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High-Voltage Switcher
for Medium Power Offline
SMPS Featuring Low
Standby Power
The NCP1027 offers a new solution targeting output power levels www.onsemi.com
from a few watts up to 15 W in a universal mains flyback application.
Our proprietary high−voltage technology lets us include a power
MOSFET together with a startup current source, all directly MARKING
connected to the bulk capacitor. To prevent lethal runaway in low DIAGRAM
input voltage conditions, an adjustable brown−out circuitry blocks
the activity until sufficient input level is reached. 8−LEAD PDIP P1027Pxxx
Current−mode operation together with an adjustable ramp P SUFFIX AWL
compensation offers superior performance in universal mains CASE 626A YYWWG
applications. Furthermore, an Over Power Protection pin brings the
ability to precisely compensate all internal delays in high input voltage
conditions and optimize the maximum output current capability. xxx = 65 or 100
Protection wise, a timer detects an overload or a short−circuit and A = Assembly Location
stops all operations, ensuring a safe auto−recovery, low duty cycle burst WL = Wafer Lot
operation. An integrated, auto−recovery, Overvoltage Protection YY = Year
permanently monitors the VCC level and temporarily shuts down the WW = Work Week
G = Pb−Free Package
driving pulses in case of an unexpected feedback loop runaway.
Finally, a great RDS(on) figure makes the circuit an excellent choice
for standby/auxiliary offline power supplies or applications requiring PIN CONNECTIONS
higher output power levels.
VCC GND
Features
• Built−in 700 V MOSFET with Typical RDS(on) of 5.8 W, TJ = 25°C Ramp Comp. OPP
• Current−Mode Fixed Frequency Operation: 65 kHz and 100 kHz
Brown−Out
• Fixed Peak Current of 800 mA
FB Drain
• Skip−Cycle Operation at Low Peak Currents
• Internal Current Source for Clean and Lossless Startup Sequence (Top View)
• Auto−Recovery Output Short Circuit Protection with Timer−Based
Detection ORDERING INFORMATION
• Auto−Recovery Overvoltage Protection with Auxiliary Winding
Device Package Shipping*
Operation
• Programmable Brown−Out Input for Low Input Voltage Detection NCP1027P065G PDIP−8 50 Units / Rail
• Programmable Over Power Protection (Pb−Free)
• Input to Permanently Latchoff the Part NCP1027P100G PDIP−8 50 Units / Rail
• Internal Frequency Jittering for Improved EMI Signature (Pb−Free)
• Extended Duty Cycle Operation to 80% Typical *For additional information on our Pb−Free strategy
• No−Load Input Standby Power of 85 mW @ 265 Vac and soldering details, please download the
ON Semiconductor Soldering and Mounting
• 500 mW Loaded, Input Power of 715 mW @ 230 Vac Techniques Reference Manual, SOLDERRM/D.
• These Devices are Pb−Free and are RoHS Compliant
Typical Applications
• Medium Power AC−DC Adapters for Chargers
• Auxiliary/Standby Power Supplies for ATX and TVS Power Supplies
Reference 230 VAC 90−265 VAC
NCP1027 − 5.8 W 25 W* 15 W*
*Typical values, open−frame, 65 kHz version, RqJA < 75°C/W, TA = 50°C.
Vout
+
OPP*
NCP1027
OVP 1 8
+
2 7
85−265 VAC
BO 3
4 5
+ +
GND
Ramp
Comp.*
*Optional component
Figure 1. Typical Application
5 Drain Drain Connection The internal drain power switch circuit connection.
− − − This unconnected pin ensures adequate creepage distance.
7 OPP Over Power Protection Driving this pin reduces the power supply capability in high line conditions. If
no Over Power Protection is needed, short this pin to ground.
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NCP1027
IC1
VCC GND
Vclamp +
Auto−Recovery OVP
VCC UVLOs
- +
Mngt 4 V rst
Fault VDD
+ 20 ms RC
-
+ S LEB
Vlatch Q
Q 50 ms RC
R
VCC < 4 V
IBO Reset
Timer OPP
BO +
-
VBO +
65 kHz or Ip Flag
100 kHz Vcc
Jittering CLOCK
S
V Q
Icomp dd
Q
R
Ramp
Comp.
25%
+ of lp
+ Skip
-
- +
Vdd
RFB
Soft−Start UVLO
Drain
FB
+ Max Ip Selection
- Over Power
Protection Input
Ip Flag
Ramp Compensation
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NCP1027
MAXIMUM RATINGS
Rating Symbol Value Unit
Power Supply Voltage on all Pins, Except Pin 5 (Drain) VCC −0.3 to 10 V
Drain Voltage BVdss −0.3 to 700 V
Drain Current Peak During Transformer Saturation IDS(pk) 1.8 A
Maximum Current into Pin 1 when Activating the 8.7 V Active Clamp I_VCC 15 mA
Thermal Resistance, Junction−to−Air – PDIP7 RqJA 100 °C/W
Thermal Resistance, Junction−to−Air – PDIP7 with 1.0 cm@ of 35 m Copper Area RqJA 75 °C/W
Maximum Junction Temperature TJMAX 150 °C
Storage Temperature Range − −60 to +150 °C
ESD Capability, Human Body Model (HBM) (All Pins Except HV) − 2.0 kV
ESD Capability, Machine Model (MM) − 200 V
Stresses exceeding those listed in the Maximum Ratings table may damage the device. If any of these limits are exceeded, device functionality
should not be assumed, damage may occur and reliability may be affected.
1. This device series contains ESD protection and exceeds the following tests:
Human Body Model 2000 V per JEDEC JESD22−A114−F.
Machine Model Method 200 V per JEDEC JESD22−A115−A.
2. This device contains latchup protection and exceeds 100 mA per JEDEC Standard JESD78.
ELECTRICAL CHARACTERISTICS (For typical values TJ = 25°C, for min/max values TJ = 0°C to +125°C, Max TJ = 150°C,
VCC = 8.0 V, unless otherwise noted.)
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NCP1027
ELECTRICAL CHARACTERISTICS (continued) (For typical values TJ = 25°C, for min/max values TJ = 0°C to +125°C,
Max TJ = 150°C, VCC = 8.0 V, unless otherwise noted.)
Final Switch Current with a Primary Slope of 200 mA/ms, − Ipeak_27_SW_ − 820 − mA
FSW = 65 kHz (Note 4) 65 k
Maximum Internal Current Setpoint, Pin 4 Open, TJ = 25°C, − Ipeak_27_CS_ 720 800 880 mA
FSW = 100 kHz (Note 3) 100 k
Final Switch Current with a Primary Slope of 200 mA/ms, − Ipeak_27_SW_ − 820 − mA
FSW = 100 kHz (Note 4) 100 k
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NCP1027
TYPICAL CHARACTERISTICS
11 8.9
8.8
10 8.7
8.6
IOVP (mA)
VCCON (V)
8.5
8.4
8 8.3
8.2
7 8.1
8.0
6 7.9
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 3. Figure 4.
7.9 0.24
7.8
7.7
7.6 0.22
7.5
VCCMIN (V)
VCCClamp (V)
7.4 0.20
7.3
7.2
0.18
7.1
7.0
6.9 0.16
6.8
6.7
0.14
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 5. Figure 6.
1.8 900
850
800
1.6
750
700
ICC1 (mA)
IC2 (mA)
650
1.4
600
550
1.2 500
450
400
1.0 350
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 7. Figure 8.
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NCP1027
TYPICAL CHARACTERISTICS
8.0 71.0
7.5 70.0
69.0
7.0
68.0
6.5 67.0
Fosc (kHz)
66.0
IC1 (mA)
6.0
65.0
5.5
64.0
5.0 63.0
4.5 62.0
61.0
4.0
60.0
3.5 59.0
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 9. Figure 10.
120 87.0
100 85.0
80 83.0
Fosc (kHz)
Dmax (%)
60 81.0
40 79.0
20 77.0
0 75.0
−40 −20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 11. Figure 12.
610 13.0
600
12.5
590
IBO HYSTERESIS (mA)
12.0
580
11.5
VBO (mV)
570
560 11.0
550
10.5
540
10.0
530
520 9.5
510 9.0
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
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NCP1027
TYPICAL CHARACTERISTICS
880 11
10
860
7
800
6
780 5
760 4
740 3
720 2
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
3.8 30
3.7 28
26
3.6
Vlatch (V)
Iopp (%)
24
3.5
22
3.4
20
3.3 Ipin 7 = 40 mA
18
3.2 16
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 17. Figure 18.
400 2.8
RAMP COMPENSATION LEVEL (V)
380
360
Tleb + Tpropdelay (ns)
340 2.7
320
300
280
2.6
260
240
220
200 2.5
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 19. Figure 20.
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NCP1027
TYPICAL CHARACTERISTICS
70 100
68 90
66 80
64 70
62
60
60
50
58
40
56
30
54
20
52
50 10
−20 0 20 40 60 80 100 120 140 −20 0 20 40 60 80 100 120 140
TEMPERATURE (°C) TEMPERATURE (°C)
Figure 21. Figure 22.
85°C
100%
125°C
90%
140°C
80%
IPEAK REDUCTION (%)
−40°C
70%
0°C
60% 25°C
−20°C
50%
40%
30%
20%
10%
0%
0 50 100 150 200 250
IOPP (mA)
Figure 23. Ipeak Reduction = F(lopp, @ temperature)
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NCP1027
APPLICATION INFORMATION
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NCP1027
Startup Sequence
The NCP1027 includes a high−voltage startup circuitry, VCC capacitor. Figure 24 details the simplified internal
directly deriving current from the bulk line to charge the arrangement.
Vbulk
+
I1
RVCC
IC1 5
ICC1 ←
1
I2 Iclamp
- +
+ VCCon +
CVCC VCCoff
Vz = 8.7 V
Iclamp > 6 mA
→ OVP fault
8
When the power supply is first connected to the mains active Zener diode, protects the switcher against lethal VCC
outlet, the internal current source is biased and charges up runaways. This situation can occur if the feedback loop
the VCC capacitor. When the voltage on this VCC capacitor optocoupler fails, for instance, and you would like to
reaches the VCCON level (typically 8.5 V), the current protect the converter against an over voltage event. In that
source turns off, reducing the amount of power being case, the internal current increase incurred by the VCC
dissipated. At this time, the VCC capacitor only supplies the rapid growth triggers the over voltage protection (OVP)
controller, and the auxiliary supply should take over before circuit and immediately stops the output pulses for 440 ms.
VCC collapses below VCC(min). This VCC capacitor, CVCC, Then a new startup attempt takes place to check whether
must therefore be calculated to hold enough energy so that the fault has disappeared or not. The OVP paragraph gives
VCC stays above VCC(min) (7.3 V typical) until the more design details on this particular section.
auxiliary voltage fully takes over. The VCC capacitor can be calculated knowing a) the
An auxiliary winding is needed to maintain the VCC in amount of energy that needs to be stored; b) the time it
order to self−supply the switcher. The VCC capacitor has takes for the auxiliary voltage to appear, and; c) the current
only a supply role and its value does not impact other consumed by the controller at that time. For a better
parameters such as fault duration or the frequency sweep understanding, Figure 25 shows how the voltage evolves
period for instance. As one can see in Figure 24, an internal on the VCC capacitor upon startup.
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NCP1027
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NCP1027
Fault Condition – Output Short−Circuit that the system has reached its maximum current limit set
As soon as VCC reaches VCCON, drive pulses are point (Ip = Ip max). The assertion of this flag triggers a
internally enabled. If everything is correct, the auxiliary 55 ms counter. If at counter completion Ipflag remains
winding increases the voltage on the VCC pin as the output asserted, all driving pulses are stopped and the part stays off
voltage rises. During the start−sequence, the controller during eight periods of 55 ms (440 ms). A new attempt to
smoothly ramps up the peak current to Imax setting, e.g. restart occurs and will last 55 ms providing the fault is still
Ipeak_HI, which is reached after a typical period of 1.0 ms. present. If the fault still affects the output, a safe burst mode
As soon as the peak current setpoint reaches its maximum is entered, affected by a low duty−cycle operation (11%).
(during the startup period but also anytime an overload When the fault disappears, the power supply quickly
occurs), an internal error flag is asserted, Ipflag, indicating resumes operation. Figure 27 depicts this particular mode.
Figure 27. In case of short−circuit or overload, the NCP1027 protects itself and the power supply via a low
frequency burst mode. The VCC is maintained by the current source and self−supplies the controller.
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NCP1027
In Figure 27, one can see that the VCC is still alive, before the timer completion. In this particular case, the
testifying for a badly coupled power secondary and Undervoltage Lock Out (UVLO) circuitry has the priority
primary auxiliary windings. Some situations exist where an and safely cuts off all driving pulses. Figure 28 describes
output short−circuit make the auxiliary winding collapse this variation.
Figure 28. The auxiliary winding collapses in presence of a short−circuit. Pulses are immediately stopped
as VCC crosses the minimum operating voltage, VCC(min).
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NCP1027
Fault Condition – Output Too Low reason, the controller becomes un−able to detect a real
This particular mode of operation occurs when the output short−circuit since Ipflag will never be asserted.
feedback is ensured by a two−loop control imposing either Due to a good winding coupling, the primary side auxiliary
constant output voltage (CV) or constant output current collapsing will ensure a proper fault detection via the
(CC), for instance in a battery charger. In CC mode, the UVLO internal circuit. Figure 29 depicts this operating
output voltage falls down below the original target but the way.
feedback loop is kept closed by the CC controller. For that
Figure 29. In this particular case, the output goes low but the timer is not started since the FB pin is still held
by the optocoupler. Due to the UVLO circuit, the controller safely stops operation at VCC = VCC(min).
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NCP1027
1 vin 2 vcmp
16.0 160
12.0 120
Vbulk VDD
Vin in Volts
Vcmp Volts
Plot1
8.00 80.0
Rupper ON/OFF
←
IBO
BO + 4.00 40.0
- BO
Rlower
+ 0 0 2
1
VBO
Figure 30a. The internal brown−out Figure 30b. Simulation results for 100/70 ON/OFF levels.
configuration with an offset current source.
Figure 30.
To the contrary, when the internal BO signal is high, the IBO source is activated and creates an hysteresis. As a result,
it becomes possible to select the turn−on and turn−off levels via a few lines of algebra.
IBO is Off
Rlower
V()) + Vbulk1 (eq. 1)
Rlower ) Rupper
IBO is On
V()) + Vbulk2
Rlower
Rlower ) Rupper
) IBO ǒRRlower Rupper
lower ) Rupper
Ǔ (eq. 2)
We can now extract Rlower from Equation 1 and plug it into Equation 2, then solve for Rupper :
Vbulk1−VBO
Rupper + Rlower
VBO
Vbulk1−Vbulk2
Rlower + VBO
IBO (Vbulk1−VBO)
If we decide to turn−on our converter for Vbulk1 equals 100 V and turn it off for Vbulk2 equals 70 V, then we obtain:
Rupper = 3.0 MW
Rlower = 18 kW
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NCP1027
The bridge power dissipation is 3302/3.018 Meg = when VCC reaches VCC(ON), ensuring a clean startup
36 mW in nominal high−line operation. Figure 30b sequence. As in fault mode conditions, the startup source
simulation result confirms our calculations. is activated on and off and self−supplies the controller in a
Figure 31 describes signal variations during a brown−out Dynamic Self−Supply (DSS) mode.
condition. Please note that output pulses only reappear
Depending on input surge tests, it might be necessary to drifting) or when an overtemperature is detected.
wire a filtering capacitor between BO and GND (close to Secondary monitoring is usually implemented when the
the circuit) to avoid adversely triggering the internal latch coupling between auxiliary and power windings does not
(unless this is a wanted feature) when the pulse train lead to a precise primary detection, hence the
appears. auto−recovery OVP on pin 1 would not satisfy the precision
requirements. Due to the addition of a comparator on the
Latchoff Protection BO pin, a simple external circuit can lift up this pin above
There are some situations where the converter shall be VLATCH and permanently disable pulses. The VCC needs
fully turned−off and stay latched. This can happen in the to be cycled down below 3.5 V typically to reset the
presence of a secondary overvoltage (the feedback loop is controller.
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NCP1027
20 ms
VCC Vbulk
RC
+ To permanent
- latch
Q1
Vout +
Rupper
Vlatch
IBO
←
VDD
BO +
BO
-
NTC Rlower
+
VBO
Figure 32. Adding a comparator on the BO pin offers a way to latch−off the controller.
In Figure 32, Q1 is blocked and does not bother the BO temperature, Q1 base is brought to ground and the BO pin
measurement as long as the NTC and the optocoupler are goes up, permanently latching off the controller. Figure 33
not activated. As soon as the secondary optocoupler senses depicts the converter behavior in case of total latch−off.
an OVP condition, or the NTC reacts to a high ambient
Figure 33. If the BO pin is lifted up to VLATCH, the controller permanently latches off.
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NCP1027
Drain
VCCON = 8.5 V
VCC(min) = 7.5 V
- Startup
+
←
+ Source
VCC Rlimit D1
+
-
+ + +
CVCC CAUX Laux
Vclamp = 8.7 V Typ.
+
Latch -
+ I > 6 mA
Ground
Since Rlimit shall not bother the controller in standby, e.g. can be seen on auxiliary windings from nominal operation
keep Vauxiliary to around 8.0 V (as selected above), we down to standby mode. Let’s select a nominal auxiliary
purposely select a Vnom well above this value. As winding of 20 V to offer sufficient margin regarding 8.0 V
explained before, experience shows that a 40% decrease when in standby (Rlimit also drops voltage in standby…).
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NCP1027
Plugging the values in Equation 3 gives the limits within experiments on a breadboard to check the auxiliary voltage
which Rlimit shall be selected: variations but also the output voltage excursion in fault.
20−8.7 v Rlimit v 12−8 , that is to say : 1.8 kW t R Once properly adjusted, the fail−safe protection will
6m 1m limit preclude any lethal voltage runaways in case a problem
t 4 kW. would occur in the feedback loop.
If we design a 65 kHz power supply delivering 12 V, then
the ratio between auxiliary and power must be: 12/20 = 0.6.
The OVP latch will activate when the clamp current
exceeds 6.0 mA. This will occur when Vauxiliary grows up
to:
1. 8.7 + 1.8 k (6 m + 1.8 m) ≈ 23 V for the first
boundary (Rlimit = 1.8 kW).
2. 8.7 + 4 k (6 m + 1.8 m) ≈ 40 V for the second
boundary (Rlimit = 4.0 kW).
Due to a 0.6 ratio between the auxiliary VCC and the
power winding, the auxiliary OVP will be seen as a lower
overshoot on the real output: > 30 ms
1. 23 0.6 ≈ 13.8 V
2. 40 0.6 ≈ 24 V
As one can see, tweaking the Rlimit value will allow the Figure 35. The burst frequency becomes so low
selection of a given overvoltage output level. Theoretically that it is difficult to keep an adequate level on the
predicting the auxiliary drop from nominal to standby is an auxiliary VCC.
almost impossible exercise since many parameters are
involved, including the converter time constants. Fine Figure 36 describes the main signal variations when the
tuning of Rlimit thus requires a few iterations and part operates in auto−recovery OVP.
Figure 36. If the VCC current exceeds a certain threshold, an auto−recovery protection is
activated and protects the design.
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NCP1027
VCC D1
Rlimit
+ Laux
Ground
Figure 37. A simple Zener diode added in Figure 38. Internal logic blocks take a certain amount
parallel with Rlimit , allows for a better of time before shutting off the driving pulses in
precision OVP. presence of an overcurrent event.
Over Power Compensation At low line, Son is relatively low and does not bother the
Over Power Compensation or Protection (OPP) final peak value. The situation differs at high line and
represents a way to limit the effects of the propagation induces a higher peak current. Therefore, the power supply
delay when the converter is supplied from its highest input output power capability increases with the input voltage.
voltage. The propagation delay naturally extends the Let us a take a look at a simple example. Suppose the peak
power capability of any current−limited converter. current is 700 mA:
Figure 38 explains why. The main parameter is the on Lp = 1.0 mH
slope, that is to say, the pace at which the inductor current
Vin lowline = 100 Vdc
grows−up when the power switch closes. For a flyback
controller, the slope is given by: Vin highline = 350 Vdc
V Ipeak,max = 700 mA
Son + in (eq. 4)
Lp tprop = 100 ns
where Lp is the transformer magnetizing/primary Pout + 1 I2 F L h (eq. 6)
2 peak, final SW p
inductance and Vin , the input voltage.
As the internal logic takes some time to react, the switch Where: Fsw is the switching frequency and h the efficiency.
gate shutdown does not immediately occur when the Usually h is bigger in high line conditions than in low line
maximum power limit is detected (just before activating conditions. This formula is valid for a Discontinuous
the overload protection circuit). Clearly speaking, it can Conduction Mode flyback.
take up to 100 ns for the NCP1027 current sense From Equation 5, we can calculate the final peak current
comparator to propagate through the various logical gates in both conditions:
before reaching the power switch and finally shutting it off. Ipeak,final = (100/1m) x 100n + 700m = 710 mA at low line.
This is the well−known propagation delay noted tprop . Ipeak,final = (350/1m) x 100n + 700m = 735 mA at high line.
Unfortunately, during this time, the current keeps growing From Equation 6, we can have an idea of the maximum
as Figure 38 depicts. The peak current will therefore be output power capability again, in both conditions with
troubled by this propagation delay. The formula to obtain respective low and high line efficiency numbers of 78%
the final value is simply: and 82% for instance:
V
Ipeak, final + in t prop ) Ipeak, max (eq. 5)
Pout,lowline = 0.5 0.712 1m 65k 0.78 = 12.8 W
Lp 2
Pout,highline = 0.5 0.735 1m 65k 0.82 = 14.4 W
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NCP1027
This difference might not be seen as a problem, but some 10 kW and ROPPU made of a series string of 4 1.0 MW
design specifications impose stringent conditions on the resistors plus a 10−turn 1.0 MW potentiometer set at its
maximum output current capability, regardless the line maximum value. An amp−meter is inserted in series with
input. Hence the need for an OPP input… pin 7 and a volt−meter monitors its voltage with respect to
Since we want to limit the power to 12.8 W at high line, ground. Once the power supply is powered, slowly rotate
let us calculate the needed peak current: the potentiometer and observe both voltage and current
From equation 6: Ipeak + ǸF2Pout = 693 mA to
SWLph
going up at pin 7. At a certain time, as voltage and current
increase, the controller will shut down the power supply.
deliver 12.8 W at high line. The current at this time is the one we are looking for.
Compared to our 735 mA, we need to decrease the Suppose these experiments lead to 80 mA with a pin 7
setpoint by 6% roughly when Vin equals 350 Vdc. activation voltage of 2.45 V. Final resistor equations are:
The NCP1027 hosts a special circuitry looking at the VbulkH = 375 Vdc ; the maximum voltage at which OPP
couple voltage/current present on pin 7. Figure 39 shows must shut down the controller
how to arrange components around the controller to obtain VbulkL = 200 Vdc ; the minimum voltage below which
Over Power Protection. OPP is not activated
IOPP = 80 mA ; the current in pin 7
Bulk Vf = 2.45 V ; the voltage of pin 7 at the above
condition
V −V
ROPPU ROPPL + bulkH bulkL Vf + 27 kW (eq. 7)
IOPP(VbulkL−Vf)
Over Power OPP
Current V −V
Setpoint Protection ROPPH + ROPPL bulkL f + 2.2 MW (eq. 8)
Vf
ROPPL If the OPP feature is not needed for some designs, it is
possible to ground it via a copper wire to the adjacent
GND ground pin. This can help to develop a larger copper area
in an application where the thermal resistance is an
important parameter.
Figure 39. A resistive network reduces the
power capability in high−line conditions. Ramp Compensation
When operating in Continuous Conduction Mode
First, you need to know the required injected current and (CCM), current−mode power supplies can exhibit
the voltage across pin 7 to start activating OPP. so−called sub−harmonic oscillations. To cure this problem,
Experiments consist in wiring Figure 39 circuit and the designer must inject ramp compensation. The ramp can
running the power supply in conditions where it must shut either be added to the current sense information or directly
down (e.g. highest input voltage and maximum output subtracted from the feedback signal. Figure 40 details the
current per specification). For this, ROPPL can be put to internal arrangement of the ramp compensation circuitry.
VDD
Gate Reset
IRR
Ramp Control
Vp
RR
Figure 40. The Internal Feedback Chain and the Ramp Compensation Network
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NCP1027
The principle consists in selecting the RR resistor, Np:Ns = 1:N = 1:0.052 transformer turn ratio
connected from pin 2 to ground, to impose a current IRR in Lp = 3.8 mH primary inductance
the transistor collector.
We can calculate the off slope, the one actually needed
to evaluate Sa , by reflecting the output voltage over the
primary inductance. The slope is projected over a complete
switching period. Here, we use a 65 kHz part.
V ) Vf
Soff + out TSW + 6 15u + 455 mAń15 ms
NLp 0.052 3.8m
(eq. 10)
Due to the internal sense arrangement, this current slope
will become a voltage slope having a value of:
SȀoff + 455m 0.375 + 170 mVń15 ms (eq. 11)
If we chose 50% of this downslope, then the final
compensation ramp will present a slope of:
Sa + 170m + 85 mVń15 ms (eq. 12)
2
We then have:
Figure 41. Maximum Peak Current Setpoint Vp2.75 k
Variations versus Ramp Compensation RR + + 2.75 2.75k + 89 kW (eq. 13)
Sa@TSW 85m
In the above calculations, the internal ESD resistor has
The equation to get the right compensation level is the purposely been omitted to avoid bringing in another
following: variable. In case no ramp compensation is required, pin 2
Vp2.75 k must be tied to VCC, the adjacent pin.
RR + (eq. 9)
Sa@TSW
Soft−Start
where Vp, the total voltage swing, equals 2.75 V. The NCP1027 features a 1.0 ms soft−start, which
Application example: reduces the power−on stress, but also contributes to lower
Suppose we have the following flyback specifications: the output overshoot. Figure 42 shows a typical operating
Vout = 5.0 V output voltage waveform. The NCP1027 features a novel patented
structure which offers a better soft−start ramp, almost
Vf = 1.0 V secondary diode forward drop
ignoring the startup pedestal inherent to traditional
@ Iout nominal
current−mode supplies.
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23
NCP1027
Jitter ramp
68.9kHz
65kHz
61.1kHz Internal
sawtooth
adjustable
Nominal peak
current
Skip cycle
current limit
Figure 44. Low Peak Current Skip Cycle Guarantees Noise−Free Operation
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24
NCP1027
5.0 V/3.0 A Universal Mains Power Supply Vin min = 120 Vdc
Due to its low RDS(on), the NCP1027 can be used in
universal mains SMPS up to 15 W of continuous power, Vin max = 375 Vdc
provided that the chip power dissipation is well under Vout = 5.0 V
control. That is to say that average power calculations and Vout = 15 W
measurements have been carried and correlated. The Operating mode is CCM
design of an SMPS around a monolithic device does not h = 0.8
differ from that of a standard circuit using a controller and 1. The lateral MOSFET body−diode shall never be
a MOSFET. However, one needs to be aware of certain forward biased, either during startup (because of a
characteristics specific of monolithic devices. Let us large leakage inductance) or in normal operation
follow the steps: as shown by Figure 45. This condition sets the
maximum voltage that can be reflected during toff .
350
250
150
50.0
> 0 !!
50.0
−
Figure 45. The reflected voltage shall always be greater Figure 46. Primary Inductance Current
than the minimum input voltage to avoid the forward Evolution in CCM
biasing of the MOSFET body−diode.
As a result, the Flyback voltage which is reflected on the turn ratio, Vout the output voltage, Vf the
drain at the switch opening cannot be larger than the input secondary diode forward drop and finally, Ipeak
voltage. When selecting components, you thus must adopt the maximum peak current. Worse case occurs
a turn ratio which adheres to the following equation: when the SMPS is very close to regulation, e.g.
N(Vout ) Vf) t Vin, min t Vin min (eq. 14) . In our case, the Vout target is almost reached and Ipeak is still
since we operate from a 120 V DC rail while delivering pushed to the maximum. For this design, we have
5.0 V, we can select a reflected voltage of 110 V selected our maximum voltage around 650 V (at
DC maximum: 120−110 > 0. Therefore, the turn ratio Vin = 375 Vdc). This voltage is given by the RCD
Vin
Np:Ns must be smaller than + 110 + 18.3 or clamp installed from the drain to the bulk
Vout ) Vf 5)1 voltage. We will see how to calculate it later on.
Np : Ns t 19. We will see later on how it affects the 3. Calculate the maximum operating duty−cycle for
calculation. this flyback converter operated in CCM:
2. Lateral MOSFETs have a poorly doped
NVout 1
body−diode which naturally limits their ability to d max + + + 0.49 (eq. 16)
NVout ) Vin, min Vin,min
1 ) NV
sustain the avalanche. A traditional RCD out
clamping network shall thus be installed to 4. To obtain the primary inductance, we have the
protect the MOSFET. In some low power choice between two equations:
applications, a simple capacitor can also be used (Vind)2 DIL
since Vdrain max + Vin ) N (Vout ) Vf) L+ (eq. 17) , where K + and
fSWKPin I1
) Ipeak ǸCLtotf (eq. 15) , where Lf is the leakage defines the amount of ripple we want in CCM
(see Figure 46).
inductance, Ctot the total capacitance at the drain • Small K: deep CCM, implying a large primary
node (which is increased by the capacitor you inductance, a low bandwidth and a large leakage
will wire between drain and source), N the Np:Ns inductance.
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25
NCP1027
• Large K: approaching BCM where the rms losses are If we take the maximum RDS(on) for a 120°C junction
the worse, but smaller inductance, leading to a better temperature, i.e. 11 W, then conduction losses worse case
leakage inductance. are:
From Equation 16, a K factor of 0.8 (40% ripple), gives Pcond + I2d, rms Rds(on) + 571 mW
an inductance of:
6. Off−time and on−time switching losses can be
(120 0.49)2 estimated based on the following calculations:
L+ + 3.8 mH
60k 0.8 18.75
IpeakVdstoff
V d Poff + + 0.447 650 40n + 130 mW
DIL + in + 120 0.49 + 258 mA peak * to * peak 6TSW 6 15u
(eq. 18)
LFSW 3.8m 60k
The peak current can be evaluated to be: IpeakN(Vout ) Vf)ton
Pon +
Iavg DIL DI 6TSW (eq. 19)
Ipeak + ) + Ipeak + 156m ) L + 447 mA
d 2 0.49 2 + 0.447 114 40n + 22 mW
6 15u
In Figure 46, I1 can also be calculated:
The theoretical total power is then 0.571 + 0.13 + 0.022
DI
I1 + Ipeak− L + 0.447−0.129 + 318 mA = 723 mW.
2
7. The ramp compensation will be calculated as
5. Based on the above numbers, we can now
suggested by Equation 13 giving a resistor of
evaluate the conduction losses:
78 kW or 82 kW for the normalized value.
Id, rms + I1 Ǹd Ǹ1 ) 13 ǒDI2I1LǓ2 + 0.318 0.7 Power Switch Circuit Protection
Ǹ1 ) 13 ǒ2 0.258
0.318
Ǔ2 + 228 mA rms As in any Flyback design, it is important to limit the drain
excursion to a safe value, e.g. below the power switch
circuit BVdss which is 700 V. Figures 47a, b, c present
possible implementations:
HV HV HV
Rclamp Cclamp Dz
D D
1 8 1 8 1 8
2 7 2 7 2 7
3 6 3 6 3 6
a. b. c.
Figure 47a: The simple capacitor limits the voltage Figure 47b: The most standard circuitry called the RCD
according to Equation 14. This option is only valid for low network. You calculate Rclamp and Cclamp using the
power applications, e.g. below 5.0 W, otherwise chances following formulae:
exist to destroy the MOSFET. After evaluating the leakage 2Vclamp(Vclamp−(Vout ) Vf) N)
inductance, you can compute C with Equation 15. Typical Rclamp + (eq. 20)
values are between 100 pF and up to 470 pF. Large LpeakI2peak FSW
capacitors increase capacitive losses… Vclamp
Cclamp + (eq. 21)
VrippleFSWRclamp
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26
NCP1027
clamp is usually selected 50−80 V above the reflected Power Dissipation and Heatsinking
value N (Vout + Vf). The diode needs to be a fast one and The NCP1027 hosting a power switch circuit and a
an MUR160 represents a good choice. One major controller, it is mandatory to properly manage the heat
drawback of the RCD network lies in its dependency upon generated by losses. If no precaution is taken, risks exist to
the peak current. Worse case occurs when Ipeak and Vin are trigger the internal thermal shutdown (TSD). To help
maximum and Vout is close to reach the steady−state value. dissipating the heat, the PCB designer must foresee large
Figure 47c: This option is probably the most expensive copper areas around the PDI7 package. When surrounded
of all three but it offers the best protection degree. If you by a surface greater than 1.0 cm@ of 35 mm copper, it
need a very precise clamping level, you must implement a becomes possible to drop the thermal resistance
Zener diode or a TVS. There are little technology junction−to−ambient, RqJA down to 75°C/W and thus
differences behind a standard Zener diode and a TVS. dissipate more power. The maximum power the device can
However, the die area is far bigger for a transient suppressor Tj max −Tamb max
than that of Zener. A 5.0 W Zener diode, like the 1N5388B, thus evacuate is: P max + (eq. 22)
RqJA
will accept 180 W peak power if it lasts less than 8.3 ms. which gives around 930 mW for an ambient of 50°C and a
If the peak current in the worse case (e.g. when the PWM maximum junction of 120°C. The losses inherent to the
circuit maximum current limit works) multiplied by the switch circuit RDS(on) can be theoretically evaluated, but
nominal Zener voltage exceeds these 180 W, then the diode the final prototype evaluation must include board
will be destroyed when the supply experiences overloads. measurements to confirm that the junction temperature
A transient suppressor like the P6KE200 still dissipates stays within safe limits. Figure 48 gives a possible layout
5.0 W of continuous power, but is able to accept surges up to help dropping the thermal resistance. When measured on
to 600 W @ 1.0 ms. Select the Zener or TVS clamping a 70 mm (2 oz.) copper thickness PCB, we obtained a
level between 40 to 80 V above the reflected output voltage thermal resistance of 75°C/W.
when the supply is heavily loaded.
When routing the printed circuit, it is important to keep to remove unwanted spikes, although less problematic than
high impedance line very short, like the brown−out signal in DCM operation. On the primary side, a resistive network
and the OPP input if used. senses the input bulk voltage and prevents the controller
from turning on for input voltages below 100 Vdc. The
Application Diagram auxiliary winding delivers 20 V nominal and thus offers
Figure 49 displays the final application schematic. The comfortable margin when the converter enters standby. As
output uses a TLV431 whose low bias current represents an we do not use any OPP, pin 7 goes to ground and offers
advantage for low standby power switch mode supplies. extended possibility to layout more copper area.
The secondary side features an additional LC filter needed
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27
Np:Ns = 1:0.062
Np:Naux = 1:0.208
Lp = 3.8 mH C5 C8 C9 Vout
D1 470 470 470 L2 5V@
MBRD640CTT4 mF mF mF 2.2 mH 3A
R5 C7
150 k 10 nF + + +
Type = 1W Type = 400 V
R4 R11 R6
D2
100 1k 10 k
R1 1N4637
20 V
2.8 M
D5
+ C11
1N4637 +
1 mF
R10
200 k R9 C3
28
5.6 k U2 100 mF
NCP1027
+ 1 8
NCP1027
C13
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C4
85−265 VAC 220 nF 2 7 C2
47 mF/
Type = X2 U1 100 nF
400 V 3
TL431
4 5
+
R3 C1 R2 C12 R7
CVCC
C10
47 mF
2.2 nF
Type = Y1
NCP1027
Transformer Specifications:
Vout = 5.0 V/3.0 A
Vaux = 20 V/10 mA
Lp = 3.8 mH
Ip, rms = 280 mA
Ip, max = 800 mA
Isec, rms = 5.0 A
Fsw = 65 kHz
Np:Nsec = 1 : 0.052
Np:Naux = 1 : 0.208
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29
NCP1027
PACKAGE DIMENSIONS
NOTES:
D A 1. DIMENSIONING AND TOLERANCING PER ASME Y14.5M, 1994.
E 2. CONTROLLING DIMENSION: INCHES.
H 3. DIMENSIONS A, A1 AND L ARE MEASURED WITH THE PACK-
AGE SEATED IN JEDEC SEATING PLANE GAUGE GS−3.
8 5
4. DIMENSIONS D, D1 AND E1 DO NOT INCLUDE MOLD FLASH
OR PROTRUSIONS. MOLD FLASH OR PROTRUSIONS ARE NOT
E1 TO EXCEED 0.10 INCH.
5. DIMENSION E IS MEASURED AT A POINT 0.015 BELOW DATUM
1 4 PLANE H WITH THE LEADS CONSTRAINED PERPENDICULAR
TO DATUM C.
6. DIMENSION E3 IS MEASURED AT THE LEAD TIPS WITH THE
NOTE 8 LEADS UNCONSTRAINED.
c 7. DATUM PLANE H IS COINCIDENT WITH THE BOTTOM OF THE
b2 B END VIEW LEADS, WHERE THE LEADS EXIT THE BODY.
TOP VIEW WITH LEADS CONSTRAINED 8. PACKAGE CONTOUR IS OPTIONAL (ROUNDED OR SQUARE
CORNERS).
NOTE 5
INCHES MILLIMETERS
A2 DIM MIN MAX MIN MAX
e/2 A −−−− 0.210 −−− 5.33
A NOTE 3 A1 0.015 −−−− 0.38 −−−
A2 0.115 0.195 2.92 4.95
L b 0.014 0.022 0.35 0.56
b2 0.060 TYP 1.52 TYP
C 0.008 0.014 0.20 0.36
D 0.355 0.400 9.02 10.16
SEATING
PLANE D1 0.005 −−−− 0.13 −−−
A1 E 0.300 0.325 7.62 8.26
C M E1 0.240 0.280 6.10 7.11
D1 e 0.100 BSC 2.54 BSC
eB −−−− 0.430 −−− 10.92
e eB L 0.115 0.150 2.92 3.81
8X b END VIEW M −−−− 10 ° −−− 10 °
0.010 M C A M B M NOTE 6
SIDE VIEW
ON Semiconductor and the are registered trademarks of Semiconductor Components Industries, LLC (SCILLC) or its subsidiaries in the United States and/or other countries.
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or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages. “Typical” parameters which may be provided in
SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including “Typicals” must
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are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications intended to support or sustain life, or
for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should Buyer purchase or use SCILLC products
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30