User Guide for FEBFSFR2100_D015v1 Evaluation Board LCD TV Power Supply Featured Fairchild Product: FSFR2100 Direct questions or comments about this evaluation board to: “Worldwide Direct Support” Fairchild Semiconductor.com © 2011 Fairchild Semiconductor Corporation 1 FEBFSFR2100_D015v1 • Rev. 1.0.0 Table of Contents 1. General Board Description ....................................................................................................... 3 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. Featured Fairchild Products ....................................................................................... 3 Power Supply Specification Table ............................................................................ 3 Schematic of the FSFR2100 Evaluation Board ......................................................... 4 Photographs of the FSFR2100 Evaluation Board...................................................... 5 Bill of Materials ......................................................................................................... 6 Transformer Specification ......................................................................................... 7 FSFR2100 (LLC) Printed Circuit Board Image ........................................................ 8 2. Test Results ............................................................................................................................... 9 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. Primary-Side MOSFET Voltage and Current Waveforms ........................................ 9 Secondary-Side Rectifier Diodes Voltage and Current Waveforms ....................... 11 On/Off Waveforms .................................................................................................. 13 Output Voltage Ripple ............................................................................................. 15 Hold-up Time Test................................................................................................... 16 Protection Operation Waveforms ............................................................................ 17 Efficiency................................................................................................................. 18 3. Revision History ..................................................................................................................... 19 © 2011 Fairchild Semiconductor Corporation 2 FEBFSFR2100_D015v1 • Rev. 1.0.0 1. General Board Description This user guide supports the evaluation kit for the FSFR2100. It should be used in conjunction with the FSFR2100 datasheet as well as Fairchild application note AN-4151 and technical support team. Please visit Fairchild’s website at www.fairchildsemi.com. 1.1. Featured Fairchild Products FSFR2100 is an integrated Pulse-Frequency-Modulation (PFM) controller and MOSFETs especially designed for Zero-Voltage-Switching (ZVS) resonant half-bridge converter topologies. Variable frequency control with 50% duty cycle for half-bridge resonant converter topology High efficiency through zero voltage switching (ZVS) Internal SuperFET®s with fast recovery type body diode (trr=120ns) Fixed dead time (350ns) Up to 300kHz operating frequency Pulse skipping for frequency limit (programmable) at light-load condition Simple remote ON/OFF control Various Protection functions: Over-Voltage Protection (OVP), Overload Protection (OLP), Over-Current Protection (OCP), Abnormal Over-Current Protection (AOCP), Internal Thermal Shutdown (TSD) 1.2. Power Supply Specification Table Table 1. Power Supply Specifications Description Input Voltage (VIN) (1) Min. 340V Output Voltage (VOUT) Output Current (IOUT) Typ. 390V (1) Max. Units 400V VDC 24V 0 Rated Output Power (PO) VDC 8 ADC 192 W Note: 1. 20ms hold-up time for VIN=390VDC. © 2011 Fairchild Semiconductor Corporation 3 FEBFSFR2100_D015v1 • Rev. 1.0.0 1.3. Schematic of the FSFR2100 Evaluation Board Figure 1. Schematic of FSFR2100 Evaluation Board (LLC Resonant Converter) 1 VDL Figure 2. © 2011 Fairchild Semiconductor Corporation 2 3 4 5 6 7 8 RT SG LVcc CON CS PG 9 10 VCTR HVcc FSFR2100 Package Diagram (9-SIP) 4 FEBFSFR2100_D015v1 • Rev. 1.0.0 1.4. Photographs of the FSFR2100 Evaluation Board Figure 3. Figure 4. © 2011 Fairchild Semiconductor Corporation Top View of Evaluation Board Bottom View of Evaluation Board 5 FEBFSFR2100_D015v1 • Rev. 1.0.0 1.5. Bill of Materials Item Part Number Reference Value Note Digi-Key Manufacturer 1 C101 220µF/450VDC Electrolytic Samyoung Electronics 2 C102 22nF/630V Film Samwha Electronics 3 C103 100pF Ceramic Samwha Electronics 4 C104 Open 5 C105 0.33µF/50V Electrolytic Samyoung Electronics 6 C106 150nF Film Samwha Electronics 7 C107 10µF/50V Electrolytic Samyoung Electronics 8 C108 12nF Film Samwha Electronics 9 C109 22µF/50V Electrolytic Samyoung Electronics 10 C110, C111 330nF/275VAC Interference Suppression Film Pilkor Electronics 11 C112 680pF Ceramic Samwha Electronics 12 C201, C202 2200µF/35V Electrolytic Samyoung Electronics 13 C203 47nF Film Samwha Electronics 14 C204 12nF Film Samwha Electronics 15 C301 3.3nF AC Ceramic Samwha Electronics 16 R101 0.2Ω 1W RS10.21%R-ND Stackpole Electronics Inc 17 R102 1kΩ 1/4W 1.00KXTR-ND YAGEO 18 R103 Short 19 R104 5.1kΩ 1/4W 5.11KXTR-ND YAGEO 20 R105 7.5kΩ 1/4W 7.50KXTR-ND YAGEO 21 R106 27Ω 1/4W 27.4XTR-ND YAGEO 22 R107 2.2kΩ 1/4W 2.21KXTR-ND YAGEO 23 R108 Open 24 R109,R110 1MΩ 1/4W 1.00MXTR-ND YAGEO 25 R111 45kΩ 1/4W 45.3KXTR-ND YAGEO 26 R112 10kΩ 1/4W 10.0KXTR-ND YAGEO 27 R113 400kΩ 1/4W 402KXTR-ND YAGEO 28 R114, R201 10kΩ 1/4W 10.0KXTR-ND YAGEO 29 R202 1kΩ 1/4W 1.00KXTR-ND YAGEO 30 R203 33kΩ 1/4W 33.2KXTR-ND YAGEO 31 R204 62kΩ 1/4W 61.9KXTR-ND YAGEO 32 R205 7KΩ 1/4W 6.98KXTR-ND YAGEO 33 R206 2kΩ 1/4W 2.00KXTR-ND YAGEO 34 RT101 5D-9 35 LF101 23mH 36 D101 1N4937 600V/1A 1N4937-ND Fairchild Semiconductor 37 D211, D212 FYP2010DN 100V/20A FYP2010DNTU-ND Fairchild Semiconductor 38 Z101 1N4736 6.8V 1N4736A-ND Fairchild Semiconductor © 2011 Fairchild Semiconductor Corporation 6 FEBFSFR2100_D015v1 • Rev. 1.0.0 Item Part Number Reference Value Note Digi-Key Manufacturer Bridge Diode Fairchild Semiconductor 39 BD101 RBV606 40 F101 3.15A/250V 41 U1 FSFR2100 FPS™ FSFR2100-ND Fairchild Semiconductor 42 U2 H11A817B Opto-Coupler H11Ab17B-ND Fairchild Semiconductor 43 U3 KA431 Voltage Reference KA431LZTA-ND Fairchild Semiconductor 44 U4 2N2222 NPN Transistor PN2222BU-ND Fairchild Semiconductor 45 U5 2N2907 PNP Transistor PN2907-ND Fairchild Semiconductor 1.6. Transformer Specification Figure 5. Table 2. Transformer specification. Winding Specification Pin (S → F) Wire Turns Winding Method Np 8→1 0.12φ×30 (Litz Wire) 36 Section Winding Ns1 12 → 9 0.1φ×100 (Litz Wire) 4 Section Winding Ns2 16 → 13 0.1φ×100 (Litz Wire) 4 Section Winding 2 Core: EER3542 (Ae=107mm ) Bobbin: EER3542 (Horizontal) Table 3. Electrical Characteristics Pins Specification Remark Primary-Side Inductance (LP) 1－8 630µH ±5% 100kHz, 1V Primary-Side Effective Leakage (LR) 1－8 135µH Max. Short one of the secondary windings © 2011 Fairchild Semiconductor Corporation 7 FEBFSFR2100_D015v1 • Rev. 1.0.0 1.7. FSFR2100 (LLC) Printed Circuit Board Image Figure 6. Figure 7. © 2011 Fairchild Semiconductor Corporation Top View of Evaluation Board PCB Bottom View of Evaluation Board PCB 8 FEBFSFR2100_D015v1 • Rev. 1.0.0 2. Test Results 2.1. Primary-Side MOSFET Voltage and Current Waveforms Figure 8. Figure 9. Operation Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C4: Transformer Primary-Side Current (2A/div); C1: Low-Side MOSFET Current (2A/div); C3: Low-Side MOSFET VDS (200V/div), Time: 5µs/div Operation Waveforms at Nominal Input Voltage [VIN=390VDC, PO=0W (24V/0A)]; C4: Transformer Primary-Side Current (2A/div); C1: Low-Side MOSFET Current (2A/div); C3: Low-Side MOSFET VDS (200V/div), Time: 5µs/div © 2011 Fairchild Semiconductor Corporation 9 FEBFSFR2100_D015v1 • Rev. 1.0.0 Figure 10. Operation Waveforms at Minimum Input Voltage [VIN=340VDC, PO=192W (24V/8A)]; C4: Transformer Primary-Side Current (2A/div); C1: Low-Side MOSFET Current (2A/div); C3: Low-Side MOSFET VDS (200V/div), Time: 5µs/div Figure 11. Operation Waveforms at Minimum Input Voltage [VIN=340VDC, PO=0W (24V/0A)]; C4: Transformer Primary-Side Current (2A/div); C1: Low-Side MOSFET Current (2A/div); C3: Low-Side MOSFET VDS (200V/div), Time: 5µs/div © 2011 Fairchild Semiconductor Corporation 10 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.2. Secondary-Side Rectifier Diodes Voltage and Current Waveforms Figure 12. Operation Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C1: Transformer Primary-Side Current (2A/div); C4: Rectifier Diode (D211) Current (10A/div); C2: Rectifier Diode (D211) Voltage (50V/div), Time: 5µs/div Figure 13. Operation Waveforms at Minimum Input Voltage [VIN=340VDC, PO=192W (24V/8A)]; C1: Transformer Primary-Side Current (2A/div); C4: Rectifier (D211) Diode Current (10A/div); C2: Rectifier Diode (D211) Voltage (50V/div), Time: 5µs/div © 2011 Fairchild Semiconductor Corporation 11 FEBFSFR2100_D015v1 • Rev. 1.0.0 Figure 14. Operation Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C1: Rectifier Diode (D211) Current (10A/div); C4: Rectifier Diode (D212) Current (10A/div); C3: Rectifier Diode Voltage (50V/div), Time: 5us/div Figure 15. Operation Waveforms at Minimum Input Voltage [VIN=340VDC, PO=192W (24V/8A)]; C1: Rectifier Diode (D211) Current (10A/div); C4: Rectifier Diode (D212) Current (10A/div); C3: Rectifier Diode Voltage (50V/div), Time: 50µs/div © 2011 Fairchild Semiconductor Corporation 12 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.3. On/Off Waveforms Figure 16 and Figure 17 show the soft-start waveforms at full-load and no-load conditions, respectively, for nominal input voltage condition. For these waveforms, the input DC bus is applied first, then VCC for FSFR2100 is supplied. Figure 16. Startup Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C1: Output Voltage (20V/div); C4: Transformer Primary-Side Current (2A/div); C3: Low-Side MOSFET VDS (500V/div), Time: 10ms/div Figure 17. Startup Waveforms at Nominal Input Voltage [VIN=390VDC, PO=0W (24V/0A)]; C1: Output Voltage (20V/div); C4: Transformer Primary-Side Current (2A/div); C3: Low-Side MOSFET VDS (500V/div), Time: 10ms/div © 2011 Fairchild Semiconductor Corporation 13 FEBFSFR2100_D015v1 • Rev. 1.0.0 Figure 18 shows startup waveforms when VCC of 18V is supplied first, then the input voltage source is applied. When the DC bus voltage reaches about 330V, the external brownout circuit connects VCC supply voltage to FSFR2100 so that it starts up. Figure 19 shows shutdown waveforms when the input voltage source is turned off. When the DC bus voltage reaches about 260V, the external brownout circuit disconnects VCC from FSFR2100 so that it stops operation. Figure 18. Power-On Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C1: Output Voltage (20V/div); C4: Transformer Primary-Side Current (2A/div); C3: Low-Side MOSFET VDS (500V/div), Time: 5ms/div Figure 19. Power-Off Waveforms at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C3: Input Voltage (100V/div); C2: VCC Supply Voltage (10V/div); C4: Transformer Primary-Side Current (2A/div), Time: 20ms/div © 2011 Fairchild Semiconductor Corporation 14 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.4. Output Voltage Ripple Figure 20 shows the output voltage ripple at nominal input voltage and full-load condition. The peak-to-peak ripple voltage is 0.5V, which is about 2% of the output voltage. Figure 21 shows the output voltage ripple with pulse load at nominal input voltage. The peak-to-peak ripple voltage is 0.8V, which is about 3% of the output voltage. Figure 20. Output Voltage Ripple at Nominal Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C2: Output Voltage (500mV/div); C4: Transformer Primary-Side Current (2A/div), Time: 20ms/div Figure 21. Output Voltage Ripple with Pulse Load Current at Nominal Input Voltage; [VIN=390VDC, (IO=0A 8A, Slew Rate=50mA/µs, Duty=50%, f=180Hz)]; C1: Output Current (5AV/div); C4: Transformer Primary-Side Current (2A/div); C2: Output Voltage Ripple, Time: 20ms/div © 2011 Fairchild Semiconductor Corporation 15 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.5. Hold-up Time Test To see the holdup time, the input DC bus is disconnected while the converter operates at full-load condition. It can be observed that the output voltage is maintained for 34ms when the input DC bus is disconnected. Figure 22. Output Voltage Waveform after Turning Off Input Voltage [VIN=390VDC, PO=192W (24V/8A)]; C3: Input Voltage (100V/div); C1: Output Voltage (10V/div), C4: Transformer Primary-Side Current (2A/div), Time: 10ms/div © 2011 Fairchild Semiconductor Corporation 16 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.6. Protection Operation Waveforms Figure 23 shows the overload protection waveforms. The output current increases from 8A to 16A. When the transformer primary-side current reaches its trip point of 3A, the over-current protection is triggered. Figure 24 shows the output-short protection waveforms. When the transformer primary-side current reaches its trip point of 3A, the over-current protection is triggered. Figure 23. Protection Waveform at Overload Condition [VIN=390VDC, (IO=8A16A)]; C3: Low-Side Drain Voltage (200V/div); C4: Transformer Primary-Side Current (2A/div), Time: 50µs/div Figure 24. Protection Waveform at Output Short Condition [VIN=390VDC, (IO=8AShort)]; C2: Current Sensing Pin (CS) Voltage (1V/div); C3: Low-Side MOSFET VDS (500V/div); C4: Transformer Primary-Side Current (2A/div), Time: 20µs/div © 2011 Fairchild Semiconductor Corporation 17 FEBFSFR2100_D015v1 • Rev. 1.0.0 2.7. Efficiency 95 94 93 92 91 Eff (%) 90 89 88 87 86 85 84 83 82 81 80 0 25 50 75 100 Po (W) 125 150 175 200 Figure 25. Measured Efficiency © 2011 Fairchild Semiconductor Corporation 18 FEBFSFR2100_D015v1 • Rev. 1.0.0 3. Revision History Rev. Date Description 1.0.0 January 2012 First draft 1.0.0 February 2012 Part number changed from FSED-FR2100-LCD-015 to FEBFSFR2100_D015v1 WARNING AND DISCLAIMER Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Users’ Guide. Contact an authorized Fairchild representative with any questions. 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EXPORT COMPLIANCE STATEMENT These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations for the ultimate destination listed on the commercial invoice. Diversion contrary to U.S. law is prohibited. U.S. origin products and products made with U.S. origin technology are subject to U.S Re-export laws. In the event of re-export, the user will be responsible to ensure the appropriate U.S. export regulations are followed. © 2011 Fairchild Semiconductor Corporation 19 FEBFSFR2100_D015v1 • Rev. 1.0.0