How To Make A Power Supply For A Flyback Power Supply

Transcription

1 Design Note DN0501/D A 0 to 5 Watt, Low Cost, Off-line Power Supply Device Application Input Voltage Output Power Topology I/O Isolation White Goods, Small NCP151B Instruments, E- NCP Vac 0 to 5 Watts DCM Flyback kv Meters, Industrial NDD04N60 Equipment Other Specification Output 1 Output Output Output 4 Output Voltage 5Vdc or 1 Vdc N/A N/A N/A Ripple < % N/A N/A N/A Nominal Current 1.8 or 4 Amps N/A N/A N/A Max Current 1.8 or 4 Amps N/A N/A N/A Min Current zero N/A N/A N/A PFC (Yes/No) Minimum Efficiency Inrush Limiting / Fuse Operating Temp. Range Cooling Method / Supply Orientation Signal Level Control No 78% for 5Vout; 81% for 1Vout Yes 0 to 50C Convection NA No Others Input EMI filter Circuit Description This Design Note describes a very simple, low cost, yet high performance off-line flyback power supply using ON Semiconductor s NCP151B controller (TSOP6 package), NDD04N60 D-Pak Mosfet, and the NCP41 programmable zener (SOT package). The flyback design operates in discontinuous conduction mode and uses the conventional optocoupler (U) feedback scheme for the voltage loop and an auxiliary Vcc winding on the flyback transformer to power the NCP151. The Design Note provides the complete circuit and transformer design details for 5 volt, 4 amp, and 1 volt, 1.8 amp output models. Other output voltages from. up to 8 Vdc are easy to implement by modifying the values (or ratings) of R11, R1, D9, C9 and T1 s secondary turns. Over-current limiting is provided by sensing the peak current in the MOSFET Q1 via R8. Once the 800 mv threshold level on U1 s pin 4 is exceeded the circuit will go a hiccup mode until the over-current condition is removed. An optional OVP circuit is implemented via Z1. Depending on the application, it may be necessary to add a small pi-network ripple filter to the output as shown in the lower section of the schematic below. Key Features Input EMI filter for conducted EMI compliance Schottky output rectifier for high efficiency Very low standby (no load) power Current mode control with adjustable output current Small pc board footprint Low cost components July 01, Rev. 1

2 Schematic 1 J1 AC Input F1 A 50Vac R1 C1 0.1uF "X" 4.7 ohms W NOTES: L1A 80uH L1B 80uH C 0.1uF "X" C8 nf R 470K R9 1K Z1 C5 1nF R4 470K MMSZ554B (7V) D1-D4 MRA4007 X 4 6 U C 47uF 400V D8 MRA 4007 NCP151B uf 50V C6 MMSD4148 R5 0 ohms R6 C7 0pF R 4K 1W NDD0N60Z Q1 D6 R7 K R 1K C4 4.7nF 1 1kV D5 1N497 T1 R8A/B ohms 1/W D7 MMSD EE0//6 MBRS60 (1V) MBRS540 (5V) C9A C9B 5 D9 6 C1 1nF "Y1" C1 0.1 R11 1K (1V) 40 (5V) R15 U K 00uF, 16V (1Vout) 00uF, 6.V (5Vout) U R16 K NCP41 R1 K C 0.1uF 50V R1 9K C11 (1V) R14 K K (5V) 0.1 J + Vout _ 1. Crossed lines on schematic are NOT connected.. U is NEC PS561L-1 or equivalent optocoupler (CTR > 50%).. R1 is for inrush limiting - use carbon comp or wire wound. 4. L1A/L1B are Wurth components (80 uh, 500mA). 5. Output caps (C9A/B) are radial lead, low impedance types (UCC LXV series or similar). 6. Z1 sets OVP trip level. 7. R5 is for Vcc trimming (< 8Vmax), typically zero ohms. 8. R8A/B sets max output current. 9. U1 is 0 khz version. See drawing for T1 details. 0 Watt NCP151 Power Supply with Universal AC Input (Rev 5A) Optional Ripple Filter To C L 4.7uH 5A J + C1 Vout 0uF _ ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note AS IS and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Frank Cathell, f.cathell@onsemi.com July 01, Rev.

3 MAGNETICS DESIGN DATA SHEET Project / Customer: ON Semiconductor - 0 watt, 5 Vout NCP151 Flyback Part Description: 0 watt, 0 khz flyback transformer, 5Vout (Wurth # ) Schematic ID: T1 Core Type: EE0//6 ferrite core; C90 material or similar Core Gap: Gap for 190 +/- 00uH across Primary A (pins 1 - ) Inductance: 750 uh total (+/- 5%) measured from pin 1 to pin 9 with pins and connected Bobbin Type: pin horizontal mount for EE0//6 Windings (in order): Winding # / type Turns / Material / Gauge / Insulation Data Primary A (1 - ) Vcc ( - 8) 5V Secondary (5-6) Primary B ( - 9) 0T of #8HN over 1 layer (0 TPL). Insulate for 1 kv to next winding. Self leads to pins. 8 turns of #8 HN over 1 layer, spiral wound over primary A. Self leads to pins. Insulate to 1 kv to next winding with tape. turns trifilar of #4 triple insulated wire over one. layer (three strands). Self leads to single pins as shown in drawing below. Same as Primary A. Insulate with tape and selfleads to pins. Hipot: kv from primaries & Vcc to secondary for 1 minute. Pri A 1 9 Pri B 8 Vcc Schematic 5 5V sec (trifilar) " pin separation (8 places) Lead Breakout / Pinout (Top View of Bobbin) " pin rows July 01, Rev.

4 MAGNETICS DESIGN DATA SHEET Project / Customer: ON Semiconductor - 4 watt, 1 vout NCP151 Flyback Part Description: 4 watt flyback transformer, 1vout, 0 khz (Wurth part # ) Schematic ID: T1 Core Type: EE0//6 ferrite core; C90 material or similar Core Gap: Gap for 190 +/- 00uH across Primary A (pins 1 - ) Inductance: 750 uh total (+/- 5%) measured from pin 1 to pin 9 with pins and connected Bobbin Type: pin horizontal mount for EE0//6 Windings (in order): Winding # / type Turns / Material / Gauge / Insulation Data Primary A (1 - ) Vcc ( - 8) 1V Secondary (5-6) Primary B ( - 9) 0T of #8HN over 1 layer (5 TPL). Insulate for 1 kv to next winding. Self leads to pins. 7 turns of #8 HN over 1 layer, spiral wound over primary A. Self leads to pins. Insulate to 1 kv to next winding with tape. 6 turns bifilar of #4 triple insulated wire over one. layer (two strands). Self leads to pins. (Note: #6 is also acceptable here if the fit is too tight for one layer) Same as Primary A. Insulate with tape and selfleads to pins. Hipot: kv from primaries & Vcc to secondary for 1 minute. Pri A 1 9 Pri B 8 Vcc Schematic 5 1V sec (bifilar) " pin separation (8 places) Lead Breakout / Pinout (Top View of Bobbin) " pin rows July 01, Rev. 4

5 Efficiency Plots 1 Volt Output 5 Volt Output July 01, Rev. 5

6 Light Load (< 500mW out) and Standby (no load) Power Plots July 01, Rev. 6

7 Bill of Materials for 1Vout, 0W NCP151 Flyback (Rev5) h6//011 Designator Qty Description Value Tolerance Footprint Manufacturer Manufacturer Part Number Substitution Lead Allowed Free Comments D9 (1Vout) 1 Schottky diode A, 60V SMC ON Semi MBRS60TG No Y 1V version D9 (5Vout) 1 Schottky diode 5A, 40V SMC ON Semi MBRS540T No Y 5V version Q1 1 Mosfet - NDD04N60Z 4A, 600V DPak ON Semi NDD04N60Z No Y D1,,, 4, 8 5 Diode - 60 Hz, 1A, 800V SMA ON Semi MRA4007 No Y D5 1 Diode - fast recov 1A, 600V axial lead ON Semi 1N497 No Y D6, D7 Signal diode 0mA, 0V SOD-1 ON Semi MMSD4148A No Y Z1 1 Zener diode 7V (OVP) SOD-1 ON Semi MMSZ554B No Y U 1 Programmable zener.5v SOIC8 / SOT ON Semi NCP41A No Y U 1 Optocoupler CTR >/= pin Vishay or NEC SFH6156A-4 or PS561L-1 Yes Y U1 1 Controller - NCP151B 0 khz TSOP6 ON Semi NCP151BSN0 No Y C1, C "X" cap, box type 0nF, X 0% LS = 15 mm Rifa, Wima Digi-Key P/N = ND Yes Y C1 1 "Y1" cap, disc type 1nF, Y1 0% LS = 7.5 mm Rifa, Wima Mouser P/N = 75-WKPMCPEJ0KR Yes Y C4 1 Ceramic cap, disc 4.7nF, 1kV 5% LS = 7.5 mm Rifa, Wima Digi-Key P/N = ND Yes Y C5 1 Ceramic cap, monolythic 1 nf, 50V % 6 AVX, Murata Digi-Key P/N = ND Yes Y C, 11, 1 Ceramic cap, monolythic 0nF, 50V % 6 AVX, Murata Digi-Key P/N = ND Yes Y C7 1 Ceramic cap, monolythic 0pF, 50V 5% 6 AVX, Murata Digi-Key P/N = ND Yes Y C8 1 Ceramic cap, monolythic nf, 50V 5% 6 AVX, Murata Digi-Key P/N = ND Yes Y C 1 Electrolytic cap 47uF, 400V % LS=7.5mm, D=16mm UCC, Panasonic Mouser P/N = 647-UCYG470MHD Yes Y C6 1 Electrolytic cap uf, 5Vdc % LS=.5mm, D=6.mm UCC, Panasonic Digi-Key P/N = ND Yes Y C9A, C9B Electrolytic cap 00uF, 16V % LS=5mm, D=1.5mm UCC, Panasonic Mouser P/N = 661-EKY160ELLMK1 Yes Y 1V version (5Vout) Electrolytic cap 00uF, 6.V % LS=5mm, D=1.5mm UCC, Panasonic Newark P/N = K4009 Yes Y 5V version R1 1 Resistor, W, Wire wound 4.7 ohm, W 5% LS=7.5mm, D=7mm Ohmite, Dale Digi-Key P/N = 4.7AECT-ND Yes Y R 1 Resistor, 1W, metal film 4K, 1W 5% Axial lead; LS=5mm Ohmite, Dale Digi-Key P/N = PPC4KW-1CT-ND Yes Y R8A/B Resistor, 1/W metal film ohms, 1/W 1% Axial lead; LS=1.5mm Ohmite, Dale Mouser P/N = 660-MF1/DCT5RR00F Yes Y R6 1 Resistor, 1/4W SMD ohms 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = FCT-ND Yes Y R, R4 Resistor, 1/4W SMD 470K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y R7, 1, 14 Resistor, 1/4W SMD K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y R11 (1Vout) 1 Resistor, 1/4W SMD 1K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y 1V version R11 (5Vout) 1 Resistor, 1/4W SMD 40 ohms 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = FCT-ND Yes Y 5V version R5 1 Resistor, 1/4W SMD Zero ohm 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = ECT-ND Yes Y R9,, 15 Resistor, 1/4W SMD 1K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y R16 1 Resistor, 1/4W SMD K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y R1 (1Vout) 1 Resistor, 1/4W SMD 9K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y 1V version R1 (5Vout) 1 Resistor, 1/4W SMD K 1% SMD 6 AVX, Vishay, Dale Digi-Key P/N = KFCT-ND Yes Y 5V version F1 1 Fuse, TR-5 style A TR-5, LS=5mm Minifuse Newark P/N = 67K094 Yes Y L1A/B 1 Inductor (EMI choke) 80 uh, 500 ma See Wurth Drawing Wurth Magnetics Yes Y T1 (1Vout) 1 Transformer E0//6 core See Mag Drawing Wurth Magnetics Yes Y 1V version T1 (5Vout) 1 Transformer E0//6 core See Mag Drawing Wurth Magnetics Yes Y 5V version J1, J Screw Terminal LS = 0." DigiKey # ND Yes Y J1, J Screw Terminal LS = 0." DigiKey # ND Yes Y Blue indicates part change with Vout change 1 01 ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note AS IS and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Frank Cathell, Frank.Cathell@onsemi.com July 01, Rev. 7