Power Electronics Technology

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1 Power Electronics Technology Exhibition & Conference 30 October 2002 Solving EMI for Low Wattage Universal Input Power Supplies ON Semiconductor Jim Spangler Carl Walding Dennis Jodlowski Schaumburg, Illinois Authors CEC Dave Pacholok Sleepy Hollow, Illinois 1

2 Author Information Jim Spangler Dennis Jodlowski Carl Walding ON Semiconductor 1515 Woodfield Rd Suite 745 Schaumburg, Illinois Dave Pacholok fax CEC 1515 Higgins Rd Sleepy Hollow, Ill

3 Purpose of the paper Cookbook to help design universal input flyback switching power supplies. Help understand the various techniques used on their effects of reducing EMI. Help reduce the engineering cycle time and improve the time to market of products. Educational tool to help novice switching power supplies engineers solve a sometimes black magic item 3

4 Example: TV Set-Top Box Universal input ( Vac Hz). 2-wire AC input (no earth ground plug). Multiple outputs all referenced to a common ground. 20 Watts. Vout = 3.3, 5.0, 12.0, and (32 or 38 LNB) Flyback topology used for tracking and cross regulation. 2 options: Fixed Frequency (NCP1000) and the Critical Conduction Mode (MC33364) 4

5 FCC limits FCC Class B (Consumer Limits) Part 15, sub-part J Spectrum Analyzer HP 8562A peak detector HP E7401A EMI Analyzer Line Impedance Stabilization Network (LISN) EMCO #3810/2 (modified 0.1 uf for FCC) Discrete Dual per FCC specification (Dave Pacholok) 5

6 Line Conducted Limits All agency measurements are made using quasi-peak. Design Limits are 6 db below agency limits. 6

7 FCC style LISN (Line Impedance Stabilization Network) 50 uh AC Hot (line 1) Variac Isolation Transformer VA 1.0 uf 1.0 uf 0.1 uf uf Coax cable Earth Ground Coax cable 50 Load termination or Sprectrum Analyzer 50 AC Neutral (line 2) 50 uh CISPR 0.47 uf Coupling Capacitor 7

8 Circuit Tools Available for Engineers Hot-Cold Ground Capacitor (Y-Capacitor) Common-Mode Choke Line-Line Capacitor (X-Capacitor) Transformer Snubber (DRC) Ferrite Beads (EMI suppression type) Switch RC Snubbber Output Diode Snubber (RC) Schottky Rectifier vs Ultra-Fast Rectifier 8

9 9 EMI Circuit Parts F1 C1 L1 D1 D4 D3 D2 C3 68uF 400V D5 C4 1000pF 1kV R2 33K 1/2W R3 1.5K 1W C5 1kV IC1 R4 27 D6 C6 22uF 25V R5 C7 22uF 25V IC2 3T 4T 6T 15T D10 D9 D8 D7 C8 220uF 50V C11 470uF 16V C uF C uF L2 47uH L3 22uH L4 10uH C12 470uF 16V C uF C uF FB1 (Ferronics B) C9 47uF 50V C10 C13 C16 C19 IC3 IC2 R6 470 R7 C20 C21 R R8 10K R9 NCP1001 R1 2.2M L N FB2 +33V@0.3A +12V@0.3A +5V@0.5A +3.3V@0.7A Vac (4) 1N4007 MUR160 MMBD914LT1 TL431ACD PS2562l1-1 MBRS1100LT3 MBRS204LT3 MURS110T3 MURS140T3 D11 MRA4004T3 T1 20W Reference Design Using NCP1001 CW 5/23/01 10T 64T 2 C pF (Ferronics J) R C21 1kV

10 NCP1001 with no filtering FCC Limit 48dB Design Limit 42 db FCC indicates using highest Line or Neutral, only Line is shown here. 10

11 Hot to Cold Ground Cap. Schematic 20W Reference Design Using NCP1001 C5 1kV R3 1.5K 1W F1 D1 FB1 (Ferronics B) T1 D7 MURS140T3 FB2 L N R1 2.2M Vac C1 L1 D2 D3 D4 (4) 1N4007 C3 68uF 400V MUR160 C4 1000pF 1kV D5 R2 33K 1/2W 64T 15T 6T D8 MURS110T3 C8 220uF 50V C11 470uF 16V (Ferronics J) L2 47uH C9 47uF 50V D11 MRA4004T3 C12 470uF 16V +12V@0.3A C10 C13 C7 22uF 25V R5 C6 22uF 25V D6 MMBD914LT1 1 R4 27 NCP1001 IC C21 1kV R T 4T 3T D9 MBRS204LT3 D10 C uF MBRS1100LT3 C uF L3 22uH L4 10uH C uF C uF +5V@0.5A +3.3V@0.7A C16 C19 IC2 PS2562l1-1 R7 R6 470 R8 10K R9 CW 5/23/01 IC2 TL431ACD IC3 C20 Y Capacitor, 4 KV Rating C12 C21 R Max. value is limited by leakage current. 3300pF 11

12 NCP1001 Hot-Cold Ground Cap (3300pF 4KV) 76 to to 68 db 12

13 13 Common Mode Choke Schematic F1 C1 L1 D1 D4 D3 D2 C3 68uF 400V D5 C4 1000pF 1kV R2 33K 1/2W R3 1.5K 1W C5 1kV IC1 R4 27 D6 C6 22uF 25V R5 C7 22uF 25V IC2 3T 4T 6T 15T D10 D9 D8 D7 C8 220uF 50V C11 470uF 16V C uF C uF L2 47uH L3 22uH L4 10uH C12 470uF 16V C uF C uF FB1 (Ferronics B) C9 47uF 50V C10 C13 C16 C19 IC3 IC2 R6 470 R7 C20 C21 R R8 10K R9 NCP1001 R1 2.2M L N FB2 +33V@0.3A +12V@0.3A +5V@0.5A +3.3V@0.7A Vac (4) 1N4007 MUR160 MMBD914LT1 TL431ACD PS2562l1-1 MBRS1100LT3 MBRS204LT3 MURS110T3 MURS140T3 D11 MRA4004T3 T1 20W Reference Design Using NCP1001 CW 5/23/01 10T 64T 2 C pF (Ferronics J) R C21 1kV

14 Common Mode Choke Line Inductance Leg 39.4 mh Neutral Inductance Leg 39.4 mh Resistance per Leg 1.3 ohms Mutual Inductance mh Coupling Coefficient Capacitance between Sections 3.0 pf 14

15 Common Mode Choke Impedance Plot AP102B Frequency Response Analyzer 15

16 Common Mode Choke with Hot-Cold Ground Capacitor 76 to 73 52dB 48dB 68 to 43.5 db 84 to 68 db 16

17 Line-Line Capacitor Schematic 20W Reference Design Using NCP1001 C5 1kV R3 1.5K 1W F1 D1 FB1 (Ferronics B) T1 D7 MURS140T3 FB2 L N R1 2.2M Vac C1 L1 D2 D3 D4 (4) 1N4007 C3 68uF 400V MUR160 C4 1000pF 1kV D5 R2 33K 1/2W 64T 15T 6T D8 MURS110T3 C8 220uF 50V C11 470uF 16V (Ferronics J) L2 47uH C9 47uF 50V C12 470uF 16V C10 D11 +12V@0.3A MRA4004T3 C13 C7 22uF 25V R5 C6 22uF 25V D6 MMBD914LT1 1 R4 27 NCP1001 IC C21 1kV R T 4T 3T D9 MBRS204LT3 D10 C uF MBRS1100LT3 C uF L3 22uH L4 10uH C uF C uF +5V@0.5A +3.3V@0.7A C16 C19 IC2 PS2562l1-1 R7 R6 470 R8 10K R9 CW 5/23/01 Line-Neutral Capacitor 0.1 uf 250 VAC, Safety Rated IC2 C pF TL431ACD IC3 C20 C21 R

18 Common Mode Choke with X Capacitor and H-C Cap 43.5 db 18

19 Met the FCC Class B limit Just above the 42 db spec. design limit. Quasi peak vs Peak detect can add up to 2 db of additional margin. Below the 48 db FCC limits (Quasi Peak). 2-Wire system with NO Ground Plane Easily meets the Class A limits. What is the ground noise floor limit? 19

20 Ground Floor (log scale) 20

21 Ground Floor (Linear scale) 21

22 Additional Reductions 43.5 db 22

23 23 Switch Voltage and Current F1 C1 L1 D1 D4 D3 D2 C3 68uF 400V D5 C4 1000pF 1kV R2 33K 1/2W R3 1.5K 1W C5 1kV IC1 R4 27 D6 C6 22uF 25V R5 C7 22uF 25V IC2 3T 4T 6T 15T D10 D9 D8 D7 C8 220uF 50V C11 470uF 16V C uF C uF L2 47uH L3 22uH L4 10uH C12 470uF 16V C uF C uF FB1 (Ferronics B) C9 47uF 50V C10 C13 C16 C19 IC3 IC2 R6 470 R7 C20 C21 R R8 10K R9 NCP1001 R1 2.2M L N FB2 +33V@0.3A +12V@0.3A +5V@0.5A +3.3V@0.7A Vac (4) 1N4007 MUR160 MMBD914LT1 TL431ACD PS2562l1-1 MBRS1100LT3 MBRS204LT3 MURS110T3 MURS140T3 D11 MRA4004T3 T1 20W Reference Design Using NCP1001 CW 5/23/01 10T 64T 2 C pF (Ferronics J) Voltage Current Probes

24 Transformer EMI Ringing Switch voltage with ring Switch current Diode-RC Transformer Snubber to limit Flyback voltage. 24

25 Ferrite Bead 140 Fair-Rite Bead Characteristics Rs 80 Z,Rs,XL OHMS Z XL Frequency (MHz) Resistance XL Z 25

26 Ferrite Bead 120 Vac 26

27 Ferrite Bead 220 Vac 27

28 Reverse Recovery Diode (t rr issues) Frequency beyond the Line conducted limits. Problems with FCC radiation start to appear. 28

29 Ferrite Bead +30 MHz Radiation Ferrite bead lowers MHz ring. 29

30 Ground Plane added beneath PC Board 20W Reference Design Using NCP1001 C5 1kV R3 1.5K 1W F1 D1 FB1 (Ferronics B) T1 D7 MURS140T3 FB2 L N R1 2.2M Vac C1 L1 D2 D3 D4 (4) 1N4007 C3 68uF 400V MUR160 C4 1000pF 1kV D5 R2 33K 1/2W 64T 15T 6T D8 MURS110T3 C8 220uF 50V C11 470uF 16V (Ferronics J) L2 47uH C9 47uF 50V D11 MRA4004T3 C12 470uF 16V +12V@0.3A C10 C13 C7 22uF 25V R5 C6 22uF 25V D6 MMBD914LT1 1 R4 27 NCP1001 IC C21 1kV R T 4T 3T D9 MBRS204LT3 D10 C uF MBRS1100LT3 C uF L3 22uH L4 10uH C uF C uF +5V@0.5A +3.3V@0.7A C16 C19 IC2 PS2562l1-1 R7 R6 470 R8 10K R9 CW 5/23/01 IC2 TL431ACD IC3 C20 C12 C21 R Ground Plane 0.5 inches below PC Board 3300pF Ground Plane 30

31 Switch Snubber 100 pf-100 ohm 31

32 EMI using European Standards NCP Vac 60 Hz No Ground Plane 32

33 Ground Plane added 33

34 34 Critical Conduction Mode F1 1.5A C8 T1 D5 D6 D7 D4 C10 68uF 400V 32T D2 MUR160 C5 1000pF 1kV R5 33K 1/2W 10T R2 27 D1 MMBD914LT1 C2 47uF 25V R6 22K IC2 PS2561L1-1 3T 4T 6T 18T D8 MBRS1100T3 D9 MBRS2040LT3 D10 MURS110T3 D11 MURS140T3 C23 180uF 50V C20 470uF 16V C uF C uF L3 47uH L2 22uH L1 10uH C21 470uF 16V C uF C uF L5 Ferrite C24 47uF 50V C28 C27 C26 C25 IC3 TL431ACD R R10 C14 C15 R R12 1 R13 R9 2.2M L N J1 L4 Ferronics J +38V@0.3A +12V@0.3A +5V@0.5A +3.3V@0.7A Vac (4) 1N4007 D12 MRA4004T3 T2 2 C pF Q1 NTB3N60 R W R1 100ohm D3 Prov. C7 Prov. R4 C4 C3 R7 100ohm C6 Prov. C1 ZVS CS VREF VFB GND DRV VCC VIN 8 IC1 MC33364D T R15 Prov. C22 Prov R16 750K Universal Input, 20watt, Multiple Output, Flyback Converter MC33364D2 Reference Design

35 Other Sources of Information Ott, Henry, Noise Reduction Techniques in Electronic Systems, 1988 John Wiley Mills, Jeffrey, Electro-Magnetic Interference Reduction in Electronic Systems, 1993 Prentice Hall Ott, Henry, Understanding and Controlling Common- Mode Emissions In High-Power Electronics, Professional Education Seminars IEEE, APEC Mar Schutten, Michael, EMI: Theory, Issues, and Solutions, Professional Education Seminars IEEE, APEC Mar Class Notes ECE-522, Electro-Magnetic Compatibility, Dr. Jeff Mills, Illinois Institute of Technology. Dr. Ridley, Power Ver 8.0, Snubber design 35

36 Thank You, Comments,? Questions? For copy of the presentation in pdf format, please give Carl, Dennis, or my self a business card. 36

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