FL7930C Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Features Description PFC-Ready Signal VIN-Absent Detection Maximum Switching Frequency Limitation Internal Soft-Start and Startup without Overshoot Internal Total Harmonic Distortion (THD) Optimizer Precise Adjustable Output Over-Voltage Protection Open-Feedback Protection and Disable Function Zero-Current Detector (ZCD) 150 μs Internal Startup Timer MOSFET Over-Current Protection (OCP) Under-Voltage Lockout with 3.5 V Hysteresis Low Startup and Operating Current Totem-Pole Output with High State Clamp +500/-800 mA Peak Gate Drive Current The FL7930C is an active power factor correction (PFC) controller for boost PFC applications that operate in critical conduction mode (CRM). It uses a voltage-mode PWM that compares an internal ramp signal with the error amplifier output to generate a MOSFET turn-off signal. Because the voltage-mode CRM PFC controller does not need rectified AC line voltage information, it saves the power loss of an input voltage-sensing network necessary for a current-mode CRM PFC controller. FL7930C provides over-voltage protection (OVP), openfeedback protection, over-current protection (OCP), input-voltage-absent detection, and under-voltage lockout protection (UVLO). The PFC-ready pin can be used to trigger other power stages when PFC output voltage reaches the proper level with hysteresis. The FL7930C can be disabled if the INV pin voltage is lower than 0.45 V and the operating current decreases to a very low level. Using a new variable on-time control method, total harmonic distortion (THD) is lower than in conventional CRM boost PFC ICs. 8-Pin, Small Outline Package (SOP) Applications Ballast General LED Lighting Industrial, Commercial, and Residential Fixtures Outdoor Lighting: Street, Roadway, Parking, Construction, Ornamental LED Lighting Fixtures Ordering Information Part Number Operating Temperature Range Top Mark Package Packing Method FL7930CMX_G -40 to +125°C FL7930CG 8-Lead, Small Outline Package (SOP) Tape & Reel © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.3 www.fairchildsemi.com FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting October 2013 DC OUTPUT Vcc FL7930C line filter AC INPUT 8 VCC 5 ZCD 3 COMP 2 Out RDY 7 CS 4 INV 1 GND 6 PFC ready Figure 1. Typical Boost PFC Application Internal Block Diagram VCC H:open VREF 2.5VREF VBIAS Internal Bias ZCD Clamp Circuit VCC 5 reset 8 VCC 7 OUT 4 CS 6 GND VZ + VTH(S/S) 8.5 12 - VCC + Restart Timer VTH(ZCD) Gate Driver fMAX limit THD Optimized Sawtooth Generator Control Range Compensation S Q R Q VO(MAX) + - 40kW Overshoot-less Control + FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Application Diagram 8pF INV - 1 VREF VREF Stair Step VCS_LIM + Clamp Circuit reset VIN Absent COMP 3 disable disable - 0.35 Thermal Shutdown 0.45 2.5 2.675 + RDY 2 INV_open OVP UVLO VBIAS 2.051 Figure 2. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 2.240 Functional Block Diagram www.fairchildsemi.com 2 VCC OUT GND ZCD FL7930CG 8-SOP INV Figure 3. RDY COMP CS Pin Configuration (Top View) Pin Definitions Pin # Name Description 1 INV This pin is the inverting input of the error amplifier. The output voltage of the boost PFC converter should be resistively divided to 2.5 V. 2 RDY This pin is used to detect PFC output voltage reaching a pre-determined value. When output voltage reaches 89% of rated output voltage, this pin is pulled HIGH, which is an (open-drain) output type. 3 COMP 4 CS 5 ZCD This pin is the input of the zero-current detection (ZCD) block. If the voltage of this pin goes higher than 1.5 V, then goes lower than 1.4 V, the MOSFET is turned on. 6 GND This pin is used for the ground potential of all the pins. For proper operation, the signal ground and the power ground should be separated. 7 OUT This pin is the gate drive output. The peak sourcing and sinking current levels are +500 mA and -800 mA, respectively. For proper operation, the stray inductance in the gate driving path must be minimized. 8 VCC This is the IC supply pin. IC current and MOSFET drive current are supplied using this pin. This pin is the output of the transconductance error amplifier. Components for the output voltage compensation should be connected between this pin and GND. This pin is the input of the over-current protection comparator. The MOSFET current is sensed using a sensing resistor and the resulting voltage is applied to this pin. An internal RC filter is included to filter switching noise. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Pin Configuration www.fairchildsemi.com 3 Stresses exceeding the absolute maximum ratings may damage the device. The device may not function or be operable above the recommended operating conditions and stressing the parts to these levels is not recommended. In addition, extended exposure to stresses above the recommended operating conditions may affect device reliability. The absolute maximum ratings are stress ratings only. Symbol VCC Parameter Min. Supply Voltage Max. Unit VZ V IOH, IOL Peak Drive Output Current -800 +500 mA ICLAMP Driver Output Clamping Diodes VO>VCC or VO<-0.3 V -10 +10 mA Detector Clamping Diodes -10 +10 mA VZ V Error Amplifier Input, Output and ZCD(1) -0.3 8.0 CS Input Voltage(2) -10.0 6.0 IDET VIN VIN (1) RDY Pin TJ Operating Junction Temperature TA V +150 °C Operating Temperature Range -40 +125 °C TSTG Storage Temperature Range -65 +150 °C ESD Electrostatic Discharge Capability Human Body Model, JESD22-A114 2.5 Charged Device Model, JESD22-C101 2.0 kV Notes: 1. When this pin is supplied by external power sources by accident, its maximum allowable current is 50 mA. 2. In case of DC input, the acceptable input range is -0.3 V~6 V: within 100 ns -10 V~6 V is acceptable, but electrical specifications are not guaranteed during such a short time. Thermal Impedance Symbol JA Parameter Thermal Resistance, Junction-to-Ambient Min. (3) 150 Note: 3. Regarding the test environment and PCB type, please refer to JESD51-2 and JESD51-10. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 Max. Unit °C/W FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Absolute Maximum Ratings www.fairchildsemi.com 4 VCC = 14 V and TA = -40°C~+125°C, unless otherwise specified. Symbol Parameter Conditions Min. Typ. Max. Unit VCC Section VSTART Start Threshold Voltage VCC Increasing 11 12 13 V VSTOP Stop Threshold Voltage VCC Decreasing 7.5 8.5 9.5 V 3.0 3.5 4.0 V 20 22 24 V 20 V HYUVLO UVLO Hysteresis VZ Zener Voltage ICC=20 mA VOP Recommended Operating Range 13 Supply Current Section ISTART Startup Supply Current VCC=VSTART-0.2 V 120 190 µA IOP Operating Supply Current Output Not Switching 1.5 3.0 mA IDOP Dynamic Operating Supply Current 50 kHz, CI=1 nF 2.5 4.0 mA 90 160 230 µA 2.465 2.500 2.535 V 0.1 10.0 mV IOPDIS Operating Current at Disable VINV=0 V Error Amplifier Section VREF1 Voltage Feedback Input Threshold1 TA=25°C VREF1 Line Regulation VREF2 Temperature Stability of VREF1(4) VCC=14 V~20 V 20 IEA,BS Input Bias Current VINV=1 V~4 V IEAS,SR Output Source Current VINV=VREF -0.1 V IEAS,SK Output Sink Current VINV=VREF +0.1 V VEAH Output Upper Clamp Voltage VINV=1 V, VCS=0 V VEAZ Zero-Duty Cycle Output Voltage gm (4) Transconductance -0.5 mV 0.5 -12 µA µA 12 µA 6.0 6.5 7.0 V 0.9 1.0 1.1 V 90 115 140 µmho Maximum On-Time Section tON,MAX1 Maximum On-Time Programming 1 TA=25°C, VZCD=1 V 35.5 41.5 47.5 µs tON,MAX2 T =25°C, Maximum On-Time Programming 2 A IZCD=0.469 mA 11.2 13.0 14.8 µs 0.7 0.8 0.9 V -1.0 -0.1 1.0 µA 350 500 ns Current-Sense Section VCS Current-Sense Input Threshold Voltage Limit ICS,BS Input Bias Current VCS=0 V~1 V tCS,D Current-Sense Delay to Output(4) dV/dt=1 V/100 ns, from 0 V to 5 V FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Electrical Characteristics Continued on the following page… © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 5 VCC = 14 V and TA = -40°C~+125°C, unless otherwise specified. Symbol Parameter Conditions Min. Typ. Max. Unit 1.35 1.50 1.65 V 0.05 0.10 0.15 V 5.5 6.2 7.5 V 0 0.65 1.00 V -1.0 -0.1 1.0 µA Zero-Current Detect Section VZCD HYZCD Input Voltage Threshold(4) Detect Hysteresis (4) VCLAMPH Input High Clamp Voltage IDET=3 mA VCLAMPL Input Low Clamp Voltage IDET= -3 mA IZCD,BS Input Bias Current VZCD=1 V~5 V (4) IZCD,SR Source Current Capability TA=25°C -4 mA IZCD,SK Sink Current Capability(4) TA=25°C 10 mA tZCD,D Maximum Delay From ZCD to Output Turn-On(4) dV/dt=-1 V/100 ns, from 5 V to 0 V 100 200 ns 9.2 Output Section VOH Output Voltage High IO=-100 mA, TA=25°C 11.0 12.8 V VOL Output Voltage Low IO=200 mA, TA=25°C 1.0 2.5 V (4) CIN=1 nF 50 100 ns (4) 50 100 ns 13.0 14.5 V 1 V tRISE tFALL Rising Time Falling Time CIN=1 nF VO,MAX Maximum Output Voltage VCC=20 V, IO=100 µA VO,UVLO Output Voltage with UVLO Activated VCC=5 V, IO=100 µA 11.5 Restart / Maximum Switching Frequency Limit Section tRST fMAX Restart Timer Delay (4) Maximum Switching Frequency 50 150 300 µs 250 300 350 kHz 2 4 mA 320 500 mV 1 µA RDY Pin IRDY,SK Output Sink Current VRDY,SAT Output Saturation Voltage IRDY,LK Output Leakage Current 1 IRDY,SK=2 mA Output High Impedance Soft-Start Timer Section tSS Internal Soft-Soft(4) 3 5 7 ms 2.166 2.240 2.314 V FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Electrical Characteristics UVLO Section VRDY HYRDY Output Ready Voltage Output Ready Hysteresis 0.189 V Protections VOVP HYOVP VEN HYEN OVP Threshold Voltage TA=25°C 2.620 2.675 2.730 V OVP Hysteresis TA=25°C 0.120 0.175 0.230 V Enable Threshold Voltage 0.40 0.45 0.50 V Enable Hysteresis 0.050 0.10 0.15 V 125 140 155 °C TSD Thermal Shutdown Temperature(4) THYS Hysteresis Temperature of TSD(4) 60 °C Note: 4. These parameters, although guaranteed by design, are not production tested. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 6 Function PFC Ready Pin Frequency Limit FL6961 None None FL7930C FL7930C Advantages Integrated Integrated VIN-Absent Detection None Integrated Soft-Start and Startup without Overshoot None Integrated THD Optimizer External Internal TSD None 140°C with 60°C Hysteresis Control Range Compensation None Integrated No External Circuit for PFC Output UVLO Versatile Open-Drain Pin Increase System Reliability by Testing for Input Supply Voltage Guarantee Stable Operation at Short Electric Power Failure Reduce Voltage and Current Stress at Startup No External Resistor Needed Reduce Power Loss and BOM Cost Caused by PFC Out UVLO Circuit Abnormal CCM Operation Prohibited Abnormal Inductor Current Accumulation Can Be Prohibited Eliminate Audible Noise due to Unwanted OVP Triggering Stable and Reliable TSD Operation Converter Temperature Range Limited Range Comparison of FL7930B and FL7930C Function FL7930B FL7930C RDY Pin None Integrated OVP Pin Integrated None © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 FL7930C Remark If PFC Rated Output Voltage is Assumed 390 V: VRDY_HIGH Trigger Voltage = 349 V, VRDY_LOW Trigger Voltage = 320 V FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Comparison of FL6961 and FL7930C www.fairchildsemi.com 7 Figure 4. Voltage Feedback Input Threshold 1 (VREF1) vs. TA Figure 6. Stop Threshold Voltage (VSTOP) vs. TA Figure 8. Operating Supply Current (IOP) vs. TA © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 Figure 5. Figure 7. Figure 9. Start Threshold Voltage (VSTART) vs. TA Startup Supply Current (ISTART) vs. TA FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Typical Performance Characteristics Output Upper Clamp Voltage (VEAH) vs. TA www.fairchildsemi.com 8 Figure 10. Zero Duty Cycle Output Voltage (VEAZ) vs. TA Figure 11. Maximum On-Time Program 1 (tON,MAX1) vs. TA Figure 12. Maximum On-Time Program 2 (tON,MAX2) vs. TA Figure 13. Current-Sense Input Threshold Voltage Limit (VCS) vs. TA Figure 14. Input High Clamp Voltage (VCLAMPH) vs. TA Figure 15. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Typical Performance Characteristics Input Low Clamp Voltage (VCLAMPL) vs. TA www.fairchildsemi.com 9 Figure 16. Output Voltage High (VOH) vs. TA Figure 18. Restart Timer Delay (tRST) vs. TA Figure 20. Figure 17. Figure 19. Output Saturation Voltage (VRDY,SAT) vs. TA © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 Figure 21. Output Voltage Low (VOL) vs. TA Output Ready Voltage (VRDY) vs. TA FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Typical Performance Characteristics OVP Threshold Voltage (VOVP) vs. TA www.fairchildsemi.com 10 VOUTPFC UVLO OVP 2.5 2.675 0.35 0.45 2.675V/2.5V + disable + VOUTPFC 0.45V/0.35V + INV open 2.240V/2.051V - disable - PFC Inductor VINPFC + 1. Startup: Normally, supply voltage (VCC) of a PFC block is fed from the additional power supply, which can be called standby power. Without this standby power, auxiliary winding for zero current detection can be used as a supply source. Once the supply voltage of the PFC block exceeds 12 V, internal operation is enabled until the voltage drops to 8.5 V. If VCC exceeds VZ, 20 mA current is sinking from VCC. 2.5V INV high - Aux. Winding 1 disable 2.051 2.240 2 3 RDY VCC’ COMP FL7930 Rev.00 External VCC circuit when no standby power exists Figure 23. FL7930 Rev.00 VREF VBIAS 2.5VREF Internal Bias Circuit Around INV Pin VOUTPFC VCC’ 413V 390Vdc VCC H:open 390V 8 reset 349V 320V VZ + VTH(S/S) 20mA 8.5 70V 12 55V VINV 2.65V 2.50V Figure 22. Startup Circuit 2.50V 2.24V 2.051V 0.45V 0.35V VCC 2. INV Block: Scaled-down voltage from the output is the input for the INV pin. Many functions are embedded based on the INV pin: transconductance amplifier, output OVP comparator, disable comparator, and output UVLO comparator. 15V 2.0V IOUTCOMP Current sourcing For the output voltage control, a transconductance amplifier is used instead of the conventional voltage amplifier. The transconductance amplifier (voltagecontrolled current source) aids the implementation of the OVP and disable functions. The output current of the amplifier changes according to the voltage difference of the inverting and non-inverting input of the amplifier. To cancel down the line input voltage effect on power factor correction, the effective control response of the PFC block should be slower than the line frequency and this conflicts with the transient response of controller. Two-pole one-zero type compensation can meet both requirements. I sinking VRDY Voltage is decided by pull-up voltage. OVP Vcc<2V, internal logic is not alive. - RDY pin is floating, so pull up voltage is shown. - Internal signals are unknown. t Figure 24. Timing Chart for INV Block 3. RDY Output: When the INV voltage is higher than 2.24 V, RDY output is triggered HIGH and lasts until the INV voltage is lower than 2.051 V. When input AC voltage is quite high, for example 240 VAC, PFC output voltage is always higher than RDY threshold, regardless of boost converter operation. In this case, the INV voltage is already higher than 2.24 V before PFC VCC touches VSTART; however, RDY output is not triggered to HIGH until VCC touches VSTART. After boost converter operation stops, RDY is not pulled LOW because the INV voltage is higher than the RDY threshold. When VCC of the PFC drops below 5 V, RDY is pulled LOW even though PFC output voltage is higher than threshold. The RDY pin output is open drain, so needs an external pullup resistor to supply the proper power source. The RDY pin output remains floating until VCC is higher than 2 V. The OVP comparator shuts down the output drive block when the voltage of the INV pin is higher than 2.675 V and there is 0.175 V hysteresis. The disable comparator disables operation when the voltage of the inverting input is lower than 0.35 V and there is 100 mV hysteresis. An external small-signal MOSFET can be used to disable the IC, as shown in Figure 23. The IC operating current decreases to reduce power consumption if the IC is disabled. Figure 24 is the timing chart of the internal circuit near the INV pin when rated PFC output voltage is 390 VDC and VCC supply voltage is 15 V. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 Current sourcing Disable FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting Applications Information www.fairchildsemi.com 11 VSTART VSTOP PFC operation 5V VINV(=VPFCOUT) 2.500V 2.240V 2.051V VRDY T VAUX AUX VAC TIND (1) T VAUX AUX VPFCOUT VAC TIND (2) FL7930C Rev0.0 where: VAUX is the auxiliary winding voltage; TIND is boost inductor turns; TIND auxiliary winding turns; VAC is input voltage for PFC converter; and VOUT_PFC is output voltage from the PFC converter. t VCC VSTART VSTOP PFC operation 5V PFC inductor VINPFC VINV(=VPFCOUT) VOUTPFC Aux winding 2.500V 2.240V 2.051V FL7930 Rev.00 VCC RZCD Negative Clamp circuit VRDY ZCD - 5 + CZCD FL7930C Rev0.0 Figure 25. Positive Clamp circuit optional Two Cases of RDY Triggered HIGH THD optimized saw-tooth generator VCC VSTART VSTOP 5V Figure 27. PFC operation restart timer VTH(ZCD) t S Q R Q fMAX limit gate driver Circuit Near ZCD Because auxiliary winding voltage can swing from negative to positive voltage, the internal block in ZCD pin has both positive and negative voltage clamping circuits. When the auxiliary voltage is negative, an internal circuit clamps the negative voltage at the ZCD pin around 0.65 V by sourcing current to the serial resistor between the ZCD pin and the auxiliary winding. When the auxiliary voltage is higher than 6.5 V, current is sinked through a resistor from the auxiliary winding to the ZCD pin. VINV(=VPFCOUT) 2.500V 2.240V 2.051V VRDY FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting 4. Zero-Current Detection: Zero-current detection (ZCD) generates the turn-on signal of the MOSFET when the boost inductor current reaches zero using an auxiliary winding coupled with the inductor. When the power switch turns on, negative voltage is induced at the auxiliary winding due to the opposite winding direction (see Equation 1). Positive voltage is induced (see Equation 2) when the power switch turns off. VCC FL7930C Rev0.0 t ISW VCC FL7930 Rev.00 IDIODE IMOSFET VACIN VSTART VSTOP 5V PFC operation VAUX & VZCD VAUX VINV(=VPFCOUT) VZCD 2.500V 2.240V 2.051V 6.2V 0.65V t VRDY Figure 28. Auxiliary Voltage Depends on MOSFET Switching FL7930C Rev0.0 t Figure 26. Two Cases of RDY Triggered LOW © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 12 Because the MOSFET turn-on depends on the ZCD input, switching frequency may increase to higher than several megahertz due to the mis-triggering or noise on the nearby ZCD pin. If the switching frequency is higher than needed for critical conduction mode (CRM), operation mode shifts to continuous conduction mode (CCM). In CCM, unlike CRM where the boost inductor current is reset to zero at the next switch on; inductor current builds up at every switching cycle and can be raised to very high current that exceeds the current rating of the power switch or diode. This can seriously damage the power switch. To avoid this, maximum switching frequency limitation is embedded. If ZCD signal is applied again within 3.3 μs after the previous rising edge of gate signal, this signal is ignored internally and FL7930C waits for another ZCD signal. This slightly degrades the power factor performance at light load and high input voltage. VDS ZCD after COMPARATOR Ignores ZCD noise VOUTPFC - VIN VOUTPFC - VIN VIN MOSFET Gate Error occurs! IINDUCTOR Max. fSW Limit FL7930 Rev.00 IMOSFET t IDIODE Inhibit Region Figure 31. VZCD 1.5V 5. Control: The scaled output is compared with the internal reference voltage and sinking or sourcing current is generated from the COMP pin by the transconductance amplifier. The error amplifier output is compared with the internal sawtooth waveform to give proper turn-on time based on the controller. 1.4V MOSFET gate 150ns Delay ON ON Maximum Switching Frequency Limit Operation VOUTPFC FL7930 Rev.00 t Figure 29. 6.2V Auxiliary Voltage Threshold THD-Optimized Sawtooth Generator When no ZCD signal is available, the PFC controller cannot turn on the MOSFET, so the controller checks every switching off time and forces MOSFET turn on when the off time is longer than 150 μs. This restart timer triggers MOSFET turn-on at startup and may be used at the input voltage zero-cross period. + Clamp Circuit COMP 3 R1 C1 Figure 32. FL7930 Rev.00 Control Circuit Unlike a conventional voltage-mode PWM controller, FL7930C turns on the MOSFET at the falling edge of ZCD signal. The “ON” instant is determined by the external signal and the turn-on time lasts until the error amplifier output (VCOMP) and sawtooth waveform meet. When load is heavy, output voltage decreases, scaled output decreases, COMP voltage increases to compensate low output, turn-on time lengthens to give more inductor turn-on time, and increased inductor current raises the output voltage. This is how a PFC negative feedback controller regulates output. VCC tRESTART 150 s MOSFET gate ZCD after COMPARATOR t Restart Timer at Startup © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 MOSFET Off - 1 VREF Stair Step VOUT VIN FL7930 Rev.00 + INV C2 Figure 30. 1V Sawtooth FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting The auxiliary winding voltage is used to check the boost inductor current zero instance. When boost inductor current becomes zero, there is a resonance between boost inductor and all capacitors at the MOSFET drain pin: including COSS of the MOSFET; an external capacitor at the D-S pin to reduce the voltage rising and falling slope of the MOSFET; a parasitic capacitor at inductor; and so on to improve performance. Resonated voltage is reflected to the auxiliary winding and can be used for detecting zero current of boost inductor and valley position of MOSFET voltage stress. For valley detection, a minor delay by the resistor and capacitor is needed. A capacitor increases the noise immunity at the ZCD pin. If ZCD voltage is higher than 1.5 V, an internal ZCD comparator output becomes HIGH and LOW when the ZCD goes below 1.4 V. At the falling edge of comparator output, internal logic turns on the MOSFET www.fairchildsemi.com 13 ZCD after COMPARATOR VCC VCOMP & Sawtooth VSTART=12V 0.155 V / s MOSFET gate VREFSS VREFEND=2.5V 5ms t FL7930 Rev.00 Figure 33. Turn-On Time Determination VINV=0.4V gM The roles of PFC controller are regulating output voltage and input current shaping to increase power factor. Duty control based on the output voltage should be fast enough to compensate output voltage dip or overshoot. For the power factor, however, the control loop must not react to the fluctuating AC input voltage. These two requirements conflict; therefore, when designing a feedback loop, the feedback loop should be least ten times slower than AC line frequency. That slow response is made by C1 at the compensator. R1 makes gain boost around operation region and C2 attenuates gain at higher frequency. Boost gain by R1 helps raise the response time and improves phase margin. ISOURCECOMP (VREFSS-VINV) VCOMP ISOURCECOMP gM=ISOURCECOMP RCOMP=VCOMP Gain FL7930 Rev.00 C1 t Integrator Figure 36. Proportional gain 7. Startup without Overshoot: Feedback control speed of PFC is quite slow. Due to the slow response, there is a gap between output voltage and feedback control. That is why over-voltage protection (OVP) is critical at the PFC controller and voltage dip caused by fast load changes from light to heavy is diminished by a bulk capacitor. OVP is triggered during startup phase. Operation on and off by OVP at startup may cause audible noise and can increase voltage stress at startup, which is normally higher than in normal operation. This operation is improved when soft-start time is very long. However, too much startup time enlarges the output voltage building time at light load. FL7930C has overshoot protection at startup. During startup, the feedback loop is controlled by an internal proportional gain controller and, when the output voltage reaches the rated value, it switches to an external compensator after a transition time of 30 ms. This internal proportional gain controller eliminates overshoot at startup and an external conventional compensator takes over successfully afterward. R1 Freq. FL7930 Rev.00 C2 High-Frequency Noise Filter Figure 34. Compensators Gain Curve For the transconductance error amplifier side, gain changes based on differential input. When the error is large, gain is large to suppress the output dip or peak quickly. When the error is small, low gain is used to improve power factor performance. ICOMP Powering 250 mho 2.6V 2.5V 2.4V Sourcing Soft-Start Sequence FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting 6. Soft-Start: When VCC reaches VSTART, the internal reference voltage is increased like a stair step for 5 ms. As a result, VCOMP is also raised gradually and MOSFET turn-on time increases smoothly. This reduces voltage and current stress on the power switch during startup. The maximum of VCOMP is limited to 6.5 V, which dictates the maximum turn-on time. Switching stops when VCOMP is lower than 1.0 V. Sinking 115 mho Braking Figure 35. Gain Characteristic © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 14 IIN Conventional Controller Startup Overshoot IINDUCTOR Startup Overshoot Control VZCD INEGATIVE Control Transition VCOMP 1.5V 1.4V Depends on Load 150ns MOSFET gate Internal Controller ON ON t Figure 37. ON ON t FL7930 Rev.00 Startup without Overshoot Figure 39. 8. THD Optimization: Total harmonic distortion (THD) is the factor that dictates how closely input current shape matches sinusoidal form. The turn-on time of the PFC controller is almost constant over one AC line period due to the extremely low feedback control response. The turn-off time is determined by the current decrease slope of the boost inductor made by the input voltage and output voltage. Once inductor current becomes zero, resonance between COSS and the boost inductor makes oscillating waveforms at the drain pin and auxiliary winding. By checking the auxiliary winding voltage through the ZCD pin, the controller can check the zero current of boost inductor. At the same time, a minor delay is inserted to determine the valley position of drain voltage. The input and output voltage difference is at its maximum at the zero cross point of AC input voltage. The current decrease slope is steep near the zero cross region and more negative inductor current flows during a drain voltage valley detection time. Such a negative inductor current cancels down the positive current flows and input current becomes zero, called “zero-cross distortion” in PFC. Input and Output Current Near Input Voltage Peak Zero Cross To improve this, lengthened turn-on time near the zero cross region is a well-known technique, though the method may vary and may be proprietary. FL7930C optimizes this by sourcing current through the ZCD pin. Auxiliary winding voltage becomes negative when the MOSFET turns on and is proportional to input voltage. The negative clamping circuit of ZCD outputs the current to maintain the ZCD voltage at a fixed value. The sourcing current from the ZCD is directly proportional to the input voltage. Some portion of this current is applied to the internal sawtooth generator, together with a fixed-current source. Theoretically, the fixed-current source and the capacitor at sawtooth generator determine the maximum turn-on time when no current is sourcing at ZCD clamp circuit and available turn-on time gets shorter proportional to the ZCD sourcing current. VAUX RZCD IIN Vcc THD Optimizer FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting VOUT N 1 IINDUCTOR IMOSFET ZCD 5 IDIODE VZCD INEGATIVE Zero-Current Detect 1.5V VREF 1.4V IMOT 150ns MOSFET gate reset ON FL7930 Rev.00 Figure 38. ON Sawtooth Generator t Input and Output Current Near Input Voltage Peak © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 CMOT Figure 40. Circuit of THD Optimizer www.fairchildsemi.com 15 VOUT VIN Though VIN is eliminated, operation of controller is normal due to the large bypass capacitor. tON not shorter tON get shorter t VAUX VZCD at FET on Figure 41. Effect of THD Optimizer By THD optimizer, turn-on time over one AC line period is proportionally changed, depending on input voltage. Near zero cross, lengthened turn-on time improves THD performance. MOSFET gate DMAX fMIN fMIN DMIN NewVCOMP 9. VIN-Absent Detection: To save power loss caused by input voltage sensing resistors and to optimize THD, the FL7930C omits AC input voltage detection. Therefore, no information about AC input is available from the internal controller. In many cases, the VCC of PFC controller is supplied by an independent power source, like standby power. In this scheme, some mismatch may exist. For example, when the electric power is suddenly interrupted during two or three AC line periods; VCC is still live during that time, but output voltage drops because there is no input power source. Consequently, the control loop tries to compensate for the output voltage drop and VCOMP reaches its maximum. This lasts until AC input voltage is live again. When AC input voltage is live again, high VCOMP allows high switching current and more stress is put on the MOSFET and diode. To protect against this, FL7930C checks if the input AC voltage exists. If input does not exist, soft-start is reset and waits until AC input is live again. Soft-start manages the turn-on time for smooth operation when it detects AC input is applied again and applies less voltage and current stress on startup. VIN Absence Detected IDS Smooth Soft-Start t Figure 43. With VIN-Absent Circuit 10. Current Sense: The MOSFET current is sensed using an external sensing resistor for over-current protection. If the CS pin voltage is higher than 0.8 V, the over-current protection comparator generates a protection signal. An internal RC filter of 40 kΩ and 8 pF is included to filter switching noise. 11. Gate Driver Output: FL7930C contains a single totem-pole output stage designed for a direct drive of the power MOSFET. The drive output is capable of up to +500 / -800 mA peak current with a typical rise and fall time of 50 ns with 1 nF load. The output voltage is clamped to 13 V to protect the MOSFET gate even if the VCC voltage is higher than 13 V. VOUT VIN Though VIN is eliminated, operation of controller is normal due to the large bypass capacitor. FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting tON is typically constant over 1 AC line frequency, but tON is changed by ZCD voltage. VZCD tON VAUX MOSFET gate fMIN DMAX VCOMP IDS High drain current! t Figure 42. Without VIN-Absent Circuit © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 16 PFC block normally handles high switching current and the voltage low energy signal path can be affected by the high energy path. Cautious PCB layout is mandatory for stable operation. 1. 2. 3. 4. 5. The gate drive path should be as short as possible. The closed-loop that starts from the gate driver, MOSFET gate, and MOSFET source to ground of PFC controller should be as close as possible. This is also crossing point between power ground and signal ground. Power ground path from the bridge diode to the output bulk capacitor should be short and wide. The sharing position between power ground and signal ground should be only at one position to avoid ground loop noise. Signal path of the PFC controller should be short and wide for external components to contact. The PFC output voltage sensing resistor is normally high to reduce current consumption. This path can be affected by external noise. To reduce noise potential at the INV pin, a shorter path for output sensing is recommended. If a shorter path is not possible, place some dividing resistors between PFC output and the INV pin — closer to the INV pin is better. Relative high voltage close to the INV pin can be helpful. The ZCD path is recommended close to auxiliary winding from boost inductor and to the ZCD pin. If that is difficult, place a small capacitor (below 50 pF) to reduce noise. The switching current sense path should not share with another path to avoid interference. Some additional components may be needed to reduce the noise level applied to the CS pin. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 A stabilizing capacitor for VCC is recommended as close as possible to the VCC and ground pins. If it is difficult, place the SMD capacitor as close to the corresponding pins as possible. Figure 44. Recommended PCB Layout FL7930C — Single-Stage Flyback and Boundary-Mode PFC Controller for Lighting PCB Layout Guide www.fairchildsemi.com 17 Application Device Input Voltage Range Rated Output Power Output Voltage (Maximum Current) LED Lighting FL7930C 90-265 VAC 195 W 390 V (0.5 A) Features Average efficiency of 25%, 50%, 75%, and 100% load conditions is higher than 95% at universal input. Power factor at rated load is higher than 0.98 at universal input. Total Harmonic Distortion (THD) at rated load is lower than 15% at universal input. Key Design Notes When auxiliary VCC supply is not available, VCC power can be supplied through Zero Current Detect (ZCD) winding. The power consumption of R103 is quite high, so its power rating needs checking. Because the input bias current of INV pin is almost zero, output voltage sensing resistors (R112~R115) should be as high as possible. However, too-high resistance makes the node susceptible to noise. Resistor values need to strike a balance between power consumption and noise immunity. Quick-charge diode D106 can be eliminated. Without D106, system operation is normal due to the controller’s highly reliable protection features. Schematic Optional D106 600V 3A D105 600V 8A 230mH, 49:6 VAUX R109 47 R108 D103,1N414 8 4.7 4 1 C111 220mF, 450V 7 R114 3.9M Q101 FCPF 20N60 R115 75k R111 0.08, 5W C110,1n F C112,470p F D104,1N414 8 R110,10k D102, UF4004 FL7930C 8 VCC Out 5 ZC D CS 3 Com 2 p INV RD Y GND 6 R113 3.9M C104, 12nF C109 ,47n F R107 C108, ,10k 220nF C105, 100nF C115 ,2.2n F C107 ,33m F LF101 ,23mH C114 ,2.2n F D101,1N474 6 R104, 30k TH101 ,5D15 C102, 680nF R112 3.9M R103, 10k,1W R102, 330k C1030,68m F,630Vdc BD101, 600V,15A DC OUTPUT LP101,EER3124N FL7930C — Critical Conduction Mode PFC Controller for Lighting Typical Application Circuit C101, 220nF R101,1MJ VCC for another power stage ZNR101 ,10D471 FS101, 250V,5 A Circuit for VCC. If external VCC is used, this circuit is not needed. Circuit for VCC for another power stage thus components structure and values may vary. Figure 45. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 Demonstration Circuit www.fairchildsemi.com 18 Figure 46. Transformer Schematic Diagram Winding Specifications Position Bottom Top No Pin (S → F) Wire Turns Winding Method Np 9, 10 → 7, 8 0.1φ×50 49 Solenoid Winding Barrier Tape TOP BOT 1 Insulation: Polyester Tape t = 0.025 mm, 3 Layers NAUX 2→4 0.3φ 6 Solenoid Winding Insulation: Polyester Tape t = 0.025 mm, 4 Layers Electrical Characteristics Inductance Ts Pin Specification Remark 9, 10 → 7, 8 230 H ±7% 100 kHz, 1 V FL7930C — Critical Conduction Mode PFC Controller for Lighting Transformer Core & Bobbin Core: EER3124, Samhwa (PL-7) (Ae=97.9 mm2) Bobbin: EER3124 © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 19 Part # Value Note Part # Value Note Resistor Switch R101 1 MΩ 1W Q101 FCPF20N60 R102 330 kΩ 1/2W R103 10 kΩ R104 1W D101 1N4746 1 W, 18 V, Zener Diode 30 kΩ 1/4W D102 UF4004 1 A, 400 V Glass Passivated High-Efficiency Rectifier R107 10 kΩ 1/4W D103 1N4148 1 A, 100 V Small-Signal Diode R108 4.7 kΩ 1/4W D104 1N4148 1 A, 100 V Small-Signal Diode R109 47 kΩ 1/4W D105 8 A, 600 V, General-Purpose Rectifier R110 10 kΩ 1/4W D106 3 A, 600 V, General-Purpose Rectifier R111 0.80 kΩ 5W R112, 113, 114 3.9 kΩ 1/4W R115 75 kΩ 1/4W C101 220 nF / 275 VAC Box Capacitor C102 680 nF / 275 VAC Box Capacitor C103 0.68 µF / 630 V Box Capacitor C104 12 nF / 50 V Ceramic Capacitor C105 100 nF / 50 V SMD (1206) C107 33 µF / 50 V Electrolytic Capacitor C108 220 nF / 50 V Ceramic Capacitor C109 47 nF / 50 V Ceramic Capacitor C110 1 nF / 50 V Ceramic Capacitor C112 47 nF / 50 V Ceramic Capacitor C111 220 µF / 450 V Electrolytic Capacitor C114 2.2 nF / 450 V Box Capacitor C115 2.2 nF / 450 V Box Capacitor Diode IC101 FL7930C FS101 5 A / 250 V Capacitor © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 20 A, 600 V, SuperFET® CRM PFC Controller Fuse NTC TH101 5D-15 Bridge Diode BD101 15 A, 600 V FL7930C — Critical Conduction Mode PFC Controller for Lighting Bill of Materials Line Filter LF101 23 mH T1 EER3124 Transformer Ae=97.9 mm2 ZNR ZNR101 10D471 www.fairchildsemi.com 20 5.00 4.80 A 0.65 3.81 8 5 B 1.75 6.20 5.80 PIN ONE INDICATOR 4.00 3.80 1 5.60 4 1.27 (0.33) 1.27 0.25 C B A LAND PATTERN RECOMMENDATION SEE DETAIL A 0.25 0.10 0.25 0.19 C 1.75 MAX 0.10 0.51 0.33 OPTION A - BEVEL EDGE FL7930C — Critical Conduction Mode PFC Controller for Lighting Physical Dimensions 0.50 x 45° 0.25 R0.10 GAGE PLANE R0.10 OPTION B - NO BEVEL EDGE 0.36 NOTES: UNLESS OTHERWISE SPECIFIED 8° 0° 0.90 0.40 A) THIS PACKAGE CONFORMS TO JEDEC MS-012, VARIATION AA. B) ALL DIMENSIONS ARE IN MILLIMETERS. C) DIMENSIONS DO NOT INCLUDE MOLD FLASH OR BURRS. D) LANDPATTERN STANDARD: SOIC127P600X175-8M. E) DRAWING FILENAME: M08Arev14 F) FAIRCHILD SEMICONDUCTOR. SEATING PLANE (1.04) DETAIL A SCALE: 2:1 Figure 47. 8-Lead, Small Outline Package (SOP) Package drawings are provided as a service to customers considering Fairchild components. Drawings may change in any manner without notice. Please note the revision and/or date on the drawing and contact a Fairchild Semiconductor representative to verify or obtain the most recent revision. Package specifications do not expand the terms of Fairchild’s worldwide terms and conditions, specifically the warranty therein, which covers Fairchild products. Always visit Fairchild Semiconductor’s online packaging area for the most recent package drawings: http://www.fairchildsemi.com/dwg/M0/M08A.pdf. © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 21 FL7930C — Critical Conduction Mode PFC Controller for Lighting © 2011 Fairchild Semiconductor Corporation FL7930C • Rev. 1.0.2 www.fairchildsemi.com 22