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FAIRCHILD Design Guidelines for Offline Forward Converters using FPS

Summary

This comprehensive application note provides detailed, step-by-step design guidelines for building efficient off-line forward converters using Fairchild Power Switches (FPS). The manual covers the entire design process—from determining system specifications and calculating component values (like DC link capacitors) to selecting optimal reset schemes. It is essential reading for electrical engineers and power electronics designers who require reliable, high-efficiency solutions for low to medium power AC-DC SMPS conversions.

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Application Note AN4134 Design Guidelines for Off-line Forward Converters Using Fairchild Power Switch (FPSTM) Abstract

helps the engineers to design a SMPS easily. In order to

This paper presents practical design guidelines for off-line

make the design process more efficient, a software design

forward converter employing FPS (Fairchild Power Switch).

tool, FPS d esign as sistant, that contains all the equations

Switched mode power supply (SMPS) design is inherently a

described in this paper, is also provided.

time consuming job requiring many trade-offs and iteration with a large number of design variables. The step-by-step design procedure described in this paper

L2 Lp2

Bridge 2CDC Np NS2

Reset Circuit VO2

rectifier Cp2

Non-doubled CO2

diode

Doubled

FPS Lp1

2CDC DR1

Drain

Ra Da

Vcc VO1

DF1 CO1 Cp1

GNDFB

Ca Na

Line Filter Rd

Rbias

CL1 817A

CB R1

RF CF

Fuse KA431

AC line

Figure 1. Basic Off-line Forward Converter Using FPS

1. Introduction transformer

Due to circuit simplicity, the forward converter has been

design, reset circuit design, output filter design, component

widely used for low to medium power conversion

selection and closing the feedback loop. The design

applications. Figure 1 shows the schematic of the basic off-

procedure described herein is general enough to be applied

line forward converter using FPS, which also serves as the

to various applications. The design procedure presented in

reference circuit for the design procedure described in this

this paper is also implemented in a software design tool (FPS

paper. Because the MOSFET and PWM controller together

design assistant) to enable the engineer to finish SMPS

with various additional circuits are integrated into a single

design in a short time. In the appendix, a step-by-step design

package, the design of SMPS is much easier than the discrete

example using the software tool is provided.

MOSFET and PWM controller solution. This paper provides step-by-step design procedure for an FPS based off-line forward converter, which includes

Rev. 1.0.0

©2003 Fairchild Semiconductor Corporation

Page Summary Contents For FAIRCHILD Design Guidelines for Offline Forward Converters using FPS

Page 1 www.fairchildsemi.com Application Note AN4134 Design Guidelines for Off-line Forward Converters Using Fairchild Power Switch (FPSTM) Abstract helps the engineers to design a SMPS easily. In order to T...
Page 2 AN4134 APPLICATION NOTE 2. Step-by-step Design Procedure In this section, design procedure is presented using the DC link voltage ripple schematic of the figure 1 as a reference. In general, most FPS ...
Page 3 APPLICATION NOTE AN4134 The maximum voltage on MOSFET and the maximum duty The maximum voltage stress and the nominal snubber capac- ratio are given by itor voltage are given by max max Np = Vds VDC ...
Page 4 AN4134 APPLICATION NOTE (5) STEP-5 : Determine the proper core and the minimum primary turns for the transformer to prevent core saturation. Np VDC Dmax⋅ Actually, the initial selection of the core is...
Page 5 APPLICATION NOTE AN4134 When the auxiliary winding reset is employed, the rms cur- Then, calculate the inductance of the reference output rent of the reset winding is as follows. inductor as min Dmax ...
Page 6 AN4134 APPLICATION NOTE the ouput capacitance of the MOSFET. Based on the power loss, the snubber resistor with proper rated wattage should be rms KRFIo n( IC (30) chosen. The ripple of the snubber ca...
Page 7 APPLICATION NOTE AN4134 (c) Place compensator zero (fzc) around fc/3. (d) Place compensator pole (fpc) above 3fc . νo1 Np wz⁄+ Gvc RL ⋅= -----------------------⋅ 38( ˆ-------- Ns1 s+ wp⁄ νFB Light loa...
Page 8 AN4134 APPLICATION NOTE Vo VOP– 2.5– IFB> (42) RD VOP 1m A> (43) Rbias where VOP is opto-diode forward voltage drop, which is typically 1V and IFB is the feedback current of FPS, which is typica...
Page 9 APPLICATION NOTE AN4134 - Summary of symbols - Aw : Window area of the core in mm2 Ae : Cross sectional area of the core in mm2 Bsat : Saturation flux density in tesla. ∆B : Maximum flux density swing...
Page 10 AN4134 APPLICATION NOTE Appendix. Design Example using FPS design Assistant Target System : PC Power Supply - Input : universal input (90V-265Vrms) with voltage doubler - Output : 5V/15A, 3.3V/10A, 12...
Page 11 APPLICATION NOTE AN4134 6. Determine the numner of turns for each outputs Vo VF # of turns Vcc (Use Vcc start voltage) 1.2 3.6 1st output for feedback 0.4 2nd output 3.3 0.4 2.06 3rd output 0.5 6.94 4...
Page 12 AN4134 APPLICATION NOTE 11. Determine the output capacitor ESR Current Voltage Capacitance re in ripple Ripple 1st output capacitor u F mΩ 1.3 0.09 2nd output capacitor u F mΩ 0.9 0.06 3rd output capa...
Page 13 APPLICATION NOTE AN4134 Design Summary For the FPS, FS7M0880 is chosen. This device has a fixed switching frequency of 67k Hz. To limit the current, a 10 ohm resistor (Ra) is used in series with the V...
Page 14 AN4134 APPLICATION NOTE by Hang-Seok Choi / Ph. D FPS Application Group / Fairchild Semiconductor Phone : +82-32-680-1383 Facsimile : +82-32-680-1317 E-mail : [email protected] DISCLAIMER FAI...