. Bottom Side (Bottom View) 18

19 Table 3. BILL OF MATERIALS FOR THE NCP1237 DEMO BOARD Designator Qty Description Value Tolerance Footprint Manufacturer Manufacturer Part Number C1, C2 2 Ceramic Capacitor 100nF 10% 1206 Kemet C1206C104K5RAC C3 1 Ceramic Capacitor 33 nf 10% 1206 Kemet C1206C333K5RAC C4, C11 2 Ceramic Capacitor 1.0 nf 10% 1206 Kemet C1206C102K5RAC C5 1 Ceramic Capacitor 1.2 nf/630 V 5% Radial TDK Corporation FK26C0G2J122J C6 1 Electrolytic Capacitor 47 F/50 V 20% Radial Koshin KLH 050V470ME110 C7 1 Ceramic Capacitor 5.6 nf/500 V 10% Disk Radial Panasonic ECK D2H562KBE C8, C9 0 Ceramic Capacitor NU 1206 CB1 1 Electrolytic Capacitor 47 mf/450 V 20% Radial United Chemi Con EKXG451ELL470MM25S COUT1, COUT2 2 Electrolytic Capacitor 1000 F/35 V 20% Radial Koshin KZH 035V102MH250 COUT3 1 Electrolytic Capacitor 220 F/35 V 20% Radial Koshin KZH 035V221MG125 CX1, CX2 2 Foil Capacitor 330 nf/x2 10% Radial Epcos B32922C3334K CY1, CX3, CX4 3 Ceramic Capacitor 2.2 nf/x1/y1 20% Disc Radial Murata DE1E3KX222MA5B D1 1 Dual Schottky Diode MBRF20H150 TO 220 ON Semiconductor MBRF20H150CTG D2, D3, D4, D5, D8, D11 6 Diode 1N4007 DO41 10B ON Semiconductor 1N4007G D6, D12 2 Diode SMA MRA4007 SMA ON Semiconductor MRA4007T3G D7, D10 2 Diode SMD MMSD4143 SOD123 ON Semiconductor MMSD4148T3G D9 2 Zener diode MMSZ15 5% SOD123 ON Semiconductor MMSZ15T3G F1 1 Fuse 1.25 A 1.2 A Radial Bel Fuse Inc RST 1.25 HS1, HS2 2 Heatsink SK 104 B SK 104 B Fischer Elektronik SK 104 B IC1 1 SMPS Controller NCP1237B65 SOIC 08 ON Semiconductor NCP1237BD65R2G L1 1 EMI filter 2 x 22 mh 1 A Epcos B82732W2102B30 L2 1 Inductor 47 H 10% DR0810 Coilcraft DR L L3 1 Inductor 10 H 10% DR0810 Coilcraft DR L LED1 0 Indicating LED NU LED 3 mm NTC 1 Sensing NTC Thermistor 330 k 5% Disc Radial Vishay NTCLE100E3334JB0 OK1 1 Optocoupler PC817 4 DIP Sharp PC817X2J000F Q1 1 N channel MOS FET NDF06N60ZG TO 220 ON Semiconductor NDF10N60ZG R1 1 Resistor SMD 680 1% 1206 Rohm MCR18EZPF6800 R2 1 Resistor SMD 22 1% 1206 Rohm MCR18EZHF22R0 R3 1 Resistor SMD 2.2 k 1% 1206 Rohm MCR18EZHF2201 R4 1 Resistor SMD 3.9 k 1% 1206 Rohm MCR18EZHF3901 R5 1 Resistor SMD 6.2 k 1% 1206 Rohm MCR18EZHF6201 R6 1 Resistor SMD 8.2 k 1% 1206 Rohm MCR18EZHF8201 R7, R13 2 Resistor Through Hole 330 k 1% 207 Vishay HVR FR500 19

20 Table 3. BILL OF MATERIALS FOR THE NCP1237 DEMO BOARD Qty Description R8 1 Resistor Through Hole R9, R10 2 Resistor Through Hole Value Designator Tolerance Footprint Manufacturer Manufacturer Part Number 15 1% 207 Vishay CMF5015R000FHEB % 207 Vishay PAC FA1000 R11 1 Surge protecting NTC B57235S509M 20% Disc Radial Epcos B57235S509M R12 1 Varistor 275 V Disc Radial Vishay VDRS05C175BSE R14 1 Resistor SMD 10 k 1% 1206 Vishay MCR18EZHF1002 R15 1 Resistor SMD 33 k 1% 1206 Vishay MCR18EZHF3302 R17 0 Resistor SMD NU 1206 R18 1 Resistor Through Hole R22 1 Resistor Through Hole 5.1 k 1% 207 Vishay SFR FR % 207 Vishay MBA02040C2208FRP00 R23, R26 R24, R25 2 Resistor SMD 2.2 1% 1206 Rohm MCR18EZHFL2R20 2 Resistor SMD 1.0 k 1% 1206 Rohm MCR18EZHF1001 R27 1 Resistor Through Hole, High Voltage 4.7 M 5% Axial Lead Welwyn VRW37 4M7JI RD1, RD2, RD3 3 Resistor SMD 1.0 M 1% 1206 Rohm MCR18EZHF1004 TR1 1 Transformer HA3776 AL HA3776 AL Coilcraft HA3776 AL WAGO1 1 Terminal Block, 3 Way CTB5000/3 W Cadem El. CTB5000/3 [1] NCP1237A/B datasheet, (onsemi.com) [2] Christophe P. Basso: Switch Mode Power Supplies, SPICE Simulations and Practical Designs, McGraw Hill, new York, 2008 [3] Dr. Ray Ridley: A New Continuous Time Model for Current Mode Control, ( [4] Application note AN1679/D, (onsemi.com) [5] Application note AND8393/D, (onsemi.com) [6] Application note AND8154/D, (onsemi.com) ENERGY STAR and the ENERGY STAR mark are registered U.S. marks. ON SemiconductorONSemiconductor Components Industries, LLC (SCILLC) SCILLC ()SCILLC SCILLC SCILLCSCILLC SCILLC SCILLCSCILLC SCILLC SCILLC PUBLICATION ORDERING INFORMATION LITERATURE FULFILLMENT: Literature Distribution Center for ON Semiconductor P.O. Box 5163, Denver, Colorado USA Phone: or Toll Free USA/Canada Fax: or Toll Free USA/Canada orderlit@onsemi.com N. American Technical Support: Toll Free USA/Canada Europe, Middle East and Africa Technical Support: Phone: Japan Customer Focus Center Phone: ON Semiconductor Website: Order Literature: For additional information, please contact your local Sales Representative AND8461JP/D