Evaluation and Finding of

Isolated Flyback Converter

© 2016 ROHM Co.,Ltd.

Evaluation and Finding of Isolated Flyback Converter

AGENDA

1. Evaluation of Isolated Flyback Converter

① Design example using the PWM AC/DC converter IC - BM2P014
② Performance evaluation using the BM2P014 evaluation board

2. Finding of Isolated Flyback Converter

① Vds and Ids of MOSFET
② Saturation of Transformer
③ Tolerance of output diode
④ Vcc pin voltage
⑤ Load transient response
⑥ Output voltage waveform at start-up
⑦ Temperature measurement

© 2016 ROHM Co.,Ltd. P. 1

Evaluation and Finding of Isolated Flyback Converter

1. Evaluation of Isolated Flyback Converter

① Design Example using the PWM AC/DC converter IC - BM2P014

• Descriptions and features of the BM2P014
• Design Target (Power supply specifications)
• Circuit design example

② Performance evaluation using the BM2P014 evaluation board

• Measurement methods of parameters
• Reference data

© 2016 ROHM Co.,Ltd. P. 2

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014

Description: BM2P014
• Easy to design various types of low power
AC/DC converter with integrated 650V
MOSFET, and configurable to both isolated
and non-isolated
• High flexibility in design with external
current sense resistor and current mode
provides cycle by cycle current limiting
and high speed load transient response.
• Low power with internal 650V start-up
circuit and high efficiency at right load
with switching frequency reduction
function
Product lineup
Part # MOSFER Ron

© 2016 ROHM Co.,Ltd. P. 3

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014

Features: BM2P014 Basic Specifications

• Integrated 650V MOSFET ・Operating Voltage VCC：8.9V～26.0V
• Internal 650V start-up circuit Range DRAIN： to 650V
• PWM frequency: 65kHz ・Operating Current Normal：0.950mA (Typ.)
• Frequency hopping function Burst：0.400mA(Typ.)
• Current mode
・Operating -40℃ ～ +105℃
• Burst operation & frequency reduction Temperature Range
at light load
• Vcc pin Under/over voltage protection Package
• SOURCE pin open/short circuit • DIP7 9.20×6.35×4.30mm
protection
• SOURCE pin leading-edge blanking
• Cycle by cycle over-current limit
Application
• Over-current limiting with AC voltage
• Wall adapter, TV, Home appliances
compensation
(cleaner, humidifier, air cleaner, air
• Soft start conditioner, refrigerator, IH cooker, rice
• Secondary side over-current protection cooker & etc)
(Isolated configuration only)
© 2016 ROHM Co.,Ltd. P. 4
 1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014

Design Target (Power supply specifications)

Parameters Min Typ. Max Unit Conditions

Input Voltage 90 264 VAC
Input Power 50 mW Vin：100VAC/230VAC
at No-Load
Output Voltage 11.4 12 12.6 V
Output Current 1.5 A
Output Ripple 100 mV Frequency range: 20MHz
Voltage
Efficiency 80 % Vout：12V/1.5A

© 2016 ROHM Co.,Ltd. P. 5

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014

Circuit Example
F1
1.6A/
ACIN_L AC250V LF1

BR1
D6
800V 1A
FRD 200V 5A Vout
AC90V ZNR1 1
T1
8,9
-264V
C1 R4 C2
47uF 120k 2200pF C12 C15 12V
400V 1000uF 0.1uF
ACIN_N
C3 D3 25V 16V 1.5A
0.1uF/X2 FRD
650V 0.5A
C8 3 6,7
100pF D4 R5 GND
1kV 200V 0.5A 5.1 4

C5
10uF
8

5
50V R11 R12
Drain

Drain

VCC
2k 43k
IC1　
BM2P014
R13
Source

5 R6 2.7k
GND
NC

1.2k
FB

C7
1

2200pF/Y1 C10 R7
0.1uF 1k
4 1
C6 PC1 IC2 R8
R3 1000pF PC817 TL431 12k
0.39 3 2

© 2016 ROHM Co.,Ltd. P. 6

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014
Parts list for Item Spec Parts name Maker
C1 47uF/400V 47uF/400V
the example C2 2200pF/500V 2200pF/1kV
circuit C3
C5
0.1uF/X2
10uF/50V
0.1uF/X2
10uF/50V
C6 1000pF/16V 1000pF/50V 1608
C7 2200pF/Y1 2200pF/Y1
C8 100pF/1kV 100pF/1kV
C10 0.1uF/25V 0.1uF/50V 1608
C12 Low-Z 1000uF/25V Low-Z 1000uF/25V
C15 0.1uF/25V 0.1uF/50V 1608
BR1 800V/1A UA80
D3 FRD 650V 0.5A UF4007
D4 200V 0.5A RR264M-400 Rohm
D6 FRD 200V 5A RF601T2D Rohm
F1 1.6A/AC250V
IC1 BM2P014 Rohm
LF1 SS11VL-10062 NEC Tokin
ZNR1 7D471K
R3 0.39Ω /0.5W MCR25JZHFJR390 Rohm
R4 120kΩ /1W 120kΩ /1W
R5 5.1Ω MCR10EZPJ5R1 Rohm
R6 1.2kΩ MCR10EZPJ122 Rohm
R7 1kΩ MCR10EZPJ102 Rohm
R8 12kΩ MCR10EZPJ123 Rohm
R11 2kΩ MCR10EZPJ202 Rohm
R12 43kΩ MCR10EZPJ433 Rohm
R13 2.7kΩ MCR10EZPJ272 Rohm
T1 EI25 YPP1183 Tomita
IC2 TL431
PC1 PC817

© 2016 ROHM Co.,Ltd. P. 7

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014
Transformer
1 12
specifications Barrier tape
NP1
YPP1183 (EI25)‫‏‬ 2 11 2mm

NP2
3 10
NP1 NS1 ND NS2 NＰ2
NS2
4 9
ND NS1
5 8 4mm

6 7 Insulation tape 3T

Tolerance P-S ： AC3.0KVrms １MIN. 2mA or AC3.6KVrms 1S 2mA Beginning of winding: Fixed with barrier tape
PS-CORE ： AC1.5KVrms １MIN. 2mA or AC1.8KVrms 1S 2mA End of winding：Drawn to form a right angle & held in
IR ： P-S，PS-CORE 100MΩ MIN. at DC 500V Winding direction: Uniformed

© 2016 ROHM Co.,Ltd. P. 8

1．Evaluation of Isolated Flyback Converter
① Design Example using the PWM AC/DC converter IC - BM2P014

Actual PCB: Board No:BM2P014/12V1.5A/ISO/Ver.0/YTC

45mm
90mm

© 2016 ROHM Co.,Ltd. P. 9

Evaluation and Finding of Isolated Flyback Converter

1. Evaluation of Isolated Flyback Converter

① Design Example using the PWM AC/DC converter IC - BM2P014

• Descriptions and features of the BM2P014
• Design Target (Power supply specifications)
• Circuit design example

② Performance evaluation using the BM2P014 evaluation board

• Measurement methods of parameters
• Reference data

© 2016 ROHM Co.,Ltd. P. 10

1．Evaluation of Isolated Flyback Converter
② Performance evaluation using the BM2P014 evaluation board

Design Target (Power supply specifications)

Parameters Min Typ. Max Unit Conditions

Input Voltage 90 264 VAC
Input Power at 50 mW Vin：100VAC/230VAC
No-Load
Output Voltage 11.4 12 12.6 V
Output Current 1.5 A
Output Ripple 100 mV Frequency range:
Voltage 20MHz
Efficiency 80 % Vout：12V/1.5A

Verify these parameters are satisfied with actual measurements

© 2016 ROHM Co.,Ltd. P. 11

1．Evaluation of Isolated Flyback Converter
② Performance evaluation using the BM2P014 evaluation board

Measurement Methods
Parameters Conditions Equipment

Input Voltage Input 90VAC, 100VAC, 230VAC and 264VAC Voltage meter (AC), Power
using a high voltage step-up/step-down meter
transformer.
Input Current Measure at each Vin with all Iout range Clamp ammeter, Power
meter
Input Voltage Measure Vin Voltage meter (AC), Power
meter, Clamp ammeter
Output Voltage Measure at each Vin with full of Iout range Voltage meter (DC)
Output Current 0A to 1.5A using adjustable load equipment Ammeter (DC)

Output Ripple Observe output voltage waveform by using Oscilloscope

Voltage an oscilloscope
Efficiency Calculate with above results Output power / Input power
(%)

© 2016 ROHM Co.,Ltd. P. 12

1．Evaluation of Isolated Flyback Converter
② Performance evaluation using the BM2P014 evaluation board

Isolated AC/DC
Converter 0A～1.2A
（＋）
IDC
Vout

Load
90VAC～
Vin VDC 12Vout
AC

VAC
264VAC

（－）

Pout
W Efficiency (%) ＝
Pin
IAC

© 2016 ROHM Co.,Ltd. P. 13

1．Evaluation of Isolated Flyback Converter
② Performance evaluation using the BM2P014 evaluation board
Reference Data
Vin(V) Pin(W) Vout(V) Iout(A) Pout(W) η (%)
0.033 12.09 0 0 -
0.179 12.09 0.01 0.121 67.5
1.479 12.09 0.1 1.209 81.7
90
7.174 12.09 0.5 6.043 84.2
14.33 12.09 1 12.09 84.3
21.64 12.08 1.5 18.13 83.8
0.032 12.09 0 0 -
0.179 12.09 0.01 0.121 67.7
1.478 12.09 0.1 1.209 81.8
100
7.165 12.09 0.5 6.043 84.3
14.30 12.09 1 12.09 84.5
21.51 12.09 1.5 18.13 84.3
0.036 12.09 0 0 -
0.183 12.09 0.01 0.121 66.1
1.497 12.09 0.1 1.209 80.7
230
7.272 12.09 0.5 6.044 83.1
14.34 12.09 1 12.09 84.3
21.49 12.09 1.5 18.13 84.4
0.045 12.09 0 0 -
0.190 12.09 0.01 0.121 63.6
1.481 12.09 0.1 1.209 81.6
264
7.240 12.09 0.5 6.044 83.5
14.39 12.09 1 12.09 84.0
21.57 12.09 1.5 18.13 84.1

© 2016 ROHM Co.,Ltd. P. 14

1．Evaluation of Isolated Flyback Converter
② Performance evaluation using the BM2P014 evaluation board
Output Ripple Voltage
If switching noise is large:
・Add a LC filter to output
・Review the GND condition of probe
(GND must be short as possible)

Vout

Achieved less 100mV as the design target

© 2016 ROHM Co.,Ltd. P. 15

Evaluation and Finding of Isolated Flyback Converter

2. Finding of Isolated Flyback Converter

① Vds and Ids of MOSFET

② Saturation of transformer
③ Tolerance of output diode
④ Vcc pin voltage
⑤ Load transient response
⑥ Output voltage waveform at start-up
⑦ Temperature measurement

© 2016 ROHM Co.,Ltd. P. 16

2．Finding of Isolated Flyback Converter
① Vds and Ids of MOSFET
• Verify not to exceed the abs max ratings of Vds and Ids when they normally start up

＜Conditions to Verify＞
 Vin: Min and max
 Load：Max
 Environment：Max and min

（Start up） （Normal state）

Vds Vds

Ids Ids

© 2016 ROHM Co.,Ltd. P. 17

2．Finding of Isolated Flyback Converter
② Saturation of transformer
• Verify that the transformer is not saturated to check the Ids
• The MOSFET and/or other components may be destroyed by the increasing Ids when
the transformer is saturated
• When the transformer is saturated, the Ids is rapidly increased like the red trace in the
following waveform. In such case, reviewing of the transformer design is needed

＜Conditions to Verify＞
Vin: Min & max at start-up & ordinary state
Load current: Max
Ambient Temperature: Min and max
Ids

© 2016 ROHM Co.,Ltd. P. 18

2．Finding of Isolated Flyback Converter
③ Tolerance of output diode
• To verify that Vr of the output diode is within the absolute max ratings of the diode

＜Conditions to Verify＞
Vin: Max and min
Load current: Max
Ambient Temperature: Min and max
Vｒ

© 2016 ROHM Co.,Ltd. P. 19

 1.6A/
ACIN_L AC250V LF1

BR1
D6

2．Finding of AC90V
Isolated Flyback Converter
800V 1A
T1 FRD 200V 5A
ZNR1 1 8,9
-264V
C1 R4 C2
120k 2200pF C12
④ Vcc pin voltage
47uF
400V 1000uF
C3 D3 25V
ACIN_N
0.1uF/X2 FRD

• Verify min and max of the Vcc pin voltage C8

650V 0.5A
3 6,7
D4 R5
• Due to the leakage inductance of transformer, 1kV
100pF
200V 0.5A 5.1 4
a large surge voltage (spike noise) occurs
when the MOSFET turns off C5
10uF

5
R11
• The surge voltage is induced by the Vcc
50V

Drain

Drain

VCC
IC1　 2k

windings, thereby the Vcc voltage is increased BM2P014

Source
5 R6

GND
NC
• R5 as limiting resistor can be used to reduce
1.2k

FB
C7

4
the surge voltage induced by the Vcc 2200pF/Y1 C10
0.1uF
windings 4 1

• Need to confirm R5 properly works as limiter

C6 PC1 IC2
R3 1000pF PC817 TL431
0.39 3 2

＜Finding＞
Vcc pin voltage > 9.7V at Vin = min & max, and load current = min (or no load)
Vcc pin voltage < 26V at Vin = min & max, and load current = max

© 2016 ROHM Co.,Ltd. P. 20

 2．Finding of Isolated Flyback Converter
⑤ Load transient response
• Verify the stability of feedback system to check the output voltage behavior at load
transient
D6
＜Conditions to 1verify＞T1
8,9
FRD 200V 5A Vout

R4 Min and
Vin: C2 max
120k 2200pF C12 C15 12V
Load: Max D3to min and min 1000uF
25V to max
0.1uF
16V 1.5A
Temperature: Min and max
FRD
Ambient 650V 0.5A Vout
3 6,7
D4 R5 GND

Vout fluctuation
200V 0.5A 5.1 4

C5
10uF
7

50V R11 R12

Drain

Drain

VCC

2k 43k
IC1　
BM2P014
R13
Source

5 R6 2.7k
GND
NC

1.2k
FB

C7 For such fluctuation,

2

2200pF/Y1
need to adjust the gain
C10 R7
0.1uF 1k
4 1 and phase characteristics
C6 PC1 IC2 R8
R3 1000pF PC817 TL431 12k
0.39 3 2

Note: Frequency Response Analyzer is useful

Components affect to the feedback system for quantitative verification of gain and
phase margin

© 2016 ROHM Co.,Ltd. P. 21

2．Finding of Isolated Flyback Converter
⑥ Output voltage waveform at start-up
• Verify overshoot and undershoot of the waveform at start-up

＜Conditions to verify＞
Vin: Min and max
Load: Max and min Vout
Ambient Temperature: Min and max

Note: Need to adjust the gain and phase

margin when an overshoot and/or
undershoot occur

© 2016 ROHM Co.,Ltd. P. 22

2．Finding of Isolated Flyback Converter
⑦ Temperature measurement
・Operation must be done under the following conditions
1. Tj must be within the absolute max ratings
2. Power dissipation must be within the allowable power dissipation

Calcuration of Tj
Ex. BM2P014 θja
Tc

θjc
Tj
MOSFET CHIP Control CHIP
FLAME FLAME

DRAIN OTHER
θjc= (Tj-Tc)/P [℃/W]
Tj = Tc + P*θjc

1st layer of1層基板：θja

PCB: = 125.0℃/W、θjc= 29℃/W ( 70 mm sq.)
nd
2 layer of 2層基板：θja
PCB: = 62.5℃/W、θjc= 16℃/W

© 2016 ROHM Co.,Ltd. P. 23

2．Finding of Isolated Flyback Converter
Measurement of power dissipation

②
②
④

Die Temperature
Calculation
Support Site
http://www.rohm.com/web/global/groups/-/group/groupname/Transistors Usability Judgment Method

© 2016 ROHM Co.,Ltd. P. 24

2．Finding of Isolated Flyback Converter
Calculation of optimum heatsink
Determine using a simulator Tj vs θheatsink
119 100k C6
V1 R9 4.7n

C9
100m
22 33p
R4 TX1 R21
180

Set Ta
DRF08L6S R12 P1 S1
D5 2.7u
100m

R6 D2
L1

R8008ANX DRF601T2D
P2
C3 Vo24
10 D1 220p D4
R1 Q4 39k
C4 R108
100 15k DRF601T2D

R7 R8
150m 3k 100m 1.5m R2
R5 R107 R19 C1 6.67

2k
R13

Set θ
BD7681beta
U1 103.3k
OUT ZTin R16
VFB 1k
(V(drain)-V(source))*I(d) U6 R3
Vcs
ARB1 GND C2
1n IC=4
I(d)
OUT POWER
POWER
drain 10n
12k
source
R20
C5

Loss model
U7

12k
R18

Change Tj to
Calculate loss & Tj calculated value

Size
ヒートシン クサイ ズ 25*20 25*43 50*54
-------
|Ta-Tj| < 0.2℃ 熱抵抗 - 20℃/W 16℃/W 13℃/W
θ0 50 50 50
1 97.2 87.7 80.6
2 115.2 98.1 87.2
Cubic volume of 16℃/W
3 128.5 103.2 89.2
is 2.5 x of 13℃/W
4 154.7 104.9 89.6
5 323.7 106.2 89.8
Fix Tj and loss 6 106.9
7 106.7

© 2016 ROHM Co.,Ltd. P. 25

2．Finding of Isolated Flyback Converter
Electrolytic capacitor
・Life time of electrolytic capacitor is considerable
1. Power loss occurs by a ripple current with the internal impedance, and it makes heat
2. The life time of electrolytic capacitor highly depends on temperature and it’s based on
the Arrenius mode (life time calculation is possible with an equation from capacitor
manufacturers.

・If the capacitor deteriorates, a leakage occurs and the capacitance lowers
⇒Affections for a power supply circuit:

Deterioration of Cin : Increase of ripple voltage,

lower the storage time
Deterioration of Cout: Increase of ripple voltage,
lower stability of feedback
system I_ripple
・Need to keep a ripple current within
the absolute max ratings

© 2016 ROHM Co.,Ltd. P. 26

Evaluation and Finding of Isolated Flyback Converter

REVIEW

1. Evaluation of Isolated Flyback Converter

① Design example using the PWM AC/DC converter IC - BM2P014
② Performance evaluation using the BM2P014 evaluation board

2. Finding of Isolated Flyback Converter

① Vds and Ids of MOSFET
② Saturation of Transformer
③ Tolerance of output diode
④ Vcc pin voltage
⑤ Load transient response
⑥ Output voltage waveform at start-up
⑦ Temperature measurement

© 2016 ROHM Co.,Ltd. P. 27

Gain margin: độ dữ trữ biên độ
Phase margin: biên pha

© 2016 ROHM Co.,Ltd.