SG6859A — Low Cost, Green-Mode PWM Controller for Flyback Converters

March 2008

SG6859A
Low-Cost, Green-Mode PWM Controller for Flyback Converters
Features Description
ƒ Green-Mode PWM This highly integrated PWM controller provides several
enhancements designed to meet the low standby-power
ƒ Supports the “Blue Angel” Standard needs of low-power SMPS. To minimize standby power
ƒ Low Start-up Current: 9μA consumption, the proprietary green-mode function
provides off-time modulation to linearly decrease the
ƒ Low Operating Current: 3mA switching frequency under light-load conditions. This
ƒ Leading-Edge Blanking green-mode function enables the power supply to meet
ƒ Constant Output Power Limit even the strictest power conservation requirements.

ƒ Universal Input The BiCMOS fabrication process enables reducing the

start-up current to 9μA and the operating current to
ƒ Built-in Synchronized Slope Compensation 3mA. To further improve power conservation, a large
ƒ Current-Mode Operation start-up resistance can be used. Built-in synchronized
slope compensation ensures the stability of peak
ƒ Cycle-by-cycle Current Limiting current mode control. Proprietary internal compensation
ƒ Under-Voltage Lockout (UVLO) provides a constant output power limit over a universal
ƒ Programmable PWM Frequency with Frequency AC input range (90VAC to 264VAC). Pulse-by-pulse current
Hopping limiting ensures safe operation during short-circuits.

ƒ VDD Over-Voltage Protection (Auto Restart) To protect the external power MOSFET from damage by
supply over voltage, the SG6859A’s output driver is
ƒ Gate Output Voltage Clamped at 17V clamped at 17V. SG6859A controllers can be used to
ƒ Low Cost improve the performance and reduce the production
cost of power supplies. The best choice for replacing
ƒ Few External Components Required linear and RCC-mode power adapters, the SG6859A is
ƒ Small SOT-26 Package available in 8-pin DIP and 6-pin SOT-26 packages.

Applications
General-purpose switching mode power supplies and
flyback power converters, such as:
ƒ Battery chargers for cellular phones, cordless
phones, PDAs, digital cameras, and power tools
ƒ Power adapters for ink jet printers, video game
consoles, and portable audio players
ƒ Open-frame SMPS for TV/DVD standby and auxiliary
supplies, home appliances, and consumer electronics
ƒ Replacements for linear transformers and RCC SMPS
ƒ PC 5V standby power

Ordering Information
Part Number Operating Temperature Range Package Packing Method
SG6859ATZ -20°C to +85°C SOT-26 Tape & reel
SG6859ADZ -20°C to +85°C DIP-8 Tube
All packages are lead free per JEDEC: J-STD-020B standard.

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Application Diagram

Figure 1. Typical Application

Internal Block Diagram

Figure 2. Functional Block Diagram

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 2
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Pin Configuration

SOT-26 DIP-8

GND GATE GATE GND

FB VDD VDD FB
RI SENSE NC NC
SENSE RI

Figure 3. Pin Configurations

Pin Definitions
DIP SOT
Name Description
Pin # Pin #
1 6 GATE The totem-pole output driver for driving the power MOSFET.
2 5 VDD Power supply.
3 NC No connection
Current sense. This pin senses the voltage across a resistor. When the voltage
reaches the internal threshold, PWM output is disabled. This activates over-
4 4 SENSE
current protection. This pin also provides current amplitude information for
current-mode control.
A resistor connected from the RI pin to ground generates a constant current
source used to charge an internal capacitor and determine the switching
5 3 RI frequency. Increasing the resistance reduces the amplitude of the current source
and the switching frequency. A 95kΩ resistor RI results in a 50μA constant
current II and a 70kHz switching frequency.
6 NC No connection
Feedback. The FB pin provides the output voltage regulation signal. It provides
7 2 FB feedback to the internal PWM comparator, so that the PWM comparator can
control the duty cycle.
8 1 GND Ground.

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

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 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Absolute Maximum Ratings
Stresses exceeding the absolute maximum ratings may damage the device. The device may not function or be
operable above the recommended operating conditions and stressing the parts to these levels is not recommended.
In addition, extended exposure to stresses above the recommended operating conditions may affect device
reliability. The absolute maximum ratings are stress ratings only.

Symbol Parameter Min. Max. Unit

(1, 2)
VVDD DC Supply Voltage 30 V
VFB Input Voltage to FB Pin -0.3 7.0 V
VSENSE Input Voltage to Sense Pin -0.3 7.0 V
TJ Operating Junction Temperature 150 °C
SOT 208.4 °C/W
ΘJA Thermal Resistance (Junction-to-Air)
DIP 82.5 °C/W
TSTG Storage Temperature Range -55 150 °C
TL Lead Temperature (Wave Soldering or IR, 10 Seconds) 260 °C
Electrostatic Discharge Capability, Human Body Model 3.5 kV
ESD
Electrostatic Discharge Capability, Machine Model 200 V
Notes:
1. All voltage values, except differential voltages, are given with respect to GND pin.
2. Stresses beyond those listed under "absolute maximum ratings" may cause permanent damage to the device.

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

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 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Electrical Characteristics
Unless otherwise noted, VDD=15V and TA=25°C.

Symbol Parameter Conditions Min. Typ. Max. Units

VDD Section
VDD-OP Continuously Operation Voltage 22 V
VDD-ON Turn-on Threshold Voltage 15.5 16.5 17.5 V
VDD-OFF Turn-off Threshold Voltage 8.5 9.5 10.5 V
IDD-ST Startup Current VDD=VDD-ON – 0.1V 9 15 μA
IDD-OP Operating Supply Current VDD=15V, CL=1nF 3.0 3.5 mA
VDD-OVP VDD Over-voltage Protection Level Auto Restart 24 25 26 V
tD-VDDOVP VDD Over-voltage Protection Debounce Auto Restart 125 μs
VDD Low-threshold Voltage to Exit VDD-OFF
VDD-G OFF V
Green-off Mode +1
Feedback Input Section
ZFB Input Impedance 5 kΩ
VFB-OPEN FB Output High Voltage 5 V
VFB-OL FB Open-loop Trigger Level 4.3 4.6 4.9 V
tD-OLP Delay of FB Pin Open-loop Protection 56 ms
VFB-N Green-Mode Entry FB Voltage 2.60 2.85 3.10 V
VFB-G Green-Mode Ending FB Voltage 2.2 V
SG Green-Mode Modulation Slope RI=95kΩ 40 75 100 Hz/mV
Current-Sense Section
ZSENSE Input Impedance 10 kΩ
tPD Delay to Output 40 55 100 ns
VSTHFL Flat Threshold Voltage for Current Limit 1 V
VSTHVA Valley Threshold Voltage for Current Limit 0.75 0.80 0.85 V
tLEB Leading-Edge Blanking Time 270 320 370 ns
DCYSAW Duty Cycle of SAW Limit 40 %
Oscillator Section
Center Frequency 65 70 75
FOSC Frequency RI=95kΩ kHz
Hopping Range ±4.9
THOP Hopping Period RI=95kΩ 3.7 ms
FOSC-G Green-Mode Frequency RI=95kΩ 20 kHz
FDV Frequency Variation vs. VDD Deviation VDD=13.5 to 22V 0 0.02 2.00 %
Frequency Variation vs. Temperature
FDT TA=-20 to 85°C 2 %
Deviation
Output Section
DCYMAX Maximum Duty Cycle 62 67 72 %
VGATE-L Output Voltage Low VDD=15V, Io=20mA 1.4 V
VGATE-H Output Voltage High VDD=13.5V, Io=20mA 8 V
tr Rising Time VDD=15V, CL=1nF 150 ns
tf Falling Time VDD=15V, CL=1nF 55 ns
VGATE-
Output Clamp Voltage VDD=22V 16 17 18 V
CLAMP

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 5
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Typical Performance Characteristics

17.0 13.0

16.8 12.0

VDD-OFF (V)
VDD-ON (V)

16.6 11.0

16.4 10.0

16.2 9.0

16.0 8.0
-40 -25 -10 5 20 35 50 65 80 95 110 125 -40 -25 -10 5 20 35 50 65 80 95 110 125
Temperature (℃) Temperature (℃)

Figure 4. Turn-on Threshold Voltage (VDD-ON) Figure 5. Turn-off Threshold Voltage (VDD-ON)
vs. Temperature vs. Temperature

3.0 3.5

2.5 3.3
IDD-OP (mA)
IDD-ST (μA)

2.0 3.1

1.5 2.9

1.0 2.7

0.5 2.5
-40 -25 -10 5 20 35 50 65 80 95 110 125 -40 -25 -10 5 20 35 50 65 80 95 110 125
Temperature (℃) Temperature (℃)

Figure 6. Start-up Current (IDD-ST) vs. Temperature Figure 7. Operating Supply Current (IDD-OP)
vs. Temperature

70.0 70.0

69.0 69.0
DCYMAX (%)
FOSC (KHz)

68.0 68.0

67.0 67.0

66.0 66.0

65.0 65.0
-40 -25 -10 5 20 35 50 65 80 95 110 125 -40 -25 -10 5 20 35 50 65 80 95 110 125
Temperature (℃) Temperature (℃)

Figure 8. Center Frequency (FOSC) vs. Temperature Figure 9. Maximum Duty Cycle (DCYMAX) vs.
Temperature

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

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 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Typical Performance Characteristics

3.2 3.0

3.0 2.8

2.8 2.6
VFB-N (V)

VFB-G (V)
2.6 2.4

2.4 2.2

2.2 2.0
-40 -25 -10 5 20 35 50 65 80 95 110 125 -40 -25 -10 5 20 35 50 65 80 95 110 125
Temperature (℃) Temperature (℃)

Figure 10. Green-Mode Entry FB Voltage (VFB-N) Figure 11. Green-Mode Ending FB Voltage (VFB-G)
vs. Temperature vs. Temperature

350.0 3.5

330.0 3.0
IDD-OP (mA)

310.0 2.5
tLEB (ns)

290.0 2.0

270.0 1.5

250.0 1.0
-40 -25 -10 5 20 35 50 65 80 95 110 125 12 13 14 15 16 17 18 19 20 21 22 23 24
Temperature (℃) VDD (V)

Figure 12. Leading-Edge Blanking Time (tLEB) Figure 13. Operating Supply Current vs. VDD Voltage
vs. Temperature

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 7
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Operation Description
SG6859A devices integrate many useful designs into output GATE drive is turned off following a short
one controller for low-power, switch-mode power propagation delay, tPD. This propagation delay
supplies. The following descriptions highlight some of introduces an additional current proportional to
the features of the SG6859A series. tPD•VIN/LP. The propagation delay is nearly constant,
regardless of the input line voltage VIN. Higher input line
Start-up Current voltages result in larger additional currents. At high
input line voltages, the output power limit is higher than
The start-up current is only 9μA. Low start-up current at low input line voltages. To compensate for this output
allows a start-up resistor with high resistance and low- power limit variation across a wide AC input range, the
wattage to supply the start-up power for the controller. A threshold voltage is adjusted by adding a positive ramp.
1.5MΩ, 0.25W, start-up resistor and a 10µF/25V VDD This ramp signal rises from 0.8V to 1V, then flattens out
hold-up capacitor are sufficient for an AC-to-DC power at 1V. A smaller threshold voltage forces the output
adapter with a wide input range (100VAC to 240VAC). GATE drive to terminate earlier, which reduces the total
PWM turn-on time and makes the output power equal to
Operating Current that of low line input. This proprietary internal
compensation ensures a constant output power limit for
The operating current has been reduced to 3mA. The
a wide AC input voltage range (90VAC to 264VAC).
low operating current results in higher efficiency and
reduces the VDD hold-up capacitance requirement.
Under-Voltage Lockout (UVLO)
Green-Mode Operation The turn-on and turn-off thresholds are fixed internally
at 16.5V and 9.5V. During start-up, the hold-up
The proprietary green-mode function provides off-time
capacitor must be charged to 16.5V through the start-up
modulation to linearly decrease the switching frequency
resistor to enable the SG6859A. The hold-up capacitor
under light-load conditions. On-time is limited to provide
continues to supply VDD until power can be delivered
stronger protection against brownouts and other
from the auxiliary winding of the main transformer. VDD
abnormal conditions. The feedback current, which is
must not drop below 9.5V during this start-up process.
sampled from the voltage feedback loop, is taken as the
This UVLO hysteresis window ensures that hold-up
reference. Once the feedback current exceeds the
capacitor is adequate to supply VDD during start-up.
threshold current, the switching frequency starts to
decrease. This green-mode function dramatically Gate Output
reduces power consumption under light-load and zero-
load conditions. Power supplies using the SG6859A The BiCMOS output stage is a fast totem pole gate
can meet even the strictest regulations regarding driver. Cross conduction has been avoided to minimize
standby power consumption. heat dissipation, increase efficiency, and enhance
reliability. The output driver is clamped by an internal
Oscillator Operation 17V Zener diode to protect power MOSFET transistors
against undesired over-voltage gate signals.
A resistor connected from the RI pin to ground
generates a constant current source used to charge an
internal capacitor. The charge time determines the Built-in Slope Compensation
internal clock speed and the switching frequency. The sensed voltage across the current-sense resistor is
Increasing the resistance reduces the amplitude of the used for current-mode control and pulse-by-pulse
input current and the switching frequency. A 95kΩ RI current limiting. Built-in slope compensation improves
resistor results in a 50µA constant current II and a stability and prevents sub-harmonic oscillations due to
70kHz switching frequency. The relationship between RI peak-current mode control. The SG6859A has a
and the switching frequency is: synchronized, positively-sloped ramp built-in at each
switching cycle. The slope of the ramp is:
6650
fPWM = (kHz) (1)
RI(kΩ) 0.36 × Duty
(2)
Duty(max.)
Leading-Edge Blanking
Each time the power MOSFET is switched on, a turn-on
spike occurs at the sense-resistor. To avoid premature
Noise Immunity
termination of the switching pulse, a 320ns leading- Noise from the current sense or the control signal can
edge blanking time is built in. Conventional RC filtering cause significant pulse-width jitter, particularly in
can be omitted. During this blanking period, the current- continuous-conduction mode (CCM). While slope
limit comparator is disabled and cannot switch off the compensation helps alleviate these problems, further
gate driver. precautions should still be taken. Good placement and
layout practices should be followed. Avoiding long PCB
Constant Output Power Limit traces and component leads, locating compensation
When the SENSE voltage across the sense resistor, and filter components near the SG6859A, and increasing
RS, reaches the threshold voltage (around 1V), the power MOS gate resistance improve performance.

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 8
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Applications Information

F1 L1
1 2
L

1
BD1
C3 R3
R1
CX1 2 4
C1 C2

R5 R4 D4 L2
10 T1 1,2 2 1 1 2
N VO

1
R2

3
9

1
D1 R10
C7

2
8
5 C8 D5 C9

2
U1
1 6 R7 1 Q1
GND GATE

2
2 5 7 3,4

3
FB VDD GND
3 4 R15
RI SENSE
C6
R9 C11 R6

D2
R8 1 2

R11
C4

1
R13
U2

R14

2
CY1 C10

3
U3
1

R12

2
Figure 14. Reference Circuit

BOM
Reference Component Reference Component
BD1 BD 1A/500V L2 10µH 6mm
CX1 (Optional) XC 0.1μF Q1 MOSFET 1A/600V
CY1 (Optional) YC 102P/400V (Y1) R1,R2 R 750KΩ 1206
C1 CC 103P/500V R3,R4 R 47KΩ 1206
C2 EC 10μF/400V 105°C R5 R 47Ω 1206
C3 CC 102P/500V R6 R 4.7Ω 1206
C4 EC 10μF/50V R7 R 100Ω 0805
C6 CC 472P 0805 R8 R 10Ω 1206
C7 (Optional) CC 102P/100V 1206 R9 R 100KΩ 0805
C8 EC 470μF/10V 105°C R10 (Optional) R 10Ω 1206
C9 EC 220μF/10V 105°C R11 R 100Ω 1/8W
C10 CC 222P 0805 R12 R 33KΩ 0805
C11 N.C. R13 R 33KΩ 1/8W
D1 Diode FRI07 R14 R 4.7KΩ 0805
D2 Diode FR102 R15 R 0Ω 0805
D4 Diode SB360 T1 EE-16
D5 (Optional) ZD 6.8V 0.5W U1 IC SG6859A
F1 R 1Ω/0.5W U2 PC817
L1 20mH 6•8mm U3 TL431

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 9
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Physical Dimensions

D
Θ ¢X
8 5

e B

E1
E

1 4

A2
A1

b1
e
b

Figure 15. 8-Pin Dip-8 Package

Dimensions

Millimeters Inches
Symbol
Min. Typ. Max. Min. Typ. Max.
A 5.334 0.210
A1 0.381 0.015
A2 3.175 3.302 3.429 0.125 0.130 0.135
b 1.524 0.060
b1 0.457 0.018
D 9.017 9.271 10.160 0.355 0.365 0.400
E 7.620 0.300
E1 6.223 6.350 6.477 0.245 0.250 0.255
e 2.540 0.100
L 2.921 3.302 3.810 0.115 0.130 0.150
eB 8.509 9.017 9.525 0.335 0.355 0.375
θ˚ 0˚ 7˚ 15˚ 0˚ 7˚ 15˚

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 10
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters
Physical Dimensions (Continued)

D
Detail A
b
6 4

E1
E

c
1 e 3

e1
1
R

L2
θ R
1
A2
A

L
θ
L1
A1

1
θ

Detail A

Figure 16. 6-Pin SOT-26 Package

Dimensions

Millimeters Inches
Symbol
Min. Typ. Max. Min. Typ. Max.
A 1.45 0.057
A1 0.15 0.006
A2 0.90 1.15 1.30 0.036 0.045 0.051
b 0.30 0.50 0.011 0.020
c 0.08 0.22 0.003 0.009
D 2.90 0.114
E 2.80 0.110
E1 1.60 0.063
e 0.95 0.037
e1 1.90 0.075
L 0.30 0.45 0.60 0.020 0.018 0.024
L1 0.60 0.024
L2 0.25 0.010
R 0.10 0.004
R1 0.10 0.25 0.004 0.010
θ° 0° 4° 8° 0° 4° 8°
θ1° 5° 10° 15° 5° 10° 15°

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 11
 SG6859A — Low-Cost, Green-Mode PWM Controller for Flyback Converters

© 2007 Fairchild Semiconductor Corporation www.fairchildsemi.com

SG6859A Rev. 1.0.0 12