Confidential MCZ5205SE APPLICATION NOTE Jan.2011 Ver1.0 SHINDENGEN ELECTRIC MFG.CO.,LTD -1- Confidential MCZ5205SE Disclaimers Thank you for purchasing our products. This manual contains important information on the safe use of our products. Your safety is of the utmost importance to us. Please read these instructions carefully before using our products. The following symbols mean: ! Warning Improper use of the products can result in death, serious injury, or expensive damage to equipment. ! Caution Improper use of the products can result in minor injuries or damage to equipment. ! Warning ! Warning Although we are constantly making every effort to improve the quality and reliability of our products, there nevertheless remains a certain probability that the semiconductor products may occasionally fail or malfunction. Please take careful precautions against product failures or malfunctions to avoid any injuries, fire accidents or social loss by implementing safety designs such as redundancy designs, designs for fire spread prevention, and designs for preventing malfunctions. Our semiconductor products listed in this document are not designed or manufactured to be used in devices or systems requiring extremely high levels of quality and reliability, or the failure or malfunction of which may directly threaten human lives or cause injury. In the cases where the products are to be used in devices or systems for special applications or devices or systems for specialized applications shown below, always make sure to consult us in advance. Special Applications Transportation devices (automotive, marine, etc.), communication devices for core network, traffic signal devices, fire prevention/anticrime devices, various safety devices, medical devices, etc. Specialized Applications Nuclear power control systems, aircraft and aerospace devices, submarine relay devices, and systems for preserving life, etc. Even if it is not for a special or specialized application, when IC products are to be used for devices or systems that are desired to last for a long period under continuous operation, please make sure to consult us in advance. ! Caution ! Caution ! ! ! Caution Caution Caution Do not attempt under any conditions to repair or modify IC products by yourself. Doing so could result in electric shock, device breakage, fire, and malfunction. When an abnormal condition occurs, an excessive voltage or under voltage may be generated across the output terminals of the circuit. Install preventative measures (e.g. over-voltage protection, over-current protection) for the device by considering the possibility of a malfunction and/or breakage of a load in an abnormal condition. Do not switch on the circuit before confirming the proper connection and polarity of input and output terminals as an erroneous connection may cause breakage of the protection device or smoke/fire. Do not use the circuit beyond the rated input voltage and install a protection device on the input rail to prevent smoke/fire that may be caused from an abnormal condition. If a breakdown or other abnormal condition occurs during the use of the device, immediately stop power to the device and consult us at your earliest possible convenience. ● We reserve the right to make any changes to the contents of this manual without prior notice in accordance with modifications to IC products. ● Details of specifications should be exchanged at the adoption of the IC products. ● All information included in this manual is believed to be accurate and reliable. However, our company takes no responsibility for any injury or damage incurred when using the IC products as described in this manual. 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SHINDENGEN ELECTRIC MFG.CO.,LTD -2- Confidential Index 1 : General Description 1.1: Features 4 1.2: Internal block diagram 5 1.3: Pin assignment 6 1.4: Functions 6 1.5: Application circuits 7 2 : Functional description 2.1: Outline 8 2.2: Power supply block 8 2.3: PFC block 9-12 2.4: LLC block 13-18 2.5: Others 19-21 2.6: Remarks 21 3 : Peripheral components setting 3.1: PFC ZCS turn on timing (ZC) 22 3.2: PFC Phase compensation (COMP) 23 3.3: PFC Output voltage / OVP threshold (FBP) 23 3.4: PFC OCP setting (CSP) 24 3.5: LLC Brown out protection (Vsen) 24 3.6: LLC Oscillator / Feedback (FBL) 25 3.7: LLC Soft start / protection delay timer (SST) 26 3.8: LLC Current limiting / capacitive mode protection (CSL) 3.9: PFC Output voltage and LLC Brown out protection (In case of common sensing line for FBP and Vsen) 26 27 4 : Circuit diagram 4.1: Typical application circuit (LLC dual output) 28 5 : Dimension 5.1: SOP22 (MCZ5205SE) 29 SHINDENGEN ELECTRIC MFG.CO.,LTD -3- Confidential 1 General description The MCZ5205SE adopts one chip solution to provide CrM PFC and LLC controller/driver in small package. This robust combo-IC eliminates external components for protective function and its multi functional terminal configuration simplifies power supply designing by using minimal components. Active standby function provides improved efficiency at light load condition. CrM PFC and Symmetric LLC combination provides excellent performance in low noise characteristics and also highly efficient power supply solution. The MCZ5205SE is most suitable for: FPD PSU (LCD / PDP / Projection) OA equipment PSU (LBP …etc.) High power adapter High power industrial equipment High power LED lighting driver 1.1 Features 1. PFC and LLC controllers are integrated in SOP22 package. 2. Active standby function improves efficiency at light load condition. 3. PFC adopts OVP multi-detective function to simplify the circuit. 4. Optimized PFC/LLC on-off timing. 5. Vcc up to 35V with 12.6 / 8.5V UVLO. [ PFC ] 1. Critical conduction mode PFC controller. 2. Peak current limiting threshold of 0.5V. 3. No input line sensing is required. 4. Various protections are installed. (feedback pin open/short, dynamic OVP, Thermal shutdown) [ LLC ] 1. Optimized Gate drive balance simplifies drive circuitry. 2. 600V floating gate drivers with individual UVLO. 3. Active standby operation eliminates a weak point of symmetric LLC that is unsatisfactory efficiency at light load condition. 4. Anti-capacitive protection 5. Various protections are installed. (Peak current limit / Timer delayed latching / Thermal shutdown) SHINDENGEN ELECTRIC MFG.CO.,LTD -4- Confidential 1.2 Internal block diagram Fig.1 MCZ5205SE internal block diagram SHINDENGEN ELECTRIC MFG.CO.,LTD -5- Confidential 1.3 Pin assignment Fig.2 MCZ5205SE Pin assignment 1.4 Functions PIN NO. symbol converter Function 1 ZC PFC Zero Current detection to determine turn on timing 2 COMP PFC Output of PFC feedback amp for phase COMPensation and soft start 3 FBP PFC Input of PFC FeedBack amp 4 Vsen LLC Line Voltage sensing for brownout protection 5 Vc1 Common Voltage source input for control circuit with 12.6V/8.5V UVLO 6 FBL LLC LLC operating frequency and duty setting FeedBack terminal 7 SST LLC Soft Start and protection Timer 8 SGND Common 9 CSL LLC 10 AS Common 11 VGL LLC Gate drive output for Low side mosfet 12 VGH LLC Gate drive output for High side mosfet 13 VS LLC Floating high side gate driver reference voltage ( : connect with Source terminal of high side mosfet) 14 VB LLC Floating Vcc Bootstrapping input 15-18 NC - 19 Vc2 Common Output terminal of supply for PFC and LLC driver 20 PGND Common Power GND 21 CSP PFC PFC mosfet source Current Sensing 22 VGP PFC Gate drive output for PFC mosfet Signal GND terminal LLC resonant Current Sensing Terminal for Active Standby mode / external latch signals input Non connection SHINDENGEN ELECTRIC MFG.CO.,LTD -6- Confidential 1.5 Application circuits Fig.3 Basic circuit example Fig.4 Basic circuit example (Without PFC) SHINDENGEN ELECTRIC MFG.CO.,LTD -7- Confidential 2 Functional description Values described in this document such as Threshold are typical, unless otherwise specified. For details, please refer to characteristic specification. 2.1 Outline The functionality of the MCZ5205SE can be grouped as follows: 1) Power supply For details, refer Section 2.2. 2) PFC Controller For details, refer Section 2.3. 3) LLC Controller For details, refer Section 2.4. 4) Others (Active Standby, Common Protection) For details, refer Section 2.5. 2.2 Power supply block 2.2.1 Power supply for controller (Vc1) Vc1 is power supply input terminal for controller. Connect a capacitor between Vc1 and GND close to the terminals to supply stable voltage. Select the capacitance value to stabilize transient conditions. (For example, start up and shut down.) If malfunction of MCZ5205SE occurs due to noise on Vc1, insert a MLCC of 1 to 4.7uF between Vc1 and GND close to the terminal. If Vc1 voltage reaches Vc1(start) 12.6V, Vc2 start charging. If Vc1 voltage falls below Vc1(stop) 8.5V, Vc2 starts discharging and controller stops its operation. If the latch-stop works due to an abnormal state, it is necessary for restarting to release the latch by reducing Vc1 voltage to less than latch reset voltage of Vc1(latch reset) 8.1V. 2.2.2 Power supply for gate driver (Vc2) Vc2 is output terminal of supply for PFC and LLC driver. Vc2 supplies stable voltage to gate drivers of PFC and LLC controllers. Connect a capacitor between Vc2 and GND close to the terminals to secure the stable driving in general and also transient conditions such as start up and shut down. Capacitance of 4.7 to 22uF is recommended. When Vc2 voltage reaches Vc2(start) 9.6V, oscillator (connected with FBL) starts operation and driving is ready. Refer to section 2.3 and 2.4 for the condition to start gate driving of PFC and LLC controllers. 2.2.3 Power supply for LLC High-side gate driver (VB) VB is output terminal of supply for LLC high-side driver. VB is connected with Vc2 via the bootstrap diode. Connect a capacitor between VB and VS. Select a capacitor with considering stable driving in transient conditions such as start up and shut down. Capacitance of 0.1 to 0.47uF is recommended. Bootstrap diode requires fast and soft recovery characteristics. For example, select a diode of 600V or higher when PFC output voltage is 400V. D1NK60(Shindengen) is recommended. VB is equipped with an independent UVLO (under voltage lock out). If VB voltage reaches VBVS(start) 7.4V, high-side gate driving starts. If VB voltage falls below VB-VS(stop) 5.3V, high-side gate driving stops. This hysteresis provides stable driving at transient condition of start up and shut down. SHINDENGEN ELECTRIC MFG.CO.,LTD -8- Confidential 2.3 PFC block 2.3.1 PFC gate driver (VGP) VGP drives a gate of PFC, and the voltage is supplied by stabilized voltage source Vc2,10.2V. Fig. 5 shows some examples of the drive circuit. In typical circuits shown in A) and B), Select the small type Schottky Barrier Diode, not hard recovery diodes. D1NS4 or M1FM3 (Shindengen) is recommended. In case of using a MOSFET with large Qg, use PNP transistor as shown in Fig. 5 C). A) R2 Qa Qb VGP B) Q1 D1 D1 Qa Q1 Qb R1 VGP R1 R2 R3 R3 CSP CSP Rcspdet GND C) GND Rcspdet Q1 Qa R1 Qb R2 VGP R3 CSP Rcspdet GND Fig.5 PFC gate drive circuit 2.3.2 PFC output voltage control and over-voltage protection PFC output voltage is stabilized by controlling the On-duty of PFC gate driving. Shown in Fig.6, PFC output voltage is monitored by FBP, and is stabilized by feeding-back the FBP voltage by comparison with internal reference voltage Vo(ref), 2.5V. COMP controls charge and discharge so that FBP voltage becomes 2.5V, consequently PFC output voltage becomes stable. (FBP voltage<2.5V --> COMP capacitor charges. and FBP voltage>2.5V --> COMP capacitor discharges.) PFC has an over-voltage protective function to protect components (e.g. capacitors) from damage due to excessive voltage. If FBP voltage exceeds Vfb(H), that is Vo(ref)×1.10, the gate driving stops (not latch-stop). Connect a capacitor of around 1000pF between FBP and GND close to the terminals for noise reduction. SHINDENGEN ELECTRIC MFG.CO.,LTD -9- Confidential Fig.6 PFC gate drive circuit 2.3.3 PFC phase compensation COMP is feedback amplifier output terminal. Phase compensation is adjusted by capacitor of 0.11.0uF connected between COMP and GND. Fig. 7 shows an example of the COMP phase compensation. For details of phase adjustment, refer to section 3.2. The relationship between VGP ON-time and COMP voltage is shown in Fig. 8. Maximum ON-time is fixed as Ton(max) 27.5us. When COMP voltage decreases to 0.8V or less, On-time becomes zero, consequently to prevent the increase of output voltage. COMP RCOMP CCOMP2 CCOMP1 Fig.7 Example circuit connected with COMP Fig.8 COMP VS ON Time 2.3.4 PFC critical conduction mode PFC block adopts critical conduction mode. PFC MOSFET turns ON by detecting the voltage across a control winding of main choke. Gate ON timing is determined by ZC signal as shown in Fig.9. Once VZC reaches ZC comparator threshold voltage(H) VZC(H), 1.55V, and then decreases beyond ZC comparator threshold voltage(L) VZC(L), 0.55V, MOSFET turns ON by detecting the negative edge. This hysteresis (:VZC(H) – VZC(L)) provides the higher noise immunity. Ton dead time of 800ns is adopted in order to prevent malfunction of MOSFET caused by ringing voltage at the timing of gate-OFF. SHINDENGEN ELECTRIC MFG.CO.,LTD - 10 - Confidential Fig.9 PFC block timing diagram (ZC) Insert a limiting resistor between control winging and ZC. This resistance has following two roles. 1. Turn on the gate at the lowest point of the Drain-Source voltage of MOSFET. 2. The resistor limits the current on ZC to +/-5mA or less, that is maximum allowable current on ZC. 2.3.5 PFC over current protection PFC over current protection is provided by monitoring the CSP voltage determined by resistors . Connected between source of PFC MOSFET and GND. MOSFET turns OFF by detecting CSP voltage exceeding the over-current threshold voltage as shown in Fig.10. To prevent malfunction of over-current protection caused by noise just after turn ON, Leading edge blank time (LEB) is adopted. Connect a capacitor of around 0.1uF close to CSP to prevent malfunctions due to noise. Adding a resistor RCSP2 of around 10ohm is more effective for the prevention. For designing the circuit, refer to section 3.4. Fig.10 CSP circuit example and timing diagram SHINDENGEN ELECTRIC MFG.CO.,LTD - 11 - Confidential 2.3.6 PFC FBP open/short protection If FBP voltage decreases to Vfb(L) 0.4V or less, PFC stops operation. Therefore, if FBP is shorted circuit to GND, PFC safely stops operation. PFC also stops operation on condition of FBP open circuit, as FBP voltage to zero. 2.3.7 PFC low input voltage protection The MCZ5205SE does not directly monitor the input voltage. Therefore, if FBP voltage exceeds 0.4V even in low input voltage condition, PFC continues the operation. However, MCZ5205SE has the limiting function for maximum ON-time internally fixed as 27.5us. decreases output current to prevent the excessive stress on MOSFET or other components. 2.3.8 PFC output over voltage protection (light load) At light load condition, the output voltage is stabilizes by narrowing the ON-time width of gate driving. However, in the case where the output voltage increases even if the ON-time width reaches the minimum set value, a function that the oscillation stops where COMP voltage decreases to Vth(burst), 0.8V or less operates to prevent the over voltage of output. SHINDENGEN ELECTRIC MFG.CO.,LTD - 12 - Confidential 2.4 LLC block 2.4.1 LLC gate driver (VGL,VGH) The gate drivers have 0.18A sourcing and 0.38A sinking current capability at Vc2=10.2V. Typical example circuits are shown in Fig.11 A). When using a diode for discharging as shown in Fig. 11 B) C), small type SBD(Schottky Barrier Diode). D1NS4(Shindengen) or M1FM3(Shindengen) are recommended. Fig.11 LLC Gate drive circuits 2.4.2 LLC Oscillator (FBL) The timing of gate drive pulse VGL and VGH is determined by charging and discharging of a timing capacitor Ct. (The timing capacitor Ct is connected with FBL.) Gate outputs are ON during the period of Ct discharging. VGL and VGH are alternately outputted to drive MOSFETs. During the time period of Ct charging, both VGL and VGH are simultaneously OFF, called as Dead time (DT), to prevent simultaneously ON of MOSFETs. FBL FBL FB VGH Ct Rt VGL PC1 DT DT DT DT Fig.12 FBL timing diagram The MCZ5205SE is the frequency and ON duty modulation type. The frequency modulates by FB current across a current limiting resistor and ON-duty modulates according to the frequency as shown in Fig. 13. Larger dead time in light load condition secures ZVS (Zero Voltage Switching) over a wide frequency range. Minimum frequency (fmin) is determined by the value of Ct capacitor and Rt resistor. SHINDENGEN ELECTRIC MFG.CO.,LTD - 13 - Confidential Maximum frequency (fmax) is determined by the value of Rt resistor and FB resistor. Maximum frequency (fmax) of 300kHz or less is recommended in continual operating condition. Soft start oscillation frequency (fss) varies depending on the value of Ct capacitance. (For details, refer to characteristic diagram sheet.) fr e qu e n c y vs du ty fr e qu e n c y vs de adtime 50 800 Ct=1500pF Ct=1200pF Ct=1000pF Ct=820pF 600 de ad t im e [ n s] du t y [ % ] 45 40 Ct=1500pF Ct=1200pF Ct=1000pF Ct=820pF 700 35 500 400 300 200 100 30 0 0 50 100 150 200 250 300 350 400 0 50 100 150 fre qu e n c y [ kHz] 200 250 300 350 400 fre qu e n c y [ kH z] Fig.13 Duty/dead time vs frequency 2.4.3 Vsen brown-out protection (Vsen) Vsen monitors the PFC output voltage for halting gate drive pulse, varying the frequency. UVLO function avoids below-resonant state caused by Vbulk supply brown-out (quick decrease of input voltage) or black-out (instantaneous interruption). Timing diagram of Vsen brown-out protection is shown in Fig.14. Vsen threshold voltage varies depending on AS mode ON or AS mode OFF. (See section 2.5.1) (1) AS mode OFF : Vsen1(ss-reset) 3.55V / Vsen2(ss-reset) 3.25V (2) AS mode ON : Vsen3(ss-reset) 1.00V / Vsen4(ss-reset) 0.90V Hysteresis characteristics of Vsen prevents malfunction of Vsen due to the PFC output voltage ripple. [Power ON] (a) Vsen voltage exceeds to 3.55V (AS mode OFF), SST capacitor starts charging. (b) SST voltage exceeds to 0.6V, LLC gate output is starts. SST is the soft start operated by gradual charging of SST capacitor. (For details of SST, refer to section 2.4.4.) [Power OFF] (a) Vsen voltage decreases to 3.25V (AS mode OFF), SST capacitor starts discharging. Frequency gradually increases. (b) SST voltage decreases to 0.5V, LLC gate output stops. Fig.14 Vsen output timing diagram SHINDENGEN ELECTRIC MFG.CO.,LTD - 14 - Confidential 2.4.4 Soft start function (SST) LLC unit has soft-start function. The frequency gradually decreases according to charging of capacitor connected between SST and GND. SST capacitor starts to be charged subject to following two conditions. (1) Vc1 voltage exceeds startup threshold voltage Vc1(start) 12.6V (2) Vsen voltage exceeds 3.55V (at AS mode OFF) or 1.00V (at AS mode ON). LLC gate output starts when SST voltage exceeds 0.6V, and then SST voltage is stabilized in 2.1V. LLC gate output stops if SST voltage decreases to 0.5V or less. For the relationship between SST voltage and frequency, refer to Fig. 15. In addition, SST equips a timer latch function to decrease the stress on MOSFETs and/or peripheral components in abnormal conditions. For details, refer to section 2.4.8. V S ST vs fre qu e n c y 500 Ct=1500pF Ct=1200pF Ct=1000pF Ct=820pF 450 fr e qu e n c y [ kHz ] 400 350 300 250 200 150 100 50 0 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 V SS T [ V] Fig.15 fss characteristics 2.4.5 Over current protection (CSL) OCP (over current protection) operates by detecting peak current of resonant tank with pulse by pulse at CSL. The detection threshold voltage is +/-0.350V (OCP input threshold voltage.) and is low enough to minimize ineffective power loss of sensing resistor. When CSL voltage exceeds OCP input threshold voltage, the gate output turns off and FBL capacitor immediately starts charging and simultaneously charging SST capacitor, and consequently output current is limited with pulse by pulse. (See Fig. 16.) In next cycle just after OCP detection, FBL capacitor stops discharging when FBL bottom voltage reaches 1.9V, thus, ON-time is limited to avoid below-resonant. (See Fig. 16.) Note that di/dt threshold is about 1/6 of OCP threshold. In order to prevent malfunction of OCP due to switching noise induced by MOSFET, OCP-mask period is adopted as shown in Fig.16. During the OCP-mask period, OCP detection does not work (period of FBL(TOP) to mask voltage, 2.8V). A filter is built-in in CSL to prevent malfunction due to random noise, and the filter causes delay time of around 200ns, that is the period of OCP detection to FBL starting to charge. SHINDENGEN ELECTRIC MFG.CO.,LTD - 15 - Confidential Fig.16 Over current protection 2.4.6 di/dt mode protection (CSL) The MCZ5205SE adopts pulse by pulse bidirectional di/dt protection to avoid below resonant mode operation. This function helps to avoid di/dt hard switching mode of MOSFETs in below ZVS boundary operation. When CSL voltage decreasing to 60mV, instantaneously FBL starts charging and gate drive turns off. In negative current direction, it operates in the same manner with threshold voltage of -60mV. Di / dt charge timer operation varies depending on AS mode ON or AS mode OFF. (See section 2.5.1) (1) AS mode OFF : timer capacitor is not charged. (2) AS mode ON : timer capacitor is charged. During OCP-mask period (FBL(Top) to mask voltage, 2.8V), di/dt detection does not work to prevent the malfunction due to noise. FBL(Top) di/dt masking time mask voltage 2.8V FBL(Bottom) +0.06V CSL 0V -0.06V VGH VGL Fig.17 di/dt protection SHINDENGEN ELECTRIC MFG.CO.,LTD - 16 - d/dt internal filter delay Confidential 2.4.7 di/dt protection at startup (Tss(3)) The MCZ5205SE has another di/dt protection at startup state to prevent the turn-off of gate drive during period of body diode. nd On 2 VGL gate drive pulse, increase the ON-time width by decreasing the voltage to start charging to 0.8V, consequently the gate drive turns-off after MOSFET current starts to flow. The operation sequence is shown in Fig.18. Fig.18 Tss(3) operating sequence 2.4.8 Timer latch protection (SST) SST capacitor starts charging to either case below. (1) OCP detection (2) di/dt detection under AS mode ON SST capacitor starts charging and continual abnormal condition keeps charging SST capacitor with 40uA constantly until SST voltage reaches 3.6V. Once SST terminal voltage reaches 3.6V, gate output stops and SST capacitor start discharging with 6uA constantly until SST voltage decreases to 0.35V. At the moment SST voltage reaches 0.35V, SST capacitor restarts charging with 28uA constantly, then, the soft start operation restarts. Timer counter counts the number of times of 3.6V charging. If count is twice, output latches off. If abnormal condition is eliminated and the controller recovers normal operation before the two counts, SST capacitor starts discharging with 500uA and the counting result is reset. To release the latch, restart with Vc1 less than 8.1V. Latch counter is reset by either condition below. (1) SST voltage reaches 2.1V by continual OCP detection. (2) SS refreshing operation (Vc1 ON/OFF operation ) Timing chart is shown in Fig.19. SHINDENGEN ELECTRIC MFG.CO.,LTD - 17 - Confidential Vc1 Vc1(start) 12.6V Vc1(stop) 8.5V Momentary overload over load mode LLC ID OCP operation Abnomaly detection signal (IC internal) OCP operation OCP operation Vtimer1 3.6V 2.1V SST 1.5V 0.6V Vtimer2 0.35V Fig.19 SST operating sequence 2.4.9 High side floating Vcc (VB) Floating High side gate drive voltage source (VB) is produced by stabilized Vc2 of 10.2V through bootstrap circuit. Recommended components at PFC output voltage of 400V are : 600V soft recovery type UFRD (ultra fast recovery diode) D1NK60 (Shindengen) or D1FK60 (Shindengen) for Dboot 16V, 0.1 to 1.0uF MCLL for Cboot VB = Vc2 – Vf (Forward voltage of Dboot) Cboot 0.1 uF 16V Np Dboot D1NK60 D1FK60 VGH VS VB VGL PGND Vc2 MCZ5205SE Fig.20 Boot Strapping configuration SHINDENGEN ELECTRIC MFG.CO.,LTD - 18 - Confidential 2.5 Others 2.5.1 Active Standby (AS) The MCZ5205SE adopts active standby function contributing to loss reduction at light load condition. The example circuit is shown in Fig. 21. Active standby function operates as below. (1) AS mode ON : If AS voltage reaches 0.8V or less. (2) AS mode OFF : If AS voltage reaches 1.0V or more. (3) AS latch stop : If AS voltage reaches 4.5V or more. To release the latch, restart with Vc1 of 8.1V or less. Connect a capacitor of 1000 to 10000pF between AS terminals to prevent malfunction due to noise even where AS function is not used. Note that AS voltage is set to 2.4V at AS load open. Fig.21 AS mode circuit example Following operations are provided after shifting to AS mode. For detailed timing diagram, refer to Fig.22. (1) LLC operating mode (2) Vsen SS-reset threshold (3) Timer charge (di/dt mode) (4) PFC operating mode : Switched from symmetric operation to asymmetric operation. : Switched from 3.55V/3.25V to 1.0V/0.9V. : Switched from ‘disable’ to ‘enable’. : Switched from ‘Oscillation start’ to ‘Oscillation stop’. Asymmetric operation can lower the peak current at light load condition and PFC oscillation stops resulted in significant efficiency improvement at light load. Vsen SS-reset threshold is automatically switched so that LLC oscillation continues even when the PFC oscillation stops. This function does not require any additional components. In addition, AS mode ON enables charging SST capacitor at di/dt mode to provide OCP. Soon after switching from AS mode ON to AS mode OFF, COMP starts charging and PFC starts operation when COMP voltage reaches 0.8V or more. Then, FBP voltage exceeds 2V and Vsen SS-reset threshold switches, LLC operation mode switches to symmetric mode (normal operation mode). AS has a latch stop function. If AS voltage exceeds AS latch stop voltage 4.5V, PFC and LLC oscillation immediately stops unlike SST timer latch. To release the latch, restart at Vc1 of 8.1V or less. SHINDENGEN ELECTRIC MFG.CO.,LTD - 19 - Confidential Fig.22 AS mode sequence SHINDENGEN ELECTRIC MFG.CO.,LTD - 20 - Confidential 2.5.2 Over temperature protection (TSD) The MCZ5205SE adopts over temperature protection. (TSD: thermal shut down) that stops the oscillation of PFC and also LLC. The operating condition is minimum 140 C. TSD is released on condition that the temperature decreases by 40 C less than the temperature at which TSD operated. 2.6 Remarks 2.6.1 PFC stand-alone operation Connect SST to GND to disable LLC. 2.6.2 LLC stand-alone operation Connect COMP to GND to disable PFC. To operate the LLC, Vsen>3.55V should be applied. (AS mode OFF) If intending to start LLC operation at low input voltage, apply 3.55V or more on Vsen. Vsen sink current should be limited to around 2mA. Note that this operation should be for test purpose only. Do not switch on/off the Vbulk when Vsen is externally biased to protect MOSFET from undesired heavy switching stress especially in mid/heavy load condition. If using the AS mode, FBP>2.0V should be applied. SHINDENGEN ELECTRIC MFG.CO.,LTD - 21 - Confidential 3 Peripheral components setting 3.1 PFC ZCS turn on timing (ZC) PFC ON timing is determined by the current limiting resistor Rzc as shown in Fig. 23. ZC sink/source current limit is +/-5mA. The resistor limits the current to +/-5mA or less. The polarity of NC winding should be designed according to Fig. 23. The voltage of NC winding at maximum input voltage must be greater than 1.55V. Design the number of turns of Nc winding on the minimum integer according to an formula(1). For example, in case of Vin (AC) max = 264V, Vo = 390V and Np=50 turns, Nc=4.5 is obtained from formula, therefore it should be 5 turns. Estimated number of turns Np and Nc is 10:1. (Vin max=264V cases.) Nc . Np ---- (1) Vo [ Vin( AC ) max] If designing ZC current as + /-4mA (80% of maximum value), select a value of Rzc greater than the value calculated from the formula (2) and (3) below. A resistor of 700 ohms is built in ZC in series. [Control winding pulse side] Vo Vin min Nc R ZC Np * 6V : ZC built-in zener voltage [ohm] ---- (2) [Control winding minus side] R ZC Vin max Nc Np Fig.23 ZC limiting resistance [Design example] At Vo=400[V], Vin(AC)max=276[V] , Np=50[turns] , Nc=5[turns] , [Control winding pulse side] . [kohm] R ZC [Control winding minus side] R ZC .[kohm] Thus, ZC current limiting resistor RZC can be designed as 9.1kohm or greater. SHINDENGEN ELECTRIC MFG.CO.,LTD - 22 - [ohm] ---- (3) Confidential 3.2 PFC Phase compensation (COMP) PFC feedback amp is trans-conductance amplifier (gm amp). Fig.24 shows a circuit for pfc phase compensation. The value of Ccomp1, Ccomp2, and Rcomp are calculated from following formula. Finally adjust the values in actual circuit. Determine the value of Ccomp1 and Ccomp2 according to formula (4), so that fc(cut off frequency) is 20Hz or less. fc u [Hz] ・・・(4) Ccomp Ccomp Fig.24 COMP circuit * 140u: the conductance of gm amp Recommended value of Ccomp2 is around 0.1uF, and Rcomp is 4.7k to 47kohm respectively. 3.3 PFC output voltage / OVP threshold (FBP terminal) PFC output voltage is determined by resistance divider (Refer to Fig. 25) and is obtained from formula (5). RFBPH value of about 2Mohm is recommended for PFC output voltage of 400V. It is effective to connect a capacitor(CFBP) of around 1000pF between FBP and GND for avoiding malfunction due to noise. *Note : Capacitance of CFBP may affect feedback characteristic and it is necessary to check and adjust the value in actual operating circuit. PFC Vo . R FBPH R FBPL [V] ----(5) R FBPL PFC OVP detection voltage is obtained from formula (6). Rated voltage of PFC output capacitor should be selected with considering the detection voltage pulse margin. PFC Vo(OVP) Fig.25 FBP resistance divider . RFBPH RFBPL RFBPL ----(6) SHINDENGEN ELECTRIC MFG.CO.,LTD - 23 - Confidential 3.4 PFC OCP setting (CSP) PFC over current protection points is obtained from formula (7). Ps is output power of PFC at the point on which over-current protection works. n is efficiency of PFC. R CSP . η AC min Vo AC min . Vo [ohm] ---- (7) Ps 3.5 LLC Brown out protection (Vsen) Vsen SS reset threshold voltage is 3.55V/3.25V. (AS mode OFF) Vsen SS reset threshold voltage is 1.0V/0.9V. (AS mode ON) 0.2uA is required for Vsen sink current and 20uA or more is recommended not to be affected by the sink current. If PFC output voltage is 400V, RvsenseH value of 2Mohm is recommended. Connect a capacitor of 3300 to 10000pF between Vsen and GND for noise reduction. Low side resistor, RvsenseL(init) is obtained from formula (8). Correct value of Vbulkreset threshold is obtained from formula (9) by using actual value of RvsenseL. Vbulk input RvsenseH AS mode ON is obtained from formula (10). SS Reset RvsenseL R VsenseL (init) Vc1＆Vc2 UVLO + 3300pF~ 10000pF Vc1 AS OFF 3.5V/3.2V AS ON 1.0V/0.9V Internal Vref 5V AS pin low : AS ON Vbulkreset 3.25 R VsenseH Vbulkreset - 3.25 R VsenseH R VsenseL 3.25 R VsenseL Vbulkreset (AS ON) Fig.26 Vsen internal circuit SHINDENGEN ELECTRIC MFG.CO.,LTD - 24 - ---- (8) ---- (9) R VsenseH R VsenseL 0.9 ---- (10) R VsenseL Confidential 3.6 LLC Oscillator / Feedback (FBL) LLC oscillator frequency is controlled by FBL. FBL sets dead time and soft start (fss), max frequency (fmax) and min frequency (fmin). 3.6.1 dead time and soft start frequency (Ct capacitor) Dead time and soft start frequency fss are determined by Ct capacitance. Select a Ct capacitance from characteristic specification sheet. Capacitance value of Ct of 820pF to 2200pF is recommended due to the relation with dead time. 3.6.2 Minimum frequency fmin (Rt resistance) Minimum frequency fmin is determined by Rt resistance. (Connect between FBL and GND.) Relation between Rt resistance and frequency is shown in characteristic specification sheet. The estimated value of fmin is obtained from formula (11) to (13). tcharge is dead time and tdischarge is turn on time of VGL/VGH. The exact value should be adjusted by using characteristic specification sheet after checking the frequency at actual circuit operation. VFBL(bottom) : 1.70V , VFBL(top) : 3.15V *Note : This value does not include overshooting and the response delay. Response delay is about 100ns. Rt Ct VFBL ( top ) t ch arg e Rt . VFBL ( top ) t disch arg e Rt Ct ln fmin VFBL (bottom ) VFBL( top ) Rt Ct VFBL (bottom ) Rt . VFBL (bottom ) ---- (12) ---- (13) t ch arg e t disch arg e 3.6.3 Maximum frequency fmax (FB resistance) Maximum frequency fmax is determined Rt resistance and FB resistance. Check the characteristic specification sheet and determine the maximum frequency. SHINDENGEN ELECTRIC MFG.CO.,LTD - 25 - ---- (11) Confidential 3.7 LLC Soft start / protection delay timer (SST) Soft start charging current is 28uA. When SST voltage rises to 0.6V, gate output starts and timer charging is enabled when SST voltage rises to 1.5V. Soft start time tss is a time in which SST voltage rises from 0.6V to 1.5V. Soft start time tss is obtained from formula (14). t ss . C ss ----(14) Timer charging current is 40uA and timer threshold voltage is 3.6V. Thus, Timer charging time ttimer is obtained from formula (15). t timer . C ss ----(15) Timer discharge current is 6uA. Timer intermittent operation time is obtained from formula (16) t timer (int ermittent ) . C ss ----(16) 3.8 LLC Current limiting / capacitive mode protection (CSL) Rocpdet is calculated from desired OCP threshold Ipk by using formula (17). Tentative value of RocpL(init) is obtained from formula(18) and correct value of Id is calculated from formula(19) by using actual value of RocpL. RocpH of 10 to 47 ohm is recommended considering OCP terminal sourcing current (95uA). Id value should be determined with care to have enough margins in low input voltage / Pomax or switching load condition. Connect a noise reduction capacitor of around 1000pF to 10000pF between CSL to GND. R ocp det 0.35 Ipk R ocpL (init ) Id [ohm] ・・・() 0.35 R ocpH Ipk R ocp det 0.35 R ocpH R ocpL R ocpL R ocp det Fig.27 CSL peripheral circuit SHINDENGEN ELECTRIC MFG.CO.,LTD - 26 - 0.35 [ohm] ・・・ () [ A ] ・・・ () Confidential 3.9 PFC Output voltage and LLC Brown out protection (In case of common sensing line for FBP and Vsen) If Vsen and FBP have a common sensing line, circuit diagram is shown in Fig. 28. RH value of 2Mohm is recommended in case of 400V of PFC output voltage. 1000pF is recommended as CVsen capacitance value and also CFBP capacitance value. *Note : Capacitance value of CVsen and CFBP is related to feedback characteristic, and it is necessary to check and adjust the value by actual operating circuit. PFC OUT LLC INPUT Value of RFBP is obtained from formula (20). Value of RVsen is obtained from formula (21). + RFBP R vsen Fig.28 Vsen FBP voltage dividing resistors SHINDENGEN ELECTRIC MFG.CO.,LTD - 27 - . RH Vbulkreset PFC Vo Vbulkreset . ---- (20) . RH RFBP ----(21) Vbulkreset . Confidential 4 Circuit diagram 4.1 Typical application circuit (LLC dual output) SHINDENGEN ELECTRIC MFG.CO.,LTD - 28 - Confidential 5 Dimension 5.1 SOP22 (MCZ5205SE) SHINDENGEN ELECTRIC MFG.CO.,LTD - 29 - Confidential Notes: SHINDENGEN ELECTRIC MFG.CO.,LTD - 30 -