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Vol.

02-05-e / June2002

MR1000 Series
Standby-compatible Partial Resonance Power Supply IC Modules

Masaaki Hayashi - Electronic Device Div.Group Advanced Power Products Div.


Device Design Dept. Assistant Manager (Joined the company in 1989)

1
Introduction

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Energy conservation guidelines from the Ministry of Economy,
Trade and Industry’s Agency of Natural Resources and Energy
place considerable emphasis on reducing standby power
consumption of domestic electrical appliances. These guidelines
designate domestic electrical appliances as 'special devices', and
set target years and criteria for achieving these reductions based
on the 'top runner' system. They are characterized by a
considerable degree of severity in that, if targets cannot be
achieved, manufacturers are legally required to publicly
proclaim the fact, and to follow the recommendations of the
Agency of Natural Resources and Energy.

Domestic electrical appliances employing remote controls are


characterized by a standby time which is considerable in
proportion to the duration of daily use. While the absolute value
of the instantaneous power consumption is low, the proportion
of standby power consumption within the total annual power consumption is large, and demands for a
reduction in standby power consumption are therefore becoming increasingly vociferous.

The MR1000 Series products introduced in this paper are standby-compatible partial resonance power
supply IC modules consisting of a multi-chip module (MCM) comprising a control IC and two
MOSFET chips. The ability to develop a standby-compatible partial resonance power supply with a
minimum of external components facilitates a reduction in design time.

2
MR1000 Series Features

< Implementation of a partial resonance power supply with a simple circuit configuration.
< Use
of the burst mode allows a reduction in standby power consumption. With a 100V input
power supply, input power is approximately 100mW at no-load.
< The module contains a start-up circuit to ensure stable start-up and to reduce start-up resistance.
< Full implementation of all protective functions.

These features are described below.

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2-1 Basic Operation

Partial resonance power supplies are an


effective means of increasing efficiency 0.2V
and reducing noise with a simple circuit
configuration. Partial resonance operation
requires detection of the secondary zero
current (0A) point, and determination of [Vz/c]
the ON timing for the main switching
device. The MR1000 Series incorporates a
zero current detection pin (Z/C, pin 1), the
negative edge of the voltage in the control [I D ]
coil (wound with opposite polarity to that
of the primary coil) being detected in the
main transformer and the main switching
device switched ON to detect the 0A point
of the secondary current. In order to [Secondary rectifying diode current]
switch the main switching device ON at
the VDS resonance trough during partial
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resonance operation it is necessary to
delay the ON timing for the primary
inductance by 1/2 of the resonance period [V DS ]
of the resonance condenser after the
secondary current reaches 0A, and simple
adjustment of the time constant of the
resistor and condenser connected to the IC
zero current detect pin (Z/C, pin 1) allows [Control coil voltage]
the main switching device to be switched
ON at the VDS resonance trough.
Fig.1 ON Trigger Operation Sequence

2-2 Standby Functions

The MR1000 Series supports a


function to reduce power consumption
during standby by switching from the
normal operation mode to the burst
mode using an external signal. The Drain pin
voltage at pin (1) is clamped to a 5 Standby signal
maximum of 2.9V (typ.) with a (external signal)
Z/C pin
microcomputer standby signal to
1
switch to the burst mode. Drain
current is then limited to I DP (burst) = F/B pin GND pin
425mA (typ.), and intermittent 2 3
operation begins in which control of
the ON width is switched from linear 2.9V
control of the voltage at the F/B pin (typ)
(pin (2)) to hysteresis operation in
which oscillation begins at V F/B >
1.8V and is halted at V F/B < 0.8V. Output voltage
error detection
feedback signal

Fig.2 Standby Mode Selector Circuit

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The burst method reduces switching V F/B(burst stop) V F/B(burst start)
losses by reducing the number of
switching cycles per unit time, and is
=0.8V =1.8V
therefore a very effective method of
reducing standby power consumption
at very small loads. The MR1000
Series burst mode employs burst
operation while controlling output, [V F/B ]
improving output ripple and transient
----------------425mA
response. Furthermore, as the IC
control current also reduces circuit
current wastage at burst oscillation
and halt, unnecessary circuit [I D ]
operation is halted, reducing control
current during normal operation by
approximately half (comparison of
normal operation at 50kHz and burst
oscillation and halt). [VOUT ripple]

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Fig.3 Standby Operation Sequence

2-3 Onboard Start-up Circuit

The IC incorporates a start-up circuit which is disconnected following power supply operation to
reduce power wastage. This circuit is particularly effective in improving efficiency during
standby, and as start-up current is limited to a fixed value, any change in start-up time is minimal
despite changes in input voltage, and thus ensuring stable start-up characteristics.

2-4 Soft Drive

The MR1000 Series supplies gate current for the main switching device from two drive circuit
systems. The first drive circuit system supplies a trigger voltage to switch the main switching
device ON without delay and with the optimum timing. The second drive circuit system supplies a
gate voltage at a constant current to the main switching device, reducing unnecessary gate drive
power, and controlling steep gate charge currents to reduce noise.

2-5 Malfunction Protection Function

The MR1000 Series incorporates a circuit to prevent ON timing malfunctions and thus ensure that
optimum partial resonance is maintained. At power supply ON and OFF, and in the case of a load
short, linking of the transformer control coil voltage used in detecting ON timing is occurs
readily when the main switching device is switched OFF, thus possibly resulting in a malfunction.
The MR1000 Series incorporates an ON-dead timer to disable the ON trigger for a period of 2.5µs
(typ.) after the main switching device is switched OFF, ensuring stable operation even under
transient conditions. A Leading Edge Blank (LEB) function is also incorporated to prevent
malfunctions due to resonance condenser discharge current and gate charge current.

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2-6 Over-current Protection Circuit

The MR1000 Series detects excess current due to ON resistance, and thus allows reduction of
primary current detection resistance and current detection losses. As over-current detection
employs an internally fixed OCP value with ON resistance detection, the normal power limitation
(power supply droop) is implemented with the ON width limit.

2-7 Other Protection Circuits

In addition to the above protection function, the overheat protection function (TSD: Thermal
Shut-down) halts latching at 150°C(typ.), and the over-voltage protection function (OVP: Over-
voltage Protection) halts latching at 20V at the Vcc pin.

3
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Product Line-up

As shown below, the MR1000 Series may be used in configuring power supplies for maximum
outputs of 50W (with 100V and 200V input systems) using the FT0-220 5-pin package.

Absolute maximum rating Maximum output capacity Po [W]


¸
Model Peak input voltage Peak input current Input voltage range Input voltage range Input voltage range

Vi n [V] I i n [A] AC 85 ~ 132V AC180 ~ 276V AC 85 ~ 276V

MR 1520 500 5 50 - -

MR 1721
*Currently 700 2.5 50 25
under
-
development.

Table 1 MR1000 Series Line-up

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Drain +0.2 4.5 0.2
Ø3.2 -0.1
5 10.0 0.2 2.7 0.2

1 Z/C

0.2
6.7
0.2
Q1 2 F/B

0.2
2.6
IC1

15.0

0.5

0.5

0.5
4 Vcc MR1520

19.6
17.0
15.0
0.3
2.7

0.2
3

1.9
GND

0.3
+0.3 +0.3
0.5 +0.3

4.2
0.7 -0.1 0.95 -0.1 -0.1
4-1.7 0.3 2.65 0.3

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1 2 3 4 5
Pin numbers

Fig.4 Equivalent Circuit Fig.5 Dimensions

4
Power Supply Characteristics (MR1520 standard power supply data)

T101 +12V,3.5A
L
TH101 C201-2 L201
F101 C102
N +12V
C101 D201 C202
FG
L101 C103 D101 C105 C201-1 R205
GND
C104
C205 C203
IC101 R201
5 R106 D104
4
R101 R103 R202 R208
2 C108 SW201
R105 R206
1 R203
C106 R209
3 C204 PC102
R102 D102 D103

R104 R207
TR201 R210
C110 C109 IC201 R204
C107 PC101 PC102

Fig.6 MR1520 Standard Power Supply Circuit


85V to 132V input, 12V, 3.5A output

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The following graphs illustrate efficiency (steady-state, standby), burst mode input power, and input
feedback noise of the MR1520 standard power supply in Fig.6. Partial resonance operation improves
efficiency in steady-state operation and reduces noise, and burst mode operation during standby
reduces the number of switching cycles per unit time, thus reducing standby power consumption.

100

80
Efficiencyη[%]

60 Vin=80V
Vin=100V
40 Vin=132V

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20

0
0 10 20 30 40
Output power [W]

Fig.7 Efficiency Characteristics (steady-state)

100

80

60 Vin=80V
Efficiencyη[%]

Vin=100V
40 Vin=132V

20

0
0 1 2 3
Output power [W]

Fig.8 Efficiency Characteristics (standby)

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3
Vin=80V

Vin=100V

Vin=132V
Input power [W] 2

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0
0 0.5 1 1.5
Output power [W]

Fig.9 Standby Power Consumption

Limit:[VCCI]Class2 150kHz~30MHz
At AC100V, 12V/3.5A
[dB V]

100

80

60

40

20

0
0.15 0.3 0.5 1 3 5 10 30
Frequency [MHz]

Fig.10 Input Feedback Noise

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5
Future Development

The MR1000 Series incorporates a start-up circuit, primary current detection resistance, various
protection circuits, and various malfunction protection circuits in a single IC. This combination
provides for a partial resonance power supply with full protection functions without the need for a
large number of external components, and simplifies power supply design and reduces design time.

The standby function (burst mode) is controlled with an external signal, and allows reduction of the
standby power consumption to approximately 100mW (100V input power supply) at no-load.

Future development of 25W small-capacity versions (100V and 200V input systems) is scheduled as
part of a program of satisfying customer requirements through series expansion.

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