Control IC for Switched-Mode Power Supplies using MOS-Transistors TDA 4605-2 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 P-DIP-8-1 Type Ordering Code Package TDA 4605-2 Q67000-A5020 P-DIP-8-1 The IC TDA 4605-2 controls the MOS-power transistor and performs all necessary regulation and monitoring 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 54 06.94 TDA 4605-2 In the different load ranges the switched-mode power supply (SMPS) behaves as follow: 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 duty factor primarily depends on the 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 55 TDA 4605-2 Pin Definitions and Functions Pin No. Function 1 Information Input Concerning Secondary Voltage. By comparing the regulating voltage - obtained from 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 load, 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-circuit. If a voltage level is reached which is derived from the control voltage at pin 1, the output impulse at pin 5 is terminated. The RC-circuit is used to set the maximum power of the foldback point. 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 for charging or discharging the gate capacity of the power MOSFET-transistor. 6 Supply Voltage Input. From the voltage at pin 6 a stable internal reference voltage VREF and the switching thresholds V6A , V6E , V6 max and V6 min for the supply voltage detector are derived. If V6 > V6E then VREF is switched on. The reference voltage will be switched off if V6 < V6A . In addition the logic is only enable, for V6 min < V6 < V6 max . 7 Input for Soft-Start and Integrator Circuit. The capacitor connected to ground causes a slow increase of the duration of the output pulse during start-up and an integrating response of the control amplifier. 8 Input for the Feedback of the Oscillator. After the oscillations of the SMPS started, every transition of the feedback voltage through zero (falling edge) triggers an output pulse at pin 5. The trigger threshold is at + 50 mV typical. Semiconductor Group 56 TDA 4605-2 Block Diagram Semiconductor Group 57 TDA 4605-2 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. The IC includes an internal circuit to avoid the turn-on of the power transistor T1 because of static charges applied to the transistors gate, during the turn-off state of the IC. The resistor R 13 helps to limit the spectrum of the radiated noise. 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 foldback point. This current added to the current flowing through R 4 and represents an additional charge to C5 in order to reduce the turn-on phase of T1. This is done to stabilize the fold-back point even under higher mains voltages. The control of the switched-mode power supply is done by means of a control voltage applied to 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 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 energy stored in the transformer is transferred into the load the control voltage passes through zero. The IC detects the zero crossing via the series R 9 connected to pin 8. But zero crossings of the control voltage can also be produced by ringing of the transformer after the turn-off of the power transistor for T1 or when a short-circuit is applied to the output of the SMPS. The capacitor C8 is connected to pin 7. During the start-up phase this capacitor assures pulses with a shorter duty cycle in order to keep the operating frequency outside the audible frequency range. On the secondary side of the transformer 3 output voltages are produced using the windings n 2 to n5 , rectified by D4 to D6 and smoothed by C9 to C11 . The resistor R 12 is used as a bleeder resistor, the resistors with implemented fuse R 15 and R 16 protect the rectifies against short circuits in the output circuits, which are designed to supply only small loads. Semiconductor Group 58 TDA 4605-2 Block Diagram Pin 1 In the control and overload amplifier the control voltage applied to this pin is compared with a stable internal reference voltage V. The output signal 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 by means of an external RC-combination in conjunction with the internal functional block primary current / voltage converter. The output of this converter is controlled by the internal functional block "logic" and is also connected to the internal reference voltage V2B . If the voltage V2 exceeds the output voltage of the "control and overload amplifier" the stop comparator will reset the control logic. Consequently the output of pin 5 is switched to low potential. Further inputs for the logic stage are the outputs of the start impulse generator with the stable reference potential VST , the supply voltage monitoring circuit as well as the primary voltage supervision circuit. Pin 3 The primary voltage applied here via a voltage divider is used to stabilize the fold-back point. In addition the logic is disable if - in comparison with the internal reference voltage VV - a mains undervoltage condition is detected. Pin 4 Ground Pin 5 In the output stage the output signals from the "logic" block are converted into driving signals suitable for power MOS-transistors. Pin 6 From the supply voltage V6 applied to this pin internally a stable reference voltage VREF as well as the switching threshold V6A , V6E , V6 max and V6 min , for the supply voltage monitor section of the IC. All other inter reference value (VR , V2B , VST and Vv) are derived for VREF . If V6 > V6E the VREF voltage source is switched on and the source is switched off if V6 < V6A . In addition the logic is enable only if V6 min < V6 < V6 max . Semiconductor Group 59 TDA 4605-2 Pin 7 By means of a resistor pin 7 is connected with the output of the control amplifier. If V1 is approx. equal to the control voltage VR the control amplifier has a proportional integrating control characteristics. The response of the control loop is derived from the capacitor connected to pin 7. If V1 is equal to 0 V the control and overload amplifier is generating a ramp-up function using the capacitor connected to pin 7. Pin 8 The zero crossing detector controlling the logic block recognizes the complete discharge of the energy stored in the transformator core by detecting the zero crossing the positive to negative voltage transition of the voltage at pin 8. This enables the logic for a new pulse. Parasitic oscillations occurring at the end of a pulse cannot lead to a new pulse because of an internal circuit which inhibits the zero detector for a certain dead time tUL after the end of each pulse. Start-Up Behaviour The start-up behaviour of the application circuit (which is given on page 68) is explained in the diagrams on page 70 for a line voltage barely above the lower acceptable lower limit of the mains voltage. After applying the mains voltage at the time t0 the following built up of different voltages can be seen: – 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 R10/R11 The current drawn by the IC in this case is less than 0.8 mA. If V6 reaches the threshold (at the time t1 in the diagram), the IC internal reference voltage is switched on. The supply current drawn by the IC rises to 12 mA max.. The primary current/voltage converter reduces V2 down to V2B and the start pulse generator generates the start pulses from time point t5 to t6 in the diagram. The feedback to pin 8 starts the next pulse and so on. The width of all pulses including the start pulse are controlled by means of the control and overload amplifier. After turn on the IC is generating a signal at pin 7 which slowly ramping up. This signal is used to increase the duration of the output pulses slowly (soft-start function). The max. output pulse width is limited by means of the overload amplifier. If the feedback control voltage V1 is increasing, the overload amplifier allows the generation of output pulses with a wider pulse width. The max. pulse width is reached at time t2 in the diagram (V2 = V2S max). The IC is then operating at the fold-back point. Thereafter the peak values of V2 decrease rapidly, because of the IC control range. The control loop is in a steady, operational state. If the voltage V6 falls below the switch-off threshold V6 min before the foldback point is reached, the attempt to start the SMPS is aborted (pin 5 is switched to low). As the internal circuits of the IC remain switched on, V6 further decreases to V6A . The IC switches off; V6 can rise again (time t4 in the diagram) and new start-up attempt begins at time t1 . Semiconductor Group 60 TDA 4605-2 If the voltage level of the rectified mains voltage is reduced strongly under the influence of the applied load it can happen that V3 is below the voltage level V3A - please refer to the time t3 in the diagram. This is because if an attempt is made to start the SMPS with a too low mains voltage. The internal primary voltage monitor circuit then clamps the voltage V3 to the voltage level V3S until the IC switches off (V6 < V6A). After this a new attempt to start the SMPS will begin at the time t1 in the diagram. Control Range, Overload and No-Load Behaviour After the IC has started, it is operating in the control range. The voltage level at pin 1 is typically 400 mV. The gain of the control circuit consist of two parts: at first a fixed proportional part which is internally fixed and an integrating part which can be set by means of the external capacitor at pin 7. If the load is applied to the output of the SMPS, the control and overload amplifier allows wider pulses (V5 = "H") .The peak voltage value at pin 2 increases up to V2S max . If the secondary load is increased further the overload amplifier begins to reduce the pulse width of the output pulse. This point is referred to as the fold-back point of the power supply. Because of the fact that the IC supply voltage is directly proportional to the secondary voltage, the supply voltage V6 will be reduced according to the behaviour of the control circuit under the overload condition. If V6 falls below the value V6 min , the IC will operate in the burst mode. Because of the large time constant of the startup circuit which is operating with half-wave rectification, only a small output power is transferred into the load during the secondary short-circuit of the SMPS. The overload amplifier reduces the output pulse width down 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 is representing. If no load is applied to the secondary side, the output pulses (V5 = H) become shorter. If the pulse width is reduced be low a certain internal limit the IC will suppress some of the output pulses. If the load is reduced further because of the decreasing duty cycle the measurement error of the rectifier network (R8 , D3, C6 of the application circuit) is increasing and therefore the secondary output voltage will increase, too. If the IC is operating with small pulse width of the output pulse the control amplifier applies an additional current to the control amplifier in order to reduce the output voltage. The value of the additional current depends on the size of the resistors R 5 , R 8 , R 7 . This can be used to compensate the increase of the secondary voltages. Behaviour if the Chip Temperature Exceeds Predefined Limits An integrated protection circuit against over temperature disables the internal logic if the chip temperature is too high. The internal logic automatically checks the chip temperature and restart the SMPS as soon as the temperature decreases to a permissible level. Semiconductor Group 61 TDA 4605-2 Absolute Maximum Ratings TA = – 20 to 85 ˚C; all voltages relatives to Vpp 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 Heat resistance Junction environment Junction package Rth JE Rth JG 100 70 K/W K/W Remarks Supply voltage tp ≤ 50 µs; v ≤ 0.1*) tp ≤ 50 µs; v ≤ 0.1 tp ≤ 50 µs; v ≤ 0.1 Operating Range *) t p= pulse width v= duty circle Semiconductor Group 62 IC "on" measured at pin 4 TDA 4605-2 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 11 mA V6 = V6E 1 Switch-off current I6A1 10 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 Control Range 43 dB 2 VR = d (V2S – V2B)/– dV1 f = 1 kHz 2 Primary Current Simulation Voltage Basic value V2B 0.97 1.00 1.03 V 2 Overload Range and Short-Circuit Operation V2O 2.9 3.0 3.1 V V1 = V1R – 10 mV 2 Peak value in the V2S 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 63 TDA 4605-2 Characteristics (cont’d) TA = 25 ˚C; VS = 10 V Parameter Symbol Limit Values min. typ. Unit Test Condition Test Circuit max. Generally Valid Data (V6 = 10 V) Voltage of the Zero Transition Detector Positive clamping voltage V8P 0.75 V I8 = 1 mA 2 Negative clamping voltage V8N – 0.2 V I8 = – 1 mA 2 Threshold value V8S 40 50 mV 2 Suppression of transformer ringing tUL 4 4.5 5.5 µs 2 Input current – I8 0 4 µA V8 = 0 2.0 1.2 1.8 V V V I5 = – 0.1 A I5 = + 0.1 A I5 = + 0.5 A Push-Pull Output Stage Saturation voltages Pin 5 sourcing Pin 5 sinking Pin 5 sinking VSat0 VSatV VSatV 1.5 1.0 1.4 Rising edge + dV5/dt 20 V/µs 2 Falling edge + dV5/dt 50 V/µs 2 50 µA 1 1 1 Output Slew Rate Reduction of Control Voltage Current to reduce the – I1 control voltage Semiconductor Group 64 V7 = 1.1 V TDA 4605-2 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 < V6 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 5 = V5 min if V3 < V3A V3A 985 1000 1015 mV Over temperature at the given chip the temperature IC will switch V5 to V5 min Tj Voltage at pin 3 if one of the protection functions was triggered; (V3 will be clamped until V6 < V6A) V3Sat Current drain during burst operation I6 Semiconductor Group 150 V2 = 0 V ˚C 0.4 0.8 8 65 1 2 V I3 = 750 µA 1 mA V3 = V2 = 0 V 1 TDA 4605-2 Test Circuit 1 Test Circuit 2 Semiconductor Group 66 TDA 4605-2 Application Circuit Semiconductor Group 67 TDA 4605-2 Diagrams Semiconductor Group 68 TDA 4605-2 Semiconductor Group 69 TDA 4605-2 Start-Up Hysteresis Semiconductor Group 70 TDA 4605-2 Operation in Test Circuit 2 Semiconductor Group 71 TDA 4605-2 Start-Up Current as a Function of the Ambient Temperature Semiconductor Group Overload Point Correction as a Function of the Voltage at Pin 3 72 TDA 4605-2 Recommended Heat Sink by 60 ˚C Ambient Temperature Narrow Range 180 V ... 120 V ~ Narrow Range 90 V ... 270 V ~ Semiconductor Group 73