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Design Kit
Fixed Frequency Switch Mode Power Supply Using
FA5311BP


           All Rights Reserved Copyright (C) Bee Technologies Corporation 2010   1
Contents (1/2)
                                                                                                                                       Slide #
     1. Background
        1.1 Flyback Converter................................................................................................          4-6
        1.2 Current Waveforms..............................................................................................            7
        1.3 Equations.............................................................................................................     8
     2. Specification...............................................................................................................   9
        2.1 Output Voltage.....................................................................................................        10
        2.2 Output Current.....................................................................................................        11
        2.3 Steady State Initial Conditions.............................................................................               12
        2.4 Output Ripple Voltage..........................................................................................            13
        2.5 Efficiency..............................................................................................................   14
     3. Design Consideration.................................................................................................          15
        3.1 DC Link Voltage VDC,IN.........................................................................................            16
        3.2 Reflected Voltage VRO..........................................................................................            17
        3.3 Transformer Primary Side Inductance LP.............................................................                        18
        3.4 Transformer Turn Ratio........................................................................................             19-20
        3.5 Transformer Leakage Inductance Lleak.................................................................                      21-23
        3.6 RCD Clamping Network.......................................................................................                24-25
     4. MOSFET Switching Device M1...................................................................................                  26
        4.1 M1 Voltage and Current Stresses.........................................................................                   27
        4.2 Losses in M1........................................................................................................       28
        4.3 MOSFET Model...................................................................................................            29




                                    All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                          2
Contents (2/2)
                                                                                                                                      Slide #
     5. Output Rectifier Diode D21...........................................................................................         30
         5.1 D21 Voltage and Current Stresses........................................................................                 31
         5.2 Losses in D21.......................................................................................................     32
     6. Output Capacitor C21 and C22......................................................................................            33-35
     7. Photocoupler PC1........................................................................................................      35-36
     Simulation Index..............................................................................................................   38-39




                                    All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                         3
1.1 Flyback Converter

        Vin     Iin                             VLS      IF,D21                                VOUT


                               LP              LS       D21
                         +
                         VLP
                         -



                            M1                                               LC filter stage
                                       +
                                       VDS
                                       -




   •   This figure shows the basic configuration of the converter ( Flyback + LCR load ).
   •   The switch M1 ON and OFF events are separated to see how the devices work.



                       All Rights Reserved Copyright (C) Bee Technologies Corporation 2010            4
1.1 Flyback Converter
During the M1 ON time

                           Vin
                                                            D21

                                                LS

                        VLS = Vin                       Reverse
                                                         Bias
                                  LP


                              M1                                               LC filter stage
                                            ON




    •   This figure shows the current path during the ON time, D21 is reverse biased, and the
        output capacitor (C21) supplies the LC filter stage on its own.



                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010     5
1.1 Flyback Converter
During the M1 OFF time

                                             VLS = N ⋅ Vin                                     VOUT
                                                            D21

                                   LP           LS




                                                            VOUT
                              M1           VDS = Vin +
                                                             N
                                           OFF




    •   During the OFF time, D21 is forward biased , LS starts conducting and charges
        C21 ,the secondary winding of the flyback transformer starts transferring energy to the
        power supply output.

                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010          6
1.2 Current Waveforms

    CCM                                                              DCM
                                    Vin × ΤΟΝ
    Iin                   ΔΙin =                                       Iin
                                       Lp
                                                                                                    Vin × ΤΟΝ
                                                                                         ΔΙin =
                                                                                                       Lp




                                  Vin × ΤΟN                                                                                           Vin × ΤΟN
    IF,D21         ΔΙF , D 21 =                                       IF,D21                                           ΔΙF , D 21 =
                                   N × Lp                                                                                              N × Lp




             ΤΟN                                                                        ΤΟN
                                                                                                            Τ
                        Τ                                 time                                                                            time
                                                                                                       Discontinuous
                                                                                                       current
•    The current waveforms of Iin and IF,D21 in CCM and DCM mode.



                              All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                          7
1.3 Equations

•   The relationship between the VOUT and Vin for the CCM and DCM mode are defined as equations
    below.

                                             NS  D                                           (1)
                           VOUT , CCM      =   ⋅        ⋅ Vin
                                             NP  1 − D 

                                                                     RL
                          VOUT , DCM = D × Vin ×                                               (2)
                                                                2 × LP × fsw

•   The primary side inductance value LP for the DCM mode is calculated as equation below.



                          LP , DCM <
                                     (1 − D )2 R ⋅  NP  2
                                                               
                                                                                               (3)
                                                 2 fS             N   S
                                                                        

     •   LP is the inductance of primary winding.
     •   D = TON/T
     •   NP is the turns number of primary winding.
     •   NS is the turns number of secondary winding.


                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010         8
2. Specifications
                                                                                                                  K K1
                                                                                                                  K_Linear
                                                                                                                  COUPLING = {K}
                                                                                                                  L1 = Lp
                                                                                                                  L2 = Ls
                                                                                                                  L3 = LsubD21
                                                                                                       Rs_Lp               SF6L20U                                       L21
                                                                                                                                                                                                    OUT
                                                                                                        0.15                                                             8RHB
                                                                                                 C2               2   1              C21          C22
                                                                                    R2           0.022u                              890uF        890uF
                                                                                    33k
             D1                 +                                                                                                 ESR21          ESR22                2.2k               +                12
                                                                                    D4           C3        Lp             Ls        33m            33m                R23                                 RL
                      D2SBA60       C1                                        R1                 150p      {Lp}           {Nsp*Nsp*Lp}       1            1                                  C23
                                    SMH200VN270-22A                          22k                                                                                                             RJJ-35V221MG5-T20
                                                                                                                  1   2
              1

                  2

                       3

                           4




                                    IC = 0       D                                                                                 ESL21         ESL22                                       IC = 0
                                                                                      MUR160                                       6.3nH         6.3nH
                                                             M1
                                                             2SK3869
                                                                  G                                ERA91-02
                                                               R3                                  D2                                        2            2
   Vac                                                         4.7k                                                   PARAMETERS:
   FREQ = 50Hz                                      S                                                             2   Np = 125                                                          R21
                                                                                                                                                         PC1_A
   VAMPL = {110*1.4142}                                                                                                                                                                 18k
                                                                                                 R7                   Ns = 24                                                 R26
                                                                                                 2.2                  Nsub = 14                                               2.2k
                                                                             R4                                       Lp = 650uH                         PC1_K
                                                                             220                                                                                                        R22
                                            R8                                                    C4                  Nsp = {Ns/Np}                                                     1.9k
                                             0.22                                   DZ1                           1                                                     R24
                                                                                                  47u                 Nsubp = {Nsub/Np}
                                                                                                                                                                        680
                                                             D3                                            Lsub    K = 0.996055
                                                             ERA91-02                                      {Nsubp*Nsubp*Lp}
                                0             C8                R9                    MTZJ24B                                                                     K          R25     C24
                                              0.22u             100                                                                                                          330k    0.22u
                                              IC = 0                                                                                                        IC2         REF
                                                                 C7                                                                                      NJM431
                                                                 1500p
                                                                                                                                                                  A
                                                                                                                                                                                        R27
                                                                                                                                                                                       2.2k
                                    R5                                        IC1
                                                    8    7        6      5
                                    220                                       FA5311BP


                                                                                                                                                     VIN = 110Vrms         0
                                                    1        2    3      4

                                                                                       C5                                        PC1_A
                                                                                                                                                     VOUT = 24V
                                                        220                        0.047u

                                                        R6
                                                                                                                                                     IOUT = 2A , DCM
                                              R10                     C6                  R11                                    PC1_K
                                                                                          2.2k
                                                                                                                      PC1                            fSW = 30kHz
                                                5.6k             6800p                                            TLP281
                                                                                                                                                     Output voltage ripple < 0.06VP-P
                                                                                                                                                     %Efficiency = 85.6
                                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                    9
2.1 Output Voltage


                                                                                               Analysis
                                         Overshoot voltage                                     Time Domain (Transient)
                                                                                                  Run to time: 500ms
                                                                                                  Start saving data after: 0
                                                                                                  Maximum step size: 10us

                                                                                               .Options
                                                                                               RELTOL:         0.01
                                                                                               VNTOL:          1.0m
                                                                                               ABSTOL:         100.0n
                                                                                               CHGTOL:         1p
                                                                                               GMIN:           1.0E-12
                                                                                               ITL1:           500
                                                                                               ITL2:           200
                                                                                               ITL4:           20




•   The output voltage is regulated at 24V(RL=12Ω) ,voltage overshoot at startup is less than 1.2V.




                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                   10
2.2 Output Current


                                                                                               Analysis
                                                                                               Time Domain (Transient)
                                                                                                  Run to time: 500ms
                                         Overshoot current                                        Start saving data after: 0
                                                                                                  Maximum step size: 10us

                                                                                               .Options
                                                                                               RELTOL:         0.01
                                                                                               VNTOL:          1.0m
                                                                                               ABSTOL:         100.0n
                                                                                               CHGTOL:         1p
                                                                                               GMIN:           1.0E-12
                                                                                               ITL1:           500
                                                                                               ITL2:           200
                                                                                               ITL4:           20




•   The output current is 2A (RL=12Ω) ,current overshoot at startup is less than 100mA.




                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                   11
2.3 Steady State Initial Conditions
                                                                                                                        K K1
                                                                                                                        K_Linear
                                                                                                                        COUPLING = {K}
                                                                                                                        L1 = Lp
                                                                                                                        L2 = Ls
                                                                                                                        L3 = LsubD21
                                                     Vin_dc
                                                                                                             Rs_Lp               SF6L20U                                       L21
                                     Vin_dc                                                                                                                                                               OUT
                                                                                                             0.15                                                              8RHB
                                                                                                       C2               2   1              C21          C22
                                                IC(C1) =                                  R2
                                                                                          33k
                                                                                                       0.022u                              890uF        890uF

              D1                      +           30V                                     D4            C3       Lp             Ls
                                                                                                                                        ESR21
                                                                                                                                          33m
                                                                                                                                                       ESR22
                                                                                                                                                         33m
                                                                                                                                                                            2.2k
                                                                                                                                                                            R23
                                                                                                                                                                                               +                12
                                                                                                                                                                                                                RL
                       D2SBA60            C1                                        R1                  150p     {Lp}           {Nsp*Nsp*Lp}       1            1                                  C23
                                          SMH200VN270-22A                          22k                                                                                                             RJJ-35V221MG5-T20
                                                                                                                        1   2                                                 IC(C23)
               1

                   2

                        3

                            4




                                          IC = 141.4   D                                                                                 ESL21         ESL22                                       IC = 23.9
                                                                                            MUR160                                       6.3nH         6.3nH
                                                                  M1                                                                                                          = 23.9V
                                                                  2SK3869
                                                                       G                                 ERA91-02
                                                                    R3                                   D2                                        2            2
    Vac                                                             4.7k                                                    PARAMETERS:
    FREQ = 50Hz                                          S                                                              2   Np = 125                                                          R21
                                                                                                                                                               PC1_A
    VAMPL = {110*1.4142}                                                                                                                                                                      18k
                                                                                                       R7                   Ns = 24                                                 R26
    PHASE = 30                                                                           MTZJ24B       2.2                  Nsub = 14                                               2.2k
                                                                                  R4
                       Initial                                                    220
                                                                                                                            Lp = 650uH                         PC1_K
                                                                                                                                                                                              R22
                                                 R8                                                                         Nsp = {Ns/Np}                                                     1.9k
                       phase                      0.22                                    DZ1                           1
                                                                                                                            Nsubp = {Nsub/Np}                                 R24
                                                                                                                                                                              680
                        = 30                                 D3                                    C4            Lsub    K = 0.996055
                                                   C8        ERA91-02                              47u           {Nsubp*Nsubp*Lp}
                                      0            0.22u         R9                                IC = 16.524                                                          K          R25     C24
                                                   IC = 2.42     100                                                                                                               330k    0.22u
                                 IC(C8) =                      C7
                                                                                                                     IC(C4) =                                     IC2         REF

                                  2.42V
                                                               1500p
                                                               IC = 2.9
                                                                                          IC(C7)                     16.524V                                   NJM431
                                                                                                                                                                        A
                                                                                          = 2.9V                                                                                              R27
                                                                                                                                                                                             2.2k
                                          R5                                       IC1
                                                         8    7        6      5
                                          220                                      FA5311BP
                                                                                                       IC(C5)
                                                                                                       = 3.37V
                                                                                                                                                                                                         0
                                                         1        2    3      4


                                                             220
                                                                                             C5
                                                                                          0.047u
                                                                                                                                       PC1_A             Initial condition are set ,so the
                                                             R6
                                                                                          IC = 3.37
                                                                                                                                                         simulation starts near the steady
                                                   R10                                          R11
                                                                       C6                       2.2k
                                                                                                                            PC1
                                                                                                                                       PC1_K
                                                                                                                                                         state.
                                                     5.6k             6800p                                             TLP281




                                            All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                        12
2.4 Output Ripple Voltage


                                                         Output ripple voltage
                                                                                                Analysis
                                                                                                Time Domain (Transient)
                                                                                                   Run to time: 60ms
                                                                                                   Start saving data after: 40ms
                                                                                                   Maximum step size: 100ns

                                                                                                .Options
                                                                                                RELTOL:         0.01
                                                                                                VNTOL:          1.0m
                                                                                                ABSTOL:         100.0n
                                                                                                CHGTOL:         0.1p
                                                                                                GMIN:           1.0E-12
                                                                                                ITL1:           500
                                                                                                ITL2:           200
                                                                                                ITL4:           20




•   The output ripple voltage is less than 60 mVP-P.




                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      13
2.5 Efficiency
           Tracing the %Efficiency of the power supply ,add trace: 100* AVG(W(RL))/ AVG(V(Vin_dc)*I(Vin_dc))


                                                                    Ploss(M1)= 4.64[W]
                                                                                                    Analysis
                                                                                                    Time Domain (Transient)
                                                                    Ploss(D21)= 1.92[W]                Run to time: 60ms
                                                                                                       Start saving data after: 40ms
                                                                                                       Maximum step size: 100ns

                                                                   Pin= 55.7[W]                     .Options
                                                                                                    RELTOL:          0.01
                                                                   Pout= 47.68[W]                   VNTOL:           1.0m
                                                                                                    ABSTOL:          100.0n
                                                                                                    CHGTOL:          0.1p
                                                                                                    GMIN:            1.0E-12
                                                                  %Efficiency = 85.6
                                                                                                    ITL1:            500
                                                                                                    ITL2:            200
                                                                                                    ITL4:            20




                                                           Tracing the %Efficiency of the power supply ,add trace: 100*
                                                          AVG(W(RL))/ AVG(V(Vin_dc)*I(Vin_dc))



•   The simulation result shows that the efficiency of the power supply is 85.6%.



                              All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      14
3. Design Considerations
                                                                                                                    K K1
                                                                                                                    K_Linear

                                           VIN ,DC                                                                  COUPLING = {K}
                                                                                                                    L1 = Lp
                                                                                                                    L2 = Ls                                                                   VOUT
                                                                                                                    L3 = LsubD21
                                                 Vin_dc
                                                                                                         Rs_Lp               SF6L20U                                   L21
                                 Vin_dc                                                                                                                                                           OUT

                                                                       -              R2
                                                                                                   C2
                                                                                                   0.022u
                                                                                                         0.15
                                                                                                                    2   1              C21
                                                                                                                                       890uF
                                                                                                                                                    C22
                                                                                                                                                    890uF
                                                                                                                                                                       8RHB



                                                                       VRO
                                                                                      33k
              D1                 +                                                                                                  ESR21          ESR22            2.2k               +                12
                                                                                      D4            C3       Lp             Ls        33m            33m            R23                                 RL
                       D2SBA60       C1
                                     SMH200VN270-22A                   +        R1
                                                                               22k
                                                                                                    150p     {Lp}
                                                                                                                    1   2
                                                                                                                            {Nsp*Nsp*Lp}       1            1                              C23
                                                                                                                                                                                           RJJ-35V221MG5-T20
               1

                   2

                        3

                            4




                                     IC = 141.4   D                                                                                  ESL21         ESL22                                   IC = 23.9

                                           +                  M1
                                                                                        MUR160                                       6.3nH         6.3nH

                                                              2SK3869
                                           VDS                  R3
                                                                   G                                 ERA91-02
                                                                                                     D2                                        2            2
    Vac
    FREQ = 50Hz                            -         S
                                                                4.7k
                                                                                                                    2
                                                                                                                        PARAMETERS:
                                                                                                                        Np = 125                           PC1_A                      R21
                                                                                                                                                                                      18k
    VAMPL = {110*1.4142}                                                                                                Ns = 24
                                                                                                   R7                                                                       R26
    PHASE = 30                                                                       MTZJ24B       2.2                  Nsub = 14                                           2.2k
                                                                              R4                                        Lp = 650uH                         PC1_K
                                                                              220                                                                                                     R22
                                             R8                                                                         Nsp = {Ns/Np}                                                 1.8k
                                              0.22                                    DZ1                           1                                                 R24
                                                                                                                        Nsubp = {Nsub/Np}
                                                                                                                                                                      680
                                                         D3                                    C4            Lsub    K = 0.996055
                                               C8        ERA91-02                              47u           {Nsubp*Nsubp*Lp}
                                 0             0.22u         R9                                IC = 16.524                                                                 R25     C24
                                               IC = 2.42     100                                                                                                           330k    0.22u
                                                           C7                                                                                                 IC2
                                                           1500p                                                                                           TL431
                                                           IC = 2.9                          Lp =650uH                                                                                R27

                                     R5
                                                     8    7        6      5
                                                                               IC1           NP:NS:NSUB = 125:24:14                                                                  2.2k

                                     220                                       FA5311BP


                                                                                                                                                                                                 0
                                                     1        2    3      4

                                                                                         C5                                        PC1_A
                                                         220                          0.047u
                                                                                      IC = 3.37
                                                         R6
                                               R10                                          R11                                    PC1_K
                                                                   C6                       2.2k
                                                                                                                        PC1
                                                 5.6k             6800p                                             TLP281




                                       All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                     15
3.1 DC Link Voltage VIN,DC

             Maximum VIN ,DC = 154V

                                                                                                    Analysis
                                                                                                    Time Domain (Transient)
                                                                                                       Run to time: 500ms
                           Minimum VIN ,DC = 139V                                                      Start saving data after: 0
                                                                                                       Maximum step size: 10us

                                                                                                    .Options
                                                                                                    RELTOL:         0.01
       VLINE, = 110Vac                                                                              VNTOL:          1.0m
                                                                                                    ABSTOL:         100.0n
                                                                                                    CHGTOL:         1p
                                                                                                    GMIN:           1.0E-12
                                                                                                    ITL1:           500
                                                                                                    ITL2:           200
                                                                                                    ITL4:           20




•   The simulation result shows the peak values of the ripple of DC link voltage VIN,DC.




                              All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                   16
3.2 Reflected Voltage VRO


                               VDS(M1) = VDC,IN + VRO = 283V               Zoomed
                                                                                               Analysis
                                   VRO = 153.71V                                               Time Domain (Transient)
        VDC,IN                                                                                    Run to time: 60ms
                                                                                                  Start saving data after: 40ms
                                                                                                  Maximum step size: 100ns

                                                                                               .Options
                                                                                               RELTOL:         0.01
                                                                                               VNTOL:          1.0m
                                                                                               ABSTOL:         100.0n
                                                                                               CHGTOL:         0.1p
        VDS(M1)                                                                                GMIN:           1.0E-12
                                                                               VDC,IN          ITL1:           500
                                                                                               ITL2:           200
                                                                                               ITL4:           20




•   This figure shows the waveform of the drain voltage of flyback converter compared to the VDC,IN.
•   When M1 is turned off ,VDS = VDC,IN + VRO
•   VRO is the voltage reflected to the primary, the value is approximately VOUT / N ,which N=NS/NP

                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      17
3.3 Transformer Primary Side Inductance LP


                                                                                                   Analysis
                                                                                                   Time Domain (Transient)
                                                                                                      Run to time: 60ms
                                                                                                      Start saving data after: 40ms
                 ΤΟN
                                                                                                      Maximum step size: 100ns
                         Τ                                                 V(PWM_OUT)
                                                                                                   .Options
                                                                                                   RELTOL:         0.01
                       ID(M1) = VDC,IN TON /Lp= 2.34A                                            VNTOL:          1.0m
                                                          IF(D21) = 11.667A                       ABSTOL:         100.0n
                                                                                                   CHGTOL:         0.1p
                               Discontinuous                                                       GMIN:           1.0E-12
                               current                                                             ITL1:           500
                                                                                                   ITL2:           200
                                                                                                   ITL4:           20




•   This figure shows the waveforms of ID(M1) and IF(D21 ) in the DCM mode. The peak currents are obtained.
•   The primary-side inductance (LP) of the transformer determines the converter operation mode.
•   Once the duty ratio is determined by the equation (1), LP is obtained as the equation (3)
•   Which the maximum load is 2A (VO=24V, RL=12Ω). At VIN,dc=141V and fs=30kHz ,this equation calls for Lp,DCM <
    1.52mH.


                             All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      18
3.4 Transformer Turn Ratio

   The turn ratio between the primary side and the secondary side is obtained as:


                                 NS VOUT + VF ( D 21)
                                    =                                                        (4)
                                 NP     VRO

   The turn ratio between the primary side and the auxiliary side is obtained as:



                               NSUB VCC + VF ( Dsub )
                                   =                                                         (5)
                                NS   VOUT + VF ( D 21)
   Which the maximum load current is 2A (VO=24V, RL=12Ω).
    • At VF(D21)≅0.6V and VRO=129V ,this equation calls for NP:NS = 125:24.
    • At VF(Dsub)≅0.6V and VCC=14V (more than VCC,OFF of FA5311BP) ,this equation calls for
       NS:NSUB = 24:14.


                       All Rights Reserved Copyright (C) Bee Technologies Corporation 2010         19
3.4 Transformer Turn Ratio
                          VP = 275V

VP
                                                                                                Analysis
                                                                                                Time Domain (Transient)
                                                                                                   Run to time: 60ms
                                                                                                   Start saving data after: 40ms
                         VS = 52.8V                                                               Maximum step size: 100ns

VS                                                                                              .Options
                                                                                                RELTOL:         0.01
                                                                                                VNTOL:          1.0m
                                                                                                ABSTOL:         100.0n
                                                                                                CHGTOL:         0.1p
                     VSUB = 30.8V
                                                                                                GMIN:           1.0E-12
VSUB                                                                                            ITL1:           500
                                                                                                ITL2:           200
                                                                                                ITL4:           20




•    This figure shows the waveforms of the voltages at each side of the transformer.



                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      20
3.5 Transformer leakage inductance

•   To model the transformer (or coupled inductors), we can use the SPICE primitive k ,which
    describes the coupling ratio between a primary and a secondary.
•   The k value is obtained as:


                                                 LP , LSS
                                          k = 1−                                               (6)
                                                 LP , LSO

     •   k is the SPICE primitive which describes the coupling ratio between a primary and a
         secondary.
     •   LP,LSS is the Inductance value of primary winding when the secondary winding is shorted.
     •   LP,LSS is the Inductance value of primary winding when the secondary winding is opened.


•   The leakage inductance of the transformer Lleak is describe as equation:


                                     Lleak = LP ⋅ (1 − k 2 )                                   (7)



                         All Rights Reserved Copyright (C) Bee Technologies Corporation 2010         21
3.5 Transformer leakage inductance
                                                                                                                  K K1
                                                                                                                  K_Linear
                                                                                                                  COUPLING = {K}
                                                                                                                  L1 = Lp                         SPICE primitive k
                                                                                                                  L2 = Ls
                                                                                                                  L3 = LsubD21
                                                                                                       Rs_Lp               SF6L20U                                       L21
                                                                                                                                                                                                    OUT
                                                                                                        0.15                                                             8RHB
                                                                                                 C2               2   1              C21          C22
                                                                                    R2           0.022u                              890uF        890uF
                                                                                    33k
              D1                  +                                                                                               ESR21          ESR22                2.2k               +                12
                                                                                    D4           C3        Lp             Ls        33m            33m                R23                                 RL
                       D2SBA60        C1                                       R1                150p      {Lp}           {Nsp*Nsp*Lp}       1            1                                  C23
                                      SMH200VN270-22A                         22k                                                                                                            RJJ-35V221MG5-T20
                                                                                                                  1   2
               1

                   2

                          3

                              4




                                      IC = 154     D                                                                               ESL21         ESL22                                       IC = 23.9
                                                                                      MUR160                                       6.3nH         6.3nH
                                                             M1
                                                             2SK3869
                                                                  G                                ERA91-02
                                                               R3                                  D2                                        2            2
                                                               4.7k                                                   PARAMETERS:
   Vac                                              S                                                             2   Np = 125                                                          R21
                                                                                                                                                         PC1_A
   FREQ = 50Hz                                                                                                                                                                          18k
   VAMPL = {110*1.4142}                                                                          R7                   Ns = 24                                                 R26
   PHASE = 30                                                                                    2.2                  Nsub = 14                                               2.2k
                                                                             R4                                       Lp = 650uH                         PC1_K
                                                                             220                                                                                                        R22
                                            R8                                                   C4                   Nsp = {Ns/Np}                                                     1.8k
                                             0.22                                   DZ1          47u              1                                                     R24
                                                                                                                      Nsubp = {Nsub/Np}
                                                                                                 IC = 22                                                                680
                                                             D3                                            Lsub    K = 0.996055
                                                             ERA91-02                                      {Nsubp*Nsubp*Lp}
                                  0            C8               R9                    MTZJ24B                                                                     K          R25     C24
                                               0.22u            100                                                                                                          330k    0.22u
                                               IC = 2.42                                                                                                    IC2         REF
                                                                 1500p                                                                                   NJM431
                                                                 C7
                                                                                                                                                                  A
                                                                 IC = 2.9                                                                                                               R27
                                                                                                                                                                                       2.2k
                                      R5                                      IC1
                                                    8    7        6      5
                                      220                                     FA5311BP


                                                                                                                                                                                                   0
                                                    1        2     3     4

                                                                                       C5
                                                                                                                                                   Which LP is 650uH , Lleak is
                                                                                                                                 PC1_A
                                                        220                         0.047u
                                                                                    IC = 3.37

                                              R10
                                                        R6
                                                                       C6                 R11
                                                                                          2.2k
                                                                                                                                 PC1_K             5.1184uH for k=0.996055 and
                                                 5.6k            6800p
                                                                                                                      PC1
                                                                                                                  TLP281                           25.74uH for k=0.98.


                                        All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                      22
3.5 Transformer leakage inductance
    M1: VDSS=450V             VDS,peak = 418V (for Lleak=25.74uH)

                               VDS,peak = 331V (for Lleak=5.1184uH)
                                                                                                Analysis
                                                                                                Time Domain (Transient)
                                                                             M1: VDS(t)            Run to time: 1000us
                                                                                                   Start saving data after: 0
                                                                                                   Maximum step size: 80ns
                                                                                                Sweep variable
                                                                                                    Global parameter: k
                                                                                                    Value list: 0.996055, 0.98

                                                                                                .Options
                                                                                                RELTOL:         0.01
                                                                                                VNTOL:          1.0m
                                                                                                ABSTOL:         100.0n
                                                                                                CHGTOL:         0.1p
                                                                                                GMIN:           1.0E-12
                                                                                                ITL1:           500
                                                                                                ITL2:           200
                                                                                                ITL4:           20




•   Simulation result shows that the smaller Lleak gets lower VDS peak voltage ,that means better
    design margin from the MOSFET VDSS


                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                     23
3.6 RCD Clamping network
                                                                                    PARAMETERS:                   K K1
                                            RCD Clamping                            Cclp = 0.022u                 K_Linear
                                                                                                                  COUPLING = {K}
                                              Network                                            CCLP             L1 = Lp
                                                                                                                  L2 = Ls
                                                                                                                  L3 = LsubD21
                                                                                                       Rs_Lp               SF6L20U                                       L21
                                                                                                                                                                                                    OUT
                                                                                                        0.15                                                             8RHB
                                                                                                 C2               2   1              C21          C22
                                                                                    R2           {Cclp}                              890uF        890uF
                                                                                    33k
              D1                  +                                                                                               ESR21          ESR22                2.2k               +                12
                                                                                    D4           C3        Lp             Ls        33m            33m                R23                                 RL
                       D2SBA60        C1                                       R1                150p      {Lp}           {Nsp*Nsp*Lp}       1            1                                  C23
                                      SMH200VN270-22A                         22k                                                                                                            RJJ-35V221MG5-T20
                                                                                                                  1   2
               1

                   2

                          3

                              4




                                      IC = 154     D                                                                               ESL21         ESL22                                       IC = 23.9
                                                                                      MUR160                                       6.3nH         6.3nH
                                                             M1
                                                             2SK3869
                                                                  G                                 ERA91-02
                                                               R3                                   D2                                       2            2
                                                               4.7k                                                   PARAMETERS:
   Vac                                              S                                                             2   Np = 125                                                          R21
                                                                                                                                                         PC1_A
   FREQ = 50Hz                                                                                                                                                                          18k
   VAMPL = {110*1.4142}                                                                          R7                   Ns = 24                                                 R26
   PHASE = 30                                                                                    2.2                  Nsub = 14                                               2.2k
                                                                             R4                                       Lp = 650uH                         PC1_K
                                                                             220                                                                                                        R22
                                            R8                                                   C4                   Nsp = {Ns/Np}                                                     1.8k
                                             0.22                                   DZ1          47u              1                                                     R24
                                                                                                                      Nsubp = {Nsub/Np}
                                                                                                 IC = 22                                                                680
                                                             D3                                            Lsub    K = 0.996055
                                                             ERA91-02                                      {Nsubp*Nsubp*Lp}
                                  0            C8               R9                    MTZJ24B                                                                     K          R25     C24
                                               0.22u            100                                                                                                          330k    0.22u
                                               IC = 2.42                                                                                                    IC2         REF
                                                                 1500p                                                                                   NJM431
                                                                 C7
                                                                                                                                                                  A
                                                                 IC = 2.9                                                                                                               R27
                                                                                                                                                                                       2.2k
                                      R5                                      IC1
                                                    8    7        6      5
                                      220                                     FA5311BP


                                                                                                                                                                                                   0
                                                    1        2     3     4

                                                                                       C5                                        PC1_A
                                                        220                         0.047u
                                                                                    IC = 3.37
                                                        R6
                                              R10                      C6                 R11                                    PC1_K
                                                                                          2.2k
                                                                                                                      PC1
                                                 5.6k            6800p                                            TLP281




                                        All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                      24
3.6 RCD Clamping network
    M1: VDSS=450V


                                                                                                Analysis
                                         VDS,peak = 374V (for CCLP = 1000pF)                   Time Domain (Transient)
                                                                                                   Run to time: 500us
                                            VDS,peak = 332V (for CCLP = 0.022uF)                  Start saving data after: 0
                                                                                                   Maximum step size: 40ns
                                                                                                Sweep variable
                                                                                                    Global parameter: Cclp
                                                                                                    Value list: 0.022u, 1000p
                                                                         M1: VDS(t)
                                                                                                .Options
                                                                                                RELTOL:         0.01
                                                                                                VNTOL:          1.0m
                                                                                                ABSTOL:         100.0n
                                                                                                CHGTOL:         0.1p
                                                                                                GMIN:           1.0E-12
                                                                                                ITL1:           500
                                                                                                ITL2:           200
                                                                                                ITL4:           20




•    Simulation result shows VDS peak voltages for the CCLP(C2) = 0.022uF and 1000pF.
•    A larger CCLP value gets lower VDS peak voltage ,that means better design margin from the
     MOSFET VDSS


                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                    25
4. MOSFET Switching Device M1
                                                                                                                 K K1
                                                                                                                 K_Linear
                                                                                                                 COUPLING = {K}
                                                                                                                 L1 = Lp
                                                                                                                 L2 = Ls
                                                                                                                 L3 = LsubD21
                                               Vin_dc
                                                                                                      Rs_Lp               SF6L20U                                       L21
                                Vin_dc                                                                                                                                                             OUT
                                                                                                      0.15                                                              8RHB
                                                                                                C2               2   1              C21          C22
                                                                                   R2           0.022u                              890uF        890uF
                                                                                   33k
             D1                 +                                                                                                ESR21          ESR22                2.2k               +                12
                                                                                   D4            C3       Lp             Ls        33m            33m                R23                                 RL
                      D2SBA60       C1                                       R1                  150p     {Lp}           {Nsp*Nsp*Lp}       1            1                                  C23
                                    SMH200VN270-22A                         22k                                                                                                             RJJ-35V221MG5-T20
                                                                                                                 1   2
              1

                  2

                       3

                           4




                                    IC = 141.4   D                                                                                ESL21         ESL22                                       IC = 23.9

                                     +                     M1
                                                                                     MUR160                                       6.3nH         6.3nH

                                                           2SK3869
                                     VDS                     R3
                                                                G                                 ERA91-02
                                                                                                  D2                                        2            2
   Vac
   FREQ = 50Hz                       -   ID       S
                                                             4.7k
                                                                                                                 2
                                                                                                                     PARAMETERS:
                                                                                                                     Np = 125                           PC1_A                          R21
                                                                                                                                                                                       18k
   VAMPL = {110*1.4142}                                                                                              Ns = 24
                                                                                                R7                                                                           R26
    PHASE = 30                                                                    MTZJ24B       2.2                  Nsub = 14                                               2.2k
                                                                           R4                                        Lp = 650uH                         PC1_K
                                                                           220                                                                                                         R22
                                          R8                                                                         Nsp = {Ns/Np}                                                     1.9k
                                           0.22                                    DZ1                           1                                                     R24
                                                                                                                     Nsubp = {Nsub/Np}
                                                                                                                                                                       680
                                                       D3                                   C4            Lsub    K = 0.996055
                                             C8        ERA91-02                             47u           {Nsubp*Nsubp*Lp}
                                0            0.22u         R9                               IC = 16.524                                                          K          R25     C24
                                             IC = 2.42     100                                                                                                              330k    0.22u
                                                         C7                                                                                                IC2         REF
                                                         1500p                                                                                          NJM431
                                                         IC = 2.9
                                                                                                                                                                 A
                                                                                                                                                                                       R27
                                                                                                                                                                                      2.2k
                                    R5                                      IC1
                                                  8     7       6      5
                                    220                                     FA5311BP


                                                                                                                                                                                                  0
                                                  1        2    3      4

                                                                                      C5                                        PC1_A
                                                      220                          0.047u
                                                                                   IC = 3.37
                                                      R6
                                            R10                                          R11                                    PC1_K
                                                                C6                       2.2k
                                                                                                                     PC1
                                               5.6k            6800p                                             TLP281




                                      All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                                                                                       26
4.1 M1 Voltage and Current Stresses


                                                                        Vin_dc(t)             Analysis
                                                                                              Time Domain (Transient)
                                  VPEAK = 333V                                                   Run to time: 500ms
                                                                                                 Start saving data after: 0
                                                                                                 Maximum step size: 10us
                                                                        VDS(M1)(t)
                                                                                              .Options
                                                                                              RELTOL:         0.01
                          IPEAK = 2.6A
                                                                                              VNTOL:          1.0m
                                                                                              ABSTOL:         100.0n
                                                                        ID(M1)(t)             CHGTOL:         0.1p
                                                                                              GMIN:           1.0E-12
                                                                                              ITL1:           500
                                                                                              ITL2:           200
                                                                                              ITL4:           20
                                                                    VOUT_24Vdc(t)




•   Simulation result shows the VDS(M1) peak voltage and the ID(M1) peak current.
•   The voltage and current should not exceed the maximum rating of the device M1 (2SK3869:
    VDSS=450V , ID,max=10A).


                        All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                   27
4.2 Losses in M1

                                                                        PLOSS_(M1)(t)
                              Switching
                            loss (turn-off)                                                   Analysis
                                                                                              Time Domain (Transient)
                                                 Switching                                       Run to time: 60ms
                                               loss (turn-on)       Conduction loss              Start saving data after: 40ms
                                                                      (VDS x ID)                 Maximum step size: 100ns
                             Loss(AVG) = 4.64[W]

                                                                                              .Options
                                                                                              RELTOL:         0.01
                                                                                              VNTOL:          1.0m
                                                                                              ABSTOL:         100.0n
                            VDS(t)
                                                                                              CHGTOL:         0.1p
                                                                                              GMIN:           1.0E-12
                                                                ID(t)
                                                                                              ITL1:           500
                                                                                              ITL2:           200
                                                                                              ITL4:           20




•   Simulation results shows waveforms of ID and VDS of MOSFET M1. Switching power loss and
    average power loss are also shown.


                        All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                                      28
4.3 MOSFET Model

•   This figure shows the verification of the MOSFET model with measured fall time
    characteristics ,that is the key to accurate PLOSS_(M1) simulation.


                                                              VGS(t)                        VDS(t)
                                                                                           90%VDS




                                                                                           tf




                                                                                           10%




                                    Measured                       Simulated                         %Error

         Fall time (tf)                40(ns)                      38.976(ns)                        -2.56



                          All Rights Reserved Copyright (C) Bee Technologies Corporation 2010                 29
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書
デザインキット・PWM ICによる電源回路の解説書

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デザインキット・PWM ICによる電源回路の解説書

  • 1. Design Kit Fixed Frequency Switch Mode Power Supply Using FA5311BP All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 1
  • 2. Contents (1/2) Slide # 1. Background 1.1 Flyback Converter................................................................................................ 4-6 1.2 Current Waveforms.............................................................................................. 7 1.3 Equations............................................................................................................. 8 2. Specification............................................................................................................... 9 2.1 Output Voltage..................................................................................................... 10 2.2 Output Current..................................................................................................... 11 2.3 Steady State Initial Conditions............................................................................. 12 2.4 Output Ripple Voltage.......................................................................................... 13 2.5 Efficiency.............................................................................................................. 14 3. Design Consideration................................................................................................. 15 3.1 DC Link Voltage VDC,IN......................................................................................... 16 3.2 Reflected Voltage VRO.......................................................................................... 17 3.3 Transformer Primary Side Inductance LP............................................................. 18 3.4 Transformer Turn Ratio........................................................................................ 19-20 3.5 Transformer Leakage Inductance Lleak................................................................. 21-23 3.6 RCD Clamping Network....................................................................................... 24-25 4. MOSFET Switching Device M1................................................................................... 26 4.1 M1 Voltage and Current Stresses......................................................................... 27 4.2 Losses in M1........................................................................................................ 28 4.3 MOSFET Model................................................................................................... 29 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 2
  • 3. Contents (2/2) Slide # 5. Output Rectifier Diode D21........................................................................................... 30 5.1 D21 Voltage and Current Stresses........................................................................ 31 5.2 Losses in D21....................................................................................................... 32 6. Output Capacitor C21 and C22...................................................................................... 33-35 7. Photocoupler PC1........................................................................................................ 35-36 Simulation Index.............................................................................................................. 38-39 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 3
  • 4. 1.1 Flyback Converter Vin Iin VLS IF,D21 VOUT LP LS D21 + VLP - M1 LC filter stage + VDS - • This figure shows the basic configuration of the converter ( Flyback + LCR load ). • The switch M1 ON and OFF events are separated to see how the devices work. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 4
  • 5. 1.1 Flyback Converter During the M1 ON time Vin D21 LS VLS = Vin Reverse Bias LP M1 LC filter stage ON • This figure shows the current path during the ON time, D21 is reverse biased, and the output capacitor (C21) supplies the LC filter stage on its own. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 5
  • 6. 1.1 Flyback Converter During the M1 OFF time VLS = N ⋅ Vin VOUT D21 LP LS VOUT M1 VDS = Vin + N OFF • During the OFF time, D21 is forward biased , LS starts conducting and charges C21 ,the secondary winding of the flyback transformer starts transferring energy to the power supply output. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 6
  • 7. 1.2 Current Waveforms CCM DCM Vin × ΤΟΝ Iin ΔΙin = Iin Lp Vin × ΤΟΝ ΔΙin = Lp Vin × ΤΟN Vin × ΤΟN IF,D21 ΔΙF , D 21 = IF,D21 ΔΙF , D 21 = N × Lp N × Lp ΤΟN ΤΟN Τ Τ time time Discontinuous current • The current waveforms of Iin and IF,D21 in CCM and DCM mode. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 7
  • 8. 1.3 Equations • The relationship between the VOUT and Vin for the CCM and DCM mode are defined as equations below. NS  D  (1) VOUT , CCM = ⋅  ⋅ Vin NP  1 − D  RL VOUT , DCM = D × Vin × (2) 2 × LP × fsw • The primary side inductance value LP for the DCM mode is calculated as equation below. LP , DCM < (1 − D )2 R ⋅  NP  2  (3) 2 fS  N S  • LP is the inductance of primary winding. • D = TON/T • NP is the turns number of primary winding. • NS is the turns number of secondary winding. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 8
  • 9. 2. Specifications K K1 K_Linear COUPLING = {K} L1 = Lp L2 = Ls L3 = LsubD21 Rs_Lp SF6L20U L21 OUT 0.15 8RHB C2 2 1 C21 C22 R2 0.022u 890uF 890uF 33k D1 + ESR21 ESR22 2.2k + 12 D4 C3 Lp Ls 33m 33m R23 RL D2SBA60 C1 R1 150p {Lp} {Nsp*Nsp*Lp} 1 1 C23 SMH200VN270-22A 22k RJJ-35V221MG5-T20 1 2 1 2 3 4 IC = 0 D ESL21 ESL22 IC = 0 MUR160 6.3nH 6.3nH M1 2SK3869 G ERA91-02 R3 D2 2 2 Vac 4.7k PARAMETERS: FREQ = 50Hz S 2 Np = 125 R21 PC1_A VAMPL = {110*1.4142} 18k R7 Ns = 24 R26 2.2 Nsub = 14 2.2k R4 Lp = 650uH PC1_K 220 R22 R8 C4 Nsp = {Ns/Np} 1.9k 0.22 DZ1 1 R24 47u Nsubp = {Nsub/Np} 680 D3 Lsub K = 0.996055 ERA91-02 {Nsubp*Nsubp*Lp} 0 C8 R9 MTZJ24B K R25 C24 0.22u 100 330k 0.22u IC = 0 IC2 REF C7 NJM431 1500p A R27 2.2k R5 IC1 8 7 6 5 220 FA5311BP VIN = 110Vrms 0 1 2 3 4 C5 PC1_A VOUT = 24V 220 0.047u R6 IOUT = 2A , DCM R10 C6 R11 PC1_K 2.2k PC1 fSW = 30kHz 5.6k 6800p TLP281 Output voltage ripple < 0.06VP-P %Efficiency = 85.6 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 9
  • 10. 2.1 Output Voltage Analysis Overshoot voltage Time Domain (Transient) Run to time: 500ms Start saving data after: 0 Maximum step size: 10us .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • The output voltage is regulated at 24V(RL=12Ω) ,voltage overshoot at startup is less than 1.2V. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 10
  • 11. 2.2 Output Current Analysis Time Domain (Transient) Run to time: 500ms Overshoot current Start saving data after: 0 Maximum step size: 10us .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • The output current is 2A (RL=12Ω) ,current overshoot at startup is less than 100mA. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 11
  • 12. 2.3 Steady State Initial Conditions K K1 K_Linear COUPLING = {K} L1 = Lp L2 = Ls L3 = LsubD21 Vin_dc Rs_Lp SF6L20U L21 Vin_dc OUT 0.15 8RHB C2 2 1 C21 C22 IC(C1) = R2 33k 0.022u 890uF 890uF D1 + 30V D4 C3 Lp Ls ESR21 33m ESR22 33m 2.2k R23 + 12 RL D2SBA60 C1 R1 150p {Lp} {Nsp*Nsp*Lp} 1 1 C23 SMH200VN270-22A 22k RJJ-35V221MG5-T20 1 2 IC(C23) 1 2 3 4 IC = 141.4 D ESL21 ESL22 IC = 23.9 MUR160 6.3nH 6.3nH M1 = 23.9V 2SK3869 G ERA91-02 R3 D2 2 2 Vac 4.7k PARAMETERS: FREQ = 50Hz S 2 Np = 125 R21 PC1_A VAMPL = {110*1.4142} 18k R7 Ns = 24 R26 PHASE = 30 MTZJ24B 2.2 Nsub = 14 2.2k R4 Initial 220 Lp = 650uH PC1_K R22 R8 Nsp = {Ns/Np} 1.9k phase 0.22 DZ1 1 Nsubp = {Nsub/Np} R24 680 = 30 D3 C4 Lsub K = 0.996055 C8 ERA91-02 47u {Nsubp*Nsubp*Lp} 0 0.22u R9 IC = 16.524 K R25 C24 IC = 2.42 100 330k 0.22u IC(C8) = C7 IC(C4) = IC2 REF 2.42V 1500p IC = 2.9 IC(C7) 16.524V NJM431 A = 2.9V R27 2.2k R5 IC1 8 7 6 5 220 FA5311BP IC(C5) = 3.37V 0 1 2 3 4 220 C5 0.047u PC1_A Initial condition are set ,so the R6 IC = 3.37 simulation starts near the steady R10 R11 C6 2.2k PC1 PC1_K state. 5.6k 6800p TLP281 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 12
  • 13. 2.4 Output Ripple Voltage Output ripple voltage Analysis Time Domain (Transient) Run to time: 60ms Start saving data after: 40ms Maximum step size: 100ns .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • The output ripple voltage is less than 60 mVP-P. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 13
  • 14. 2.5 Efficiency  Tracing the %Efficiency of the power supply ,add trace: 100* AVG(W(RL))/ AVG(V(Vin_dc)*I(Vin_dc)) Ploss(M1)= 4.64[W] Analysis Time Domain (Transient) Ploss(D21)= 1.92[W] Run to time: 60ms Start saving data after: 40ms Maximum step size: 100ns Pin= 55.7[W] .Options RELTOL: 0.01 Pout= 47.68[W] VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p GMIN: 1.0E-12 %Efficiency = 85.6 ITL1: 500 ITL2: 200 ITL4: 20  Tracing the %Efficiency of the power supply ,add trace: 100* AVG(W(RL))/ AVG(V(Vin_dc)*I(Vin_dc)) • The simulation result shows that the efficiency of the power supply is 85.6%. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 14
  • 15. 3. Design Considerations K K1 K_Linear VIN ,DC COUPLING = {K} L1 = Lp L2 = Ls VOUT L3 = LsubD21 Vin_dc Rs_Lp SF6L20U L21 Vin_dc OUT - R2 C2 0.022u 0.15 2 1 C21 890uF C22 890uF 8RHB VRO 33k D1 + ESR21 ESR22 2.2k + 12 D4 C3 Lp Ls 33m 33m R23 RL D2SBA60 C1 SMH200VN270-22A + R1 22k 150p {Lp} 1 2 {Nsp*Nsp*Lp} 1 1 C23 RJJ-35V221MG5-T20 1 2 3 4 IC = 141.4 D ESL21 ESL22 IC = 23.9 + M1 MUR160 6.3nH 6.3nH 2SK3869 VDS R3 G ERA91-02 D2 2 2 Vac FREQ = 50Hz - S 4.7k 2 PARAMETERS: Np = 125 PC1_A R21 18k VAMPL = {110*1.4142} Ns = 24 R7 R26 PHASE = 30 MTZJ24B 2.2 Nsub = 14 2.2k R4 Lp = 650uH PC1_K 220 R22 R8 Nsp = {Ns/Np} 1.8k 0.22 DZ1 1 R24 Nsubp = {Nsub/Np} 680 D3 C4 Lsub K = 0.996055 C8 ERA91-02 47u {Nsubp*Nsubp*Lp} 0 0.22u R9 IC = 16.524 R25 C24 IC = 2.42 100 330k 0.22u C7 IC2 1500p TL431 IC = 2.9 Lp =650uH R27 R5 8 7 6 5 IC1 NP:NS:NSUB = 125:24:14 2.2k 220 FA5311BP 0 1 2 3 4 C5 PC1_A 220 0.047u IC = 3.37 R6 R10 R11 PC1_K C6 2.2k PC1 5.6k 6800p TLP281 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 15
  • 16. 3.1 DC Link Voltage VIN,DC Maximum VIN ,DC = 154V Analysis Time Domain (Transient) Run to time: 500ms Minimum VIN ,DC = 139V Start saving data after: 0 Maximum step size: 10us .Options RELTOL: 0.01 VLINE, = 110Vac VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • The simulation result shows the peak values of the ripple of DC link voltage VIN,DC. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 16
  • 17. 3.2 Reflected Voltage VRO VDS(M1) = VDC,IN + VRO = 283V Zoomed Analysis VRO = 153.71V Time Domain (Transient) VDC,IN Run to time: 60ms Start saving data after: 40ms Maximum step size: 100ns .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p VDS(M1) GMIN: 1.0E-12 VDC,IN ITL1: 500 ITL2: 200 ITL4: 20 • This figure shows the waveform of the drain voltage of flyback converter compared to the VDC,IN. • When M1 is turned off ,VDS = VDC,IN + VRO • VRO is the voltage reflected to the primary, the value is approximately VOUT / N ,which N=NS/NP All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 17
  • 18. 3.3 Transformer Primary Side Inductance LP Analysis Time Domain (Transient) Run to time: 60ms Start saving data after: 40ms ΤΟN Maximum step size: 100ns Τ V(PWM_OUT) .Options RELTOL: 0.01 ID(M1) = VDC,IN TON /Lp= 2.34A VNTOL: 1.0m IF(D21) = 11.667A ABSTOL: 100.0n CHGTOL: 0.1p Discontinuous GMIN: 1.0E-12 current ITL1: 500 ITL2: 200 ITL4: 20 • This figure shows the waveforms of ID(M1) and IF(D21 ) in the DCM mode. The peak currents are obtained. • The primary-side inductance (LP) of the transformer determines the converter operation mode. • Once the duty ratio is determined by the equation (1), LP is obtained as the equation (3) • Which the maximum load is 2A (VO=24V, RL=12Ω). At VIN,dc=141V and fs=30kHz ,this equation calls for Lp,DCM < 1.52mH. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 18
  • 19. 3.4 Transformer Turn Ratio The turn ratio between the primary side and the secondary side is obtained as: NS VOUT + VF ( D 21) = (4) NP VRO The turn ratio between the primary side and the auxiliary side is obtained as: NSUB VCC + VF ( Dsub ) = (5) NS VOUT + VF ( D 21) Which the maximum load current is 2A (VO=24V, RL=12Ω). • At VF(D21)≅0.6V and VRO=129V ,this equation calls for NP:NS = 125:24. • At VF(Dsub)≅0.6V and VCC=14V (more than VCC,OFF of FA5311BP) ,this equation calls for NS:NSUB = 24:14. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 19
  • 20. 3.4 Transformer Turn Ratio VP = 275V VP Analysis Time Domain (Transient) Run to time: 60ms Start saving data after: 40ms VS = 52.8V Maximum step size: 100ns VS .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p VSUB = 30.8V GMIN: 1.0E-12 VSUB ITL1: 500 ITL2: 200 ITL4: 20 • This figure shows the waveforms of the voltages at each side of the transformer. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 20
  • 21. 3.5 Transformer leakage inductance • To model the transformer (or coupled inductors), we can use the SPICE primitive k ,which describes the coupling ratio between a primary and a secondary. • The k value is obtained as: LP , LSS k = 1− (6) LP , LSO • k is the SPICE primitive which describes the coupling ratio between a primary and a secondary. • LP,LSS is the Inductance value of primary winding when the secondary winding is shorted. • LP,LSS is the Inductance value of primary winding when the secondary winding is opened. • The leakage inductance of the transformer Lleak is describe as equation: Lleak = LP ⋅ (1 − k 2 ) (7) All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 21
  • 22. 3.5 Transformer leakage inductance K K1 K_Linear COUPLING = {K} L1 = Lp SPICE primitive k L2 = Ls L3 = LsubD21 Rs_Lp SF6L20U L21 OUT 0.15 8RHB C2 2 1 C21 C22 R2 0.022u 890uF 890uF 33k D1 + ESR21 ESR22 2.2k + 12 D4 C3 Lp Ls 33m 33m R23 RL D2SBA60 C1 R1 150p {Lp} {Nsp*Nsp*Lp} 1 1 C23 SMH200VN270-22A 22k RJJ-35V221MG5-T20 1 2 1 2 3 4 IC = 154 D ESL21 ESL22 IC = 23.9 MUR160 6.3nH 6.3nH M1 2SK3869 G ERA91-02 R3 D2 2 2 4.7k PARAMETERS: Vac S 2 Np = 125 R21 PC1_A FREQ = 50Hz 18k VAMPL = {110*1.4142} R7 Ns = 24 R26 PHASE = 30 2.2 Nsub = 14 2.2k R4 Lp = 650uH PC1_K 220 R22 R8 C4 Nsp = {Ns/Np} 1.8k 0.22 DZ1 47u 1 R24 Nsubp = {Nsub/Np} IC = 22 680 D3 Lsub K = 0.996055 ERA91-02 {Nsubp*Nsubp*Lp} 0 C8 R9 MTZJ24B K R25 C24 0.22u 100 330k 0.22u IC = 2.42 IC2 REF 1500p NJM431 C7 A IC = 2.9 R27 2.2k R5 IC1 8 7 6 5 220 FA5311BP 0 1 2 3 4 C5 Which LP is 650uH , Lleak is PC1_A 220 0.047u IC = 3.37 R10 R6 C6 R11 2.2k PC1_K 5.1184uH for k=0.996055 and 5.6k 6800p PC1 TLP281 25.74uH for k=0.98. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 22
  • 23. 3.5 Transformer leakage inductance M1: VDSS=450V VDS,peak = 418V (for Lleak=25.74uH) VDS,peak = 331V (for Lleak=5.1184uH) Analysis Time Domain (Transient) M1: VDS(t) Run to time: 1000us Start saving data after: 0 Maximum step size: 80ns Sweep variable  Global parameter: k  Value list: 0.996055, 0.98 .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • Simulation result shows that the smaller Lleak gets lower VDS peak voltage ,that means better design margin from the MOSFET VDSS All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 23
  • 24. 3.6 RCD Clamping network PARAMETERS: K K1 RCD Clamping Cclp = 0.022u K_Linear COUPLING = {K} Network CCLP L1 = Lp L2 = Ls L3 = LsubD21 Rs_Lp SF6L20U L21 OUT 0.15 8RHB C2 2 1 C21 C22 R2 {Cclp} 890uF 890uF 33k D1 + ESR21 ESR22 2.2k + 12 D4 C3 Lp Ls 33m 33m R23 RL D2SBA60 C1 R1 150p {Lp} {Nsp*Nsp*Lp} 1 1 C23 SMH200VN270-22A 22k RJJ-35V221MG5-T20 1 2 1 2 3 4 IC = 154 D ESL21 ESL22 IC = 23.9 MUR160 6.3nH 6.3nH M1 2SK3869 G ERA91-02 R3 D2 2 2 4.7k PARAMETERS: Vac S 2 Np = 125 R21 PC1_A FREQ = 50Hz 18k VAMPL = {110*1.4142} R7 Ns = 24 R26 PHASE = 30 2.2 Nsub = 14 2.2k R4 Lp = 650uH PC1_K 220 R22 R8 C4 Nsp = {Ns/Np} 1.8k 0.22 DZ1 47u 1 R24 Nsubp = {Nsub/Np} IC = 22 680 D3 Lsub K = 0.996055 ERA91-02 {Nsubp*Nsubp*Lp} 0 C8 R9 MTZJ24B K R25 C24 0.22u 100 330k 0.22u IC = 2.42 IC2 REF 1500p NJM431 C7 A IC = 2.9 R27 2.2k R5 IC1 8 7 6 5 220 FA5311BP 0 1 2 3 4 C5 PC1_A 220 0.047u IC = 3.37 R6 R10 C6 R11 PC1_K 2.2k PC1 5.6k 6800p TLP281 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 24
  • 25. 3.6 RCD Clamping network M1: VDSS=450V Analysis VDS,peak = 374V (for CCLP = 1000pF) Time Domain (Transient) Run to time: 500us VDS,peak = 332V (for CCLP = 0.022uF) Start saving data after: 0 Maximum step size: 40ns Sweep variable  Global parameter: Cclp  Value list: 0.022u, 1000p M1: VDS(t) .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n CHGTOL: 0.1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 • Simulation result shows VDS peak voltages for the CCLP(C2) = 0.022uF and 1000pF. • A larger CCLP value gets lower VDS peak voltage ,that means better design margin from the MOSFET VDSS All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 25
  • 26. 4. MOSFET Switching Device M1 K K1 K_Linear COUPLING = {K} L1 = Lp L2 = Ls L3 = LsubD21 Vin_dc Rs_Lp SF6L20U L21 Vin_dc OUT 0.15 8RHB C2 2 1 C21 C22 R2 0.022u 890uF 890uF 33k D1 + ESR21 ESR22 2.2k + 12 D4 C3 Lp Ls 33m 33m R23 RL D2SBA60 C1 R1 150p {Lp} {Nsp*Nsp*Lp} 1 1 C23 SMH200VN270-22A 22k RJJ-35V221MG5-T20 1 2 1 2 3 4 IC = 141.4 D ESL21 ESL22 IC = 23.9 + M1 MUR160 6.3nH 6.3nH 2SK3869 VDS R3 G ERA91-02 D2 2 2 Vac FREQ = 50Hz - ID S 4.7k 2 PARAMETERS: Np = 125 PC1_A R21 18k VAMPL = {110*1.4142} Ns = 24 R7 R26 PHASE = 30 MTZJ24B 2.2 Nsub = 14 2.2k R4 Lp = 650uH PC1_K 220 R22 R8 Nsp = {Ns/Np} 1.9k 0.22 DZ1 1 R24 Nsubp = {Nsub/Np} 680 D3 C4 Lsub K = 0.996055 C8 ERA91-02 47u {Nsubp*Nsubp*Lp} 0 0.22u R9 IC = 16.524 K R25 C24 IC = 2.42 100 330k 0.22u C7 IC2 REF 1500p NJM431 IC = 2.9 A R27 2.2k R5 IC1 8 7 6 5 220 FA5311BP 0 1 2 3 4 C5 PC1_A 220 0.047u IC = 3.37 R6 R10 R11 PC1_K C6 2.2k PC1 5.6k 6800p TLP281 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 26
  • 27. 4.1 M1 Voltage and Current Stresses Vin_dc(t) Analysis Time Domain (Transient) VPEAK = 333V Run to time: 500ms Start saving data after: 0 Maximum step size: 10us VDS(M1)(t) .Options RELTOL: 0.01 IPEAK = 2.6A VNTOL: 1.0m ABSTOL: 100.0n ID(M1)(t) CHGTOL: 0.1p GMIN: 1.0E-12 ITL1: 500 ITL2: 200 ITL4: 20 VOUT_24Vdc(t) • Simulation result shows the VDS(M1) peak voltage and the ID(M1) peak current. • The voltage and current should not exceed the maximum rating of the device M1 (2SK3869: VDSS=450V , ID,max=10A). All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 27
  • 28. 4.2 Losses in M1 PLOSS_(M1)(t) Switching loss (turn-off) Analysis Time Domain (Transient) Switching Run to time: 60ms loss (turn-on) Conduction loss Start saving data after: 40ms (VDS x ID) Maximum step size: 100ns Loss(AVG) = 4.64[W] .Options RELTOL: 0.01 VNTOL: 1.0m ABSTOL: 100.0n VDS(t) CHGTOL: 0.1p GMIN: 1.0E-12 ID(t) ITL1: 500 ITL2: 200 ITL4: 20 • Simulation results shows waveforms of ID and VDS of MOSFET M1. Switching power loss and average power loss are also shown. All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 28
  • 29. 4.3 MOSFET Model • This figure shows the verification of the MOSFET model with measured fall time characteristics ,that is the key to accurate PLOSS_(M1) simulation. VGS(t) VDS(t) 90%VDS tf 10% Measured Simulated %Error Fall time (tf) 40(ns) 38.976(ns) -2.56 All Rights Reserved Copyright (C) Bee Technologies Corporation 2010 29