www.fairchildsemi.com AN-9737 Design Guideline for Single-Stage Flyback AC-DC Converter Using FL6961 for LED Lighting Summary Basic Operation: High Power Factor Flyback Converter This application note presents single-stage Power Factor Correction (PFC) and focuses on how to select and design the flyback transformer for 16.8W (24V/0.7A) solution for universal input for LED lighting applications using FL6961. The flyback converter using FL6961 operates in Critical Conduction Mode (CRM) and has functions such as CC/CV feedback circuit, soft-starting, and the cycle-by-cycle current limit for LED lighting applications. The basic idea of achieving high power factor (PF) flyback converter is to use a Critical Conduction Mode (CRM) PFC controller. The conventional PFC IC, such as FL6961, has constant on-time and variable off-time control method, which means the input average current always follows the input voltage shape. Figure 1 shows the typical application schematic of singlestage PFC topology. The main difference of normal CRM boost converter is that single-stage PFC doesn’t use a large electrolytic capacitor after the full rectification diode. Normally, the single-stage PFC method uses a small capacitor (C1 in Figure 1) to act as a noise filter to attenuate high-frequency components and doesn’t use the INV pin for output voltage regulation. Introduction These days, engineers use various types of LEDs for general lighting systems because of their long life, excellent efficacy, price, environmental benefits, and requirements from end users. At the same time, high power factor (PF), isolation for safety, and constant current control (CC) for constant LED color are becoming requirements. Conventional regulation is the minimum power factor correction for input power base above 25W, but many want to reduce power ratings and the new Energy-Star directive for solid-state lighting requires a power factor greater than 0.9 for commercial applications. Expect PF regulations to become more stringent. T1 BR D3 C4 R8 R5 D2 R1 D1 C5 U101 R2 VCC INV 1 Fuse C1 MOT R3 C2 CS EMI filter C3 2 3 4 8 FL6961 COMP 7 6 OUT GND R6 Q1 R7 ZCD 5 R4 R8 Feedback Figure 1. Simplified Schematic of High-Power Factor Flyback Converter with FLS6961 © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com AN-9737 APPLICATION NOTE (NS) and naturally decreases to zero. The average current of the secondary side is: Figure 2 shows typical waveforms of the simplified circuit of a flyback converter with CRM. When the MOSFET (Q1) turns on, the primary current in primary side linearly increases and is clamped at a certain internal level because the FL6961 doesn’t have cycle-by-cycle current limit like a conventional current mode control IC (such as FAN7527B). Its peak level is determined by the primary magnetizing inductance value and the fixed on-time. Instead of the cycleby-cycle primary current limit, the FL6961 has an overcurrent protection (OCP) function. If the current sensing signal is larger than internal detection level, the FL6961 doesn’t get output signal for operating the MOSFET (Q1). I AVG ( DIODE ) = (3) Since the diode forward-voltage drop decreases as current decreases, the output voltage reflects the primary winding and adds additional voltage due to overshoot made by resonance between the leakage inductance on primary-side winding and parasitic capacitance on the MOSFET (Q1). As a result, a superimposed voltage occurs on the MOSFET during off-time as: VMOSFET ( off ) = V IN + V R + VOS IDS (MOSFET Drain-to-Source Current)) IPK ( MOSFET 1 NP I PK toff 2 NS ) IAVG (MOSFET where VR is the reflected voltage and VOS is the voltage overshoot term. ) The reflected voltage, VR, is affected by the turns ratio between the primary and secondary side of the transformer and the output voltage, calculated as: time ID (Diode Current) (4) IPK ( DIODE ) IAVG (DIODE VR = ) NP VO NS (5) Figure 3 shows the ideal waveforms of the primary-side current at MOSFET (Q1) and the secondary-side current at the diode. The input peak and average current on the primary side follows input voltage instantaneously. Normally, secondary-side current on the diode is larger than the primary side because of the turns ratio. time VDS (MOSFET Voltage) VOS VR VIN time tOFF tON tS Figure 2. Key Waveforms of Flyback Converter on CRM The FL6961 has a constant on-time across the whole range. The input average current always follows the peak input current, as shown in the equation: 1 I AVG ( MOSFET ) = I PK tON (1) 2 This is also proportional to the instantaneous input voltage. This means the input current shape is always the same as the input voltage shape. The reverse diode voltage is linearly increased and is equal to: VPK ( DIODE ) = VO + VIN NS NP Figure 3. Ideal Waveforms (2) During the MOSFET off-time, which is also the diode ontime; the input current instantly drops to zero, the diode in the secondary side conducts, and the diode current linearly decreases. The peak current of the secondary side is the same as the multiplication of the primary peak current and turns ratio between the primary side (NP) and secondary side © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 2 AN-9737 APPLICATION NOTE As a result, designers should consider two conditions before component selection: voltage and current capacity on primary-side MOSFET(Q1) and secondary-side diode (D3) to make a stable system with margin. Figure 4 shows a guide to deciding two components on the boundary condition of flyback converter topology. Figure 4. Boundary Conditions of Flyback Converter Topology (Refer to AN-8025) Design Example P = I o (Vo + Vd ) = 0.7(24 + 1) = 17.5 [W] A. Transformer Design A design guideline of 16.8W single-stage flyback AC-DC converter using FL6961 is presented. The applied system parameters are shown in Table 1. Table 1. Step 4. Calculate the maximum input current, Imax: Po I in (max) = Vminη System Parameters Parameter Main Input Voltage Range, VAC(main) = 17.5 = 0.168 [A] ( 2 × 90)(0.82) Step 5. Calculate the MOSFET voltage drop, Vvd: Value Vvd = I in (max) RMOS = 0.168 [V] 90V~265V Output Voltage, VOUT 24V Step 6. Calculate the primary voltage on transformer, Vp: Output Current, IOUT 0.7A VP = Vmin −V vd= 127 − 0.168 ≈ 127 [V] Vp=126.83 use 127 Minimum Switching Frequency at VAC(min)_pk 50kHz Diode Voltage Drop, Vd 1V MOSFET On Resistance, RMOS 1Ω Window Utilization 0.4 Target System Efficiency 0.82 Maximum Duty at Vac(min)_pk 0.35 Operating Maximum Flux Density 0.35 Regulation, α 0.5% Step 7. Calculate the primary peak current, Ippk: I ppk = 2TP 2( 20 × 10 −6 )(17.5) = = 0.96 [A] ηV p t on (max) 0.82(127)(7 × 10 −6 ) Step 8. Calculate the primary rms current, Iprms: I prms = I ppk Note: 1. Regulation is strongly related with the copper loss and 0.5% regulation means 0.084W loss on transformer. t on (7 ×10 −6 ) = 0.96 = 0.32 [A] 3T 3(20 ×10 −6 ) Step 9. Calculate the required minimum inductance, L: L= There are many ways to decide core and coil size and turns, such as using AL value and following common practices. In this note, use the Kg value related with the core geometry to find optimum core and coil information. V p t on (max) I ppk = 127(7 ×10 −6 ) = 0.926 [mH] 0.96 L=0.926[mH] use 1[mH] Step 10. Calculate the energy-handing capability in wattseconds, w-s: Step 1. Calculate the total period, T: 1 = 20 [µs] f Step 2. Calculate the maximum on-time at MOSFET in primary side. ENG = T= 2 LI ppk 2 = (1× 10 −3 )(0.96 2 ) = 0.0004608 [w-s] 2 Step11. Calculate the electrical conditions, Ke: K e = 0.145PBm2 × 10−4 = 0.145(17.5)(0.352 ) × 10−4 = 0.00003108 −6 t on = TDmax = (20 × 10 )(0.35) = 7 [µs] Step 12. Calculate the core geometry, Kg: Step 3. Calculate the output power: © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 3 AN-9737 Kg = APPLICATION NOTE 5 ( ENG ) 2 (0.0004608) 2 = = 0.0136 [cm ] 0.00003108(0.5) K eα AW ( B ) = Step 23. Calculate the skin depth at expected operating frequency at low input voltage. The skin depth is the radius of the wire. Step 13. See Table 2 for core size. To prevent core saturation, select a little big core after comparing two Kg values: calculate value at Step 12 vs. the existing value in Table 2. γ= The PQ-42016 has a little bit big Kg value (0.01327) in Table 2 with 2500 permeability (µi). 2 ( ENG ) × 10 B m AP K u 4 = 2 WireA = π (r 2 ) = 0.0027535 [cm ] 2 2 ( 0 . 0004608 ) × 10 4 = 265 [A/cm ] 0 . 35 ( 0 . 2484 )( 0 . 4 ) Step 25. Select a wire size with the required area from Table 4. If the area is not within 10% of the required area, then go to the next smallest size. Step 15. Calculate the required wire area. AW(B): AW ( B ) = I rms 0 . 32 = = 0 . 001207 J 265 [cm2] AWG=#23 AW(B)=0.00259[cm2] Step 16. Calculate the number of turns, N: N = µΩ/cm=666 WaKu 0 . 4283 × 0 . 4 = = 141 . 93 [T] 0 . 001207 Aw( B ) Step 26. Calculate the required number of primary strands, Snp: N=141.93; use 142 turns. S np = Step 17. Calculate the required gap, lg: lg = 0.4π ( N)(∆I ) ×10−4 0.4π (142)(0.96) ×10−4 = = 0.0489 [cm] ∆Bm 0.35 N= MPL µi 0.4π ( Ac ) = Ns = (V p Dmax ) N aux = Step 19. Calculate the fringing flux, F: Ac ln 2G 0.0489 2(1.001) ) = (1 + ln ) = 1.238 lg 0.0489 0.58 −8 (0.4π )( Ac ) F (10 ) = I spk = 74(15 + 1)(1 − 0.35) = 17.31 ( 2 × 90)(0.35) (1 − Dmax ) (1 − 0.35) = 2.153 = 1.0021 [A] 3 3 Step 30. Calculate the secondary wire area, Asw(B): I PK 0.96 ) F (10 − 4 ) (0.4π )(74)( )(1.238)(10 − 4 ) [T] 2 2 = = 0.113 lg 0.0489 ASW ( B ) = I rms 1.0021 2 = = 0.003781 [cm ] J 265 Step 31. Select a wire size with the required area from Table 4. If the area is not within 10% of the required area, go to the next smallest size. Step 22. Calculate the new wire size, AW(B) : © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 = 2I o 2(0.7) = = 2.153 [A] (1 − Dmax ) 1 − 0.35 I srms = I spk Step 21. Calculate the AC flux density in Tesla, BAC: (0.4π ) N ( (V p Dmax ) Step 29. Calculate the secondary rms current, Isrms: 0.0489 × 1 × 10 5 = 73.6 [T] (0.4π )(0.58)(1.238) Nnew=73.6; use 74. B ac = N p (Vo + Vd )(1 − Dmax ) Step 28. Calculate the secondary peak current, Ispk: Step 20. Calculate the new turns, Nnew: lg L 74(24 + 1)(1 − 0.35) = 27.05 ( 2 × 90)(0.35) Naux=17.31; use 17. where G is window height of selected core. N= = Ns=27.05; use 27. where µi is permeability of selected core material and MPL is Magnetic Path Length of selected core. lg 0.002315 = 0.8938 0.00259 N p (Vo + Vd )(1 − Dmax ) N=83.153; use 83[T]. F = (1 + = Step 27. Calculate the secondary and auxiliary turns, Ns Naux: 3.74 )(10 8 ) [T] 2500 = 83.153 0.4π (0.58) 1 × 10 −3 (0.0489 + ) Aw( B ) Wire A This means that the selected wire from the Step 25, AWG23, is enough or has enough margins for supplying the primaryside current on the flyback converter. Step 18. Calculate the new turns using a gap from Step 15. L(l g + 6.62 6.62 = = 0.02960 [cm] f 50 ×103 Step 24.Calculate the required wire area under considering skin depth : Step 14. Calculate the current density, J.: J = 2 Wa K u 0.4283 × 0.4 = = 0.002315 [A/cm ] N new 74 www.fairchildsemi.com 4 AN-9737 APPLICATION NOTE AWG=#22 C. Sensing Resistor AW(B) =0.003243[cm2] The CS pin of FL6961 has over-current protection (OCP) over the whole operating period and its internal clamping level, VLIMIT, is 0.8V. µΩ/cm=531.4 Step 32. Calculate the required number of primary strands, Snp: S np = Asw( B ) Wire A = 0.003243 = 1.2521 0.00259 This requires the AWG21 wire with two strands for secondary-side winding on the flyback converter. Adapted Core Size Turns PQ-42614 AWG Primary 74 23 Secondary 27 22/ 2 Strands Auxiliary 17 Estimated gap[mm] 0.489 Figure 5. Switching Current Limit B. MOSFET and Diode Selection Normally, it is reasonable to set the OCP level to 1.5 times higher than the peak current at primary side. Step 33. Calculate the maximum voltage of MOSFET drain voltage at primary side: VMOSFET(off ) = VIN + VR + VOS = VIN + NP VO + VOS = 490.54 [V] NS I LIMIT = 1.5I PPK = where VOS is assumed ~50V and its peak can degrade external snubber circuit performance. This means a 600V MOSFET can be used with some margin. Minimum requirements of the MOSFET are summarized below. Current Rating [A] +20% Margin Calculation +20% Margin 0.96 1.152 490.54 588.65 Rsen sin g ≤ 0 .8 I LIMIT = 0.55 [Ω ] D. Voltage and Current Feedback for CC/CV Function The constant voltage and current output is adapted by measuring the actual output voltage and current with external passive components and an op amp in the evaluation board. Because the output loads, the High Bright LED (HB LED) and passive components are effected by ambient temperature. Use the feedback path for stable operation. Step 34. Calculate the maximum voltage of diode at secondary side: VPK ( DIODE ) = VO + VIN = 1.44 Calculate the sensing resistor as: Voltage Rating [V] Calculation 3TP ηV p t on (max) NS 27 = 24 + 265 2 = 160.74 [V] NP 74 This means a 200V diode can be used with some margin. The minimum requirement of the secondary diode as summarized below. Current rating [A] Voltage rating [V] Calculation +20% Margin Calculation +20% Margin 2.153 2.584 160.74 192.88 Figure 6. Feedback Circuit for CC/CV Operation © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 5 AN-9737 APPLICATION NOTE E. Soft-Start / Overshoot Prevention Function Normally, the CC block is dominate over the CV block in steady state and the CV block acts as the Over-Voltage Protection (OVP) at transient or abnormal mode, such as noload condition. Normally, the High Bright (HB) LED has a forward-current limitation to prevent the LED burn-out due to over-power dissipation. Thererfore, the output overshoot function is needed through the whole operating period. Though there are CC/CV blocks for output regulation, those blocks do not operate in transient modes, because they block have a long response time and cannot act instantly. Figure 7 shows the output voltage overshoot compression method using diode and resistor. The current flows through resistor, R9, and diode, D204, at startup, which is the period before activating the CC/CV block, and then decrease at steady state. The quantity of by-passing current goes into the feedback block on the control IC, FL6961, and controls the output power gradually. The output signal of CC block is determined as: VO _ cc = R4 ( Vsen sin g _ CC R2 − Vref R3 )+ 1 Vsen sin g _ CC Vref ( − )dt C1 ∫ R2 R3 where the Vsensing_CC means the sensing voltage from the sensing resistor (R1) and its values is as: Vsen sin g _ CC = I o × R1 The output signal of CV block is determined as: VO _ CV = ( R6 R R6 )Vsen sin g _ CV + 8 [( ) R5 + R6 R7 R5 + R6 Vsen sin g _ CV − Vref ] + 1 1 R6 ( Vsen sin g _ CV − Vref )dt ∫ C2 R7 R5 + R6 where the Vsensing_CV means the output voltage on this circuit and this voltage is divided by two resistors, R5 and R6, and connected to non-inverted pin at the op amp. Normally, set this divided voltage, ( R6 )Vsen sin g _ CV , to R5 + R6 Vref or a little bit smaller value in steady state condition because the main role of this block is over-voltage protection. There are more high-voltage transfers to the output stage at transient or an abnormal case such as overvoltage output condition than in the steady state. Figure 7. Soft-Start / Overshoot Prevention Method © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 6 AN-9737 APPLICATION NOTE Table 2. Various Core Types and Size Part # MLT [cm] MPL [cm] G[cm] AC [cm] Wa 2 [cm ] Ap 4 [cm ] Kg 5 [cm ] Perm AL Manufacturer RM-42316 4.17 3.80 1.074 0.640 0.454 0.2900 0.017820 2500 2200 Magnetics PQ-42610 5.54 2.94 0.239 1.05 0.1177 0.1235 0.00937 2500 6310 Magnetics PQ-42614 5.54 3.33 0.671 0.709 0.3304 0.2343 0.01200 2500 4585 Magnetics PQ-42016 4.34 3.74 1.001 0.580 0.4283 0.2484 0.01327 2500 2930 Magnetics EPC-25 4.930 5.92 1.800 0.4640 0.8235 0.3810 0.01438 2300 1560 Magnetics EI-44008 7.77 5.19 0.356 0.9950 0.3613 0.3595 0.018416 2500 4103 Magnetics EFD-25 4.78 5.69 1.86 0.5810 0.6789 0.3944 0.01917 1800 1800 Philips Table 3. PQ-42016 Core Dimensions (Magnetics: http://www.mag-inc.com/home/Advanced-Search-Results?pn=42016 Table 4. AWG Wire Table Bare Wire Area Cm2 CIR-MIL 20 0.005188 1024.0 21 0.004116 812.30 22 0.003243 23 24 µΩ/cm Heavy Insulation Cm2 Turns/cm Turns/cm2 332.3 0.006065 11.37 98.93 418.9 0.004837 12.75 124.0 640.10 531.4 0.003857 14.25 155.5 0.002588 510.80 666.0 0.003135 15.82 191.3 0.002047 404.0 842.1 0.002514 17.63 238.6 25 0.001623 320.40 1062.0 0.002002 19.8 299.7 26 0.001280 252.80 1345.0 0.001603 22.12 374.2 27 0.001021 201.60 1687.6 0.001313 24.44 456.9 28 0.008048 158.80 2142.7 0.0010515 27.32 570.6 29 0.0006470 127.70 2664.3 0.0008548 30.27 701.9 © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 7 AN-9737 APPLICATION NOTE Schematic FL6961 Figure 8. Schematic © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 8 AN-9737 APPLICATION NOTE Bill Of Materials Item Number Part Reference Value Quantity Description (Manufacturer) 1 U101 FL6961 1 CRM PFC Controller (Fairchild Semiconductor) 2 U102 FOD817 1 Opto-Coupler (Fairchild Semiconductor) 3 U201 KA431 1 Shunt Regulator (Fairchild Semiconductor) 4 U202 KA358A(LM2904) 1 Dual Op Amp (Fairchild Semiconductor) 5 Q101 FQPF3N80C 1 800V/3A MOSFET (Fairchild Semiconductor) 6 D101 DF04 1 1.5A SMD Bridge-Diode (Fairchild Semiconductor) 7 D102 RS1M 1 1000V/1A Ultra-Fast Recovery Diode (Fairchild Semiconductor) 8 D103 RS1G 1 400V/1A Fast Recovery Diode (Fairchild Semiconductor) 9 D201,D204 EGP30D 2 200V/3A Ultra-Fast Recovery Diode (Fairchild Semiconductor) 10 D202,D203, D205,D206 LL4148 3 General-Purpose Diode (Fairchild Semiconductor) 11 R101,R102, R103 82KΩ 3 SMD Resistor1206 12 R104 120kΩ 1 SMD Resistor1206 13 R105 10KΩ 1 SMD Resistor1206 14 R106 20KΩ 1 SMD Resistor1206 15 R107 9.1kΩ 1 SMD Resistor1206 16 R108 47Ω 1 SMD Resistor 1206 17 R109 10Ω 1 SMD Resistor 1206 18 R110 220KΩ 1 2W 19 R111 30KΩ 1 SMD Resistor 1206 20 R112,R113 1Ω 2 SMD Resistor 1206 21 R201,R202, R203 1Ω 3 SMD Resistor 1206 22 R204 2.2Ω 1 SMD Resistor 0806 23 R205 4.3KΩ 1 SMD Resistor 0806 24 R206 1.5KΩ 1 SMD Resistor 0806 25 R207 30KΩ 1 SMD Resistor 0806 26 R208 51KΩ 1 SMD Resistor 0806 27 R209 33KΩ 1 SMD Resistor 0806 28 R210 3.9KΩ 1 SMD Resistor 0806 29 R211 120KΩ 1 SMD Resistor 0806 30 R212 47KΩ 1 SMD Resistor 0806 31 R213 4.7KΩ 1 SMD Resistor 0806 32 R214 47KΩ 1 SMD Resistor 0806 © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 9 AN-9737 APPLICATION NOTE Bill Of Materials (Continued) Item Number Part Reference Value Quantity Description (Manufacturer) 33 C101 100nF/250V 1 X – Capacitor 34 C102 47nF/250V 1 X – Capacitor 35 C103 100nF/630V 1 Film Capacitor 36 C104 33µF/35V 1 Electrolytic Capacitor 37 C105 2.2nF/1kV 1 Y-Capacitor 38 C106 2.2µF 1 SMD Capacitor 0805 39 C107 30pF 1 SMD Capacitor 0805 40 C108 100nF 1 SMD Capacitor 0805 41 C201,C202 470µF/35V 2 Electrolytic capacitor 42 C203 1µF 1 SMD Capacitor 0805 43 C204 470nF 1 SMD Capacitor 0805 44 C205 10µF/35V 1 Electrolytic Capacitor 45 LF101,LF102 80mH 2 Line Filter 46 L101 27µH 1 Line Filter 47 L102 6.8µH 1 Line Filter 48 L201 5µH 1 Output Inductor 49 F101 1A/250V 1 Fuse 50 T1 PQ-42016 1 1mH © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 www.fairchildsemi.com 10 AN-9737 APPLICATION NOTE Related Datasheets FL6961 — Single-Stage Flyback and Boundary Mode PFC Controller for Lighting AN-8025 — Design Guideline of Single-Stage Flyback AC-DC Converter Using FAN7530 for LED Lighting DISCLAIMER FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION, OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS. LIFE SUPPORT POLICY FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR CORPORATION. As used herein: 1. Life support devices or systems are devices or systems which, (a) are intended for surgical implant into the body, or (b) support or sustain life, or (c) whose failure to perform when properly used in accordance with instructions for use provided in the labeling, can be reasonably expected to result in significant injury to the user. © 2011 Fairchild Semiconductor Corporation Rev. 1.0.0 • 4/13/11 2. A critical component is any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness. www.fairchildsemi.com 11