12V Power Supply From Universal Mains

8/13/2019 12V Power Supply From Universal Mains

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Copyright © 2013, Texas Instruments Incorporated 1 ti.com/webench

WEBENCH ® Design Report LM5023MM-2/NOPB : LM5023MM-2/NOPB90.0V-250.0V to 11.862745098039216V @ 2.0A November 7, 2013 16:12:38 GMT-8

WEBENCH ® Design Report

Design : 1180682/40 LM5023MM-2/NOPBLM5023MM-2/NOPB 90.0V-250.0V to 11.862745098039216V @ 2.0A

VinMin = 90.0VVinMax = 250.0VVout = 12.0VIout = 2.0A

Device = LM5023MM-2/NOPBTopology = FlybackCreated = 11/7/13 4:12:11 PMBOM Cost = $0.00Total Pd = 4.59WFootprint = 2,929.0mm2BOM Count = 38

Ccomp1.0 nF384.0 mOhm

Ccs100.0 pF

Cd68.0 pF94.0 mOhm

Cfb12.0 nF

Cgnd2.2 nF120.0 mOhm

C n4.7 µF15.0 mOhmQ y = 3

Cout82.0 µF27.0 mOhmQ y = 3

Cs4.7 nF

Css12.0 nF

Cvcc4.7 µF

Cvcc1100.0 nF64.0 mOhm

Cvcc222.0 µF

D1VF@o= 1.3 VVRRM= 40 0.0 V

D2VF@o= 770.0 mVVRRM= 100.0 V

D3VF@o= 850.0 mVVRRM= 20 0.0 V

~

~

- +

DacVF@o= 1.1 VVRRM= 1 00 0 V

Dz4

M1VdsMax= 800.0 VIdsMax= 2.5 Amps

M2VdsMax= 600.0 VIdsMax= 3.9 Amps

O1

Rcs4.53 kOhm63.0 mW

R bb10.2 kOhm63.0 mW

R bt86.6 kOhm63.0 mWopto

649.0 kOhm250.0 mW

Rqrb7.68 kOhm63.0 mW

Rqrt25.5 kOhm125.0 mW

Rs12.1 kOhm250.0 mW

Rsense430.0 mOhm500.0 mW

Rvcc100.0 Ohm125.0 mWRvin

10.0 kOhm63.0 mW

Rvsd2.0 MOhm0.0 W

T1

Lp= 1.263 mHRp= 6.211 OhmLeakage_L= 25.255 µHNs1toNp= 0.086Rs1= 10.727 mOhmsNs2toNp= 0.072Rs2= 9.045 kOhms

LM5023

QR

VSD

SS

COMP

CS

GND

OUT

VCC

U1

SHUNT_VREF

Cathode

Ref

AnodeR

V n Iout

1. Rbld is a starting point, but may need to be experimented with in order to get minimum current needed to hold Vout at no load. Rlc and thefeedback resistors may also need adjustment based on the actual transformer used. For more information please click the design assistancebutton.

Electrical BOM# Name Manufacturer Part Number Properties Qty Price Footprint

1. Ccomp Kemet C0805C102K5RACTUSeries= X7R

Cap= 1.0 nFESR= 384.0 mOhmVDC= 50.0 VIRMS= 214.0 mA

1 $0.010805 7mm2

2. Ccs MuRata GRM033R71C101KA01DSeries= X7R

Cap= 100.0 pFVDC= 16.0 VIRMS= 0.0 A

1 $0.010201 2mm2

3. Cd Kemet C0805C680J5GACTUSeries= C0G/NP0

Cap= 68.0 pFESR= 94.0 mOhmVDC= 50.0 VIRMS= 603.0 mA

1 $0.010805 7mm2

4. Cfb MuRata GRM155R71E123KA61DSeries= X7R

Cap= 12.0 nFVDC= 25.0 VIRMS= 0.0 A

1 $0.010402 3mm2

5. Cgnd TDK C4532X7R3D222KSeries= X7R

Cap= 2.2 nFESR= 120.0 mOhmVDC= 2.0 kVIRMS= 0.0 A

1 $0.21

1812 27mm2

http://www.tdk.co.jp/tefe02/e4142_c.pdf

http://search.murata.co.jp/Ceramy/PnsearchViewAction.do?HnOFG%3DON%26HnNFG%3DON%26SEL%5FCNT%3D50%26sLang%3Den%26sKey%3DGRM155R71E123KA61D%26x%3D9%26y%3D9%26search%3Dstartwith

http://www.kemet.com/kemet/web/homepage/kechome.nsf/file/Partial%20Copy%20-%20Ceramic%20Surface%20Mount%20Capacitors/%24file/F3102_CE.pdf

http://search.murata.co.jp/Ceramy/PnsearchViewAction.do?HnOFG%3DON%26HnNFG%3DON%26SEL%5FCNT%3D50%26sLang%3Den%26sKey%3DGRM033R71C101KA01D%26x%3D9%26y%3D9%26search%3Dstartwith




WEBENCH ® Design



# Name Manufacturer Part Number Properties Qty Price Footprint

6. Cin EPCOS Inc B32924C3475MSeries= 303

Cap= 4.7 µFESR= 15.0 mOhmVDC= 630.0 VIRMS= 457.0 mA

3 $1.83

B32924_33mm 670mm2

7. Cout Sanyo 16SVPF82MSeries= 1273

Cap= 82.0 µFESR= 27.0 mOhmVDC= 16.0 VIRMS= 3.0 A

3 $0.35

CAPSMT_62_E61 53mm2

8. Cs MuRata GRM155R72A472KA01DSeries= X7R


1 $0.010402 3mm2

9. Css MuRata GRM155R71E123KA61DSeries= X7R


1 $0.010402 3mm2

10. Cvcc MuRata GRM21BC81E475KA12LSeries= 379

Cap= 4.7 µFVDC= 25.0 VIRMS= 0.0 A

1 $0.040805 7mm2

11. Cvcc1 Kemet C0805C104K5RACTUSeries= X7R

Cap= 100.0 nFESR= 64.0 mOhmVDC= 50.0 VIRMS= 1.64 A

1 $0.010805 7mm2

12. Cvcc2 Nippon Chemi-Con EMVA160ADA220MD55GSeries= MVA

Cap= 22.0 µFVDC= 16.0 VIRMS= 26.0 mA

1 $0.07

CAPSMT_62_D55 28mm2

13. D1 Diodes Inc. RS1G-13-F VF@Io= 1.3 VVRRM= 400.0 V

1 $0.07

SMA 37mm2

14. D2 Vishay-Semiconductor 50WQ10FNPBF VF@Io= 770.0 mVVRRM= 100.0 V

1 $0.41

DPAK 102mm2

15. D3 Diodes Inc. DFLS1200-7 VF@Io= 850.0 mVVRRM= 200.0 V

1 $0.21PowerDI123 13mm2

16. Dac Vishay-Semiconductor DF10SA VF@Io= 1.1 VVRRM= 1,000 V

1 $0.24

DF-S 99mm217. Dz4 ON Semiconductor BZX84C15LT1G Zener 1 $0.02

SOT-23 14mm2

18. M1 ST Microelectronics STD3NK80ZT4 VdsMax= 800.0 VIdsMax= 2.5 Amps

1 $0.68

DPAK 102mm2

19. M2 Fairchild Semiconductor FCD4N60TM VdsMax= 600.0 VIdsMax= 3.9 Amps

1 $0.49

DPAK 102mm2

20. O1 CUSTOM Custom Optocoupler 1 NA

CUSTOM 0mm221. Rcs Vishay-Dale CRCW04024K53FKED

Series= CRCW..e3Res= 4.53 kOhmPower= 63.0 mWTolerance= 1.0%

1 $0.010402 3mm2

http://www.vishay.com/docs/20035/dcrcwe3.pdf

http://www.fairchildsemi.com/ds/FC/FCD4N60.pdf

http://www.st.com/stonline/books/pdf/docs/9565.pdf

http://www.onsemi.com/pub_link/Collateral/BZX84C2V4LT1-D.PDF

http://www.vishay.com/docs/88574/dfsa.pdf

http://www.diodes.com/datasheets/ds30628.pdf

http://www.vishay.com/docs/94235/50wq10fn.pdf

http://www.diodes.com/datasheets/ds15002.pdf

http://www.chemi-con.co.jp/e/catalog/pdf/al-e/al-sepa-e/003-chip/al-mva-e-111201.pdf


http://search.murata.co.jp/Ceramy/PnsearchViewAction.do?HnOFG%3DON%26HnNFG%3DON%26SEL%5FCNT%3D50%26sLang%3Den%26sKey%3DGRM21BC81E475KA12L%26x%3D9%26y%3D9%26search%3Dstartwith

http://search.murata.co.jp/Ceramy/PnsearchViewAction.do?HnOFG%3DON%26HnNFG%3DON%26SEL%5FCNT%3D50%26sLang%3Den%26sKey%3DGRM155R71E123KA61D%26x%3D9%26y%3D9%26search%3Dstartwith

http://search.murata.co.jp/Ceramy/PnsearchViewAction.do?HnOFG%3DON%26HnNFG%3DON%26SEL%5FCNT%3D50%26sLang%3Den%26sKey%3DGRM155R72A472KA01D%26x%3D9%26y%3D9%26search%3Dstartwith

http://industrial.panasonic.com/www-data/pdf/AAB8000/AAB8000CE1.pdf

http://www.epcos.com/inf/20/20/db/fc_2009/X2_B32921_926.pdf



WEBENCH ® Design



# Name Manufacturer Part Number Properties Qty Price Footprint

22. Rfbb Vishay-Dale CRCW040210K2FKEDSeries= CRCW..e3

Res= 10.2 kOhmPower= 63.0 mWTolerance= 1.0%

1 $0.010402 3mm2

23. Rfbt Vishay-Dale CRCW040286K6FKEDSeries= CRCW..e3


1 $0.010402 3mm2

24. Ropto Panasonic ERJ-8ENF6493V

Series= ERJ-8E

Res= 649.0 kOhm

Power= 250.0 mWTolerance= 1.0%

1 $0.01

1206 11mm2

25. Rqrb Vishay-Dale CRCW04027K68FKEDSeries= CRCW..e3


1 $0.010402 3mm2

26. Rqrt Vishay-Dale CRCW080525K5FKEASeries= CRCW..e3


1 $0.010805 7mm2

27. Rs Panasonic ERJ-8ENF1212VSeries= ERJ-8E


1 $0.011206 11mm2

28. Rsense Rohm MCR25JZHFLR430Series= 298

Res= 430.0 mOhmPower= 500.0 mW

Tolerance= 1.0%

1 $0.04

1210 15mm2

29. Rvcc Vishay-Dale CRCW0805100RFKEASeries= CRCW..e3

Res= 100.0 OhmPower= 125.0 mWTolerance= 1.0%

1 $0.010805 7mm2

30. Rvin Vishay-Dale CRCW040210K0FKEDSeries= CRCW..e3


1 $0.010402 3mm2

31. Rvsd CUSTOM CUSTOMSeries= ?

Res= 2.0 MOhmPower= 0.0 WTolerance= 0.0%

1 NACUSTOM 0mm2

32. T1 CUSTOM CUSTOM Lp= 1.263 mHRp= 6.211 OhmLeakage_L= 25.255 µH

Ns1toNp= 0.086Rs1= 10.727 mOhmsNs2toNp= 0.072Rs2= 9.045 kOhms

1 NACUSTOM 0mm2

33. U1 Texas Instruments LM5023MM-2/NOPB Switcher 1 $0.38

S-PDSO-G8 36mm2

34. VR Texas Instruments LMV431 Voltage References 1 $0.21

R-PDSO-G3 16mm2

IC Tj

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0.75 1 1.25 1.5 1 .75 2

Iout(A)

31.401889995

31.401889996

31.401889997

31.401889998

31.401889999

31.401890000

31.401890001

31.401890002

31.401890003

31.401890004

31.401890005

I C T j ( d e g

C )

Duty Cycle

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0.75 1 1.25 1 .5 1 .75 2

Iout(A)

5

10

15

20

25

30

35

40

45

50

D u

t y C y c l e ( %

)



http://www.ti.com/product/LMV431

http://www.ti.com/product/lm5023



http://www.rohm.com/products/databook/r/pdf/mcr25_ttk.pdf

http://www.panasonic.com/industrial/components/pdf/AOA0000CE2.pdf



http://www.panasonic.com/industrial/components/pdf/AOA0000CE2.pdf





WEBENCH ® Design



T1 Iprim pk

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

0.15

0.20

0.25

0.30

0.35

0.400.45

0.50

0.55

0.60

0.65

0.70

0.75

0.80

0.85

T 1 I p r i m

p k ( A )

Cin IRMS

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1.75 2

Iout(A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

C i n I R M S ( A )

Frequency_

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0.75 1 1.25 1 .5 1.75 2

Iout(A)

55,000

60,000

65,000

70,000

75,000

80,000

85,000

90,000

95,000

100,000

105,000

110,000115,000

120,000

125,000

130,000

F r e q u e n c y_

( H z )

T1 Is1 RMS

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

1.00

1.25

1.50

1.75

2.00

2.25

2.50

2.75

3.00

3.25

3.50

3.75

T 1 I s 1 R M S ( A )

Peak Rectified Vin

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0.75 1 1.25 1 .5 1.75 2

Iout(A)

12 5

15 0

17 5

20 0

22 5

25 0

27 5

30 0

32 5

35 0

P e a k R e c t i f i e d

V i n ( V )

Diode2 Pd

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

0.75

1.00

1.25

1.50

1.75

2.00

2.25

2.50

2.75

3.00

D i o d e 2

P d ( W )



WEBENCH ® Design



Efficiency

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

60.0

62.5

65.0

67.5

70.0

72.5

75.0

77.5

80.0

82.5

85.0

E f f i c i e n c y ( %

)

Vout p- p

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1.75 2

Iout(A)

0.015

0.020

0.025

0.030

0.035

0.0400.045

0.050

0.055

0.060

0.065

0.070

0.075

0.080

0.085

0.090

V o u

t p - p

( V )

T1 Iprim RMS

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1.75 2

Iout(A)

0.000

0.025

0.050

0.075

0.100

0.125

0.150

0.175

0.200

0.225

0.250

0.275

0.300

0.325

0.350

T 1 I p r i m

R M S ( A )

M2 TjOP

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1 .75 2

Iout(A)

29

30

31

32

33

34

35

36

37

38

39

40

41

M 2 T j O P ( d e g

C )

Iin rms

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1.75 2

Iout(A)

0.000

0.025

0.050

0.075

0.100

0.125

0.150

0.175

0.200

0.225

0.250

0.275

0.300

0.325

I i n r m s ( A

)

Cin Pd

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1.75 2

Iout(A)

0.0000

0.0001

0.0002

0.0003

0.0004

0.0005

0.0006

0.0007

0.0008

0.0009

0.0010

0.0011

0.0012

0.0013

C i n P d ( W )



WEBENCH ® Design



Cout Pd

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1.75 2

Iout(A)

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

0.065

0.070

C o u t P d ( W )

Xformer Pd

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

X f o r m

e r P d ( W )

Pout

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

22.5

P o u

t ( W )

Min Rectified Vin

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0.75 1 1.25 1 .5 1.75 2

Iout(A)

12 5

15 0

17 5

20 0

22 5

25 0

27 5

30 0

32 5

35 0

M i n R e c t i f i e d

V i n ( V )

M2 Pd

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1 .25 1 .5 1.75 2

Iout(A)

0.075

0.100

0.125

0.150

0.175

0.200

0.225

0.250

0.275

0.300

0.325

0.350

M 2 P d ( W )

Total Pd

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

T o

t a l P d ( W )



WEBENCH ® Design



Cout IRMS

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

2.50

2.75

C o u

t I R M S ( A )

Avg Bridge Diode Pd

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1.75 2

Iout(A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

A v g

B r i d g e

D i o d e

P d ( W )

IC Pd

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0.5 0 .75 1 1.25 1.5 1 .75 2

Iout(A)

0.007009445

0.007009446

0.007009447

0.007009448

0.007009449

0.007009450

0.007009451

0.007009452

0.007009453

0.007009454

0.007009455

I C P d ( W )

Avg Rectified Vin

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0.75 1 1.25 1 .5 1.75 2

Iout(A)

12 5

15 0

17 5

20 0

22 5

25 0

27 5

30 0

32 5

35 0

A v g

R e c t i f i e d

V i n ( V )

Vin_OP_RMS

Vin= 90 .0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0.75 1 1.25 1 .5 1.75 2

Iout(A)

8090

10 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 0

V i n

_ O P

_ R M S ( V )

T1 Is1 pk

Vin= 90 . 0V Vin= 170 .0V Vin= 250 .0V

0.25 0 .5 0 .75 1 1.25 1 .5 1 .75 2

Iout(A)

1.5

2.02.53.03.54.04.55.05.56.06.57.07.58.08.59.09.5

10.0

T 1 I s 1 p

k ( A )

Operating Values# Name Value Category Description1. Cin IRMS 325.771 mA Current Input capacitor RMS ripple current2. Cout IRMS 1.202 A Current Output capacitor RMS ripple current3. Iin rms 113.27 mA Current RMS Input Current4. T1 Iprim RMS 245.53 mA Current Transformer Primary RMS Current5. T1 Iprim pk 541.832 mA Current Transformer Primary Peak Current6. T1 Is1 RMS 3.091 A Current Transformer Secondary1 RMS Current

7. T1 Is1 pk 6.283 A Current Transformer Secondary1 Peak Current8. Avg Rectified Vin 353.35 V General Average Rectified Voltage for the AC Line Period9. BOM Count 38 General Total Design BOM count

10. FootPrint 2.929 kmm2 General Total Foot Print Area of BOM components11. Pout 23.725 W General Total output power



WEBENCH ® Design


WEBENCH ® D i R LM5023MM 2/NOPB LM5023MM 2/NOPB

# Name Value Category Description12. Total BOM $0.0 General Total BOM Cost13. Vout OP 11.863 V Op_Point Operational Output Voltage14. Duty Cycle 69.894 % Op_point Duty cycle15. Efficiency 83.781 % Op_point Steady state efficiency16. Frequency 130.0 kHz Op_point Switching frequency17. IC Tj 32.962 degC Op_point IC junction temperature18. ICThetaJA 200.0 degC/W Op_point IC junction-to-ambient thermal resistance19. IOUT_OP 2.0 A Op_point Iout operating point20. M2 TjOP 34.951 degC Op_point M2 MOSFET junction temperature

21. Min Rectified Vin 353.15 V Op_point Minimum voltage seen at rectified input22. Peak Rectified Vin 353.55 V Op_point Peak voltage seen at rectified input23. Vin_OP_RMS 250.0 V Op_point AC Input RMS Voltage24. Vout p-p 56.548 mV Op_point Peak-to-peak output ripple voltage25. Avg Bridge Diode Pd 367.163 mW Power Average Power Dissipation in the Bridge Diode over the AC Line Period26. Cin Pd 530.633 µW Power Input capacitor power dissipation27. Cout Pd 13.003 mW Power Output capacitor power dissipation28. Diode2 Pd 2.38 W Power Diode2 power dissipation29. IC Pd 14.809 mW Power IC power dissipation30. M2 Pd 377.702 mW Power M2 MOSFET total power dissipation31. Total Pd 4.593 W Power Total Power Dissipation32. Xformer Pd 823.135 mW Power Transformer power dissipation

Design Inputs# Name Value Description1. Iout 2.0 A Maximum Output Current2. Iout1 2.0 Amps Output Current #13. VinMax 250.0 V Maximum input voltage4. VinMin 90.0 V Minimum input voltage5. Vout 12.0 V Output Voltage6. Vout1 12.0 Volt Output Voltage #17. base_pn LM5023 Base Product Number8. source DC Input Source Type9. Ta 30.0 degC Ambient temperature

Design Assistance1. Application Hints Rbld The European Standard for offline power supplies reuires that power supplies with an output power greater than 70Wneed to have a PFC front end. There may be application#s where a PFC front end is not required, so please make a choice based on whateverworks for you Rlc provides the function of feed-forward line compensation to eliminate change in IPP due to change in di/dt and the propagationdelay of the internal comparator and MOSFET turn-off time. For best results the chosen value may need to be adjusted based on board, FETand transformer parasitics. Rfbt & Rfbb The feedback resistors will set the output voltage of the circuit. The values chosen may need to be finedtuned based on the final Transformer turns ratios and the voltage across the output diode at close to zero current. Please see the datasheet forfurther design guidance. http://www.ti.com/lit/ds/symlink/lm5023.pdf

2. LM5023 Product Folder : http://www.ti.com/product/lm5023 : contains the data sheet and other resources.

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