Control IC for Switched-Mode Power Supplies using MOS-Transistor TDA 4605-3 Bipolar IC Features ● Fold-back characteristics provides overload protection for ● ● ● ● ● ● ● ● external components Burst operation under secondary short-circuit condition implemented Protection against open or a short of the control loop Switch-off if line voltage is too low (undervoltage switch-off) Line voltage depending compensation of fold-back point Soft-start for quiet start-up without noise generated by the transformer Chip-over temperature protection implemented (thermal shutdown) On-chip ringing suppression circuit against parasitic oscillations of the transformer AGC-voltage reduction at low load P-DIP-8-1 Type Ordering Code Package TDA 4605-3 Q67000-A5066 P-DIP-8-1 The IC TDA 4605-3 controls the MOS-power transistor and performs all necessary control and protection functions in free running flyback converters. Because of the fact that a wide load range is achieved, this IC is applicable for consumer as well as industrial power supplies. The serial circuit and primary winding of the flyback transformer are connected in series to the input voltage. During the switch-on period of the transistor, energy is stored in the transformer. During the switch-off period the energy is fed to the load via the secondary winding. By varying switch-on time of the power transistor, the IC controls each portion of energy transferred to the secondary side such that the output voltage remains nearly independent of load variations. The required control information is taken from the input voltage during the switch-on period and from a regulation winding during the switch-off period. A new cycle will start if the transformer has transferred the stored energy completely into the load. Semiconductor Group 74 06.94 TDA 4605-3 In the different load ranges the switched-mode power supply (SMPS) behaves as follows: No load operation The power supply is operating in the burst mode at typical 20 to 40 kHz. The output voltage can be a little bit higher or lower than the nominal value depending of the design of the transformer and the resistors of the control voltage divider. Nominal operation The switching frequency is reduced with increasing load and decreasing AC-voltage. The output voltage is only dependent on the load. Overload point Maximal output power is available at this point of the output characteristic. Overload The energy transferred per operation cycle is limited at the top. Therefore the output voltages declines by secondary overloading. Semiconductor Group 75 TDA 4605-3 Pin Definitions and Functions Pin No. Function 1 Information Input Concerning Secondary Voltage. By comparing the regulating voltage - obtained trom the regulating winding of the transformer - with the internal reference voltage, the output impulse width on pin 5 is adjusted to the load of the secondary side (normal, overload, short-circuit, no load). 2 Information Input Regarding the Primary Current. The primary current rise in the primary winding is simulated at pin 2 as a voltage rise by means of external RC-element. When a voltage level is reached thats derived from the regulating voltage at pin 1, the output impulse at pin 5 is terminated. The RC-element serves to set the maximum power at the overload point set. 3 Input for Primary Voltage Monitoring: In the normal operation V3 is moving between the thresholds V3H and V3L (V3H > V3 > V3L). V3 < V3L: SMPS is switched OFF (line voltage too low). V3 > V3H : Compensation of the overload point regulation (controlled by pin 2) starts at V3H : V3L = 1.7. 4 Ground 5 Output: Push-pull output provides ± 1 A for rapid charge and discharge of the gate capacitance of the power MOS-transistor. 6 Supply Voltage Input: A stable internal reference voltage VREF is derived from the supply voltage also the switching thresholds V6A , V6E , V6 max and V6 min for the supply voltage detector. If V6 > V6E then VREF is switched on and swiched off when V6 < V6A . In addition the logic is only enable for V6 min < V6 < V6 max. 7 Input for Soft-Start. Start-up will begin with short pulses by connecting a capacitor from pin 7 to ground. 8 Input for the Oscillation Feedback. After starting oscillation, every zero transition of the feedback voltage (falling edge) through zero (falling edge) triggers an output pulse at pin 5. The trigger threshold is at + 50 mV typical. Semiconductor Group 76 TDA 4605-3 Block Diagram Semiconductor Group 77 TDA 4605-3 Circuit Description Application Circuit The application circuit shows a flyback converter for video recorders with an output power rating of 70 W. The circuit is designed as a wide-range power supply for AC-line voltages of 180 to 264 V. The AC-input voltage is rectified by the bridge rectifier GR1 and smoothed by C1 . The NTC limits the rush-in current. In the period before the switch-on threshold is reached the IC is suppled via resistor R 1 ; during the start-up phase it uses the energy stored in C2 , under steady state conditions the IC receives its supply voltage from transformer winding n1 via diode D1. The switching transistor T1 is a BUZ 90. The parallel connected capacitor C3 and the inductance of primary winding n 2 determine the system resonance frequency. The R 2-C4-D2 circuitry limits overshoot peaks, and R 3 protects the gate of T1 against static charges. During the conductive phase of the power transistor T1 the current rise in the primary winding depends on the winding inductance and the mains voltage. The network consisting of R 4-C5 is used to create a model of the sawtooth shaped rise of the collector current. The resulting control voltage is fed into pin 2 of the IC. The RC-time constant given by R 4-C5 must be designed that way that driving the transistor core into saturation is avoided. The ratio of the voltage divider R 10/R 11 is fixing a voltage level threshold. Below this threshold the switching power supply shall stop operation because of the low mains voltage. The control voltage present at pin 3 also determines the correction current for the fold-back point. This current added to the current flowing through R 4 and represents an additional charge to C5 in order to reduce the turnon phase of T1. This is done to stabilize the fold-back point even under higher mains voltages. Regulation of the switched-mode power supplies via pin 1. The control voltage of winding n1 during the off period of T1 is rectified by D3, smoothed by C6 and stepped down at an adjustable ratio by R 5 , R 6 and R 7 . The R 8-C7 network suppresses parasitic overshoots (transformer oscillation). The peak voltage at pin 2, and thus the primary peak current, is adjusted by the IC so that the voltage applied across the control winding, and hence the output voltages, are at the desired level. When the transformer has supplied its energy to the load, the control voltage passes through zero. The IC detects the zero crossing via series resistors R 9 connected to pin 8. But zero crossings are also produced by transformer oscillation after T1 has turned off if output is short-circuited. Therefore the IC ignores zero crossings occurring within a specified period of time after T1 turn-off. The capacitor C8 connected to pin 7 causes the power supply to be started with shorter pulses to keep the operating frequency outside the audible range during start-up. On the secondary side, five output voltages are produced across winding n3 to n7 rectified by D4 to D8 and smoothed by C9 to C13 . Resistors R 12 , R 14 and R 19 to R 21 are used as bleeder resistors. Fusable resistors R 15 to R 18 protect the rectifiers against short circuits in the output circuits, which are designed to supply only small loads. Semiconductor Group 78 TDA 4605-3 Block Diagram Pin 1 The regulating voltage forwarded to this pin is compared with a stable internal reference voltage VR in the regulating and overload amplifier. The output of this stage is fed to the stop comparator. If the control voltage is rather small at pin 1 an additional current is added by means of current source which is controlled according the level at pin 7. This additional current is virtually reducing the control voltage present at pin 1. Pin 2 A voltage proportional to the drain current of the switching transistor is generated there by the external RC-combination in conjunction with the primary current transducer. The output of this transducer is controlled by the logic and referenced to the internal stable voltage V2B . If the voltage V2 exceeds the output voltage of the regulations amplifier, the logic is reset by the stop comparator and consequently the output of pin 5 is switched to low potential. Further inputs for the logic stage are the output for the start impulse generator with the stable reference potential VST and the supply voltage motor. Pin 3 The down divided primary voltage applied there stabilizes the overload point. In addition the logic is disabled in the event of low voltage by comparison with the internal stable voltage VV in the primary voltage monitor block. Pin 4 Ground Pin 5 In the output stage the output signals produced by the logic are shifted to a level suitable for MOSpower transistors. Pin 6 From the supply voltage V6 are derived a stable internal references VREF and the switching threshold V6A , V6E , V6 max and V6 min for the supply voltage monitor. All references values (VR , V2B , VST) are derived from VREF . If V6 > VVE , the VREF is switched on and switched off when V6 < V 6A . In addition, the logic is released only for V6 min < V6 < V6 max . Pin 7 The output of the overload amplifier is connected to pin 7. A load on this output causes a reduction in maximal impulse duration. This function can be used to implement a soft start, when pin 7 is connected to ground by a capacitor. Semiconductor Group 79 TDA 4605-3 Pin 8 The zero detector controlling the logic block recognizes the transformer being discharged by positive to negative zero crossing of pin 8 voltage and enables the logic for a new pulse. Parasitic oscillations occurring at the end of a pulse cannot lead to a new pulse (double pulsing), because an internal circuit inhibits the zero detector for a finite time tUL after the end of each pulse. Start-Up Behaviour The start-up behaviour of the application circuit per sheet 88 is represented an sheet 90 for a line voltage barely above the lower acceptable limit time t0 the following voltages built up: – V6 corresponding to the half-wave charge current over R1 – V2 to V2 max (typically 6.6 V) – V3 to the value determined by the divider R 10/R 11 . The current drawn by the IC in this case is less than 1.6 mA. If V6 reaches the threshold V6E (time point t1), the IC switches on the internal reference voltage. The current draw max. rises to 12 mA. The primary current- voltage reproducer regulates V2 down to V2B and the starting impulse generator generates the starting impulses from time point t5 to t6 . The feedback to pin 8 starts the next impulse and so on. All impulses including the starting impulse are controlled in width by regulating voltage of pin 1. When switching on this corresponds to a shortcircuit event, i.e. V1 = 0. Hence the IC starts up with "short-circuit impulses" to assume a width depending on the regulating voltage feedback (the IC operates in the overload range). The IC operates at the overload point. Thereafter the peak values of V2 decrease rapidly, as the starting attempt is aborted (pin 5 is switched to low). As the IC remains switched on, V6 further decreases to V6 . The IC switches off; V6 can rise again (time point t4) and a new start-up attempt begins at time point t1 . If the rectified alternating Iine voltage (primary voltage) collapses during load, V3 can fall below V3A , as is happening at time point t3 (switch-on attempt when voltage is too low). The primary voltage monitor then clamps V3 to V3S until the IC switches off (V6 < V6A). Then a new startup attempt begins at time point t1 . Semiconductor Group 80 TDA 4605-3 Regulation, Overload and No-Load Behaviour When the IC has started up, it is operating in the regulation range. The potential at pin 1 typically is 400 mV. If the output is loaded, the regulation amplifier allows broader impulses (V5 = H). The peak voltage value at pin 2 increases up to V2S max . If the secondary load is further increased, the overload amplifier begins to regulate the pulse width downward. This point is referred to as the overload point of the power supply. As the IC-supply voltage V6 is directly proportional to the secondary voltage, it goes down in accordance with the overload regulation behaviour. If V6 falls below the value V6 min , the IC goes into burst operation. As the time constant of the half-wave charge-up is relatively large, the short-circuit power remains small. The overload amplifier cuts back to the pulse width tpk . This pulse width must remain possible, in order to permit the IC to start-up without problems from the virtual short-circuit, which every switching on with V1 = 0 represents. If the secondary side is unloaded, the loading impulses (V5 = H) become shorter. The frequency increases up to the resonance frequency of the system. If the load is further reduced, the secondary voltages and V6 increase. When V6 = V6 max the logic is blocked. The IC converts to burst operation.This renders the circuit absolutely safe under no-load conditions. Behaviour when Temperature Exceeds Limit An integrated temperature protection disables the logic when the chip temperature becomes too high. The IC automatically interrogates the temperature and starts as soon as the temperature decreases to permissible values. Semiconductor Group 81 TDA 4605-3 Absolute Maximum Ratings TA = – 20 to 85 ˚C Parameter Voltages Currents Symbol pin 1 pin 2 pin 3 pin 5 pin 6 pin 7 V1 V2 V3 V5 V6 V7 pin 1 pin 2 pin 3 pin 4 pin 5 pin 6 pin 7 pin 8 I1 I2 I3 I4 I5 I6 I7 I8 Limit Values min. max. – 0.3 – 0.3 – 0.3 – 0.3 – 0.3 – 0.3 3 V6 20 3 3 3 – 1.5 – 0.5 –5 Unit V V V V V V 1.5 0.5 3 3 mA mA mA A A A mA mA 125 ˚C Junction temperature Tj Storage temperature Tstg – 40 125 ˚C Supply voltage V6 7.5 15.5 V Ambient temperature TA – 20 85 ˚C Remarks Supply voltage tp ≤ 50 µs; v ≤ 0.1*) tp ≤ 50 µs; v ≤ 0.1 tp ≤ 50 µs; v ≤ 0.1 Operating Range IC "on" Heat resistance Junction to environment Rth JE 100 K/W Junction case Rth JC 70 K/W *) t p= pulse width v= duty circle Semiconductor Group 82 measured at pin 4 TDA 4605-3 Characteristics TA = 25 ˚C; VS = 10 V Parameter Symbol Limit Values min. Unit Test Condition Test Circuit V6 = V6E 1 typ. max. 0.6 0.8 mA Start-Up Hysteresis Start-up current drain I6E0 Switch-on voltage V6E 11 12 13 V 1 Switch-off voltage V6A 4.5 5 5.5 V 1 Switch-on current I6E1 7 11 14 mA V6 = V6E 1 Switch-off current I6A1 5 10 13 mA V6 = V6A 1 I2 = 1 mA I3 = 1 mA 1 1 Voltage Clamp (V6 = 10 V, IC switched off) At pin 2 (V6 ≤ V6E) At pin 3 (V6 ≤ V6E) V2 max V3 max 5.6 5.6 6.6 6.6 8 8 V V Control input voltage V1R 390 400 410 mV Voltage gain of the control circuit in the control range – VR 30 43 60 dB 1.00 1.03 V Control Range 2 VR = d (V2S – V2B) / – dV1 f = 1 kHz 2 Primary Current Simulation Voltage Basic value V2B 0.97 2 Overload Range and Short-Circuit Operation V2B 2.9 3.0 3.1 V V1 = V1R – 10 mV 2 V2K Peak value in the range of secondary short-circuit operation 2.2 2.4 2.6 V V1 = 0 V 2 300 500 650 µA V3 = 3.7 V 1 Peak value in the range of secondary overload Fold-Back Point Correction Fold-back point correction current Semiconductor Group – I2 83 TDA 4605-3 Characteristics (cont’d) TA = 25 ˚C; VS = 10 V Parameter Symbol Limit Values min. typ. max. 0.75 0.82 Unit Test Condition Test Circuit V I8 = 1 mA 2 I8 = – 1 mA 2 Generally Valid Data (V6 = 10 V) Voltage of the Zero Transition Detector Positive clamping voltage V8P 0.7 Negative clamping voltage V8N – 0.25 – 0.2 – 0.15 V Threshold value V8S 40 50 76 mV 2 Suppression of transformer ringing tUL 3.0 3.5 3.8 µs 2 Input current – I8 0 4 µA V8 = 0 2 Push-Pull Output Stage Saturation voltages Pin 5 sourcing VSat0 1.5 2.0 V I5 = – 0.1 A 1 Pin 5 sinking VSatV 1.0 1.2 V I5 = + 0.1 A 1 Pin 5 sinking VSatV 1.4 1.8 V I5 = + 0.5 A 1 Rising edge + dV5/dt 70 V/µs 2 Falling edge + dV5/dt 100 V/µs 2 Output Slew Rate Reduction of Control Voltage Current to reduce the – I1 control voltage Semiconductor Group 50 130 84 µA V7 = 1.1 V, V1 = 0.4 V TDA 4605-3 Characteristics (cont’d) TA = 25 ˚C; VS = 10 V Parameter Symbol Limit Values min. typ. max. Unit Test Condition Test Circuit Protection Circuit Undervoltage protection for V6 : voltage at pin 5 = V5 min if V6 < V5 min V6 min 7.0 7.25 7.5 V 2 Undervoltage protection for V6 : voltage at pin 5 = V5 min if V6 > V6 max V6 max 15.5 16 16.5 V 2 Undervoltage protection for VAC : voltage at pin 4 = V5 min if V3 < V3A V3A 985 1000 1015 mV Over temperature at the given chip temperature the IC will switch V5 toV5 min Tj 150 Voltage at pin 3 if one of the protection function was triggered; (V3 will be clamped until V6 < V6A) V3Sat 0.4 Current drain during burst operation 8 Semiconductor Group I6 V2 = 0 V ˚C 0.8 85 1 2 V I3 = 750 µA 1 mA V3 = V2 = 0 V 1 TDA 4605-3 Test Circuit 1 Test Circuit 2 Semiconductor Group 86 TDA 4605-3 Application Circuit Semiconductor Group 87 TDA 4605-3 Diagrams Semiconductor Group 88 TDA 4605-3 Semiconductor Group 89 TDA 4605-3 Start-Up Hysteresis Semiconductor Group 90 TDA 4605-3 Operation in Test Circuit 2 Semiconductor Group 91 TDA 4605-3 Start-Up Current as a Function of the Ambient Temperature Semiconductor Group Overload Point Correction as a Function of the Voltage at Pin 3 92 TDA 4605-3 Recommended Heat Sink by 60 ˚C Ambient Temperature Narrow Range 180 V ... 120 V ~ Narrow Range 90 V ... 270 V ~ Semiconductor Group 93