Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Starter IC with High-Efficiency Burst Function MCZ5303 MCZ5305SG is an optional IC for LLC control IC to allow you to use a current resonance power supply in various applications. It is an IC that adds selfstart function, burst function, and AC line monitoring function to an existing control IC. MCZ5303SH is an IC made by removing the AC line monitoring function and the control logic from MCZ5305SG. It can be also used as start circuit part of general power supply control ICs. <Note> The functions, specifications, etc. described in this document are subject to change without notice. Do not disclose the contents to outside parties. Shindengen Electric Manufacturing Co., Ltd. Electronic Device Division CAT.No. 1H0400-1E –1– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Cautions for Use Thank you for purchasing our products. This manual contains important information on the safe use of our products. Your safety is of the utmost importance to us. Please read these instructions carefully before using our products. The following symbols mean: ! ! ! Warning Improper use of the products can result in death, serious injury, or expensive damage to equipment. ! Caution Improper use of the products can result in minor injuries or damage to equipment. Warning Warning Although we are constantly making every effort to improve the quality and reliability of our products, there nevertheless remains a certain probability that the semiconductor products may occasionally fail or malfunction. Please take careful precautions against product failures or malfunctions to avoid any injuries, fire accidents or social loss by implementing safety designs such as redundancy designs, designs for fire spread prevention, and designs for preventing malfunctions. Our semiconductor products listed in this document are not designed or manufactured to be used in devices or systems requiring extremely high levels of quality and reliability, or the failure or malfunction of which may directly threaten human lives or cause injury. In the cases where the products are to be used in devices or systems for special applications or devices or systems for specialized applications shown below, always make sure to consult us in advance. Special Applications Transportation devices (automotive, marine, etc.), communication devices for core network, traffic signal devices, fire prevention/anticrime devices, various safety devices, medical devices, etc. Specialized Applications Nuclear power control systems, aircraft and aerospace devices, submarine relay devices, and systems for preserving life, etc. Even if it is not for a special or specialized application, when IC products are to be used for devices or systems that are desired to last for a long period under continuous operation, please make sure to consult us in advance. ! Caution ! Caution ! ! ! Caution Do not attempt under any conditions to repair or modify IC products by yourself. Doing so could result in electric shock, device breakage, fire, and malfunction. When an abnormal condition occurs, an excessive voltage or under voltage may be generated across the output terminals of the circuit. Install preventative measures (e.g. over-voltage protection, over-current protection) for the device by considering the possibility of a malfunction and/or breakage of a load in an abnormal condition. Do not switch on the circuit before confirming the proper connection and polarity of input and output terminals as an erroneous connection may cause breakage of the protection device or smoke/fire. Caution Do not use the circuit beyond the rated input voltage and install a protection device on the input rail to prevent smoke/fire that may be caused from an abnormal condition. Caution If a breakdown or other abnormal condition occurs during the use of the device, immediately stop power to the device and consult us at your earliest possible convenience. ● We reserve the right to make any changes to the contents of this manual without prior notice in accordance with modifications to IC products. ● Details of specifications should be exchanged at the adoption of the IC products. ● All information included in this manual is believed to be accurate and reliable. However, our company takes no responsibility for any injury or damage incurred when using the IC products as described in this manual. Neither do we take any responsibility for issues arising from infringement of patent or other rights caused by using this manual. ● The provision of this manual does not guarantee the right to use any third party’s patent or other rights, or grant permission to use the patent or other rights of our company. ● No part of this manual may be reproduced or copied without the specific written consent of Shindengen Electric Mfg. Co., Ltd. We are happy to provide circuit design support for safe use of the IC. Please consult our sales representative. CAT.No. 1H0400-1E –2– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Table of contents Contents 1 Page Overview of Product 1-1. Features 1-2. Example of Circuit Configuration •••• •••• 4 4 2 Block Diagram •••• 5 3 Pin Assignment and Pin Function List 3-1. Pin Assignment Diagram 3-2. Pin Function List •••• •••• 6 6 MCZ5303SG 4-1. Introduction 4-2. LSin Terminal (pin1) and LSout Terminal (pin2) 4-3. GND Terminal (pin3) 4-4. COMPin Terminal (pin4) and COMPout Terminal (pin5) 4-5. KSST Terminal (pin6) 4-6. KAS Terminal (pin7), ASin Terminal (pin11) and STBY Terminal (pin10) 4-7. SSC Terminal (pin8) 4-8. KVc1 Terminal (pin9) 4-9. Vcc Terminal (pin12) 4-10. Vw Terminal (pin13) 4-11. Vin Terminal (pin16) •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• 7 7 8 8 9 9 9 10 10 11 11 MCZ5303SH 5-1. Introduction 5-2. GND Terminal (pin1) 5-3. COMPin Terminal (pin2) and COMPout Terminal (pin3) 5-4. Vcc Terminal (pin12) 5-5. Vcc Terminal (pin12) 5-6. Vw Terminal (pin6) 5-7. Vin Terminal (pin7) •••• •••• •••• •••• •••• •••• •••• 12 12 12 13 13 13 14 Package Dimensions 6-1. SOP16 (MCZ5303SG) 6-2. SOP7J (MCZ5303SH) •••• •••• 15 16 Application Example 7-1. Main Components 7-2. Power Supply Specifications 7-3. About Control IC 7-4. Circuit Block Diagram 7-5. Standby (Burst) Operation 7-6. Start/Stop/Mode Sequential Operation 7-7. Static Operation 7-8. Figure of Actual PSU 7-9. Circuit Diagram •••• •••• •••• •••• •••• •••• •••• •••• •••• 17 17 17 18 19 22 25 26 27 4 5 6 7 CAT.No. 1H0400-1E –3– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 1 Overview of Product MCZ5303SG is a function IC in which the standby IC is removed from the conventional two-converter configuration to realize a one-converter configuration while keeping high efficiency. MCZ5303SH of SOP7J package is also in the lineup in case only start circuit is required. • • • • • • • • SOP7J(MCZ5303SH), SOP16(MCZ5303SG) package 500V HV startup function Optimised burst mode control 35V supply withstanding 18.5V internal dropper Specialized burst sequence circuit for using LLC controllers like Shindengen MCZ5205 and MCZ5207 (MCZ5303SG only) Input main line sensing Thermal shutdown function eliminates external protective components 1.1 Features • When using MCZ5303, the sub converter for Vcc supplying in existing 2 converter configuration (PFC&LLC + sub converter) is no longer required. • Open load 0.1W consumption is possible in single LLC converter solution. • Total component counts can be much reduced. 1.2 Example of Circuit Configuration MCZ5205SE(PFC/LLC combo IC) + MCZ5303SG MCZ5205 CAT.No. 1H0400-1E –4– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 2 Block Diagram Figure 1. MCZ5303SG : SOP16 Figure 2. MCZ5303SH : SOP7J CAT.No. 1H0400-1E –5– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 3 Pin Assignment and Pin Function List 3.1 Pin Assignment Diagram 1. GND 7. Vin 2. COMPin 3. COMPout 6. VW 4. KVc1 5. Vcc Figure 3. MCZ5303SG : SOP16 Figure 4. MCZ5303SH : SOP7J 3.2 Pin Function List Symbol Pin No. Function SOP16 SOP7J LSin 1 - Input main line sensing terminal: Input main line voltage sensing comparator input. LSout 2 - Input main line sensing terminal output: Input main line voltage sensing comparator output. GND 3 1 GND terminal: GND connection terminal for IC. COMPin 4 2 Burst control comparator input terminal: Terminal to control burst operation by detecting the voltage. COMPout 5 3 Comparator output terminal for burst operation: Used to adjust the hysteresis of the burst control comparator. KSST 6 - Output terminal for SST reset: Terminal to reset the SST terminal by synchronizing with burst. KAS 7 - AS switching signal output terminal: Outputs switching signals of active standby mode. Becomes Lo in standby mode or active standby mode. SSC 8 - Soft start circuit switching terminal: Control terminal to switch the time constant of soft start at the time of burst operation. KVc1 9 4 Vcc supply terminal: Supplies power to the control IC. STBY 10 - Standby mode switching terminal: Switches to burst mode. Burst mode with terminal open. ASin 11 - AS switching signal input terminal: Input terminal of active standby signals. Vcc 12 5 Power supply terminal (start circuit output): A current is supplied from the Vin terminal at the time of start, and a voltage is supplied from the VW terminal after start. VW 13 6 Vcc winding voltage input terminal: Terminal for voltage input from the Vcc winding. Has an 18.5V dropper. NC 14,15 - Unused terminal Vin 16 7 Start circuit input terminal: A current is supplied from the Vin terminal to the Vcc terminal at the time of start, and the start circuit becomes off when Vw exceeds 19.5V. Table 1. Pin Function List CAT.No. 1H0400-1E –6– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 4 MCZ5303SG * Unless otherwise specified, values such as threshold values are represented in TYP. For details, refer to the characteristic specifications. 4-1. Introduction MCZ5303SG(SOP16) had three control modes depending on the states of the STBY terminal and the ASin terminal. Here, they are defined as follows (with circuit configuration with MCZ5205 and MCZ5207). 1) Normal mode: Performs normal operation (symmetrical control) when the STBY terminal is shorted to GND and the ASin terminal is left opened. 2) Active Standby mode (AS mode) *: Performs continuous asymmetric LLC operation when the STBY and ASin terminal are both shorted to GND. When using MCZ5205, PFC is also forced to stop. 3) Burst mode: Performs burst oscillation control with the STBY terminal open. Accordingly, the mode becomes AS mode and the PFC is also stopped. * The AS mode is an energy-saving mode in our LLC controller MCZ5205/5207. The standby power is further reduced by applying AS mode in addition to burst mode. The SST terminal is a function terminal of MCZ5205 or MCZ5207 that performs soft start and timer protection operation. 4-2. LSin Terminal (pin1) and LSout Terminal (pin2) The LSin terminal is an input terminal of the hysteresis comparator for input main line sensing. It monitors the AC input voltage with voltage divider from AC and turns on/off the KVc1 terminal output according to the voltage. It also outputs the detection result to the LSout terminal. LSin terminal input LSout terminal Operation threshold voltage output 1.05V or more Oscillation start (KVc1 supply start) Hi 0.75V or less Oscillation stop (KVc1 supply stop) Lo KVc1 terminal: Refer to 4-8 KVc1 terminal. Figure 5 is a connection example of the LSin terminal. Input lines are detected by connecting resistances R1 and R2 from the AC line to divide the resistance voltage and smoothing by C1. Figure 5 shows detection with half-wave rectification. Since the C1 capacity can be reduced by connecting diodes from both AC terminals for full-wave rectification, response at a higher speed can be obtained. Voltage VLSin that is generated in LSin at the time of half-wave rectification can be obtained with an approximation of formula 3-1. Capacitor C1 sets the capacity so that the amplitude of the ripple does not exceed the hysteresis width. If the capacitor capacity is unnecessarily large, delay in start and stop becomes longer. In addition, since the operating point is affected when the amplitude of the ripple changes with the capacity of capacitor C1, check and adjust R1 or R2 in actual machine. In the configuration example of Figure 5, settings are made as R1=4M, R2=100k, C1=2.2uF as reference constant examples in the case of 90Vrms to 264Vrms input specification. Actually, R1 should be divided into several pieces and installed in consideration of withstand voltage. When installing parts, place R2 and C1 just proximal to the IC terminal. Voltage VLSin of the LSin terminal for AC input AC (rms) is, VLSin AC(rms) R2 1.72 R1 R 2 〔V〕 ...Formula 4-1 Sensing resistor consumption Rloss is approximately as follows. 2 AC(rms) Rloss R1 R 2 〔W〕 1 .3 ...Formula 4-2 Figure 5. Typical line sensing circuit configuration (MCZ5303SG) CAT.No. 1H0400-1E –7– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 4-3. GND Terminal (pin3) This is a GND terminal for IC. Connect it with the control GND of the main control IC. 4-4. COMPin Terminal (pin4) and COMPout Terminal (pin5) The COMPin terminal is a comparator input terminal for burst control. To operate it in indirect control, detect the Vcc winding rectified voltage on the primary side with voltage divider and connect it to the COMPin terminal. Voltage supply to KVc1 is controlled according to the state of the COMPin terminal (in burst mode). Connect KVc1 to Vcc(Vc1 terminal of MCZ5205 and MCZ5207) of the LLC controller. In normal mode, COMPin input becomes ineffective and the output voltage is continuously supplied to the KVc1 terminal. In burst mode (STBY: Open) COMPin terminal input threshold voltage Operation COMPout terminal Upper limit of 1.06V Lower limit of 0.96V Converter operation stop (KVc1 supply stop) Converter operation start(KVc1 supply start) Open Short (Lo) The LLC controller repeats start and stop in burst duration as shown in Figure 6, set the voltage divider to be connected to the COMPin terminal in a way that KVc1 supply start voltage setting should be equal to the start voltage Vc1(start) of the LLC controller or more. In the case of MCZ5303SG, the COMPout terminal is open drain, and the burst duration can be adjusted by connecting a resistor between the COMPout and the COMPin terminal. 1.06V 0.96V COMPin Vc1(start) KVc1 LLC IC_ SS LLC MOS_ ID Vo LLC IC_SS: Soft start signal of LLC part Figure 6. Burst operation sequence drawing (MCZ5303SG) 5RE-125294-2 –8– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 4-5. KSST Terminal (pin6) KSST is a terminal to send halt trigger to convert controller and has open drain output. In MCZ5205/5207 case, it is connected to the SST (soft start) terminal of the LLC controller. The KSST terminal is controlled by the COMPin terminal at the time of burst operation and operates in synchronization with the burst duration. In normal mode, it is always open. Unnecessary oscillation is restrained by performing reset operation of soft start at the time of burst operation and in every burst duration to reduce the standby power. In burst mode (STBY: Open) COMPin terminal input Operation threshold voltage 1.06V or more Oscillation stop (KVc1 supply stop) 0.96V or less Oscillation start (KVc1 supply start) KSST terminal output Lo (reset SST) Open SS: Soft start of LLC controller 4-6. KAS Terminal (pin7), ASin Terminal (pin11) and STBY Terminal (pin10) The KSST terminal voltage is controlled in response to COMPin terminal voltage and changes its status of high and low according to the burst duration. The KAS terminal enters sink operation (Lo) in burst mode and is set to AS mode (asynchronous control) during burst operation. With ASin terminal input, it can be set to AS mode during light load operation in continuous mode. The STBY terminal is a terminal to switch between normal mode and burst mode. When the STBY terminal is open, the mode becomes burst mode with COMPin terminal detection. STBY terminal input ASin terminal input Short (Lo) Short (Lo) Short (Lo) Open Open － Operation Continuous mode/symmetrical mode Continuous mode/AS mode Burst mode/AS mode KAS terminal output Open Short (Lo) Short (Lo) 4-7. SSC Terminal (pin8) The SSC terminal is a circuit to switch the time constant of soft start. Output is open drain, and the terminal is in sink (Lo) state in static operation and in open state in burst operation. Figure 7 is an example of connection with the LLC controller. The soft start time constant circuit of the SST terminal is switched with SSC terminal control. Since SSC is Lo and Css2 is shorted in normal operation, the soft start time is decided by Css1. When in burst mode, the SSC terminal becomes open. Therefore, in the time constant circuit with series connection of Css1 and Css2 and parallel connection of Css2 and Rss2, the start time is set shorter than in normal mode. However, the time of soft start operation in the beginning of start is the soft start time of normal mode (Css1) even if the mode is standby mode. STBY terminal input Operation SSC terminal output Short (Lo) Normal mode (Css1) Burst & AS mode (Cssi + Css2/Rss configuration) Open Open Short (Lo) 5RE-125294-2 –9– Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Figure 7. Connection diagram with LLC controller (MCZ5303SG) 4-8. KVc1 Terminal (pin9) The KVc1 terminal is a terminal for Vcc supply to the control IC. In burst operation, it makes the LLC perform burst operation by repeating start and stop of supply from the KVc1 terminal to reduce wasteful IC power consumption in the oscillation stop period. In burst mode (STBY: Open) COMPin terminal input threshold voltage Set with 1.06V Reset with 0.96V Operation KVc1 SW Oscillation stop (KVc1 supply stop) Oscillation start (KVc1 supply start) ON --> OFF OFF --> ON KVc1 SW: See Figure 8. 4-9. Vcc Terminal (pin12) The Vcc terminal receives a current supplied from the Vin at the time of start and from the Vw terminal after start. The UVLO threshold value of Vcc is 7V, and output of KVc1 is turned off when the value is below the threshold. For the Cvcc capacitor, select a capacity of 220uF or below with which the power supply can be started. Figure 8. Connection diagram of Vcc system (MCZ5303SG) 5RE-125294-2 – 10 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 4-10. Vw Terminal (pin13) The Vw terminal inputs voltage in which output from the Vcc winding is rectified. The maximum input voltage of the Vw terminal is 35V. It is connected from the Vw terminal to the Vcc terminal with an 18.5V dropper circuit and a Vw switch. When oscillation of the LLC is started and the Vw terminal voltage is increased to (Vcc+1V) or more at the time of start, the start circuit stops. When the Vw terminal voltage decreases to 7.5V or below, the start circuit starts operation. Since the maximum allowable current of the Vw terminal is 200mA, the current should be limited with resistance, etc., in consideration of charging to Cvcc when the KVc1 SW is on. VW terminal input threshold voltage (Vcc+1V) or more 7.5V or less Operation Start circuit stop Start circuit operation start 4-11. Vin Terminal (pin16) The Vin terminal is a terminal to supply a current from the rectified high voltage part to Vcc at the time of power supply start and consists of a high withstand voltage switch and a constant current circuit. The supply current is 14.5mA with Vin=100VDC. When Vcc is 1V, it is reduced to 2.7mA. Operation of the high withstand voltage switch is controlled by the above-mentioned VW terminal. When the high withstand voltage switch is turned on at the time of start, charging to the Vcc terminal capacitor is started and continued until the Vcc terminal voltage is clamped to 17V. The high withstand voltage switch is turned off when the LLC converter oscillates and the voltage of the Vw terminal becomes Vcc+1V or more with supply from the primary Vcc winding. Figure 9 is a start/stop sequence drawing in burst mode. Figure 9. Start/stop sequence drawing in burst mode (MCZ5303SG) 5RE-125294-2 – 11 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 5 MCZ5303SH * Unless otherwise specified, values such as threshold values are represented in TYP. For details, refer to the characteristic specifications. 5-1. Introduction MCZ5303SH is an IC that is a SOP7J package with the input main line sensing function and the burst sequence circuit removed from MCZ5303SG. It is optimum when you use MCZ5207 as a main control IC to use the burst function of MCZ5207 itself or need only a start circuit. 5-2. GND Terminal (pin1) This is a GND terminal for IC. Connect it with the control GND of the main control IC. 5-3. COMPin Terminal (pin2) and COMPout Terminal (pin3) The COMPin terminal is a comparator input terminal for burst control. Supply to the main control IC can be turned on/off with input signals of COMPin. To operate in primary side control, voltage divider shall be connected to COMPin terminal from Vcc self bias winding rectified DC voltage. Voltage supply to KVc1 is controlled according to the state of the COMPin terminal. Connect KVc1 to Vcc (Vc1 terminal of MCZ5205 and MCZ5207) of the LLC controller. Since the LLC controller repeats start and stop in every burst duration as shown in Figure 10, Vcc sensing voltage is applied to COMPin terminal through voltage divider to adjust burst duration, notice that KVc1 supplying voltage should be more than Vc1(start) of the LLC controller. (For the circuit configuration, see Figure 11.) The COMPout terminal has a logic with reverse polarity of that of MCZ5303SG and the output circuit configuration is also different (Lo/Hi output). It can used to control the soft start terminal of the main control IC, etc. COMPin terminal input threshold voltage Upper limit of 1.06V Lower limit of 0.96V COMPout terminal Operation Converter operation stop (KVc1 supply stop) Converter operation start (KVc1 supply start) Lo Hi LLC IC_SS: Soft start signal of LLC part Figure 10. Burst operation sequence drawing (MCZ5303SH) 5RE-125294-2 – 12 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 5-4. KVc1 Terminal (pin4) The KVc1 terminal is a terminal for Vcc supply to the main control IC. In burst control, it makes LLC perform burst operation by repeating start and stop of supply from the KVc1 terminal to reduce wasteful IC power consumption in the oscillation stop period. In addition, it can be also used as an on/off control switch of the main control IC with use of COMPin terminal, instead of use for burst. In burst mode COMPin terminal input threshold voltage Set with 1.06V Reset with 0.96V Operation KVc1 SW Oscillation stop (KVc1 supply stop) Oscillation start (KVc1 supply start) ON --> OFF OFF --> ON KVc1 SW: See Figure 11. 5-5. Vcc Terminal (pin12) The Vcc terminal receives a current supplied from the Vin at the time of start and from the Vw terminal after start. The UVLO threshold value of Vcc is 7V, and output of KVc1 is turned off when the value is below the threshold. For the Cvcc capacitor, select a capacity of 220uF or below with which the power supply can be started. Figure 11. Connection diagram of Vcc system (MCZ5303SH) 5-6. Vw Terminal (pin6) The Vw terminal inputs voltage in which output from the Vcc winding is rectified. The maximum input voltage of the Vw terminal is 35V. It is connected from the Vw terminal to the Vcc terminal with an 18.5V dropper circuit and a Vw switch. When oscillation of the LLC is started and the VW terminal voltage is increased to (Vcc+1V) or more at the time of start, the start circuit stops. When the Vw terminal voltage decreases to 7.5V or below, the start circuit starts operation. Since the maximum allowable current of the Vw terminal is 200mA, the current should be limited with resistance, etc., in consideration of charging to Cvcc when the KVc1 SW is on. VW terminal input threshold voltage (Vcc+1V) or more 7.5V or less Operation Start circuit stop Start circuit operation start 5RE-125294-2 – 13 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 5-7. Vin Terminal (pin7) The Vin terminal is a terminal to supply a current from the rectified high voltage part to Vcc at the time of power supply start and consists of a high withstand voltage switch and a constant current circuit. The supply current is 14.5mA with Vin=100VDC. When Vcc is 1V, it is reduced to 2.7mA. Operation of the high withstand voltage switch is controlled by the above-mentioned VW terminal. When the high withstand voltage switch is turned on at the time of start, charging to the Vcc terminal capacitor is started and continued until the Vcc terminal voltage is clamped to 17V. The high withstand voltage switch is turned off when the LLC converter oscillates and the voltage of the Vw terminal becomes Vcc+1V or more with supply from the primary Vcc winding. Figure 12 is a start/stop sequence drawing when COMPin is Lo. Figure 12. Start/stop sequence drawing in burst mode (MCZ5303SH) 5RE-125294-2 – 14 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 6 Package Dimensions (For Formal Dimensions, Refer to Delivery Specifications) 6.1 SOP16 (MCZ5303SG) 5RE-125294-2 – 15 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 6.2 SOP7J (MCZ5303SH) 5RE-125294-2 – 16 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7 Application Example 7.1 Main Components <Control IC> PFC+LLC Control ID: MCZ5205SE Control IC for Start-up and STBY: MCZ5303SG <Main Switch> MOSFET for PFC: F11F60C3M （CoolMOS） MOSFET for LLC: P6B52HP2 （Hi-Pot MOS） 7.2 Power Supply Specifications Line input voltage: Output in static operation: 90Vrms to 264Vrms (50Hz ,60Hz) Vo=24V Io(typ)=3.0A Io(max)=3.5A Vo=12V Io(typ)=1.0A Io(max)=2.0A Vo=5V Io=100mA Stabilization output by 5V dropper circuit Output in standby state: Standby electrical power: Efficiency: Vo=5V Io=0mA to 100mA Stabilization output by 5V dropper circuit Power factor: 0.983PF (100Vrms) 0.955PF (230Vrms) Burst control method: Output ripple voltage With lower limit (6V) detection 50mW (100Vrms with no load) 89.1% (100Vrms) 91.9% (230Vrms) Load: 24V/3.0A, 12V/1A Load: 24V/3.0A, 12V/1A 7.3 About Control IC MCZ5205SE (IC with PFC+LLC controller mixed) The control IC is an IC with PFC and LLC integrated. It is a package of SOP22 with high functionality. The main features are as follows. <PFC controller part> ■ Boundary-mode PFC controller ■ Overcurrent detection threshold value 0.5V, detection resistance loss is reduced ■ With on width (voltage) control, input line detection is not necessary ■ Equipped with various protection functions • Feedback open/short protection • Overvoltage oscillation stop protection (OVP) • Thermal shutdown (common to LLC part) • Equipped with an output voltage increase protection function for light load <LLC controller part> ■ Vicinity of the gate is simplified with optimization of drive capability ■ MOSFET is driven directly by a 600V high withstand voltage gate driver ■ Efficiency of light load is significantly increased with an active standby function installed ■ Equipped with various protection functions • Overcurrent protection (OCP) • di/dt protection • Timer latch • Insufficient voltage protection • Thermal shutdown (common to PFC part) 5RE-125294-2 – 17 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 MCZ5303SG (self-start circuit + burst control function IC) The standby converter is removed from the conventional configuration of converter dedicated to standby + main converter to realize one converter configuration while maintaining high efficiency. The main features are as follows. ■ Equipped with a drain kick (lossless start circuit) ■ Input power of 50mW or less at the time of no load can be realized with a high-efficiency burst control circuit ■ Equipped with an input main line sensing circuit 7.4 Circuit Block Diagram Figure -1 The main control IC MCZ5205SE controls PFC and LLC, and MCZ5303SG detects AC input and controls the start circuit and burst. LLC outputs 24V and 12V as secondary output and performs feedback control with 24V. At the time of standby, control is performed with ripple detection of 12V output, and standby power is supplied with 5V regulator output. In this circuit example, the load range that can be handled is expanded by detecting the lower limit of the secondary output voltage at the time of standby. When the load is constant at the time of standby, the number of part items can be reduced by deleting the output ripple lower limit detection circuit to control only with detection of the primary side control. 5RE-125294-2 – 18 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7.5 Standby (Burst) Operation PFC is in stop state at the time of standby, and LLC performs burst oscillation with asymmetrical control. This allows low input power to be realized in wide input. Graph 1 and 2 are those of input power at the time of standby operation. The measurement conditions are input voltage of 100Vrms and 230Vrms, and output is 5V, 0 to 150mA. Graph 1 is an enlarged graph with output current up to 20mA, and Graph 2 with up to 150mA. The input power with 100Vrms and no load is 48mW. Input power at the time of standby operation 24V system, 12V system output: No load Input AC voltage: YOKOGAWA WT210 integration mode Io vs. ( Io=0mA-20mA ) Pin 300 Pin [mW] 250 200 150 100 AC100V 50 AC230V 0 0 5 10 15 20 Io [mA] Graph 1 Pin [mW] Io 1800 1600 1400 1200 1000 800 600 400 200 0 vs. Pin ( Io=0mA-150mA ) AC100V AC230V 0 50 100 150 Io [mA] Graph 2 Figures 1 to 10 are burst waveforms when the load is changed from 0 to 100mA in 100Vrms and 230Vrms. The displayed waveforms are LCC switching current waveform, Vc1 voltage waveform of MCZ5205SE, and 12V output voltage waveform from the top. The Vc1 voltage, which is the power supply of the main control IC MCZ5205SE is turned on/off in every burst duration, and start is repeated with soft start in every cycle. When the load increases and the ripple lower limit of 12V output reaches 6V, LCC is restarted and oscillates. When output voltage increases with oscillation start, oscillation is stopped. Burst operation is performed by repeating this operation. The upper limit is detected indirectly with the output voltage of the Vcc winding on the primary side and controlled. With no load, Figures 1 and 6 are in a state when the output does not reach the ripple lower limit 6V. In this case, the oscillation period and the stop period depend on voltage ripple detection of the Vcc winding output on the primary side. 5RE-125294-2 – 19 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 At the timing of oscillation stop, the soft start circuit (SST terminal of MCZ5205SE) is also reset by the KSST terminal. Burst operation waveform Input AC voltage: 100Vrms, 230Vrms Output: 5V system (via dropper) Io=0 to 100mA, no load for 24V system and 12V system output Top: LLC switching current (high side MOSFET) 0.5A/div Middle: KVc1 voltage (Vc1 voltage of MCZ5205SE) 5V/div Bottom: 12V output voltage (dropper input side) 2V/div [100Vrms] Figure 1 200mSec/div [230Vrms] 200mSec/div Figure 6 Io=0mA Cycle: Io=0mA Cycle: 1.28Sec 928mSec Figure 2 Io=6mA Figure 7 Io=6mA Cycle: Cycle: 617mSec Figure 3 594mSec Figure 8 Io=10mA Cycle: Io=10mA Cycle: 389mS Figure 4 366mS Figure 9 Io=50mA Cycle: Io=50mA Cycle: 85mS Figure 5 74mS Figure 10 Io=100mA Cycle: Io=100mA Cycle: 45mS 39mS 5RE-125294-2 – 20 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Oscillation period enlarged waveform at the time of burst Input AC voltage: 100Vrms, 230Vrms Output: 5V system (via dropper) Io=6mA, no load for 24V system and 12V system output 1 : LLC switching current (high side MOSFET) 0.5A/div 2 : KVc1 voltage (Vc1 voltage of MCZ5205SE) 5V/div 3 : 12V output voltage (5V dropper input side) 2V/div 4 : Vcc winding output voltage 5V/div 5 : KSST voltage (SST of MCZ5205SE) 0.5V/div The voltage generated in KSST is generated by charging by MCZ5205SE function. [100Vrms] Figure 11 2mSec/div [230Vrms] 2mSec/div Figure 12 ID: 0.5A/div 111111111111 Io=6mA Io=6mA KVc1: 5V/div Output voltage: 2V/div Control winding output: 5V/div KSST: 0.5V/div Main IC operation: Start SST operation: Stop (Vc1_stop threshold value) Oscillation start threshold value Start SST reset (Soft start) In standby mode, soft start time is switched by the SSC terminal of MCZ5303. At the time of start and in static operation, the switch in the SSC terminal is on. The capacity of the SST terminal is 4.7uF and the soft start time is prolonged. In STBY mode, the switch in the SSC terminal is off and the parallel circuits of C307 and R314, and C214 are in serial connection. This reduces the SST terminal capacity, which shortens the soft start time. The constants of C307 and R311 are adjusted to stably oscillate in the required input range and to decrease the power at the time of standby (Figure 2). Figure -2 5RE-125294-2 – 21 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7.6 Start/Stop/Mode Sequential Operation Operation waveform at the time of start Figures 13 and 12 shows start waveforms. AC is input and the Vcc terminal capacitor C306 is charged from the Vin terminal. At the same time, voltages proportional to R301 to R304, partial voltage in R205, and AC voltage smoothed by C301 are applied to the LSin terminal, which is a terminal for input main line sensing. When this terminal voltage reaches 1.05V, oscillation is started by starting supply from Vcc to KVc1 and Vc1 of MCZ5205SE. As the condition of oscillation start, when Vcc is 10V (UVLO) or more, and the LSin terminal becomes 1.05V or more, output is made to KVc1. In 100Vrms input, the LLC controller is started with detection of LSin, however, with 230Vrms, it is started when Vcc reaches UVLO because LSin is started earlier than Vcc. Input AC voltage: 100Vrms, 230Vrms Output: 5V system (via dropper) Io=6mA, no load for 24V system and 12V system output 1: LLC switching current (high side MOSFET) 1A/div 2: KVc1 voltage (Vc1 voltage of MCZ5205SE) 5V/div 3: Vcc 5V/div 4: LSin 0.5V/div 5: Vcc winding output voltage 5V/div 6: 12V output voltage (5V dropper input side) 2V/div [100Vrms] 500mSec/div ID: 1A/div Figure 13 [230Vrms] 500mSec/div Figure 14 Io=6mA Io=6mA KVc1: 5V/div 10V Vcc: 5V/div 1.05V LSin: 0.5V/div Control winding output: 5V/div Output voltage: 2V/div Main IC operation: Start Main IC operation: Start 5RE-125294-2 – 22 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Operation waveform at the time of stop Figures 15 and 16 shows waveforms at the time of stop. When input main voltage is disconnected, the voltage of the LSin terminal decreases. When the LSin terminal voltage becomes 0.75V or below, output to KVc1 is stopped and MCZ5025SE stops operation. The Vcc voltage once decreases after oscillation stop. Since main bulk voltage still remains in input smoothing capacitor C106, the start circuit operates again when the Vw terminal voltage decreases to 7.5V, and the voltage increases again. After that, it decreases with decrease of the input smoothing capacitor voltage. Input AC voltage: 100Vrms, 230Vrms Output: 5V (via dropper) Io=6mA, no load for 24V and 12V output 1: LLC switching current (high side MOSFET) 1A/div 2: KVc1 voltage (Vc1 voltage of MCZ5205SE) 5V/div 3: Vcc 5V/div 4: LSin 0.5V/div 5: Vcc winding output voltage 5V/div 6: 12V output voltage (5V dropper input side) 2V/div [100Vrms] 500mSec/div [230Vrms] Figure 15 ID: 1A/div 111111111 Figure 16 Io=6mA 500mSec/div Io=6mA KVc1: 5V/div Vcc: 5V/div 0.75V LSin: 0.5V/div 0.75V Control winding output: 5V/div Output voltage: 2V/div Main IC operation: Stop Main IC operation: Stop 5RE-125294-2 – 23 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 Operation waveform at the time of mode switching Figures 17 and 18 are operation waveforms when standby mode is switched to normal oscillation mode. In addition, figures 17 and 18 are waveforms when normal oscillation mode is switched to standby mode. Burst operation is cancelled when standby mode is switched to normal mode. With operation of PFC, the LLC operation is switched from asymmetrical control to symmetrical control. Input AC voltage: 100Vrms, 230Vrms Output: 5V (via dropper) Io=6mA, no load for 24V and 12V output Top: LLC switching current (high side MOSFET) 0.5A/div Middle: KVc1 voltage (Vc1 voltage of MCZ5205SE) 5V/div Bottom: 12V output voltage (dropper input side) 2V/div [100Vrms] 500mSec/div [230Vrms] Figure 17 From STBY to ON Figure 18 From STBY to ON Figure 19 From STBY to ON Figure 20 From STBY to ON 500mSec/div 5RE-125294-2 – 24 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7.7 Static Operation AC-DC efficiency vs output power characteristics Measurement condition Input: 100Vrms, 230VAV Output: 24V system Io=0.1A to 4A, 12V system Io=1.0A fixed, 5V system no load efficiency efficiency [%] 100% 95% 90% 85% AC100V AV230V 80% 75% 70% 0 1 2 3 24V_Io 4 [A] Graph 1 Temperature increase of main part T Measurement condition Input: 100Vrms, 230Vrms Output: 24V system Io=3.0A, 12V system Io=1.0A fixed, 5V system no load D101 L111 T201 Unit: °C Q201 Q111 Input voltage B.D PFC core PFC line surface LLC core LLC line surface 100Vrms 43.9 30.4 35.2 25.6 230Vrms 21.9 19.5 21.9 24.8 PFC MOS LLC MOS 26.4 34 22.7 25.8 32.2 22.5 Operation waveform at the time of max load Input AC voltage: 100Vrms, 230Vrms Output: 24V system Io=3.5V, 12V system Io=1.0A Top: LLC switching current (high side MOSFET) 0.5A/div Bottom: PFC switching current 0.2A/div [100Vrms] Upper row: 2mSec/div [230Vrms] Enlarged lower row: 2uSec/div Figure 21 Figure 22 Max load Frequency around peak Upper row: 2mSec/div Enlarged lower row: 2uSec/div Max load LLC 124kHz LLC 124kHz PFC 86kHz PFC 133kHz 5RE-125294-2 – 25 – Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7.8 Figure of Actual PSU MCZ5303 MCZ5205 LLC FET P6B52HP2 PFC FET F11F60C3M : Installed on the back side of the substrate 5RE-125294-2 – 26 – – 27 – CN101 F101 3.15A C101 0.1u XCAP C102 470p YCAP C104 0.22u XCAP R305 100k R304 1M L101 8.2mH 2A C103 470p YCAP R316 1.2k R312-2 33k R312-1 120k C303 100p R313 10k C105 2.2u 450V TH101 4D2-11 KVc1 STBY KAS out SSC AS in KSST Vcc VW Comp out NC Comp in NC Vin GND LS out LS in IC301 MCZ5303SG ＋ R310 22k R311 100k C301 2.2u16V R303 1M R302 1M R301 1M － D101 D6JBB60V C305 0.1u C306 220u 25V 4-6 ZD301 24V R318 R196 15k 1% R194 270k 1% R193 680k 1% R192 680k 1% R191 680k 1% R113 100 D112 M1FM3 1k 0.25W 12-13 Q301 D1207 R117 22k Nc=6 Np=62 Q302 C4018 10 R317 8-9 1-3 L111 PQ2020 240uH C112 1 R115 15k R195 12k 1% ZC VGP C111 150p 1kV C113 0.47 C114 1000p F201 0.2 Vc 2 (NC) (NC) D201 D1FK60 ±1% 0.1u C214 AS C213 0.01 CSL VS R203 22 R202 10k R201 22 C216 0.1 VB C212 0.01 S GND (NC) R314 33k SST C307 4.7u FBL C217 R205 C215 1000p 9.1k 1500p C123 1 Vc1 IC101 MCZ5205SE (NC) C106 100μ 450V COMP FBP Vsen P GND C115 C116 0.1 4.7 CSP R116 10 R110 0.12 2W R112 10k Q115 2SA2094 R114 4.7 Q111 F11F60C3M D111 SF5K60 ±1% R208 15 ±1% R207 10 VGL VGH 2 1 6 4 PC203 PC123 PC202 PC123 1.8k R206 C308 50V 220u R315 1.5 D113 D1FL20U R211 0.56 1W R210 0.56 1W 0.0068u 1kV C202 Q202 P6B52HP2 Q201 P6B52HP2 4- 6pin 4- 6pin (Ns: All Short) C201 R204 150p 10k 150p 1kV Lp=930uH : Lr=210uH : Np=55T ,Nc=5T Ns1=6T ,Ns2=6T Ns3=3T ,Ns4=3T T201 SWD2834F1 (TAMURA) PC201 PC123 R606 47k R601 4.7k R432 47k R422 3.3k R431 2.2k C601 1u C403 1000u 16V C401 1500u 35V IC401 HA17431H R602 4.7k R603 7.5k 3 Vss C411 R416 0.01u 4.7k SW401 R605 22k R604 33k C602 1u IC601 NJU7223F50 新日本無線 2 Vin 1 Vout IC602 HA17431H Q601 ZD601 2SC4081 2.7V R429 0 D409 SG8SC4M D406 SG20TC10M C211 1000p 14 13 12 11 10 9 R417 3.3k T201 EER28 R415 10k ±1% R414 68k ±1% R413 15k ±1% R412 3.3k ±1% R411 short C603 22u Vo1 24V CN401 Vo2 12V CN402 Vo3 5V CN403 stand-by : off normal：on 8 GND 7 STBY CN404 stand-by：high normal：low 6 GND 5 4 GND 3 2 GND 1 Confidential MCZ5303SG, MCZ5303SH Application Manual Vol. 1.0 7.9 Circuit Diagram 5RE-125294-2