jeffrey hwang 10 min to design your power supply (v) 1 design a champion ac adapter jeffrey h. hwang...

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Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

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Page 1: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

1

Design a

Champion AC Adapter

Jeffrey H. Hwang

CM6805/CM6806/CM6903/CM6201

Page 2: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

2

CM6805/CM6806/CM6903/CM6201

Championand

FairChild

Two Sources:

Page 3: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

3

CM6805/CM6806/CM6903/CM6201

WithCM6805, CM6806, CM6903

vs.

CRM +PWM

Cost Reduction by $0.30 to $0.20

Page 4: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

4

Jeffrey Hwang10 min to design your power supply (V) CM6805/CM6806/CM6903/CM6201

If the Microprocessor

Is the brain of the system,then the

Power Supplyis the heart.

Page 5: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

5

Jeffrey Hwang10 min to design your power supply (V) CM6805/CM6806/CM6903/CM6201

High Density AC Adapter

The Challenge: High Efficiency at Low Line (90VAC)

Page 6: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

6

Jeffrey Hwang10 min to design your power supply (V) CM6805/CM6806/CM6903/CM6201

Typical Power vs. Efficiency

Page 7: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

7

Jeffrey Hwang10 min to design your power supply (V) CM6805/CM6806/CM6903/CM6201

High Density AC Adapter

Page 8: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

8

CM6805/CM6806/CM6903/CM6201

How to increase the Efficiency?(Rule of Thumb)

• Full Load due to Conduction Loss = I x I x R:

1. Spend more money to reduce R such as reduce Rdson of Mosfet

2. Reduce I by increasing VIN

• Light Load due to Switching Loss = fsw x C x V x V:

1. Reduce C

2. Reduce V = ZVS

3. Reduce fsw => Green Mode

Page 9: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

9

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Failure Rate Vs. Temperature

Page 10: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

10

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

It is desired to have a uniform Surface Temperature for Convection and Radiation

By Proper Layout/Package/Enclosure

Page 11: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

11

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Maximum Power Dissipation vs. Shape

By Proper Layout/Package/Enclosure

Page 12: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

12

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

The Maximum Output Power vs. Shape

h , Po

h , Po

By Proper Layout/Package/Enclosure

Page 13: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

13

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Use the better Core Shape

By Proper Layout/Package/Enclosure

Due to the smooth surface, it has the better heat convection

Page 14: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

14

Full Load Condition Analysis

A Good AC Adapter Layout

Keep the temperature uniform through out the board

By Proper Layout/Package/Enclosure

Page 15: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

15

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

36W Fly Back AC Adapter Experimental Result

Design a Flyback Converter

Page 16: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

16

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

36W Fly Back AC Adapter Experimental Result

Design a Flyback Converter

η~85.6% @ 90VAC with full load

Page 17: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

17

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Improve Flyback Transformer Power Loss?

1. Reduce the n, Turn Ratio to reduce the Secondary Peak Current

• When n ,Ip ,Is , D , Lm , Ls , then Maximum Secondary Voltage .

• When n , Ip , Is , D is , Lm , Ls ,then Maximum Secondary Voltage .

2. Increase the Flyback input voltage3. Use the better RM core instead of EPC core

Design Flyback Converter

Page 18: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

18

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Improve Flyback Transformer Power Loss?

Design Flyback Converter

Page 19: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

19

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

• Increase the Flyback input Voltage

• Use SR, Synchronous Rectification + DCM

• Reduce the secondary current by reducing n, the turn

ratio of Transformer (This will increase Mosfet Loss.)

Design a Flyback Converter

Page 20: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

20

Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

Use a Synchronous Rectifier

Page 21: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

21

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has the lower efficiencydue to Trr, body diode recovery issue

Page 22: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

22

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has Trr, body diode recovery issue

Page 23: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

23

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has Trr, body diode recovery issue

Page 24: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

24

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has Trr, body diode recovery issue

DCM Efficiency vs. Input voltage

86%,Efficiency @ 200V, Vin

Page 25: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

25

Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has Trr, body diode recovery issue

Solution:

•Use DCM + SR, Synchronous Rectifier + Vin >200V + Reduce n

Page 26: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

26

Full Load Condition Analysis

How To Reduce Flyback Diode Rectifier Power Loss?

Design a Flyback Converter

CCM + Synchronous Rectification has Trr, body diode recovery issue

Solution:Use DCM + SR, Synchronous Rectifier + Vin > 200V + Reduce n

Load=3A / Fans

75.00%

80.00%

85.00%

90.00%

60 80 100 120 140 160 180 200 220 240 260 280

Input Voltage

Effici

ency Only Schottky

Only SR

SR+Schottky

Page 27: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

27

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

How To Improve Flyback MOSFET Power Loss?

• Increase the Flyback input voltage so conduction loss can be reduced due to D drops.

• Using DCM to prevent the Trr, diode reverse current issue

• Use a lower Rdson Mosfet• Use ZVS

Design Flyback Converter

Page 28: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

28

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Conventional Flyback Converter:

Design Flyback Converter

LC tank’s C is due to S1and

It is very small, so Ring frequency

(resonant frequency) is high.

Page 29: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

29

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Conventional Flyback Converter:

Design Flyback Converter

Vds,S1

Ip

The Energy Stored in leakage inductor is wasted in the ringing.

resonant f is high so it is difficult to control (manufacture control) it.

Page 30: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

30

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

ZVS Flyback Converter: Active Clamp

Design Flyback Converter

LC tank’s C is due to Cclamp~1uFand

It is relative big, so Ring frequency

(resonant frequency) is lower.

Page 31: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

31

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

ZVS Flyback Converter: Active Clamp

Design Flyback Converter

No RingandZVS

The energy is stored in the core;release to the input

Page 32: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

32

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

ZVS Flyback Converter: Active Clamp

Design Flyback Converter

No RingandZVS

Page 33: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

33

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

ZVS Flyback Converter: Active Clamp

Design Flyback Converter

4.5% Improvement

Page 34: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

34

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

ZVS Flyback Converter: Active Clamp

Design Flyback Converter

4.5% Improvement due to:•Energy in leakage L and Snubber is saved (Clamped)•Energy in Vds-parasitic capacitor is saved (ZVS)

However, it is expensive:• It needs a high side driver, an extra high side Mosfet

and a simple control circuit• Can we do it without additional cost?

Page 35: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

35

Full Load Condition Analysis

ZVS Flyback:Secondary Synchronous Rectifier

with CM6201 (smart driver)

Design Flyback Converter

LC tank’s C becomes to Co/(n x n)~25uF to 50uF

andIt is big,

so Ring frequency (resonant frequency) is very

low.

Page 36: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

36

Full Load Condition Analysis

ZVS Flyback:Secondary Synchronous Rectifier

with CM6201 (smart driver)

Design Flyback Converter

Benefits:• It does not need high side driver and high side mosfet

• Synchronous Rectification at DCM

Fly back full load Efficiency is increased from

~86% to~90% at Flyback input=200V

Page 37: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

37

Full Load Condition Analysis

Summary:designing Flyback Converter @ full load & Vin=200V

Design Flyback Converter

Without additional cost: Efficiency~87.5% @Full load•Vin >= 200V (with PFC-PWM combo CM6805/06/CM6903)…. Δη =3%• n, turn ratio = 5 or 6….Reduce Is peak current• Full load at DCM but approach to CCM….remove Trr• ZVS by controlling LC variation….Δη=1.5%

With additional cost: Efficiency~93% @Full load• Secondary Synchronous Rectifier +ZVS: (CM6201) # Total additional Δ$~ $0.3 at high volume…. Δη=2%• RM core #Δ$ ~$0.2 at high volume….. Δη=1.5%• ZVS Active Clamp at primary side….Δ$ ~$0.8 with Δη=2%

Without the proper design, efficiency could be below 80%.

Page 38: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

38

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Design a Follower Boost PFC

Choose Follower Boost InductorCM6805 family vs. CRM, 6561

• L ↑, Efficiency ↑• For CRM, 6561, it cannot increase boost inductance.

1. L↑, frequency needs to go lower and it can go below 20Khz2. Ton=L / Rload; for a given load, Ton is a constant3. L ~ 471uH cannot go higher for the Po = 100W 4. Ipeak = Iin Peak x 2 (I x I x R is big; efficiency is poor!)5. At high line and light load, frequency can go above 400Khz (EMI

issue is severe.)• For CM6805/CM6806/CM6903 fixed switching frequency=67.5Khz,

1. Lcm6805 family ~ Lcrm (67.5khz) x 5 (Optimal Inductance Value)2. Lcrm ~ 209uH @ 90VAC3. Loptimal = 1050 uH @ 100W to L= 698 uH @150W4. L ↑, Efficiency ↑5. Both the cost of Boost Mos and Boost Rectifier can be reduced

• Efficiency (CCM) – Efficiency (CRM) > 3% (total system)

Page 39: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

39

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

η=91.37%, Vin=90VAC, Po=1KW

2%

MOSFETMOSFET

MOSFET

Boost Power Dissipation Breakdown

Boost 400V Cap

Design a Follower Boost PFC

1%

Page 40: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

40

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

η=91.37%, Vin=90VAC, Po=1KW

Design a Follower Boost PFC

Page 41: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

41

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Power Dissipation in Boost Diode

Design a Follower Boost PFC

Page 42: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

42

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Power Dissipation in Boost Mosfet

Dominated One

Design a Follower Boost PFC

Page 43: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

43

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Design a Follower Boost PFC

4.5% Improvement

Page 44: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

44

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

PFC Boost with 380V only

Design a Follower Boost PFC

Page 45: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

45

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Continuous Boost Follower

Added Circuit

VlineDC needs to be closed to Dc and > = 5V.

4.5% Improvement….cost~$0.03

Design a Follower Boost PFC

Page 46: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

46

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Two Level Boost Follower (Q1 on, 200V @ low line and Q1 off 380V @ high line)

4.0% Improvement….cost~$0.02

Added Circuit

VlineDC @ high line will turn off Q1 and @ low line will turn on Q1.

Design a Follower Boost PFC

Page 47: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

47

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Two Level Boost Follower or

Continuous Boost Follower

4.0% to 4.5% Efficiency Improvement….cost~$0.02 to $0.03

Design a Follower Boost PFC

Page 48: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

48

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

PFC Boost Rectifier Trr issue

Design a Follower Boost PFC

Page 49: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

49

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Use SiC to solve PFC Boost Rectifier Trr issue

Δη~1%Δ$~$1.0

Design a Follower Boost PFC

Page 50: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

50

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

SiC will help if the frequency is high.

Design a Follower Boost PFC

Page 51: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

51

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Use Soft Switching to solve Trr issue

Design a Follower Boost PFC

Page 52: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

52

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Use Soft Switching to solve Trr issue

Δη=2%Δ$~$1.3

Design a Follower Boost PFC

Page 53: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

53

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Bridgeless PFC

Design a Follower Boost PFC

Page 54: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

54

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Bridgeless PFC

Δη=1%......Δ$~$0.5

Design a Follower Boost PFC

Page 55: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

55

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Efficiency Improved due to LETE

Design a Follower Boost PFC

Page 56: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

56

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Efficiency Improved due to LETE

Design a Follower Boost PFC

Page 57: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

57

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

CM68XX

CM68XX

Δ$ = -0.1 at no cost…Δη=1% with LETE

Design a Follower Boost PFC

Page 58: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

58

Jeffrey Hwang10 min to design your power supply (V) Full Load Condition Analysis

Design a Follower Boost PFC

Without Cost: Efficiency~95.5% @full load•2 level Boost Follower(200V/380V)….Δη~4%

•CM6805/CM6806/CM6903…. Δη~1%

Summary:design a Boost PFC @ full load and Vin=90Vac

With Cost: Efficiency~97% @full load•SiC…. Δ$~1.0 and Δη~1%

•Soft Switching…. Δ$~1.0 and Δη~1%•Bridgeless PFC…. Δ$~1.0 and Δη~1%

Page 59: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

59

•Without Additional Cost (CM6805/CM6806/CM6903):Efficiency~84.4% @full load & Vin = 90VAC

η pfc x η flyback = 96.5% x 87.5%= 84.4%

Full Load Condition Analysis

Design a Follower Boost PFC

Summary:Design a Champion AC Adapter @ Full Load and Vin=90Vac

•With Δ$~$0.3 (CM6201):Efficiency~86.85% @full load & Vin = 90VAC

η pfc x η flyback = 96.5% x 90%= 86.85%

•With Δ$~$3.3 :Efficiency~90.7% @full load & Vin = 90VAC

η pfc x η flyback = 97.5% x 93%= 90.7%

Page 60: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

60

Jeffrey Hwang10 min to design your power supply (V)

Green Mode

Build-in-Green-ModeCM6805/CM6806/CM6903

The Best Way

to Save Energy

is to “Turn Off”

Your Appliance

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Page 61: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

61

Jeffrey Hwang10 min to design your power supply (V)

Green Mode

Build-in-Green-ModeCM6805/CM6806/CM6903

User Defined GMth, Green-Mode Threshold

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Page 62: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

62

Jeffrey Hwang10 min to design your power supply (V)

CM6805/CM6806/CM6903 Build-In Green Mode Functions

Build-in-Green-ModeCM6805/CM6806/CM6903

•Reduce the switching frequency when the load is light

•Turn off PFC @ GMth

•Bleed Resistor can be 2 Mohm or higher

without influence the turn-on time

•Reduce operating current

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Page 63: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

63

Jeffrey Hwang10 min to design your power supply (V)

Green Mode

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Page 64: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

64

Jeffrey Hwang10 min to design your power supply (V)

The Timing Diagram of fRtCt = 2 x fPWM = 4 x fPFC in CM6805, CM6806 and CM6903

CLK

RTCT

TIME

TIME

TIME

280K Hz

280K Hz

140K HzPWMCLK=Maximum

PWM Duty Cycle

Exactly 50%

No Jitter

TIME

TIME

70K Hz

70K HzPFCCLK

PFC Modulation Ramp

fRtCt

fpwmCM6805

fPFC

fpwmCM6806

Pulse Skipping from the controller

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Page 65: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

65

Jeffrey Hwang10 min to design your power supply (V)

280K Hz TIME

280K Hz

CLK

TIME

RTCTPin 7

140K HzPWMComparatorOutput

TIME

TIME

PWM DutyCycle 140K Hz

No Jitter

Exactly 50% 140K HzMaximum

TIME

PWMCLK=

PWM Duty Cycle

PWM Green Mode Pulse Skipping Timing Diagram

70K Hz/

70K Hz/

70K Hz/

Light Load Efficiency ↑, Goes up, as fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Page 66: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

66

Jeffrey Hwang10 min to design your power supply (V)

Light Load Efficiency ↑, Goes up, as V↓& fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Turn Off PFC!When Load is below

Green Mode Threshold, GMth

Page 67: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

67

Jeffrey Hwang10 min to design your power supply (V)

Light Load Efficiency ↑, Goes up, as V↓& fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Po=100W Design for V+I pin and PWMtrifault

Page 68: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

68

Jeffrey Hwang10 min to design your power supply (V)

Light Load Efficiency ↑, Goes up, as V↓& fpwm↓, Goes down

Build-in-Green-ModeCM6805/CM6806/CM6903

Spread Sheet for the PWM Design for a FlyBackCM6805/CM6806 PWM SECTION for FlyBack Design User Inputs All Resistors, inductor and VCC Units User Inputs the Optical Couple Current and VCC Units

If the cell is filled with yellow color, it is a user input cell. Flyback Input Voltage (minimum) 200 V 200 V

Flyback Output Voltage 19 V 19 VLm p (Primary Side Flyback Inductance) 3.36E-04 H 3.36E-04 HLs (Secondary Side Flyback Inductance) 9.33E-06 H 9.33E-06 H

Turn Ratio, n = Np/Ns 6.00 6.00Switching frequency, fsw 6.75E+04 Hz 6.75E+04 Hz

Switching Period 1.48E-05 S 1.48E-05 SDuty Cycle, D (DCM but use CCM formula) 36.31% % 36.31% %

1-D 63.69% % 63.69% % Maximum Output Power 100 W 100 W

PWM system only efficiency 86% % 86% %Maximum input Power 116 W 116 W

Primary Peak Current @ Full load & Steady State 3.20E+00 A 3.20E+00 A Primary Peak Current with D=Dmax=50% @200V 4.41E+00 A 4.41E+00 A

Secondary Peak Current @200V 2.65E+01 A 2.65E+01 ARpwmsense 3.90E-01 OHM 3.90E-01 OHM

RV+I 500 OHM 500 OHMQphoto Couple Current @ 100% load 5.00E-04 A 5.00E-04 A

Voltage Drop cross RPWMRSENSE @ 100% load 1.25E+00 V 1.25E+00 V Voltage Drop cross RV+I @ 100% load 2.50E-01 V 2.50E-01 VQphoto Couple Current @ 50% load 1.75E-03 A 1.75E-03 A

Voltage Drop cross RPWMRSENSE @ 50% load 6.25E-01 V 6.25E-01 VVoltage Drop cross RV+I @ 50% load 8.75E-01 V 8.75E-01 VQphoto Couple Current @ 20% load 2.50E-03 A 2.50E-03 A

Voltage Drop cross RPWMRSENSE @ 20% load 2.50E-01 V 2.50E-01 VVoltage Drop cross RV+I @ 20% load 1.25E+00 V 1.25E+00 V

RPWMTRIFAULT1 2.60E+03 OHM 2.68E+03 OHMRPWMTRIFAULT2 + RNTC1 4.20E+04 OHM 4.20E+04 OHM

VCC=15V 15 V 15 VPWMTRIFAULT Voltage @ 20% load VCC="B12" 7.76E+00 V 6.80E+00 VPWMTRIFAULT Voltage @ 50% load VCC="B12" 9.71E+00 V 9.57E+00 V

Short Threshold ~ 14.3 V 14.3 VGreen Mode Threshold ~ 6.8 V 6.8 V

VCC=13V 13 V 13 VPWMTRIFAULT Voltage @ 20% load VCC="B18" 5.76E+00 V 5.56E+00 VPWMTRIFAULT Voltage @ 50% load VCC="B18" 7.71E+00 V 7.57E+00 V

Short Threshold ~ 12.3 V 12.3 VGreen Mode Threshold ~ 5.8 V 5.8 V

VCC=10V 10 V 10 VPWMTRIFAULT Voltage @ 20% load VCC="B22" 2.76E+00 V 2.56E+00 VPWMTRIFAULT Voltage @ 50% load VCC="B22" 4.71E+00 V 4.57E+00 V

Short Threshold ~ 9.3 V 9.3 VGreen Mode Threshold ~ 4.3 V 4.3 V

CPWMTRIFAULT 2.24E-07 F 2.24E-07 F CV+I 1.50E-10 F 1.50E-10 F

Design OK or Not TRUE TRUE

Page 69: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

69

Jeffrey Hwang10 min to design your power supply (V)

Increase Start-Up Resistor above 2M ohm without

Increasing Turn-On Time

Build-in-Green-ModeCM6805/CM6806/CM6903

Light Load Efficiency ↑, Goes up, as Rac ↑,V↓& fpwm↓

Page 70: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

70

Jeffrey Hwang10 min to design your power supply (V)

Light Load Efficiency ↑, Goes up, as Rac ↑,V↓& fpwm↓

Build-in-Green-ModeCM6805/CM6806/CM6903

Page 71: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

71

Jeffrey Hwang10 min to design your power supply (V)

Light Load Efficiency ↑, Goes up, as Rac ↑,V↓& fpwm↓

Build-in-Green-ModeCM6805/CM6806/CM6903

RAC functions:

• Serve as a Start-Up Resistor

• Feed-forward input Sine wave for PFC

1. Leading-edge-modulation-PFC-current-loop

slope compensation

2. Power Limit

Page 72: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

72Light Load Efficiency ↑, Goes up, as Rac ↑,V↓& fpwm↓

Build-in-Green-ModeCM6805/CM6806/CM6903

Improve Efficiency @ Light Load

CM6805/CM6806:

•Reduce PWM switching frequency by pulse skipping

•Turn Off PFC @ Green-Mode Threshold, GMth

•Increase Start-Up resistor, RAC > 2M ohm

@ No Load, Pin<0.3W

Page 73: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

73

Jeffrey Hwang10 min to design your power supply (V)

CM6805, CM6806 and CM6903

PFC - FlyBack

AC Adapter Controller

CM6805/CM6806/CM6903/CM6201

Page 74: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

74

Jeffrey Hwang10 min to design your power supply (V)

PFC Start Up then PWM Start Up

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 75: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

75

Jeffrey Hwang10 min to design your power supply (V)

Soft Start for both PFC and Flyback

PFC Soft Start with PWM Soft StartCM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 76: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

76

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

Speed up the PFC Voltage Loop

by 3X

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 77: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

77

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

Error Amplifier

Transconductance Amp, GM vs.

Operational Amp, OP

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 78: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

78

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

Transconductance Amp, GM

Operational Amp, OP

Output Impedance, Zout ?

Output Impedance, Zout ?

Input Impedance Zin?

Input Impedance Zin ?

Zin ~ High

Zin ~ High

Zout ~ High

Zout ~ Low

Transconductance Amp, GM vs.

Operational Amp, OP

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 79: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

79

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

2 Main Purposes of the Error Amp

1. Force V+ = V- and it means Vfb = 2.5V

2. Compensation: It needs the Rc and Cc

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 80: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

80

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

VFB

OP Integrator

The Miller Effect slows down the Vfb node.Also, PFC Voltage Loop is very slow.The consequence: Vfb becomes very slow.

This local feedback is bad!

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 81: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

81

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

For GM,there is no local feedback.There is only one outer loop and there is no inner loop.Vfb is a much faster node.

GM Integrator

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 82: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

82

Jeffrey Hwang10 min to design your power supply (V)

Fast PFC Voltage Loop

GMV (mho)

0

12u/div

2.5V0V 3.0V

Iveao (uA)

12u/div69.3u mho

-208.6nA

0uA

-60uA

60uAFB

VEAOV ΔV

ΔIGM

VFB

VFB=2.51V

CM6805, CM6806 and CM6903CM6805/CM6806/CM6903/CM6201

Page 83: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

83

Jeffrey Hwang10 min to design your power supply (V)

Easy to meet UL1950

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 84: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

84

Jeffrey Hwang10 min to design your power supply (V)

• Leading Edge Modulation PFC• Synchronize with Trailing Edge Modulation PWM• Smaller 400V Bulk Capacitor with 1% better efficiency and 30% ripple reduction• Simplest PFC control, Input Current Shaping Technique, ICST (Open Loop Current Mode)• It works for both CCM or DCM• Fixed Switching Frequency, fpfc = 67.5Khz for easy input EMI filter design• Automatic Slope Compensation with IAC• Rac at IAC pin serves as a Start-Up Resistor• 3X PFC Voltage Loop• PFC has a Tri-fault protections for UL1950• PFC Soft Start• PFC OVP + VCC OVP• PFC Current Limit• Universal Input• AC Brown Out• Automatic Turn Off @ Green Mode• Easy to configure into Boost Follower

PFC Features

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 85: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

85

Jeffrey Hwang10 min to design your power supply (V)

PWM Features

• Design for FlyBack Converter• Constant Maximum Power• Current Mode with inherent slope compensation• Constant Switching Frequency, fpwm = 67.5Khz (CM6805 and

CM6903), fpwm = 135Khz (CM6806)• Exact 50% maximum duty cycle• PWM has a PWMTri-fault protections for short and Green Mode• PWMTrifault can be programmed to turn off PFC @ Green Mode• PWMTrifault can be programmed to detect the short or can be

programmed to do thermal protection• PWM has 10 mS digital soft start• CM6805/CM6806 in 10 pin SOIC packages• CM6903 in 9 pin SIP package

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 86: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

86

Jeffrey Hwang10 min to design your power supply (V)

More Features

· Input Power, Pin<0.3 W @ No Load

· 23V BiCMOS (it can drive IGBT)

· ISTART ~ 100µA

· IOPERATING ~ 2mA without load

· Industry First CM6805/CM6806 PFC-PWM Combo in 10 pin

SOIC packages

· Industry First PFC-PWM Combo CM6903 in 9 pin SIP package

CM6805, CM6806 and CM6903

CM6805/CM6806/CM6903/CM6201

Page 87: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

87

Jeffrey Hwang10 min to design your power supply (V)

CM6903

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6805, CM6806 and CM6903

Page 88: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

88

Jeffrey Hwang10 min to design your power supply (V)

CM

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6805, CM6806 and CM6903

Page 89: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

89

Jeffrey Hwang10 min to design your power supply (V)

CM6903

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6805, CM6806 and CM6903

Page 90: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

90

Jeffrey Hwang10 min to design your power supply (V)

How does it work?

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6805, CM6806 and CM6903

Page 91: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

91

Jeffrey Hwang10 min to design your power supply (V)

10pin SOIC PFC-PWM combo: CM6805/CM6806

Input Current Shaping Technique PFC with Leading Edge Modulation

Page 92: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

92

Jeffrey Hwang10 min to design your power supply (V)

9pin SIP PFC-PWM combo: CM6903

Input Current Shaping Technique PFC with Leading Edge Modulation

Page 93: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

93

Jeffrey Hwang10 min to design your power supply (V)

Typical CM6805/CM6806 & CM6903 application circuit

Circuit configuration has been modified.

400V Rated Capacitors Can Be Used!

6

ISENSE

8VFB

4

PFCOUT

7

VEAO

9IAC

2

VCC

3

PWMOUT

1

DCILIMIT

5

GND

VOUT

2.5V

VREF OK

2.75V

2.5V

-1V

0.5V

18V

VCC_CIRCLE

PWM CLK

19.4V

VREF OK

2.5V

VCC

VFB

1.5V

0.75V

0.5V

VEAO

SS

VCC

+

-

PWMCMP

-

.-

+

R13R14

UVLO

. .

R17

R16

SR1

C21

R2

D8

R15

D10

C1

U2

R10Q3

F1

L1

D1

D2Z1

S

R

Q

Q

R

100K ohm

VCC OVP+

-

.-

+

-

.

PFC OVP+

-

.-

PFC ILIMIT+

-

.

+

-

.

PFCCMP+

-

.

RAC

VIN OK

+

-

.+

. .

S

R

Q

Q

R

D10

R5

400K ohm

R4

10mS

. .

.

C5

C4

D8D9D11

R19

C13

D6

C14R11

C15

C11 C7

C16

C8

R3

C9

D3

R11

C8

R7

R20 T2

C9

T1

C10

D7

R8

R12

PFCCLKB

PWMCLK.

.

R9

Q1

CFilter

Q2

D5

PWMOFF

+

-

.

S

R

Q

Q

R

R

RFIlter

T1

+

+ OUT

U1

SUM

..

.

.

D13

D12

D4

C17

L2

1K ohm

C19

C18

VREFOK

AC IN

FAULTB

PFCCLKB

RAMP

fpfc= 67KHz

R1A

fpwm= 67KHz

67KHz

fpwm=

R1B

fpfc=

134KHz

CM6903 CM6904

Tri-FaultDetect

gmv

ISENSEAMP

OSC

R1C

UVLO

SS

PWMCLK

1V

Input Current Shaping Technique PFC with Leading Edge Modulation

Page 94: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

94

Jeffrey Hwang10 min to design your power supply (V)

PWM SECTIONCM6805, CM6806 and CM6903

Page 95: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

95

Jeffrey Hwang10 min to design your power supply (V)

CM6805/CM6806/CM6903 PFC Controller:

Leading Edge Modulation

with Input Current

Shaping Technique

(ICST)

Input Current Shaping Technique PFC with Leading Edge Modulation

PFC Control

Page 96: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

96

Jeffrey Hwang10 min to design your power supply (V)

•ICST is based on the following equations:

in

ine IVR

inl II

•Equation 2 means: average boost inductor current equals to input current.•Assume that input instantaneous power is about to equal to the output instantaneous power.

doutlin IVIV

•For steady state and for the each phase angle, boost converter DC equation at continuous conduction mode is:

)1(1

dVV

in

out

(3)

Input Current Shaping Technique PFC with Leading Edge Modulation

PFC ControlCM6805, CM6806 and CM6903

Page 97: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

97

Jeffrey Hwang10 min to design your power supply (V)

•Rearrange above equations, (1), (2),(3), and (4) in term of Vout and d, boost converter duty cycle and we can get average boost diode current equation (5):

e

outd R

VdI 2)1(

•Also, the average diode current can be expressed as:

dttIT

IoffT

dsw

d )(1

0

(5)

Input Current Shaping Technique PFC with Leading Edge Modulation

PFC ControlCM6805, CM6806 and CM6903

Page 98: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

98

Jeffrey Hwang10 min to design your power supply (V)

•If the value of the boost inductor is large enough, we can assume

dd ItI ~)(

•It means during each cycle or we can say during the sampling, the diode current is a constant.•Therefore, equation (6) becomes:

)1(' dIdITtI

I ddsw

offdd

, Id is constant during each switching period, 1/67.5khz.

Input Current Shaping Technique PFC with Leading Edge Modulation

PFC ControlCM6805, CM6806 and CM6903

Page 99: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

99

Jeffrey Hwang10 min to design your power supply (V)

•Using this simple equation (8), we implement the PFC control section of the PFC-PWM controller, CM6805, CM6806, CM6903 & CM6501

sw

off

e

outd

e

outd

e

outd

T

t

R

VI

RVdI

RVddI

'

2'' )(

(8)

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

PFC Control

CM6805, CM6806 and CM6903

Page 100: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

100

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

PFC Control

Review Leading Edge Modulation & Average Current Mode PFC Control

CM6805, CM6806 and CM6903

Page 101: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

101

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

ModulationCM6805, CM6806 and CM6903

Page 102: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

102

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

ModulationCM6805, CM6806 and CM6903

Page 103: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

103

Jeffrey Hwang10 min to design your power supply (V)

Usually, the pole of Isense filter ~ 1/6 of the switchingfrequency, and it is 67.5khz/6 = 1/(2×π×Rfilter×Cfilter)

If Rfilter =1K Ω, Cfilter=14.15nF.

2 purposes to add Isense filter:• Protect IC during inrush current• Using smaller inductor and still having good THD

Input Current Shaping Technique (ICST) PFC with Leading Edge

ModulationCM6805, CM6806 and CM6903

Page 104: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

104

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 105: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

105

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 106: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

106

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 107: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

107

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 108: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

108

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 109: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

109

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 110: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

110

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 111: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

111

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 112: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

112

Jeffrey Hwang10 min to design your power supply (V) Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 113: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

113

Jeffrey Hwang10 min to design your power supply (V)

PFC Section

For CM6805/CM6806 & CM6903,Bleed Resistor Not Required

Negative Charge Pump Not Requiredfor the PFC section

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope CompensationCM6805, CM6806 and CM6903

Page 114: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

114

Jeffrey Hwang10 min to design your power supply (V)

TIME

IACTIME

ISENSEOUT

TIME

ISENSEOUT+IAC

IAC enhances the THD during light load and high line ftSinB 2

ftSinA 2

ftSinBA 2)(

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

D<50% needs Slope Compensation

CM6805, CM6806 and CM6903

Page 115: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

115

Jeffrey Hwang10 min to design your power supply (V)

CM6800 or CM6805 Family

For CM6800 family, ΔVEAO=6V-0.625V=5.375V and For CM6805, CM6806 and CM6903, ΔVEAO=(6V-0.625V)/4=1.34V

Input Current Shaping Technique PFC with Leading Edge Modulation

Voltage LoopCM6805, CM6806 and CM6903

Page 116: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

116

Jeffrey Hwang10 min to design your power supply (V)

CM6805/CM6806 & CM6903 PWM Control:

1.5V Precision Current CMP +

10 ms Digital Soft Start

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation&

Trailing Edge Modulation PWM

Page 117: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

117

Jeffrey Hwang10 min to design your power supply (V)

PWM Section

6

ISENSE

8VFB

4

PFCOUT

7

VEAO

9IAC

2

VCC

3

PWMOUT

1

DCILIMIT

5

GND

VOUT

2.5V

VREF OK

2.75V

2.5V

-1V

0.5V

18V

VCC_CIRCLE

PWM CLK

19.4V

VREF OK

2.5V

VCC

VFB

1.5V

0.75V

0.5V

VEAO

SS

VCC

+

-

PWMCMP

-

.-

+

R13R14

UVLO

. .

R17

R16

SR1

C21

R2

D8

R15

D10

C1

U2

R10Q3

F1

L1

D1

D2Z1

S

R

Q

Q

R

100K ohm

VCC OVP+

-

.-

+

-

.

PFC OVP+

-

.-

PFC ILIMIT+

-

.

+

-

.

PFCCMP+

-

.

RAC

VIN OK

+

-

.+

. .

S

R

Q

Q

R

D10

R5

400K ohm

R4

10mS

. .

.

C5

C4

D8D9D11

R19

C13

D6

C14R11

C15

C11 C7

C16

C8

R3

C9

D3

R11

C8

R7

R20 T2

C9

T1

C10

D7

R8

R12

PFCCLKB

PWMCLK.

.

R9

Q1

CFilter

Q2

D5

PWMOFF

+

-

.

S

R

Q

Q

R

R

RFIlter

T1

+

+ OUT

U1

SUM

..

.

.

D13

D12

D4

C17

L2

1K ohm

C19

C18

VREFOK

AC IN

FAULTB

PFCCLKB

RAMP

fpfc= 67KHz

R1A

fpwm= 67KHz

67KHz

fpwm=

R1B

fpfc=

134KHz

CM6903 CM6904

Tri-FaultDetect

gmv

ISENSEAMP

OSC

R1C

UVLO

SS

PWMCLK

1V

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation&

Trailing Edge Modulation PWM

Page 118: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

118

Input Current Shaping Technique (ICST) PFC with Leading Edge

Modulation

Page 119: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

119

Design High Density AC Adapter

8 Pin 12V Secondary Fly Back Smart Driver, CM6201

VREF1

VCC2

VL_VTH3

VL4

AGND6

DCM_DET5

SRDRV7

PGND8

VCC

VOUT

VBUS

PWM

D2

D3

D4

R3

R2

R1

D1

C3

C2

C1

R5

R4

+

-

R6

-25mVM2

DIGITALCONTROL

DRV

CM62

01

VCC

DCM_DET

VREF

AGNDVL_VTH

VL

SRDRV

PGND

+

-

UVLOBIASBG

M1

OSC

Page 120: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

120

Design High Density AC Adapter

8 Pin 12V Secondary Fly Back Smart Driver, CM6201

• Pin to pin compatible with STSR30• Supply voltage range: 7 to 13.2V• Feed-Forward Peak Detect for wide input range• CCM or DCM Fly-back operation• Operating Frequency: up to 750 KHz• Automatic turn off for duty cycle less than 12.5%• Smart turn off (240nS)• Output driver: 15 Ohms sourcing and 6 Ohms

sinking capability

Page 121: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

121

24-hour Engineering Supports

• Champion Design Center– www.champion-micro.com

• Design Excel Spread Sheets– PWM design for Flyback Converter Section– CM6805, CM6806, CM6903 Design Tool

Input Current Shaping Technique PFC with Leading Edge Modulation

Page 122: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

122

PWM design for Flyback Converter Section

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6805/CM6806 PWM SECTION for FlyBack Design User Inputs All Resistors, inductor and VCC Units User Inputs the Optical Couple Current and VCC

If the cell is filled with yellow color, it is a user input cell. Flyback Input Voltage (minimum) 200 V 200

Flyback Output Voltage 19 V 19Lm p (Primary Side Flyback Inductance) 3.36E-04 H 3.36E-04Ls (Secondary Side Flyback Inductance) 9.33E-06 H 9.33E-06

Turn Ratio, n = Np/Ns 6.00 6.00Switching frequency, fsw 6.75E+04 Hz 6.75E+04

Switching Period 1.48E-05 S 1.48E-05Duty Cycle, D (DCM but use CCM formula) 36.31% % 36.31%

1-D 63.69% % 63.69%Maximum Output Power 100 W 100

PWM system only efficiency 86% % 86%Maximum input Power 116 W 116

Primary Peak Current @ Full load & Steady State 3.20E+00 A 3.20E+00Primary Peak Current with D=Dmax=50% @200V 4.41E+00 A 4.41E+00

Secondary Peak Current @200V 2.65E+01 A 2.65E+01Rpwmsense 3.90E-01 OHM 3.90E-01

RV+I 500 OHM 500Qphoto Couple Current @ 100% load 5.00E-04 A 5.00E-04

Voltage Drop cross RPWMRSENSE @ 100% load 1.25E+00 V 1.25E+00Voltage Drop cross RV+I @ 100% load 2.50E-01 V 2.50E-01

Qphoto Couple Current @ 50% load 1.75E-03 A 1.75E-03Voltage Drop cross RPWMRSENSE @ 50% load 6.25E-01 V 6.25E-01

Voltage Drop cross RV+I @ 50% load 8.75E-01 V 8.75E-01Qphoto Couple Current @ 20% load 2.50E-03 A 2.50E-03

Voltage Drop cross RPWMRSENSE @ 20% load 2.50E-01 V 2.50E-01Voltage Drop cross RV+I @ 20% load 1.25E+00 V 1.25E+00

RPWMTRIFAULT1 2.60E+03 OHM 2.68E+03RPWMTRIFAULT2 + RNTC1 4.20E+04 OHM 4.20E+04

VCC=15V 15 V 15PWMTRIFAULT Voltage @ 20% load VCC="B12" 7.76E+00 V 6.80E+00PWMTRIFAULT Voltage @ 50% load VCC="B12" 9.71E+00 V 9.57E+00

Short Threshold ~ 14.3 V 14.3Green Mode Threshold ~ 6.8 V 6.8

VCC=13V 13 V 13PWMTRIFAULT Voltage @ 20% load VCC="B18" 5.76E+00 V 5.56E+00PWMTRIFAULT Voltage @ 50% load VCC="B18" 7.71E+00 V 7.57E+00

Short Threshold ~ 12.3 V 12.3Green Mode Threshold ~ 5.8 V 5.8

VCC=10V 10 V 10PWMTRIFAULT Voltage @ 20% load VCC="B22" 2.76E+00 V 2.56E+00PWMTRIFAULT Voltage @ 50% load VCC="B22" 4.71E+00 V 4.57E+00

Short Threshold ~ 9.3 V 9.3Green Mode Threshold ~ 4.3 V 4.3

CPWMTRIFAULT 2.24E-07 F 2.24E-07CV+I 1.50E-10 F 1.50E-10

Design OK or Not TRUE TRUE

Page 123: Jeffrey Hwang 10 min to design your power supply (V) 1 Design a Champion AC Adapter Jeffrey H. Hwang CM6805/CM6806/CM6903/CM6201

Jeffrey Hwang10 min to design your power supply (V)

123

CM6805 CM6806 CM6903 Design Tool

Input Current Shaping Technique PFC with Leading Edge Modulation

CM6803 CM6804 CM6805 CM6806 CM6903 CM6904 Design Tool / Jeffrey H. Hwang Yellow cells are for user inputGreen-Mode Design USER INPUT INDUCTOR and CAPACITOR CALCULATED INDUCTOR and CAPACITOR

Output Pow er (Watt) 300 300PFC Output Voltage (V) 380 380

High LineEff iciency at High Line (%) 96 96High Line; Maximum Line Input Voltage (Vrms) (V) 260 260Peak Input Voltage at High Line(V) 367.6955262 367.6955262Input Line Current at High Line (Irms) (A) 1.201923077 1.201923077Peak High Line Current (A) 1.699775916 1.699775916Peak High Line Sw itching Current (A) 1.87616188 2.124719895Ripple Current at Peak High Line (%) 9.40142561 50Ripple Current at Peak High Line (A) 1.76E-01 0.424943979 Input Pow er at High Line (Watt) 312.5 312.5System Sw itching Frequency (Hz); Fixed fsw = 67.5 Khz 6.75E+04 6.75E+04Tperiod, Sw itching Cycle (Sec); Fixed fsw = 67.5 Khz 1.48E-05 1.48E-05Sw itch-On-Time at Peak input voltage (Sec) Assumed in CCM 4.80E-07 4.80E-07Sw itch-Off-Time at peak input voltage (Sec) Assumed in CCM 1.43E-05 1.43E-05Sw itching Duty Cycle at peak input voltage (%) Assumed in CCM 3.24E+00 3.24E+00

Low LineEff iciency at Low Line (%) 94 94Low Line; Minimum Line Input Voltage (Vrms) (V) 80 80Peak Input Voltage at Low Line (V) 113.137085 113.137085 Input Line Current at Low Line (Irms) (A) 3.989361702 3.989361702Peak Low Line Current (A) 5.641809424 5.641809424 Peak Low Line Sw itching Current (A) 6.82E+00 7.06E+00Ripple Current at Peak High Line (%) 17.26204392 20.08431848Ripple Current at Peak High Line (A) 1.18E+00 1.42E+00 Input Pow er at Low Line (Watt) 319.1489362 319.1489362Sw itch-On-Time at Peak input voltage (Sec) Assumed in CCM 1.04E-05 1.04E-05Sw itch-Off-Time at peak input voltage (Sec) Assumed in CCM 4.41E-06 4.41E-06Sw itching Duty Cycle at peak input voltage (%) Assumed in CCM 7.02E+01 7.02E+01

EXTERNAL POWER COMPONENTS RSENSE (Ohm) 0.08862405 0.08862405RAC (Ohm) 1.430E+06 1.430E+06 OPTION1: RACvcc (Ohm): the resistor betw een VCC and IAC 5.000E+05 5.000E+05Input Inductor for PFC Boost (H) 5.000E-04 4.151E-04Output Capacitor for PFC Boost (F) 2.50E-04 9.72E-05PFC Boost Output Before Droping for the Hold-Up Time Calculation

(V) 380 380PFC Boost Output After Droping for the Hold-Up Time Calculation

(V) 114 114Hold-Up Time (Sec) 0.051466567 0.02

COMPENSATION AND FEEDBACK for PFC Voltage Loop VEAO is a GMv, a Slew Rate Enhancement Transconductance

Amplif ier, a Voltage Loop Error Amplif ier

GMv, Transconductance at the w orse condition (mho) 9.00E-05 9.00E-05dVEAO for the maximum Pow er (V) 1.980E+00 1.980E+00Rvfb1 + Rvfb2 (Ohm) 3.00E+06 3.00E+06 Rvfb1 (Ohm) for VFB=2.5V 2.98E+06 2.98E+06Rvfb2 (Ohm) for VFB=2.5V 1.97E+04 1.97E+04R1c, Compensation Resistor for f tv =20Hz (Ohm) 1.25E+05 4.86E+04

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Jeffrey Hwang10 min to design your power supply (V)

124

Summary High Density AC Adapter Design

• without additional cost– PFC: Efficiency~95.5% without additional cost

• 2 Level Boost Follower (200V and 380V)• Use LETE, CM6805, CM6806 and CM6903 family

– FlyBack: Efficiency~87.5% (without SR)– FlyBack: Efficiency~90% (with SR,

CM6201)– Total Efficiency ~ from 83.56% to 86%

Input Current Shaping Technique PFC with Leading Edge Modulation