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Design of a QR Adapter with Improved Efficiency and Low Standby Power
Agenda
1. Quasi-Resonance (QR) Generalities
2. The Valley Lockout Technique
3. The NCP1379/1380
4. Step by Step Design Procedure
5. Performances of a 60 W Adapter Featuring
Valley Lockout
Agenda
1. Quasi-Resonance (QR) Generalities
2. The Valley Lockout Technique
3. The NCP1379/1380
4. Step by Step Design Procedure
5. Performances of a 60 W Adapter Featuring
Valley Lockout
What is Quasi-Square Wave Resonance ?
• MOSFET turns on when VDS(t) reaches its minimum value.
Minimizes switching losses
Improves the EMI signature
MOSFET turns on in first valley MOSFET turns on in second valley
valley
Quasi-Resonance Operation
• In DCM, VDS must drop from (Vin + Vreflect) to Vin
• Because of Lp-Clump network oscillations appear
• Oscillation half period:
Vin + Vreflect
Vin
VDSLp
Vin
SW Clump
RloadCout1 : N Vout
VDS
Vin
x p lumpt L Cπ=
A Need to Limit the Switching Frequency
• In a self-oscillating QR, Fsw increases as the load decreases
• 2 methods to limit Fsw:– Frequency clamp with frequency foldback
– Changing valley with valley lockout
Higher losses at light load if Fsw is not limited
Frequency Clamp in QR Converters
In light load, frequency increases and hits clampMultiple valley jumpsJumps occur at audible rangeCreates signal instability
Second valley First valley
QR mode
Agenda
1. Quasi-Resonance (QR) Generalities
2. The Valley Lockout Technique
3. The NCP1379/1380
4. Step by Step Design Procedure
5. Performances of a 60 W Adapter Featuring
Valley Lockout
0
10000
20000
30000
40000
50000
60000
70000
80000
0 10 20 30 40 50 60
OUTPUT POWER (W)
SWIT
CHIN
G F
REQ
UENC
Y (H
z)
1st2nd3rd4th
VCO mode
QR operation
The Valley Lockout• As the load decreases, the controller changes valley (1st to 4th valley in
NCP1380)• The controller stays locked in a valley until the output power changes
significantly.
12 3 4
VCO mode
– No valley jumping noise– Natural switching frequency limitation
The Valley Lockout• FB comparators select the valley and pass the information to a
counter.• The hysteresis of FB comparators locks the valley.• 2 possible operating set points for a given FB voltage.
VFB decreases (POUT decreases)
VFB increases (POUT increases)
1st
2nd
3rd
4th
VCO
3.22.82.01.20.8 1.6 VFB (V)2.4
Agenda
1. Quasi-Resonance (QR) Generalities
2. The Valley Lockout Technique
3. The NCP1379/1380
4. Step by Step Design Procedure
5. Performances of a 60 W Adapter Featuring
Valley Lockout
• Operating modes:– QR current-mode with valley lockout for noise immunity– VCO mode in light load for improved efficiency
• Protections– Over power protection– Soft-start– Short circuit protection– Over voltage protection– Over temperature protection– Brown-Out
NCP1379/1380 Features
HV-bulk
DovpZCD / OPP
1
2
3
4 5
8
6
7
NC
P138
0 C
/DFB
CS
Rzcd1
GND
Rzc
d2
Czc
d
Rst
art
Ct
Cvcc
Ct
DRV
Vcc
OVP/BO
Rbol
Rbou
Mass production: Q4 2009
QR Mode with Valley Lockout• Operating principle:
– Locks the controller into a valley (up to the 4th) according to FB voltage.– Peak current adjusts according to FB voltage to deliver the necessary
output power.
12 3 4
VCO mode
• Advantages– Solves the valley jumping instability in QR converters– Achieves higher min Fsw and lower max Fsw than in traditional QR converters– Reduce the transformer size
Fsw (Pout) for a 60 W adapter
0.00E+00
2.00E+04
4.00E+04
6.00E+04
8.00E+04
1.00E+05
1.20E+05
1.40E+05
0 10 20 30 40 50 60Pout (W)
Fsw
(Hz)
1st2nd3rd4th
QR operationVCO mode
VCO Mode
• Occurs when VFB < 0.8 V (Pout decreasing) or VFB < 1.4 V (Pout increasing)
• Fixed peak current (17.5% of Ipk,max), variable frequency set by the FB loop.
Constant peak current (17.5% of Ipk max)
Fsw1 @ Pout1 Fsw2 @ Pout2 Pout1 > Pout2
Ipk max
Combined ZCD and OPP
• Zero-Crossing Detection (ZCD) and Over Power Protection (OPP) are achieved by reading the Aux. winding voltage– ZCD function used during the off-time of MOSFET (positive voltage).
– OPP function used during the on-time of MOSFET (negative voltage)
2
1
0 V
50 mV
Possible restarts for ZCD VOPP
VDRV
VZCD
0.8 V + Vopp
ZCD/OPP IpFlag+0.8 V
+
-
ESDprotectionAux
Ropu
Ropl
1
Rzcd
CS
+
-Vth
DRV Tblank
leakage blanking
Demag
NCP1380 Versions
• 4 versions of NCP1380: A, B, C and D
XXXNCP1380 / D
XXXNCP1380 / C
XXXNCP1380 / B
XXXNCP1380 / A
LatchedOver current protection
Auto-RecoveryOver current protectionBOOVPOTP
OTP: Over Temperature ProtectionOVP: Over Voltage ProtectionBO: Bown-Out
Short-Circuit Protection• Internal 80 ms timer for short-circuit validation.
• Additional CS comparator with reduced LEB to detect winding short-circuit.
• VCS(stop) = 1.5 * VILIMIT
ZCD/OPP
Laux
CS
Rsense
LEB1 +
-
grandreset
IpFlag
PWMreset
Up
Down
TIMERReset
FB/4
OPP
VILIMIT
+
-
LEB2
VCS(stop)
CsStop
DRVS
R
Q
Q
Stop controller
S
R
Q
Q
CS after LEB1 +
-
S
R
Q
Q
Vcc
aux
managementlatch
Vdd
faultgrandreset
grandreset
DRV
IpFlag+
-
PWMreset
Up
Down
TIMERReset
VCCstop
FB/4
VILIMIT
VOPP+
+
-VCS(stop)
CS after LEB2 CSstop
t LEB2 < tLEB1
VCC
CSstop
Short-Circuit Protection (A and C versions)• A and C versions: the fault is latched.
– VCC is pulled down to 5 V and waits for ac removal.
SCR delatcheswhen ICC < ICCLATCH
• Auto-recovery short circuit protection: the controller tries to restart
• Auto-recovery imposes a low burst in fault mode.
VDS
VCC
Low average input power in fault condition
Short Circuit Protection (B and D)
S
R
Q
Q
+
-
Vcc
auxVdd
faultgrandreset
to DRV stage
IpFlag+
-
+
-
PWMreset
Up
Down
TIMERReset
VCCstopCS after LEB1
FB/4
VILIMIT
VOPP+
CS after LEB2
t LEB2 < tLEB1
CSstop
VCS(stop)
grandreset
managementVCC
Fault Pin Combinations
• OVP and OTP or OVP and BO combined on one pin.• Less external components needed.
time
VFault
OK
Latch!
Latch!
time
VFault
OK
BO
Latch!
• OVP / OTP– NCP1380 A & B versions
• OVP / BO– NCP1380 C & D versions,
NCP1379
Agenda
1. Quasi-Resonance (QR) Generalities
2. The Valley Lockout Technique
3. The NCP1379/1380
4. Step by Step Design Procedure
5. Performances of a 60 W Adapter Featuring
Valley Lockout
Step by Step Design Procedure
• Calculating the QR transformer
• Predicting the switching frequency
• Implementing Over Power Compensation
• Improving the efficiency at light load with the VCO mode
• Choosing the startup resistors
• Implementing synchronous rectification
Design Example• Power supply specification:
– Vout = 19 V
– Pout = 60 W
– Fsw,min = 45 kHz (at Vin = 100 Vdc)
– 600 V MOSFET
– Vin = 85 ~ 265 Vrms
– Standby power consumption < 100 mW @ 230 Vrms
T1
..
Vout
Gnd
Vbulk
Turns Ratio Calculation
,ds max dss DV BV k=
Derate maximum MOSFET BVdss:
For a maximum bulk voltage, select the clamping voltage:
Deduce turns ratio:
, ,clamp ds max in max osV V V V= − −
( )c out fsps
p clamp
k V VNNN V
+= =
BVdss
Vds,max
Vclamp
Vbulk,max
15% derating
Vos
Vreflect
kc: clamping coef.
kc = Vclamp / Vreflect )
Vos: diode overshoot
kD: derating factor
How to Choose kc• kc choice dependant of Lleak (leakage inductance of the transformer) • kc value can be chosen to equilibrate MOS conduction losses and
clamping resistor losses.
1out c
Rclamp leakc
P kP kkη
=−2
, 2, , ,
4 13
out cMOS on dson
in min in min dss D in max os
P kP RV V BV k V Vη
⎛ ⎞= +⎜ ⎟⎜ ⎟− −⎝ ⎠
1.2 1.5 1.8 2.1 2.4 2.7 30
1
2
3600-V MOSFET
PRclamp
PMOS,on @ Vin,min
P los
s(W
)
kc
Ptot ≈ 2.5 Wkleak=0.005
kleak=0.008
kleak=0.01
Curves plotted for:Rdson = 0.77 Ω at Tj = 110 °CPout = 60 WVin,min = 100 Vdc
Primary Peak Current and Inductance
, ,
,
pri peak pri pri peak pri pssw pri lump
in min out f
I L I L NT L C
V V Vπ= + +
+
2,
12out pri pri peak swP L I F η=
,
212 ps out lump swoutpri peak
in,min out f
N P C FPIV V V
πη η
⎛ ⎞= + +⎜ ⎟⎜ ⎟+⎝ ⎠
2,
2 outpri
pri peak sw
PLI F η
=
ton toff
tv
Ipri,peak
ton toff tv0
DCM
Coss contributionalone.
RMS Current• Calculate maximum duty-cycle at maximum Pout and minimum Vin:
• Deduce primary and secondary RMS current value:
, , 3max
pri rms pri peakdI I=
,,
13
pri peak maxsec rms
ps
I dIN
−=
,,
,
pri peak primax sw min
in min
I Ld F
V=
Ipri,rms and Isec,rms Losses calculation
Design Example
, , ,0.433.32 1.26
3 3max
pri rms pri peak pri rmsdI I I A= = ⇒ =
,, ,
1 3.32 1 0.43 5.83 0.25 3
pri peak maxsec rms sec rms
ps
I dI I AN
− −= = ⇒ =
,,
,
3.32 285 45 0.43100
pri peak primax sw min max
in min
I L µd F k dV
×= = ⇒ =
,
( ) 1.3 (19 0.8) 0.25600 0.85 375 10
c out fps ps
Vdss D in max os
k V VN N
B k V V+ × +
= = ⇒ ≈− − × − −
,
,
22 1
2 60 1 0.25 2 60 250 45 3.320.85 100 19.8 0.85
ps out lump swoutpri peak
in,min out f
pri peak
N P C FPIV V V
p k I A
πη η
π
⎛ ⎞= + +⎜ ⎟⎜ ⎟+⎝ ⎠
× × × ×⎛ ⎞= + + ⇒ =⎜ ⎟⎝ ⎠
2 2,
2 2 60 2853.32 45 0.85
outpri pri
pri peak sw
PL L µHI F kη
×= = ⇒ =
× ×
Based on equations from slides 11 to 14:
Turns ratio:
Peak current:
Inductance:
Max. duty-cycle:
Primary rms current:
Secondary rms current: