NCP1568 Ultra-High Density USBPD Laptop Adapter
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1 DN05119/D Design Note DN05119/D NCP1568 Ultra-High Density USBPD Laptop Adapter Device Application Input Voltage Output Power Topology I/O Isolation NCP1568 NCP51530 NCP4306 FDMS86202 Ultra-High Density USBPD Laptop Adapter 90 Vac 265 Vac 60 Watt Active-Clamp Flyback Isolated (3kV) SPECIFICATIONS Output Voltage Ripple Nominal Current Max Current Min Current 20 V 1 V 3 A 3 A Zero Circuit Description This design notes describes a 60 W universal input 5 V, 9 V, 15 V and 20 V output ultra-high density power supply for laptop adapters. This featured power supply is an active-clamp flyback topology utilizing ON Semiconductor s NCP1568 PWM controller, NCP51530 HB Driver, NCP4306 SR Controller and FDMS86202 SR FET. This design note provides complete circuit schematic, PCB, BOM and transformer information of the evaluation board. It also provide efficiency, transient response, output ripple and thermal data of the evaluation board. This design utilized NCP1568 and NCP51530 for the active-clamp flyback topology. Active-clamp flyback topology effectively recycles the leakage energy. Another feature of this topology is the ZVS operation of the power MOSFETS. Because of no leakage losses and ZVS operation, this topology is suited for high frequency operation which results in size reduction of the transformer. Hence active-clamp flyback topology is well suited for high power density sub 100 W power supplies. A ZVS fixed switching frequency power converter also simplifies EMI design and can be easily designed to avoid interference with other sensitive circuits in the system. NCP1568 is a highly integrated AC-DC PWM controller designed to implement an active-clamp flyback topology. It features adaptive frequency scheme which optimizes frequency of operation and hence the efficiency over all load and input voltages. The NCP1568 features a HV startup circuit along. It also has integrated X2 discharge circuit. NCP51530 is a 700 V high side and low side driver with 2 A current drive capability for AC-DC power supplies and inverters. NCP51530 offers best in class propagation delay, low quiescent current and low switching current at high frequencies of operation. This device is tailored for highly efficient power supplies operating at high frequencies. NCP4306 is high performance driver tailored to control a synchronous rectification MOSFET in switch mode power supplies. January, 2019, Rev.0 1
2 DN05119/D Key Features Universal AC input operation ( Vac) High full load and average efficiency Low standby power Very low ripple and noise High frequency operation up to 450 khz Inherent SCP and OCP protection Thermal and OVP protection Adaptive frequency operation based on AC input and output load conditions Adaptive ZVS operation Smaller EMI components Smooth startup operation Figure 1 Full Top View of UHD Board January, 2019, Rev.0 2
3 DN # Figure 2 Full Bottom View of UHD Board January, 2019,Rev.0 3
4 DN # Figure 3 Top View of the UHD Board January, 2019,Rev.0 4
5 DN # Figure 4 Bottom View of the Demo Board January, 2019,Rev.0 5
6 DN # Figure 5 Bottom View of Daughter Card January, 2019,Rev.0 6
7 DN # Figure 6 Top View of Daughter Card January, 2019,Rev.0 7
8 DN # Main Board Layout Top (Layer 1) Inner Signal (Layer 2) January, 2019,Rev.0 8
9 DN # Inner Signal (Layer 3) Bottom (Layer 4) January, 2019,Rev.0 9
10 DN # Board Schematic NOTE: For detailed version, see separate Schematic PDF January, 2019,Rev
11 Magnetic Design January, 2019, Rev
12 Efficiency (%) High Density Board Efficiency Data 5 V Efficiency vs. Load Vac 115 Vac 230 Vac 265 Vac % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Load (%) Figure 7 5V Efficiency Plot January, 2019, Rev
13 Efficiency (%) Efficiency (%) 9 V Efficiency vs. Load Vac 115 Vac 230 Vac 265 Vac % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Load (%) Figure 8 9V Efficiency Plot V Efficiency vs. Load Vac 115 Vac 230 Vac 265 Vac % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Load (%) Figure 9 15V Efficiency Plot January, 2019, Rev
14 Efficiency (%) Efficiency (%) 20 V Efficiency vs. Load Vac 115 Vac 230 Vac 265 Vac % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Load (%) Figure 10 20V Efficiency Plot 92 4 Point Average Efficiency Vac 230 Vac Limit Output Voltage (V) Figure 11 4-Point Average Efficiency Plot January, 2019, Rev
15 Waveforms Figure 12 Steady State ACF Operation Figure 13 Steady State DCM Operation January, 2019, Rev
16 Figure 14 DCM to ACF Transition January, 2019, Rev
17 Time from Applying Vac to First Switch Figure Vac Input, Time from Vac to First Switch Figure Vac Input, Time from Vac to First Switch January, 2019, Rev
18 Time from Switch to 5 Vout Figure Vac Input, Time from First Switch to 5 Vout Figure Vac Input, Time from First Switch to 5 Vout January, 2019, Rev
19 Output Ripple (Taken at output for 3A Load) Figure VAC 5 Vout Ripple Figure VAC 5 Vout Ripple Zoom January, 2019, Rev
20 Figure VAC 5 Vout Ripple Figure VAC 5 Vout Ripple Zoom January, 2019, Rev
21 Figure VAC 9 Vout Ripple Figure VAC 9 Vout Ripple Zoom January, 2019, Rev
22 Figure VAC 9 Vout Ripple Figure VAC 9 Vout Ripple Zoom January, 2019, Rev
23 Figure VAC 15 Vout Ripple Figure VAC 15 Vout Ripple Zoom January, 2019, Rev
24 Figure VAC 15 Vout Ripple Figure VAC 15 Vout Ripple Zoom January, 2019, Rev
25 Figure VAC 20 Vout Ripple Figure VAC 20 Vout Ripple Zoom January, 2019, Rev
26 Figure VAC 20 Vout Ripple Figure VAC 20 Vout Ripple Zoom January, 2019, Rev
27 Transient Response (0.1A 3A, 150 ma/us, 20 ms) Figure VAC 5 Vout Transient Figure VAC 5 Vout Transient January, 2019, Rev
28 Figure VAC 9 Vout Transient Figure VAC 9 Vout Transient January, 2019, Rev
29 Figure VAC 15 Vout Transient Figure VAC 15 Vout Transient January, 2019, Rev
30 Figure VAC 20 Vout Transient Figure VAC 20 Vout Transient January, 2019, Rev
31 Thermal Data 115 VAC Full Load January, 2019, Rev
32 January, 2019, Rev
33 230 VAC Full Load January, 2019, Rev
34 January, 2019, Rev
35 BOM MAIN BOARD Reference Qty Value Tolerance Footprint Manufacturer Manufacturer Part Number BD V/2A 4-SMD Comp Chip Z4DGP408L-HF C10 C20 2 1nF ±5% 402 Murata GMD155R71H102KA01D C uF ±20% (13X5x11)mm Kemet R46KF310000P1M C uF/25V ±20% (10.5x13)mm Kemet A750MS477M1EAAE (4520 C12 C pF ±10% Metric) Knowles Syfer 1808YA250331KXTSY2 C pf ±10% 603 TDK C1608CH2E151K080AA C pf ±5% 402 Kemet C0402C331J3GAC7867 C15 C29 2 NI 402 C17-18 C23-24 C26 C µF ±10% 402 TDK CGA2B3X5R1V104K050BB C uf ±20% 603 Murata GCM188R71E104KA57D C uf ±20% 1210 KEMET C1210C104KBRAC7800 C25 1 NI ±10% 805 C uf ±10% 805 Taiyo Yuden HMK212BBJ105KG-TE C uF ±20% 603 Kemet GRM188R6YA225MA12D C uF ±20% (12.X5)mm Wurth Electronics Inc C32 C38-39 C µF ±10% 1210 TDK Corporation C3225X7T2W224K200AA C uF ±20% 603 Kemet GRM188R6YA225MA12D C34-35 C40 C pF ±5% 402 Murata GRM1555C1H391JA01J C36 C45 C50 C uf ±20% 1206 TDK C3216X5R1V226M160AC C37 C49 2 NI 402 C n ±5% 402 Kemet C0402C822J5RAC786 C µf ±20% (8X14)mm Wurth C nF ±10% 402 Murata GCM155R71H103KA55D C nf ±10% 402 TDK C1005X6S1H473M050BB C uf ±20% 603 Murata GRT188R61C106ME13D C48 1 1uF ±5% 402 TDK C1005x5R1E105k050BC C5 C uf ±5% 402 TDK CGA2B3X7S1A334M050BB C uf ±20% 603 Murata GRT188R6YA475ME13D C6 C19 C uF ±10% 603 Samsung CL10A105KL8NNNC C µf ±20% (14.5X42)mm United Chemi-Con EKXJ401ELL101MU40S 1808 ( R29W102KV3E-****- C8 C pF ±10% Metric) Johanson Dielectrics Inc. SC C pf ±5% 402 Kemet C0402C101J1HACTU CON1 1 NA NA THT/SM Wurth D10 D V NA X2DFN2 ON Semiconductor NSPU3051N2T5G D V NA X2DFN2 ON Semiconductor ESD7241N2T5G D17 1 NI SOD-523 D3 D V 1 A NA SOD-123T ON Semiconductor ES1JFL D4 D V 200mA NA SOD-323F Panasonic DA2JF8100L D5 D11 D13 D V 1.5A NA DSN2(0603) ON Semiconductor NSR15405NXT5G D V 200mA NA SOD-323 ON Semiconductor MMDL914T1G January, 2019, Rev
36 Reference Qty Value Tolerance Footprint Manufacturer Manufacturer Part Number D7 D14 D V 200mA NA SOD-523 ON Semiconductor NSD914XV2T1G D V 2A NA SMA STMicroelectronics STPS2150A F A 250V (8.5x4x8) mm Littelfuse Inc F-1 S-1 2 WP NA WURTH r00 F-2 S-2 2 WP 32AWG NA WURTH r00 J NA NA 2X3mm NA NA L N 2 L uh 20% (5.50x 5.30) Wurth L uh 10% D = 7.8mm Wurth Q V 9A NA ThinPak 8X8 Infineon Technologies IPL60R385CPAUMA1 Q15 1 NI SOT-23 Q mohm 5X6 SO8 Vishay SI7145DP-T1-GE3 Q V 9A NA ThinPak 8X8 Infineon Technologies IPL60R299CP 120V 11 Q7 1 mohm NA SOIC8_FL ON Semiconductor/Fairchild FDMS86202 R1 R k ±1% 402 Yageo RC0402FR-07365KL R11 1 1M ±5% 1206 Vishay CRCW12061M00JNEAHP R R ±1% 402 Yageo RC0402FR-07732RL R13 R k ±1% 402 Yageo RC0402FR-0749K9L R14 1 1R0 NA 603 Vishay CRCW06031R00JNEA R R ±1% 805 Vishay RCS RJNEA R16 R m ±1% 805 Vishay RCWE0805R430FKEA R k ±1% 402 Vishay CRCW040223K2FKEDC R k ±1% 402 stackpole RMCF0402FT59K0 R2 R k ±1% 402 stackpole RMCF0402FT100K R k ±1% 402 Yageo RC0402FR-077K32L R24 R k ±1% 1206 Vishay CRCW12061K50JNEA R k ±1% 402 Yageo C0402FR-0749K9L R26 1 5mOhm ±1% 1206 Visahy WSLP12065L000FEA R k ±1% 402 Yageo RC0402FR-07165KL R28 1 0R0 NA 402 Panasonic Electronic Components ERJ-2GE0R00X R29 1 1R0 ±1% 402 Vishay CRCW04021R00JNEDIF R k ±1% 402 Yageo RC0402FR-0746K4L R30 R34 2 0R0 NA 402 Panasonic Electronic Components ERJ-2GE0R00X R k ±1% 402 Vishay CRCW040247K0FKEDC R R ±1% 402 Vishay CRCW040251R0JNED R k ±1% 402 Vishay CRCW040211K5FKED R35 1 NI 402 R k ±1% 402 Vishay CRCW040215K0JNED R k ±1% 402 Yageo RC0402FR-0722K1L R k ±1% 402 Vishay CRCW KFKEDC R40 R R ±1% 402 Vishay CRCW040222R1FKED R k ±1% 402 Yageo RC0402FR-072K32L January, 2019, Rev
37 Reference Qty Value Tolerance Footprint Manufacturer Manufacturer Part Number R R0 ±1% 402 Vishay CRCW040210R0FKED R46 1 1M ±1% 402 Vishay CRCW04021M00FKEDC R k ±1% 402 Vishay CRCW04025K11FKTD R k ±1% 402 Vishay RC0402FR-07121KL R k ±1% 402 Murata NCP15WM224J03RC R5 1 1k ±1% 402 Vishay CRCW04021K00FKTD R k ±1% 603 Vishay CRCW060310K0FKEB R k ±1% 402 Vishay RC0402FR-07365KL R M ±1% 402 Vishay CRCW04022M55FKED R53 R55 2 NI 402 R6 R R0 NA 603 Vishay CRCW060315R0JNEA R7 1 10R0 ±1% 402 Vishay CRCW040210R0FKED R8 R R0 NA 603 Vishay CRCW060322R0JNEA R k ±1% 402 Vishay CRCW04024K02FKEDHP T uf 10% RM8LP Wurth rev 04 T2 1 NI U1 1 65W na QFN16 Weltrend WT6615F 30V 1000 U2 1 MHz Tssop 16 ON Semiconductor NCP1568C U3-4 2 ADJ 1% XDFN6 ON Semiconductor NCP4623HMXADJTCG U5 1 20V NA DFN8 ON Semiconductor NCP4306AADZZZAMNTWG U % DFN 3X3 TI LT3014BEDD#PBF U7 1 NA DFN 10 4X4mm ON Semiconductor NCP51530AMNTWG 4-SMD, Gull U V 50mA NA Wing CEL FODM8801BV Z V 200mW ±5% SOD ON Semiconductor MM5Z6V8T1G Z3 1 NI SOD Z4 1 22V 500mW ±5% SOD ON Semiconductor MM5Z22VT1G January, 2019, Rev
38 2019 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: Bryan McCoy, Bryan.McCoy@onsemi.com Anthony Nasir, Anthony.Nasir@onsemi.com January, 2019, Rev
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