Discontinuous Conduction Mode (DCM) Interleaved PFC IC SSC2102S General Descriptions Package SSC2102S is controller ICs intended to implement a DCM (Discontinuous Conduction Mode) interleaved PFC (Power Factor Correction) circuit. Using the two-phase interleaved control incorporated in this IC, it is possible to achieve a low cost, high performance PFC system with low input / output ripple currents, low noises and few external components. SOP8 Features COMP 1 8 IS VIN 2 7 OUT1 VFB 3 6 GND VCC 4 5 OUT2 Not to scale No Auxiliary Windings on Inductors Required Voltage Mode Control Maximum ON Time Control Circuit Soft-start Function Built-in High Speed Response Function (HSR) Protections Dual level Overcurrent Protection (OCP) Pulse-by Pulse Dual level Overvoltage Protection (OVP)---Auto-Restart Under Voltage Protection (UVP) ---------- Auto-Restart Thermal Shutdown with Hysteresis (TSD) --------------------------------------------------- Auto-Restart Open Loop Detection (OLD) --------------- Auto-Restart VFB pin /VIN pin / IS pin Open Pin Protection (OPP) Electrical Characteristics Maximum ON Time, tONMAX = 20.7 μs(typ.) Error Amplifier Reference Voltage, VFB(REF) = 3.5 V(typ.) OUT Pin Peak Source Current, IOUT(SO) = – 0.5 A* OUT Pin Peak Sink Current, IOUT(SI) = 0.5 A* *Design assurance item Applications Typical Application Circuit PFC Circuit up to 300 W of Output Power such as: AC/DC Power Supply Digital Appliances (Large Size LCD Television and DBYP BR1 so forth) L1 VOUT D1 VAC L2 Q1 Q2 C2 LINE GND RCS R5 U1 1 RIN1 COMP IS forth) Communication Facilities Other SMPS D2 C1 OA Equipment (Computer, Server, Monitor, and so 8 C4 2 VIN OUT1 VFB GND VCC OUT2 7 ROUT1 RIN2 CP 4 NC 3 6 5 SSC2102S External Power supply ROUT2 Cf SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 1 SSC2102S CONTENTS General Descriptions ----------------------------------------------------------------------- 1 1. Absolute Maximum Ratings --------------------------------------------------------- 3 2. Electrical Characteristics ------------------------------------------------------------ 3 3. Functional Block Diagram ----------------------------------------------------------- 6 4. Pin Configuration Definitions ------------------------------------------------------- 6 5. Typical Application Circuit --------------------------------------------------------- 7 6. Package Outline ------------------------------------------------------------------------ 8 7. Marking Diagram --------------------------------------------------------------------- 8 8. Operational Description -------------------------------------------------------------- 9 8.1 Operational Description of Interleaved DCM -------------------------- 9 8.2 Startup Operation ------------------------------------------------------------ 9 8.3 Voltage Control Operation ------------------------------------------------ 10 8.4 High Speed Response Function (HSR) ---------------------------------- 11 8.5 Gate Drive --------------------------------------------------------------------- 12 8.6 Overcurrent Protection (OCP) ------------------------------------------- 12 8.7 Overvoltage Protection (OVP) -------------------------------------------- 13 8.8 Open Loop Detection (OLD) ---------------------------------------------- 14 8.9 Open Pin Protection (OPP) ------------------------------------------------ 14 8.10 Input Undervoltage Protection (UVP) ---------------------------------- 14 8.11 Thermal Shutdown (TSD) ------------------------------------------------- 14 9. Parameters Design -------------------------------------------------------------------- 15 9.1 Inductor Design -------------------------------------------------------------- 15 9.2 Overcurrent Detection Resistor, RCS ------------------------------------ 17 10. Design Notes --------------------------------------------------------------------------- 18 10.1 External Components------------------------------------------------------- 18 10.2 PCB Trace Layout and Component Placement ----------------------- 18 OPERATING PRECAUTIONS -------------------------------------------------------- 20 IMPORTANT NOTES ------------------------------------------------------------------- 21 SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 2 SSC2102S 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 Parameter Symbol Pins Rating Units VCOMP 1–6 − 0.3 to 5.5 V VIN Pin Voltage VIN 2–6 − 0.3 to 5.5 V VIN Pin Current IIN 2–6 − 1 to 1 mA VFB Pin Voltage VFB 3–6 − 0.3 to 5.5 V VFB Pin Current IFB 3–6 − 1 to 1 mA VCC Pin Voltage VCC 4–6 − 0.3 to 30 V OUT2 Pin Voltage VDR2 5–6 − 0.3 to 30 V OUT1 Pin Voltage VDR1 7–6 − 0.3 to 30 V IS Pin Voltage VIS 8–6 − 16.0 to 5.5 V IS Pin Current IIS 8–6 − 1.75 to 1 mA Operating Frame Temperature TFOP − − 40 to 85 °C Storage Temperature Tstg − 40 to 125 °C Junction Temperature Tj − 40 to 125 °C COMP Pin Voltage 2. Test Conditions − 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 =15 V Parameter Symbol Test Conditions Pins Min. Typ. Max. Units Power Supply Startup Operation Operation Start Voltage VCC(ON) 4–6 10.8 11.6 12.4 V Operation Stop Voltage VCC(OFF) 4–6 9.8 10.6 11.4 V VCC Pin Voltage Hysteresis Circuit Current in Pre-operation Circuit Current in Operation Circuit Current in Overvoltage Protection Operation Circuit Current in Standby Operation VCC(HYS) 4–6 0.8 1.0 1.2 V 4–6 − 40 100 µA 4–6 − 11.0 15.0 mA Oscillation Control OUT1 Pin Maximum ON Time On-time matching between OUT1 and OUT1 OUT1 Pin and OUT2 pin Phase Difference SSC2102S-DS Rev.1.2 Dec. 08, 2014 ICC(OFF) VCC = 11 V ICC(ON) ICC(OVP) VFB = 3.9 V 4–6 − 8.0 10.0 mA ICC(Standby) VFB = 0.5 V 4–6 − 100 200 μA 7–6 19.2 20.7 22.2 μs −5 0 5 % 170 180 190 deg tONMAX tRATIO PHASE 5–6 7–6 5–6 7–6 SANKEN ELECTRIC CO.,LTD. 3 SSC2102S Parameter Symbol Error Amplifier Operation Error Amplifier Reference Voltage Error Amplifier Transconductance Gain Error Amplifier Maximum Source Current Error Amplifier Maximum Voltage VFB Pin High Speed Response Enable Voltage(1) VFB Pin High Speed Response Activating Voltage COMP Pin Source Current in High Speed Response Operation VFB Pin Input Bias Current COMP Pin Voltage in Output Open Loop Detection Operation Test Conditions Pins Min. Typ. Max. Units VFB(REF) 3–6 3.4 3.5 3.6 V gmEA ― 80 100 120 μS ICOMP(SO) VFB = 2.8 V 1–6 – 36 – 30 – 24 μA VCOMP(MAX) VFB = 3.0 V 1–6 4.00 4.12 4.25 V VFB(HSR)EN 3–6 3.3 3.4 3.5 V VFB(HSR)AC 3–6 3.1 3.2 3.3 V ICOMP(SO)HSR VFB = 2.5 V 1–6 – 120 – 100 – 80 μA IFB(BIAS) VFB = 3.5 V 3–6 ― ― 1.5 μA ICOMP = 100 µA 1–6 0.7 0.9 1.1 V − − 0.3 V − 10.2 − V − 70 − ns − 35 − ns − – 0.5 − A − 0.5 − A VCOMP(OLD) Drive Output OUT1 and OUT2 Pin Voltage (Low) OUT1 and OUT2 Pin Voltage (High) OUT1 and OUT2 Pin Rise Time(2) OUT1 and OUT2 Pin Fall Time(2) OUT1 and OUT2 Pin Peak Source Current(1) OUT1 and OUT2 Pin Peak Sink Current(1) (1) Design assurance item (2) Shown in Figure 3-1 VOUT(L) IOUT = 20 mA VOUT(H) VCC = 12 V tr VCC = 20 V tf VCC = 20 V IOUT(SO) IOUT(SI) 5–6 7–6 5–6 7–6 5–6 7–6 5–6 7–6 5–6 7–6 5–6 7–6 90% VOUT 10% tr tf Figure 3-1 Switching time SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 4 SSC2102S Parameter Protection Operation VFB Pin Output Open Loop Detection Voltage VFB Pin Output Open Loop Detection Release Voltage VFB Pin Soft Overvoltage Protection Threshold Voltage VFB Pin Overvoltage Protection Threshold Voltage IS Pin Overcurrent Protection Threshold Voltage (Low) IS Pin Overcurrent Protection Threshold Voltage (High) COMP Sink Current in Protection Mode VIN Pin Protection Threshold Voltage VIN Pin Protection Delay Time Thermal Shutdown Activating Temperature (1) Thermal Shutdown Release Temperature (1) Hysteresis Temperature of Thermal Shutdown(1) Thermal Resistance Thermal Resistance from Junction to Frame (1) Design assurance item SSC2102S-DS Rev.1.2 Dec. 08, 2014 Symbol Test Conditions Pins Min. Typ. Max. Units VFB(OLDL) 3–6 0.46 0.50 0.54 V VFB(OLDH) 3–6 0.64 0.70 0.76 V VFB(SOVP) 3–6 3.60 3.68 3.76 V VFB(OVP) 3–6 3.64 3.72 3.80 V VIS(OCPL) 8–6 − 0.48 − 0.42 − 0.36 V VIS(OCPH) 8–6 − 0.62 − 0.55 − 0.48 V 1–6 80 100 120 μA VIN(P) 2–6 0.1 0.3 0.5 V tVIN 2–6 7 14 21 ms TjTSDH – 150 – – °C TjTSDL – 140 – – °C TjTSDHYS – – 10 – °C θj-F – − 65 85 °C/W ICOMP(SI) VIS = − 0.5 V SANKEN ELECTRIC CO.,LTD. 5 SSC2102S 3. Functional Block Diagram COMP + Gain Control WDT IS - Peak Current Limitation VCC VIN(P) - R Q S Qb + VFB 3.5V gm + GND 3.72V - OVP + R Q S Qb + 0.7/0.5V OUT1 OUT2 OLD + Phase Management - VIN 0.3V VIN(P) OLD UVLO + VCC 4. Vreg5V OVP TSD Pin Configuration Definitions COMP 1 8 IS VIN 2 7 OUT1 VFB 3 6 GND VCC 4 5 OUT2 SSC2102S-DS Rev.1.2 Dec. 08, 2014 Pin Name Descriptions 1 COMP Error amplifier output and phase compensation 2 VIN 3 VFB Rectified input voltage detection Constant voltage control signal input / Overvoltage signal input / Open loop detection signal input 4 VCC Power supply for control circuit input 5 OUT2 2nd Gate driver output 6 GND Ground 7 OUT1 1st Gate driver output 8 IS Peak current detection signal input SANKEN ELECTRIC CO.,LTD. 6 SSC2102S 5. Typical Application Circuit DBYP BR1 L1 VAC D1 VOUT L2 D2 Q2 Q1 C1 C2 R2 RCS RIN1 COMP R1 R3 LINE GND R5 U1 1 R4 IS 8 C4 2 VIN OUT1 7 ROUT1 RS RIN2 CVIN CS 4 CP VFB GND VCC OUT2 6 5 SSC2102S CFB SSC2102S-DS Rev.1.2 Dec. 08, 2014 NC 3 Cf External Power supply SANKEN ELECTRIC CO.,LTD. ROUT2 7 SSC2102S 6. Package Outline SOIC8 NOTES: All liner dimensions are in mm Pb-free. Device composition compliant with the RoHS directive 7. Marking Diagram 8 SC2102 Part Number SKYMD 1 Lot Number Y is the last digit of the year (0 to 9) M is the month (1 to 9,O,N or D) D is a period of days 1 : 1st to 10th 2 : 11th to 20th 3 : 21st to 31st Sanken Control Number SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 8 SSC2102S 8. Operational Description IL1 D1 L1 All of the parameter values used in these descriptions are typical values. With regard to current direction, "+" indicates sink current (toward the IC) and "–" indicates source current (from the IC). ION1 VAC Q1 IL1 D1 L2 IL Q2 C1 8.1 Operational Description of Interleaved DCM Figure 8-1 through Figure 8-4 show the PFC (Power Factor Correction) circuits and the operational waveforms of both single phase and two phase interleaved DCM (Discontinuous Conduction Mode). Single phase DCM is well known as a technique that achieves low switching noises because the drain current increases from zero when a power MOSFET turns on, and is not steep shape waveforms as shown in Figure 8-2. However, the usable power level of the single phase DCM is limited by the very high input / output ripple currents. The two phase interleaved DCM incorporates two boost converters, and is able to cancel the input ripple currents and to reduce the output ripple currents due to the phase difference of 180°between two converters as shown in Figure 8-3. The interleaved DCM achieves a PFC system with lower switching noise and smaller input filter areas, compared with the single phase DCM. Because lower input / output ripple currents increase the filtering effect of EMI filters and reduce switching noises. IOFF1 C2 ION2 IOFF2 RCS Figure 8-3 Two phase interleaved DCM PFC circuit Inductor Ccurrent ION1 Composite inductor current ILCMP IL1 IL2 IOFF1 ION2 IOFF2 Figure 8-4 Operational waveform of two phase interleaved DCM D1 IOFF C1 VAC ION Q1 C2 RCS Figure 8-1 Single phase PFC circuit IL ILPEAK 1 ILPEAK 2 The peripheral circuits around VCC pin and COMP pin is shown in Figure 8-5. VCC pin is the external power supply for the IC. AC input voltage and the external voltage for VCC terminal are provided, and when following conditions are satisfied, the control circuit starts switching operation. FB pin voltage increases to more than VFB(OLDH) = 0.70 which is equivalent to about 20% of rated output voltage. VCC pin voltage VCC(ON) = 11.6 V. ION IOFF Figure 8-2 Operational waveform of single phase DCM SSC2102S-DS Rev.1.2 Dec. 08, 2014 8.2 Startup Operation increases to more than When VFB pin voltage decreases to VFB(OLDL) = 0.50 V or less, the control circuit stops switching operation and enters into the standby mode even if VCC pin voltage increases to VCC(ON) or more. Figure 8-6 shows the operational waveform at startup. At startup, COMP pin is charged by ICOMP(SO) = – 30 μA, and thus the output power increases gradually until VFB SANKEN ELECTRIC CO.,LTD. 9 SSC2102S pin voltage becomes 3.2V (corresponds to about 90% of rated output voltage). This Soft-start Function reduces the stress on power devices. External Power supply 8 VCC 8.3 Voltage Control Operation The PFC circuit with a general single phase DCM is shown in Figure 8-8. The L1 current is detected by auxiliary winding D and the off time of MOSFET is controlled. U1 ICOMP(SO) Cf VIN(DC) RS CP D1 L1 COMP 3 GND C2 C1 VAC Control IC 6 CS VOUT D Q1 Figure 8-5 Peripheral circuit of VCC pin and COMP pin Figure 8-8 General current detection circuit of single phase PFC Soft start period Constant voltage operation Drain Current, IDS(Q1), IDS(Q2) In the boost PFC converter, the tON is a function of load power. In case of DCM, tOFF is expressed as follows: 0 VFB pin voltage VFB(REF) about 3.2V t OFF > VFB(OLDH) 0 VIN(DC) VOUT-VIN(DC) t ON (8-1) COMP pin current where, VIN(DC): C1 voltage VOUT: Output voltage tON: On time of MOSFET 0 ICOMP(SO) VCC pin voltage VCC(ON) 0 Time Figure 8-6 operational waveforms at startup As shown in Figure 8-7, when VCC pin voltage decreases to VCC(OFF) = 10.6 V or less, the control circuit stops switching operation by UVLO (Undervoltage lockout) circuit, and reverts to the standby mode before startup. ICC Since the IC does not require the D winding for current detection, simple PFC circuit is achieved. Figure 8-9 shows the peripheral circuit of VIN pin, VFB pin and COMP pin. The IC makes both tON and tOFF internally using VIN pin voltage, FB pin voltage and COMP pin voltage. VAC VIN(DC) L1 D2 C1 Q1 ICC(ON) VOUT D1 L2 Q2 C2 LINE GND Startup Stop RCS ROUT1 U1 RIN1 2 GND VIN VFB RV VCC(OFF) VCC(ON) VCC pin voltage RIN2 6 3 COMP 1 CVIN RS CFB CP ROUT2 CS Figure 8-7 Relationship of VCC pin voltage and circuit current ICC Figure 8-9 Peripheral circuit of VIN, VFB and COMP SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 10 SSC2102S tON is proportional to COMP pin voltage which depends on the output voltage. The maximum on time tONMAX = 20.7 µs is specified by VIN= 0.5 V and VCOMP= 4V. The maximum on time depends on VIN pin voltage. Figure 8-10 shows the typical relationship between VIN pin voltage and the maximum on time tONMAX(VIN) (VCOMP= 4V). Maximum on time tONMAX(VIN) (µs) 22 20 18 16 14 12 10 0.5 1.0 1.5 2.0 2.5 3.0 3.5 VIN pin voltage (V) Figure 8-10 relation between VIN pin voltage and maximum on time (VCOMP= 4 V) VIN Pin and VFB Pin Parameter Design VIN pin detects input voltage and VFB pin detects output voltage. Since these voltages are used for internal calculation of off time, the voltage detection circuits should be well matched. Thus RIN1、RIN2 、 CVIN values of the input portion should be equal to ROUT1、ROUT2、CFB values of the output portion. RIN1 and ROUT1 are recommended the resistors in several hundreds kΩ to several MΩ range and anti-electromigration type, such as metal oxide film resistor. The variation in the value of RIN1, RIN2, ROUT1 and ROUT2 affect the accuracy of output voltage. Thus these resistors are recommended to be high accuracy type. As shown in Figure 8-9, resistor RV is recommended to add for adjustment.CIN and CFB are for noise reduction. Capacitors of about 0.1 nF to 10 nF are recommended, if necessary. Since the dividers of input portion and output portion are designed to be equal, Equation(8-1) can be expressed as Equation(8-2) using VIN pin voltage and VFB voltage. t OFF > VIN t ON VFB-VIN COMP Pin Parameter Design (Error Amplifier Phase Compensation) COMP pin is the output of the internal error amplifier. The error amplifier system consists of a transconductance amplifier and switched current sources that implement the enhanced response functions. The phase compensation circuit is connected between COMP and GND COMP pins. This response is set below 20 Hz to maintain power factor correction at standard commercial power frequencies of 50 or 60 Hz. In Figure 8-9, the phase compensation components, CP, CS and RS, are recommended as follows and may be adjusted to reduce ripple or to enhance transient load response at the output voltage. CP: 0.047 μF to 0.47 μF CS: 0.47 μF to 10 μF RS: 10 kΩ to 100 kΩ 8.4 High Speed Response Function (HSR) The boost PFC is input the sinusoidal waveform of AC input voltage with commercial frequency, and the voltage control has the characteristic of responding to low frequency. As a result, the dynamic load response becomes slow, and may cause the output voltage VOUT to drop more easily. High Speed Response Function (HSR) is built-in to reduce variation of the output voltage under dynamic load change conditions. Figure 8-11 shows the operational waveform of HSR. When VFB terminal voltage increases to VFB(HSR)EN = 3.4 V or more, the control circuit enables HSR operation. After this, when VFB terminal voltage decreases to VFB(HSR)AC = 3.2 V or less due to dynamic load change conditions or others, the control circuit starts HSR operation. During this operation, COMP terminal is charged by ICOMP(SO)HSR = – 100 μA and the output power increases until VFB pin voltage increases to 3.2 V. VFB(HSR)AC = 3.2 V is equivalent to about 91.4% of the rated output voltage, VOUT. VFB pin voltage HSR Enable VFB(REF) VFB(HSR)EN VFB(HSR)AC (8-2) HSR Active 0 COMP pin current 0 where, VIN: VIN pin voltage VFB: FB pin voltage tON: On time of MOSFET ICOMP(SO) Time ICOMP(SO)HSR Figure 8-11 Operational waveform of HSR SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 11 SSC2102S 8.5 Gate Drive 8.6 Overcurrent Protection (OCP) OUT1 pin and OUT2 pin are the gate drive pins for driving the external MOSFET directly. The specification is listed in Table 8-1. Table 8-1 Current and Voltage specifications of OUT1pin and OUT2 pin Parameter OUT1, OUT2 Pin Voltage (Low) OUT1, OUT2 Pin Voltage (High) OUT1, OUT2 Pin Peak Source Current OUT1, OUT2 Pin Peak Source Current Symbol Figure 8-13 shows IS pin peripheral circuit. The Overcurrent Protection (OCP) detects the inductor current of both L1 and L2 by using current detection resistor RCS. The voltage of both ends of RCS is induced into IS pin BR1 Rating VOUT(L) 0.3 V(max.) VOUT(H) 10.2 V IOUT(SO) – 0.5 A IL1 + IL2 IOUT(SI) R1 R3 1 COMP LINE GND R5 U1 0.5 A IS 8 C4 OUT1 VFB GND VCC OUT2 NC 4 VIN 7 6 5 SSC2102S Figure 8-13 Peripheral circuit of IS pin There are two threshold voltages, VIS(OCPL) and VIS(OCPH) in OCP operation. The details are as follows. IS Pin Overcurrent Protection Threshold Voltage (Low):VIS(OCPL) When the inductor current increases and IS terminal voltage decreases to VIS(OCPL) = − 0.42 V, control circuit turns off the external power MOSFET. The control is different depending on the state of V OUT1 and VOUT2. 1) When either VOUT1 or VOUT2 is High, the output, which is set High, is set to Low as shown in Figure 8-14. D1 L2 OUT1 R4 RCS D2 U1 VIN C2 R2 L1 2 Q2 Q1 3 IS VOUT D2 C1 Figure 8-12 shows the peripheral circuit of OUT1 and OUT2. Resistors, R1, R2, R3 and R4 in Figure 8-12 should be adjusted for actual operation because these values relate to the board layout patterns and power MOSFET capacitances. The gate resistors R1 and R3 are recommended in several to several tens of Ω range, and should be adjusted to reduce gate voltage ringing and EMI noise. R2 and R4 help to prevent malfunctions caused by steep dV/dt during power MOSFET turns off. The recommended values are in the 10k to 100kΩ range, and should be placed close to power MOSFET’s gate and source terminals. Power MOSFET should be selected so that these VGS(th) threshold voltages are less than VOUT(H) enough over entire operating temperature range. COMP D1 L2 2 1 L1 VAC 8 7 IS pin voltage Q1 R1 0 C2 VFB NC 3 GND 6 R2 4 VCC OUT2 5 SSC2102S Q2 R3 VIS(OCPL) OUT1 pin voltage,VOUT1 R4 0 Figure 8-12 Peripheral circuit of OUT1 pin and OUT2 pin OUT2 pin voltage, VOUT2 0 Figure 8-14 OCP operation by VIS(OCPL) (either VOUT1 or VOUT2 is high) SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 12 SSC2102S L1 2) When both VOUT1 and VOUT2 are High, the output which is set to High ahead is set to Low as shown in Figure 8-15。. VOUT D1 L2 D2 C1 Q1 Q2 C2 RCS IS pin voltage ICOMP(SI) 0 U1 1 COMP VFB RS VIS(OCPL) GND 6 ROUT1 3 CP CFB CS LINE GND ROUT2 OUT1 pin voltage, VOUT1 Figure 8-17 VFB pin peripheral circuit 0 OUT2 pin voltage, VOUT2 VFB pin voltage VFB(OVP) VFB(SOVP) 0 VFB(REF) Figure 8-15 OCP operation by VIS(OCPL) (Both VOUT1 and VOUT2 are High) IS Pin Overcurrent Protection Threshold Voltage (High):VIS(OCPH) This protection operates on such abnormal conditions as the inductor is shorted or is saturated. When the inductor current of L1 and L2 increases abnormally and IS terminal voltage decreases to VIS(OCPH) = − 0.55 V or less, the control circuit sets both VOUT1 and VOUT2 to Low on pulse-by-pulse basis as shown in Figure 8-16. IS pin voltage 0 VIS(OCPH) OUT1 pin voltage, VOUT1 OUT1 pin voltage, VOUT1 OUT2 pin voltage, VOUT2 Figure 8-18 Operational waveform of OVP Soft Overvoltage Protection (SOVP) When VFB pin voltage increases to VFB(SOVP) = 3.68 V, Soft Overvoltage Protection (SOVP) is activated. Thus, COMP pin is discharged by ICOMP(SI) = 100 μA and the output voltage is decreased. VFB(SOVP) is equivalent to about 105% of the rated output voltage. The output voltage, which operates SOVP, is calculated approximately as follows. VOUT (SOVP ) 0 OUT2 pin voltage, VOUT2 0 Figure 8-16 OCP operation by VIS(OCPH) 8.7 Overvoltage Protection (OVP) Figure 8-17 shows VFB pin peripheral circuit and Figure 8-18 shows the operational waveforms of Overvoltage Protection (OVP). The output overvoltage is detected by using VFB pin. There are two threshold voltages, VFB(SOVP) for Soft Overvoltage Protection (SOVP) and VFB(OVP) for OVP. The operations are shown below. SSC2102S-DS Rev.1.2 Dec. 08, 2014 ICOMP(SK) COMP pin current VOUT VFB (SOVP ) (V) VFB(REF) (8-3) where, VOUT :Output voltage in normal operatioin VFB(REF) :Error AMP reference voltage, 3.5 V Overvoltage Protection (OVP) When VFB pin voltage increases to VFB(OVP) = 3.72 V, Overvoltage Protection (OVP) is activated. And thus both OUT1 and OUT2 are set to Low. When VFB pin voltage decreases to VFB(SOVP), the control circuit deactivate both OVP and SOVP, and reverts to switching operation. VFB(OVP) is equivalent to about 106 % of the rated output voltage. The output voltage, which operates OVP, is calculated approximately as follows. SANKEN ELECTRIC CO.,LTD. 13 SSC2102S 8.10 Input Undervoltage Protection (UVP) VOUT ( OVP ) VOUT VFB ( OVP ) (V) VFB(REF) (8-4) where, VOUT :Output voltage in normal operatioin VFB(REF) :Error AMP reference voltage, 3.5 V 8.8 Open Loop Detection (OLD) Figure 8-19 shows VFB pin peripheral circuit. The Open Loop Detection (OLD) is activated when the output voltage detection resistor ROUT1 is open. In case the ROUT1 becomes open in normal operation, VFB pin voltage starts to decrease. When VFB pin voltage decreases to VFB(OLDL) = 0.50 V, the IC stops switching operation. When VFB pin voltage increases to VFB(OLDH) = 0.70 V or more, the control circuit starts switching operation. VFB(OLDH) is equivalent to about 20% of the rated output voltage. L1 L2 C1 VOUT D1 Instantaneous power failure Soft start VIN pin voltage tVIN D2 Q1 Q2 C2 RCS 6 Input voltage is detected by VIN pin. When input voltage decreases due to the instantaneous power interruption etc., Input Undervoltage Protection (UVP) is activated. Figure 8-20 shows the operational waveforms. When input voltage decrease and the VIN pin voltage decreases to VIN(P) = 0.3 V or more for the internal setting delay time, tVIN = 14 ms or more, the High Speed Response Function (HSR) (refer to Section 8.4) is disabled, the capacitor connected to COMP pin is discharged by ICOMP(SI) and COMP pin voltage is nearly zero. After instantaneous power failure, input voltage increases and VIN pin voltage increase to VIN(P) or more, output power is increased slowly by Soft-start Function (refer to Section 8.2) in order to reduce the stress on power devices. Since the over current is inhibited by UVP at return from instantaneous power failure, output voltage can increase again smoothly. GND LINE GND 0 COMP pin current U1 VFB VIN(P) ROUT1 3 ICOMP(SI) 0 ROUT2 COMP pin voltage CFB Figure 8-19 VFB pin peripheral circuit 0 Output Voltage 8.9 Open Pin Protection (OPP) VFB, IS and VIN pins have Open Pin Protection (OPP) internally. These pins are internally connected with pull-up current sources. In case the pins are open, each pin voltage is pulled up to each internal supply voltage. The protection operations are as follows. VFB pin Open: VFB pin voltage increases and the Overvoltage Protection (OVP) is activated. Thus, both OUT1 and OUT2 are set to Low. IS pin Open: IS pin voltage increases and Overcurrent Protection (OCP) is activated. Thus, both OUT1 and OUT2 are set to Low. 0 Figure 8-20 the instantaneous power failure operationwaveform 8.11 Thermal Shutdown (TSD) When the temperature of the IC increases to TjTSDH = 150 °C (min.) or more, the control circuit stops switching operation. Conversely, when that decreases to TjTSDL = 140 °C (min.) or less, the control circuit starts switching operation. VIN pin Open: VIN pin voltage increases and the control circuit limits its operation, or stops. SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 14 SSC2102S 9. Parameters Design PIN( MAX ) Symbols in this section are defined as follows. PO: PFC Output power per phase (W) η: PFC Efficiency tON: On time (s) VINRMS(MIN): Minimum input RMS voltage (V) VINRMS(MAX): Maximum input RMS voltage (V) VOUT: PFC output voltage (V) IINRMS: Input RMS current (A) DBYP L1 VIN(DC) VOUT D1 VAC L2 D2 C1 Q1 Q2 RIN1 COMP IS LINE GND 8 VIN OUT1 VFB GND VCC OUT2 7 ROUT1 RIN2 CP 4 NC 3 I LPEAK( MAX ) 2 2 PIN( MAX ) VINRMS ( MIN ) (A) (9-3) (3) Calculation of Maximum On Time The IC makes both on time and off time internally using VIN pin voltage, FB pin voltage and COMP pin voltage. Maximum on time is calculated as follows. C4 2 Calculation of Maximum Inductor Peak Current Maximum inductor peak current, I LPEAK(MAX) is calculated using the above results and Equation (9-3). R3 U1 1 (9-2) The values of KOM and KLM are generally in the range of 1.2 to 1.3. η depends on the ON-resistance, RDS(ON), of the power MOSFET and the forward voltage, VF of the rectifier diode. η is generally in the range of 0.90 to 0.97. C2 RCS (W) Where, KOM: Coefficient of the output power margin KLM: Coefficient of the inductor saturation margin η: PFC Efficiency The symbols of components are defined as shown in Figure 9-1. BR1 K OM K LM PO 6 5 SSC2102S External Power supply Calculation of VIN pin voltage, VIN Defining the VIN pin voltage as VIN and the voltage of C2 as VIN(DC), The relationship between VIN(DC) and input detection resistors, RIN1 and RIN2 is as follows. ROUT2 Cf Figure 9-1 IC peripheral circuit R IN1 R IN 2 VIN( DC ) R IN 2 VIN 9.1 Inductor Design Inductor is designed as follows. (1) Setting of Output Voltage, VOUT At farst, output voltage of PFC should be set. Input voltage must always be lower than output voltage in a boost converter. Generally, output voltage, VOUT, is set to at least 10 V higher than the peak voltage of the maximum commercial AC input voltage. VOUT 2 VINRMS ( MAX ) 10 (V) (9-1) (2) Calculation of Maximum Inductor Peak Current (per phase) The waveform of the inductor current is triangular. The maximum peak current, ILPEAK(MAX), running through each inductor is calculated as follows. Calculation of Maximum Input Power Maximum input power, PIN(MAX) is calculated as follows. SSC2102S-DS Rev.1.2 Dec. 08, 2014 (9-4) The relationship between output voltage, VOUT and output detection resistors, ROUT1 and ROUT2 is as follows. R OUT 1 R OUT 2 VOUT R OUT 2 VFB ( REF) (9-5) The values of RIN1 and RIN2 should be equal to the values of ROUT1 and ROUT2. From Equation (9-4) and Equation (9-5), VIN is calculated as follows. VIN( DC ) VIN ⇒ VIN SANKEN ELECTRIC CO.,LTD. VOUT VFB ( REF) VIN( DC ) VFB ( REF) VOUT (V) 15 SSC2102S In case of minimum AC input voltage, on time becomes maximum. VIN at maximum on time is calculated as follows. VIN 2 VINRMS ( MIN ) VFB ( REF) VOUT (V) (9-6) Maximum on time Maximum on time depends on VIN pin voltage as shown in Figure 8-10 (Section 8.2). Maximum on time can be gotten from result of Esuation (9-6) and Figure 8-10. (2) Calculation of ILPEAK(MAX) In case KOM = 1.2, KLM = 1.2, η = 0.92 and VINRMS(MIN) = 85 V, the maximum input power for a single phase is calculated as follows. PIN( MAX ) 2 VINRMS ( MIN ) t ONMAX ( VIN ) I LPEAK ( MAX ) (H) (9-7) (5) Calculation of Inductor Turns The turns number of inductor, N is calculated as follows using the results of (2) and (4). N I LPEAK( MAX ) L MAX Ae BMAX (turns) (9-8) where, Ae : the effective area of inductor core (m2) ΔBMAX : maximum magnetic flux density (T) < Inductor Design Example > Inductor design examle is shown below. The specifications of power suply are as follows. VINRMS(MIN) = 85V VINRMS(MAX) = 265V PO = 150 W for each phase (Total output power of two phase Interleaved PFC = 300 W) (1) Setting of Output Voltage, VOUT VOUT 2 VINRMS ( MAX ) 10 2 265 10 385(V) hence, VOUT is set to 390 V(DC) SSC2102S-DS Rev.1.2 Dec. 08, 2014 1.2 1.2 150 235( W) 0.92 Then the maximum peak inductor current for a single phase is calculated as follows. I LPEAK( MAX ) (4) Calculation of Inductance value for a single phase. The maximum inductance for a single phase, LMAX is calculated as follows using the results of (2) and (3). L MAX K OM K LM PO 2 2 PIN( MAX ) VINRMS ( MIN ) 2 2 235 7.8 ( A) 85 (3) Calculation of tONMAX(VIN) Using VFB(REF) = 3.5 V(typ.) and the result of (1), VIN is calculated as follows. VIN 2 VINRMS ( MIN ) VFB ( REF) VOUT 2 85 3.5 1.08 ( V) 390 The relation in Figure 8-10 shows tONMAX(VIN) at VIN = 1.08 V is about 18.6 μs. (4) Using the results of (2) and (3) L MAX 2 VINRMS ( MIN ) t ONMAX ( VIN ) I LPEAK ( MAX ) 2 85 18.6 10 6 7.8 286 10 6 (H) (5) When Ae is 102 mm2 and ΔBMAX is 250 mT, N is calculated as follows using the results of (2) and (4). N I LPEAK( MAX ) L MAX Ae BMAX 7.8 286 10 6 102 10 6 0.25 87(turns) SANKEN ELECTRIC CO.,LTD. 16 SSC2102S 9.2 Overcurrent Detection Resistor, RCS Overcurrent detection resistor, RCS, detects the composite inductor current of both converters. As the peak value of composite inductor current varies by ON-duty DON(MAX), the coefficient defined as KR is calculated from its DON(MAX) and RCS is calculated by ILCMP. (1) Calculation of Maximum ON-duty DON(MAX) DON(MAX) is calculated as follows using VOUT derived in Section 9.1 (1). D ON ( MAX ) VOUT- 2 VINRMS ( MIN ) (9-9) VOUT (2) Calculation of Inductor Current Coefficient, KR From the result of (1), R CS VIS( OCPL ) I LCMP ( MAX ) (Ω) (9-13) where, VIS(OCPL) : IS Pin Overcurrent Protection Threshold Voltage (Low) is − 0.42 V(typ.) <RCS Design Example> RCS design example is shown below. The specifications of power suply are as follows. VINRMS(MIN) = 85V VINRMS(MAX) = 265V PO = 150 W for each phase (Total output power of two phase Interleaved PFC = 300 W) Output Voltage: VOUT = 390 V When DON(MAX) ≥ 0.5 (1) Calculation of DON(MAX) KR 1 D ON ( MAX ) 0.5 (9-10) D ON ( MAX ) When DON(MAX) < 0.5 KR 1 0.5 D ON ( MAX ) (9-11) 1 D ON ( MAX ) VOUT 2 VINRMS ( MIN ) D ON ( MAX ) VOUT 390 2 85 0.69 390 (2) Calculation of KR Using the the result of (1) and Equation (9-10), KR is calculated as follows. (3) Calculation of Composite Inductor Current, ILCMP(MAX) Using the result of (2), ILCMP(MAX) is calculated as follows. KR 1 1 I LCMP(MAX) K R 2 2 K OM PO (A) η VINRMS(MIN) D ON ( MAX ) 0.69 0.5 1.28 0.69 (9-12) where, KOM :Output power margin coefficient PO :Output power for a single phase (W) η :PFC efficiency Generally, KOM is the range of 1.2 to 1.3. η depends on the ON-resistance, RDS(ON), of the power MOSFET and the forward voltage, VF of the rectifier diode. η is generally in the range of 0.90 to 0.97. (4) Calculation of Over Current Detection Resistor, RCS Using the result of (3), RCS is calculated as follows. (3) Calculation of ILCMP(MAX) I LCMP(MAX) K R 2 2 K OM PO η VINRMS(MIN) 1.28 2 2 1.2 150 8.3(A) 0.92 85 (4) Calculation of RCS Using the result of (3), RCS is calculated as follwos. R CS SSC2102S-DS Rev.1.2 Dec. 08, 2014 D ON ( MAX ) 0.5 VIS( OCPL ) I LCMP ( MAX ) 0.42 SANKEN ELECTRIC CO.,LTD. 8.3 0.05() 17 SSC2102S Output Electrolytic Capacitor, C2 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. 10. Design Notes 10.1 External Components Take care to use properly rated, including derating as necessary and proper type of components. Figure 10-1 shows the IC peripheral circuit. Inductor, L1 and L2 Apply proper design margin to temperature rise by core loss and copper loss. DBYP BR1 L1 VIN(DC) VOUT D1 VAC L2 D2 C1 Q1 Q2 C2 LINE GND RCS R3 U1 1 RIN1 COMP IS 8 C4 2 VIN OUT1 VFB GND VCC OUT2 7 10.2 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 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. ROUT1 RIN2 CP 4 NC 3 6 Figure 10-2 shows the circuit design example. 5 SSC2102S External Power supply ROUT2 Cf Figure 10-1 The IC peripheral circuit. High Resistance and High Voltage Applied Resistor, RIN1 and ROUT1 Since RIN1 and ROUT1 have applied high voltage and have high resistance value, RIN1 and ROUT1 should be selected from resistors designed against electromigration or use a combination of resistors for that. Current Detection Resistor, RCS RCS is the resistor for the current detection. A high frequency switching current flows to RCS, and may cause poor operation if a high inductance resistor is used. Choose a low inductance and high surge-tolerant type. Boost Diode, D1 and D2 Choose a boost diode having proper margin of a peak reverse voltage VRSM against output voltage VOUT. A fast recovery diode is recommended to reduce the switching noise and loss. Please ask our staff about our lineup. The size of heat sink is chosen taking into account some loss by VF and recovery current of boost diode. Bypass Diode, DBYP Bypass diode protects the boost diode from a large current such as an inrush current. A high surge current tolerance diode is recommended. Please ask our staff about our lineup. SSC2102S-DS Rev.1.2 Dec. 08, 2014 (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) 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 a single point grounding of point A in Figure 10-2 as close to the RCS pin as possible. (3) RCS Trace Layout RCS should be placed as close as possible to the Source pin and the IS pin. The peripheral components of IS pin should be connected by dedicated pattern from root of RCS. The connection between the power ground of the main trace and the IC ground should be at a single point ground (point A in Figure 10-2) which is close to the base of RCS. (4) Peripheral Component of IC The components for control connected to the IC should be placed as close as possible to the IC, and should be connected as short as possible to the each pin. (5) Gate Resistor (R2 and R4) Trace Layout Gate resistor should be connected as short as possible to the Source pin and Gate pin of each MOSFET. SANKEN ELECTRIC CO.,LTD. 18 SSC2102S DBYP BR1 L1 VAC L2 D2 Q2 Q1 (1) Main trace should be wide trace and small loop C1 C2 (3)RCS should be as close to Source pin as possible. (3) Connected by dedicated pattern from root of RCS CP RS RIN2 1 COMP 2 CFB 4 OUT1 VFB GND VCC OUT2 NC 3 VIN A (5)Gate resistor should be as close to Source pin and Gate pin as possible. 8 RIN1 CVIN External Power supply R5 IS R4 R2 RCS U1 CS VOUT D1 7 C4 6 LINE GND R1 (2) Control GND trace should be connected at a single point as close to the RCS as possible 5 R3 Cf ROUT2 ROUT1 (4)The components connected to the IC should be as close to the IC as possible, and should be connected as short as possible Figure 10-2 Example of connection of peripheral component SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 19 SSC2102S 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. 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) 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. SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 20 SSC2102S 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. SSC2102S-DS Rev.1.2 Dec. 08, 2014 SANKEN ELECTRIC CO.,LTD. 21