CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter GENERAL DESCRIPTION FEATURES The CM6807 is the Green-Mode PFC/PWM Combo Patent Filed #5,565,761, #5,747,977, #5,742,151, controller for High Density AC Adapter. For the power #5,804,950, #5,798,635 supply less than 200Watt, it’s input current shaping PFC Both PFC and PWM have the Green Mode to meet blue performance could be very close to the performance of the angel and energy star spec. CM6800 or ML4800 leading edge modulation average 10-Pin SOIC package current topology. PWM pulse skipping for the green mode CM6807 offers the use of smaller, lower cost bulk Use RAC as the Startup resistor which can be > 2000K or higher at IAC pin capacitors, reduces power line loading and stress on the It can use the HV bipolar to start up the chip and it helps switching FETs, and results in a power supply fully green mode. compliant to IEC1000-3-2 specifications. The CM6807 Easy to configure into Boost Follower includes circuits for the implementation of a leading edge, Enable lowest BOM for power supply with PFC input current shaping technique “boost” type PFC and a Internally synchronized PFC and PWM in one IC trailing edge, PWM. Patented slew rate enhanced voltage error amplifier with advanced input current shaping technique The CM6807’s PFC and PWM operate at the same Universal Line Input Voltage frequency, 67.5kHz. A PFC OVP comparator shuts down CCM boost or DCM boost with leading edge modulation the PFC section in the event of a sudden decrease in load. PFC using Input Current Shaping Technique The PFC section also includes peak current limiting for Feedforward IAC pin to do the automatic slope enhanced system reliability. compensation Both PFC and PWM have the Green Mode Functions. PFCOVP, VCCOVP, Precision -1V PFC ILIMIT, PFC Tri-Fault Detect comparator to meet UL1950 When the load is below GMth, Green Mode Threshold, Low supply currents; start-up: 100uA typical, operating PFCOUT is turned off. The GMth can be programmed by current: 2mA typical. the designer. PWM Green Mode will happen when the Synchronized leading PFC and trailing edge modulation PWMCMP (PWM Comparator) Duty Cycle is less than ~ PWM to reduce ripple current in the storage capacitor 6%, in the next cycle, the PWMOUT pulse will be removed between the PFC and PWM sections and to reduce until PWMCMP Duty Cycle is greater than 6%, then the switching noise in the system next cycle, PWMOUT pulse appears. VINOK Comparator to guarantee to enable PWM when PFC reach steady state PWM has a PWMtrifault pin which can sense the PWM High efficiency trailing-edge current mode PWM short and determine the GMth to turn off PFC. Exact 50% PWM maximum duty cycle UVLO, REFOK, and brownout protection Digital PFC and PWM soft start, ~10mS Precision PWM 1.5V current limit for current mode operation PWMtrifault to sense DC to DC short and Turn off PFC at GMth PWMtrifault also can be programmed to do the Thermal Protection 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 1 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter APPLICATIONS PIN CONFIGURATION 10 Pin SSOP (R10) Top View AC Adaptor Open Frame 1 GND PWM OUT 10 2 IAC PFC OUT 9 3 ISENSE VCC 8 4 VEAO PWMTRIFAULT 7 5 VFB V+I 6 PIN DESCRIPTION Operating Voltage Pin No. Symbol Description Min. Typ. Max. Unit 1 GND Ground 2 IAC Feedforward input to do slope compensation and to start up the system. During the start up, IAC is connected to VCC until VCC is greater than 13V. 0 7 V 3 ISENSE Current sense input to the PFC current limit comparator -5 0.7 V 4 VEAO PFC transconductance voltage error amplifier output 0 6 V 5 VFB PFC transconductance voltage error amplifier input 0 3 V 6 V+I PWM current limit comparator input 0 1.5 V 7 PWMTRIFAULT PWMTRIFAULT input; it can sense PWM Short or OVP 0 VCC V 8 VCC Positive supply 10 18 V 9 PFC OUT PFC driver output 0 VCC V 10 PWM OUT PWM driver output 0 VCC V 2.5 ORDERING INFORMATION Initial Accuracy (KHz) Part Number Operation Frequency Min Typ Max Temperature Range Package CM6807GIR* Fpwm = Fpfc = 67.5Khz 60 67 74 -40℃ to 125℃ 10 Pin SSOP(R10) CM6807GIRTR* Fpwm = Fpfc = 67.5Khz 60 67 74 -40℃ to 125℃ 10 Pin SSOP(R10) CM6807XIR* Fpwm = Fpfc = 67.5Khz 60 67 74 -40℃ to 125℃ 10 Pin SSOP(R10) CM6807XIRTR* Fpwm = Fpfc = 67.5Khz 60 67 74 -40℃ to 125℃ 10 Pin SSOP(R10) Note: 1. G : Suffix for Pb Free Product 2. X : Suffix for Halogen Free and PB Free Product 3. TR : Package is Typing Reel 4. Initial Accuracy : TA=25℃ 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 2 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter BLOCK DIAGRAM IAC . R1B 1 1 3 . R1A 2 2 4 2 . IAC R1C . - ISENSE 2 .VEAO . VCC UVB 8 PFC CMP VCC - 1 + . + V To Ramp VFB 5 - Q R . . 2.5V S GMV . R Q UVB + VCC OVP 9 VREFDK FAULT PFCOUT + 17.9V 16.4V . - UVLO VCC - . BROKENWIRE PFCCLK . 0.5V . + PWMCLK . . PFC CLK PWM CLK fpfc=70KHz PFC OVP + 2.75V 2.5V . - VIN-OK VFB - PFC ILIMIT . PWMTRIFAULT VCC-0.7V - 0.75V Q R1 . R2 UVB Q 10 VREFDK + PWMOUT + -1V S + 2.45V PWM SHORT GREENPWM - 7 + (VCC-1.4V)/2 - V=17uA PWMFAULT GREENMODE 10mS GND PWMCLK 1.5V . . GND SS - PWM CMP 1 GND . + PROTECTED BY PATENT SOFT START 6 V+I ABSOLUTE MAXIMUM RATINGS Absolute Maximum ratings are those values beyond which the device could be permanently damaged. Parameter VCC MAX IAC (before start up) IAC (after start up) ISENSE Voltage PFC OUT PWM OUT VEAO PWMTrifault Voltage on Any Other Pin Peak PFC OUT Current, Source or Sink Peak PWM OUT Current, Source or Sink PFC OUT, PWM OUT Energy Per Cycle Min. GND-0.3 GND-0.3 -5 GND – 0.3 GND – 0.3 0 GND – 0.3 GND-0.3 Junction Temperature Max. 20 VCC + 0.3 7.0 0.7 VCC + 0.3 VCC + 0.3 6.3 VCC + 0.3 VCC + 0.3 0.5 0.5 1.5 150 Units V V V V V V V V V A A μJ ℃ Storage Temperature Range -65 150 ℃ Operating Temperature Range -40 125 ℃ Lead Temperature (Soldering, 10 sec) 260 ℃ Thermal Resistance (θJA) 80 ℃/W 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 3 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter ELECTRICAL CHARACTERISTICS Unless otherwise stated, these specifications apply Vcc=+14V, TA=Operating Temperature Range (Note 1) Symbol Parameter Test Conditions CM6807 Min. Typ. Unit Max. Voltage Error Amplifier (gmv) Input Voltage Range 0 Transconductance VNONINV = VINV, VEAO = 3.75V Feedback Reference Voltage Input Bias Current 30 65 90 μmho 2.5 2.56 V -0.5 -1.0 μA 5.8 Output Low Voltage Sink Current VFB = 3V, VEAO = 6V Source Current VFB = 1.5V, VEAO = 1.5V V 2.43 Note 2 Output High Voltage 5 6.0 V 0.1 0.4 V -35 -20 μA 30 40 μA 50 60 dB 11V < VCC < 16.5V 50 60 dB IAC ISENSE = 0V, TA=25℃ 35 40 45 K Threshold Voltage 17.3 17.9 18.5 V Hysteresis 1.3 1.5 1.75 V 2.64 2.77 2.85 V 300 mV -1 -0.9 V 150 300 ns 2.30 2.45 2.55 V 1.65 1.75 1.85 V Open Loop Gain Power Supply Rejection Ratio Input Impedance VCC OVP Comparator PFC OVP Comparator Threshold Voltage Hysteresis 230 PFC ILIMIT Comparator Threshold Voltage -1.1 Delay to Output VIN OK Comparator Threshold Voltage Hysteresis PWM Digital Soft Start Digital Soft Start Timer (Note 2) Right After Start Up 10 ms V + I Comparator Threshold Voltage Normal operation without soft start 1.38 1.5 1.62 V 150 300 Ns 100 150 200 mV 2.70 2.77 2.85 V 2 4 ms 0.5 0.6 V VCC-0.1 V Delay to Output (Note 2) Threshold Voltage During soft start condition PFC Tri-Fault Detect Comparator Fault Detect HIGH Time to Fault Detect HIGH VFB=VFAULT DETECT LOW to VFB = OPEN, 470pF from VFB to GND Fault Detect LOW 0.4 PWM Tri-Fault Detect Comparator DC to DC Short Sweep PWMtrifault Green Mode Threshold Sweep PWMtrifault VCC-0.9 -400mV+ (VCC-1. 4)/2 2010/04/20 Rev1.0 Champion Microelectronic Corporation (VCC-1.4) /2 +400mV +(VCC-1 .4)/2 Page 4 V CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter ELECTRICAL CHARACTERISTICS (Conti.)Unless otherwise stated, these specifications apply Vcc=+14V, TA=Operating Temperature Range (Note 1) CM6807 Symbol Parameter Test Conditions Unit Min. Typ. Max. Oscillator Voltage Stability 10V < VCC < 15V Temperature Stability Total Variation Line, Temp PFC Dead Time (Note 2) 1 % 2 % 60 67 74.5 kHz 0.3 0.45 0.65 us 1 % PFC Minimum Duty Cycle IAC=100uA,VFB=2.55V, ISENSE = 0V Maximum Duty Cycle IAC=0uA,VFB=2.0V, ISENSE = 0V 90 Output Low Rdson Output Low Voltage 22.5 ohm IOUT = -100mA 0.8 1.5 V IOUT = -10mA, VCC = 8V 0.4 0.8 V 30 45 ohm IOUT = 100mA, VCC = 15V Rise/Fall Time (Note 2) % 15 Output High Rdson Output High Voltage 95 13.5 CL = 1000pF 14.2 V 50 ns PWM Duty Cycle Range IC 0-46 0-50 % 15 22.5 ohm IOUT = -100mA 0.8 1.5 V IOUT = -10mA, VCC = 8V 0.7 1.5 V 30 45 ohm Output Low Rdson Output Low Voltage Output High Rdson Output High Voltage IOUT = 100mA, VCC = 15V Rise/Fall Time (Note 2) 13.5 CL = 1000pF 14.2 V 50 ns Supply Start-Up Current VCC = 11V, CL = 0 100 150 uA Operating Current VCC = 15V, CL = 0 2 4.0 mA Undervoltage Lockout Threshold 12.35 13 13.65 V Undervoltage Lockout Hysteresis 2.7 3 3.3 V Note 1: Limits are guaranteed by 100% testing, sampling, or correlation with worst-case test conditions. Note 2: Guaranteed by design, not 100% production test. 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 5 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter TYPICAL PERFORMANCE CHARACTERISTIC 127 Transconductance (umho) 120 113 106 99 92 85 78 71 64 57 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 VFB (V) Voltage Error Amplifier (gmv) Transconductance 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 6 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter Functional Description The CM6807 consists of an ICST (Input Current Shaping Technique), CCM (Continuous Conduction Mode) or DCM (Discontinuous Conduction Mode) boost PFC (Power Factor Correction) front end and a synchronized PWM (Pulse Width Modulator) back end. The CM6807 is designed to replace FAN6803 (8 pin SOP package), which is the second generation of the ML4803 with 8 pin package. It is distinguished from earlier combo controllers by its low count, innovative input current shaping technique, and very low start-up and operating currents. The PWM section is dedicated to peak current mode operation. It uses conventional trailing-edge modulation, while the PFC uses leading-edge modulation. This patented Leading Edge/Trailing Edge (LETE) modulation technique helps to minimize ripple current in the PFC DC buss capacitor. The main improvements from ML4803 are: 1. Add Green Mode Functions for both PFC and PWM 2. Remove the one pin error amplifier and add back the slew rate enhancement gmv, which is using voltage input instead of current input. This transconductance amplifier will increase the transient response 5 to 10 times from the conventional OP 3. VFB PFC OVP comparator 4. PFC Tri-Fault Detect for UL1950 compliance and enhanced safety 5. A feedforward signal from IAC pin is added to do the automatic slope compensation. This increases the signal to noise ratio during the light load; therefore, THD is improved at light load and high input line voltage. 6. CM6807 does not require the bleed resistor and it uses the more than 800k ohm resistor between IAC pin and rectified line voltage to feed the initial current before the chip wakes up. 7. VINOK comparator is added to guaranteed PWM cannot turn on until VFB reaches 2.5V in which PFC boost output is about steady state, typical 380V. 8. A 10mS digital PWM soft start circuit is added 9. 10 pin SOP package 10. No internal Zener but with VCCOVP comparator The CM6807 operates both PFC and PWM sections at 67kHz. This allows the use of smaller PWM magnetic and output filter components, while minimizing switching losses in the PFC stage. Several protection features have been built into the CM6807. These include soft-start, redundant PFC overvoltage protection, PFC Tri-Fault Detect, VINOK, peak current limiting, duty cycle limiting, under-voltage lockout, reference ok comparator and VCCOVP. 2010/04/20 Rev1.0 Detailed Pin Descriptions IAC (Pin 2) Typically, it has a feedforward resistor, RAC, 2KK~10KK ohm resistor connected between this pin and rectified line input voltage. This pin serves 2 purposes: 1.) During the startup condition, it supplies the startup current; therefore, the system does not requires additional bleed resistor to start up the chip. 2.) The current of RAC will program the automatic slope compensation for the system. This feedforward signal can increase the signal to noise ratio for the light load condition or the high input line voltage condition. Optional Resistor between IAC and VCC: This resistor is about 100K ohm, it can improve the THD of the input current at high line and light load ISENSE (Pin 3) This pin ties to a resistor which senses the PFC input current. This signal should be negative with respect to the IC ground. It internally feeds the pulse-by-pulse current limit comparator and the current sense feedback signal. The ILIMIT trip level is –1V. The ISENSE feedback is internally multiplied by a gain of four and compared against the internal programmed ramp to set the PFC duty cycle. The intersection of the boost inductor current downslope with the internal programming ramp determines the boost off-time. It requires a RC filter between ISENSE and PFC boost sensing resistor. VEAO (Pin 4) This is the PFC slew rate enhanced transconductance amplifier output which needs to connected with a compensation network Ground. VFB (Pin 5) Besides this is the PFC slew rate enhanced transconductance input, it also tie to a couple of protection comparators, PFCOVP, and PFC Tri-Fault Detect V + I (Pin 6) This pin is tied to the primary side PWM current sense resistor or transformer. It provides the internal pulse-by-pulse current limit for the PWM stage (which occurs at 1.5V) and the peak current mode feedback path for the current mode control of the PWM stage. Besides current information, the optocouple also goes into V + I pin. Therefore, it is the SUM Amplifier input. Soft Start can be triggered by the following conditions: 1.) During the startup (VCC is less than 10V) 2.) DC to DC short (PWMtrifault is greater thanVCC-0.7V) Champion Microelectronic Corporation Page 7 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter PWMtrifault (Pin 7) This pin is to monitor the DC to DC faults. PWMtrifault monitors the voltage which is translated by the photocouple output current. When the output is short, photocouple and TL431 will not draw any current and PWMtrifault will go toward VCC. When PWMtrifault is above VCC-0.7V, the soft start will be triggered and PWMOUT is turned off. When the load is lighter, the TL431 will increase the Photocouple current. When PWMtrifault is below (VCC-1.4)/2, which means it is below GMth, Green Mode Threshold. PFCOUT will be turned off due the load is below GMth. The GMth can be programmed by the user. Typical the GMth is 20% of the full load. VCC (Pin 8) VCC is the power input connection to the IC. The VCC start-up current is 100uA. The no-load ICC current is 2mA. VCC quiescent current will include both the IC biasing currents and the PFC and PWM output currents. Given the operating frequency and the MOSFET gate charge (Qg), average PFC and PWM output currents can be calculated as IOUT = Qg x F. The average magnetizing current required for any gate drive transformers must also be included. The VCC pin is also assumed to be proportional to the PFC output voltage. Internally it is tied to the VCC OVP comparator (17.9V) providing redundant high-speed over-voltage protection (OVP) of the PFC stage. VCC also ties internally to the UVLO circuitry and VREFOK comparator, enabling the IC at 13V and disabling it at 10V. VCC must be bypassed with a high quality ceramic bypass capacitor placed as close as possible to the IC. Good bypassing is critical to the proper operation of the CM6807. VCC is typically produced by an additional winding off the boost inductor or PFC Choke, providing a voltage that is proportional to the PFC output voltage. Since the VCC OVP max voltage is 17.9V, an internal shunt limits VCC overvoltage to an acceptable value. An external clamp, such as shown in Figure 1, is desirable but not necessary. VCC PFCOUT (Pin 9) and PWM OUT (Pin 10) PFC OUT and PWM OUT are the high-current power driver capable of directly driving the gate of a power MOSFET with peak currents up to -1A and +0.5A. Both outputs are actively held low when VCC is below the UVLO threshold level which is 15V or VREFOK comparator is low. Power Factor Correction Power factor correction makes a nonlinear load look like a resistive load to the AC line. For a resistor, the current drawn from the line is in phase with and proportional to the line voltage, so the power factor is unity (one). A common class of nonlinear load is the input of most power supplies, which use a bridge rectifier and capacitive input filter fed from the line. The peak-charging effect, which occurs on the input filter capacitor in these supplies, causes brief high-amplitude pulses of current to flow from the power line, rather than a sinusoidal current in phase with the line voltage. Such supplies present a power factor to the line of less than one (i.e. they cause significant current harmonics of the power line frequency to appear at their input). If the input current drawn by such a supply (or any other nonlinear load) can be made to follow the input voltage in instantaneous amplitude, it will appear resistive to the AC line and a unity power factor will be achieved. To hold the input current draw of a device drawing power from the AC line in phase with and proportional to the input voltage, a way must be found to prevent that device from loading the line except in proportion to the instantaneous line voltage. The PFC section of the CM6807 uses a boost-mode DC-DC converter to accomplish this. The input to the converter is the full wave rectified AC line voltage. No bulk filtering is applied following the bridge rectifier, so the input voltage to the boost converter ranges (at twice line frequency) from zero volts to the peak value of the AC input and back to zero. By forcing the boost converter to meet two simultaneous conditions, it is possible to ensure that the current draws from the power line matches the instantaneous line voltage. One of these conditions is that the output voltage of the boost converter must be set higher than the peak value of the line voltage. A commonly used value is 385VFB, to allow for a high line of 270VACrms. The other condition is that the current that the converter is allowed to draw from the line at any given instant must be proportional to the line voltage. 1N5250B GND Figure 1. Optional VCC Clam p This limits the maximum VCC that can be applied to the IC while allowing a VCC which is high enough to trip the VCC OVP. An RC filter at VCC is required between boost trap winding and VCC. 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 8 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter PFC Control: Leading Edge Modulation with Input Current Shaping Technique (I.C.S.T.) The only differences between the conventional PFC control topology and I.C.S.T. is: the current loop of the conventional control method is a close loop method and it requires a detail understanding about the system loop gain to design. With I.C.S.T., since the current loop is an open loop, it is very straightforward to implement it. The end result of the any PFC system, the power supply is like a pure resistor at low frequency. Therefore, current is in phase with voltage. In the conventional control, it forces the input current to follow the input voltage. In CM6807, the chip thinks if a boost converter needs to behave like a low frequency resistor, what the duty cycle should be. The following equations is CM6807 try to achieve: Re = Vin (1) I in I l = I in (2) Equation 2 means: average boost inductor current equals to input current. ∴Vin × I l ≈ Vout × I d (3) Therefore, input instantaneous power is about to equal to the output instantaneous power. For steady state and for the each phase angle, boost converter DC equation at continuous conduction mode is: Vout Vin = 1 Therefore, equation (6) becomes: Id = I d × toff Tsw = I d × d ' = I d × (1 − d ) (7) Combine equation (7) and equation (5), and we get: Id × d ' = ∴ Id = ∴ Id = ( d ' ) 2 × Vout d ' × Vout Re Re (8) Vout toff × Re Tsw From this simple equation (8), we implement the PFC control section of the CM6807. Leading/Trailing Modulation Conventional Pulse Width Modulation (PWM) techniques employ trailing edge modulation in which the switch will turn ON right after the trailing edge of the system clock. The error amplifier output is then compared with the modulating ramp. When the modulating ramp reaches the level of the error amplifier output voltage, the switch will be turned OFF. When the switch is ON, the inductor current will ramp up. The effective duty cycle of the trailing edge modulation is determined during the ON time of the switch. Figure 2 shows a typical trailing edge control scheme. In case of leading edge modulation, the switch is turned OFF right at the leading edge of the system clock. When the modulating ramp reaches the level of the error amplifier output voltage, the switch will be turned ON. The effective duty-cycle of the leading edge modulation is determined during OFF time of the switch. Figure 3 shows a leading edge control scheme. (4) (1 − d ) Rearrange above equations, (1), (2),(3), and (4) in term of Vout and d, boost converter duty cycle and we can get average boost diode current equation (5): Id = (1 − d ) 2 × Vout Re (5) Also, the average diode current can be expressed as: Id = 1 Tsw ∫ Toff 0 I d (t ) ⋅ dt (6) If the value of the boost inductor is large enough, we can assume I d (t ) ~ I d . It means during each cycle or we can say during the sampling, the diode current is a constant. 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 9 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter One of the advantages of this control technique is that it required only one system clock. Switch 1(SW1) turns OFF and switch 2 (SW2) turns ON at the same instant to minimize the momentary “no-load” period, thus lowering ripple voltage generated by the switching action. With such synchronized switching, the ripple voltage of the first stage is reduced. Calculation and evaluation have shown that the 120Hz component of the PFC’s output ripple voltage can be reduced by as much as 30% using this method, substantially reducing dissipation in the high-voltage PFC capacitor. Typical Applications PFC Section: PFC Voltage Loop Error Amp, VEAO The ML4803 utilizes an one pin voltage error amplifier in the PFC section (VEAO). In the CM6807, it is using the slew rate enhanced transconductance amplifier, which is the same as error amplifier in the CM6800. The unique transconductance profile can speed up the conventional transient response by 10 times. The internal reference of the VEAO is 2.5V. The input of the VEAO is VFB pin. PFC Voltage Loop Compensation The voltage-loop bandwidth must be set to less than 120Hz to limit the amount of line current harmonic distortion. A typical crossover frequency is 30Hz. The Voltage Loop Gain (S) ΔVOUT ΔVFB ΔVEAO * * ΔVEAO ΔVOUT ΔVFB PIN * 2.5V ≈ * GMV * ZCV 2 VOUTDC * ΔVEAO * S * CDC = 2010/04/20 Rev1.0 ZCV: Compensation Net Work for the Voltage Loop GMv: Transconductance of VEAO PIN: Average PFC Input Power VOUTDC: PFC Boost Output Voltage; typical designed value is 380V. CDC: PFC Boost Output Capacitor ΔVEAO: This is the necessary change of the VEAO to deliver the designed average input power. The average value is 6V-3V=3V since when the input line voltage increases, the delta VEAO will be reduced to deliver the same to the output. To over compensate, we choose the delta VEAO is 3V. Internal Voltage Ramp The internal ramp current source is programmed by way of VEAO pin voltage. When VEAO increases the ramp current source is also increase. This current source is used to develop the internal ramp by charging the internal 30pF +12/ -10% capacitor. The frequency of the internal programming ramp is set internally to 67kHz. Design PFC ISENSE Filtering ISENSE Filter, the RC filter between Rs and ISENSE: There are 2 purposes to add a filter at ISENSE pin: 1.) Protection: During start up or inrush current conditions, it will have a large voltage cross Rs, which is the sensing resistor of the PFC boost converter. It requires the ISENSE Filter to attenuate the energy. 2.) Reduce L, the Boost Inductor: The ISENSE Filter also can reduce the Boost Inductor value since the ISENSE Filter behaves like an integrator before going ISENSE which is the input of the current error amplifier, IEAO. Champion Microelectronic Corporation Page 10 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter The ISENSE Filter is a RC filter. The resistor value of the ISENSE Filter is between 100 ohm and 50 ohm. By selecting RFILTER equal to 50 ohm will keep the offset of the IEAO less than 5mV. Usually, we design the pole of ISENSE Filter at fpfc/6, one sixth of the PFC switching frequency. Therefore, the boost inductor can be reduced 6 times without disturbing the stability. Therefore, the capacitor of the ISENSE Filter, CFILTER, will be around 283nF. IAC, RAC, Automatic Slope Compensation, DCM at high line and light load, and Startup current There are 4 purposes for IAC pin: 1.) For the leading edge modulation, when the duty cycle is less than 50%, it requires the similar slope compensation, as the duty cycle of the trailing edge modulation is greater than 50%. In the CM6807, it is a relatively easy thing to design. Use an more than 2KK ohm resistor, RAC to connect IAC pin and the rectified line voltage. It will do the automatic slope compensation. If the input boost inductor is too small, the RAC may need to be reduced more. 2.) During the startup period, Rac also provides the initial startup current, 100uA;therefore, the bleed resistor is not needed. 3.) Since IAC pin with RAC behaves as a feedforward signal, it also enhances the signal to noise ratio and the THD of the input current. 4.) It also will try to keep the maximum input power to be constant. However, the maximum input power will still go up when the input line voltage goes up. Start Up of the system, UVLO, VREFOK and Soft Start During the Start-up period, RAC resistor will provide the start up current~100uA from the rectified line voltage to IAC pin. Inside of CM6807 during the start-up period, IAC is connected to VCC until the VCC reaches UVLO voltage which is 13V (UVB) and internal reference voltage is stable, it will disconnect itself from VCC. During the Start up, the soft start function is triggered and the duration of the soft start will last around 10mS. PFC section wakes up after Start up period After Start up period, PFC section will softly start since VEAO is zero before the start-up period. Since VEAO is a slew rate enhanced transconductance amplifier (see figure 3), VEAO has a high impedance output like a current source and it will slowly charge the compensation net work which needs to be designed by using the voltage loop gain equation. Before PFC boost output reaches its design voltage, it is around 380V and VFB reaches 2.5V, PWM section is off. 2010/04/20 Rev1.0 PWM section wakes up after PFC reaches steady state PWM section is off all the time before PFC VFB reaches 2.45V. Then internal 10mS digital PWM soft start circuit slowly ramps up the soft-start voltage. PFC OVP Comparator PFC OVP Comparator sense VFB pin which is the same the voltage loop input. The good thing is the compensation network is connected to VEAO. The PFC OVP function is a relative fast OVP. It is not like the conventional error amplifier which is an operational amplifier and it requires a local feedback and it make the OVP action becomes very slow. The threshold of the PFC OVP is 2.5V+10% =2.75V with 250mV hysteresis. PFC Tri-Fault Detect Comparator To improve power supply reliability, reduce system component count, and simplify compliance to UL1950 safety standards, the CM6807 includes PFC Tri-Fault Detect. This feature monitors VFB (Pin 5) for certain PFC fault conditions. In case of a feedback path failure, the output of the PFC could go out of safe operating limits. With such a failure, VFB will go outside of its normal operating area. Should VFB go too low, too high, or open, PFC Tri-Fault Detect senses the error and terminates the PFC output drive. PFC Tri-Fault detect is an entirely internal circuit. It requires no external components to serve its protective function. VCC OVP and generate VCC For the CM6807 system, if VCC is generated from a source that is proportional to the PFC output voltage and once that source reaches 17.9V, PFCOUT, PFC driver will be off. The VCC OVP resets once the VCC discharges below 16.4V, PFC output driver is enabled. It serves as redundant PFC OVP function. Typically, there is a bootstrap winding off the boost inductor. The VCC OVP comparator senses when this voltage exceeds 17.9V, and terminates the PFC output drive. Once the VCC rail has decreased to below 16.4V the PFC output drive be enabled. Given that 16V on VCC corresponds to 380V on the PFC output, 17.9V on VCC corresponds to an OVP level of 460V. It is a necessary to put RC filter between bootstrap winding and VCC. For VCC=15V, it is sufficient to drive either a power MOSFET or a IGBT. Champion Microelectronic Corporation Page 11 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter UVLO The UVLO threshold is 13V providing 3V hysteresis. PFCOUT and PWMOUT Both PFCOUT and PWMOUT are CMOS drivers. They both have adaptive anti-shoot through to reduce the switching loss. Its pull-up is a 30ohm PMOS driver and its pull-down is a 15ohm NMOS driver. It can source 0.5A and sink 1A if the VCC is above 15V. PWM Section Green Mode CM6807 has the green mode function to improve the light load efficiency. PWM Green Mode will happen when the PWMCMP (PWM Comparator) Duty Cycle is less than ~ 6%, in the next cycle, the PWMOUT pulse will be removed until PWMCMP Duty Cycle is greater than 6%, then the next cycle, PWMOUT pulse appears. In other words, during the green mode, PWM switching frequency will reduce to improve the efficiency. With the proper external components, CM6807 can easily meet energy star and blue angel specification. After 10mS digital soft start, CM6807’s PWM is operating as a typical current mode. It requires a secondary feedback, typically, it is configured with CM431, and photo couple. At normal operation, the threshold voltage of the V + I pin is 1.5V. When the V + I is greater than 1.5V, PWM output driver will turn off the PWM Power MOSfet. When the Soft Start is triggered, the V+I threshold is around 150mV. Soft Start Can be triggered by the following conditions: 1.) During the startup (VCC is less than 10V) 2.) DC to DC short (PWMtrifault is greater than VCC-0.7V) During above 2 conditions, the V + I threshold is around 150mV until the conditions have been removed. After above 2 conditions have been removed, the internal Soft Start D to A will ramp up the voltage from ~150mV to 2V. Each Soft Start Ramp can last around 10mS. Short (PWMtrifault) When PWMtrifault is greater VCC-0.7V, PWMOUT will be turned off. It can be used to detected the following 2 things: 1.) Short Protection 2.) Thermal Shut Down To achieve above item, it requires a negative temperature coefficient Resistor. The following figure shows the typical circuit for PWMtrifault and V + I pins. Turn off PFC(PWMtrifault) Since PWM Section is different from CM6800 family, it needs the emitter of the photo couple to connected with V + I instead of the collector. The PWM current information also goes into V + I. Usually, the PWM current information requires a RC filter before goes into the V + I. Therefore, V + I actually is a summing node from voltage information which is from photo couple and CM431 and current information which is from one end of PWM sensing resistor and the signal goes through a single pole, RC filter then enter the V + I pin. This RC filter at V+I also serves several functions: 1.) It protects IC. 2.) It provides level shift for voltage information. 3.) It filters the switching noise from current information. 2010/04/20 Rev1.0 When PWMtrifault is less than (VCC-1.4V)/2, CM6807 will turn off PFC. Usually; it means load has been reduced to a level, which is the level of the Green Mode threshold. Usually, we set the Green Mode threshold around 20% of the full load. After turning off PFC, the efficiency will be increased due to the input voltage is higher and less switching events. Component Reduction Components associated with the VRMS and IEAO pins of a typical PFC controller such as the CM6800 have been eliminated. The PFC power limit and bandwidth does vary with line voltage. Champion Microelectronic Corporation Page 12 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter VCC PWMSHORTCMP PWMSHORT 2 VCC-0.7 RPWMTrif ault1 +380V 1K + PWMTRIFAULT RPEMTrif ault2 Diode 1 2 2 1 33K 1 1N4148 TX1 - TURN OFF PFC + (VCC-1.4)/2 17uA 4 1 3 2 PHOTOCouple PC1 Secondary Side V GND 2 GREENMODE MPWM1 1 PWMCMP . - 1 RV+I 500 SS 1.5V CV+I 0.15nF I 2 3 V+I + PWMON PWMout Q9 2 RPWMRsense 0.390 1 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 13 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter APPLICATION CIRCUIT 1 1 2 2 2 1 2 2 2 2222 3 1 2 2 0 2 HS 1 2 1 R27 0.0045 B001 3.5*9*1.3 D13 1N4935 4.7K 1 1 1 1 ZD6 C28 47uF/25V 2 NC R51 NC NC 0.1UF 1 1 R37 1 1 2 NC PWM Trifault 2 1 2 2 C20 R52 C31 +24V Q13 NC 2 ZD5 Z.D 15V 3 3 C17 R33 100uF NC 2 1 NC 2 R28 1 1 1 1 3 1 R30 C16 0.1UF GND J1 0.39 2W 3 D12 R29 1 47K 2 21N4148 1 Q10 2 1 C11 680uF/35V 2 3 1 2 1 21 2 1 C34 102pF 2 1 3 2 1 FLY1 2 2 1 C10 680uF/35V 2 1 2 2 2 NC 1 R24 R25 47K 1 Q14 1 4T NC NC 220K 105PF 1M R351 680K 3 1 2 1 1 11 R341 C32 R54 R35 R34 HSA2 1 Q9 SPP20N60C3 68K R31 1 100uF/400V 2 1 2 1 1 C191 ZD4 Z.D 27V C19 2 1 1 Z.D 27V 105PF 1M 2N7002 11 3 2N7002 Q111 3 ZD4 1 1 1 +24V J3 Q11 2 3 Iac GND J2 7 C7 3.5*6*1.2 2 R008-1 1 RT2 NC +24V 4 2 1 1 HS VCC Boost follower PR2007 B002 3 16T D8 R21 10 R55 NC NC 47K 2 2 2 1 2 C30 D10 D11 1N4001 1N4001 6 V+I 1 1 2 1 R48 1 2 21 VFB 2 D9 R19 1N4148 2 0 21 1 D15(20A/150V) DIODE SCHOTTKY 2 12 2 5 2.2M 7 VEAO PwmTrif ault 1 R18 HSA1 VCC 8 VCC FCP11N60 1 1 470PF 0.1UF(104) 470nF(474) 1 2 684 C26 C27 C13 0.27 2W 1 R26 2 2 C15 Isense 21 1 1 2 220K 1 4 2 R23 9 PFC OUT 2 1 1 1 3 IAC 6T FLY2 R14 2.2M 1 2 222 2 Q7 R17 10 10 C52 D6 1N4148 2 1 3 750 U1 CM6807 1 GND PWM OUT 2 68k VCC Iac 1 Radd 2 NC 1 R22 2 47 1 2 2 2 1 R131 0.47UF/450V FG J3 R16 0 1 2 1N4148 D7 1 R531 2 1 47K 16T 1 2 1 2 2 3 GMBTA44 33k 2 2 C5 Q5 1 1M 1 R13 TA1 5 R8 1000PF 22k 2 1M C3 R53 1 R15 2 1 1 1 2 2 R151 2 PIN 1 1 J1 R11 2.7M 3 Pot-C3319/PC44 B001 2 3.5*9*1.3 22k 4.7M R111 2.7M 1 RT1 2.5 1 R5 R7 2 2 3 3 4 2 2 1 1 1.5M 2 2 1 1 D2 MBR860 + 1 C1 0.22UF R6 D16(20A/150V) DIODE SCHOTTKY 2 L5 MPP/1.2mH 4 - 1 2 1 1 1 1.5M 1 D1 KBP206G 2 FG PIN FG1 R3 3 N1N PIN 1 4 L1 L PIN L2 FR16*12*8 2 L3 OR12*6*4 F1 3.15A,250V 1 2 1 3K R41 10K NC 2 1 1 0.1UF2 1 2 22K 1UF 3 U2 R44 5 220K 2 1 0.1UF C25 R46 1UF R49 R47 NC 4.7K R50 11K 2010/04/20 Rev1.0 Champion Microelectronic Corporation 1 1 1 1 1 3.9K 2 0.1UF C24 2 C23 1 0 2 R45 TSM103 2 D14 BAW56 7 2 12K 1 1 1 2 2 2 1 1 4 1 2 11K 8 R42 R43 3 2 10pF(100) 2 1 C22 C51 C50 R40 C21 6 2 1 470 PC817C 2 3 1 R39 2 2 1 PC1 2 2 V+I 4 2 620 2 R38 Page 14 R36 51 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter PACKAGE DIMENSION 10 Pin-SSOP (R10) PIN 1 ID θ B F ZD θ NUMBERING SCHEME Ordering Number : CM6807GIR (note) Ordering Number : CM6807XIR (note) Note1 : G : Suffix for Pb Free Product X : Suffix for Halogen Free and PB Free Product note 2 : I : -40℃~+125℃ note 3 : R: SSOP-10 2010/04/20 Rev1.0 Champion Microelectronic Corporation Page 15 CM6807 10-PIN Green-Mode PFC/PWM Combo CONTROLLER for High Density AC Adapter IMPORTANT NOTICE Champion Microelectronic Corporation (CMC) reserves the right to make changes to its products or to discontinue any integrated circuit product or service without notice, and advises its customers to obtain the latest version of relevant information to verify, before placing orders, that the information being relied on is current. A few applications using integrated circuit products may involve potential risks of death, personal injury, or severe property or environmental damage. CMC integrated circuit products are not designed, intended, authorized, or warranted to be suitable for use in life-support applications, devices or systems or other critical applications. Use of CMC products in such applications is understood to be fully at the risk of the customer. In order to minimize risks associated with the customer’s applications, the customer should provide adequate design and operating safeguards. HsinChu Headquarter Sales & Marketing 5F, No. 11, Park Avenue II, Science-Based Industrial Park, HsinChu City, Taiwan 21F., No. 96, Sec. 1, Sintai 5th Rd., Sijhih City, Taipei County 22102, T E L : +886-3-567 9979 F A X : +886-3-567 9909 http://www.champion-micro.com T E L : +886-2-2696 3558 F A X : +886-2-2696 3559 2010/04/20 Rev1.0 Taiwan, R.O.C. Champion Microelectronic Corporation Page 16