Part I

INTRODUCTION

1.1 Theories/Concept of the Design

A fixed variable transformer has an input of 220V and steps-down to a wide variety of fixed AC
Voltage, the outputs are 12V, 9V, 6V, 4.5V, and 3V. These voltages are the range needed by some
electronic devices. These ranges will be used to convert AC to DC Voltage without the aid of voltage drop,
potentiometer or any devices that will alter the voltage to get the desired value. Through these we could
have a fixed variable DC Voltage.
The desired DC output voltages are 12V, 9V and 3V, these outputs are necessary due to the
design are made to supply a parallel set of LED. The variety of DC Voltage is also been sighted in order to
get the desired amount of luminance in the LED. The luminance of the LED is directly proportional to the
output voltage of the power supply but inversely proportional to the life span of the LED. So we came up
with the idea that it should be user-choice to manipulate the output voltage of the power supply.
From the transformer, we have a supply of AC voltage 12V, 9V and 3V and we need 12V, 9V and
3V of DC Voltage, so therefore the component or circuits needed are rectifier (to rectify the AC wave),
capacitor (to fill-out the ripples), voltage regulator (to regulate the voltage output).
1.2 Previous Research and Studies
Creating a simple power supply based upon our studies is possible, but in order to create an
industry standard power supply, we looked for some researches and studies that are probably related to
and connected to our design.
These are some ideas that we had considered to create our design:

Phase-controlled AC to DC power conversion has the disadvantages of low power factor and
harmonic pollution on the utility side, particularly in the case where DC voltage regulation is required. This
paper presents a one-stage single-phase controlled rectifier which has a wide output variation on the DC
output maintaining unity power factor and sinusoidal current on the input side. This scheme also provides
galvanic isolation which is required in most of the industrial applications with a transformer of small size
compared to the ones used with the phase-controlled converters. Three control strategies for the operation
of the converter are proposed and verified experimentally. The harmonic spectra on the AC side is
analytically derived and its low frequency harmonics up to half of the switching frequency or higher orders
have been eliminated depending on the control strategies.
AC TO DC POWER CONVERSION WITH UNITY POWER FACTOR AND SINUSOIDAL INPUT
CURRENT
Geunhie Rim and R.Krishnan
Dept. of Electrical Engineering
VPI & SU. Blacksburg, VA 24061

The aim of this design is to present a theoretical and practical analysis of one of the most popular
AC-DC converter topology. This topology is used to feed a DC-DC switchmode converter from dual input
voltage operation (230Vrms, 50Hz / 115Vrms, 60 Hz). Simple expressions are obtained for all RMS and
peak currents and voltages, the mathematical analysis of this multifunctional AC-DC converter becomes
very simple if the suitable assumptions are made. There is a good agreement between experimental results
and the mathematical analyis predictions
Line Input AC to DC Conversion and Filter Capacitor Design
J. Doval-Gandoy, C. Castro, C. Martnez
Dpto. Tecnologia Electonica

Universidad de Vigo
Vigo, Spain
jdoval@uvigo.es
The basic half-bridge topology provides some implicit problems for designers who wish to create a
high-linearity power converter. The power stage switches are normally operated in strict time alternation.
The topology has an inherent fault path when both switches are enabled. Therefore, it is common practice
to add a third state to the switching sequence with all switches off (dead time) to reduce the probability of
common-mode (shootthrough) currents. The insertion of the dead-time state creates an inherent
nonlinearity in the conversion cycle for output currents near zero current as the converter does not remain
in continuous current mode (CCM). The effects of a dead zone are additive to the distortion resulting from
switch and freewheel diode losses.
When used as amplifiers, wide-bandwidth dc-to-ac power converters often require relatively highswitching frequencies to provide ample bandwidth for processing and filtering a full-band signal. For
example, audio pulse width modulation (PWM) amplifiers can be designed to have adequate 20- kHz
bandwidth and acceptably low-output impedance when switched at 500 kHz. The higher the operating
frequency (shorter conversion cycle), the larger the proportion of the switching cycle that is lost by a given
dead-time interval. This also increases the amount of nonlinearity created by the dead zone in the
conduction cycle.
A number of partial solutions have been suggested for improving this problem. A better solution is
to develop a topology that eliminates the shoot hrough high current path and allows the sum total switch
duty cycle to be unity.
Precision DC-to-AC Power Conversion by Optimization of the Output Current WaveformThe Half Bridge
Revisited
Gerald R. Stanley, Member, IEEE, and Kenneth M. Bradshaw, Member, IEEE

Based on what weve researched it is possible to create an adjustable power supply using a rotary
switch that alter the source and same way changes our output.

1.3 Applicable Standards Part II

Overview
ON Semiconductor was the first Semiconductor company to provide an 80 PLUS open reference
design for an ATX Power Supply in 2005. This 1st generation reference design, was certified and met all
the requirements of the 80 PLUS program. Following on this successful 1st generation design, ON
Semiconductor is introducing its improved 2nd Generation reference design. This 2nd generation design
utilizes newer ICs from ON Semiconductor that enable this design to exceed 80% efficiency starting at 20%
load across different line conditions with ample margin to spare.
This reference document provides the details behind this 2nd 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 2nd 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. With the use of these new ICs, ON Semiconductor has proven again that the emerging
requirements for high efficiency desktop power supplies can be met and further, can be optimized to meet
specific performance vs. cost goals.

This 2nd 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. As seen in figure 1, this design employed an
Active Clamp forward topology using the new, highly integrated Active Clamp Controller IC from ON
Semiconductor NCP1562. A Continuous Conduction Mode (CCM) Power Factor Correction (PFC) IC was
employed for the active PFC circuit. This IC, the NCP1653 provides an integrated, robust and costeffective
PFC solution. The standby controller, NCP1027, is an optimized IC for the ATX power supply and
incorporates a high-voltage MOSFET. On the secondary side, this architecture employs a post regulator
approach for generating the 3.3 V output. This is an alternative approach to the traditional magnetic
amplifier (Mag Amp) approach. Though ON Semiconductor believes that this post regulator approach
provides the highest efficiency amongst the different means of generating these outputs in the power
supply, it is important to note that if the customer desires to use a different approach, that is possible i.e. a
similar design can be developed that utilizes all the other pieces of this architecture without the post
regulator and still achieve very good results.
With the introduction of this 2nd generation, high-efficiency ATX Power Supply, ON Semiconductor
has shown that with judicious choice of design tradeoffs, optimum performance is achieved at minimum
cost.

Figure 1: Reference Design Architecture Block Diagram

Specifications
The design closely follows the ATX12V version 2.2 power supply guidelines and specifications
available from www.formfactors.org, unless otherwise noted. For instance, our reference design had a
target of +/- 5% tolerance for both the 5 V and 5 Vstandby outputs. Further, the efficiency targets for the 80
PLUS program and the EPAs Energy Star specification Energy Star Program Requirements for
Computers, version 4.0 that is set to take effect from July 20, 2007 were targeted. Key specifications are
included in Table 1 below.

Table 1: Target Specifications

Target specifications for other key parameters of the reference design include:
- Efficiency: Minimum efficiency of 80% for 20%, 50% and 100% of rated output load conditions as
defined by the 80 PLUS requirements as well as the Energy Star specification.
- Power Factor: Power factor of 0.9 or greater at 100 % load.
- Input Voltage: Universal Mains 90 Vac to 265 Vac, 47 63 M Hz.
- Output Power: Total maximum output power is 305 W.
- Safety Features: As per the ATX12V specification, this design includes safety features such as
OVP, UVP, and OCP.
- This design meets the IEC1000-3-2 requirements over the input line range and under full load
conditions.
- This converter was designed for a 20 ms minimum Hold-up time.
- Physical dimensions: This converter is designed to fit into the standard ATX enclosure with
dimensions of 150 mm x 140 mm x 86 mm.

Architecture Overview
Before discussing the power supply architecture of the Generation 2 design, it is worth reiterating
the design goals. We are tasked with providing a flexible power platform, which is required to have the
lowest cost and highest efficiency that can be packaged in a small volume. The architecture must deliver a
minimum of 80% efficiency over a wide range of operating conditions (high-line and low-line) as well as
rated output load conditions (20% load and above). In addition we require a robust design solution having
low parts count to provide the same performance on a unit to unit basis in a high volume manufacturing
environment.

The architecture selected follows a traditional two stage conversion approach as illustrated in
Figure 1. It is worth noting that in order to achieve 80% efficiency overall, the efficiency of each of the two
conversion stages must exceed 90 %. The front-end is a universal input, active power factor boost stage
delivering a constant output voltage of 385 V to the active clamp stage. The second stage consists of two,
dc-dc converters. The first down-stream converter processes 290 W required by the system in the form of
tightly regulated +/-12 V, +5 V and +3.3 V outputs. The second converter delivers 15 W of standby power to
another isolated 5 V rail.
ON Semiconductor has developed multiple power management controllers and MOSFET devices
in support of the ATX program. Web based data sheets, design tools and technical resources are available
to assist design optimization. The ICs, supporting the ATX Generation 2 platform, are the NCP1653 PFC
controller, the NCP1562 active clamp controller, the NCP4330 post regulator, the NCP1027 standby
controller, and the NTP48xx family of MOSFET synchronous rectifiers. It is not possible to discuss the
tradeoffs involved in each conversion stage at length, but the selection of the active 9 clamp forward
converter topology is a key one and will be covered in depth. Each controller is highly integrated and offers
the lowest external parts count available.

Part II
DESIGN SPECIFICATION
2.1 Design Simulation Lay-out

Rectifier (3N246)

Voltage Regulator (MC7815CT)

AC Input
DC Output

Capacitor

Item
Rectifier
Capacitor
Regulator

Value
3N246
100F
MC7815CT

2.2 Block Diagram

Input
AC Voltage

Transforme
r

Quantity
1
1
1

Bridge Rectifier

Smoothing
Capacitor

Voltage
Regulator

Output
DC Voltage

The design is composed of many steps; transformer, step down the level of AC current from the
wall current. Full-wave bridge type-rectifier provides a full-wave rectified voltage. Capacitor Filters, produce
a DC Voltage supply but it still has some ripples voltages. IC Regulator, removes and varies the voltage
output.
2.3 Schematic Diagram

2.4 Circuit Description and Operation

Firstly let us discuss about the need for the smoothing capacitance. As you know the output of the
bridge rectifier will be as follows

Output of Brige Rectifier

As you can see, although the waveform can be considered to be a DC voltage since the output
polarity does not invert itself, the large ripples that exist in the output makes sit almost impossible to be
used in any powering applications. So it is to remove these ripples that the smoothing capacitor is used.
Now the output after the capacitor will be

Output of Capacitor Filter

Now all we need to know is the value of Vr which can be selected according to our need. Normally
we take it as 0.4V which means that the maximum size of ripples in the output waveform will be 0.4v. One

dis advantage of this method is that the ripple factor depends in output current, ie. the ripples may become
larger or smaller while we vary the load. This is the reason why it is absolutely necessary for the capacitor
to be followed by a voltage regulator IC.
The most important part of this circuit is the MC7815CT variable voltage regulator. The MC7815CT is
a monolithic integrated circuit with adjustable 3-terminal positive-voltage regulator designed to supply
more than 1.5 A of load current with an output voltage adjustable over a 1.2 V to 37 V range. It also comes
with internal current limiting, thermal shutdown, and safe area compensation. All this makes it a very good
candidate for a regulator if we need a moderately accurate supply with medium power output. For more
details you may refer its data sheet. As you can see it has three pins,

INPUT

This is where we give the unregulated input

OUTPUT

This is where we will get the regulated output

ADJUST

The variable resistor connected to this pin, controls the output voltage

AC TO DC POWER CONVERSION

By

Amparo, Veenee Grace

Cezar, Sean
Imam, Mohamad
Rodriguez, Yven
Rosero, Leomer
Placidas, Sarah

A Project Report Submitted to the Electronics Engineering Department

in Partial Fulfilment of the Requirements for the course
ELECRONIC DEVICES AND CIRCUITS (ECE 001)

Technological Institute of the Philippines