Methods of Designing

Non-isolated PWM Flyback Converter

© 2016 ROHM Co.,Ltd.

Methods of Designing Non-isolated Flyback Converter

AGENDA
Design example using a PWM AC/DC converter IC with internal high
voltage MOSFET
1.Description of AC/DC converter IC for the design
2.DCM non-isolated buck converter design example
3.Basic operation of the buck converter
4.Selection for peripheral parts
① Selection of IC1
② Input capacitor： C1
③ Vcc pin capacitor: C2
④ Inductor: L1
⑤ Current sense resistor： R1
⑥ Output capacitor： C5
⑦ Output diode: D4
5.EMI countermeasures
6.Output noise countermeasures
7.PCB layout example
© 2016 ROHM Co.,Ltd. P. 1
 Methods of Designing Non-isolated Flyback Converter

1. Descriptions: BM2P094F AC/DC Converter IC with internal 650V MOSFET

Descriptions
• The BM2P094F, from the BM2P0XX
series, is an IC for PWM switching
regulator including an internal MOSFET
and a start-up circuit
• The integrated high speed switching
MOSFET developed by ROHM provides
a larger peak current while makes
magnetic components smaller
• The output power is 5W with SOP8
package (Max power of the series is
8W with SOP and 20W with DIP7)
• Configurable to both isolated and non-
isolated
• The series includes 8 parts with SOP
and 16 parts with DIP7 for various
types of application

© 2016 ROHM Co.,Ltd. P. 2

Methods of Designing Non-isolated Flyback Converter

1. Descriptions: BM2P094F AC/DC Converter IC with internal 650V MOSFET

Features Basic Specs

• Internal 650V switching MOSFET ・Operating Supply VCC：8.9V～26.0V
• Integrated 650V start-up circuit Voltage Range VH： < 600V
• PWM frequency: 65kHz
• Frequency hopping function ・Operating Normal: 0.50mA (Typ.)
• Current mode Current Burst: 0.40mA(Typ.)
• Burst operation at light load/frequency
・Operating Temp. -40℃ ～ +105℃
reduction function
• VCC pin under-voltage and over-voltage
protection
• SOURCE pin open and short circuit Package Type
protection • SOP8 4.90mm x 3.90mm
• SOURCE pin Leading-Edge-Blanking
function
• Cycle by cycle over-current limiting
• Current protection with AC voltage Applications
compensation • Wall adopter, TV, Home appliances (cleaner,
• Soft start humidifier, air cleaner, air conditioner,
• Over current protection for the secondary refrigerator, IH cooker, rice cooker & etc)
side (for isolated configuration)

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 Methods of Designing Non-isolated Flyback Converter

BM2P0XX Series
MOSFET Max output power *1 Functions
Part Number Package
RDS(ON) (max) IDP(max) 85-265VAC Brown-out VCC OVP
BM2P051F Latch
Yes
BM2P052F Auto retry
5.5Ω 2.6A 8W
BM2P053F Latch
No
BM2P054F Auto retry
SOP8
BM2P091F Latch
Yes
BM2P092F Auto retry
12Ω 1.3A 5W
BM2P093F Latch
No
BM2P094F Auto retry
BM2P011 Latch
Yes
BM2P012 Auto retry
2.0Ω 10.4A 20W
BM2P013 Latch
No
BM2P014 Auto retry
BM2P031 Latch
Yes
BM2P032 Auto retry
3.6Ω 5.4A 15W
BM2P033 Latch
No
BM2P034 Auto retry
DIP7
BM2P051 Latch
Yes
BM2P052 Auto retry
5.5Ω 2.6A 10W
BM2P053 Latch
No
BM2P054 Auto retry
BM2P091 Latch
Yes
BM2P092 Auto retry
12Ω 1.3A 7W
BM2P093 Latch
No
BM2P094 Auto retry
*1 Approx. value of a isolated configuration with a transformer. Need to limit output power depending on the circuit configuration and Ta.

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 Methods of Designing Non-isolated Flyback Converter

2. DCM (Discontinuous mode) non-isolated buck converter design example

D2
600V 0.1A

C2
IC1　 10uF PC1
BM2P094F 50V PC817
4 1
1 8
VCC FB

7 3 2
GND
C4
1000pF Vout
Vin 20V 0.2A
4 D S 5
AC90V Filter
R1 L1
-264V 1 470uH
R4
680
0.5W 0.8A

C1 C8 C5 R5
10uF D4 1k
R10 470uF
450V RFN1L6S
35V
600V 0.8A
C9 ZD1
18V GND

© 2016 ROHM Co.,Ltd. P. 5

 Methods of Designing Non-isolated Flyback Converter

Non-isolated flyback converter: Discontinuous Mode vs Continuous Mode

Item Discontinuous Mode Continuous Mode

I I
L
IL=0 L

IOUT IOUT
Operation

t t
tON tOFF tON tOFF
Zero current period exists between the off and A current flows continuously and turns
on, them a current flows discontinuously. on and off as same as fSW

Transformer Inductance: down, Size: down, Cost: down Inductance: up, Size: up, Cost: up
Rectifier
FRD, Cost: down Faster FRD, Cost: up
Diode
Switching
Power: up, Size: up, Cost: up Power: down, Size: down, Cost: down
Transistor
Efficiency Switching loss: down, Efficiency: up Switching loss: up, Efficiency: down

© 2016 ROHM Co.,Ltd. P. 6

Methods of Designing Non-isolated Flyback Converter

3. Basic operation of the buck converter

Switch ON Switch OFF

OFF
ON VOUT VOUT
VIN VIN
IL IL
OFF ON

• When the MOSFET turns on, a current
flows to the load through the inductor,
and energy accumulates in the inductor
as well.
• In this case the diode remains off.
• When the MOSFET turns off, the energy
stored in the inductor is supplied to the
load through diode D2.
• During this operation the MOSFET
remains off.

VIN - VOUT VOUT

IL   ton IL   toff
L L

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Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ① IC1

• The peak current of non-isolation circuit is increased to compare with the isolated circuit
• Derating 50% to 75% of the isolated circuit will be proper for non-isolated circuit

Pout = 20V x 0.2A = 4W ⇒ IC1: BM2P094F

4. Selection for peripheral parts: ② Input capacitor C1

Input Capacitor Capacitance (rough estimate)
• Calculation for C1 capacitance with the right table
Pout = 20V x 0.2A = 4W Input Voltage (VAC) Cin (μF)
C1: 2 x 4 = 8 ⇒ Considered as 10μF 85 to 264 2 X Pout (W)
180 to 264 1 x Pout (W)
• Withstand voltage is estimated as
* The above conversion factors are a rough estimate
VAC(max) x 1.41 for the full-bridge rectification. Further considerations
will be needed depending on requirements of power
Ex. When 264VAC: supply, e.g. Vout hold time.

264V x 1.41 = 372V ⇒ Considered as 400V

© 2016 ROHM Co.,Ltd. P. 8

Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ③ VCC capacitor C2

• The VCC capacitor C2 is needed to settle the VCC voltage of the IC
• > 2.2μF is required (ex. 50V 10μF)
• C2 also works to determine the start-up time
• See the chart for C2 vs start-up time as a reference

1.0
0.9
0.8
time (sec)

0.7
起動時間[sec]

0.6
0.5
Start-up

0.4
0.3
0.2
0.1
0.0
0 5 10 15 20 25 30 35 40 45 50

Cvcc [uF]
Start-up Time (as a reference)

© 2016 ROHM Co.,Ltd. P. 9

Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ④ Inductor L1

• The inductance is determined to operate in discontinuous mode as possible

• In continuous mode, the loss of output diode is increased due to a reverse
current during trr of diode
• Additionally the reverse current becomes as the peak current of MOSFET on
state and the loss of MOSFET is increased

Calculation of inductance
Considered as VIN = 101V (AC90V x 1.4 x 0.8)：
Vo 20V Duty(max) 0.198
Duty(max)    0.198 ton(max)    3.3us
VIN(min) 101V fsw(min) 60kHz

Iomax = 0.2A x 1.2 = 0.24A to be the critical point → IL= 2×Io = 0.48A
VIN(min) - Vo 101V - 20V
L  ton(max)   3.3us   557uH　
Ip 0.48A

Select 470µH capacitor

© 2016 ROHM Co.,Ltd. P. 10

Methods of Designing Non-isolated Flyback Converter

Calculation of inductor current

• The inductor current is to max when the input voltage is max

• The BM2P094F operates with its min on-time when the Vin is max (264VAC)
• The min on-time will be 0.6 to 1.5µs depending on conditions of Vout and inductance

When the min on-time is 1µs at 264VAC:

VIN(max) - Vo 372V - 20V

ILpeak  ton (min on - time)   1us   0.749A
L 470uH

Considered as IL > 0.8A

• Therefore, select an inductor with IL > 0.8A and 470µH

• Need to check the actual IL and not to be saturated

© 2016 ROHM Co.,Ltd. P. 11

Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ⑤ Current sense resistor R1

• The current sense resistor is used for output over loading protections and slope
compensation of current mode, limiting the switching
• Due to these functions, the primary side inductance or the input voltage may affect the
R1 setting
• The BM2P094Fincludes the over load protection with AC voltage compensation which
compensate a fluctuation of over load protection activation threshold by the input voltage
level

Vcs_limit
R1 
IL
Vcs  ton(max)  20mV/us

　　 　
IL
0.4V  3.3us  20mV/us
　
　　  0.97 Ω　
 　Considered as 1 Ω
0.48A

* Checking for the over load protection threshold at the actual circuit is necessary.

© 2016 ROHM Co.,Ltd. P. 12

Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ⑥ Output capacitor C5

• The selection of the output capacitor is determined by a peak to peak ripple voltage ΔVpp and a
ripple current which are allowed by output load devices
• When the MOSFET turns on, the output diode turns off, then the output capacitor provides a
current to loads
• When the MOSFET turns off, the output diode turns on, then the output capacitor is charged and
also provides a current to loads
ΔVpp 0.1V
Set ΔVpp = 100mV: Z_C5＜   0.134 Ω　　
@　60kHz (fsw　
min) 　
ILpeak 0.749A
• Converting the 60kHz impedance to 100kHz (Impedance of typical low-impedance electrolytic
60
capacitor for switching is given at fsw = 100kHz)： Z_C5＜0.134 Ω　   0.08 Ω　　
@100kHz　
100
1 1
Ripple current Is(rms) : Is(rms)  ILspk  0.749A  　  0.432A
3 3
• The withstand voltage of electrolytic capacitor is estimated 2x for the output voltage
VOUT x 2 = 20V x 2 = 40V → as considered > 35V
• Selection example: Low-impedance 35V 470μF electrolytic capacitor for switching regulators)

* Need to check the actual ripple voltage and ripple current at the actual circuit.

© 2016 ROHM Co.,Ltd. P. 13

Methods of Designing Non-isolated Flyback Converter

4. Selection for peripheral parts: ⑦ Output rectifier diode D4

• A fast output rectifier diode should be selected, e.g. a FRD (Fast recovery diode)
• The reverse voltage to D4 with a margin (>70%):

Vdr = VIN (max)÷0.7 = 372V÷0.7 = 531V → as considered 600V

• The loss of diode (rough estimate)：

Pd = Vf x Iout = 1V×0.2A = 0.2W

• Select: RFN1L6S (600V/0.8A PMDS pakage)

* Checking the Tj and loss at the actual circuit is needed.

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Methods of Designing Non-isolated Flyback Converter

5. EMI Countermeasures

• Possible EMI Countermeasures:

Adding a filter to the input

Adding a capacitor between the drain and the source of the MOSFET
Ex. 500V 47 to 100pF

* This makes losses of the MOSFET increase. Need to check the temperature raise of
the MOSFET and modify as needed.

Adding a RC snubber to the diode Ex. C9 = 1000pF/500V, R10 = 10Ω/1W

** All values are a reference value. Need to check actual EMI and modify as needed.

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Methods of Designing Non-isolated Flyback Converter

6. Output Noise Countermeasures

 Adding a LC filter to the output

Ex. L = 10μH, C10 = 10μ to 100μF
4 1

** All values are a reference value. Need to

check actual output noises and modify as 3 2

needed.
Vout
L2
20V 0.2A
L1
R4
470uH
680
0.8A C10

C5 R5
470uF 1k
35V
ZD1
18V GND

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Methods of Designing Non-isolated Flyback Converter

PCB Layout Example: Basic Considerations for a PCB Layout

• Basic Considerations for a PCB Layout

* Single sided PCB and top side

* Parts with red letter are SMD
PC1
D2
C4

C2

ZD1
30mm

R5
R4
IC1 R1 L1
VH IN Vout

GND GND
C1 D4
C5

35mm

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Methods of Designing Non-isolated Flyback Converter

REVIEW
Design example using a PWM AC/DC converter IC with internal
high voltage MOSFET
1.Description of AC/DC converter IC for the design
2.DCM non-isolated buck converter design example
3.Basic operation of the buck converter
4.Selection for Peripheral Parts
① Selection of IC1
② Input capacitor： C1
③ Vcc pin capacitor: C2
④ Inductor: L1
⑤ Current sense resistor： R1
⑥ Output capacitor： C5
⑦ Output diode: D4
5.EMI countermeasures
6.Output noise countermeasures
7.PCB layout example
© 2016 ROHM Co.,Ltd. P. 18
 Web Support

http://www.rohm.com/web/global/acdc-support
http://www.rohm.com/web/global/acdc-ww

© 2016 ROHM Co.,Ltd. P. 19

© 2016 ROHM Co.,Ltd.