For Non-Isolated Buck Convertor Off-Line PWM Controllers with Integrated Power MOSFET STR5A464D General Descriptions Package The STR5A464D is power ICs for switching power supplies, incorporating a MOSFET and a current mode PWM controller IC for non-isolated buck convertor. Buck convertor can be designed with commercial power input. Both positive and negative output configuration are available. The low standby power is accomplished by the automatic switching between the PWM operation in normal operation and the burst-oscillation under light load conditions. The product achieves high cost-performance power supply systems with few external components. DIP8 Features Buck Converter Recommended Operating Condition FB 1 8 S/GND VCC 2 7 S/GND 6 S/GND 5 S/GND D/ST 4 Not to scale Buck Convertor Positve or Negative Output Configuration Auto Standby Function Operation Normal Operation ----------------------------- PWM Mode Light Load Operation ------------------------- Green Mode Standby ---------------------------- Burst Oscillation Mode Build-in Startup Function (reducing power consumption at standby operation, shortening the startup time) Current Mode Type PWM Control Build-in Error Amplifier for Phase Compensation Random Switching Function Leading Edge Blanking Function Soft Start Function Protections Overload Protection (OLP); auto-restart Overvoltage Protection (OVP); auto-restart Thermal Shutdown with hysteresis (TSD); auto-restart Output Voltage (+) Input Voltage AC 85 V to AC 265 V D/ST Input Voltage Output Voltage Range* Output Voltage (–) Input Voltage ≥ 40 V > 11 V < 27.5 V AC 85 V~AC 265 V D/ST Input Voltage Output Voltage Range* ≥ 40 V > – 27.5 V < – 11 V *Add zener diode or transistor (dropper) to VCC pin when target output voltage is high. Lineup Typical Application Circuit D1 Electrical Characteristics fOSC(AVG) = 60 kHz VD/ST = 700V (max.) D2 R3 R2 STR5A400 1 FB S/GND VCC S/GND 2 8 C4 R1 C3 7 Products RDS(ON) (max.) IDLIM STR5A464D 13.6 Ω 0.41 A 6 S/GND VOUT L1 DR1 5 4 D/ST S/GND (+) L2 Applications VAC C1 C2 D3 C5 White goods R4 DR2 (-) Other SMPS TC_STR5A400D_1_R1 STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 1 STR5A464D CONTENTS General Descriptions ----------------------------------------------------------------------- 1 1. Absolute Maximum Ratings --------------------------------------------------------- 3 2. Electrical Characteristics ------------------------------------------------------------ 3 3. Functional Block Diagram ----------------------------------------------------------- 5 4. Pin Configuration Definitions ------------------------------------------------------- 5 5. Typical Application Circuit --------------------------------------------------------- 6 6. Package Outline ------------------------------------------------------------------------ 7 7. Marking Diagram --------------------------------------------------------------------- 7 8. Operational Description -------------------------------------------------------------- 8 8.1 Startup Operation of IC----------------------------------------------------- 8 8.2 Undervoltage Lockout (UVLO) ------------------------------------------- 8 8.3 Power Supply Startup and Soft Start Function ------------------------ 8 8.4 Constant Voltage (CV) Control ------------------------------------------- 9 8.5 Leading Edge Blanking Function ---------------------------------------- 12 8.6 Random Switching Function ---------------------------------------------- 12 8.7 Auto Standby Function ----------------------------------------------------- 12 8.8 Overload Protection (OLP) ------------------------------------------------ 12 8.9 Overvoltage Protection (OVP) -------------------------------------------- 13 8.10 Thermal Shutdown (TSD) ------------------------------------------------- 13 9. Design Notes --------------------------------------------------------------------------- 13 9.1 External Components------------------------------------------------------- 13 9.2 D/ST pin ----------------------------------------------------------------------- 14 9.3 Output Inductor Value Setting ------------------------------------------- 14 9.4 PCB Trace Layout and Component Placement ----------------------- 16 10. Pattern Layout Example ------------------------------------------------------------ 19 10.1 Positive Output --------------------------------------------------------------- 19 10.2 Negative Output ------------------------------------------------------------- 20 11. Reference Design of Power Supply ----------------------------------------------- 21 11.1 Positive Output --------------------------------------------------------------- 21 11.2 Negative Output ------------------------------------------------------------- 22 OPERATING PRECAUTIONS -------------------------------------------------------- 23 IMPORTANT NOTES ------------------------------------------------------------------- 24 STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 2 STR5A464D 1. Absolute Maximum Ratings The polarity value for current specifies a sink as "+," and a source as "−," referencing the IC. Unless otherwise specified, TA = 25 °C, 5 pin = 6 pin = 7 pin = 8 pin. Parameter Symbol Test Conditions Pins Rating Units FB Pin Voltage VFB 1–5 − 0.3 to 7 V VCC Pin Voltage VCC 2–5 − 0.3 to 32 V D/ST Pin Voltage VD/ST 4–5 − 0.3 to 700 V 4–5 1.7 A 4–5 − 0.2~0.97 A – 1.55 W Drain Peak Current IDP Single pulse, Within 500 ns pulse width, VD/ST ≤ 400 V Negative: Within 2 μs pulse width Maximum Switching Current IDMAX MOSFET Power Dissipation PD1 Operating Ambient Temperature TOP – − 40 to 125 °C Storage Temperature Tstg – − 40 to 125 °C * Junction Temperature Tj – 150 * When embedding this hybrid IC onto the printed circuit board (cupper area in a 15mm×15mm) 2. Notes °C Electrical Characteristics The polarity value for current specifies a sink as "+," and a source as "−," referencing the IC. Unless otherwise specified, TA = 25 °C, VCC = 18 V, VD/ST = 10 V, 5 pin = 6 pin = 7 pin = 8 pin. Parameter Symbol Test Conditions Pins Min. Typ. Max. Units Notes Power Supply Startup Operation Operation Start Voltage VCC(ON) 2–5 13.6 15.0 16.6 V Operation Stop Voltage VCC(OFF) 2–5 7.3 8.0 8.7 V VCC = 12 V 2–5 – – 2.0 mA VSTARTUP VCC = 13.5 V 4–5 19 29 39 V ISTARTUP VCC = 13.5 V VD/ST = 100 V 2–5 − 2.7 − 1.5 − 0.5 mA fOSC(AVG) VFB= 2.44 V 4–5 53 60 67 kHz Δf 4–5 – 2.8 – kHz VFB(REF) 1–5 2.44 2.50 2.56 V 1–5 − 2.4 − 0.8 − μA Circuit Current in Operation Startup Circuit Operation Voltage Startup Current PWM Operation Average PWM Switching Frequency PWM Frequency Modulation Deviation Feedback Reference Voltage ICC(ON) Feedback Current IFB(OP) Minimum Sampling Time tFBMS 1-5 – – 2.5 μs Standby Drain Current IDSTB 4–5 – 50 – mA Standby Operation Cycle TSTBOP 4–5 530 740 940 μs Maximum ON Duty DMAX 4–5 50 57 64 % STR5A464D-DS Rev.1.2 Feb.19, 2015 VFB = 2.3 V SANKEN ELECTRIC CO.,LTD. 3 STR5A464D Parameter Symbol Test Conditions Pins Min. Typ. Max. Units tBW – – 230 – ns IDLIM 4–5 0.37 0.41 0.45 A VCC(OVP) 2–5 27.5 29.3 31.3 V VFB= 0 V 4–5 – 72 – ms VFB= 2.6 V 4–5 3.5 5.2 6.8 ms Tj(TSD) – 135 – – °C Tj(TSDHYS) – – 70 – °C Tj = 125 °C VD/ST = 584 V 4–5 – – 50 µA ID = 41 mA 4–5 – 11 13.6 Ω tf 4–5 – – 250 ns θj-C – – – 15 °C/W Notes Protection Leading Edge Blanking Time(1) Drain Current Limit OVP Threshold Voltage OLP Delay Time at Startup Standby Blanking Time at Startup Thermal Shutdown Operating Temperature(1) Thermal Shutdown Hysteresis(1) tOLP tSTB(INH) Power MOSFET Drain Leakage Current On Resistance Switching Time Thermal Characteristics Thermal Resistance Junction to Case(1)(2) (1) (2) IDSS RDS(ON) Design assurance Case temperature (TC) measured at the center of the case top surface STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 4 STR5A464D 3. Functional Block Diagram 2 VCC STARTUP D/ST 4 UVLO OVP REG PROTECTION TSD DRV PWM OSC S Q R OCP 1 FB S/H E/A Feedback Control VFB(REF) LEB S/GND 5, 6, 7, 8 BD_STR5A400D_R1 4. Pin Configuration Definitions Pin Name FB 1 8 S/GND 1 FB VCC 2 7 S/GND 2 VCC 6 S/GND 3 – 4 D/ST 5 S/GND D/ST 4 Descriptions Constant voltage control signal input Power supply voltage input for control part and overvoltage protection (OVP) signal input (Pin removed) MOSFET drain and startup current input 5 6 7 S/GND MOSFET source and ground 8 STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 5 STR5A464D 5. Typical Application Circuit Figure 5-1 and Figure 5-2 are the example circuits in buck-converter configuration. In order to enhance the heat dissipation, the wide pattern layout of S pin (5 through 8 pin) is recommended. When the target output voltage |VOUT|is higher than 27.5 V, zener diode DZ1 is connected to D1 in serial as shown in Figure 5-3. The output voltage should be in the range of equation (1) or (2) according to the configuration, where VZ is the zener voltage. Positive Output: 11V VOUT VZ 27.5V (1) Negative Output: 11V VOUT VZ 27.5V (2) D1 FB S/GND VCC S/GND 2 R3 R2 STR5A400 1 D2 8 7 R1 C4 C3 NC 6 S/GND L1 DR1 D/ST C1 L2 VOUT 5 4 S/GND (+) C5 C2 R4 D3 VAC DR2 (-) TC_STR5A400D_2_R1 Figure 5-1 Positive Output (+) D1 FB S/GND VCC S/GND 2 R3 R2 STR5A400 1 D2 8 7 R1 C4 C3 NC 6 S/GND L1 DR1 D/ST C1 D3 5 4 VOUT (-) S/GND C5 C2 VAC R4 L2 DR2 (+) TC_STR5A400D_3_R2 Figure 5-2 Negative Output (–) U1 D1 DZ1 D2 (+) VCC 2 C4 S C3 5,6,7,8 TC_STR5A400D_4_R1 Figure 5-3 Absolute value of target output voltage |VOUT| is high STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 6 STR5A464D 6. Package Outline DIP8 NOTES: 1) Units:mm (inch) 2) Control dimension is in inches. (values in mm are for reference) 3) Pb-free. Device composition compliant with the RoHS directive 7. Marking Diagram DIP8 8 5A4××D Part Number SKYMD 1 Lot Number Y = Last Digit of Year (0-9) M = Month (1-9,O,N or D) D = Period of days (1 to 3) 1 : 1st to 10th 2 : 11th to 20th 3 : 21st to 31st Sanken Control Number STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 7 STR5A464D 8. Operational Description All of the parameter values used in these descriptions are typical values, unless they are specified as minimum or maximum. With regard to current direction, "+" indicates sink current (toward the IC) and "–" indicates source current (from the IC). The reference ground of the value of voltage is S/GND pin in this section. Figure 8-1 shows the current path in normal operation. During the on state of internal MOSFET, the energy is stored in the inductor, L2. When the MOSFET turns off, C4 is charged by the inductor current through D1 and D2. In normal operation, the voltage between VCC pin and S/GND pin is calculated as follows, where VFD1, VFD2 and VFD3 are the forward voltage of D1, D2 and D3 respectively: VCC VOUT VFD 3 VFD1 VFD 2 8.1 Startup Operation of IC (4) Figure 8-1 shows the circuit around VCC pin. ISTRTUP D2 Normal Operation STARTUP Contro1 VCC D/ST C2 C3 C4 S/GND VOUT (+) L2 VIN D3 C5 R4 (-) Figure 8-1 VCC pin peripheral circuit at positive output t START C4 VCC( ON )-VCC( INT ) (3) I STARTUP where, tSTART : Startup time of IC (s) VCC(INT) : Initial voltage on VCC pin (V) STR5A464D-DS Rev.1.2 Feb.19, 2015 Figure 8-2 shows the relationship of VCC pin voltage and circuit current ICC. When VCC pin voltage increases to VCC(ON) = 15.0 V, the control circuit starts switching operation and the circuit current ICC increases. When VCC pin voltage decreases to VCC(OFF) = 8.0 V, the control circuit stops operation by Undervoltage Lockout (UVLO) circuit, and reverts to the state before startup. Circuit current, ICC ICC(ON) Stop The IC incorporates the startup circuit. The circuit is connected to D/ST pin. When D/ST pin voltage reaches to Startup Circuit Operation Voltage V STARTUP = 29 V, the startup circuit starts operation. During the startup process, the constant current, ISTARTUP = − 1.5 mA, charges C4 at VCC pin. When VCC pin voltage increases to VCC(ON) = 15.0 V, the control circuit starts switching operation. After switching operation begins, the startup circuit turns off automatically so that its current consumption becomes zero. The approximate value of auxiliary winding voltage is about 18V, taking account of the winding turns of D winding so that VCC pin voltage becomes Equation (3) within the specification of input and output voltage variation of power supply. The approximate startup time tSTART is calculated as follows: 8.2 Undervoltage Lockout (UVLO) VCC(OFF) Start Startup D1 U1 VCC pin VCC(ON) voltage Figure 8-2 Relationship between VCC pin voltage and ICC 8.3 Power Supply Startup and Soft Start Function The IC has the Soft Start Function. This function reduces the voltage and the current stress of MOSFET and freewheel diode. Figure 8-3 shows the startup waveforms. Since the voltage of internal comparator is low at startup, the IC is in no load condition. The IC has the Standby Blanking Time at Startup, tSTB(INH) = 5.2 ms, that inhibits the burst oscillation mode so that the soft start is operated after the IC starts. The IC activates the soft start circuitry during the startup period. Soft start time is fixed to around 5.2 ms. During the soft start period, the over current threshold is increased step-wisely (7 steps). The IC does switching SANKEN ELECTRIC CO.,LTD. 8 STR5A464D operation by the frequency responding to FB pin voltage until the output becomes setting voltage. The tLIM is the period until FB pin voltage reaches 1.6 V after the IC starts. When tLIM is tOLP of 72 ms and more, the IC stops switching operation. Thus, it is necessary to adjust the value of output capacitor so that the tLIM is less than tOLP. If VCC pin voltage reaches VCC(OFF) and a startup failure occurs as shown in Figure 8-4, increase the C4 value or decrease the C5 value. Since the larger capacitance causes the longer startup time of IC, it is necessary to check and adjust the startup process based on actual operation in the application. Since the Leading Edge Blanking Function (refer to Section 8.5) is deactivated during the soft start period, there is the case that ON time is less than the leading edge blanking time, tBW = 230 ns. 8.4 Constant Voltage (CV) Control The IC achieves the constant voltage (CV) control of the power supply output by using the peak-current-mode control method, which enhances the response speed and provides the stable operation. The IC controls the peak value of the voltage of build-in sense resistor (VROCP) to be close to target voltage (VSC), comparing VROCP with VSC by internal FB comparator. The IC sampless the FB pin voltage at the sampling point that is tFBFS = 2.5 μs (max.) after the power MOSFET turns off, by pulse-by-pulse. Feedback Control circuit receives the target voltage, VSC, reversed FB pin voltage by an error amplifier (refer to Figure 8-5 and Figure 8-6). U1 Feedback Control Startup of IC VCC pin voltage FB comp Normal opertion Startup of SMPS + VSC R2 R3 E/A + - S/H 1 FB tSTART VCC(ON) VCC(OFF) R1 PWM Control ROCP 4 tSTB(INH) Time C3 VROCP L2 S/GND D/ST ION Soft start period approximately 5.2 ms (fixed) D/ST pin current, ID VOUT (+) 5,6,7,8 D3 C2 R1 C5 (-) Figure 8-5 FB pin peripheral circuit at positive output Time tLIM < tOLP FB pin voltage VFB(REF) 1.6V Time - VSC + VROCP FB comparator Voltage on both side of ROCP Figure 8-3 Startup waveforms Drain current, ION VCC pin voltage Startup success IC starts operation Target operating voltage VCC(ON) Increase with rising of output voltage Figure 8-6 Drain current ID and FB comparator in steady operation VCC(OFF) Startup failure Time Startup time of IC, tSTART Figure 8-4 VCC pin voltage during startup period STR5A464D-DS Rev.1.2 Feb.19, 2015 Light Load Conditions The FB pin voltage increases with the increase of the output voltage when the output load becomes light. Accordingly, the output voltage of internal error amplifier (target voltage VSC) decreases. As a result, the peak value of VROCP is controlled to be lower so that the peak of the drain current decreases. This control prevents the output voltage from increasing. SANKEN ELECTRIC CO.,LTD. 9 STR5A464D Heavy Load Conditions The control circuit performs reverse operations to the former. The target voltage VSC of internal comparator becomes higher and the peak drain current increases. This control prevents the output voltage from decreasing. U1 Contro1 C2 Figure 8-7shows the output current path in case that the output voltage is positive. Figure 8-8 shows the operational waveforms. In this case, the operation range satisfies the Equation (5), (6) and (7). VOUT DMAX VIN VRON (5) VIN VSTARTUP (max .) (6) V CC( OFF ) (max .) VF VOUT VCC(OVP ) (min .) VF (7) where, VIN: C2 voltage VOUT: output voltage DMAX: Maximum ON Duty VRON: on voltage of internal MOSFET VSTARTUP (max.): maximum value of Startup Circuit Operation Voltage VCC(OFF) (max.): maximum value of Operation Stop Voltage VCC(OVP) (min.): minimum value of OVP Threshold Voltage VF: summation of forward voltage of D1 and D2 C4 C3 IL ROCP VIN Buck-Converter Operation at Positive Output D2 D1 FB VROCP D/ST 8.4.1 VCC L2 S/GND VOUT (+) VL ION (MOSFET ON) D3 IOFF (MOSFET OFF) C5 R4 (-) Figure 8-7 Output current flow at positive output (2) PWM Off-Time Period When the internal power MOSFET turns off, the freewheeling diode, D3, is forward biased by the back electromotive force in the inductor, L2 and D3 turns on. Then the energy stored in L2 during the PWM on-time flows through the IOFF path shown in Figure 8-7. After the Average PWM Switching Cycle, 1 / fOSC(AVG), the internal power MOSFET turns-on again, and the PWM on-time period repeats as shown in Figure 8-8. VL MOSFET ON OFF ON VIN-VRON-VOUT 0 t -(VOUT-VFD3) IL t ION t IOFF When the output voltage is positive, the current control of internal PWM is described in the following. t (1) PWM On-Time Period At startup or during normal operation before the current reaches the target level, internal power MOSFET turns on and the current flows through the ION path shown in Figure 8-7. When ION flows through the internal current detection resistor, ROCP, IC detects VROCP that is the voltage between both ends of ROCP. The divided voltage of C3 is input to FB pin. The target voltage, VSC is made from FB pin voltage. When the current detection voltage, VROCP, reaches to VSC, the power MOSFET turns off. STR5A464D-DS Rev.1.2 Feb.19, 2015 1/fOSC(AVG) Figure 8-8 Operational waveforms at positive output SANKEN ELECTRIC CO.,LTD. 10 STR5A464D Buck-Converter Operation at Negative Output U1 Figure 8-9 shows the output current path in case that the output voltage is negative. Figure 8-10 shows 1(2) C3 C4 4 D VOUT MAX VIN VRON 1 D MAX (8) VIN VSTARTUP (max .) (9) VOUT (-) D3 5~8 D/ST S/GND IL C2 VIN FB D2 D1 ROCP In this case, the operation range satisfies the Equation (8), (9) and (10) . CC( OFF ) 2(1) VROCP the operational waveforms. V VCC Contro1 8.4.2 ION (MOSFET ON) VL IOFF (MOSFET OFF) C5 R4 L2 (+) (max .) VF VOUT VCC(OVP ) (min .) VF (10) where, VIN: C2 voltage VOUT: output voltage DMAX: Maximum ON Duty VRON: on voltage of internal MOSFET VSTARTUP (max.): Maximum value of Startup Circuit Operation Voltage VCC(OFF) (max.): Maximum value of Operation Stop Voltage VCC(OVP) (min.): Minimum value of OVP Threshold Voltage VF: Summation of forward voltage of D1 and D2 Figure 8-9 Output current flow at negative output (2) PWM Off-Time Period When the internal power MOSFET turns off, the freewheeling diode, D3, is forward biased by the back electromotive force in the inductor, L2 and D3 turns on. Then the energy stored in L2 during the PWM on-time flows through the IOFF path shown in Figure 8-9. After the Average PWM Switching Cycle, 1 / fOSC(AVG), the internal power MOSFET turns-on again, and the PWM on-time period repeats as shown in Figure 8-10. In negative (–) output configuration, the output current is supplied only in the off period. Thus, output ripple becomes larger compared with positive (+) output configuration. When the output voltage is negative, the current control of internal PWM is described in the following. (1) PWM On-Time Period At startup or during normal operation before the current reaches the target level, internal power MOSFET turns on and the current flows through the ION path shown in Figure 8-9. When ION flows through the internal current detection resistor, ROCP, the IC detects VROCP that is the voltage of both end of ROCP. The divided voltage of C3 is input to FB pin. The target voltage, VSC is made from FB pin voltage. When the current detection voltage, VROCP, reaches to VSC, the power MOSFET turns off. VL MOSFET ON OFF ON VIN‐VRON t 0 -(VOUT-VFD3) IL t ION t IOFF t 1/fOSC(AVG) Figure 8-10 Operational waveforms at negative output STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 11 STR5A464D 8.5 Leading Edge Blanking Function Since the IC uses the peak-current-mode control method for the constant voltage control of output, there is a case that the power MOSFET turns off due to unexpected response of FB comparator or overcurrent protection circuit (OCP) to the steep surge current in turning on a power MOSFET. In order to prevent this response to the surge voltage in turning-on the power MOSFET, the Leading Edge Blanking (tBW = 230 ns) is built-in. Switching Frequency, fOSC Normal operation 60kHz B About 23kHz A Burst oscillation mode Green mode TSTBOP = 740 µs Output power PO(MAX) Light load Figure 8-12 Relationship between PO and fOSC tBW Point A ID TSTBOP Time Surge pulse voltage width at turning on Point B ID TSTBOP Figure 8-11 Leading Edge Blanking Time 8.6 Random Switching Function The IC modulates its switching frequency randomly by superposing the modulating frequency on fOSC(AVG) in normal operation. This function reduces the conduction noise compared to others without this function, and simplifies noise filtering of the input lines of power supply. 8.7 Auto Standby Function Auto Standby Function automatically changes the oscillation mode to green mode or burst oscillation mode, when the output load becomes lower, the drain current ID decreases and the oscillation frequency becomes lower gradually (Green Mode) as shown in Figure 8-12. In order to reduce the switching loss, the number of switching is reduced in green mode and the switching operation is stopped during a constant period in burst oscillation mode. Figure 8-13 shows the drain current waveforms of point A and B in Figure 8-12. The burst oscillation mode operates by the Standby Operation Cycle, TSTBOP = 740 ms. In light load, the number of minimum switching times is one in TSTBOP as shown in Figure 8-13. Since the oscillator of burst oscillation cycle setting and the oscillator of switching oscillation frequency setting are not synchronized each other, the switching frequency may be high. Figure 8-13 Switching waveform at burst oscillation mode 8.8 Overload Protection (OLP) When output power reaches certain power, the drain current of MOSFET is limited by IDLIM and the output voltage decreases. Thus, the current characteristic is as shown in Figure 8-14. The switching frequency is decreased with decreasing output voltage in order to inhibit increasing output current at low output voltage. When output voltage decreases in the state such as output short mode, FB pin voltage decreases. After it passes Startup OLP Delay Time, tOLP = 72 ms from the period when FB pin voltage decreases to VFB(REF) = 2.50 V or less, when FB pin voltage is 1.6 V or less, the IC stops switching operation and restarts After the output voltage increases, until the FB pin voltage keeps about 1.6 V and more, the IC repeats the intermittent operation. Output voltage, VOUT CV mode Output current, IOUT Figure 8-14 Overload characteristics STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 12 STR5A464D 8.9 Overvoltage Protection (OVP) When a voltage between VCC pin and S/GND terminal increases to VCC(OVP) = 29.3 V or more, Overvoltage Protection (OVP) is activated and stops switching operation. When OVP is activated, VCC pin voltage decreases to Operation Stop Voltage VCC(OFF) = 8.0 V. After that, the IC reverts to the initial state by Undervoltage Lockout (UVLO) circuit, and the IC starts operation when VCC pin voltage increases to VCC(ON) = 15.0 V by Startup Current. Thus the intermittent operation by UVLO is repeated in OVP condition. This intermittent operation reduces the stress of parts such as power MOSFET and secondary side rectifier diode. In addition, this operation reduces power consumption because the switching period in this intermittent operation is short compared with oscillation stop period. When the abnormal condition is removed, the IC returns to normal operation automatically. The approximate value of output voltage VOUT(OVP) in OVP condition is calculated by using Equation (11). VOUT (OVP ) VCC(OVP ) VFD1 VFD 2 VFD 3 Junction Temperature, Tj Tj(TSD) Tj(TSD)−Tj(TSD)HYS Bias assist function ON ON OFF OFF VCC pin voltage VCC(ON) VCC(BIAS) VCC(OFF) Drain current ID Figure 8-15 TSD operational waveforms 9. Design Notes (11) 9.1 External Components where, VOUT(OVP): voltage of between VOUT(+) and VOUT(−) VFD1: forward voltage of D1 VFD2: Forward voltage of D2 VFD3: Forward voltage of D3 Take care to use properly rated, including derating as necessary and proper type of components. D1 D2 R3 R2 STR5A400 1 8.10 Thermal Shutdown (TSD) FB S/GND VCC S/GND 2 Figure 8-15 shows the Thermal Shutdown (TSD) operational waveforms. When the temperature of control circuit increases to Tj(TSD) = 135 °C (min.) or more, the TSD is activated, and the IC stops switching operation. After that, VCC pin voltage decreases. When the VCC pin voltage decreases to about 9.4 V, the bias assist function is activated and VCC pin voltage is kept to over the VCC(OFF). When the temperature reduces to less than Tj(TSD)−Tj(TSD)HYS, the Bias Assist function is disabled and the VCC pin voltage decreases to VCC(OFF). At that time, the IC stops operation by the Undervoltage Lockout (UVLO) circuit and reverts to the state before startup. After that, the startup circuit is activated, the VCC pin voltage increases to VCC(ON), and the IC starts switching operation again. In this way, the intermittent operation by TSD and UVLO is repeated while there is an excess thermal condition. When the fault condition is removed, the IC returns to normal operation automatically. STR5A464D-DS Rev.1.2 Feb.19, 2015 8 C4 R1 C3 7 6 S/GND VOUT L1 DR1 5 4 D/ST S/GND (+) L2 VAC C1 C2 D3 C5 R4 DR2 (-) Figure 9-1 Peripheral circuit of IC Input and Output Electrolytic Capacitor Apply proper derating to ripple current, voltage, and temperature rise. Use of high ripple current and low impedance types, designed for switch mode power supplies, is recommended. The value of output capacitor is about 56 μF to 220 μF. The value of output capacitor, C5, is recommended according to VOUT as follows; C5 = 220 μF to 470 μF for 11 V ≤ VOUT < 15 V. C5 = 100 μF to 220 μF for 15 V ≤ VOUT < 27.5 V. SANKEN ELECTRIC CO.,LTD. 13 STR5A464D Inductor Apply proper design margin to core temperature rise by core loss and copper loss. The value of inductor should be designed so that the inductor current does not saturate. The on time must be longer than Leading Edge Blanking Time in order to control the output voltage constantly. In the universal input voltage design, the on time becomes short in the condition of maximum AC input voltage and light road. Be careful not to reduce the value of inductor ( ≥ 820 μH recommended) too much. VCC Pin Peripheral Circuit The reference value of C4 (see Figure 9-1) is generally from 10 μF to 47 μF. The startup time is determined by the value of C4 (refer to Section 8.1 Startup Operation). FB Pin Peripheral Circuit The divided voltage of output voltage, VOUT(+), is input to FB pin as shown in Figure 9-1. C3 is capacitor for smoothing of output. The value of C3 depends on the value of output electrical capacitor and is 0.022 μF to 0.22 μF. When C3 value is set larger, the line regulation characteristic becomes better. But the dynamic response of the output voltage becomes worse. R1, R2 and R3 is set by the reference voltage, VFB(REF) = 2.50 V, and the output voltage, VOUT. When S/GND pin is ground reference, there is the relationship as following Equation (9). The target value of R1 is about 10 kΩ to 22 kΩ. R2 and R3 should be adjusted in actual operation condition. VOUT VFB ( REF) ⇒ VOUT VFD 2 VFD 3 R1 R1 R 2 R 3 R4 VOUT 3mA (13) 9.2 D/ST pin The internal power MOSFET connected to D/ST pin is permanently damaged when the D/ST pin voltage and the current exceed the Absolute Maximum Ratings. The D/ST pin voltage is tuned to be less than about 90 % of the Absolute Maximum Ratings (630 V) in all condition of actual operation, and the value of transformer and components should be selected based on actual operation in the application. And the D/ST pin voltage in normal operation is tuned to be less than 560 V. 9.3 Output Inductor Value Setting In general, the inductance value is set so that the inductance current becomes Continuous Conduction Mode (CCM) in normal operation. On duty, D, is set within the range of Equation (14); t ON ( MIN ) f OSC ( AVG ) D D MAX (14) where, tON(MIN): minimum on time, ≥ 400 ns fOSC(AVG): Average PWM Switching Frequency 60 kHz DMAX: Maximum ON Duty 57 % (R1 R 2 R3) VFD 2 VFD 3 R1 VFB ( REF) Bleeder resistance For light load application, the breeder resistance, R4, should be connected to both ends of output capacitor, C5, as shown in Figure 9-1, in order to prevent the increase of output voltage. The value of R4 should satisfy Equation (10). R4 should be adjusted in actual operation condition. (12) 9.3.1 Where, VFD2: forward voltage of D2 VFD3: forward voltage of D3 Positive Output Figure 9-2 shows the output current flow, Figure 9-3 shows the operational waveforms U1 The VF of D2 and D3 affects the output voltage. Thus, diodes of the low VF should be selected. Freewheeling diode D3 is freewheeling diode shown in Figure 9-1. When the internal power MOSFET turns on, recovery current flows through D3. Recovery current affects power loss and noise. The VF affects the output voltage. Thus, fast recovery and low V F characteristic diode should be selected. VL D/ST L2 S/GND (+) IL VRON ION VIN C2 VOUT VFD3 IOFF D3 C5 R4 (-) Figure 9-2 The output current flow at positive output STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 14 STR5A464D D VL VIN-VRON-VOUT t ON V VFD 3 OUT t ON t OFF VIN VRON (19) Average switching frequency, fOSC(AVG) is as follows; t 0 -(VOUT-VFD3) IL f OSC ( AVG ) ΔIOFF IR IO(AVG) IRP tOFF Figure 9-3 Operational waveforms at positive output The condition of CCM operation is expressed as follows; IR 0 2 (15) where, IO(AVG): average output current, IO, (average of IL) IR: output ripple current There are relationship between ΔION and ΔIOFF and IR as follows; I ON VIN VRON VOUT t ON L I OFF VOUT VFD 3 t OFF L I ON I OFF I R V OUT VFD 3 1 D I R f OSC ( AVG ) (21) In the universal input voltage design, be careful not to reduce the value of inductor too much. (≥ 820 μH recommended) The maximum ripple current, IRP, and minimum ripple current IRL, are as follows; I RP I O( AVG ) IR I DLIM 2 (22) I RL I O( AVG ) IR 2 (23) The saturation current of inductor should be selected to be larger than IDLIM. (16) 9.3.2 (17) (18) where, tON: on time tOFF: off time ΔION: inductor current change during on time ΔIOFF: inductor current change during off time VIN: input voltage (C2 voltage) VFD3 : forward voltage of D3 VOUT: output voltage VRON: the voltage between D/ST pin and S/GND pin during on time Using Equation (16), (17) and (18), D is the transfer factor of VOUT and ( VIN VRON ) as shown in Equation (19). STR5A464D-DS Rev.1.2 Feb.19, 2015 Using Equation (16) to (20), the inductance of L2, L, is expressed as follows; L t I O( AVG ) (20) IRL ΔION tON 1 t ON t OFF Negative Output Figure 9-4 shows the output current flow, Figure 9-5 shows the operational waveforms Since output current is flowed in off time, the output ripple becomes larger than positive output. U1 VFD3 4 D/ST S/GND 5~8 (-) D3 VRON ION VIN C2 C5 R4 IL VL L2 IOFF VOUT (+) Figure 9-4 The output current flow at negative output SANKEN ELECTRIC CO.,LTD. 15 STR5A464D Using Equation (25), (26) and (27), D is as shown in Equation (19). VL VIN-VRON D t 0 -(VOUT+VFD3) IL f OSC ( AVG ) IR IO(AVG) IRP IRL ΔION (28) Average switching frequency, fOSC(AVG) is as follows; ΔIOFF t tON t ON VOUT VFD 3 t ON t OFF VIN VRON VOUT VFD 3 t ON 1 t OFF (29) Using Equation (25), (26), (27), (28) and (29), the inductance of L2, L, is expressed as follows; tOFF L V IN VRON D I R f OSC ( AVG ) (30) Figure 9-5 Operational waveforms at negative output The condition of CCM operation is expressed as follows; I O( AVG ) IR 0 2 (24) where, IO(AVG): average output current, IO, (average of IL) IR: output ripple current There are relationship between ΔION and ΔIOFF and IR as follows; I ON I OFF VIN VRON t ON L VOUT VFD 3 t OFF L I ON I OFF I R (25) (26) In the universal input voltage design, be careful not to reduce the value of inductor too much. (≥ 820 μH recommended) The maximum ripple current, IRP, and minimum ripple current IRL, are as follows; I RP I L ( AVG ) IR 2 (31) I RL I L ( AVG ) IR 2 (32) where, IL(AVG): average current of inductor Average output current, IO(AVG), is the average current during off time. IO(AVG) is as follows; I O( AVG ) I L( AVG ) (1 D) (33) Using Equation (31) and (33), the peak current of inductor, IRP , is calculated as follows: (27) where, tON: on time tOFF: off time ΔION: inductor current change during on time ΔIOFF: inductor current change during off time VIN: input voltage (C2 voltage) VFD3 : forward voltage of D3 VOUT: output voltage VRON: the voltage between D/ST pin and S/GND pin during on time I RP IO I R I DLIM 1 D 2 (34) The saturation current of inductor should be selected to be larger than IDLIM. 9.4 PCB Trace Layout and Component Placement Since the PCB circuit trace design and the component layout significantly affects operation, EMI noise, and power dissipation, the high frequency PCB trace should STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 16 STR5A464D be low impedance with small loop and wide trace. In addition, the ground traces affect radiated EMI noise, and wide, short traces should be taken into account. Figure 9-6 shows the circuit design example. (1) Main Circuit Trace Layout This is the main trace containing switching currents, and thus it should be as wide trace and small loop as possible. (2) Freewheeling Loop Layout This is the trace for the current of freewheeling diode, D3, and thus it should be as wide trace and small loop as possible. (3) Control Ground Trace Layout Since the operation of IC may be affected from the large current of the main trace that flows in control ground trace, the control ground trace should be separated from main trace and connected at single point grounding. the IC are distant from each other, placing a capacitor such as film capacitor Cf (about 0.1 μF to 1.0 μF) close to the VCC pin and the S/GND pin is recommended. (5) FB Trace Layout The divided voltage by R2, R3 and R1 of output voltage is input to FB. In order to increase the detection accuracy, R3 and R1 should be connected to bottom of C3 and S/GND, The trace between R1, R2 and FB pin should be as short as possible. (6) Thermal Considerations Because the power MOSFET has a positive thermal coefficient of RDS(ON), consider it in thermal design. Since the copper area under the IC and the S/GND pin trace act as a heatsink, its traces should be as wide as possible. (4) VCC Trace Layout This is the trace for supplying power to the IC, and thus it should be as small loop as possible. If C4 and (6) Trace of S/GND pin should be wide for heat release D1 D2 (4) Loop of the power supply should be small R3 (5) The trace between R1, R2 and FB pin should be as short as possible. R2 1 FB S/GND 2 VCC S/GND 8 C3 C4 R1 7 6 S/GND VOUT 5 4 D/ST (+) S/GND L2 U1 C5 D3 C2 R4 (-) (1)Main trace should be wide trace and small loop (2) Freewheeling Loop trace should be wide trace and small loop (3) Control GND trace should be connected at a single point Figure 9-6 Peripheral circuit example around the IC at positive output STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 17 STR5A464D (6) Trace of S/GND pin should be wide for heat release D1 D2 (4) Loop of the power supply should be small R3 (5) The trace between R1, R2 and FB pin should be as short as possible. R2 1 FB S/GND VCC S/GND 2 8 C3 C4 R1 7 6 S/GND D/ST VOUT D3 5 4 (-) S/GND U1 C2 C5 R4 L2 (+) (1)Main trace should be wide trace and small loop (2) Freewheeling Loop trace should be wide trace and small loop (3) Control GND trace should be connected at a single point Figure 9-7 Peripheral circuit example around the IC at negative output STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 18 STR5A464D 10. Pattern Layout Example 10.1 Positive Output The following show the PCB pattern layout example and the schematic of circuit using STR5A464D series. The PCB pattern layout example is made usable to other ICs in common. The parts in Figure 10-1 are only used. Figure 10-1 PCB circuit trace layout example for positive output circuit Z1 1 FB S/GND VCC S/GND 2 D5 JW10 R2 R3 D6 8 7 R1 C4 C5 6 S/GND L2 L1 D/ST VAC D4 S/GND D3 C1 VOUT 5 4 C2 (+) D7 C6 R6 F1 JW9 D2 D1 (-) TC_STR5A400D_5_R1 Figure 10-2 Circuit schematic for PCB circuit trace layout for positive output circuit STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 19 STR5A464D 10.2 Negative Output The following show the PCB pattern layout example and the schematic of circuit using STR5A464D. The above circuit symbols correspond to these of Figure 10-3. Figure 10-3 PCB circuit trace layout example for negative output circuit D5 R2 Z1 1 FB S/GND VCC S/GND 2 D6 R3 8 7 R1 C4 C5 6 S/GND L1 JW1 D/ST VAC DR4 VOUT D7 5 4 S/GND (-) DR3 C1 C2 F1 L2 DR2 DR1 C6 C7 R6 L3 (+) TC_STR5A400D_6_R2 Figure 10-4 Circuit schematic for PCB circuit trace layout for negative output circuit STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 20 STR5A464D 11. Reference Design of Power Supply 11.1 Positive Output As an example, the following show the power supply specification, the circuit schematic, the bill of materials, and the transformer specification. Power supply specification IC Input voltage Maximum output power Output voltage Output current STR5A464D AC 85 V~AC 265 V 3 W (max.) 15 V 0.2 A Circuit schematic D1 FB S/GND VCC S/GND 2 R3 R2 U1 1 D2 8 7 R1 C4 C3 6 S/GND F1 L2 L1 DR1 D/ST C1 VOUT 5 4 S/GND (+) C5 C2 VAC R4 D3 DR2 (-) TC_STR5A400D_7_R1 Bill of materials Symbol DR1 DR2 F1 L1 L2 C1 C2 C3 C4 C5 R1 R2 R3 R4 D1 D2 D3 U1 (1) (2) Ratings(1) Part type General General Fuse (2) (2) (2) (2) CM inductor Inductor Electrolytic Electrolytic Ceramic Electrolytic Electrolytic, Low impedance General General General General Fast recovery Fast recovery Fast recovery IC 600 V, 1 A 600 V, 1 A 250 V, 1 A 680μH 1 mH 400 V, 4.7 μF 400 V, 4.7μF 50 V, 0.22 µF 50 V, 10 µF 50 V, 220 µF 10 kΩ 47 kΩ 5.6 kΩ 4.7 kΩ 200V, 1 A 500 V, 1 A 500 V, 1 A Recommended Sanken Parts AM01A AM01A SJPL-D2 SJPD-D5 SJPD-D5 STR5A464D Unless otherwise specified, the voltage rating of capacitor is 50 V or less and the power rating of resistor is 1/8 W or less. It is necessary to be adjusted based on actual operation in the application. STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 21 STR5A464D 11.2 Negative Output As an example, the following show the power supply specification, the circuit schematic, the bill of materials, and the transformer specification. Power supply specification IC Input voltage Maximum output power Output voltage Output current STR5A464D AC 85 V~AC 265 V 3 W (max.) − 15 V 0.2 A Circuit schematic D1 R2 U1 1 FB S/GND VCC S/GND 2 D2 R3 8 7 R1 C4 C3 6 S/GND L1 F1 DR1 D/ST C1 D3 5 4 VOUT S/GND (-) C5 C2 VAC R4 L2 DR2 (+) TC_STR5A400D_8_R1 Bill of materials Symbol DR1 DR2 F1 L1 L2 C1 C2 C3 C4 C5 R1 R2 R3 R4 D1 D2 D3 U1 (1) (2) Ratings(1) Part type General General Fuse (2) (2) (2) (2) CM inductor Inductor Electrolytic Electrolytic Ceramic Electrolytic Electrolytic, Low impedance General General General General Fast recovery Fast recovery Fast recovery IC 600 V, 1 A 600 V, 1 A 250 V, 1 A 680μH 1 mH 400 V, 10 μF 400 V, 10 μF 50 V, 0.22 µF 50 V, 10 µF 50 V, 220 µF 10 kΩ 47 kΩ 5.6 kΩ 4.7 kΩ 200 V, 1 A 500 V, 1 A 500 V, 1 A Recommended Sanken Parts AM01A AM01A SJPL-D2 SJPD-D5 SJPD-D5 STR5A464D Unless otherwise specified, the voltage rating of capacitor is 50 V or less and the power rating of resistor is 1/8 W or less. It is necessary to be adjusted based on actual operation in the application. STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 22 STR5A464D OPERATING PRECAUTIONS In the case that you use Sanken products or design your products by using Sanken products, the reliability largely depends on the degree of derating to be made to the rated values. Derating may be interpreted as a case that an operation range is set by derating the load from each rated value or surge voltage or noise is considered for derating in order to assure or improve the reliability. In general, derating factors include electric stresses such as electric voltage, electric current, electric power etc., environmental stresses such as ambient temperature, humidity etc. and thermal stress caused due to self-heating of semiconductor products. For these stresses, instantaneous values, maximum values and minimum values must be taken into consideration. In addition, it should be noted that since power devices or IC’s including power devices have large self-heating value, the degree of derating of junction temperature affects the reliability significantly. Because reliability can be affected adversely by improper storage environments and handling methods, please observe the following cautions. Cautions for Storage Ensure that storage conditions comply with the standard temperature (5 to 35°C) and the standard relative humidity (around 40 to 75%); avoid storage locations that experience extreme changes in temperature or humidity. Avoid locations where dust or harmful gases are present and avoid direct sunlight. Reinspect for rust on leads and solderability of the products that have been stored for a long time. Cautions for Testing and Handling When tests are carried out during inspection testing and other standard test periods, protect the products from power surges from the testing device, shorts between the product pins, and wrong connections. Ensure all test parameters are within the ratings specified by Sanken for the products. Remarks About Using Thermal Silicone Grease When thermal silicone grease is used, it shall be applied evenly and thinly. If more silicone grease than required is applied, it may produce excess stress. The thermal silicone grease that has been stored for a long period of time may cause cracks of the greases, and it cause low radiation performance. In addition, the old grease may cause cracks in the resin mold when screwing the products to a heatsink. Fully consider preventing foreign materials from entering into the thermal silicone grease. When foreign material is immixed, radiation performance may be degraded or an insulation failure may occur due to a damaged insulating plate. The thermal silicone greases that are recommended for the resin molded semiconductor should be used. Our recommended thermal silicone grease is the following, and equivalent of these. Type Suppliers G746 Shin-Etsu Chemical Co., Ltd. YG6260 Momentive Performance Materials Japan LLC SC102 Dow Corning Toray Co., Ltd. Soldering When soldering the products, please be sure to minimize the working time, within the following limits: • 260 ± 5 °C 10 ± 1 s (Flow, 2 times) • 380 ± 10 °C 3.5 ± 0.5 s (Soldering iron, 1 time) Soldering should be at a distance of at least 1.5 mm from the body of the products. Electrostatic Discharge When handling the products, the operator must be grounded. Grounded wrist straps worn should have at least 1MΩ of resistance from the operator to ground to prevent shock hazard, and it should be placed near the operator. Workbenches where the products are handled should be grounded and be provided with conductive table and floor mats. When using measuring equipment such as a curve tracer, the equipment should be grounded. When soldering the products, the head of soldering irons or the solder bath must be grounded in order to prevent leak voltages generated by them from being applied to the products. The products should always be stored and transported in Sanken shipping containers or conductive containers, or be wrapped in aluminum foil. STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 23 STR5A464D IMPORTANT NOTES The contents in this document are subject to changes, for improvement and other purposes, without notice. Make sure that this is the latest revision of the document before use. Application examples, operation examples and recommended examples described in this document are quoted for the sole purpose of reference for the use of the products herein and Sanken can assume no responsibility for any infringement of industrial property rights, intellectual property rights, life, body, property or any other rights of Sanken or any third party which may result from its use. Unless otherwise agreed in writing by Sanken, Sanken makes no warranties of any kind, whether express or implied, as to the products, including product merchantability, and fitness for a particular purpose and special environment, and the information, including its accuracy, usefulness, and reliability, included in this document. Although Sanken undertakes to enhance the quality and reliability of its products, the occurrence of failure and defect of semiconductor products at a certain rate is inevitable. Users of Sanken products are requested to take, at their own risk, preventative measures including safety design of the equipment or systems against any possible injury, death, fires or damages to the society due to device failure or malfunction. Sanken products listed in this document are designed and intended for the use as components in general purpose electronic equipment or apparatus (home appliances, office equipment, telecommunication equipment, measuring equipment, etc.). When considering the use of Sanken products in the applications where higher reliability is required (transportation equipment and its control systems, traffic signal control systems or equipment, fire/crime alarm systems, various safety devices, etc.), and whenever long life expectancy is required even in general purpose electronic equipment or apparatus, please contact your nearest Sanken sales representative to discuss, prior to the use of the products herein. The use of Sanken products without the written consent of Sanken in the applications where extremely high reliability is required (aerospace equipment, nuclear power control systems, life support systems, etc.) is strictly prohibited. When using the products specified herein by either (i) combining other products or materials therewith or (ii) physically, chemically or otherwise processing or treating the products, please duly consider all possible risks that may result from all such uses in advance and proceed therewith at your own responsibility. Anti radioactive ray design is not considered for the products listed herein. Sanken assumes no responsibility for any troubles, such as dropping products caused during transportation out of Sanken’s distribution network. The contents in this document must not be transcribed or copied without Sanken’s written consent. STR5A464D-DS Rev.1.2 Feb.19, 2015 SANKEN ELECTRIC CO.,LTD. 24