TND359/D Rev 0, Jan-09

High-Efficiency 255 W ATX Power Supply Reference Design Documentation Package

 2009 ON Semiconductor Disclaimer: ON Semiconductor is providing this reference design documentation package AS IS and the recipient assumes all risk associated with the use and/or commercialization of this design package. No licenses to ON Semiconductors or any third partys Intellectual Property is conveyed by the transfer of this documentation. This reference design documentation package is provided only to assist the customers in evaluation and feasibility assessment of the reference design. The design intent is to demonstrate that efficiencies beyond 85% are achievable cost effectively utilizing ON Semiconductor provided ICs and discrete components in conjunction with other inexpensive components. It is expected that users may make further refinements to meet specific performance goals.

Table of Contents
1. Overview................................................................................................... 4 2. Specifications .......................................................................................... 5 3. Architecture Overview............................................................................. 7 3.1 Primary Side: PFC Stage................................................................................. 7 3.2 Primary Side: Half bridge resonant LLC Converter.......................................... 7 3.3 Secondary Side: Synchronous Rectification .................................................... 7 3.4 Secondary Side: DC-DC Conversion Stage .................................................... 8 3.5 Secondary Side: Monitoring and Supervisory Stage........................................ 8 3.6 Standby Power ................................................................................................ 8 4. Performance Results ..................................................................................9 4.1 Total Efficiency ............................................................................................................9 4.2 Power Factor ...............................................................................................................9 4.3 Standby Power ..........................................................................................................10 4.4 Input Current..............................................................................................................10 4.5 Inrush Current............................................................................................................10 4.6 Output Transient Response (Dynamic Loading) ........................................................11 4.7 Overshoot at Turn-On/Turn-Off..................................................................................11 4.8 Output Ripple / Noise.................................................................................................13 4.9 Hold-up Time .............................................................................................................20 4.10 Timing / Housekeeping / Control..............................................................................21 4.11 Output Protection.....................................................................................................23 5. Evaluation Guidelines ..............................................................................26 6. Schematics................................................................................................28 7. Parts List ...................................................................................................29 8. Resources/Contact Information ..............................................................36 9. Appendix ...................................................................................................36

1. Overview
ON Semiconductor was the first semiconductor company to provide an 80 PLUS-certified open reference design for an ATX power supply in 2005. A second generation 80 PLUS-certified open reference design with improved efficiency was then introduced in 2007. ON Semiconductor is now introducing its third generation 80 PLUS-certified open reference design with a drastic efficiency improvement. This is a 255 W multi-output power supply for the ATX form factor. Achieving a maximum efficiency of 90% at 50% load, and at 230 and 240 Vac, this third generation reference design achieves >88% efficiency at 50% load, and 100 and 115 Vac. All efficiency measurements were obtained at the end of a 41 cm (16 in.) cable, ensuring the design can be used as is in all standard desktop PC configurations. This reference document provides the details behind this third generation design. The design manual provides a detailed view of the performance achieved with this design in terms of efficiency, performance, thermals and other key parameters. In addition, a detailed list of the bill-of-materials (BOM) is also provided. ON Semiconductor will also be able to provide technical support to help our customers design and manufacture a similar ATX power supply customized to meet their specific requirements. The results achieved in this third generation design were possible due to the use of advanced new components from ON Semiconductor. These new ICs not only speeded up the overall development cycle for this new design, but also helped achieve the high efficiencies while at the same time keeping a check on the overall cost. This third generation design consists of a single PCB designed to fit into the standard ATX enclosure along with a fan. Figure 1 below presents the overall architecture employed in this design. Detailed schematics are included later in this design manual.

Figure 1: Reference Design Architecture Simplified Block Diagram

As seen in figure 1, the first stage, active Power Factor Correction (PFC) stage, is built around ON Semiconductors Continuous Conduction Mode (CCM) PFC controller, NCP1654. The NCP1654 provides an integrated, robust and cost-effective PFC solution. The second stage features a resonant half-bridge LLC topology using ON Semiconductors controller, NCP1396. This topology ensures maximum efficiency and minimizes EMI. The NCP1027, standby controller, is used to generate the 5 V standby output. The NCP1027 is an optimized integrated circuit for the ATX power supply and incorporates a high-voltage MOSFET. On the secondary side, this architecture uses a synchronous rectification scheme built around ON Semiconductors NCP4302 controller in order to generate a 12 V output. Finally, two identical DC-DC controllers are used to down-convert the 12 V into +5 V, +3.3 V and -12 V. The DC-DC controller is the NCP1587, a low voltage synchronous buck controller in a very small surface mount 8-pin package. Each DC-DC controller drives two NTD4809 (30 V, 58 A, single N-channel power MOSFET) in a synchronous rectification scheme. With the introduction of this third generation, high-efficiency ATX Power Supply, ON Semiconductor has shown that with judicious choice of design tradeoffs, optimum performance is achieved at minimum cost.

2. Specifications
The design closely follows the ATX12V version 2.2 power supply guidelines and specifications available from www.formfactors.org, unless otherwise noted. This 255 W reference design exceeds the 80 PLUS Silver (www.80plus.org), ENERGY STAR 5.0 (www.energystar.gov), and Climate Savers Computing Initiative (CSCI) Step 3 (www.climatesaverscomputing.org) efficiency targets for desktop PC multi-output power supplies. Table 1 hereafter shows a summary of the efficiency targets from these different organizations.
Levels Specification 20% of 50% of 100% of rated rated rated output output output
80% 80% efficiency efficiency 80% efficiency

Compliance
ENERGY STAR rev. 4.0 & CSCI step #1 Effective date: July 2007 ENERGY STAR rev. 5.0 (Effective date: July 2009) & CSCI step #2 (June 2008 thru July 2009)

Multi-Output ATX Power Supplies

Multiple-Output Non-Redundant PFC 0.9 at 100% of rated output

Multiple-Output Non-Redundant PFC 0.9 at 50% of rated output

82% 85% efficiency efficiency

82% efficiency

Multiple-Output Non-Redundant PFC 0.9 at 50% of rated output

85% 88% efficiency efficiency

85% efficiency

CSCI step #3 (July 2009 thru June 2010)

Multiple-Output Non-Redundant PFC 0.9 at 50% of rated output

87% 90% efficiency efficiency

87% efficiency

CSCI step #4 (July 2010 thru June 2011)

Table 1: Summary of Efficiency Targets

Key specifications for this reference design are included in Table below.
Input Voltage (Vac) Min. Typ. Max. Output Voltage (Vdc) +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB 90 100 115 230 240 264 Full Load DC Current (A) 9.50 5.12 9.44 5.03 0.32 2.39 Frequency (HZ) 47 50 60 50 50 63 Output Voltage (Vdc) +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB DC Output Current Min Full Load Max DC Current DC Current DC Current (A) (A) (A) 0 9.50 13.0 0 5.12 7.0 0.3 9.44 15.0 0.3 5.03 8.0 0 0.32 0.4 0 2.39 3.0 Output Power Full Load Output Power (W) 114.0 61.4 47.2 16.6 3.8 11.95 Full Load Total Output Power = 255 W Output Voltage Regulation (V) Tolerance (%) Min. Typ. Max. +11.4 +11.4 +4.75 +3.14 -10.8 +4.75 +12 +12 +5 +3.3 -12 +5 +12.6 +12.6 +5.25 +3.47 -13.2 +5.25 5 5 5 5 10 5 Output Ripple / Noise (mVpp) 120 120 70 50 250 100 Notes Peak +12 VAdc output current up to 14 A. Peak +12 VBdc output current to be 8 A. The maximum combined load on the +12 VAdc and +12 VBdc outputs shall not exceed 220 W. The maximum continuous combined load on the +5Vdc and +3.3 Vdc outputs shall not exceed 80 W.

Output Voltage (Vdc) +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB

Table 2: Target Specifications Target specifications for other key parameters of the reference design include: Efficiency: Minimum efficiency of 85% at 20% and at 100% of rated output power, and 88% at 50% of rated output power as defined by the 80 PLUS requirements. Power Factor: Power factor of 0.9 or greater at 100 % load. Input Voltage: Universal Mains: 90 Vac to 265 Vac, frequency: 47 to 63 Hz. Safety Features: As per the ATX12V version 2.2 power supply guidelines, this design includes safety features such as OVP, UVP, and OCP.

3. Architecture Overview
The architecture selected is designed around a succession of conversion stages as illustrated in Figure 1. The first stage is a universal input, active power factor boost stage delivering a constant output voltage of 385 V to the second stage, the half bridge resonant LLC converter. On the secondary side, this architecture uses a synchronous rectification scheme built around ON Semiconductors NCP4302 controller in order to generate a +12 V output. Finally, the +12 V is downconverted +5 V, +3.3 V and -12 V by a DC-DC conversion stage, built around two identical DC-DC controllers. In addition, a small integrated flyback converter delivers 12 W of standby power to another isolated 5 V rail. All the different voltage rails are monitored by a dedicated supervisory controller. ON Semiconductor has developed multiple power management controllers and MOSFET devices in support of the ATX program. Web-downloadable data sheets, design tools and technical resources are available to assist design optimization. The semiconductor components, supporting the ATX Generation 3 platform, are the NCP1654 PFC controller, the NCP1396 half-bridge resonant LLC controller, the NCP4302 synchronous rectification, the NCP1027 standby controller, the NCP1587 DCDC controller with synchronous rectification, and the NTD4809 single N-channel power MOSFET driven by the NCP1587, in synchronous rectification.

3.1 Primary Side: PFC Stage

There are a variety of PFC topologies available. These include discontinuous conduction mode (DCM), critical conduction mode (CRM) and continuous conduction mode (CCM). At this power level, CCM is the preferred choice and the NCP1654 will implement an IEC61000-3-2 compliant, fixed frequency, peak current mode or average current mode PFC boost converter with very few external components.

3.2 Primary Side: Half bridge resonant LLC Converter

The heart of the half-bridge resonant LLC converter stage is the NCP1396 resonant mode controller. Thanks to its proprietary high-voltage technology, this controller includes a bootstrapped MOSFET driver for half-bridge applications accepting bulk voltages up to 600 V. Protections featuring various reaction times, e.g. immediate shutdown or timer-based event, brown-out, broken optocoupler detection etc., contribute to a safer converter design, without engendering additional circuitry complexity. An adjustable dead-time also helps lower the shoot-through current contribution as the switching frequency increases. More information about LLC structure can be found in the ON Semiconductor application note AND8311/D (Understanding the LLC Structure in Resonant Applications).

3.3 Secondary Side: Synchronous Rectification

The 12 V output generated by the half-bridge resonant LLC converter is rectified using a proprietary synchronous rectification scheme built around two NCP4302 and two external single N-channel MOSFETs.

3.4 Secondary Side: DC-DC Conversion Stage

Two identical DC-DC controllers are used to down-convert the 12 V into +5 V and +3.3 V. The DC-DC controller is the NCP1587, a low voltage synchronous buck controller in a very small surface mount 8pin package. The NCP1587 is a low cost PWM controllers designed to operate from a 5 V or 12 V supply. This device is capable of producing an output voltage as low as 0.8 V. The NCP1587 provides a 1 A gate driver design and an internally set 275 kHz (NCP1587) oscillator. Other efficiency enhancing features of the gate driver include adaptive non overlap circuitry. The NCP1587 also incorporates an externally compensated error amplifier and a capacitor programmable soft start function. Protection features include programmable short circuit protection and under voltage lockout. Each DC-DC controller drives two NTD4809 (30 V, 58 A, single N-channel power MOSFET) in a synchronous rectification scheme. The -12 V is generated from the +5 V using a small discrete-based converter.

3.5 Secondary Side: Monitoring and Supervisory Stage

The four dc outputs +5 V, +3.3 V, +12 VA and +12 VB are monitored by a dedicated monitoring controller which also provides over-current protection, over-voltage protection, under-voltage protection and generates the Power Good logic signal.

3.6 Standby Power

The NCP1027 integrates a fixed frequency current mode controller and a 700 volt MOSFET. The NCP1027 is an ideal part to implement a flyback topology delivering 15 W to an isolated 5 V output. At light loads the IC will operate in skip cycle mode, thereby reducing its switching losses and delivering high efficiency throughout the load range.

4. Performance Results
Measurements are done at three loading conditions, the load being expressed as a % of the rated output power, i.e. at 20%, 50% and at 100% of rated output power. Measurements are also done at four AC line voltages, at 100 Vac, 115 Vac, 230 Vac and 240 Vac, at 50 Hz, 60 Hz and 63 Hz. All measurements are taken at the end of the 41 cm-long (16 inches) cable. The converter efficiency is measured according to the loading conditions detailed in Table 3: Load as % of rated output power 20% 50% 100% Max. Output Current (A) +5V +3.3V 1.89 1.01 4.72 2.52 9.44 5.03 15.0 8.0

+12VA 1.90 4.75 9.50 13.0

+12VB 1.02 2.56 5.12 7.0

-12V 0.06 0.16 0.32 0.4

+5VSB 0.48 1.20 2.39 3.0

Table 3: Load Matrix for Efficiency Measurements

4.1 Total Efficiency

AC Input 100 VAC / 50 HZ 115 VAC / 60 HZ 230 VAC / 50 HZ 240 VAC / 63 HZ Total Efficiency (%) 20% Load 50% Load 100% Load 85.9% 88.3% 85.9% 86.3% 88.8% 86.8% 86.5% 90.1% 88.7% 86.5% 90.1% 88.8% Table 4: Efficiency Results

The converter achieves over 85% efficiency with room to spare over all load conditions. All measurements are done at the end of the power cable.

4.2 Power Factor

The power factor exceeds 0.9 over all operating conditions as shown in Table . Power Factor Specification AC Input 20% Load 50% Load 100% Load 100 VAC / 50 HZ 0.96 0.983 0.987 PF > 0.90 @100% 115 VAC / 60 HZ 0.945 0.978 0.986 & 50% of rated 230 VAC / 50 HZ 0.714 0.912 0.966 output power 240 VAC / 63 HZ 0.689 0.902 0.962 Table 5: Power Factor vs Load as % of Rated Output Power

4.3 Standby Power

AC Input 100 VAC / 50 HZ 115 VAC / 60 HZ 230 VAC / 50 HZ 240 VAC / 63 HZ Output Current on +5VSB (A) 0.147 0.171 0.244 0.312 Input Power (W) 0.36 0.31 0.55 0.57 Specification < 1W
U.S. Department of Energy, FEMP (Federal Energy Management Program): http://www1.eere.energy.gov/femp/procurement/index.html Executive Order 13221 of July 31, 2001: http://www1.eere.energy.gov/femp/pdfs/eo13221.pdf

Table 6: Standby Power vs AC Line Voltage

4.4 Input Current

AC Input 90 VAC / 47 HZ 100 VAC / 50 HZ 115 VAC / 63 HZ 180 VAC / 50 HZ 230 VAC / 53 HZ 240 VAC / 60 HZ 264 VAC / 63 HZ Measurement (A) Specification 20% Load 50% Load 100% Load 0.673 1.609 3.245 0.614 1.458 2.952 0.544 1.271 2.549 90V (max 3.6A) 180V (max.1.8A) 0.363 0.799 1.573 @ 100% load 0.355 0.667 1.266 0.353 0.646 1.217 0.339 0.597 1.092 Table 7: Input Current vs Load and AC Line Voltage

4.5 Inrush Current

Parameter Description Min. Typ. Initial In-rush Current Secondary In-rush Current Table 8: Inrush Current Specification AC Input 90 VAC/47 HZ 120 VAC/63 HZ 220 VAC/50 HZ 264 VAC/63 HZ Max. 55 35 Units A (Peak) A (Peak)

Output Measurement (A) Specification Load 100% Initial In-rush Current 9.9 Load Secondary In-rush Current 8.0 100% Initial In-rush Current 17.9 Initial In-rush Current < 55 A Load Secondary In-rush Current 16.2 100% Initial In-rush Current 25.4 Secondary In-rush Current < 35 A Load Secondary In-rush Current 24.5 100% Initial In-rush Current 34.1 Load Secondary In-rush Current 33.3 Table 9: Inrush Current vs AC Line Voltage

10

4.6 Output Transient Response (Dynamic Loading) Output Transient starting Load T1 / T2 (0.1 A/sec), T1 / T2 (1 ms)
DC Output +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB Load (A) Voltage Max. (V) Min. Load Step Max. Overshoot Undershoot 0.5 6.5 6.5 0.6 0.6 0.5 3.5 3.5 0.6 0.6 0.3 5 10 0.25 0.25 0.3 2.66 5.34 0.17 0.17 0 0.17 0.33 0.6 0.6 0 1.33 2.67 0.25 0.25 Table 10: Output Transient Response (Dynamic Loading)

4.7 Overshoot at Turn-On/Turn-Off

DC Output +12VA +12VB +5V +3.3V -12V +5VSB Min. Load Load Step Specification Step Max. 0.34 N/A 1.2 0.38 N/A 1.2 0.21 0.23 0.5 0.15 0.17 0.33 0.18 0.20 -1.2 0.21 0.20 0.5 Table 11: Overshoot at Turn-On/Turn-Off Unit

VP-P

Measured and Calculated Data at 115V / 60HZ DC Output Min. Load Step

Load Step Max.

+12 VA

N/A

+12 VB

N/A

11

+5 V

+3.3 V

-12 V

+5 VSB

Figure 2: Dynamic Load Test Waveforms

12

4.8 Output Ripple / Noise

The ripple voltage of each output is measured at no load and at the maximum load for each output., and at the four different line voltages. The output ripple is measured across 10 F/MLC parallel 1000 F low ESR/ESL termination capacitors. Figure 3 through 6 show the output voltage ripple measurements. All outputs meet the voltage ripple requirements. DC Output +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB No Load (A) 0 0 0 0 0 Full Load (A) 9.50 5.12 9.44 5.03 0.32 Output Ripple / Noise Max (mVp-p) 120 120 70 50 250

0 2.39 100 Table 12: Output Ripple / Noise Specification

4.8.1 100 VAC / 50 HZ - Ripple / Noise Test Waveform No Load Full Load

+12 VA

No Load

Full Load

+12 VB

13

No Load

Full Load

+5 V

No Load

Full Load

+3.3 V

No Load

Full Load

-12 V

No Load

Full Load

+5 VsB

Figure 3: 100 VAC / 50 HZ - Ripple / Noise Test Waveform

14

4.8.2 115 VAC / 60 HZ - Ripple / Noise Test Waveform

No Load

Full Load

+12 VA

No Load

Full Load

+12 VB

No Load

Full Load

+5 V

No Load

Full Load

+3.3 V

15

No Load

Full Load

-12 V

No Load

Full Load

+5 VSB

Figure 4: 115 VAC / 60 HZ - Ripple / Noise Test Waveform

16

4.8.3 230 VAC / 50 HZ - Ripple / Noise Test Waveform

No Load

Full Load

+12 VA

No Load

Full Load

+12 VB

No Load

Full Load

+5 V

No Load

Full Load

+3.3 V

17

No Load

Full Load

-12 V

No Load

Full Load

+5 VSB

Figure 5: 230 VAC / 50 HZ - Ripple / Noise Test Waveform

18

4.8.3 240 VAC / 63 HZ - Ripple / Noise Test Waveform

No Load

Full Load

+12 VA

No Load

Full Load

+12 VB

No Load

Full Load

+5 V

No Load

Full Load

+3.3 V

19

No Load

Full Load

-12 V

No Load

Full Load

+5 VSB

Figure 6: 240 VAC / 63 HZ - Ripple / Noise Test Waveform

4.9 Hold-up Time

The required holdup time at 50% load is 16 ms. Holdup time is measured from the moment the AC power is removed to when the PWR_OK signal goes low. Figure 7 shows the holdup time at 50% load, and at 115 Vac and 230 Vac. Channel 4 is the AC power and Channel 1 is the PWR_OK signal. AC Input 115 VAC / 60 HZ 230 VAC / 50 HZ Dropout Loading Measurement Condition (msec) 50% Load 22 50% Load 23 Table 13: Hold-up Time Specification Specification > 16 ms

20

115 VAC 60HZ - 50% Load

230 VAC / 50 HZ - 50% Load

Figure 7: Hold-up Time

4.10 Timing / Housekeeping / Control

4.10.1 AC On / Off Control

AC On / Off Test Parameter Description Main Outputs Rise Time 2 ms < T2 < 20 ms POK delay 100 ms < T3 < 500 ms Power down warning 1 ms < T4 Hold-up time T6 > 16 ms PS_ON Timing (on) T7 < 1000 ms Main Outputs Rise Time 2 ms < T2 < 20 ms Figure 8: AC On / Off Control

21

4.10.2 PS_ON On / Off Control

PS_ON On / Off Test Parameter Description Rise Time 2 ms < T2 < 20 ms POK delay 100 ms < T3 < 500 ms Power down warning 1 ms < T4 PS_ON Timing (off) T8 < 60 ms PS_ON Timing (on) T9 < 350 ms -12VDC Rise Time 0.1 ms < T10 < 20 ms Figure 9: PS_ON On / Off Control 4.10.3 Logic Timings
Parameter Description T1 Description Delay from Standby within regulation to DC outputs turn on Standby, +3.3VDC, +5VDC,and 12VDC output rise time Min. Max. DC Output N/A +12V +5V +3.3V +5Vsb +12V +5V +3.3V +12V +5V +3.3V -12V +12V +5V +3.3V N/A +12V +5V +3.3V +12V +5V +3.3V +12V +5V +3.3V -12V Measurements Units AC IN 148 2.8 2.6 2.8 14 250 244 244 1.6 4.8 6.8 6 608 600 600 604 143 178 179 PS_ON N/A 4.2 2.4 2.2 N/A 256 250 252 28.4 30 32.4 12 ms

300

T2

20

T3

Delay from output voltages within regulation limits to POK asserted at turn on Delay from POK deasserted to output voltages (3.3V, 5V, 12V, -12V) dropping out of regulation limits Delay from DC output deasserted to Standby out of regulation at turn off. Delay from loss of AC to desertions of PWOK. PS_ON Timing (on)

100

500

T4

T5 T6 T7

5 16 1000

T8

PS_ON Timing (off)

60

T9 T10

Delay from PS-ON reasserted to output turn on -12VDC output rise time 0.1

350 20

1.822

65.6 67.2 69.2 80.8 86.8 86.8 1.239

Table 14: Logic Timings

22

4.10.4 PWR_OK
PWR_OK Full Load CONTROL AND LOGIC SIGNALS RIPPLE/NOISE Measurement Max. Unit 35 400 mVP-P

Table 15: PWR_OK Timings 4.10.5 PS_ON

PS_ON Full Load CONTROL AND LOGIC SIGNALS RIPPLE/NOISE Measurement Max. Unit 30 400 mVP-P

Table 16: PS_ON Timings

4.11 Output Protection

4.11.1 Output Over-Voltage Protection DC Output +12 VA / B +5 V +3.3 V -12 V +5 VSB Specification Measurements (V) Min. (V) Max. (V) 13.5 15 5.6 7 6.36 3.76 4.3 4.2 -13.5 -15 5.6 7 Table 17: Output Over-Voltage Protection

4.11.2 Output Under-Voltage Protection +12VA

+12 VB

+5 V

+3.3 V

Figure 10: 115 VAC / 60 HZ DC Output Under-Voltage Protection @ Full Load

23

4.11.3 Short Circuit Protection +12 VA +12 VB

+5 V

+3.3 V

+5 VSB

Figure 11: 115 VAC / 60 HZ DC Output Short circuit protection @ Full Load

24

4.11.3 Over-Current Protection DC Output +12 VA +12 VB +5 V +3.3 V -12 V +5 VSB Over Current Protection Measurements (A) Min. (A) Max. (A) 15 21 (< 240 VAC) 19.6 8.5 11.5 (< 240 VAC) 10.0 18 24 20.5 10 13 10.9 N/A N/A N/A 3 6 6.0 Table 18: Over-Current Protection +12 VB

+12 VA

+5 V

+3.3 V

+5VSB

Figure 12: DC Output Short circuit protection @ Full Load

25

5. Evaluation Guidelines
Evaluation of the reference design should be attempted only by persons who are intimately familiar with power conversion circuitry. Lethal mains referenced voltages and high dc voltages are present within the primary section of the ATX circuitry. All testing should be done using a mains high-isolation transformer to power the demonstration unit so that appropriate test equipment probing will not affect or potentially damage the test equipment or the ATX circuitry. The evaluation engineer should also avoid connecting the ground terminal of oscilloscope probes or other test probes to floating or switching nodes (e.g. the source of the active clamp MOSFET). It is not recommended to touch heat sinks, on which primary active components are mounted, to avoid the possibility of receiving RF burns or shocks. High impedance, low capacitance test probes should be used where appropriate for minimal interaction with the circuits under investigation. As with all sensitive switchmode circuitry, the power supply under test should be switched off from the ac mains whenever the test probes are connected and/or disconnected.

The evaluating engineer should also be aware of the idiosyncrasies of constant current type electronic loads when powering up the ATX demonstration unit. If the loads are adjusted to be close to the ATXs maximum rated output power, the unit could shut down at turn on due to the instantaneous overloading effect of the constant current loads. As a consequence, electronic loads should be set to constant resistance mode or rheostats should be used for loads. The other alternative is to start the supply at light to medium load and then increase the constant current electronic loads to the desired level. The board is designed to fit in a traditional ATX enclosure as shown in Figure .

26

Figure 13: ON Semiconductors 255 W Reference Design for ATX Power Supplies

27

6. Schematics
The power supply is implemented using a single sided PCB board. Added flexibility is provided by using daughter cards for the PFC (NCP1654) circuit and the NCP1396 resonant mode controller. The individual PCB board schematics are shown in figure 14.

28

ACL

To +5Vsb system
ACN

D1 STTH310(UF5407G) BD1 10A600V

1

R133 R13 10- 2W L2 LQA08TC600 D2 TO220 R7 1.8M(1%)

HV+

SW1 0-1 Switch

F1 5A/250V
L CON1 2 1 N

CX3 0.33 1M(1/4W) MOV 471K R1

LF1 0.8*25t 3mH CX2 0.47

R132 Q3 STP12NM50 T1/P1 0.1*50 33t 1,2 Ls=80uH Lm=620uH TO220 Q4 STP12NM50 R11 10K R12 5,6 N.C. 24K 223/630V C4 C4-1 T1 EE35 12,13,14 0.1*80 2T R130 2.2A

IC14 10K
1 SYNC/CS VCC8 2 TRIG 3 CATH 4 REF GATE 7 GND 6 Dlyadj 5

104 C132 L6 0.8uH C136 C137 C138 C139 2200uF/16V 2200uF/16V 2200uF/16V

LF3 0.8*25 3mH

IS12A/B

L3 120uH

3A1000V 0.1*50t 680uH R6 3.3M

0.002 RS12A-1 RS12A 0.002

VS12A

Peak 14A
+12VA VS12B E

C144 1n/50V

R146 22R147 1K D78 7.5B

CX1

N.C.

3.96 1uF

D3

R10 TO220 10K

E Peak 8A +12VB T1(1/3)

NCP4302 C146 R134 6.2K R135 3.3K D72 R137 1N4148 80A55V 10R138 10TO220 80A55V

RS12B 2200uF/16V C140 0.002

AC INLET AC IN
AC IN 85-264V

CORE RH16*17*9 GND WIRE 2t

CY1 472

CY2 472

CY3 472

CY4 472

C1 474 R3

2 3 4

Q1 SPP15N60C3

220uF/450V

C6 474 R5 10K

TO220

R9 0-(1%)

T1/P2 10,11 333/630V

10-(2W) D70 MBR60L45CTG STP80NF55 STP80NF55

TO220

220uF/16V

R8 1.8M(1%)

3 2 1

C2

2200uF/16V

C130561

RS12B-1 0.002 (EE35) F L9 0.8uH

GND

C145 1n/50V

R148 1K R149 22-

D77 7.5B
B

D4

CY5

Q30

nc.

0.1-3Ws R3-1 0.5- 1W 4 2 1

R12A 24K C5 220P

Q31

D73 R142
1K

R52 3.6K(1%) R51 3.3M IC1

1 2 3 4 8 7 6 5

R53 10-(1206) C56 47uF/25V R56 C55 C54 2.2uF 220nF

HV

8,9 T1/P3 2T

D71 MBR60L45CTG C131 R13110-(2W) 561 R141 2.2B

1N4148

R57 23.2K

C52 0.1uF R55 1K

D5 4148

R140 10K IC15

1 SYNC/CS VCC8 2 TRIG 3 CATH GATE 7 GND 6 Dlyadj 5

R143 68K 104 C134 IC16

AZ431

R144 C141 18K(1%)

223

C50 0.47uF

R54 R55 47K 82.5K

C53 1nF

NCP1654 65Khz

12K

R145
4.7K(1%)

R303 15TM2 T204K D120 6.2B CON3

1 2 + A -

+12V

D20 R56 30K C60 47uF/25V 18-(1206)

UF 1A600V

IC23 R68 107 6 817

4 REF

J9 33C57 1uF R77 33R57 30K Q10 NC C64 R76 1.8K 10uF/25V Q12 D26 NC D27 NC MMBT2907 C58 4.7uF/50V PFC OK R61 150K R60 8.2K(1%) R62 R63 10K C59 222 R58 15K R59 6.8K IC2 NCP1396A
1 Css 2 FMAX 3 CTMR 4 RT 5 BO 6 FB 7 DT 8 FF VBOOT 16 MVPP 15 HB 14 NC. 13 VCC 12 MLOW 11 GND 10 SF 9

NCP4302

FAN 12V

2.54

R65 C61 104

16

Q11 2SC4672

R75 NC
C

R69 1K R70 1K

R71 10R72 10K Q5

D24

D25

D121 6.2B R302 10K

SSS8050(TO92)

CTL1

jump

R300 10K

Q20 MMBT2222 R301 1K

FAN Control
Q21

1N4148 1N4148

C262 100/25V

R67 10K

MMBT2907 D21 1N4148

D23 3.6B D22 7.5B IC3 AZ431

3,14
VCC1 VCC1

C62 R74 3.3K 683

GND -12V/0.32A

SO16 R64 1.1K(1%)

2K

R66 5.1K

R216 D110 1N4744 C209-1 224(1812) D102 SR24E

IS12V IS12A/B

15

Jump Q13 R78 NC NC D28 NC R79 10K Q14 2SA1797 R80 10K

IC20 11 10 817 +5Vsb

+5Vsb

PGO
PGO

PS_ON
PS_ON

L10 3uH C200 C201 NC. 220uF/25V C202 100P D100 ES1D C204 104 Q32 R212 10-

C143 220uF/25V L9

C230 NC.

R269 330-

5VSB

+5Vsb
IS12A

C209 224(1812)

HV+

IS12A

HV+ D29 R81 499K(1%) R82 499K(1%) 12 R83 6.8K(1%) R84 1K C65 104 C66 105 R85 470K R86 10K 4148

IS12B P4-1 P4-1 R258 200R257100-

IS12B

VS12B VS12BVS12A VS12A P4-3 R259 47R260 47P4-2 P5-6 P5-5

VS5 NTD4809N DPAK 10t N2

IS5 IS5 VS5

VCC1

1 BST

Vcc 5

PGI R89 R87 22K IC5 100R88 LM393(1/2) 4.7K IC5 8 9 IC21 817 R250 1K
+5Vsb

P5-2 Q16 R252 470R253 1K

IS5 IS33

IC18
2 TG Phase 8 3 Gnd 4 BG

RS5-1 NC. RS5 75K

+5V

VS33

VS5

R261 47-

IS5

IS33 R255 470R256 240-

MMBT2222

MMBT2222 R251 4.7k

Q17

R262 47C250104 C252 104

R263 2K

C251 474 C220 2200uF/16V

R202 1K

C203
Comp.

D112 4148

563
6 FB

10R213

Q33 NTD4809N

L7 6.8uH

C216 104

NC. RS5 1uH 330uF/10V C208 Add 2200uF/10V PPTC(NSMD100) C207

NCP1587 R203 27K R204 5.11K

R206

D101 SR24E

1.5uH C142 330uF/25V

IC20 AZ431

R73 1.1K

C63 103

18K

L11 Be core

IC4 AZ431 SOT23 C67 105

LM393(1/2)

C253104 C254 104 C255 C258 IC17

12 8 VS12A VS12B VS5 VS33 IS12B IS12A IS33 IS5 VCC GND RI PGO PGI PSONB FPOB 2 6 16 1 4 3 OTP 9

4148 DPAK D113 R205 NC. C205 NC.

C206 2200uF/10V

+5V/9.44A 47.2W

TM1 T10K OPT. R264 2.2K C261 104 R265 1K

GND GND

TO D-D
FPBO

C256 104 IS12A/B

IS12A/B

104 104

D103 ES1D C210A 220uF/25V C210 NC. C211 100P R208 C212
Comp. 3 Gnd

C213 104 R21410-

Q34 C232 NTD4809N

+5V/+3.3V Max.80W
NC. L8 6.8uH
IS33 VS33

14 13

P5-3 FPBO

7 5 11 10 15

1 BST

Vcc 5

C257104 D105 4148 R254 47D104 4148 C259 104 C260 10/50V

IC19
2 TG Phase 8

IS33 RS33 C217 0.002

VS33 L13 3uH

+3.3V

D1064148

DPAK Q35

1K

563
6 FB

4 BG

R215 10NTD4809N D107 4148 R211 NC. C214 NC. DPAK C215 2200uF/10V

NCP1587 R209 R268 62K R267 1K R266 10K 16K R210 5.11K

104 C218 2200uF/10V

PS223

+3.3V/5.03A 16.6W
C219 2200uF/10V
GND

DC-DC Stage (CTL2)

P5-1
HV-B+ HV-B+

ACL
ACL

D122
VCC1

T2 EE25 D48 D51 R99 2.2M C105 220uF/25V VCC1 R105 0ES1D R103 3.3K(1206) C104 100uF/35V IC10 R100 2.2M
1 VCC GND 8 2 Ramp Comp. OPP 7 3 Brown-Out 4 FB Drain 5

P5-4 10-(2W)C110 102 R111 D52 MBR20L45CT S1 5t L5

+5Vsb/2.39A

1N4006 ACN
ACN

D123 1N4006

P6KE200

D50 P1 UF4007 55t L=0.9mH

DR6*8 C108 2200uF/10V C109 1000uF/10V

C103 10uF/25V C100 22uF400V

100R106

D49 LL4148 P2 19t

D54 1N4734A 1W 5.32-5.88V

GND

IC12 817(1/2)

R110100R108 R150 1K C107 684 IC11 10K(1%)

C101 103

R101 27K

R102 78.7K

NCP1027 IC12 817(1/2) C102 104 CY6 222

R109 10K(1%)

2008.12.10
Title Size A1 Date: File:

AZ431

ON SEMICONDUCTOR.
Number

POWER SUPPLY ATX 255W >85%

Revision

ON -Semi ATX255W
11-Dec-2008 D:\WORK\layout\MAINSTAY_F.K.ddb Sheet of Drawn By:

V8
D

D70,D71,C133,C135,R4,R134,R135,R139

Figure 14: Schematics

7. Parts List
The bill of materials (BOM) for the design is provided in this section. To reflect the schematics shown in the previous section, the BOM have also been broken into different sections and provided in separate tables Table 19 through 22. It should be noted that a number of components used during the development cycle were based on availability. As a result, further cost reductions and better inventory management can be achieved by component standardization, i.e. the unique part numbers can be SIGNIFICANTLY reduced by standardization and re-use of component values and case sizes. This will result in a lower cost BOM and better inventory management.
QTY 1 1 1 1 2 1 4 4 4 1 2 1 2 5 5 5 1 1 3 1 1 1 1 1 3 1 2 1 1 1 2 HS1 BD1 D2 Q1 Q3, Q4 SCREW(BD1) SCREW(D2, Q1, Q3, Q4) SL(D2, Q1, Q3, Q4) B(D2, Q1, Q3, Q4) HS2 Q30, Q31 D52, D70, D71 SCREW(D52, Q32, Q31, Q70, Q71) SL(Q30, Q31, D70, D71, D52) B(Q30, Q31, D70, D71, D52) R3 R13 R130, R131, R111 D48 D50 D1 C109 R1 RS12A, RS12A-1, RS12B F1 LF1.LF3 L2 L3 L5 L6, L9 SYMBOL DESCRIPTION HEAT SINK 93*60*4 AL4.0t DIO.BRI 10A 600V / TS10P05G DIO.NR LQA08TC600 8A 600V TO-220AC FET.NCH SPP15N60C3 TO220 FET.NCH STP12NM50 TO-220 SCREW PAN-HEAD M3*10 SCREW PAN-HEAD M3*6 SLTO-220 13*19*0.3mm BUSHING TO-220 HEAT SINK 93*60*4 AL4.0t STP80NF55-06 80A55V TO220 MBR20L45CT 20A 45V TO-220 MBR60L45CTG 60A 45V TO-220 SCREW PAN-HEAD M3*6 SLTO-220 13*19*0.3mm BUSHING TO-220 RES.WW. 0.1R 3WS NKNP RES.MO. 10- 2W RES.CR. 10- 2WS P6KE200A DO-15 UF4007 DO-41 STTH310 3A 1000V / UF5407G CAP.ELE 1000uF 10V 10*16KY RES.CR. 1M 1/4W COPPER 0.002MST 5A/250V 0.8*25t L=3mH+30% L=2.5mm POT3319 0.1*50t*61t L=0.68uH T80-26+UL L=120uH20% DR6*8 L=3.6uH R8*20+UL L=0.8uH 2.4*5.5t CONQUER MEIHUA MEIHUA MEIHUA MEIHUA J.X.E. J-YH-R8*20-789 (ASC-2203VGH)25T VENDOR Taizhi PANJIT QSPEED INFINEON ST LONGFEI LONGFEI JUNHO JUNHO Taizhi ST ON ON LONGFEI JUNHO JUNHO Synton-Tech Synton-Tech Synton-Tech PANJIT PANJIT DII SU'SCON VENDOR P/N

MAIN BOARD (PFC Stage, Synchronous Rectification Output Stage)

29

1 1 1 1 4 1 2 1 1 2 1 1 1 1 1 1 1 1 1 5 1 1 2 1 2 1 3 3 8 1 1 1 3 2 2 2 1 8 1 1 1 5 2 2

T1 T2 MOV IC10 IC23, IC12, IC20, IC21 D54 D122, D123 C4-1 C4 C1, C6 CX3 CX2 C100 C55 C2 C56 C105 C103 C104 C136, C137, C138, C139, C140 C108 C110 C130, C131 C146 CY3, CY4 CY6 J4, J5, J6 J7, J19, J22 J1, J2, J3, J8, J11, J15, J18, J24 J23 MB CONNECT CPU CONNECT P3, P4, P5 P6, P7 P8, P9 HS3, HS4 CON1 J10, J12, J13, J14, J16, R9, J20, R105 J9 J21 R3-1 R5, R10, R11, R133, R140 R7, R8 R12, R12A

YC3501 L=0.63mH Ls=80uH EE25 TVR10471KSY NCP1027P065G DIP-8 PHOTO PC817B DIP-4P 1N4734A 1W 5.32-5.88V 1N4006 CAP.PEI 0.022uF 630V CAP.PEI 0.033uF 630V CAP.MEF 0.47uF 400V P=10 CAP.MPP 0.33uF 275vac p=15 CAP.MPP 0.47uf 275V HQX P=15 CAP.ELE 22uF 450V 8*11 CAP.ELE 2.2uF 50V 5*11 CAP.ELE 220uf 450V CAP.ELE 47uF 25V 5*11 CAP.ELE 220uF 25V 6.3*11 CAP.ELE 10uF 50V 5*11 CAP.ELE 100uF 35V 6*11 CAP.ELE 2200uF 16V 10*25 KZE CAP.ELE 2200uF 10V 10*16 CAP.CER 1000PF 1KV Y5P P=5 CAP.CER 560PF 1KV Y5P CAP.ELE 220uF 16V 6.3*11 CAP.CER 4700PF Y2 CAP.CER 2200PF Y1 JUMP 0.8 P=12.5mm JUMP 0.8 P=20mm JUMP 0.8 P=10mm JUMP 0.8 P=5mm MB CONNECT 24-PORT CPU CONNECT 4-PORT(2*2) SATA+SATA CONNECT SATA CONNECT FDD CONNECT 4-PORT HEAT SINK 28*38*5 CU1.2t WAFER 3.96(3-1)PIN 180 RES.SMD 0- 5% 0805 RES.SMD 33- 5% 0805 RES.SMD 0- 5% 1206 RES.SMD 0.5- 1% 2512 RES.SMD 10K 5% 0805 RES.SMD 1.8M 5% 0805 RES.SMD 24K 5% 0805

MEIHUA MEIHUA TKS ON SHARP

PAC UTX UTX UTX SU'SCON NDB NDB NDB NDB NDB NDB NDB SEC SEC SEC SEC

R75PI2330JEMEJ

2Y5P102K102C56E

EVERBIZ EVERBIZ EVERBIZ EVERBIZ EVERBIZ Taizhi SUNDA

30

1 1 1 1 2 1 2 1 2 1 1 1 6 2 1 2 1 1 2 1 1 1 1 2 1 1 1 1 1 2 2 3 3 1 1 4 2 2 1 2 2 1

R54 R55 R56 R57 R51, R6 R52 R81, R82 R83 R99, R100 R101 R102 R103 R142, R147, R148, R250, R253, R150 R108, R109 R110 R132, R141 R134 R135 R137, R138 R53 R143 R144 R145 R146, R149 R251 R252 R269 C5 C50 C101, C102 C107, C54 C53, C144, C145 C134, C132, C52 C141 D51 D5, D72, D73, D49 D77, D78 Q16, Q17 IC1 IC11, IC16 IC14, IC15 PCB

RES.SMD 47K 1% 0805 RES.SMD 82.5K 1% 0805 RES.SMD 12K 5% 0805 RES.SMD 23.2K 5% 0805 RES.SMD 3.3M 5% 0805 RES.SMD 3.6K 1% 0805 RES.SMD 499K 1% 0805 RES.SMD 6.8K 1% 0805 RES.SMD 2.2M 5% 0805 RES.SMD 27K 5% 0805 RES.SMD 78.7K 1% 0805 RES.SMD 3.3K 5% 1206 RES.SMD 1K 5% 0805 RES.SMD 10K 1% 0805 RES.SMD 100- 5% 0805 RES.SMD 2.2- 5% 0805 RES.SMD 6.2K 5% 0805 RES.SMD 3.3K 5% 0805 RES.SMD 10- 5% 0805 RES.SMD 10- 5% 1206 RES.SMD 68K 5% 0805 RES.SMD 18K 1% 0805 RES.SMD 4.7K 1% 0805 RES.SMD 22- 5% 0805 RES.SMD 4.7K 5% 0805 RES.SMD 470- 5% 0805 RES.SMD 330- 5% 0805 CAP.MON 220P 50V 0805 X7R CAP.MON 0.47uF 50V X7R 0805 CAP.MON 0.01uF 50V X7R 0805 CAP.MON 0.22uF 50V X7R 0805 CAP.MON 1000PF 50V X7R 0805 CAP.MON 0.1uF 50V X7R 0805 CAP.MON 0.022uF 50V X7R 0805 ES1D 1A 200V SMA DIO.NR LL4148 DIO.ZEN RLZ7.5B MMBT2222 SOT23 NCP1654A 65Khz SO-8 TL431 NCP4302 SO-8 CEM-1 1oz 1.6t 145*108.5 NO.SPB011V5 ON ON ON TSC TSC ROHM

Table 19: Main Board (PFC Stage, Synchronous Rectification Output Stage)

31

QTY 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 3 1 2 4 1 1 1 5 1 1 1 1 1 1 5 1 1 2 C220 L11 RS33 C208

SYMBOL

DESCRIPTION CAP.ELE 2200uF 16V 10*25 BEAD RH035100ST-A8 COPPER 0.002CAP.ELE PSC 680uF 10V 10*11.5 CAP.ELE 2200uF 16V 10*25 CAP.ELE 10uF 50V 5*11 KY CAP.ELE 330uF 25V 8*15 KY CAP.ELE 220uF 25V KY 6.3*11 CAP.PEI 0.47uF 100V P=10 CAP.ELE 100uF 25V 6.3*11 1N4744 S8050L-C EBC TO92 HKH080 L=6.8uH HKH080 L=6.8uH DR6*8 L=3.6uH R6*20+UL L=3.0uH20% 1.2*11.5t R8*20+UL L=1uH20% T10K T204K HEAT SINK 25.5*12.5 Cu1.2t HEAT SINK 40.5*12.5 Cu1.2t WAFER P=2.5*2 90 Pin Header 3pin 90 P=2.54mm Pin Header 6pin 90 P=2.54mm Fuse 1A 1206 RES.SMD 10K 5% 0805 RES.SMD 27K 1% 0805 RES.SMD 5.11K 1% 0805 RES.SMD 10- 5% 0805 RES.SMD 75K 5% 1206 RES.SMD 18K 5% 1206 RES.SMD 16K 1% 0805 RES.SMD 47- 5% 0805 RES.SMD 470- 1% 0805 RES.SMD 240- 1% 0805 RES.SMD 100- 1% 0805 RES.SMD 200- 1% 0805 RES.SMD 2K 5% 0805 RES.SMD 2.2K 5% 0805 RES.SMD 1K 5% 0805 RES.SMD 62K 1% 0805 RES.SMD 15- 5% 0805 CAP.MON 0.22uF 50V X7R 1812

VENDOR NDB Tzai Yuan NDB NDB NDB NDB NDB NDB UTC MEIHUA MEIHUA MEIHUA TKS TKS Taizhi Taizhi SUNDA SUNDA SUNDA CONQUER

VENDOR P/N

DC-DC Converter Stage, Supervisory Stage (referred to as CTL2 in schematics of figure 14)

C206, C207, C215, C218, C219 C260 C142 C143, C200, C200A C209 C262 D110 Q21 L7 L8 L9 L10, L13 RS5 TM1 TM2 HS7 HS8, HS9 CON3 P4(CTL3-PCB) P5(CTL3-PCB) PPTC R266, R300, R302 R203 R204, R210 R212, R214, R213, R215 R206 R216 R209 R254, R259, R260, R261, R262 R255 R256 R257 R258 R263 R264 R265, R267, R301, R202, R208 R268 R303 C209, C209-1 C204, C213, C216, C217, C250, C252, C253, C254, C255, C256, C257, C258, C259, C261 C202, C211 C203, C212

HKH-080CE/034 R6*20-0003 TTC05103KSY TTC05204KSY

nSMD100

14

CAP.MON 0.1uF 50V X7R 0805

2 2

CAP.MON 100P 50V X7R 0805 CAP.MON 0.056uF 50V X7R 0805

32

1 2 2 6 2 1 4 1 2 1 1

C251 D100, D103 D101, D102 D104, D105, D112, D113, D106, D107 D120, D121 Q20 Q32, Q33, Q34, Q35 IC17 IC18, IC19 IC20 PCB

CAP.MON 0.47uF 16V X7R 0805 ES1D 1A 200V SMA DIO.SB SR24 2A 40V SMA DIO.ZEN LL4148 DIO.ZEN RLZ6.2B MMBT2222 SOT23 NTD4809N-D 58A 30V DPAK PS223 SOP-16 NCP1587 SO-8 TL431 FR4 1oz 1.6t 62*83.5 NO.PB011V5-CTL3 ON SITI ON ON TSC PANJIT TSC ROHM

Table 20: DC-DC Converter Stage, Supervisory Stage (referred to as CTL2 in schematics of figure 14)

33

P/N

QTY 1 1 1 1 1 1 1 4 2 1 1 1 1 1 2 6 1 1 2 1 1 1 1 1 1 1 1 2 1 1 3 1 4 1 1 2 1 1 1 2 1 1

SYMBOL DESCRIPTION VENDOR HB Resonant LLC-Stage (referred to as CTL1 in schematics of figure 14 ) C58 CAP.ELE 4.7uF 50V KMG 5*11 NDB C60 CAP.ELE 47/25V KMG 5*11 NDB C64 CAP.ELE. 10uF 25V NDB P2 (CTL2-PCB) Pin Header 3pin 90 P=2.54mm SUNDA P3 (CTL2-PCB) Pin Header 13pin 90 P=2.54mm SUNDA HS 25*16*8 PCB HOLD RCC-5 KANGYANG R55, R69, R70, R84 RES.SMD 1K 5% 0805 R56, R57 RES.SMD 30K 5% 0805 R58 RES.SMD 15K 5% 0805 R59 RES.SMD 6.8K 5% 0805 R60 RES.SMD 8.2K 1% 0805 R61 RES.SMD 150K 5% 0805 R62 RES.SMD 2K 5% 0805 R64, R73 RES.SMD 1.1K 1% 0805 R63, R67, R72, R79, R80, R86 R65 R66 R68, R71 R74 R76 R77 R88 R85 R87 R89 C59 C61, C65 C62 C63 C66, C67, C57 D20 D21, D24, D25, D29 D22 D23 Q5, Q12 Q11 Q14 IC2 IC3, IC4 IC5 PCB RES.SMD 10K 5% 0805 RES.SMD 18- 5% 1206 RES.SMD 5.1K 5% 0805 RES.SMD 10- 5% 0805 RES.SMD 3.3K 5% 0805 RES.SMD 1.8K 5% 0805 RES.SMD 33- 5% 0805 RES.SMD 100- 5% 0805 RES.SMD 470K 5% 0805 RES.SMD 22K 5% 0805 RES.SMD 4.7K 5% 0805 CAP.MON 2200PF 50V X7R 0805 CAP.MON 0.1uF 50V X7R 0805 CAP.MON 0.068uF 50V X7R 0805 CAP.MON 0.01uF 50V X7R 0805 CAP.MON 1uF 25V X7R 0805 UF 1A600V / US1J DIO.ZEN. LL4148 DIO.ZEN. RLZ7.5B DIO.ZEN. RLZ3.6B MMBT2907 2SC4672 2SA1797 NCP1396A SO-16 TL431 LM393 SO-8 FR4 1oz 1.6t 44*56 NO.SPB011V4-CTL2

VENDOR P/N

PANJIT TSC ROHM ROHM PANJIT ROHM ROHM ON ON ON

LM393D

Table 21: HB Resonant LLC-Stage (referred to as CTL1 in schematics of figure 14)

34

QTY 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 4 1 4 4 1 1 1

SYMBOL SW1 SW-INLET SW-INLET SW-INLET INLET(G)-GND CORE(INLET-GND) DTOD-BOARD FAN CY1, CY2 CX1 AC INLET CASE CASE MYLAR SCREW(AC INLET) SCREW(CASE) SCREW(INLET-GND)) SCREW(S1~S4) SCREW(FAN) SCREW(GND)

DESCRIPTION Mechanical and Miscellaneous Items 0-1 4P 10A Look SW UL1015#18 L=115mm UL1015#16 L=60mm White UL1015#16 L=60mm Black UL1015#18 L=125mm RH16*9*17 80*80*25mm 12V CAP.CER 4700PF Y2 CAP.MPP 1uF 275VAC HQX P=22.5 10A/15A 250V CASE 150.2*140*84mm CASE 140*148.2*85.5mm MYLAR FILM 165*110*0.35mm SCREW F3*10 ISO(BLACK) SCREW F3*6 ISO(BLACK) SCREW F3*5 ISO(BLACK) SCREW MAIN BOARD M3*4 ISO SCREW I5*10 TAP (BLACK) SCREW K/NUT 8#32T FAN GUARD 80*80mm COLOR-GOLD SANP BUSHING NB-27A

VENDOR SWEETA CHARNG MIN CHARNG MIN CHARNG MIN CHARNG MIN

VENDOR P/N SS21-BBIWG-R

SUNON SEC UTX SWEETA

SC-9-1

JUNHO LONGFEI LONGFEI LONGFEI LONGFEI LONGFEI LONGFEI PRO-CROWN KANGYANG

Table 22: Mechanical and Miscellaneous Items

35

8. Resources/Contact Information
Data sheets, applications information and samples for the ON Semiconductor components are available at www.onsemi.com. Links to the datasheets of the main components used in this design are included in the Appendix. Authors of this document are: Edward Weng, Patrick Wang, Roman Stuler, and Laurent Jenck.

9. Appendix
Link to ON Semiconductors web site: ON Semiconductor Home Page Industry information links: ENERGY STAR 80 PLUS Efficiency Requirements Climate Savers Computing Initiative IEC61000-3-2 Requirements ATX 12 V Form Factor European Union (EU) Energy Star Page Additional collateral from ON Semiconductor:
NCP1654 Continuous conduction mode PFC controller NCP1396 Resonant mode controller with high voltage drivers NCP4302 Synchronous rectification controller NCP1587 Low voltage synchronous buck controller NCP1027 High voltage integrated switcher NTD4809 Single N-Channel MOSFET 30 V, 58 A MBR20L45 20 A, 45 V dual schottky rectifier

36