High Efficiency 200W Power Supply for LEDs

Lighting Applications

Marco Farneti
Field Application Engineer Southern Europe
Marco.farneti@fairchildsemi.com
Phone +39 02 24911124
Mobile +39 335 5327831

www.fairchildsemi.com

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 The Power Franchise® :
Driving Energy-Efficient Solutions
• World energy concerns are driving the quest for increased
energy efficiency and regulations aimed towards power
savings and efficiency
• Fairchild’s innovative product solutions increase energy-
efficiency while simplifying system design, reducing board
space, improving manufacturing reliability and decreasing
time to market
• Fairchild is focused on enabling energy-efficiency in
electronic applications including home appliances, power
adaptors, power supplies, lighting, motor control and
automotive electronics

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 European Union EcoDesign Impact

Regulations from 2008

• Street lighting products
• Office lighting products
• Stand-by and off-mode losses
• External power supplies
• Simple set top boxes

Regulations from 2009

• Domestic lighting products (including incandescent bulbs)
• Televisions

Under discussion for later implementation

• Boilers Water heaters Washing machines
• Dishwashers Freezers Domestic refrigeration,
• Circulators Electric motors Commercial refrigeration
• Computers Imaging equipment Other domestic lighting products
• Domestic fans Solid fuel boilers Room air conditioners
• Laundry dryers Vacuum cleaners Complex set top boxes
• Electric pumps Industrial fans

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 Increase Energy Efficiency, Extend
System Life, Reduce lifetime cost

• Lighting applications offer the greatest opportunity to reduce wasted energy

because incandescent bulbs are only ten percent efficient. These applications are
transitioning to fluorescent and LED or HID lamps, which drive significant
efficiency improvements. Fairchild’s ballast control ICs, IGBTs, MOSFETs, HVICs,
PFC/PWM controllers, Green FPSTM products, transistors, rectifiers, diodes and
optocouplers increase efficiency, extend system life and provide greater flexibility
for lighting applications.
• Converting from incandescent light bulbs to fluorescent or LED lighting
75% savings

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 Focused Lighting Systems
Fairchild Offering

Light Power-LED Fluorescent Lamp HID

Source
Output <5W <25W <100W >100W <20W >25W 150/250W
Power
PFC FAN6961
FAN7527 FAN7529 FAN7529 FAN7529
CCM PFC FAN6961 FAN7535
Controller (EOLL) FAN7387
FAN100* FSFR FAN7710 FAN7711 (Inverter)
FSEZ Series (EOLL) FAN7371
series (Buck)
Switch MOSFET MOSFET MOSFET MOSFET FDP18N50
FDP33N25
Topology Isolated / Non-isolated Isolated LLC Resonant Resonant Resonant Full Bridge
Flyback (PSR) PFC Resonant Half-Bridge Half-Bridge Half-
Flyback Half-Bridge Bridge

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 Fairchild Power LED Lighting
Product Selection

Products <5W <25W <100W >100W >500W

PFC Switch
MOSFET MOSFET

Controller BCM PFC

FAN6961 CCM PFC
BCM PFC FAN7529
Main Controller PSR PWM FAN7527 LLC Controller
DC-DC PSR Switch FAN100 LLC Converter FAN7621
(CC) FSEZ1016A FSFR Series
Switch (1A 600V 2x 600V
MOSFET) MOSFETs
MOSFET MOSFET MOSFET

Additional Controller Green PWM Green PWM

Current SG6858 Controller
Source SG6859
Switch
MOSFET MOSFET

Topology Isolated / Non- Isolated / Non- Isolated Power LLC Resonant LLC Resonant
isolated Flyback isolated Flyback Factor Flyback Half-Bridge Half-Bridge
(PSR) (PSR)

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 Reference Design Introduction

High Power Factor LED Ballast using:

• FSFR2100 Fairchild Power Switch (FPS) for Half-Bridge Resonant converters.
• FAN6961 Critical Conduction Mode PFC Controller.
• SG6858 Green Mode PWM controller.

• Universal AC Input : 90 ~ 265VRMS

• Total Output Power : 200W
• Six DC Outputs : 700mA CC@48Vmax (x 6)
* Can be changed to 350mA@96Vmax

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 Mechanical Specification

The board size is 201mm x 79mm x 20mm (L x W x H)

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 LLC Resonant Half-Bridge Converter
FSFR Series – Key Features & Line-up
Key Features Cblock DO1 LO

• Variable frequency control with 50% duty cycle for

half-bridge resonant converter topology Vin Aux. Circ uit CO
817
• High efficiency through zero voltage switching VCC DRAIN

(ZVS) HS
H-Vcc

Cpump 431

Controller
VFB
• Internal MOSFETs with Fast Recovery Type Body
Drv

PWM
CENTRE

Diode (trr=120ns)
LS
Drv

Tdead
Rdead
• All products are performed electric beam process CFB GND SOURCE
DO2
Rsense
to improve the Trr characteristic of body diode of
internal MOSFET
• Internally optimized dead time (fixed. 350ns)
• Up to 300kHz operating frequency
• Pulse skipping at light load condition
• Simple remote ON/OFF control
• Various Protection functions: OVP, OCP, AOCP, TSD

Product Line-up
Part Number Package Operating Rds(on) Output Power max.(Vin=350-400V)
Junction max. without heat with heat sink
FSFR2100 9SIP -40 to +130°C 0.38 ohm sink
200W 450W
FSFR2000 9SIP -40 to +130°C 0.67 ohm 160W 350W
FSFR1900 9SIP -40 to +130°C 0.85 ohm 140W 300W
FSFR1800 9SIP -40 to +130°C 0.95 ohm 120W 260W
FSFR1700 9SIP -40 to +130°C 1.25 ohm 90W 200W
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 LLC Half-Bridge Resonant Controller
FAN7621 vs FSFR series
Key Features
• Variable Freq. Control (PFM)
• High Efficiency (ZVS)
• Sourcing Current (400mA)
• Fixed Dead Time (350ns)
• Up to 300kHz Operating Freq.
• Pulse Skipping at Light Load
• Protection :
• OVP, OLP, OCP, AOCP, TSD
• 16DIP/SOP

Applications
• Flat Display : PDP, LCD
• Desktop PC and Servers
• Adapters LVcc VDL
• Telecom Power
• Audio Power HVcc
RT

Availability
• Sample : Sep ’08 Control
• Full production : Nov. ‘08 VCTR
IC CON
CS

FSFR Series
SG PG
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 High Power LED driver
Reference Design

Schematic – Main DC-DC & Current Source

Fairchild Contents
IC1 FSFR2100 D98, D205 FDLL4148 (x4)
IC92 ~ IC97 SG6858/9TZ (x6) D105, D106

Q1~Q6 FQD4N25TM (x6) D101 RS1J

IC2 KA78L18 D201~D204 ES3J (x4)

OC1 FOD2741BTV D206 BZX79C30

D207~D211 ES1F (x6)
D214~D215
D216~ D221 1N4148 (x6)
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 FAN6961
CCM PFC Controller

Circuit description
• The FAN6961 is an 8-pin, critical conduction
mode PFC controller IC intended for controlling
PFC pre regulators.
• The FAN6961 provides a controlled on-time to
regulate the output DC voltage and achieve
natural power factor correction.
• The maximum on-time of the external switch is
programmable to ensure safe operation during
AC brownouts.
• An innovative multi-vector error amplifier is built
in to provide rapid transient response and
precise output voltage clamping.
• A built-in circuit disables the controller if the
output feedback loop is opened.
• The start-up current is lower than 20μA and the Fairchild Contents
operating current has been reduced to under IC91 FAN6961SZ
6mA
Q91 FCP11N60
D94~ IN5407 (x4)
D97
D91 FDLL4148
D98
D92 EGP30K
D93 BZX85C22

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 FSFR2100 Fairchild Power Switch
(FPS™) LLC Resonant HB Converter

Circuit description
• The FSFR-series is a highly integrated power
designed for high efficiency half-bridge resonant
converter.
• The FSFR-series simplifies designs and
improves productivity while improving
performance combining power MOSFETs with
fast recovery type body diodes, high-side gate
drive circuit, an accurate current controlled
oscillator, frequency limit circuit, soft-start and
built-in protection functions.
• The high side drive circuit has a common mode
noise cancellation capability, which guarantees
stable operation with excellent noise immunity.
• The fast recovery body diode of the MOSFETs
improves reliability against abnormal operation
condition while minimizing the effect of the
reverse recovery.
• Using the zero-voltage-switching (ZVS)
technique, the switching losses are dramatically
reduced and therefore the efficiency also has
been significantly improved.
• The zero-voltage-switching also reduces the
switching noise noticeably, which allows using
small size EMI filter.

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 SG6858
Green Mode PWM Controller

Circuit description
• This highly integrated PWM controller provides several special
enhancements designed to meet the low standby-power needs
of low-power SMPS.
• To minimize standby power consumption, the proprietary
green-mode function provides off-time modulation to linearly
decrease the switching frequency under light-load conditions.
• This green-mode function enables the power supply to easily
meet even the strictest power conservation requirements.
• The BiCMOS fabrication process enables reducing the start-
up current to 9uA, and the operating current to 3mA.
• Built-in synchronized slope compensation ensures the stability
of peak current mode control.
• Proprietary internal compensation provides a constant output
power limit over a universal AC input range (90VAC to
264VAC).
• Pulse-by-pulse current limiting ensures safe operation even
during short-circuits.

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 Main Transformer and Electrical
Characteristics cont.

Winding Details

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 Main Transformer and Electrical
Characteristics

• Parameter, Specification and Conditions

• Primary Inductance 600 uH +/- 5% @ 100kHz, 100mV, all secondaries open
• Leakage inductance 15 uH max @ 10kHz, 100mV, all other pins shorted
• Core and Bobbin
• Core: EFD 30
• Material: N87 (EPCOS) or equivalent
• Bobbin: EFD 30 horizontal / 12 pins e.g. EPCOS B66424W….
• Gap in center leg: approx. 0.5 mm for AL of 191 nH/Turns2
• Safety
• High voltage test: 3000Vrms for 1 minute between primary and secondary

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 LLC Choke

• Winding Details

• Electrical Characteristics
• Parameter, Specification and Conditions
• Inductance 100 uH +/- 5% @ 100kHz, 100mV
• Core and Bobbin
• Core: EFD20
• Material: N87 (EPCOS) or equivalent
• Bobbin: EFD20 / 8 Pin / Horizontal e.g. EPCOS B66418W…
• Gap in center leg: aprox. 2.5 mm for an AL of 32 nH/Turns2

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 PFC Choke

• Winding Details

• Electrical Characteristics
• Parameter, Specification and Conditions
• Inductance 160 uH +/- 5% @ 100kHz, 100mV
• Core and Bobbin
• Core: EFD 30
• Material: N87 (EPCOS) or equivalent
• Bobbin: EFD 30 horizontal / 12 pins e.g. EPCOS B66424W….
• Gap in Centre leg: aprox. 2.5 mm for an AL of 64 nH/Turns2
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 Full Load Efficiency, Power Factor
and Line Regulation vs Input Voltage
Test Condition and Method
• The power supply was set up with all outputs loaded at rated load.
• The input voltage was swept across the specified range.
• The output loads were kept constant.
• The input power was measured and efficiency calculated.

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High Power LEDs applications
PCIM Europe 2008

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Thank you

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