AN-9750-High-PowerFactorFlybackConverterforLEDDriverwith
AN-9750-High-PowerFactorFlybackConverterforLEDDriverwith
com
AN-9750
High-Power Factor Flyback Converter for LED Driver with
FL7732 PSR Controller
efficiency and simple design. FL7732 provides protection
Introduction functions such as open-LED, short-LED and over-
temperature protection. The current-limit level is
This highly integrated PWM controller, FL7732, provides automatically reduced to minimize the output current and
several features to enhance the performance of low-power protect external components in short-LED condition.
flyback converters. The proprietary topology enables
simplified circuit design for LED lighting applications. By This application note presents practical design consideration
using single-stage topology with primary-side regulation, a for an LED driver employing Fairchild Semiconductor
LED lighting board can be implemented with few external PWM PSR controller FL7732. It includes designing the
components and minimized cost, without requiring an input transformer, selecting the components, and implementing
bulk capacitor and feedback circuitry. To implement high constant current regulation. The step-by-step design
power factor and low THD, constant on-time control procedure helps engineers design a power supply. The
utilizes an external capacitor connected at the COMI pins. design procedure is verified through an experimental
prototype converter. Figure 1 shows the typical application
Precise constant-current control regulates accurate output circuit of primary-side controlled flyback converter using
current across changes in input voltage and output voltage. FL7732 created in the design example.
The operating frequency is proportionally changed by the
output voltage to guarantee DCM operation with higher
Bridge-Diode
D
L
RSN CSN
C1 NP NS
CO
N RSTART
DSN
DVDD
CVDD NA
FL7732 QMOSFET
7 COMI VDD 4
5 2 RVS1
NC Gate
8 GND VS 6
3 GND CS 1
CCOMI
RSENSE RVS2 CVS
ID D
VIN.peak n:1
Basic Operation
- VD + +
Generally, Discontinuous Conduction Mode (DCM) Lm
operation is preferred for primary-side regulation because it CO VOUT
allows better output regulation. The operation principles of IM
DCM flyback converter are as follows: -
IDS
Q +
Mode I
VDS
During the MOSFET turn-on time (tON), input voltage -
(VIN.pk) is applied across the primary-side inductor (Lm).
Then, drain current (IDS) of the MOSFET increases linearly
from zero to the peak value (Ipk), as shown in Figure 2. Figure 3. Mode I: Q[ON], D[OFF]
During this time, the energy is drawn from the input and
stored in the inductor.
Mode II ID D
VIN.peak n:1
VDS
nVOUT ID D
VIN.peak n:1
VIN - VD + +
Lm
CO VOUT
IM IM
IDS ID
IDS -
Q +
IDS VDS
-
Mode III
VA NA
VO
NS When the diode current reaches zero, the transformer
auxiliary winding voltage begins to oscillate by the
resonance between the primary-side inductor (Lm) and the
effective capacitor loaded across MOSFET (Q).
tDIS
tS
Constant Current Regulation Output voltage is detected by the auxiliary winding and
resistive divider connected to the VS pin, as shown in
The output current (IO) can be estimated by using the peak Figure 7.
drain current (Ipk) of MOSFET and discharging time (tDIS) of
inductor current because output current (IO) is same as the OSC
average of the diode current (ID) in steady state. The output
current estimator identifies the peak value of the drain VOUT
current with a peak-detection circuit and calculates the Linear Frequency
output current using the inductor discharging time and Controller
switching period (tS). This output information is compared Freq. 6
VS
with an internal precise reference to generate error voltage
(VCOMI), which determines the duty cycle of the MOSFET in VS
Constant Current Mode. With Fairchild’s innovative
TRUECURRENT® technique, the constant output current
can be precisely controlled.
Figure 8. Linear Frequency Control
1 t N 1
I o DIS VCS P (1)
2 tS N S RSENSE
When output voltage decreases, secondary diode conduction
TRUECURRENT ®
calculation makes a precise output time is increased and the linear frequency control lengthens
current prediction. the switching period, which retains DCM operation in the
wide output voltage range, as shown in Figure 8. The
frequency control also lowers primary rms current with
7 COMI better power efficiency in full-load condition.
1 CS
VO =
VREF TrueCurrent® VO.nom
Calculation
t DIS T
3
tDIS n VO
6 VS 4
VO = Lm
Detector
75% VO.nom
IO
5
5 T
t DIS 3
3
IDS ID
t Figure 9. Primary and Secondary Current
tDIS
tS
LED Open !
Protections VDD
VDD_OFF
Open-LED Protection
FL7732 protects external components, such as diode and VOUT
capacitor at secondary side, in open-LED condition. During
switch-off, the VDD capacitor is charged up to the auxiliary VDD_OVP
winding voltage, which is applied as the reflected output x NS/NA
voltage. Because the VDD voltage has output voltage
information, the internal voltage comparator at the VDD pin
can trigger output over-voltage protection (OVP), as shown
in Figure 9. When at least one LED is open-circuited, output GATE
load impedance becomes very high and output capacitor is
quickly charged up to VOVP x NS / NA. Then switching is shut
down and the VDD block goes into “Hiccup Mode” until the
open-LED condition is removed, as shown in Figure 10.
Figure 11. Waveforms at Open-LED Condition
Internal
Bias Short-LED Protection (OCP)
In case of short-LED condition, the switching MOSFET and
secondary diode are usually stressed by the high powering
VDD good
current. However, FL7732 changes the OCP level in the
VDD 4 + short LED condition. When VS voltage is lower than 0.4 V,
VOVP - OCP level changes to 0.2 V from 0.7 V, as shown in Figure
12 so that powering is limited and external components
current stress is relieved.
+
-
VCS
Over-Temperature Protection (OTP)
0.2V The built-in temperature-sensing circuit shuts down PWM
output if the junction temperature exceeds 150°C. There is
hysteresis of 10°C.
VDD
VDD_ON
VDD_OFF
0.87 90 2 65 10 3 (7.4 10 6 ) 2
The single-stage flyback using FL7732 is assumed to Lm 743µH
operate in DCM due to constant tON and tS. Input voltage is 2 16.8
applied across the magnetizing inductance (Lm) during tON,
charging the magnetic energy in Lm. Therefore, the The maximum peak current of MOSFET at nominal output
maximum peak switch current (ISW.pk) of MOSFET occurs at power is calculated as:
peak point of line voltage, as shown Figure 14. The peak
input current (IIN.pk) is also shown at the peak input voltage
of one line cycle. Once the maximum tON is decided, ISW.pk of 7.4 106 2 90
I SW . pk 1.26 A
MOSFET is obtained at the minimum line input voltage and 743 106
full-load condition as:
(typical: 0.67 V) at 20~30% higher than CS peak voltage link capacitor, auxiliary winding voltage cannot be clamped
(VCS.pk) at full-load condition. MOSFET peak current (ISW.pk) to reflected output voltage due to the small Lm current,
is converted into VCS,pk as: which induces VS voltage sensing error. Then, frequency
decreases rapidly at the zero-crossing point of line voltage,
VCS. pk I SW . pk RS (9) which can cause flicker. To maintain constant frequency
over the whole sinusoidal line voltage, FL7732 has VS
blanking to disable sampling of VS voltage at less than a
According to Equation (1), the transformer turn ratio is particular line voltage by sensing the auxiliary winding.
determined by the sensing resistor and nominal output
current as: Considering the maximum switching frequency at rated
power and VS blanking level, RVS1 and RVS2 are obtained as:
n ps 10.5 I O RS (10)
where10.5 is a constant.
(VO VF )n AS VVS .max
1 t DIS 1 RVS (13)
VCS (11) VVS .max
2 tS 10.5
RVS 1 rVS RVS 2 (14)
(Design Example) Once VCS,pk is set as 0.5 V, the sensing where VVS.max is the VS value to set the maximum
resistor value is obtained as: switching frequency for constant output current in rated
power and VF is secondary diode forward voltage.
VCS. pk 0.5
RS 0.396
I SW .PK 1.26
1 VVS .bnk VIN bnk n AP (15)
RVS 2 (VVS .bnk )
I VS .bnk RVS
n ps 10.5 0.7 0.396 2.91
where VIN.bnk and nAP are the blanking level of input
voltage and the turn ratio of auxiliary to primary,
respectively. The nAP can be calculated as the ratio of
Step 3. nAS Selection nAS to nPS. IVS.bnk and VVS.bnk are decided internally at
1 µA and 0.545 V.
When VDD voltage is 23 V, FL7732 stops switching
operation due to over-voltage protection (OVP). So nAS can
be determined as follows:
(Design Example) The voltage divider network is
VDD.OVP 23 determined as:
nAS (12)
VO.OVP VO.OVP (24 0.7) 0.77 2.35
RVS 7.06
where (nAS=NA/NS) is the turns ratio the of secondary to 2.35
auxiliary of transformer. Therefore, VO.OVP can be set by
changing the nAS value. Once VIN.bnk level is set to 50 V, RVS2 is obtained as.
0.77
0.545 50
1 2.91 )
(Design Example) Once output over-voltage level is set as RVS 2 (0.545
30 V, nAS is obtained as: 100 10 6 7.06
23 24.86k
n AS 0.77
30 Then RVS1 is determined to be 175.5 kΩ.
Step 4. Resistor Selection (RVS1 and RVS2) It is recommended to place a bypass capacitor of 10 ~ 30 pF
closely between the VS pin and the GND pin to bypass the
The first consideration for RVS1 and RVS2 selection is that VS switching noise and keep the accuracy of the VS sensing for
is 2.35 V at the end of diode current conduction time to CC regulation. The value of the capacitor affects constant-
operate at maximum switching frequency at rated power. current regulation. If a high value of VS capacitor is selected,
The second consideration is VS blanking, as explained the discharge time tDIS becomes longer and the output
below. The output voltage is detected by auxiliary winding current is lower, compared to small VS capacitor.
and a resistive divider connected to the VS pin, as shown in
Figure 7. However, in a single-stage flyback without DC
© 2012 Fairchild Semiconductor Corporation www.fairchildsemi.com
Rev. 1.0.4 • 4/17/13 7
AN-9750 APPLICATION NOTE
2 90 7.4 10 6 tON f S
N p ,min 54.5T I SW .rms I pk (18)
0.27 64 10 6 6
Considering the tolerance of the transformer and high
ambient temperature, NP should be selected with a margin (Design Example) Assuming that drain voltage
about 5% ~ 10% to avoid core saturation: overshoot is the same as the reflected output voltage, the
N p 54.5 1.1 59.95T maximum drain voltage across the MOSFET is calculated
as:
Once the turn number of the primary side (NP) is 60
determined as 60 T, the turn number of the secondary side VDS (max) 374 (24 0.7) 2 522V
20
(NS) is obtained by:
The rms current though the MOSFET is
N S 60 2.91 20.5T 7.4 0.065
I SW .rms 1.26 0.357 A
6
Once the turn number of the secondary side (NS) is
determined as 20 T, the auxiliary winding turns (NA) is
Secondary-Side Diode: The maximum reverse voltage and
obtained by:
rms current of the rectifier diode are obtained as:
N A 20 0.77 15.4T NS
VD VO Vin. max . pk (19)
NA is determined to be 15 T. NP
Vin. min . pk N P
I D.rms I SW .rms (20)
2 VRO N S
Step 6. Calculate the Voltage and Current of
the Switching Devices (Design Example) The diode voltage and current are
obtained as:
Primary-Side MOSFET: The voltage stress of the
MOSFET was discussed when determining the transformer 20
turns ratio. Assuming the drain voltage overshoot is the VD 24 374 148.7V
60
same as the reflected output voltage, the maximum drain
voltage is given as: 127 60
I D.rms 0.357 0.991A
2 74.1 20
VSN
VSN (23)
VIN.peak n:1 D CSN RSN f S
-
+
VSN RSN CSN
Lm
CO In general, 5 ~ 20% ripple of the selected capacitor voltage
+ VOUT
is reasonable. In this snubber design, neither the lossy
- discharge of the inductor nor stray capacitance is considered.
DSN
Llk
(Design Example) Since the voltage overshoot of drain
voltage has been determined to be the same as the
+
reflected output voltage, the snubber voltage is:
VGate VDS
- VSN VRO VOS 150V
Lab Notes
1. Before modifying or soldering/desordering the power 2. In case of LED-short condition, VDD voltage charged
supply, discharge the primary capacitors through the at VDD capacitor should touch VDD off level rapidly to
external bleeding resistor. Otherwise, the PWM IC may stop switching. Therefore, VDD capacitor value is
be destroyed by external high-voltage during the process. recommended under 22 µF.
This device is sensitive to electrostatic discharge (ESD).
To improve the yield, the production line should be ESD
protected as required by ANSI ESD S1.1, ESD S1.4, ESD
S7.1, ESD STM 12.1, and EOS/ESD S6.1 standards.
CS1
MOV1 CF1 CF2 C1 R1 Np Ns
R2
Co1 Ro1 24V/0.7A
N Co2
F1 DS1
R3
D1
R6
C3 C2 Na CY1
U1
7 COMI VDD 4
RG1 Q1 R4
5
NC Gate 2
C5 8 GND VS 6
3 GND CS 1
R5 C4
RCS1 RCS2
NA(6 à5)
NP2(1 à2)
NS (7 à8)
NP1(12 à1)
Bill of Materials
Item Part
Part Number Qty. Description Manufacturer
No. Reference
Fairchild
1 BD1 DF06S 1 1.5 A / 600 V Bridge Diode
Semiconductor
2 CF1 MPX AC275V 104K 1 104 / AC275V X-Capacitor Carli
3 CF2 MPX AC275V 473K 1 473 / AC275V X-Capacitor Carli
4 CS1 C1206C103KDRACTU 1 103 / 1 kV SMD Capacitor 3216 Kemet
5 CY1 SCFz2E472M10BW 1 472 / 250V Y-Capacitor Samwha
6 Co1, Co2 KMG 470 µF / 35 V 2 470 µF / 35 V Electrolytic Capacitor Samyoung
7 C1 MPE 630V104K 14S 1 104 / 630 V MPE film Capacitor Sungho
8 C2 KMG 22 µF / 50 V 1 22 µF / 35V Electrolytic Capacitor Samyoung
9 C3 C0805C104K5RACTU 1 104 / 50 V SMD Capacitor 2012 Kemet
10 C4 C0805C200J5GACTU 1 200 / 50V SMD Capacitor 2012 Kemet
11 C5 C0805C225Z3VACTU 1 225 / 25V SMD Capacitor 2012 Kemet
Fairchild
12 DS1 RS1M 1 1000 V / 1 A Ultra Fast recovery Diode
Semiconductor
Fairchild
13 Do1 ES3D 1 200 V / 3 A, Fast Rectifier
Semiconductor
Fairchild
14 D1 1N4003 1 200 V / 1 A, General Purpose Rectifier
Semiconductor
15 F1 SS-5-1A 1 250 V / 1 A Fuse Bussmann
16 LF1 R10402KT00 1 4 mH Inductor, 10Ø Bosung
17 MOV1 SVC 471 D-07A 1 Metal Oxide Varistor Samwha
Fairchild
18 Q1 FDD5N60NZ 1 600 V / 4 A, N-Channel MOSFET
Semiconductor
19 RG1, R6 RC1206JR-0710L 2 10 Ω SMD Resistor 3216 Yageo
20 RS1, RS2 RC1206JR-07100KL 2 100 kΩ SMD Resistor 3216 Yageo
21 Rcs1, Rcs2 RC1206JR-071RL 2 1 Ω SMD Resistor 3216 Yageo
22 Rcs3 RC1206JR-072R4L 1 2.4 Ω SMD Resistor 3216 Yageo
23 Ro1 RC1206JR-0720KL 1 20 KΩ SMD Resistor 3216 Yageo
24 R4 RC1206JR-07150KL 1 150 KΩ SMD Resistor 3216 Yageo
25 R1, R2, R3 RC1206JR-0768KL 3 68 KΩ SMD Resistor 3216 Yageo
26 R5 RC1206JR-0724KL 1 24 KΩ SMD Resistor 3216 Yageo
27 T1 RM8 Core 1 12-Pin, Transformer TDK
Fairchild
28 U1 FL7732M_F116 1 Main PSR Controller
Semiconductor
Related Datasheets
FL7732 — Single-Stage PFC Primary-Side-Regulation Offline LED Driver
Reference Designs— http://www.fairchildsemi.com/referencedesign/
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