This application note describes the operation and features of
the FAN7601. This device is a BCDMOS programmable
frequency current mode PWM controller which is designed
for off-line adapter applications and auxiliary power
supplies. To reduce power loss at light and no load, the
FAN7601 operates in burst mode and it includes a start-up
switch to reduce the losses in the start-up circuit.
Because of the internal start-up switch and burst mode operation, it is possible to supply an output power of 0.5W with
under 1W input power when the input line voltage is 265V.
On no load condition, input power is under 0.3W.
The FAN7601 offers a latch protection pin for the protection
of the system e.g. over voltage protection and/or thermal
shutdown.
The internal over voltage protection function shuts down the
IC operation when the supply voltage reaches 19V.
In addition, a soft start function is provided, and the soft start
time can be varied. Figure 1 shows a block diagram for the
The FAN7601 contains a start-up switch to reduce power
loss in the external start-up circuit of conventional PWM
converters. The internal start-up circuit charges the Vcc
capacitor with a 1mA current source if the line is connected
until the soft start is completed as shown in Fig. 2. The soft
start function starts when the Vcc voltage reaches the start
threshold voltage(typically 12V) and it ends when the
LATCH/SS pin voltage reaches 1V. The internal start-up
circuit starts charging the Vcc capacitor again if the Vcc
voltage is lowered to the minimum operating voltage
(typically 8V). In such a case the UVLO block shuts down
the output drive circuit and some other blocks to reduce the
IC current, and the soft start capacitor is discharged to zero
voltage. If the Vcc voltage reaches the start threshold voltage, the IC starts switching again and the soft start capacitor
is charged from zero voltage. The internal start-up circuit
supplies
current until the soft start is completed .
Vcc
V
TH
V
TL
Start-up
Current
Soft Start
1.5V
1V
Figure 2. Start-up Current and Vcc Voltage
Voltage
Soft Start
Time
current is supplied to the Vcc capacitor from the Vcc winding. Therefore the Vcc capacitor must be large enough to
supply sufficient current during the soft start time when
starting up. The value of the Vcc capacitor is determined by
(1) where 4V is the UVLO hysteresis and 2mA is the IC
operating current and 1mA is the start-up current.
Figure 4 shows the Vcc voltage when starting up with a 47uF
capacitor and a FQPF7N60 MOSFET. The input line voltage
is 265V and the soft start time is about 40ms.
V
TH
V
TL
Start-up
Current
1.5V
1V
Soft Start
Time
Figure 3. Typical Start-up Sequence for FAN7601
t
Vcc
Soft Start
Voltage
t
Figure 3 shows a typical start-up sequence for the FAN7601.
The Vcc voltage should be higher than the minimum
operating voltage at start-up to enter a steady state. If the
Vcc voltage is higher than 19V, the over voltage protection
function works. There is some delay in the over voltage
protection circuit. The Vcc capacitor can be selected
according to the soft start time and total gate charge(Qg) of
the MOSFET. In the data sheet, the operating supply current
is measured with a 1nF capacitor connected at the OUT pin.
Therefore the real operating current necessary for the IC
operation excluding the MOSFET drive is typically 2mA.
During the soft start period (Tss), the Vcc capacitor is
charged by a 1mA start-up current from the Vstr pin and the
Vcc capacitor is discharged by a 2mA IC operating current
and the MOSFET gate drive current. The MOSFET gate
drive current is Qg×fsw. Qg increases according to the MOSFET drain source voltage, therefore the drive current is maximum when the input line voltage is highest. During the soft
start period , the converter output voltage is very low, so few
2
Figure 4. Vcc Voltage Waveform at Start-up
The FAN7601 provides the Vref pin. The reference output
voltage is 5V. Because this voltage is the reference of the IC
operation, a 100nF ceramic capacitor must be connected
between the Vref pin and the GND pin to filter the switching
noise as close as possible to the IC.
The oscillator frequency is programmed by selecting the
values of Rt and Ct. The capacitor Ct is charged from the 5V
reference through the resistor Rt to approximately 2.5V and
discharged to 1.25V by an internal current sink. Figure 5
shows the oscillator frequency characteristics according to
the variation of Rt and Ct. The values of Rt and Ct can be
chosen with reference to Fig. 5.
R1
NTC
R2
PNP
Css
1
2
3
4
Latch
/SS
Vref
8
7
6
5
1000
100
10
Frequency (kHz)
1
0 1020304050
Figure 5. Oscillator Frequency Characteristics
Rt (kΩ)
Ct=
680pF
820pF
1nF
2.2nF
3.3nF
4.7nF
8.2nF
10nF
3. Soft Start and Latch
The 12uA current source charges the soft start capacitor Css
when the Vcc voltage reaches the start threshold voltage.
The soft start ends when the Latch/SS pin voltage becomes
1V and the Latch/SS pin is charged up to 1.5V. The soft start
capacitor is reset when the Vcc voltage is lower than the
minimum operating voltage.
The soft start time Tss is calculated by (2).
Tss = Css/12µA (2)
The latch protection is provided to protect the system.
The latch protection pin can be used for output over voltage
protection and/or thermal protection etc. If the Latch/SS pin
voltage is made greater than 2.5V by the external circuit,
then the IC is shut down. The latch protection is reset when
the Vcc voltage is lower than 5V.
Figure 6 shows a thermal protection circuit which uses an
NTC thermistor. As the temperature rises the resistance of
the NTC drops so the base voltage of the PNP transistor
drops. Then the PNP transistor turns on and charges the Css.
When the Latch/SS pin voltage is higher than 2.5V, the IC
goes to the shut down mode. The exact values of resistors
and NTC must be selected by an experiment because the
V
transistors and the leakage current of Css vary according to
the temperature.
BE(sat)
of PNP
Figure 6. Thermal Protection Circuit
Figure 7 shows an output over voltage protection circuit. If
the output voltage exceeds the sum of the zener diode
voltage and the photo coupler forward voltage drop, then the
capacitor Css is charged. In parallel with Css, a 1MΩ resistor
is connected because of the leakage
current of the photo coupler. If a 1MΩ is not connected the
leakage current of the photo coupler charges the Css up, and
the latch protection operates abnormally.
VoutVcc
1
Latch
2
3
4
1
23
/SS
4
Css
1M
Zener
Diode
Figure 7. Output Over Voltage Protection Circuit
4. Current Sense and Feedback
The FAN7601 performs current sensing and output voltage
feedback with only one pin. To achieve the two functions
with one pin, an internal LEB(Leading Edge Blanking)
circuit for filtering current sensing noise is not included
because an external RC filter is necessary to add output
voltage feedback and current sensing information.
Figure 8 shows the current sensing and feedback circuits.
Rs is the current sensing resistor for sensing the switch
current. The current sensing information is filtered by an RC
filter composed of Rf and Cf. The current Ifb flowing
through the photo transistor varies according to the feedback
information and add an offset voltage on the sensed current
information as shown in Fig. 8 and Fig. 9. When the CS/FB
pin voltage touches 1V, the output drive circuit turns the
MOSFET off. The higher the DC offset is, the shorter the
switch-on time is. By varying the Ifb, the duty cycle is con-
The FAN7601 contains a burst mode block to reduce power
loss at light and no load. A hysteresis comparator senses the
CS/FB offset voltage for the burst mode. The FAN7601
enters burst mode when the offset voltage of the CS/FB pin
is higher than 0.97V and exits the burst mode while the offset voltage is lower than 0.9V. The offset voltage is sensed
during the switch-off time. In the burst mod block, there are
about 4~8 switching cycles delay to filter the noise. By this
burst mode, a power consumption of less than 1W can be
achieved in standby mode.
6. Output Drive
The FAN7601 contains a single totem-pole output stage,
designed specifically for a direct drive of a power MOSFET.
The drive output is capable of up to 100mA peak current
with typical rise and fall times of 45ns, 35ns respectively
with a 1.0nF load. Additional circuitry has been added to
keep the drive output in a sinking mode whenever the UVLO
is active. This characteristic eliminates the need for an
external gate pull-down resistor.
The output drive capability can be improved by adding one
PNP bipolar transistor as shown in Fig. 10. In general, the
on-resistance is high to prevent voltage spike at turn-on, only
the turn-off characteristic is improved.
DC
Offset
Figure 10. Circuit for Improving the Turn-Off
Characteristic
3. Design Example
A 50W adapter is designed to illustrate the design procedure.
The system parameters are as follows.
-Maximum output power(Po) : 50W
-Input voltage range : 85Vrms~265Vrms
-Output voltage(Vo) : 12.1V
-AC line frequency(fac) : 60Hz
-Adapter efficiency(η) : > 80%
-Switching frequency(fsw) : 91kHz
1. DC Link Capacitor and Bridge Diode
The DC link voltage becomes minimum when the output
power is maximum and input line voltage is lowest. The
minimum DC link voltage can be calculated using (3).
2
Po_max
Vdc_min2 Vac_min
If the minimum voltage is chosen then the capacitance can
be calculated by (4).
If we choose the minimum voltage to be 70% of the peak
line voltage( ) then Cdc must be larger than 142uF.
285V⋅
The selected value is 150uF.
Figure 11 shows an experimental result for a 50W demo
board with a 150uF capacitor. Because the measured
efficiency is 84%, the minimum voltage is about 90V.
The bridge diode conduction time can be calculated by (5)
and the diode RMS current can be calculated by (6).
Vdc_link
Vac
Iac
Figure 11. DC Link Voltage and Current Waveforms
Table 1:
Rated Input Power
European Commission Regulation Specification
Phase 1
1.1.2001
0.3W and < 15W1.0W0.75W0.30W
≥
1
--------------------=arc
tc
2π fac⋅
I
BD RMS()
2=2 Vac_min⋅Vdc_min–()Cdc
Vdc_min
--------------------------------------
cos× (5)
2 Vac_min⋅
2fac⋅
----------------⋅⋅⋅ (6)
3tc⋅
The calculated value is 1.3A and the selected bridge diode is
KBP206(600V/2A).
2. Transformer Design
Since 2001, the European Commission has been regulating
no load losses for AC adapters, battery chargers and
external power supplies under 75W.
Table 1 shows the regulation target specification.
No Load Power Consumption
Phase 2
1.1.2003
Phase 3
1.1.2005
15W and < 50W1.0W0.75W0.50W
≥
50W and < 75W1.0W0.75W0.75W
≥
At light and no load, the FAN7601 operates in burst mode to
reduce the power loss. To meet the regulation specification
the most important thing is to minimize the number of
MOSFET switchings. The flyback converter transfers energy
during the switch-off time. As the primary inductance of the
flyback transformer increases, the energy transferred to the
secondary side increases during one switching cycle. Therefore it is better to use a higher inductance transformer, but
inductance is restricted by the size and cost of the transformer. In this design example, a 600uH transformer is
selected and the ferrite core is EER2828. The transformer
turns ratio is calculated when the input line voltage is lowest
and the output power is maximum. The maximum duty ratio
must be lower than 0.45 to prevent subharmonic oscillation.
In this design example, the turns ratio must be higher than
0.174 by (7).
n
>
–
1 D
-----------------------
D
Vo V
max
max
+
Diode
--------------------------------
⋅ (7)
Vdc_min
Once the minimum turns ratio is determined, then the
numbers of primary and secondary turns is calculated when
input line voltage is highest and the output power is
maximum. If the converter operates in the CCM (Continuous
Conduction Mode) then the turn-on time can be calculated
Then the number of primary turns can be obtained as in (9).
Ae is the effective cross sectional area of the core and Bmax
is the maximum flux density. Ae of EER2828 is 82.1mm
2
and Bmax is 0.15T. The calculated number of primary turns
is 54. Then the number of secondary turns can be calculated
by (10). The calculated number of secondary turns is 10.
The air gap length can be calculated by (11).
Vdc_max t
---------------------------------------
= (9)
Np
Ae Bmax⋅
Vo V
NsNp=
-------------------------------Vdc_min
lg4π=10
⋅⋅⋅ (11)
⋅
on
+
Diode
7–
–
1D
max
-----------------------
⋅ (10)
D
max
2
N
P
----------
Ae
L
If the primary inductance is not high enough, the converter
can operate in the DCM(Discontinuous Conduction Mode)
when the input line voltage is highest and the output power is
maximum. For the DCM, the turn-on time can be calculated
as in (12).
The maximum average current of the output diode is the
2LIon⋅⋅ ⋅
= (12)
t
----------------------------
on
Vdc_max
Then the number of primary turns and secondary turns can
be calculated by (9) and (10), respectively.
An adequate IC supply voltage is 12V considering the
minimum operating voltage and the over voltage protection
level. In this design example, the number of Vcc windings is
selected so as to be the same as that of the secondary
windings, namely 10 turns. If the number of windings is too
small, the supply voltage can touch minimum operating
voltage at no load; then the UVLO circuit comes into
operation, increasing the power loss. If the number of
windings is too large, the supply voltage can reach the over
voltage protection level. If it proves difficult to prevent over
voltage protection operation in normal mode, the circuit as
shown in Fig. 12 is recommended for the Vcc circuit.
same as the maximum load current. In this case, 4.167A is
the maximum load current. For better efficiency, two 100V,
20A schottky diodes are used. The diode is reverse biased
when MOSFET is turned on. The reverse voltage depends on
the MOSFET switching characteristic. If the MOSFET
switching is fast, the diode junction capacitance and
transformer leakage inductance resonate. Then the diode
reverse voltage can exceed the diode rating. Therefore the
MOSFET gate drive on resistance must be high enough to
limit diode reverse voltage. Figure 13 shows the output
diode voltage and MOSFET gate voltage waveforms when
input line voltage is 265V and output power is 50W.
The gate drive on resistance is 75Ω. As shown in the figure,
the diode reverse voltage exceeds the diode rating, 100V.
To reduce the diode reverse voltage, gate drive resistance is
changed to 150Ω. Figure 14 shows the output diode voltage
and MOSFET gate voltage waveforms with a 150Ω resistor.
The diode reverse voltage is lowered because of MOSFET's
slow turn-on characteristic.
Vcc
18V
Figure 12. Zener Clamped Vcc Circuit
3. MOSFET Current Sensing Resistor
Selection
Once the turns ratio of the transformer is determined, peak
MOSFET current can be calculated. The sensed current
information must be lower than 1V. If the resistance is too
high, the output power can not be delivered because the
MOSFET current is limited to the lower value.
The resistance can be determined as in (13). In this design
example, a 0.5Ω resistor has been selected.
The value of the output capacitor depends on the output
voltage ripple and noise specification. In this design example
two 1000uF capacitors are used.
5. MOSFET and Diode Selection
The current of MOSFET is highest when the input line
voltage is lowest and the output power is at maximum.
The MOSFET RMS current can be approximated as in (14).
The calculated value is 0.94A. A 600V, 2.7A(Tc=100°C)
MOSFET FQPF7N60 has been selected.
6. Output Voltage Sensing Resistor and
Feedback Loop Design
The output voltage sensing circuits cause power loss if the
impedance is too low. The values of the output voltage
sensing resistors are selected so that that power loss is under
10mW. The designed values are 27kΩ for the upper resistor
and 7kΩ for the bottom resistor.
To control output voltage, a KA431 and an optocoupler are
used as shown in Fig. 15. Equation (15) is the compensator
transfer function. In this equation, k is the current transfer
ratio of the optocoupler and this value is nonlinear.
V
--------k=
V
The FAN7601 does not contain an LEB(Leading Edge
Blanking) circuit, but the parasitic capacitance and
resistance of the internal circuit work as an RC filter which
filters switching noise. The parasitic capacitance is about
10pF and the parasitic resistance is about 20kΩ. These
values are sufficient to filter switching noise; therefore a
small capacitor can be used for C
be 1000~2000 times higher than that of Rs. The filter resistor
R
causes some sensing delay so that the peak value of the
f
filtered information is less than that of the real current
information. The higher resistance causes a greater
difference as shown in Fig. 16. The black line is the CS/FB
voltage and the red and blue lines are the real current
waveforms before filtering . The red line is the current
waveform when the resistance is low and the blue line is the
current waveform when the resistance is high. Because the
R
fb
O
f
--------
⋅⋅⋅ (1
R3
1
---------------------------------
RfC
s⋅⋅ 1+
f
Vcc
1
1
----------------------------+
R1 C1 s⋅⋅
R3
C1
R
fb
R
f
CS/FB
C
f
Figure 15. Output Voltage Compensation Circuit
R
S
. The value of Rf should
f
Vo
R1
R2
current peak of the blue line is higher than that of the red
line, more energy is transferred to the secondary side.
Therefore standby power is lower with the higher resistance.
But if the resistance is too high, the system can become
unstable. The selected values are 10pF for C
and 1kΩ for R
f
.
High resistance
Low resistance
1V
Filtered informations
CS/FB
Figure 16. Current Sense Waveforms
For the stability of the system, capacitor C1 must be high
enough. C1 can be selected as in (16). The selected value is
1nF.
C1
10
--------->
fsw
1
-------------------
⋅ (16)
2π R1⋅
R3 determines the control loop gain. If the value is too low,
the system can become unstable. And if the value is too high,
the output voltage regulation characteristics may be poor.
The selected value is 1.5kΩ. If the value of R
is too high
fb
then the output voltage is not regulated at no load because
the offset voltage of the CS/FB pin is lower than necessary.
If the value is too low the audible noise increases. Because
the current transfer ratio of the photocoupler is nonlinear, the
value of R
has to be selected by experiment at no load.
fb
The selected value is 3.9kΩ.
7. Transformer Audible Noise
Because the FAN7601 operates in burst mode at light load
and no load, it has a switching period and a non-switching
period. Figure 17 shows the gate and output voltage at no
load. Burst operation frequency is about 114Hz. The burst
operation frequency varies according to load condition and
the frequency is in the range of the audible frequency.
Therefore the transformer may generate audible noise.
The audible noise level depends on the control loop
characteristic. If the loop speed is fast, audible noise
increases but power loss decreases. If the loop speed is slow,
audible noise decreases but power loss increases. There has
to be a compromise between power loss and audible noise.
Varnishing the transformer helps in reducing audible noise.
greater than 0.5 for CCM, the slope compensation is necessary. Figure 18 shows the slope compensation circuit.
Vout
Vref
Rt
Rt/Ct
Ct
Vgate
2k
CS/FB
R
C
f
f
Figure 17. Burst Mode Operation Waveforms
8. How to Reduce Standby Power
1) Make the transformer inductance sufficiently high .
2) Make the control loop speed fast.
3) Use a higher resistor for R
makes the system unstable.
. But too high resistance
f
9. Slope Compensation
To prevent subharmonic oscillation when the duty ratio is
Figure 18. Slope Compensation Circuit
Figure 19 shows the designed application circuit diagram,
table 2 shows the test results and table 3 shows the 50W
adapter demo board components list. As can be seen in the
table, the input power is less than 0.3W in the whole input
voltage range at no load. The power was measured with a
power meter from Voltech, PM3000.
10. On/Off Control
The Latch/SS pin can be used for the On/Off control with an NPN transistor. Figure 19 shows the On/Off control circuit.
FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY
PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY
LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER
DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.
LIFE SUPPORT POLICY
FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES
OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR
CORPROATION. As used herein:
1. Life support devices or systems are devices or systems
which, (a) are intended for surgical implant into the body,
or (b) support or sustain life, or (c) whose failure to perform
when properly used in accordance with instructions for use
provided in the labeling, can be reasonably expected to
result in significant injury to the user.
2. A critical component is any component of a life support
device or system whose failure to perform can be
reasonably expected to cause the failure of the life support
device or system, or to affect its safety or effectiveness.
www.fairchildsemi.com
5/22/03 0.0m 002
2003 Fairchild Semiconductor Corporation
Stock#ANxxxxxxxxx
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