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Application Note AN4102

A Fairchild Power Switch based SMPS
for Color Television Receivers

Introduction
A switched mode power supply (SMPS) typically consists of capacitor is added between the MOSFET drain and source,
a power transformer, secondary side rectifier diodes, a which lowers both the rising slope of the voltage Vds between
switching semiconductor device, a control IC, and peripheral the MOSFET's drain and source and the falling slope of the
circuits. Besides its basic function of supplying power to the reverse voltage across the secondary side rectifier diodes
load on the secondary side, an SMPS may have to perform when the MOSFET turns off. The shallower slopes reduce the
other, special functions, depending on the system. For dV/dt switching noise and switching loss, because the
example, an SMPS for a color television receiver must MOSFET turns on when Vds is at a minimum or zero. To
minimize the effect of switching noise on the screen and comply with regulatory trends aimed at reducing standby
reduce power consumption in standby. If the level of power consumption, KA5Q-series Fairchild Power Switch
integration of the switching circuitry is not high enough, then (FPS) features a built in burst mode. Burst mode operation
additional, separate circuits will be required to accommodate make it possible to reduce output voltages in standby to
all functions; these additional components raise the overall almost half those of the normal on mode. This can reduce
SMPS cost and not uncommonly reduce reliability. The standby input power demand to under 3W at 230Vac or, if few
highly integrated Fairchild Power Switch (FPS) combines a peripheral components are added, to possibly even 1.5W.
high power MOSFET and control IC into one package and, Moreover, as implemented in the KA5Q-series, burst mode
moreover, enhances IC functionality. It includes protective operation causes no audible noise and requires almost no
functions, thereby minimizing the number of additional additional components. To reduce losses further, KA5Q-
components needed in an SMPS. Fairchild Power Switch series Fairchild Power Switch (FPS) has lower IC start up and
(FPS) is widely used in the power circuits of a variety of operating currents than the KA3S-series, and quasi resonant
equipment, such as color TVs, printers, PCs, monitors, and, operation can continue even in burst mode. Also, the KA5Q-
of course, battery chargers and ac adapters. The KA3S-series series can perform primary side regulation using a built in
Fairchild Power Switch (FPS) series was first introduced for error amplifier, which replaces the secondary side error amp
color TVs; the SMPS described in this application note uses and eliminates its peripheral circuits. Overall, the KA5Q-
a KA5Q-series Fairchild Power Switch (FPS). KA5Q-series series incorporates five protection features to increase SMPS
Fairchild Power Switch (FPS) incorporates enhanced reliability:
protection functions and has a much reduced power • Pulse by pulse over current protection.
consumption in standby mode. • Over voltage protection.
The most frequently used power circuits in household • Over load protection.
appliances are the flyback converter and the forward • Thermal protection.
converter, both of which use the pulse width modulation • Over current latch.
(PWM) control method for fixed frequency switching. This application note contains working design example
However, a general purpose PWM based SMPS cannot be (Section 8) of an SMPS for use with color TVs or other high
used for a monitor or color TV, because the SMPS's switching power applications. It is a universal input supply adaptable to
noise would seriously affect the display quality. The ac input voltages world wide, and uses the Fairchild Power
switching noise would appear in the form of picture noise. To Switch (FPS)'s burst mode capability to achieve very low
significantly reduce the effect of switching noise on the standby power consumption: less than 2W at 230Vac. The
screen a power supply for a monitor has to be able to SMPS features variable frequency, quasi resonant switching;
synchronize its switching frequency to an external signal, current mode control; built in secondary side regulation; and
typically the monitor's horizontal sync flyback signal. Such a an array of built in protection features, including pulse by
sync technique cannot be used in color TVs, however, since, pulse over current protection and shutdown, over voltage
unlike monitors, a color TV's horizontal deflection frequency protection with auto restart, overload protection with auto
is too low. Instead, an SMPS for a color TV makes use of the restart, and thermal shutdown.
so called quasi resonant technique. In this technique a
Rev. 1.0.2
©2002 Fairchild Semiconductor Corporation
AN4102 APPLICATION NOTE

1. Quasi resonant Operation

MOSFET MOSFET
When a hard switched SMPS is used for a color TV, the off on
MOSFET generates a very high frequency current spike at
turn on, and this spike shows up as noise on the screen. Also,
Vgs
because the MOSFET's output capacitance, Coss is small, a
0
fast MOSFET turn off abruptly increases its drain to source
voltage Vds at a high dV/dt. This generates a voltage spike
that produces common mode noise on the secondary side, Vds nVo
which again results in on screen noise. Figure 1 shows a Vin nVo
flyback converter that uses the quasi resonant technique. Lm 0
is the transformer's primary side magnetizing inductance,
and D1 is the MOSFET body diode. Neither the inductor nor Ids
the diode is a physically separate component. They are Ip
integral and implicit to the transformer and MOSFET, 0
respectively, and are shown in Figure 1 for explanatory Figure 2. Waveforms for the circuit of Figure 1.
purposes. Current Id, that flows to the MOSFET increases at
a constant rate when the MOSFET is on. After all the energy stored in the transformer is delivered to
the secondary side, Lm and Cr resonate and Vds starts to
decrease. In the ideal case with no losses, the minimum
D2 IO value for Vds would be Vin - Vo. The actual value is slightly
higher. At minimum Vds the sensing circuit turns on the
ILm MOSFET. (See Section 5 for a description of the sensing
+ + method.) Because the MOSFET is turned on when Vds, is
VLm CO VO minimum and not zero, the potential stored in Cr discharges
- Lm - as soon as the MOSFET turns on, which generates a large
+ current spike. To reduce this spike, the Fairchild Power
Vi Switch (FPS)'s control IC is configured to slow the
- IDS ICR MOSFET's turn-on.The time required for Vds to reach
+
minimum is T R ( T R = π LmCr ) , a fixed value
Vds independent of the input voltage or output current. Varying
- the switching frequency regulates the output voltage: the
D1 CR
lower the switching frequency, the lower the input voltage
and the higher the load current.

Figure 1. Simplified diagram of a flyback converter using 2. Secondary Side vs. Primary
the quasi resonant technique.
Side Regulation
The MOSFET turns off when Id reaches the peak value (Ip Secondary side regulation requires an error amplifier and an
in Figure 2) set by the control circuit, at which time the opto coupler on the secondary side. The amplified error is
transferred to the primary side through the opto coupler to
energy stored in the transformer in the form of flux charges
control the MOSFET's on time and thereby precisely control
capacitor Cr connected between the MOSFET's drain and the output voltage. The opto coupler also transfers the MCU
source. This raises Vds. The rising slope of Vds increases as signal received on the secondary side to the primary side to
Ip increases and characteristic impedance Zr = (Lm/Cr)1/2 operate the burst mode. As explained in the following
decreases. Cr, which is much larger than the MOSFET's section, the burst mode allows low standby power to be
output capacitance Coss, controls dV/dt when the MOSFET achieved. Therefore, should it be necessary to guarantee a
turns on and off, reducing it from what it would be minimum standby power, an error amp and opto coupler
would be required on the secondary side and the increased
otherwise. The charging of Cr continues until the secondary
cost these components contribute to the design would have
side rectifier diode D2 turns on, after which the transformer to be accepted. Primary side regulation is a method that
delivers current to the output. D2 is on for an interval regulates secondary side voltage indirectly, by controlling
proportional to Ip, during which Vds = Vin + nVo, (Figure the primary side voltage. In the KA5Q-series Fairchild
2). Power Switch (FPS), the error amp in the control IC senses

©2002 Fairchild Semiconductor Corporation

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APPLICATION NOTE AN4102

the IC's Vcc. This is compared internally to a built in their respective levels as determined by R24, R26, and R25.
reference. Use of this block may allow the secondary side Vcc
opto coupler and error amplifier to be eliminated. Primary 24V
side regulation will be more cost effective than secondary
side regulation. However, primary side regulation is not so 12V
precise as secondary side regulation, and its response to load
11V
variations is slow. Therefore, primary side regulation is
advantageous only when considerations of lower cost out
weigh the accompanying increase in standby power 0V
consumption and reduction in regulation performance. VO2

3. Burst Mode Operation 45.8%

The KA5Q-series Fairchild Power Switch (FPS)s burst mode 0V

capability allows all output voltages to be reduced to almost
half those in normal (On mode) operation. It switches the VF/B
Fairchild Power Switch (FPS)'s MOSFET by fixing the peak 0V
current (IP) flowing to it, exhibits a very low audible noise
and makes possible an input power in standby mode of less Ids
than 2W at 230 Vac input. No external devices are required.
Figure 4. Normal (properly designed) burst mode
VO2 operation, in which Vcc decreases faster than Vo2.
5V
7805 µ-COM
MCU VCC, which powers the Fairchild Power Switch (FPS) on the
primary side, is regulated to 24V (see the circuit of Section
VO1 R26 8, Fairchild Power Switch (FPS) pin 3). The operation of the
R5 burst mode controller depends on Vcc. If Vcc drops to 11V
R4 Photo before the output voltages reduce to their respective levels as
OPTO
coupler R25 determined by R24, R26, and R25, the burst mode controller
COUPLER turns on; if it rises to 12V, the controller stops switching. The
R6
burst mode controller controls the MOSFET switching by
Picture off
Q1
ON/OFF restricting its peak current to a fixed value. This prevents the
C C1
generation of audible noise and also maintains the Fairchild
R24 Power Switch (FPS)'s Vfb at 0V (Figure 4).
KA431LZ REF
When the picture on signal goes high again, operation
(LM431) A
returns to the normal mode. The high picture on signal turns
on Q1. Vo1, is divided by R24 and R25, and the resulting
Figure 3. Reference diagram to demonstrate Fairchild voltage is compared to the reference voltage in the error
Power Switch burst mode operation. amplifier. Vfb increases, which regulates the MOSFET duty
Figure 3 is a secondary side regulated circuit that demon- and output voltages increase to normal.
strates the Fairchild Power Switch (FPS)'s burst mode
operation. Vo2 in the figure is a low value output voltage that 3.2 Design comments and a caution
also powers the MCU through the linear regulator 7805. Vo1
is the controlled output voltage that powers horizontal Note that when the MOSFET stops switching (because the
deflection and is the highest power output. picture on signal has gone low), the output voltages
3.1 Burst mode operation in standby decrease, but at different rates. The rates depend on output
current and output capacitance. Because the example of the
Refer to Figure 3. When the picture on signal is low, Q1 previous section is a real design, Figure 4 shows that Vcc
turns off and Vo2 is applied directly through R26 and the decreases faster than Vo2.
diode to the LM431’s reference pin, thereby increasing the Figure 5 however, shows how the burst mode would operate
voltage at this point and in turn increasing the current flow to should Vo2 decrease faster than Vcc. Vo2 would decrease to
the opto coupler. The voltage Vfb on the Fairchild Power the voltage set by R24, R26, and R25 before Vcc drops to
Switch (FPS)'s feedback pin (pin 4) goes to zero (Figure 4; 11V. The error amp would start to regulate, and the Fairchild
see also the complete circuit shown in Section 8), stopping Power Switch (FPS)'s Vfb, would increase slightly to a value
the Fairchild Power Switch (FPS) MOSFET's switching just above 0V, as shown. Because the load is off, load current
action. As also shown in Figure 4, Vcc and Vo2 decrease to is low and Vfb is not at 0V, the MOSFET starts to switch

©2002 Fairchild Semiconductor Corporation

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AN4102 APPLICATION NOTE

(see Ids, Figure 5), but the output voltage Vo2 remains at determine the output voltage, which is calculated as follows:
45.8% of its normal mode voltage. When Vcc finally drops R 24 //R 26 R 25 //R 24
to 11V (45.8% of 24V, its normal mode level), the burst 2.5 = --------------------------------------------- V′ 1 + --------------------------------------------- ( V′ 2 – 0.7 )
mode controller starts and Vcc and Vo2 increase. When Vcc R + R //R R + R //R
25 24 26 26 25 24
rises to 12V, the MOSFET stops switching and the above R 25 R 24 ( V′ 2 – 0.7 – 2.5 )
operations repeat. ∴R 26 = -----------------------------------------------------------------------
2.5 ( R 25 + R 24 ) – V′ 1 R 24
Vcc
24V
where, V1, and V2 are the normal mode output voltages, Vo1
12V
and Vo2; an V'1 and V'2 are the desired control loop values
for Vo1 and Vo2 in standby (45.8% of their normal mode
11V
values). This value is set since the Fairchild Power Switch
(FPS) regulates its Vcc voltage to 11V in standby mode and
0V Vcc is normally set to 24V in normal mode.
VO2
4.1.Transformer turns ratio
45.8% If Vo2 drops to V'2, before Vcc drops to 11V in standby
mode, the error amp starts to feed back. If V'2 is too low, the
MCU could be reset. Therefore, select V'2 such that the
0V linear regulator (7805) can properly maintain the output.
This means the turns ratio should be selected such that (11 /
Vfb Vcc) > (V'2 / V2). In other words, the transformer should be
0V designed so that Vo2 is maintained slightly higher than V'2.
This allows the error amp output to saturate low, permitting
Ids the primary side Vfb to remain at ground level.

Figure 5. Abnormal burst mode operation in an improper

design allowing Vo2 to decrease faster than Vcc.
5. Fairchild Power Switch Sync Pin
Circuitry Design
This kind of operation, where Vo2 decreases faster than Vcc In quasi resonant operation, the voltage level at the Fairchild
extends the switching period and increases the switching Power Switch (FPS) Sync pin (pin 5) determines when the
loss. To prevent these effects, increase the value of the MOSFET turns on. This should be when Vds is lowest.
output rectifier capacitance (see, e.g., the circuit of Section 8
and Table 1, the parts list for that circuit). Figure 6 shows the reference voltages, Vrh and Vrf for both
normal and burst mode operation. They are used to detect the
time required for the voltage across the MOSFET to reach its
4. Feedback Circuit Design minimum. The MOSFET turns on when the Sync pin voltage
becomes lower than Vrf.
When secondary side regulation is used, the output voltage is
Vcc
determined by comparing the voltage to be controlled, Vo1,
to the reference in the error amp. In this example it is 2. 5 V C15
for an LM431. As shown in Figure 3, when the MCU picture
on signal goes high, Q1 turns on and the diode in its collector R15
turns off. Thus, R24 and R25 around the error amp are Vsync(t)
determined as follows 5 +
OSC
–
: R16 C12

R 24
2.5 = -------------------------- V 1 BURST MODE
R 24 + R 25 CONTROLLER
NORMAL : Vrh=4.5V
4.6V
V 1 – 2.5 Vrf= 2.6V
2.5V
∴R 25 = ---------------------- R 24
2.5 BURST MODE : Vrh=2.5V
3.6V
Vrf= 1.25V
1.3V
In standby mode, however, with the picture on signal low, Figure 6. Reference voltages for normal and burst mode
Q1 is off and the diode is on. Now R24, R25, and R26 operation, Vrh and Vrf.

©2002 Fairchild Semiconductor Corporation

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APPLICATION NOTE AN4102

Figure 7 shows the waveform of Vsync in normal mode. The and does not change once the circuit is set.
peak value of Vsync(t), when divided by R15 and R16 must OVP
be greater than the threshold voltage of the sync pin. In LEVEL
TQ2
normal mode the threshold voltage is 4.6 V, and in standby Vsync(t) TQ1
mode it is 3.6V. Vsync(t) is the voltage across C15. It (ST-BY)
increases to Vc, which is the maximum voltage of Vsync(t) Vrh Vc2
determined by the auxiliary winding voltage and the ratio of Vrf
R15 and R16, after the MOSFET turns off. When the
transformer current drops to zero, it drops exponentially as Vrh
shown in Figure 7. SYNC Vrf
REF

OVP MOSFET
GATE Vg
LEVEL

Vsync(t)
(normal)
Vrh Figure 8. Stand by mode Vsync waveform.
Vc1
Vrf
TQ1 The output voltage in standby drops to 45-50% of its value in
Vrh normal mode, and so does Vc. Therefore, to guarantee quasi
SYNC.
REF. Vrf resonant operation in standby mode, tQ must equal tR,
regardless of the mode. To achieve this, the reference in the
MOSFET Vg Fairchild Power Switch (FPS)'s Sync pin comparator
GATE changes with the mode.

Figure 7. Normal mode waveforms for Vsync(t).

6. Protection
The time tQ that it takes for Vsync(t) to drop from Vc to Vrf ,
is calculated as follows:
6.1 Over voltage protection
V rf – 1
t Q = τ1n  1 – -------- Refer to Figure 8. A problem in the feedback loop can be
 V  c indicated either when switching shuts down or the output
R 16 voltage is continuing to increase because it is not regulated.
where τ = R 16 C 12 V c = -------------------------- V cc In response to increasing output voltage, a KA5Q-series
R 15 + R 16
Fairchild Power Switch (FPS) enters latch mode when the
When tQ1 as calculated from Vc1 and Vrf1 equals tQ2 as sync pin voltage reaches 12V (typ.) The Fairchild Power
Switch (FPS) stops, and all output voltages start to drop.
calculated from Vc2 and Vrf2, the following relationship can
be derived: When Vcc reaches 9V, the Fairchild Power Switch (FPS)
unlatches and restarts and Vcc again increases. Switching
V rf1 V rf2
------------ = -----------
- restarts when Vcc reaches 15V. This operation is called auto
V C1 V C2 restart. Be careful of the rising slope of Vsync(t). Its time
Therefore, tQ1= tQ2 and are independent of t, and tQ will not constant is C12x(R15//R16). If the time constant is too short,
change so long as the ratio of Vc to Vrf is constant. When the the waveform can oscillate causing an over voltage
transformer flyback current becomes zero, Vds starts to protection (OVP) malfunction. If Vc, the peak value of
decrease. The time required for the voltage across the Vsync(t) approaches the OVP level (12V, typ.) and there are
MOSFET to drop to its minimum value is: problems in the feedback loop. Output voltage overshoot is
reduced but care must be taken so that the OVP does not
tR = π L m Cr
malfunction due to a slight overshoot, etc. in the output
The equation shows that the time required to drop to voltage. If Vc is set too low, the Fairchild Power Switch
minimum voltage is a function of the primary inductance, (FPS)'s Primary Side Regulation (PSR) block can start
Lm, and capacitance, Cr, across the MOSFET. This means before OVP and regulate Vcc. In that case operation
that tR is independent of changes in input and output voltage continues, but with an abnormally increased output voltage.

©2002 Fairchild Semiconductor Corporation

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AN4102 APPLICATION NOTE

6.2 Thermal shutdown

If the ambient temperature is high, or the temperature inside
the device becomes too high due to abnormal operation, the
junction temperature of the device can become too high. If it
exceeds 150°C, the Fairchild Power Switch (FPS) enters
latch mode and stops.

6.3 Over current latch

A short circuit in a secondary side rectifier diode or on a
transformer pin is equivalent to a leakage inductor of several
mH connected to the input bulk capacitor. A large current
spike can flow through the MOSFET in the Fairchild Power
Switch (FPS), and the MOSFET will be destroyed if the
current is not turned off within a few hundred nanoseconds.
Although ICs with current mode control generally have over
current protection, it may not execute properly due to delays
in the IC's internal blocks. Hence, besides using pulse by
pulse over current protection to turn off the MOSFET, the
Fairchild Power Switch (FPS) also uses an over current
latch. This allows the Fairchild Power Switch (FPS) to turn
off the MOSFET within 200 ns if the current flow is higher
than the over current protection level threshold. The
Fairchild Power Switch (FPS) also operates in latch mode to
reduce stress on the MOSFET that would result from
repeated auto restarts. Once the Fairchild Power Switch
(FPS) enters latch mode, the input ac power is cut off. The
Fairchild Power Switch (FPS) will unlatch and restart only
when Vcc drops below 5V.

6.4 Over load protection (OLP)

Refer to Figure 9, next page. The feedback loop causes the
voltage Vfb, on the Fairchild Power Switch (FPS) feedback
pin to increase when the output current increases. In the case
of a persistent overload condition, Vfb continues to increase
because 5mA current source in the Fairchild Power Switch
(FPS) charges the compensation capacitor attached to the FB
pin. If this voltage reaches 7.5V, the MOSFET stops
switching. The delay between Vfb reaching the over current
protection level and when the MOSFET stops switching is
calculated as follows:
( 7.5 – 3 ) ⋅ C 13
t delay = -------------------------------------- [ sec ]
–6
5 × 10
Auto restart begins after overload protection triggers.

©2002 Fairchild Semiconductor Corporation

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APPLICATION NOTE AN4102

7. PCB Layout

3
C

H B

D EF
A
1
2

Figure 9.
A proper PCB layout not only reduces the set EMI, but also of output which is regulated and the ground of secondary
minimizes the noises that can produce device malfunction. error Amp. is simple and close as possible.
Cautionary items when designing the PCB layout of the (H↔3 in the fig9, very important)
5Q-series are as follows: • when the primary side control is used, the transformer
• The space between 2 pin in the 5Q-series and the bulk Vcc (pin 3) winding must be made so as to result in the
capacitor (DC link capacitor) - (Ground) terminal should best coupling coefficient between it and the most
be simple and close as possible. A thick pattern should be important winding.
used.
(C↔2 in the fig9, very important)
• PCB pattern should be made such that Cr is as close as
possible to pin 1,2. If not, pulse like current flow path
becomes longer every time the switch turns on, worsening
the noise.
(A↔1, B↔2 in the fig9, very important)
• The distance between 2 pin in the 5Q-series and the
negative terminal of Vcc capacitor should be close as
possible.
(D↔2 in the fig9, very important)
• The distance between 2 pin in 5Q-series and the negative
terminal of Vcc capacitor should be close as possible.
(E↔2 in the fig9,important)
• The distance between 2pin in the 5Q-series and the
negative terminal of Vfb capacitor should be close as
possible.
(F↔2 in the fig9,important)
• The feedback loop PCB pattern should be simple and not
be placed close to a comparatively high current flow
connection or device. The connection between the ground

©2002 Fairchild Semiconductor Corporation

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AN4102 APPLICATION NOTE

PICTURE- PICTURE- PICTURE-

OVP ON
START-UP ON ST-BY ON OLP

Vcc

VST-UP

VSTOP
AUTO-
RESTART

VF/B
VSd

MAX.
DUTY

Vout

Vds

Vovp

Vsync

Figure 10. Operation Waveform.

©2002 Fairchild Semiconductor Corporation

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APPLICATION NOTE AN4102

8. KA5Q Fairchild Power Switch

Based SMPS for a Color TV
8.1 Secondary Side Regulation.

BD101 R102 T101

D207 BEAD204
fuse LF101 7

C210 C211
C101 C206
C102

D102 D205 BEAD203

5

C208 C209
C207
R103

6
R104
5Q
SERIES BEAD202
D203
4

BEAD101 D105 C214 C215

C206

C107 3
D103
R106 BEAD201
D202
D106 R107 2

C201
R105 C105 C202
C104 C205

ZD101
OPT101
C108 C213
C103
C109

R201 R206

R203 OPT101 VR202

VR201
R204 D201
MCU
Q202
R207
C203
Q201 R205
R208

©2002 Fairchild Semiconductor Corporation

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AN4102 APPLICATION NOTE

8.2 Primary Side Regulation

R102 T101
D207 BEAD20
4
fuse LF101 7

BD101 C211
C210
C101 C206
C102

D205 BEAD20
3
5

C208
C207
R103 C209

6
R104
5Q
SERIES BEAD20
D203
2 4

BEAD10
D105 C214
1 C206
C215

3
C107
D103
R106 D202 BEAD20
R107 1
2

C105 C202
C104 R105 C205
C201

ZD101

OPT101 C108 C213

C103
C109

R201

OPT101 R205

Micom
Q201
R207

Q202
R208

©2002 Fairchild Semiconductor Corporation

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APPLICATION NOTE AN4102

Table 1. Parts List for KA5Q based SMPS

Part # Value Rating Note Part # Value Rating Note
[Resister] C104 47µF 50V electrolytic
R101 open 1/2W - C105 3.9nF 50V film
R102 NTC 4.7Ω - C106 open 50V electrolytic
R103 68kΩ 1/2W - C107 2.2nF 1000V film
R104 68kΩ 1/2W - C108 560pF 2000V film
R105 470Ω 1/4W - C109 47nF 50V film
R106 600Ω 1/4W - C201 1000µF 50V electrolytic
R107 10Ω 1/4W - C202 1000µF 50V electrolytic
R108 open 1/4W - C203 22nF 50V film
R109 open 1/4W - C204 open 50V film
R201 1kΩ 1/4W - C205 470pF 1000V film
R202 short fuse - C206 470pF 1000V film
R203 1kΩ 1/4W - C207 470pF 1000V film
R204 40kΩ 1/4W - C208 1000µF 50V electrolytic
R205 4.7kΩ 1/4W - C209 1000µF 50V electrolytic
R206 220kΩ 1/4W - C210 1000µF 50V electrolytic
R207 5kΩ 1/4W - C211 1000µF 50V electrolytic
R208 5kΩ 1/4W - C212 470pF 1000V film
VR201 30kΩ box - C213 560pF 2000V film

VR202 20 kΩ box - C214 100µF 200V electrolytic

(100W)
220µF
[Diodes] - 200V electrolytic
(150W)
330µF
D101 open ZNR - - (200W) 200V electrolytic

330µF
D102 1N4004 400V, 1A - - (270W) 200V electrolytic

D103 1N4937 600V, 1A - C215 47µF (100W) 200V electrolytic

D104 short 600V, 1A - - 100µF 200V electrolytic

(150W)

D105 1N4937 600 V, 1A - - 220µF 200V electrolytic

(200W)
75V, 220µF
D106 1N4148 - - 200V electrolytic
0.15A (270W)
D201 1N4148 75V, 0.15A - - - - -
D06U20S(100W) 200V, 6A TO-220F - - - -
D202 D06U20S(150W) 200V, 6A TO-220F - - - -
D06U20S(200W) 200V, 10A TO-220F - - - -

©2002 Fairchild Semiconductor Corporation

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AN4102 APPLICATION NOTE

Table 1. Parts List for KA5Q based SMPS (continued)

Part # Value Rating Note Part # Value Rating Note

[Diodes] [Beads]
D202 D06U20S(270W) 200V,20A TO-220F BEAD101 ferrite bead - -
D203 D10U60S 600V,10A TO-220F BEAD201 ferrite bead - -
D20U60S(270W) 600V,20A TO-220F BEAD202 100 µH 5A -
open - - BEAD203 ferrite bead - -
D06U20S 200V,10A TO-220F BEAD204 ferrite bead - -
open - - - - - -
D06U20S 200V,10A TO-220F - - - -
open - - - - - -
[Zener] [Others]
ZD101 4.7V 0.5W - OPT101 H11A817A - Fairchild
- - - T101 EER3542 KA5Q0765RT -
- EER4042 KA5Q12656RT -
C101 220nF 275V box - EER4942 KA5Q1265RT -
220µF (100W) 400V electrolytic - EER5354 KA5Q1565RT -
330µF (150W) 400V electrolytic CON201 PWR CONN. - -
C102
470µF (200W) 400V electrolytic CON202 PWR CONN. - -
560µF (270W) 400V electrolytic Q201 KA431LZ - -
C103 100nF 50V film Q202 C945 npn (E.B.C) -

©2002 Fairchild Semiconductor Corporation

12
APPLICATION NOTE AN4102

9. Example Transformer Design for 9.2. Calculate minimum dc input voltage,

Color TV SMPS Vinmin:
The table below shows typical values of Vinmin, Lm, Fsmin
9.1 Define system specifications: for various Pin values. The maximum power input is
Output power, Po = 80W (125V,0.56A for B+ and Po 80W
13V,0.76A) Pin_max = ------------------------------- = ------------- = 100W
efficiency 0.8
P B – OUT = 70W ,P 13V – OUT = 10W
For 100W Pin_max, there are two option for capacitor value;
Input voltage, 85 to 265 V., (universal input), 60Hz 220uF or 330uF. Here, select the 220uF.
Efficiency η≥80% Then, 93V is the minimum dc input voltage.
Core = EER3542 (Ae = 108mm2)

Pin (W) Cin [uF] Vin_min [V] Lm [uH] Fs_min [kHz]

700 26.1
220 98 675 27.0
650 27.9
80
700 28.0
330 105 675 29.0
650 30.0
600 23.6
220 93 575 24.5
550 25.6
100
600 25.9
330 102 575 27.0
550 28.1
500 23.3
330 96 475 24.4
450 25.7
130
500 25.0
470 103 475 26.3
450 27.6
400 26.6
330 93 375 28.2
350 30.0
150
400 26.6
470 101 375 28.2
350 30.0
350 24.7
470 97 325 26.5
300 28.5
180
350 25.7
560 101 325 27.5
300 29.6
325 23.4
470 94 300 25.3
275 27.4
200
325 24.5
560 98 300 26.4
275 28.7

©2002 Fairchild Semiconductor Corporation

13
AN4102 APPLICATION NOTE

Pin (W) Cin [uF] Vin_min [V] Lm [uH] Fs_min [kHz]

275 23.3
560 94 250 25.5
225 28.1
240
275 24.5
680 99 250 26.8
225 24.5
250 22.0
560 91
200 24.3
270 250 23.4
680 96
200 25.9

However, because of voltage drops from the line filter, gap calculation to give the correct flux density.
bridge diode, and NTC (negative thermal coefficient), set 2 2
V in × D max
Vinmin to 100V to allow for a design margin and convenient L m = --------------------------------
-
calculation. 2P in f s
2 2
93 × 0.62
9.3 Determine turns ratio, n = Np/Ns: L m = -------------------------------------- = 554µH
2 × 100 × 30K
Turns ratio is a factor in determining Dmax, device operat- Estimated gap length (lg) is
ing voltage, and device and transformer dissipation.
650V + – 2 V ( acmax ) – 120 2
n = ----------------------------------------------------------------------- NP µo A e 3
Vo l g = ---------------------- × 10
Lm
650 – 2 × 265 – 120 2 –7 –6
n = ---------------------------------------------------------- 63 × 4π × 10 × 108 × 10 3
125 = ------------------------------------------------------------------------------- × 10
–6
= 1.25 620 × 10
= 0.868mm
where Vo is the output voltage used for B+ (125V) and 120V
is the margin voltage. It can be determined by the designer, Ae is the cross sectional area of the core
or the transformer, etc. µο= 4π × 10-7

9.4 Calculate maximum duty, Dmax: 9.6 Calculate minimum primary turns, Npmin:

Vo The primary turns count must be made larger than Npmin to

D max = ---------------------------------
-
V inmin + nV o prevent the transformer from saturating below the Fairchild
Power Switch (FPS) Ipeak specification.
1.25 × 125 - = 0.62
D max = ------------------------------------------ V inmin D max
93 + 1.25 × 125 N pmin = ------------------------------------------------
-
( dB ) ( Ae ) ( Fsmin )
6
93 × 0.62 × 10
9.5 Calculate transformer inductance, Lm: N pmin = -------------------------------------------- ≈ 59T
0.3 × 108 × 30K
Fs, is the minimum operating frequency at the where dB is the absolute amount of flux density variation in
condition of maximum load and minimum input voltage. the core.
Therefore Fs, should be set around 25-40kHz. Vinmin
condition is calculated as above at operating frequency of
any load. From the operating frequency, it is possible to
estimate the device and transformer dissipation. Using Fs =
30kHz we calculate Lm. Fs should be corrected to 30×103 in
the equation below.
Following this there should be some explanation of the core
©2002 Fairchild Semiconductor Corporation
14
APPLICATION NOTE AN4102

9.7 Calculate the maximum current, Ipeak,.

At full load and at minimum Vin, Ipeak must be lower than 2

PB – OUT × 2 × ( N pmin ⁄ N 125V ) 1
the Ipeak specification of the device to be used. I = -------------------------------------------------------------------------------------------------- × ------- × 1 – D
B – rms L × f – min 3
m s
V inmin D max
I peak = ------------------------------
- 2
L m f smin = 70W × 2 × 1.25 - × ------
--------------------------------------------
1
- × 0.38
554uH × 30kHz 3
93 × 0.62 = 1.291A
I peak = ------------------------------------ = 3.46A
554µH × 30k
The wire diameter f of B+ is 0.60mm.
9.8 Determine each output turns count:
Φ 2
= 1.291A ;π  ----
2
• 125V output: N125V = Npmin./ n = 47turns 5A ;1mm
 2
• Volts per turn: (125V + 1V) 50 turns = 2.68V / turn
• 13V output: (13V + 1V) / 2.68V / turn = 5.22 = 5turns Φ 2
π  ---- = 0.258mm
2
• Vcc winding: (24V + 1V) / 2.68V/turn = 9.32 = 9turns  2

9.9 Determine wire diameter Φ = 0.573mm

Calculated as above, the wire diameter f of 13V bias
The copper coil's current capability is Idensity, 5A/mm . The winding is 1mm.
rms current through primary Np is 1.479A in the example.

IPEAK = 3.28A

References
1. Transformer and Inductor Design Handbook. 2nd ed.
Col. Wm. T. McLyman. Marcel Dekker, Inc., 1988.

D = 0.61 2. Flyback converter design using Fairchild Power

Switch. Application note AN4105. Fairchild
Electronics, 2000.
KA3S0680RB, KA3S0680RFB, KA3S0880RB,
1 KA3S0880RFB, KA3S0765R, KA3S0765RF, KA3S0965R,
I = I × ------- × D
rms PEAK 3 KA3S0965RF, KA3S1265R, KA3S1265RF, KA5Q0765RT,
1 KA5Q12656RT, KA5Q1265RF, KA5Q1565RF,
= 3.46A × ------- × 0.62 KA5Q0740RT, KA5Q0945RT
3
= 1.577A
The wire diameter f of Np is 0.65mm.

Φ 2
I d e nsity ;1mm = Irms ;π  ----
2
 2

Φ 2
5A ;1mm = 1.479A ;π  ----
2
 2

Φ 2
π  ---- = 0.295mm
2
 2
Φ ≥ 0.613mm ⇒ 0.65mm
The rms current through secondary B+ is 1.246A in the
example.

©2002 Fairchild Semiconductor Corporation

15
AN4102 APPLICATION NOTE

DISCLAIMER
FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY
PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION, OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY
LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER
DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.

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FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES
OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR
CORPORATION. As used herein:
1. Life support devices or systems are devices or systems 2. A critical component is any component of a life support
which (a) are intended for surgical implant into the body, or device or system whose failure to perform can be
(b) support or sustain life, or (c) whose failure to per-form reasonably expected to cause the failure of the life support
when properly used in accordance with instructions for use device or system, or to affect its safety or effectiveness.
provided in the labeling can be reasonably expected to
result in significant injury to the user.

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3/19/04 0.0m 002

 2002 Fairchild Semiconductor Corporation