Multi-Output Flyback Off-Line

Power Supply
 Basic Concept
• Add additional secondary windings, using the same
turns/volt as the original secondary.
Vout 1
Vin
nD
1 n Load (R1) Vout 1 = Vin
D'
Vout 2
mD
m Load (R2) Vout 2 = Vin
D'

• Outputs can be positive or negative, depending on which side of

the output (top or bottom) is grounded.
• Either output can be the “master” by connecting it to the feedback
sensing circuit
• Formulas are not exact, due to the diode drops not being
proportional to the number of turns!

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 Example of Adding a Negative Output
• There is no theoretical limit to the number of outputs.
Vin Vout 1
nD
1 n Load (R1) Vout 1 = Vin
D'

Vout 2
mD
m Load (R2) Vout 2 = Vin
D'

Vout 3
pD
p Load (R3) Vout 3 = Vin
D'

• In this case, the negative output drawn like the positive

ones, with the diode reversed and the polarity of the winding
as shown.

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 Two Outputs with Feedback Regulation

• Typical regulated flyback converter

– One output is the master (output 2 in this case)
– Second output (output 1, in this case) is the “slave” (quasi-regulated).
– For output voltages less than 2.5 V, a TLV431 (1.25 V) or other can
be used.
– Why do we need R3?

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 Improvement #1 – Stacked Windings

• Regulation of second output is improved, because only part of it is “alone.”

– Only the “n” portion is unregulated. (Leakage inductance of n is less.)
• Again, one output is the master (output 2 in this case)
– Second output (output 1, in this case) will vary with the load on the main output,
due to its current flowing through the winding of output 2.

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 Improvement #2 Stacked Outputs

Vout 1
m+n)D
Vin n Load (R1) Vout 1 = Vin
D'
1
Vout 2

mD
PWM m Load (R2) Vout 2 = Vin
Controller D'

Optocoupler

R3
R4

TL431
2.5 V ref. amplifier R5

• Now, output 1 current flows through output #2’s diode.

– Output 1 is less dependent on output 2’s load, because the
bottom of its output doesn’t move.

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 Improvement #3 No-Load Clamp
12 V Vout 1
m+n)D
Vin n Load (R1) Vout 1 = Vin
D'
1
9 V Zener
5V Vout 2

mD
PWM m Load (R2) Vout 2 = Vin
Controller D'

Optocoupler

R3
R4

TL431
2.5 V ref. amplifier R5

• When output 1 is unloaded, its stray output current

flows down through the Zener and into the 5 V output.
• In this case, output 1 would be clamped at 14 V.

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 Improvement #4 – Combined Feedback
Vout 1
m+n)D
Vin n Load (R1) Vout 1 = Vin
D'
1
Vout 2

mD
PWM m Load (R2) Vout 2 = Vin
Controller D'

Optocoupler
R6
R3
R4

TL431
2.5 V ref. amplifier R5

• Now, both outputs are sensed, and the regulator controls the
combination of outputs.
– Remember: There’s only one feedback point. Neither output will be as
tightly regulated as the main one when it had the feedback to itself!

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 Weighting the Feedback
Vout 2 Vout 1
Optocoupler

i2 = W2 • i0 R2 R1 i1 = W1 • i0

TL431 Vref
2.5 V ref. i0 R0
amplifier

i0 = i1 + i2 = W1 • i0 + W2 • i0 = i0 (W1 + W2)

Therefore, W1 + W2 = 1
Wn is the “weight” of the feedback from output n.

• If W1 = 0.9 and W2 = 0.1, then output 1 is nine times as important as

output 2.
– (W1 has a weight of 90%, and W2 has a weight of 10%)

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 Designing the Feedback

( i1 + i2 = i0 )
Vout1 − Vref = i1 R1

Vout1 − Vref Vout1 − Vref

R1 = =
i1 W1i0

Vout 2 − Vref Vout 2 − Vref

R2 = =
i2 W2i0

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 Example
Procedure:
– Given: Vout 1 = 5, Vout 2 = 12, Vref = 2.5
– Choose i0 = 1 mA
– Choose W1 = 0.7 and W2 = 0.3

Calculating the values:

Vref
2.5
R0 = = = 2.5 kΩ
i0 1 mA
Vout1 − Vref 5 − 2.5
R1 = = = 3.57 kΩ
W1i0 0.7 ⋅1 mA
Vout 2 − Vref 12 − 2.5
R2 = = = 31.7 kΩ
W2i0 0.3 ⋅1 mA

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 More Outputs? No Problem
Vout 2 Vout 1 Vout n
Optocoupler

i2 = W2 • i0 R2 R1 i1 = W1 • i0 Rn in = Wn • i0

TL431 Vref
2.5 V ref. i0 R0
amplifier

• Feedback can be from any number of outputs.

• Provided that: W1 + W2 + ……..+Wn = 1

Vout n − Vref
Rn =
Wn ⋅ i0

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 The “Magic” Capacitor

With cap: Clean pulse; improved

regulation at low-current load
Vout 1 nD
n Vout 1 = Vin
D'
Vin Low-current load (R1 = large)
1

Vout 2
nD
PWM m=n Vout 2 = Vout 1 = Vin
Controller D'
Load (R2)

Optocoupler

R3
R4

TL431
2.5 V ref. amplifier R5

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 Another Version of the “Magic” Capacitor
n 2m+n)D
Load (R1) Vout 1 = Vin
D'
Vin m
Example: 12 V
1
Vout 2

mD
PWM Load (R2) Vout 2 = Vin
m
Controller D'
Example: 5 V

Optocoupler

R3
R4

TL431
2.5 V ref. amplifier R5

• Here, since the bottom of upper secondary is tied to Vout 2 (which is dc),
waveforms at each end of the capacitor are identical.
• Overshoot & ringing at light load on Vout 1 is reduced by 5/7, since 5 of
the 7 added turns are tightly coupled via the capacitor. (m = 5, n = 2,
m+n = 7).

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 Adding an Output to a Buck Converter

• During the “off” time of the switch, the output voltage across the
inductor is coupled to a new output via an added winding!
• No free lunch. There must be enough energy stored in the choke
to feed the new output.
• Ampere-turns are preserved, so current drawn from the new
output causes discontinuous current in the main output.
– Ripple current in the main output capacitor increases.

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 Design Example, Built and Tested

65 Watt, 8 Output
Set Top Box
Power Supply

Frank Cathell,
Senior Applications Engineer

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 General Specifications
• Input: 90 to 135 Vac, 47 – 63 Hz
• Inrush current: 30 A cold start; 60 A warm start
• Efficiency: > 80% at nominal loading
• Output Voltages/Regulation/Ripple:
Channel Vout Output type Regulation Max Ripple Current Surge
1 2.6 V Buck reg. +/-1% 40 mVp/p 3A 4A
2 3.3 V Buck reg. +/-1% 40 mVp/p 4A 5A
3 5V Main output +/-2% 50 mVp/p 3A 4A
4 6.2 V Quasi-reg. +/-6% 50 mVp/p 1.5 A 2A
5 9V 3-T reg. +/-1% 30 mVp/p 100 mA 200 mA
6 12 V Main output +/-2% 50 mVp/p 1A 3A
7 30 V Quasi-reg. +/-8% 100 mVp/p 20 mA 40 mA
8 -5 V 3-T reg. +/-1% 30 mVp/p 30 mA 60 mA
• Output overshoot: 5% max; typically <1%
• Overcurrent/short circuit protection: Protected against accidental overloads via reduced duty
cycle, burst mode operation
• No load: Output voltages are controlled and stable under no load conditions
• Hold-up time/power fail detection: Output will hold up for 20 ms following drop out at 100 V ac
and nominal load; power fail warning following holdup period with 5 ms minimum delay to output
voltage dropout.
• Temperature: Operation from 0 to 50O C (no over temp protection included)

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 Circuit Features
• Critical conduction mode flyback converter
¾NCP1207
• 2.6 V and 3.3 V outputs derived from 12 V output
¾NCP1580 synchronous buck controllers
• Low current outputs on -5 V and +9 V allowed use of conventional 3-T
regulators
• Control loop closed via sum of 5 V & 12 V outputs; all other outputs quasi-
regulated
• Transformer main secondary made from foil winding for low leakage
inductance
• “Stacked” secondary windings utilized for improved cross-regulation
• Simple but effective power fail detection circuit utilizing TL431 and 2N2222
• Overcurrent protection implemented by initiating burst mode of NCP1207A
• 2-wire ac input with dual common mode EMI filter inductors
• Single-sided printed circuit board

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 Set-Top Box Test Results
Regulation Data (120VAC input)
Outputs
Parameter 2.6V 3.3V 5V 6V 9V 12V 30V neg 5V

Output type Buck Buck Main Quasi-reg 3-T reg Main Quasi-reg 3-T reg

Vout setpoint at
typical loads 2.53V 3.4V 4.89V 6.27V 8.94V 12.54V 31.0V 4.96V

Vout setpoint at
minimum loads 2.55V 3.42V 4.96V 6.38V 8.94V 12.33V 32.70V 4.98V

Vout setpoint at
maximum loads 2.54V 3.34V 4.90V 6.29V 8.94V 12.53V 30.10V 4.95V

Vout setpoint at
no output loading 2.56V 3.43V 5.02V 6.54V 8.93V 12.13V 29.60V 4.97V

Note: Vout setpoints measured at PC board

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 More Test Results
E ffic ie n c y M e a s u re m e n ts (1 2 0 V A C in p u t)
O u tp u ts
P a ra m e te r 2.6V 3.3V 5V 6V 9V 12V 30V n e g 5V

O u tp u t V o lta g e 2 .5 4 3.42 4.91 6.31 8.94 12.48 30.06 4.96

O u tp u t C u rre n t 3 .8 A 2.9A 1.56A 1.3A 91m A 1.0A 30m A 73m A

O u tp u t P o w e r (W ) 9 .6 5 9.92 7.66 8.2 0.81 12.48 0.9 0.36 (4 9 . 9 8 W t o t a l)

T o ta l P o u t = 4 9 . 9 8 W

P in a t 1 2 0 V A C = 6 1 . 4 W

E ffic ie n c y = 8 1 .4 %
Outputs
Parameter 2.6V 3.3V 5V 6V 9V 12V 30V neg 5V

Output Ripple
(@ max loads) 27mV 45mV 50mV 50mV 40mV 30mV 100mV 20mV (10:1 scope probe)

Output Overshoot
(turn-on) none none none none none none none none

Holdup Time (prior to PF warning) at 100 Vac in, maximum output loads: 25ms

Power Fail warning time (Vout decay to 90%): 15ms

Line Regulation: Minimal on all outputs; +/- 20mV max

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 Schematic
FIGURE 1: Schematic
560pf 1KV
C5
8
T1
16
R40 10 D13

MUR120 Stacked windings

C11
+
R21
1
30V

330/50V 30K C13

R2 0.1uf

D1 D4
15,
1W 6
12V-BUCKS
Before diode

2
F1 D12 12V

After diode
1N5406 1N5406 15 1
L1 L2 Q1 1
P1 3A 1 IRF740 MBR1645 L3 4.7uH
R1 + + + +
1 C1 C2 1M .5W C3 C14 C15 C16 C17
2 0.22/250V 0.22/250V 470/250V 560pf 1KV 680/16V 680/16V 680/16V 0.1uf

3
TH1 C6
AC INPUT 1 2 BU10-1311R6B BU16-4021R5B D2 D3
R5 R4 R3 U3 MC78M09 9V
t 1N5406 1N5406 4.7 4.7K 0.33 1W 1
I O
3 1
1
10 Ohm 4A

G
+ R19
C18 10K C19
270/25V 0.1uf

2
C4
Y -CAP D11 1N5820 L4 4.7uH 6V
Not installed 12 1
11 1
+ + + C23 R18
C20 C21 C22 1K
680/16V 680/16V 680/16V 0.1uf
MBR1635 L5 4.7uH 5V
10 1
R6 D10 1
3.6K U1
+ + +
8

NCP1207A C24 C25 C26 C27

D6 1N4148 R7 100 14 1200/6.3V 1200/6.3V 1200/6.3V 0.1uf COM
8

5 6 3 13 1
5 6 1
+ + R17
R8 22K
Combined, weighted

1
NC 7 7 1
1 JP3 C28 C51 10K
1 2 2 9 270/25V 270/25V C29

G
2 3 0.1uf -5V
I O
2
2 3
3 R9 1K
JUMPER
U5 D9 MUR110 U4 MC79L05 feedback 1
1
4

4 1
R12
C8 + 1K R11 270 D8 1N4148 R10 10
4

C7 22/25V C9 C10 3 2
1nf Not installed 470 pf
H11A817A C30 0.1uf R14 30K
R13 1K

3
1
U6
TL-431
R26

2
6.2K R25 PF
R15 47K Q2 1
6.8K D7 PN2222A 1

R27

3
12V-BUCKS 1K U7 1N5226B
C31 TL-431 R22
R16 10nf 1 R24 R23 1K
3.6K R28 4.7K 4.7K
4.7K C32
1

0.1uf

2
JP5
JUMPER
2

D14 MUR110 D16 MUR110

12V-BUCKS

2
C36 0.1uf C47 0.1uf JP4
2

NTD60N02R 1 2
Q4
U9 JUMPER
U8 1
5

1 NCP1580 NCP1580
2 1 1 2 Q5
5

2 1 C39 1nf C42 1nf 1 2 NTD60N02R L6 10uH 2.6V

1

3
1 JP2 2 8 8 1 JP1 2 1
3

3-3V L7 10uH 8 7 7 8
1 JUMPERD15 7 7 JUMPER +
1 R30 33K R36 33K
1N5818 R29 C40 10nf C43 10nf R38 D17 + C49 C50
Q3
2

2
4.7 6 6 4.7 1N5818 C48 1200/6.3V 0.1uf
NTD60N02R 4 6 6 4 680/16V
4 R31 68 4
3

C33 1200/6.3V R37 68

C41 10nf
0.1uf C34 + + 1 C38 C44 10nf 1
3

C35 0.1uf Q6
680/16V C37
NTD60N02R
1nf C45 C46
0.1uf 1nf
3

3
R32 33K R33 10.5K R34 10K R35 22K
Title
Schematic - 60W set-top box

Size Document Number Rev

<Doc> C

Date: Tuesday , May 31, 2005 Sheet 1 of 1

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 Conclusion
• Multiple output switched-mode power supplies save space,
save cost, and can have high performance.
– The “tricks” you’ve seen here can make them even better!

• Flybacks are popular, because there is only one magnetic

component.
• They work best where the load ranges of the outputs are well-
known.
– This allows the designer to tailor the regulation characteristics to the
load regulation requirements, favoring certain loads when necessary.

• For good cross-regulation, construction of the transformer is

important.
– Beware of changing vendors during production!

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 For More Information

• View the extensive portfolio of power management products from ON

Semiconductor at www.onsemi.com

• View reference designs, design notes, and other material supporting

the design of highly efficient power supplies at
www.onsemi.com/powersupplies

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