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LLC Half-Bridge Converter Design Tool for FSFR series & FAN7621 by Fairchild Semiconductor

Specification & Parameter Input Dim.


Output Voltage 1 6.3 V
Output Current 1 8 A
Output Voltage 2 250 V
Output Current 2 0.2 A
1. Output Specifications Output Voltage 3 0 V
Output Current 3 0 A
Output Power
Select Configuration of Output Rectifier 1
Maximum VF of Output Diode 0.7 V
Maximum Input Voltage 352 V
Nominal Input Voltage 315 V
Estimated Efficiency 0.9
Expected Input Power
DC-Link Capacitor 200 uF
Frequency & Ripple voltage @ Nominal 0 Hz
Minimum Input Voltage 340 V
2.5

2.4
m=2.5
2.3 m=3

2.2 m=3.5
m=4
2.1 m=4.5
2.0 m=5
m=6
1.9
m=7
Peak
1.8Gain m=15
m= 5
1.7

1.6

1.5

1.4

1.3

1.2

1.1

1.0
1 2 3 4 5 6 7 8 9 1
0. 0. 0. 0. 0. 0. 0. 0. 0.

Quality Factor

m= 5
Boundary Voltage 409 V

3. Gain & Turn ratio


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Specification & Parameter Input Dim.
Gain @ Resonant Freq. of Lr & Cr
Margin of Maximum Gain 15 %
3. Gain & Turn ratio
Required Maximum Gain
Turn-ratio (Np/Ns1)
Turn-ratio (Np/Ns2)
Turn-ratio (Np/Ns3)

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Specification & Parameter Input Dim.
AC Resistor
DC Resistor
Q factor 0.300
Expected Resonant Frequency 90 kHz
4. Resonant Parameters Recommended Cr
Recommended Lr
Selected Cr / Vcr_max 15.0 nF
Selected Lr 200.0 uH
Estimated Lp
Magnetizing Inductance
Leakage Inductance of Primary-side
Inductance of Secondary-side 1
5. Transformer Leakage Inductance of Secondary-side 1
Parameters
for Simulation Inductance of Secondary-side 2
Leakage Inductance of Secondary-side 2
Inductance of Secondary-side 3
Leakage Inductance of Secondary-side 3
Phase Angle of Lr & Cr
Phase Angle of Lp & Cr
Resonant Freq. of Lr & Cr
6. Operating Parameters Resonant Freq. of Lp & Cr
Operating Freq. @ Max. Input Voltage
Operating Freq. @ Nom. Input Voltage
Operation Freq. @ Min. Input Voltage

2.5
2.4
Load of 100%
2.3
80%
2.2
2.1 60%
2.0 40%
1.9
20%
1.8
1.7
1.6
Gain 1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
30000 50000 70000 90000 110000 130000
© 2008 Fairchild Semiconductor Corporation 3 / 21 Frequency (kHz) http://www.fairchilsemi.com
1.1
1.0
0.9
0.8
0.7
Specification & Parameter Input Dim.
0.6
0.5
30000 50000 70000 90000 110000 130000

Frequency (kHz)

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Specification & Parameter Input Dim.
Minimum Operating Frequency of IC 50 kHz
Maximum Operating Frequency of IC 112.5 kHz
Rmin
7. Parameter of Rmax
Control Part Soft-start Time 20.00 msec
Rss
Css
Recommended Sensing Resistor
IRMS of Primary-side @ Nominal Input
IPEAK of Primary-side @ Nominal Input
8. Current on IRMS of Output 1
Input & Output Stage
IRMS of Output 2
IRMS of Output 3
Margin of Rated Voltage 50 %
Margin of Rated Current 100 %

Rated Current & Voltage of Output 1 Diode


9. Secondary-Side
Diode Specification
Rated Current & Voltage of Output 2 Diode

Rated Current & Voltage of Output 3 Diode

Expected BMAX 0.2 Tesla


Ae of Core 123 ㎟
Min. Number of Primary Winding Turns
Number of Expected Primary Winding Turns 64 Turns
Number of Output 1 Winding Turns
Number of Output 2 Winding Turns
10. Transformer Number of Output 3 Winding Turns
Specifications Primary-side Inductance (Lp)
Resonant Inductance (Lr)
Current Density 5 A/㎟
Area of Primary Winding Wire
Area of Output 1 Winding Wire
Area of Output 2 Winding Wire
Area of Output 3 Winding Wire

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irchild Semiconductor ver. 1.3

Output Dim.

100.4 W

111.6 W

0 V

m=2.5
m=3
m=3.5
m=4
m=4.5
m=5
m=6
m=7
m=15
m= 5

8 9 1
0. 0.

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Output Dim.
1.12

1.55
32.66
0.91
-

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Output Dim.
422.5 ohm
0.5 ohm

14.0 nF
224.2 uH
460 V

1000.0 uH
894.4 uH
105.57 uH
0.84 uH
0.10 uH
1075.37 uH
126.93 uH
- uH
- uH
577.4 krad/s
258.2 krad/s
91.9 kHz
41.1 kHz
71.8 kHz
63.3 kHz
69.6 kHz

Load of 100%

80%

60%

40%

20%

110000 130000
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Output Dim.

110000 130000

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Output Dim.

10.4 kohm
7.5 kohm

1.7 kohm
30.3 uF
0.35 ohm
0.69 Arms
0.98 A
9.59 Arms
0.24 Arms
- Arms

18.9 V
8.60 A
750.0 V
0.20 A
- V
- A

46.5 Turns

2.0 Turns
70.2 Turns
- Turns
1000.0 uH
200.0 uH

0.14 ㎟
1.25 ㎟
0.03 ㎟
- ㎟

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Schematic for FSFR-series with Center-tap Configura

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Schematic for FSFR-series with Bridge-rectifying Config

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Item Part
Value
Number Reference
1 U1 FSFR-series
2 U2 FOD817
3 U3 KA431
4 U4 2N2222
5 U5 2N2907
6 C101 200 uF / 450V
/
7 C102 15 nF 460.294464634
997 V
8 C103 100 pF
9 C105 0.33 uF
10 C106 220 nF
11 C107 33 uF
12 C108 12 nF
13 C109 22 uF
14 C112 680pF
15 C201, C202
16 C203
17 C204
18 C301 AC 250V
19 D101 UF4007
D211, D212,
20
(D213, D214)
21 ZD101 1N5235 (6.8V)
22 R101 0.35 Ω / 0.5 W
23 R102 1kΩ
24 R104 7.49 kΩ
25 R105 10.40 kΩ
26 R106 10 Ω
27 R107 1.65 kΩ
28 R109
29 R110
30 R111
31 R112
32 R113
33 R114

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34 R201
35 R202 1kΩ
36 R203
37 R204
38 R205
39 R206

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es with Center-tap Configuration

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with Bridge-rectifying Configuration

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Description

FPSTM
Opto-Coupler
Precision Shunt Regulator
NPN transistor for Line-UVLO
PNP transistor for Line-UVLO
DC Link Capacitor - Electrolytic

Cr (Resonant Capacitor) - MPP

Current sensing Filter - Ceramic


Vcc Capacitor - Ceramic
Bootstrap Capacitor - Ceramic or Film
Soft-start Capacitor - Electrolytic
Control Capacitor - Ceramic
Vcc Capacitor - Electrolytic
Noise Absorber - Ceramic (Optional)
Output Capacitor -Electrolytic
Feedback Capacitor - Ceramic or Film
Feedback Capacitor - Ceramic or Film
Noise Filter - AC ceramic
Bootstrap Diode - Ultra Fast Recovery
Secondary Rectifying Diode
(Use the diode in Bridge-rectifying type)
Line-UVLO - Zener Diode
Rsense (Sensing Resistor)
Current Sensing Filter
Rmax - Maximum Frequency Setting Resistor
Rmin - Minimum Frequency Setting Resistor
Bootstrap Resistor
Soft-start Resistor
Line-UVLO - Resistor
Line-UVLO - Resistor
Line-UVLO - Resistor
Line-UVLO - Resistor
Line-UVLO - Resistor
Line-UVLO - Resistor

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Feedback Resistor
Feedback Resistor
Feedback Resistor
Feedback Resistor
Feedback Resistor
Feedback Resistor

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Transformer Schematic with Center-tap Configuration

Winding Minimum Area of Wire Turns


Np 0.138 ㎟ 64.0
Ns11 1.247 ㎟ 2.0
Ns12 1.247 ㎟ 2.0
Ns21 0.031 ㎟ 70.2
Ns22 0.031 ㎟ 70.2
Ns31 - -
Ns32 - -

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Parameter Spec. Remark
Primary-side Inductance (Lp) 1000.0 uH 100kHz, 1V
Resonant Inductance (Lr) 200.00 uH Short one of the output winding

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Transformer Schematic with Bridge-rectifying Configuration

Winding Minimum Area of Wire Turns


Np Refer to Center-tap N/A
Ns1 N/A N/A
Ns2 N/A N/A
Ns3 N/A N/A
Parameter Spec. Remark
Primary-side Inductance (Lp) N/A 100kHz, 1V
Resonant Inductance (Lr) N/A Short one of the output winding

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