2nd Generation LLC Current Resonant Control IC,

“FA6A00N Series”
CHEN Jian * YAMADAYA Masayuki * SHIROYAMA Hironobu㾙

ABSTRACT

issue: Power Semiconductors Contributing in Energy Management

LLC current resonant power supply, which is characterized by soft switching, resonance control with a duty ratio
of 50% and leakage transformer structure, is suitable for efficiency improvement, noise reduction and profile lower-
ing in switching power supply. Fuji Electric has developed the 2nd generation “FA6A00N Series,” which inherits the
characteristics of the 1st generation LLC current resonant control IC, “FA5760N,” and is enhanced with lower standby
power and improved protective functions. It integrates the world’s first high-precision secondary side over-load pro-
tection function while further reducing the standby power by approximately 20%. For the over-current protection
function, the delay time can be externally adjusted.

1. Introduction standby converter and allows a power management

system configuration that offers high efficiency, low
Switching power supply products, which are used standby power and compactness. This has expanded
in various types of electronic equipment, are rapidly the scope of its application such that it is adopted to a
being improved in terms of efficiency, noise reduction power supply of about 50 W without a PFC converter.
and low profile to meet the demands for energy ef- Fuji Electric has recently developed the “FA6A00N
ficiency and space saving. An LLC current resonant Series,” the 2nd-generation LLC current resonant con-
power supply is characterized by its use of high-effi- trol IC. With the characteristics of the 1st-generation
ciency, low-noise soft switching technology and low- LLC current resonant control IC “FA5760N” inherited,
profile leakage transformer structure. These charac- it is enhanced with a lower standby power, improved
teristics facilitate efficiency improvement, noise reduc- protective functions, higher quality and lower system
tion and profile lowering and make it suitable for use cost and offers a higher degree of design freedom.
as a power supply of 100 to 500 W, which is a medium
capacity range for a switching power supply. The LLC 2. Overview of Product
current resonant power supply, however, is prone to a
switching shoot-through phenomenon*1 during a start- Figure 1 shows the external appearance of the
up, heavy load conditions or low input voltage condi- FA6A00N Series and Fig 2 the block diagram. Table
tions. The power supply has problems including a 1 lists the major ratings, Table 2 the major functions
breakdown of a power metal-oxide-semiconductor field- and Table 3 shows the product lineup. The following
effect transistor (MOSFET) due to this phenomenon outlines the LLC current resonant control IC of the
and efficiency degradation with a light load due to an FA6A00N Series.
excitation current, and these factors limited its scope
of application.
In order to solve these problems, Fuji Electric
commercialized “FA5760N,” an LLC current reso-
nant control IC that uses its unique new control sys-
tem. FA5760N is an LLC resonant converter that
eliminates the need for a PFC converter and dedicated

*1: Switching shoot-through phenomenon: a phenomenon

in which, when a current flows through the body diode
of one power MOSFET in a bridge switching circuit, the
opposing power MOSFET turns on to instantaneously
generate a large current.

* Electronic Devices Business Group, Fuji Electric Co., Ltd.

㾙 Sales Group, Fuji Electric Co., Ltd. Fig.1 “FA6A00N Series”

245
 VCC VH STB MODE

Intemal
Supply Regu- X-Cap
lator Start-up discharge Standby control State control
circuit circuit
circuit
VCC_UVLO VH
BO voltage VHOVP Msstb Mstb Smode
BO + BOPINP UVLO - detection
/PGS - circuit BOP
+
VB
UVLO

DTadj High side

on_trg control circuit HO
FB
CS High side
Oscillator HO driver
Pulse by
pulse off_trg control
VS
protection Continuous
protection VCC
LO
control
FB LO
FB Low side driver
Control
circuit

CS OLP
OCP
Continuous
VHOVP Protection
UVLO Protection
circuit
BOP
BOPINP
Mstb
Msstb Soft start Pulse-by-
control FTO Dadj VW_OLP pulse
circuit Pulse-by- Protection
pulse
Self- VW OLP protection
CS Control turn-off adjusting detection circuit
CS dead time circuit
VCC Standby
Smode control Mstb Smode
Mstb circuit GND
Msstb

IS VW

Fig.2 “FA6A00N Series” block diagram

Table 1 Major ratings Table 3 Product lineup

Item Rated value Product Overload Over-current
Terminal 3
name protection protection
High side power supply voltage to ground – 0.3 to + 630 V
FA6A00N PGS terminal Auto-restart Latch stop
High side power supply voltage (VBS) – 0.3 to + 30 V
FA6A01N PGS terminal Auto-restart Auto-restart
Low side power supply voltage (VCC) – 0.3 to + 30 V
FA6A10N BO terminal Auto-restart Auto-restart
VH terminal input voltage – 0.3 to + 600 V
FA6A11N BO terminal Latch stop Latch stop
Maximum allowable offset power supply
± 50 kV /μs (max.)
voltage dv/dt
Total loss 0.83 W
(a) Control circuit with 3.3 V, 5 V and 30 V break-
Operating junction temperature – 40 to +150 °C
down voltage for controlling the LLC current
resonant circuit
Table 2 Major functions and terminals (b) Driver circuit with 630 V breakdown voltage
Function Terminal (No.) capable of directly driving the high side and low
Start-up circuit VH (1), VCC (10)
side switching devices in the half bridge circuit
(c) Built-in 600 V breakdown voltage start-up de-
Low voltage malfunction prevention circuit VCC (10), VB (16)
vice realizing IC start-up with low power con-
State setting function MODE (7)
sumption
X-Cap discharge function VH (1)
(d) JEDEC-compliant 16-pin small outline package
Fixed brown-in / brown-out VH (1)
The high side and low side outputs alternately op-
Variable brown-in / brown-out BO (3) erate with a high-precision duty cycle of 50% and the
Overvoltage protection VH (1), VCC (10) operating frequency range is 38 to 350 kHz.
Over-current protection with variable
IS (8), MODE (7)
delay time
3. Features
Overload protection VW (9), FB (4)
Overheat protection Integrated 3.1 Low power dissipation burst control
External latch signal input MODE (7) FA5760N, the 1st-generation product, used the
Forced turn-off function VW (9), IS (8) VCC and CS terminals for hysteresis burst control and
Automatic dead time adjustment function VW (9) achieved a world-class low standby power without the
High-precision overload protection function VW (9) standby converter. The FA6A00N Series, which is the
Soft start function CS (5) 2nd generation, is additionally provided with burst
VCC (10), CS (5), control optimization to further reduce the standby
Low standby power operation mode
VH (1) power by approximately 20% from FA5760N.
Power Good signal PGS (3) The LLC current resonant control has a high side

246 FUJI ELECTRIC REVIEW vol.59 no.4 2013

 3
Range of frequency variation
during normal operation +
S1
Range of frequency
variation during HO P1
burst operation
2
+ S2
Vi
Gain

VS

Aux

1 LO
P2

issue: Power Semiconductors Contributing in Energy Management

0
0 50 100 150 200
Frequency (kHz) Fig.5 Schematic circuit diagram of current resonance

Fig.3 Current resonant gain diagram protecting the power management system, is a func-
tion that stops switching when a certain delay time
has elapsed after a load increases to approximately
High
Invalid region
1.5 times the rated load. Degradation of the preci-
Region with high conversion efficiency sion of this function causes insufficient output power
Region with low conversion efficiency
or failure to limit the output power, thus the overload
protection cannot perform adequately. In addition, the
Frequency

(1) overload protection level must be maintained within

a certain range (about ± 20%) even if an input voltage
(2)
varies in a wide range.
(3) Figure 6 shows the circuit configuration of the high-
Low precision overload protection function of the FA6A00N
FA5760N FA6A00N Series Series. The auxiliary winding voltage is detected by
the resistor-divided voltage, VW voltage. The recom-
Fig.4 Frequency during burst operation mended precision of this voltage-dividing resistor is
±1%. The VW voltage exceeding the threshold voltage
and low side duty cycle of 50% and controls the gain Volpvw is recognized as an overload state, and when
by the switching frequency. Figure 3 shows the current the overload state continues for 76.8 ms, switching is
resonant gain diagram. The frequency variation range stopped. In order to improve the detection precision,
is narrow in principle during normal operation and variation of Volpvw has been specified to be within ±3%,
widened during burst operation. which is highly precise. The commercialized versions
Figure 4 shows the frequency during burst opera- are the auto-restart version, which restarts when the
tion. The high frequency region (1) is an invalid region switching stop time has reached 550 ms, and the latch
in which the gain is low and switching cannot trans- stop version that does not restart.
fer energy. In the low frequency region (3), the gain Figure 7 shows a waveform during overload pro-
is high and excitation current is large, which makes tection operation. In overload protection operation,
energy transfer inefficient; hence there is a low conver- switching is suspended and the output voltage drops
sion efficiency. With the FA6A00N Series, the invalid along with an energy transfer stop.
region and the region with low conversion efficiency Figure 8 shows how the overload protection oper-
have been reduced to widen the region with high con- ating power depends on the input voltage. FA5760N
version efficiency (2), resulting in successful reduction provides overload protection with general resonant
of standby power. Audible noise has also been sup- current detection. With this method, the overload
pressed.
Aux
3.2 High-precision overload protection function
The 1st-generation product FA5760N used the pri- P2
R1 VW
+
mary side auxiliary winding P2 (see Fig. 5) to supply Delay circuit
Tolpdly = 76.8 ms
S Q Stop
R2 - switching
power to the VCC terminal and realized hard switch-
Volpvw Delay circuit
ing protection and shoot-through current prevention. Tolpoff = 550 ms
R

The FA6A00N Series, which is the 2nd generation,

uses this auxiliary winding to integrate the high-pre-
cision overload protection function for the first time in
the world while inheriting the functions of FA5760N. Fig.6 Circuit configuration of high-precision overload protection
The overload protection, which is intended for function

2nd Generation LLC Current Resonant Control IC, “FA6A00N Series” 247
 Resonant current
Output voltage Vo

IS voltage

Peak value of VW voltage: 2.8 V MODE voltage

VS voltage

VW voltage

Reference value of VW voltage: 0 V

Fig.9 Waveform during over-current protection operation

Fig.7 Operation waveform during overload protection
degree of flexibility in power supply design.
With the FA6A00N Series, adjustment of Tocp is
400 shared by the MODE terminal for state setting, which
has led to the realization of the over-current protection
Overload protection level (W)

300 function with a variable delay time without increasing

the number of terminals. Figure 9 shows a measured
FA5760N
waveform. When a resonant current rapidly increases,
200 FA6A00N Series an over-current state is detected on the IS terminal.
The MODE terminal voltage is clamped to 0.5 V after
100 state setting and, when an overload state is detected,
oscillates between 0.6 and 0.8 V. When the number of
0 oscillations reaches 36, switching stops and provides
50 100 150 200 250 300
over-current protection. The duration of one oscilla-
Input voltage (V)
tion can be adjusted by the capacitor connected to the
MODE terminal.
Fig.8 Input voltage and overload protection operating power
4. Effect on Application to Power Circuit
protection level is highly dependent on the input volt-
age when the input voltage range is wide, and this has 4.1 Standby power reduction effect
necessitated the addition of a dedicated overload pro- Figure 10 shows a sample application circuit and
tection circuit. With the FA6A00N Series, variation of Tables 4 and 5 the specification of the sample appli-
the overload protection level is small even if the input cation circuit and major semiconductor components
voltage varies, allowing for a high-accuracy overload in the circuit. Figure 11 shows the measured standby
protection function without a dedicated overload pro- power with a 35 mW load. The FA6A00N Series can
tection circuit. As a result, the number of power sup- reduce the standby power by approximately 20% from
ply system components can be reduced, allowing for a FA5760N, which allows elimination of the standby
cost reduction of a power supply system. converter even if requirements for standby power are
severe.
3.3 Over-current protection function with variable delay
time 4.2 Number of circuit components reduction effect
When a load short circuit occurs and an over- Figure 12 shows the configuration of a general LLC
current state has continued for the specified time Tocp, current resonant power supply. A general LLC cur-
switching stops. This is called the over-current protec- rent resonant power supply is composed of a filter for
tion function. The power device has a possibility of EMI (electromagnetic interference) noise elimination,
being damaged if the Tocp setting is too long. If the PFC converter for power factor correction, standby con-
Tocp setting is too short, it causes an over-current state verter and LLC converter. Use of the FA6A00N Series
at start-up, and this may be detected as a load short allows significant reduction in the number of compo-
circuit state and might hinder the start-up. The opti- nents, making it possible to build a low-cost LLC cur-
mum Tocp depends on a power supply and capability to rent resonant power supply (see Table 6).
adjust Tocp with an external component offers a higher

248 FUJI ELECTRIC REVIEW vol.59 no.4 2013

 YG865C10R
(100 V/20 A)
Output 1
FA6A00N Series + 24 V/3 A
S1
Input 85 to 16 GND
264 V AC 1
+ VH VB
HO 15
FMV23N50E P1 S2
6 STB
（500 V/23 A/ YG862C06R
5 CS 0245 Ÿ） (60 V/10 A)
VS 14
3 BO/PGS /0.245 Ÿ） Output 2
10 VCC FMV23N50E + 12 V/2 A
7 MODE (500 V/23 A/
LO 11 S3
4 FB 0.245 Ÿ) GND
9 VW
/0.245 Ÿ)
PC1 GND IS
12 8 S4

issue: Power Semiconductors Contributing in Energy Management

+ P2
PC2
Output 3
5 V/1 A

GND

On-Off signal
PC2 input
+ 8 7 6 5 PC1 GND
FA7764 +
1 2 3 4

Fig.10 Sample application circuit

Table 4 Specifications of sample application circuit

200
Item Characteristic, etc.
FA5760N
Input voltage 85 to 264 V AC
Standby power (mW)

Output voltage / current 24 V / 3 A, 12 V / 2 A, 5 V / 1 A 150

Output power 100 W (max.)

100
Table 5 Major semiconductor components in sample applica-
tion circuit
50 FA6A00N Series
Component Model
Control IC FA6A00N Series
Bridge MOSFET FMV23N50E (500 V / 23 A / 0.245 Ω) 0
50 100 150 200 250 300
Diode (24 V) YG865C10R (100 V / 20 A) Input voltage (V)
Diode (12 V) YG862C06R (60 V / 10 A)
5 V AC / DC converter FA7764AN Fig.11 Standby power with 35 mW load

Filter PFC converter LLC converter

V ac + Output
S1 1
P1
PFC Vi
control + S2
IC LLC VS DC-DC
control circuit
IC

OLP circuit

+
V CC
+ Output
2
PWM
(pulse width
modulation)
control IC
Standby converter

Fig.12 Configuration of general LLC current resonant power supply

2nd Generation LLC Current Resonant Control IC, “FA6A00N Series” 249
Table 6 Comparison on number (approximate number) of components
LLC converter
PFC Standby Total number of
Filter High-precision
converter converter Main DC-DC components
OLP
FA5760N 10 30 40 60 Not required 10 150
FA6A00N 75 W or more 10 30 Not required 60 20 Not required 120
Series less than 75 W 10 Not required Not required 60 20 Not required 90

tion of current resonant control with features including

5. Postscript the high-precision overload protection function.
We intend to continue working on establishing new
This paper has described the 2nd-generation LLC technologies that realize even higher efficiency and
current resonant control IC “FA6A00N Series.” This further noise reduction, and developing power supply
IC, which inherits the characteristics of the 1st-gener- control ICs that contribute to the miniaturization and
ation product “FA5760N,” has achieved further evolu- profile lowering of power supply.

250 FUJI ELECTRIC REVIEW vol.59 no.4 2013

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