© Semiconductor Components Industries, LLC, 2018
August, 2018 − Rev. 1
1Publication Order Number:
EVBUM2566/D
EVBUM2566/D
Implementing All‐in‐One PC
Power Supply Evaluation
Board User's Manual
PC Power Supply with the NCP13992,
NCP1616, NCP4306 and NCP431
Description
This evaluation board user’s manual provides basic information
about a high efficiency, low no-load power consumption reference
design that was tailored to power All-in-One PC or similar type of
equipment that accepts 12 VDC on the input. The power supply
implements PFC front stage to assure unity power factor and low
THD, current mode LLC power stage to enhance transient response
and secondary side synchronous rectification to maximize efficiency.
This design note focuses mainly on the NCP13992 current mode LLC
controller description. Please use links in literature section to get
materials about NCP1616, NCP4306 and NCP431 to gain more
information about these devices.
The NCP13992 is a high performance current mode controller for
half bridge resonant converters. This controller implements 600 V
gate drivers, simplifying layout and reducing external component
count. The Controller also features built-in high voltage startup. The
Brown-Out input function eases implementation of the controller in all
applications. In applications where a PFC front stage is needed, the
NCP13992 features a dedicated output to drive the PFC controller.
This feature together with quiet skip mode technique further improves
light load efficiency of the whole application. The NCP13992
provides a suite of protection features allowing safe operation in any
application. This includes: overload protection, over-current
protection to prevent hard switching cycles, brown-out detection, open
optocoupler detection, automatic dead-time adjust, over-voltage
(OVP) and over-temperature (OTP) protections. The LLC current
mode means that the operating frequency of an LLC converter is not
controlled via voltage (or current) controlled oscillator but is directly
derived from the resonant capacitor voltage signal and actual feedback
level. This control technique brings several benefits compare to
traditional voltage mode controllers like improved line and load
transient response and inherent out of zero voltage switching
protection.
Table 1. GENERIC PARAMETERS
Device Applications Input Voltage
Nominal Output
Voltage/Current Output Power VOUT Ripple
NCP1616,
NCP13992, NCP4306
AOI,
Server Power
90 – 265 Vac 12 Vdc / 20 A 240 W < 150 mV
@ Full load
Efficiency
@ 230 V AC Standby Power
Operating
Temperature Cooling Topology Board Size
4 point AVG 94.11% < 135 mW 0 – 40°CConvection Open
Frame, Forced in
Frame
PFC CrCM
LLC + SR
194 × 108 × 27 mm
7.11 W/inch3
www.onsemi.com
Figure 1. Evaluation Board Picture
EVAL BOARD USER’S MANUAL
Key Features
•Wide Input Voltage Range
•High Efficiency
•Low No−load Power Consumption
•No Auxiliary SMPS, Fast Startup
•X2 Capacitor Discharge Function
•Near Unity Power Factor
•Low Mains & Overload Protection
•Thermal Protection
•Regulated Output Under any Conditions
•Excellent Load & Line Transient Response
•All Magnetics Available as Standard Parts
•Small Form Factor
•Universal Design for Multiple Controllers
Assembling Possibilities
•Extremely Low No−load Consumption
EVBUM2566/D
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2
Figure 2. AOI Demo-board Schematic − Primary Side
(Assembled Options on Standard Revision of the Demo)
VDR H10S 275TS E
T−4A
2n2/Y12n2/Y1
1uF /275Vac
0.05R / 2W
22k
GND
1uF /275Vac
1uF /275Vac
820n 100n
22k
22k
33nF /2kVdc
5k6
GND
100n
GND
2n2/Y1
4M7
V bulk
F C PF 22N60
F C PF 13N60
F C PF 13N60
100
0R
22R
22R
100n
MS R 860
5R 6
27k
FOD817B
220p/1kV
10n
13k
0R
10n
GND
MUR A160
1N5408
strap
MBR 2H100S FT3G
BC 807−16
47
1N4148
KBU810
33nF /2kVdc
NU
NU
3n9
GND
+17V
22R
30k
2u2
GND
GND GND
0R
470p
GND
0R
15V
22k
10n
GND
220u/35V
1M81M81M61M6
0R
20k
200k
100n
MBR 0540 MBR 0540
1R
1R
NCP13992AIOGE VB
GND
FOD817B
100u/25
GND
5k1
100p
GND
330k
20k
GND
BS S 138
4k7
100u/450V
100u/450V
100u/450V
0R
1k5
GND
4V3
2R
BAT54T1
220p/1kV
2k
90uH, 7447013
90uH, 7447013
GND
2k72k7
1n
GND
VC C INT
VC C INT
GND
S K129_GNDL
75k
220n
MR A4007T 3G
MR A4007T 3G
BAT54T1
VC C INT
+17V
220uF/35V
GND
2k72k7
1N4148
1N4148 33k
1M
1n
0R
150k
0R
1N4148
0R
0R
0R
0R
0R
47k
10n
0R
1n
GND
86k
86k
0R
10n
GND
680k
330k
1N4148
1k
BS S 138
GND
50uH, 750370249
NCP1616A1
GND GND
GND
GND
LN AC INPUT
90 − 265Vac
R 48
F 1
C Y1C Y2
C 15
R 38
R 33
C 33
C 47
C 40 C 41
R 20
R 36
C 18
R 104
C 54
C Y3
R 107
Q4
Q3
Q5
R 64
R 42
R 54
R 55
C 53
D5
R 96
R 105
3
4
OK1
C 29
C 34
R 67
R 72
C 57
D23
D4
R 91
D3
Q7
R 25
D7
B1
C 7
D9
D6
C 32
R 26
R 75
C 36
R 52
C 50
R 5
D2
R 4
C 2 C 3
R 18R 27R 35R 47
R 56
R 70
R 80
C 43
D13 D12
R 58
R 62
X2−1
X2−2
HV_IN
1
VB/PF C −F B
3
R E M
4
LLC _F B
5
LLC _C S
6
OVP/OT P
7
P_ON/OF F
8MODE 9
VC C 10
GND 11
MLOW 12
MUP 14
HB 15
VBOOT 16
IC3
3
4
OK3
C 37
R 126
C 44
NTC 1
R 133
Q6
R 66
C 38
C 55
C 16
R 147
R 148
D21
R 150
D26
C 17
R 63
L5
L6
R 87R 92
C 62
HE ATS INK_1
R 137
C 66
D22
D28
D19
C 56
R 6R 15
D1
D8
R 28
R 31
C 31
R 34
3
4
2
5*2
1
P E
R 1
R 16
D14
R 43
R 50
R 57
R 61
R 69
R 74
C 26
R 94
C 13
R 2
R 158
R 13
C 27
R 49
R 102
D17
R 24
Q8
L1
F B
1
VC NT R L
3
F F C NT R L
4
S T DBY/FAULT
2
C S /ZC D
5GND 6
DR V 7
VC C 8
HV 10
U1
+
+
+
+
+
INT
INT
INT
+
EVBUM2566/D
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3
Figure 3. AOI Demo-board Schematic − Secondary Side
(Assembled Options on Standard Revision of the Demo)
1000u/16V
1000u/16V
1000u/16V
220u/25V
820R
39k
47k
11k
150k
2n7
GND1
1000u/16V
1000u/16V
1000u/16V
1000u/16V
1000u/16V
GND1
GND1
0R
68k
56R
56R
0R0R
5k6
36k
6n8
6n8
1uF100n
100n 1uF
5k6
36k
22k
22k
4R 74R 7
56R
56R
NC P 4306AAAZZZA
GND1
GND1
NC P 4306AAAZZZA
GND1 GND1
GND1
GND1 GND1GND1 GND1
GND1
GND1GND1
NTMFS 5C 442
NTMFS 5C 442
NTMFS 5C 442
NTMFS 5C 442
0R
47k
12k
10n
82k
68k
1k
GND1
NC P 431
NC P 431
0R
0R
WW006
27k
27k
GND1GND1
GND1 GND1
100n100n
100n100n
GND1
C 21
C 22
C 23
C 12
R 85
R 89
R 95
R 98
R 99
C 51
1
2
C 9
C 24
C 8
C 10
C 11
X1−1
X1−2
X1−3
X1−4
R 78
R 88
R 9
R 41
R 3R 30
R 39
R 37
C 25
C 4
C 6C 5
C 19 C 20
R 11
R 7
R 12
R 51
R 10R 32
R 8
R 40
IC 4
DR V 8
GND 7
T R IG/DIS 5
C S 6
VCC
1
MIN_TOF F
2
MIN_TON
3
LLD
4
IC 5
DR V 8
GND 7
T R IG/DIS 5
C S 6
VC C
1
MIN_TOF F
2
MIN_TON
3
LLD
4
Q20
Q21
Q2
Q9
R 68
1
2
R 76
R 77
C 30
R 79
R 82
R 84
IC 6
AC
R
AC
R
IC 7
R 140
R 142
L4
11
9*2
8
R 100
R 101
C 59
C 63
C 71
C 73
+
+
+
+
+
+
+
+
+
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4
Figure 4. AOI Demo-board Schematic − Primary Side
(Assembled and also All Other Possible Options in PCB Layout)
VDR H10S 275TS E
T−4A
2n2/Y12n2/Y1
1uF/275Vac
0.05R / 2W
22k
GND
1uF/275Vac
1uF/275Vac
820n
NU 100n
GND
22k
22k
33nF/2kVdc
5k6
NU
GND
GND
NU
100n
NU
GND
2n2/Y1
4M7
V bulk
FC P F22N60
FC P F13N60
FC P F13N60
100
0R
22R 22R
100n
MS R 860
5R 6
27k
FOD817B
NU
220p/1kV
10n
13k
0R
10n
GND
MUR A160
NU
1N5408
strap
NU
MBR 2H100S FT3G
BC807−16
47 1N4148
KBU810
33nF/2kVdc
NU
NU
3n9
GND
+17V
NU
22R
30k
2u2
GND
GND GND
0R
GND
GND
GND
470p
GND
0R
15V
22k
10n
GND
220u/35V
1M8
1M8
1M6
1M6
0R
20k
200k
100n
MBR 0540 MBR 0540
1R 1R
NCP1399AIOGE VB
GND
NU
FOD817B
100u/25
GND
5k1
GND
100p
GND
330k
GND
NU
NU
20k
GND
NU
BS S 138
GND
4k7
NU
GND
100u/450V
100u/450V
100u/450V
NU
NU
0R
1k5
GND
4V3
1R
BAT54T1
220p/1kV
2k
90uH, 7447013
90uH, 7447013
GND
NU
2k7 2k7
1n
GND
NU
VC C INT
VC C INT
GND
S K129_GNDL
NCP1616A1
GND
75k
220n NU
NU
MR A4007T3G
MR A4007T3G
NU
NU
NU
NU
BAT54T1
VC C INT
+17V
220uF/35V
GND
2k7 2k7
1N4148
1N4148
NU
33k
GND
NU
1M
1n
0R
150k
0R
1N4148
0R
NU 0R
NU
0R
NU
NU
0R
0R NU
47k
NU
10n
0R
NU
NU
1n
GND
86k
86k
0R
10n
GND
680k
330k
NU
GND
1N4148
1k
BS S 138
GND
50uH, 750370249
LN AC INP UT
90 − 265Vac
Dual footprint
package
Dual footprint
package
Dual footprint
package
R 48
F1
C Y1C Y2
C 15
R 38
R 33
C 33
C 47
C 40
C 39 C 41
R 20
R 36
C 18
R 104
R 103
C 28
C 54
C 42
C Y3
R 107
Q4
Q3
Q5
R 64
R 42
R 54 R 55
C 53
D5
R 96
R 105
3
4
OK1
R 71
C 29
C 34
R 67
R 72
C 57
D23
L12
D4
R 91
L13
D3
Q7
R 25 D7
B1
C 7
D9
D6
C 32
R 97
R 26
R 75
C 36
R 52
C 50
R 5
D2
R 4
C 2
C 3
R 18
R 27
R 35
R 47
R 56
R 70
R 80
C 43
D13 D12
R 58 R 62
X2−1
X2−2
HV_IN
1
VB/P FC −FB
3
R E M
4
LLC _FB
5
LLC _C S
6
OVP /OTP
7
P _ON/OFF
8MODE 9
VC C 10
GND 11
MLOW 12
MUP 14
HB 15
VBOOT 16
IC3
3
4
OK2
3
4
OK3
C 37
R 126
C 44
NTC 1
D11
R 132
R 133
C 46
Q6
R 66
C 35
C 38
C 55
C 16
R 144
R 146
R 147
R 148
D21
R 150
D26
C 17
R 63
L5
L6
R 83
R 87 R 92
C 62
R 93
HE ATS INK_1
HVFB
1*2
FB
2*2
R S T
3
FOVP /BUV
4*2
VC NTR L
5*2
FFC NTR L
6
FAULT
7
S TDBY
8P S TMR 9
P FC OK 10
C S /ZC D11
GND 12*2
DR V 13*2
VC C 14
HV 16*2
U1
R 137
C 66 C 67
NTC 2
D22
D28
R 17
C 68
D18 R 14
D19
C 56
R 6 R 15
D1
D8
R 23
R 28
R 29
R 31
C 31
R 34
3
4
2
5*2
1
PE
R 1
R 16
D14
R 43
R 46 R 50
R 53
R 57
R 59
R 60
R 61
R 69 R 73
R 74
R 81
C 26
R 94
D15
D16
C 13
R 2
R 158
R 13
C 27
R 49 R 102
C 74
D17
R 24
Q8
L1
+
+
+
+
+
+
INT
INT
INT
+
2.5V
EVBUM2566/D
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5
Figure 5. AOI Demo-board Schematic − Secondary Side
(Assembled and also All Other Possible Options in PCB Layout)
1000u/16V
1000u/16V
1000u/16V
220u/25V
820R 39k
47k
11k 150k
2n7
NU
GND1
GND1
1000u/16V
1000u/16V
1000u/16V
1000u/16V
1000u/16V
GND1
GND1
NU
NU
NU
NU
GND1
0R
68k
56R
56R
0R
0R
5k6
36k
6n8
6n8
1uF
100n
100n
1uF
5k6
36k
22k
22k
4R 7
4R 7
56R
56R
NC P4306AAAZZZA
GND1
GND1
NC P4306AAAZZZA
GND1 GND1
GND1
GND1 GND1
GND1 GND1
GND1
GND1GND1
NTMFS 5C 442
NTMFS 5C 442
NTMFS 5C 442
NTMFS 5C 442
0R
GND1
NU NU
NU
NU
NU
NU
NU
NU
NUNUNU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU
NU(MMS D4148)
NU
NU
NU
NU
NU
47k
12k
10n
82k
68k
1k
GND1
NU
GND1
GND1
GND1GND1
GND1 GND1
NC P431
NC P431
0R
NU
0R
NU
NU
NU
NU
WW006
NU
NU
NU
27k
27k
NU
GND1
GND1
NU
GND1
GND1
100n100n
NUNU
NU
100n
NU
100n
C 21
C 22
C 23
C 12
R 85 R 89
R 95
R 98 R 99
C 51
C 49
1
2
C 9
C 24
C 8
C 10
C 11
X1−1
X1−2
X1−3
X1−4
C 48
R 86
D20
C 45
R 78
R 88
R 9
R 41
R 3
R 30
R 39
R 37
C 25
C 4
C 6
C 5
C 19
C 20
R 11
R 7
R 12
R 51
R 10
R 32
R 8
R 40
IC 4
DR V 8
GND 7
TR IG/DIS 5
C S 6
VC C
1
MIN_TOFF
2
MIN_TON
3
LLD
4
IC 5
DR V 8
GND 7
TR IG/DIS 5
C S 6
VC C
1
MIN_TOFF
2
MIN_TON
3
LLD
4
Q20
Q21
Q2
Q9
R 68
C 60 C 61
1
2
1
2
C 1
R 19
C 106
R 21
D105
IS NS 4
VS NS 1
OFFDE T 2
VMIN 3
VC C
8
DR IVE
6
LE D
5
GND
7
IC 101
R 117
R 118
R 127
R 119
R 120
C 108
R 22
C 111 R 128
R 116
C 109
LE D1
R 122
R 44
R 45
R 65
C 110
C 107
Q100
D112
R 125
R 124
C 14
R 123
D10
R 76
R 77
C 30
R 79
R 82
R 84
R 90
FBC
6
GND
7
IS NS 3
LE D 4
OFFDE T 2
ONOFF
5
VC C
8VS NS 1
IC 6
AC
R
AC
R
IC 7
R 140
R 141
R 142
R 143
Q10
R 121
R 131
L4
R 138
C 65
D27
11
9*2
8
R 100
R 101
C 52
C 58
C 59
C 63
C 64
C 69
C 70 C 71
C 72 C 73
+
+
+
+
+
+
+
+
+
+
EVBUM2566/D
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6
Detailed Descriptions of the Evaluation Board
The input EMI filter is formed by components L15, L5,
L6, C47, C33, CY1, CY2 and R48 – refer to Figure 2. The
inrush current limiting resistor R91 is substituted by strap in
this demo revision – one can replace it by appropriate NTC
inrush current limiter if needed. The U1 − NCP1616
(Figure 2) with diodes D22, D28 and resistors R6, R15 is
used to X2 capacitor discharge function after application is
disconnected from the mains. This circuit also provides PFC
Vcc Start-up feature and input voltage sensing, also is partly
shared for the LLC controller IC. The Power Factor
Corrector (PFC) power stage uses standard boost PFC
topology formed by power components B1, C15, L2, D4,
D5, Q4, R38, and bulk capacitors C16, C38, C55. The PFC
controller U1 (NCP1616) senses input voltage directly via
pin 10 (HV) through network above mentioned. The PFC
inductor current is sensed by the shunt resistor R38. The
series resistor R38 sets maximum PFC front stage peak
current. Maximum peak current level is to 10 A. The PFC
feedback divider is shared with LLC brown-out sensing
network in order to reduce application no-load power
consumption. The PFC FB divider is formed by resistors
R18, R27, R35, R47, R158, R63, R56, R34, R69, R74 and
R31. The FB signal is filtered by capacitor C13 and C31 to
overcome possible difficulties caused by the parasitic
capacitive coupling between pin and other nodes that handle
high dV/dt signals. The internal bulk voltage regulator
compensation C40, C36, R75 is connected through R61 to
the U1 pin 3. The PFC MOSFET is driven via circuitry R25,
D7, R26, R33 and Q7. This solution enables to define needed
turn-on and turn-off process speed for Q4. The PNP
transistor Q7 is connected directly source of Q4 (not through
sensing shunt R38) to minimize discharge loop and thus
allow fast turn off PFC switch and also minimizing EMI
caused by the driver loop. The PFC coil auxiliary winding
voltage after rectifying with D14 provides ZCD signal for
PFC controller. The NCP1616 has shared pin 5 − CS/ZCD
for current limit and zero current detection. During
turned-on Q4 is sensed and limited maximum input current
and after turning-off Q4 is detected zero current condition.
The resistance of R66 should be bigger than 3.9 kW to avoid
wrong detection of destroyed R38. Also, resistance R28
should be reasonable high enough to limit no-load and
light-load consumption.
The LLC power stage primary side converter composes
from these devices: MOSFETs Q3, Q5, external resonant
inductor L1, transformer TR1 and resonant capacitors C7,
C18. The IC3(NCP13992AIOGEVB) LLC controller
senses primary current indirectly – via resonant capacitor
voltage monitoring which is divided down by capacitive
divider C17, C29, C32 and C62.The capacitive divider has
to provide minimum phase shift between resonant capacitor
signal and divided signal on the LLC_CS pin. The capacitive
divider has to be loaded in the same time to assure fast
LLC_CS pin signal stabilization after application startup –
this is achieved by resistor R148.The series resistor R64 is
used to limit maximum current that can flow into the
LLC_CS pin. The FB optocoupler OK1 is connected to the
LLC_FB pin and defines converter output voltage by pulling
down this pin when lower output power is needed. Capacitor
C51 forms high frequency pole in FB loop characteristics
and helps to eliminate eventual noise that could be coupled
to the FB pin by parasitic coupling paths. The Brow-out
signal for LLC controller is derived from PFC feedback
divider – described before. A voltage taken from node R13,
R47 and R158, is impedance separated by voltage follower
Q8, which helps to avoid influencing bulk voltage
regulation. The voltage follower output feds R2 and R133
divider, which is minimizing Q8 thresh-hold voltage
temperature dependency. Divider output is filtered with C34
and connected to IC3 VB/PFC−FB pin. The Skip/REM pin
of the NCP13992 issued for skip threshold adjustment.
Resistors R103 and R104 are used for this purpose together
with noise filtering capacitor C57. The over-voltage and
over-temperature protections are implemented via
OVP/OTP pin by using resistors R126 and R67, temperature
dependent resistor NTC1, Zener-diode D21, filtering
capacitor C44 and optocoupler OK3. The OVP comparator
is located on the secondary side to assure maximum OVP
circuitry accuracy. The pin 8 P_ON/OFF is actually used for
defining minimum feedback voltage – lower saturation
level, which influences maximum switching frequency. For
this purpose serve R105 and C26 decouples noise. The
stand-by mode − burst mode of the PFC stage and bulk
voltage are controlled by NCP13992 via MODE pin 9,
which goes high during LLC stage switching and during idle
falls to low level. While skip mode operation occurs, the
LLC controller forces the PFC controller into STAND-BY
mode by the MODE pin 9 via circuitry R80, C43, R70 and
R50. Positive hiccup mode is implemented such way, that
MODE pin influences FB divider and changes lower restart
level from lower value to higher value. This is realized by
network with D17, R102 and 49. These changes help to
achieve very low no-load consumption.
The VCC decoupling capacitor C54 and also bootstrap
capacitor for high side driver powering C53 are located as
close to the LLC controller package as possible to minimize
parasitic inductive coupling to other IC adjust components
due to high driver current peaks that are present in the circuit
during drivers rising and falling edges transitions. The
bootstrap capacitor is charged via HV bootstrap diode D23
and series resistor R96 which limits charging current and
Vboot to HB power supply slope during initial C53 charging
process. The gate driver currents are reduced by added series
resistors R54, R55 to optimize EMI signature of the
application. For fastening the mosfets turn-off process are
used serial R−D particles composed with R58−D13 and
R62−D12. The primary controllers bias voltage limiter
circuitry is used in order to restrict upper value of the
primary VCC voltage to approximately 13 V. The VCC
limiter composes of these components: resistors R150,R4,
R5 capacitors C2, C3, diodes D3, D26 and transistor Q6.The
secondary side synchronous rectification uses IC4 and IC5
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7
SR controllers – NCP4306. Two MOSFTEs are connected
in parallel for each SR channel to achieve low total drop −
Q2, Q9 and Q20, Q21. RC snubber circuits C4, R8, R9 and
C25, R40, R41 are used to damp down the parasitic ringing
and thus limit the maximum peak voltage on the
SRMOSFETs. The SR controllers are supplied from
converter output via resistors R68, R10 and R32. These
resistors form RC filter with decoupling capacitors C5, C6
and C19, C20. The minimum on-time – R11, R39 and
minimum off-time – R7, R37 resistors define needed
blanking periods that help to overcome SR controllers false
triggering to ringing in the SR power stage. Each SR
controller uses very clever light load detection feature
(LLD). After first incoming pulse from burst, the LLD
feature wakes-up controller from low power mode (50 mA)
and prepare it to operate. As last pulse from the burst ends
controller enters to stand-by mode after defined period,
which is set with resistor (R100 and R101). Instead of the
complicated light-load guard circuitry, just one additional
resistor is needed for setup. The NCP4306 LLD feature
offers great benefits compare to the traditional solutions, in
which SR operation and no-load consumption is much less
efficient. The output filtering capacitor bank composes from
low ESR electrolytic capacitors C8 to C11, C21 to C24 and
ceramic capacitors C59 to C73. Output filter L4, C12 is used
to smooth output voltage from switching glitches. L4 is
600 nH inductor in case of need can be replaced with
different product which enables higher dI/dt slope load. The
output voltage of the converter is regulated by standard
shunt regulator NCP431−IC6. The regulation optocoupler
OK1 is driven via resistor R85 which defines loop gain. The
NCP431 is biased via resistor R88 in case there is no current
flowing via regulation optocoupler – which can happen
before the nominal VOUT level is reached or during
transients from no-load to full-load conditions. The output
voltage is adjusted by divider R89 and R98, R99. The
feedback loop compensation network is formed partially by
resistor R95 and capacitor C51. The secondary side OVP
sense circuitry is also using NCP431 reference (IC7) to
achieve precise OVP trip point. The OVP threshold is
adjusted by resistor divider R76, R77and R79. The bias
current of OVP optocoupler OK3 is limited by resistor R84
and IC7 is biased via resistor R82. Capacitor C30 slows
down OVP reaction speed and helps overcome false
triggering by noise. There are several options prepared in the
PCB layout so that customer can modify demo-board
according to required of target application – please refer to
Figure 4 and 5 for schematic that shows all options included
in the PCB. The PCB consists of a 2 layer FR4 board with
70 mm copper thickness to minimize parasitic resistance in
secondary side where high currents are conducted. Leaded
components are assembled form the top side of the board and
all SMT components are place from the bottom only so that
wave soldering process can be used for production. The
board was design to work as open frame with natural air flow
cooling. The LLC transformer temperature reaches
approximately 90°C for Tambient = 25°C and full load.
Forced air flow cooling management should be considered
in case the board is packed into some box or target
application.
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Figure 12. Overall Efficiency vs. Output Power
76
78
80
82
84
86
88
90
92
94
96
0 50 100 150 200 250
Efficiency [%]
Output Power [W]
Overall Efficiency at 115 V AC
Overall Efficiency at 230 V AC
Table 2. EFFICIENCY DATA MEASURED AND AVERAGED FROM 10 BUILT DEMO_BOARDS
LOAD
Consumption [mW] of Efficiency [%]
@ 120 VAC @ 230 VAC
NO−LOAD < 115 mW < 125 mW
Load 250 mW 0,466 0,475
Load 500 mW 0,72 0,823
Load 20% − 4A 90,22 91,47
Load 25% − 5A 91,82 92,95
Load 50% − 10 A 93,39 94,36
Load 75% − 15 A 93,13 94,62
Load 100% − 20 A 92,57 94,5
4 point AVG 92,73 94,11
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The following figures illustrate conduced EMI signatures under full loading for different input line voltage levels.
Figure 13. EMI Signature Comparison @ 120 VAC & Full-load (Measured MAX Peak)
Figure 14. EMI Signature Comparison @ 230 VAC & Full-load (Measured MAX Peak)
Figures 15 to 16 are focused on transient response, which
is highly depended (when is expected correct feedback loop
behavior) on loading current slope and output optional post
filter composed of L4 and C12. In case, that higher current
slope and lower voltage drop are needed inductor L4 can be
replaced by new one with lower inductance. Figure 17 show
power supply input current shape for different input line
voltage levels under full loading. Figures 18–20 are
intended to LLC stage operation.
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Figure 15. Step Load Response 20 A to 2 A − 50 A/s (Right Measured without Post Inductor)
Figure 16. Step Load Response 20 A to 2 A − 50 A/s (Right Measured without Post Inductor)
Figure 17. PFC Input Current @ 240 W Load @ 115 VAC − Left, @ 230 VAC Right
CH1 – LLC Low Side
M OSFET Gate−Drive Voltage
CH2 – Output Voltage CH3 – LLC HB Node Voltage CH4 – Loading current
CH1 – LLC Low Side
M OSFET Gate−Drive Voltage
CH2 – Output Voltage CH3 – LLC HB Node Voltage CH 4 – Loading current
CH1 – N/A CH 2 – N/A CH3 – N/A CH4 – Input line current
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Figure 18. LLC Stage Start-up Sequence into Full-load Detail − Left, LCC Stage NO-LOAD Burst Detail − Right
Figure 19. LLC Stage SKIP Mode Operation at 0.5 A Load (Burst Detail) − Left,
Light-load Mode Operation at 2 A Load − Right
Figure 20. LLC Stage Normal Operation 10 A Load − Left, LLC Stage Normal Operation 20 A Load − Right
CH1 – LLC Low Side
M OSFET Gate−Drive Voltage
CH 2 – N/A CH3 – LLC HB Node Voltage CH4 – Resonant tank current
CH1 – LLC Low Side
M OSFET Gate−Drive Voltage
CH2 – N/A CH3 – LLC HB Node Voltage CH 4 – Resonant tank current
CH1 – LLC Low Side
M OSFET Gate−Drive Voltage
CH2 – N/A CH3 – LLC HB Node Voltage CH 4 – Resonant tank current
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Figure 21. PFC Vbulk Building @ 230 VAC @ 20 A Load − Left,
PFC SKIP MODE at 0.5 A Load (Burst Detail) − Right
Figure 22. PFC, DCM @ 120 VAC 1.5 A Load − Left, PFC, CrM @ 120 VAC 20 A Load − Right
Figure 23. SR Waveforms during VOUT Building into Full Load − Left, SR NORMAL MODE @ Load 20 A − Right
CH1 – PFC M OSFET Gate−
Drive Voltage
CH 2 – Bulk Voltage CH3 – PFC M OSFET Drain
Voltage
CH4 – PFC inductor current
CH1 – PFC M OSFET Gate−
Drive Voltage
CH 2 – Bulk Voltage CH3 – PFC M OSFET Drain
Voltage
CH4 – PFC inductor current
CH1 – PFC M OSFET Gate−
Drive Voltage
CH 2 – Bulk Voltage CH3 – PFC M OSFET Drain
Voltage
CH4 – PFC inductor current
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Figure 24. SR Waveforms during Overload from 20 A to 25 A (FB Fault 100 ms) − Left,
SR Waveforms during Hard Overload from 20 A to 50 A (CS Stop) − Right
CH1 – SR1 V DS Voltage CH1 – SR2 V DS Voltage CH 3 – Output Voltage CH4 – Load current
Literature
•High Performance Current Mode Resonant Controller with Integrated High Voltage Drivers:
NCP13992: http://www.onsemi.com/PowerSolutions/product.do?id=NCP13992
•Power Factor Controller, High Voltage Active X2:
NCP1616: http://www.onsemi.com/PowerSolutions/product.do?id=NCP1616
•Secondary Side Synchronous Rectifier Controllers:
NCP4306: http://www.onsemi.com/PowerSolutions/product.do?id=NCP4306
•Voltage Reference, Programmable Shunt Regulator:
NCP431: http://www.onsemi.com/PowerSolutions/product.do?id=NCP431
•N-Channel SupreMOS® MOSFET 600 V, 22 A, 165 mW
FCPF22N60NT: http://www.onsemi.com/PowerSolutions/product.do?id=FCPF22N60NT
•Power Rectifier, Soft Recovery, Switch-mode, 8 A, 600 V
MSR860: http://www.onsemi.com/PowerSolutions/product.do?id=MSRF860G
•N-Channel SupreMOS® MOSFET 600 V, 13 A, 258 mW
FCPF13N60NT: http://www.onsemi.com/PowerSolutions/product.do?id=FCPF13N60NT
•Single N-Channel Power MOSFET 40 V, 130 A, 2.5 mW
NVMFS5C442NL: http://www.onsemi.com/PowerSolutions/product.do?id=NVMFS5C442NL
EVBUM2566/D
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Table 3. BILL OF MATERIALS
Reference Qty. Description Value Footprint Manufacturer
Manufacturer
Part Number Substitution
B1 1 Bridge Rectifier KBU8M Through Hole Vishay KBU8M−E4/51 Yes
C12 1 Electrolytic Capacitor 220 mF/25 V Through Hole Panasonic EEU FC1E221 Yes
C13, C31, C62 3Ceramic Capacitor 1 nF/50 V C 0805 Various
C15, C33, C47 3MKP Capacitor 1mF/275 Vac Through Hole Würth Elektronik MXXP225105K310ASPB
46000
Yes
C16, C38, C55 3Electrolytic Capacitor 100 mF/450 V Through Hole Rubycon 450BXW100MEFC18X30 Ye s
C17, C29 2Ceramic Capacitor 220 pF/1 kV Through Hole Vishay S221M39SL0N63K7R Yes
C2, C26, C27, C30,
C34, C57
6Ceramic Capacitor 10 nF/50 V C 0805 Various −Ye s
C3 1 Electrolytic Capacitor 220 mF/35 V Through Hole Panasonic EEU FM1V221L Yes
C32 1 Ceramic Capacitor 39 nF/50 V C 0805 Various −Ye s
C36 1 Ceramic Capacitor 2.2 mF/16 V C 0805 Various −Ye s
C37 1 Electrolytic Capacitor 100 mF/25 V Through Hole Panasonic EEU−TA1E101BJ Yes
C4, C25 2Ceramic Capacitor 6.8 pF/50 V 1206 Various −Yes
C40 1 Ceramic Capacitor 820 nF/16 V C 0805 Various −Yes
C44 1 Ceramic Capacitor 100 pF/50 V C 0805 Various −Yes
C5, C19, C41, C43,
C53, C54, C59, C63,
C71, C73
10 Ceramic Capacitor 100 nF/50 V C 0805 Various −Yes
C50 1 Ceramic Capacitor 470 pF/50 V C 0805 Various −Yes
C51 1 Ceramic Capacitor 27 nF/50 V C 0805 Various −Ye s
C56 1 Electrolytic Capacitor 220 mF/35 V Through Hole Panasonic EEU FM1V221L Yes
C6, C20 2Ceramic Capacitor 1mF/25 V C 0805 Various −Yes
C66 1 Ceramic Capacitor 220 nF/16 V C 0805 Various −Yes
C7, C18 2Metal Film Capacitor 33 nF/630 V Through Hole Epcos B32652A6333J Yes
C8, C9, C10, C11,
C21, C22, C23, C24
8Electrolytic Capacitor 1000 mF/16 V Through Hole Panasonic P15332CT ND Yes
CY1, CY2, CY3 3Y Capacitor 22 nF/Y1 Through Hole Murata DE1E3KX222MA5BA01
D1, D7, D8, D14,
D17
5 Diode MMSD4148 SOD123 ON Semiconductor MMSD4148T3G No
D12, D13 2Schottky Diode MBR0540 SOD123 ON Semiconductor MBR0540T1G No
D19, D26 2Schottky Diode BAT54 SOD123 ON Semiconductor BAT54T1G No
D2 1 Zener Diode 15 V SOD123 ON Semiconductor MMSZ15T1G No
D21 1 Zener Diode 4.3 V SOD123 ON Semiconductor MMSZ4V3T1G No
D22, D28 2Power Rectifier Diode MRA4007T3G SMA ON Semiconductor MRA4007T3G No
D23 1 Ultrafast Power
Rectifier Diode
MURA160 SMA ON Semiconductor MURA160T3G No
D3 1 Schottky Diode MBR2H100 SOD123 ON Semiconductor MBR2H100SFT3G No
D4 1 Standard Recovery
Rectifier Diode
1N5408 Through Hole ON Semiconductor 1N5408RLG No
D5 1 Soft Recovery
Rectifier Diode
MSR860 TO220 ON Semiconductor MSRF860G No
D6, D9 2 Diode NU − − − −
F1 1 FUSE HOLDER +
4A/T Fuse
T−4A Through Hole Various −Yes
IC3 1 LLC Controller NCP13992 NCP1399 ON Semiconductor NCP13992AIOGEVB No
IC4, IC5 2 Synchronous
Rectifier Controller
NCP4306 SOIC8 ON Semiconductor NCP4306AAAZZZA No
IC6, IC7 2Shunt Regulator NCP431 SOT23 ON Semiconductor NCP431AVSNT1G No
L1 1 Power Resonant
Inductor
50 mHRM8 Würth Elektronik 750370249 Ye s
L15 1 Common Mode
Inductor
2.9 mH Through Hole ICE Components LF−28030−0029−H No
L2 1 PFC Inductor 260 mHPQ3225 Würth Elektronik 750315036 Yes
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Table 3. BILL OF MATERIALS (continued)
Reference Substitution
Manufacturer
Part Number
ManufacturerFootprintValueDescriptionQty.
L4 1 High Current Inductor 300 nH/30 A Through Hole Würth Elektronik WW006 Yes
L5, L6 2EMI Inductor 90 mHThrough Hole Würth Elektronik 7447013 Yes
NTC1 1 NTC Thermistor 330 kWThrough Hole Vishay NTCLE100E3334JB0 Yes
OK1, OK3 2 Optocoupler FOD817B Through Hole ON Semiconductor FOD817B No
Q2, Q9, Q20, Q21 4 N−channel MOSFET NTMFS5C442 SO−8FL/DFN−5ON Semiconductor NTMFS5C442NLTT1G No
Q3, Q5 2 N−channel MOSFET FCPF13N60 TO220 ON Semiconductor FCPF13N60NT No
Q4 1 N−channel MOSFET FCPF22N60 TO220 ON Semiconductor FCPF22N60NT No
Q6 1 N−channel MOSFET BSS138 SOT23 ON Semiconductor BSS138LT1G Yes
Q7 1 PNP Transistror BC807−16 SOT23 ON Semiconductor BC807−16LT1G Yes
Q8 1 N−channel MOSFET BSS138 SOT23 ON Semiconductor BSS138LT1G Yes
R1, R99 2 Resistor 150 kWR 0805 Various −Yes
R10, R32 2 Resistor 4.7 W/5% R 0805 Various −Yes
R100, R101, R105 3 Resistor 27 kWR 0805 Various −Ye s
R102 1 Resistor 330 kWR 0805 Various −Yes
R107 1 Resistor 47 MW/5% Through Hole Vishay VR37000004704JA100 Yes
R11, R39, R104 3 Resistor 5.6 kWR 0805 Various −Yes
R126 1 Resistor 5.1 kWR 0805 Various −Yes
R137 1 Resistor 75 kWR 0805 Various −Ye s
R148 1 Resistor 1.5 kWR 0805 Various −Yes
R150 1 Resistor 2W/5% R 0805 Various −Yes
R18, R27 2 Resistor 1.8 MWR 0805 Various −Yes
R2, R158 2 Resistor 86 kWR 0805 Various −Yes
R24, R84 2 Resistor 1kWR 0805 Various −Yes
R25 1 Resistor 47 W/5% R 0805 Various −Yes
R26, R54, R55 3 Resistor 22 W/5% R 0805 Various −Yes
R28 1 Resistor 33 kWR 0805 Various −Yes
R3, R5, R13, R16,
R30, R34, R43, R50,
R56, R57, R61, R69,
R72, R78, R94,
R140, R142, R147
18 Resistor 0WR 0805 Various −Yes
R31 1 Resistor 1MWR 0805 Various −Yes
R35, R47 2 Resistor 1.6 MWR 0805 Various −Yes
R38 1 Resistor 0.05 W/3 W Through Hole Vishay/ Dale LVR03R0500FR50 Yes
R4, R12, R20, R33,
R36, R51
6 Resistor 22 kWR 0805 Various −Yes
R42, R52, R68 3 Resistor 0WR 1206 Various −Yes
R48 1 VARISTOR 275 VAC Through Hole Würth Elektronik 820512711 Yes
R49 1 Resistor 680 kWR 0805 Various −Yes
R58, R62 2 Resistor 1W/5% R 0805 Various −Ye s
R6, R15, R87, R92 4 Resistor 2.7 kWR 1206 Various −Yes
R63 1 Resistor 2kWR 0805 Various −Ye s
R64 1 Resistor 100 WR 0805 Various −Yes
R66 1 Resistor 4.7 kWR 0805 Various −Yes
R67 1 Resistor 13 kWR 0805 Various −Yes
R7, R37 2 Resistor 36 kWR 0805 Various −Yes
R70, R133 2 Resistor 20 kWR 0805 Various −Yes
R74, R76, R95 3 Resistor 47 kWR 0805 Various −Yes
R75 1 Resistor 30 kWR 0805 Various −Yes
R77 1 Resistor 12 kWR 0805 Various −Yes
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Table 3. BILL OF MATERIALS (continued)
Reference Substitution
Manufacturer
Part Number
ManufacturerFootprintValueDescriptionQty.
R79 1 Resistor 82 kWR 0805 Various −Yes
R8, R9, R40, R41 4 Resistor 56 W/5% R 1206 Various −Yes
R80 1 Resistor 200 kWR 0805 Various −Yes
R82, R88 2 Resistor 68 kWR 0805 Various −Yes
R85 1 Resistor 820 WR 0805 Various −Yes
R89 1 Resistor 39 kWR 0805 Various −Yes
R91 1 VARISTOR strap − − − Yes
R96 1 Resistor 5.6 /5% R 0805 Various −Ye s
R98 1 Resistor 11 kWR 0805 Various −Yes
TR1 1 LLC Transformer Lpri = 600 mHPQ3225 Würth Elektronik 750314580 Yes
U1 1 Power Factor
Controller
NCP1616A1 SO9 ON Semiconductor NCP1616A1 No
X1 1 Wire to board
terminal
Pitch 5 mm Through Hole IMO 20.700M/2 Yes
X2 1 Wire to board
terminal
Pitch 5 mm Through Hole Lumberg KRE 02 Yes
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