Fairchild FAN6208 Secondary-side synchronous rectifier (sr) for llc resonant converter Datasheet

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AN-6208
Secondary-Side Synchronous Rectifier (SR) for
LLC Resonant Converter Using FAN6208
Introduction
The LLC resonant converter has drawn a lot of attention
recently due to its advantages over a conventional series
resonant converter and parallel resonant converter: narrow
frequency variation over wide load, input variation, and
Zero Voltage Switching (ZVS) for the entire load range.
In an LLC resonant converter, rectifier diodes are typically
used to obtain DC output voltage from the transformer
secondary winding. The conduction loss of diode rectifier
contributes significantly to the overall power losses in an
LLC resonant converter; especially in low output voltage
applications. The conduction loss of a rectifier is
proportional to the product of its forward-voltage drop and
the forward conduction current. Using synchronous
rectification (SR) where the rectifier diode is replaced by
MOSFET with a small on resistance (RDSON), the forwardvoltage drop of a synchronous rectifier can be lower than
that of a diode rectifier and, consequently, the rectifier
conduction loss can be reduced.
FAN6208 is a synchronous rectification controller for
isolated LLC or LC resonant converters that can drive two
individual SR MOSFETs emulating the behavior of rectifier
diodes. FAN6208 measures the SR conduction time of each
switching cycle by monitoring the drain-to-source voltage of
each SR and determines the optimal timing of SR gate
drive. FAN6208 also uses the change of opto-coupler diode
current to adaptively shrink the duration of SR gate drive
signals during load transients to prevent shoot-through. To
improve light-load efficiency, Green Mode disables the SR
drive signals, minimizing gate drive power consumption at
light-load conditions.
This application note describes the design procedure for a
SR circuit using FAN6208. The guidelines for printed
circuit board (PCB) layout and a design example with
experiment results are also presented. Figure 1 shows the
typical application circuit of FAN6208.
Figure 1. Typical Application
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
LLC Resonance Converter with SR
Q1 Gate
Figure 2 shows the simplified schematic of a half-bridge
LLC resonant converter, where Lm is the magnetizing
inductance that acts as a shunt inductor, Lr is the series
resonant inductor, and Cr is the resonant capacitor. Since the
magnetizing inductor is relatively small, a considerable
amount of magnetizing current (Im) exists, which freewheels
in the primary side without being involved in the power
transfer. The primary-side current (Ip) is sum of the
magnetizing current and the secondary-side current referred
to the primary.
Figure 3 shows the typical gain curve of the half-bridge
LLC resonant converter. To allow Zero Voltage Switching
(ZVS) for the primary-side switches, gain curves with
inductive impedance characteristics should be used, where
the gain decreases as frequency increases. The resonant
network has a resonant frequency determined by the
resonance between Lr and Cr. When the switching frequency
is lower than the resonant frequency (below resonance), the
half resonance of reflected secondary-side current (diode
current) finishes before the primary-side switch is turned
off, as shown in Figure 4. When the switching frequency is
higher than the resonant frequency (above resonance) the
primary-side switch is turned off before the half resonance
of reflected secondary-side current (diode current) is
completed, as shown in Figure 5.
Q2 Gate
IP
Im
ID
VSR2
ISR1
ISR2
2*Vo
SR On-time
SR1 Gate
Figure 4. Key Waveforms Below -Resonance Operation
Figure 2. Schematic of LLC Resonant
Converter with SR
1
2π Lr Cr
Gain ( 2nVO / VIN )
fo =
Figure 5. Key Waveforms of Above-Resonance
Operation
Q=
Lr / Cr
Rac
Figure 3. Typical Gain Curves of LLC
Resonant Converter
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
Application Circuit
Figure 6 shows the typical application circuit of FAN6208
and Figure 7 shows the typical timing diagram of SR gate
drive signal. FAN6208 senses the drain-to-source voltage of
each SR to determine the gate drive timing. Once the body
diode of SR begins conducting, the drain-to-source voltage
drops to zero, which causes low detection (DETL) pin
voltage to drop to zero. FAN6208 turns on the MOSFET
after tON-ON-DETL (about 350ns), when the voltage on DETL
drops below 2V. As depicted in Figure 8, the turn -on delay
(after tSR-ON-DETL) is a sum of debounce time (150ns) and
propagation delay (200ns).
tSR-ON-DETL
DETL1
2V
350ns
VDETL1
tDB
tPD
GATE1 150ns 200ns
tSR-ON-DETL
350ns
DETL1
2V
VDETL1
tDB
FAN6208 measures the SR conduction duration (tDETL),
during which DETL voltage stays lower than 2V, and uses
this information to determine the turn-off instant of SR
gates of the next switching cycle, as shown in Figure 7. The
turn-off instant is obtained by subtracting a dead time
(tDEAD) from the measured SR conduction duration of the
previous switching cycle.
tPD
GATE1
150ns 200ns
tSR-ON-DETL
350ns
DETL1
VDETL1
2V
tDB
GATE1
tPD
150ns 200ns
Figure 8. Timing Diagram for Turning On SR
Figure 6. Application Circuit of FAN6208
DETL Pin Configuration
Allowable voltage on the DETL pin is from -0.3V to 7V.
Since the maximum voltage of the SR drain-to-source
voltage is twice that of the output voltage, a diode (DDETL) is
required for the DETL pin to prevent high voltage. Diode
1N4148 is typically used for DDETL. Since the DETL
internal current source is 50µA, RDETL should be determined
such that the DETL voltage is lower than the low detection
threshold (2V) with enough margin when the SR conducts.
Since the forward-voltage drop of SR can be as low as zero
when SR current is small, the DETL resistor should be:
RDETL ⋅ <
(2 − VFD )
50µ A
(1)
where VFD is the forward-voltage drop of DETL diode.
Figure 7. SR Conduction Time Determination
RDETL larger than 20kΩ is not typically recommended for
proper low-voltage detection on DETL pin.
RDETL should be determined such that the DETL voltage is
higher than -0.3V when the maximum voltage drop occurs
across SR, such as:
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
RDETL >
I SR max RDS .ON − VFD − 0.3
50 µ A
The RP pin has an internal constant current source (41.5µA)
and the pin voltage is determined by the Rp resistor.
Depending on the RP pin voltage, the Green Mode threshold
of tDETL is determined as shown in Figure 12. When RRP is
less than 36KΩ, FAN6208 operates in Low-Frequency
Mode, where Green Mode is enabled when tDETL is smaller
than 3.75µs. When RRP is larger than 36KΩ, HighFrequency Mode is selected and Green Mode is enabled for
tDETL smaller than 1.90µs.
(2)
where ISRmax is the maximum current of SR and RDS.ON is
the maximum on-resistance of the SR MOSFET at high
temperature.
The RP pin also has two internal thresholds for pin-open /
short protection. Using RP pin short protection, remote on /
off control can be implemented as shown in Figure 13.
Figure 9. Application Circuit of DETL Pin
RP Pin Configuration
The dead time can be programmed using a resistor on the
RP pin. The relationship between the dead time and SR
conduction duration (tDETL) for different resistor values on
the RP pin are given in Figure 10 and Figure 11. Since the
SR conduction time is shrunk by the protection function
(gate-shrink function) when tDEAD is smaller than 125ns, Rp
should be properly selected such that the gate-shrink
function does not operate at maximum switching frequency.
Figure 12. RP Pin Operation
Original PSON Circuit
Disable RP Pin Circuit
5VB
VDDSB
RP
41.5µA
RD
VDDM
RG
PSON
Figure 10. tDEAD vs. tDETL for Different RP (Low Frequency)
QRP
RP
QPSON
RGS
5VB
Figure 13. Application Circuit of RP Pin for Remote
ON / OFF
Gate-Shrink Functions
In normal operation, the turn-off instant is determined by
subtracting a dead time (tDEAD) from the measured SR
conduction duration of the previous switching cycle, as
shown in Figure 7. This allows proper driving timing for the
SR MOSFETS when the converter is in steady state and the
switching frequency does not change much. However, this
control method may cause shoot-through of SR MOSFETs
when the switching frequency increases fast and switching
Figure 11. tDEAD vs. tDETL for Different RP (High Frequency)
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
Figure 15. Application Circuit of FD Pin
transition of the primary-side MOSFETs takes place before
the turn-off command of the SR is given. To prevent the
shoot-through problem, FAN6208 has gate-shrink functions.
Gate shrink takes place in the following three conditions:
1.
When an insufficient dead time is detected in the
previous switching cycle. When the DETL becomes
HIGH within 125ns of the detection window after SR
gate is turned off, the SR gate drive signal in the next
switching cycle is reduced by tSHRINK-DT (about 1.25µs)
to increase the dead time as shown in Figure 14.
Figure 16. Gate Shrink by Feedback Detection
3.
Figure 14. Gate Shrink by Insufficient Dead Time
2.
When the feedback information changes fast. FAN6208
monitors the current through the opto-coupler diode by
measuring the voltage across the resistor in series with
opto-diode, as depicted in Figure 15. If the feedback
current through the opto diode increases by more than
20% of the feedback current of the previous switching
cycle, SR gate signal is shrunk by tSHRINK-FD (about
1.4µs) for tD-SHRINK-FD (about 90µs), shown in Figure 16.
When the DETL voltage has ringing around zero. As
depicted in Figure 17, the drain voltage of SR has
ringing around zero at light-load condition after the
switching transition of primary-side switches. When
DETL voltage rises above 2V within 350ns after DETL
voltage drops to zero and stays above 2V longer than
150ns, the gate is shrunk by 1.2µs (tSHRINK-RNG), as
shown in Figure 17.
Figure 17. Gate Shrink by the DETL Voltage Ringing
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
Printed Circuit Board Layout
In Figure 18, the power traces are marked as bold lines.
Good PCB layout improves power system efficiency and
reliability and minimizes EMI.
As indicated by 4, the ground of the feedback loop
Guidelines
For feedback detection, the FD pin should be connected
to the anode of the opto diode. Connecting the FD pin
through a resistor can improve surge immunity of the
system. Keep trace 1 away from any power trace with
high pulsating current.
The control ground (trace 2) and power ground (trace 7)
should meet at a single point to minimize interference.
The connecting trace should be as short as possible.
should be connected to the negative terminal of
output capacitor CO.
Trace 5 should be long and far from Vo terminal.
Keep trace 6 as short as possible.
As indicated by 7, the source terminals of Q1 and Q2
are connected to the negative terminal of Co. Keep
trace 10 short, direct, and wide.
As indicated by 8, the negative terminal of Co should
be connected to the case directly.
Figure 18. Layout Considerations
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
Design Example
Table 1.
The following example is a 12V/300W single output power
supply with LLC resonant converter topology. As Figure 19
shows, the FAN7621 controller is used for the LLC resonant
converter. The integrated CCM PFC controller FAN6982 is
used for PFC stage.
System Specification
Input Voltage Range
PFC Output
PFC Controller
Main power Controller
Output Voltage (Vo)
Output Power (Po)
PFC Switching Frequency
LLC resonant converter Switching Frequency
The key system parameters are listed in Table 1 and the Bill
of Materials (BOM) is summarized in Table 2.
The two-level PFC output voltage function of FAN6982 is
used where the typical PFC output voltage is 390V. The
PFC output voltage is reduced to 360V for low-line and
light-load condition to improve efficiency of the PFC stage.
The typical switching frequency (fs) is 65kHz for PFC stage.
90~264VAC
360~390VDC
FAN6982
FAN7621
12V
300W
65kHz
60~140kHz
The turn ratio n of TX1 is 13.5, Lm is 1.2mH, Lr is 150µH,
and Cr is 47nH. 1N4148 is used for D201 & D202 whose
voltage rating is 100V. 27kΩ is used for R204 (RRP) for the
Low-Frequency Mode setting.
Figure 19. Complete Circuit Diagram
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
Table 2.
Part
APPLICATION NOTE
Bill of Materials
Value
Note
Part
Resistor
Value
Note
Capacitor
R101
10Ω
1/4W
C108
10µF
25V
R102
3.3Ω
1/4W
C201
3300µF
16V
R103
3.3Ω
1/8W
C202
3300µF
16V
R104
10kΩ
1/8W
C203
47nF
50V
R105
10kΩ
1/8W
C204
47nF
50V
R106
1kΩ
1/8W
C205
470nF
25V
R107
0.2Ω
2W
C206
100nF
50V
R108
5.1kΩ
1/8W
C301
22nF/250V
Y-Capacitor
R109
9.1kΩ
1/8W
R110
5.6kΩ
1/8W
R201
10kΩ
1/8W
R202
10kΩ
1/8W
D101
UF1007
R203
10kΩ
1/8W
D102
1N4148
R204
27kΩ
1/8W
D103
1N4148
R205
Transformer
TX1
Lr =10µH/ Lm =1200µH
Diode
10kΩ
1/8W
D201
1N4148
R206
10kΩ
1/8W
D202
1N4148
R207
10kΩ
1/8W
R208
1kΩ
1/8W
L101
L = 150µH
R209
91kΩ
1/8W
L201
L = 1.8µH
R210
1kΩ
1/8W
R211
33kΩ
1/8W
Q1
FCPF11N60F
R212
24kΩ
1/8W
Q2
FCPF11N60F
Q3
FDP025N06
Q4
FDP025N06
1A/1000V
Inductor
QP2914
MOSFET
Capacitor
C101
270µF
450V
C102
0.33µF
50V
C103
150nF
1kV
U1
FAN7621
C104
47nF
1kV
U2
PC817
C105
12nF
50V
U3
FAN6208
C106
100pF
50V
U4
TL431
C107
680pF
50V
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
PQ3230
IC
LLC Controller
SR Controller
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AN-6208
APPLICATION NOTE
Figure 20 and Figure 21 show the SR gate drive waveforms
for different RP. As can be seen, the dead time of SR drive
can be programmed.
The efficiency test results of the Schottky diode and
synchronous rectification are shown in Table 3 and Table 4.
Figure 22 compares the efficiencies of Schottky diode and
synchronous rectification. As can be seen, 1~2% efficiency
improvement can be obtained using synchronous
rectification. Figure 22 also shows how the dead time of SR
affects the efficiency. By fine-tuning the dead time,
efficiency can be maximized.
Table 3. Efficiency Measurements at VAC=115V on
300W PC Power with Schottky Diodes (MBRP3045)
Load
Input Watts(W)
Output
Watts(W)
Efficiency
100%
50%
20%
358.070
176.38
73.30
307.658
154.91
62.19
85.920%
87.82%
84.80%
Table 4. Efficiency Measurements at VAC=115V on
300W PC Power with SRs (FDP025N06 and
RRP=30kΩ
Ω)
Figure 20. Secondary Side Current and SR
Gate Signal by RRP=24kΩ
Load
Input
Watts
(W)
Output
Watts
(W)
Efficiency
vs.
Schottky
Diode
100%
50%
20%
347.70
172.81
72.41
307.62
154.77
62.21
88.47%
89.56%
85.91%
+2.55%
+1.74%
+1.11%
Figure 22. Efficiency Analysis
Figure 21. Secondary Side Current and SR
Gate Signal by RRP=27kΩ
© 2010 Fairchild Semiconductor Corporation
Rev. 1.0.1 • 3/10/11
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AN-6208
APPLICATION NOTE
Related Resources
FAN6208 — Secondary Synchronous Rectifier Controller for LLC Topology
FAN7621 — PFM Controller for Half-Bridge Resonant Converters
FAN6982 — CCM Power Factor Correction Controller
FDP025N06 —FDP025N06 N-Channel PowerTrench® MOSFET 60V,265A, 2.5mΩ
1N/FDLL 914/A/B / 916/A/B / 4148 / 4448 — Small Signal Diode
FSFR2100 — Fairchild Power Switch for Half-Bridge Resonant Converters
AN4137 — Design Guidelines for Off-line Flyback Converters Using Fairchild Power Switch (FPS)
AN-4151 — Half-Bridge LLC Resonant Converter Design Using FSFR-Series Fairchild Power Switch (FPS)
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