4-5 EE462L MOSFET Firing Circuit

EE462L, Spring 2014
MOSFET Firing Circuit
Power MOSFETs
(high-speed, voltage-controlled switches that allow us
to operate above the 20kHz audible range)
D: Drain
If desired, a series
blocking diode can be
inserted here to prevent
reverse current
G: Gate
S: Source
Switch closes when

VGS 4V, and opens
when VGS= 0V
N channel MOSFET equivalent circuit
Controlled turn on, controlled turn off

(but there is an internal antiparallel diode)
2
We Avoid the Linear (Lossy) Region, Using

Only the On and Off States
MOSFET on
MOSFET off
when VGS = 12V
when VGS = 0V
3
We Want to Switch Quickly to Minimize Switching Losses

Turn Off
Turn On
VDS(t)
VDS(t)
I(t)
toff
I(t)
PLOSS(t)
PLOSS(t)
Energy lost per

turn off
ton
Energy lost per

turn on
Turn off and turn on times limit the frequency of operation because
their sum must be considerably less than period T (i.e., 1/f)
Consider, for example, the turn off

Turn Off
VDS(t)
V I toff ,
so we want to keep turn off
(and turn on) times as small
as possible.
0
I(t)
I
The more often we switch, the more

energy loss areas we experience per
second.
toff
Thus, switching losses (average W)

are proportional to switching
0
PLOSS(t)
0
Energy lost per turn off is

proportional to
Energy lost per

turn off
frequency f, V, I, toff, and ton.
And, of course, there are conduction losses that are

proportional to squared I
Advantages of Operating Above 20kHz

Yes, switching losses in power electronic switches do increase with
operating frequency, but going beyond 20kHz has important
advantages. Among these are
Humans cannot hear the circuits
For the same desired smoothing effect, Ls and Cs can be smaller
because, as frequency increases and period T decreases, Ls and
Cs charge and discharge less energy per cycle of operation.
Smaller Ls and Cs permit smaller, lighter circuits.
Correspondingly, L and C rms ripple currents decrease, so current
ratings can be lower. Thus, smaller, lighter circuits.
AC transformers are smaller because, for a given voltage rating, the
peak flux density in the core is reduced (which means transformer
cores can have smaller cross sectional areas A).
v(t ) N
d Bmax sin(t )
d
dB
NA
NA
NABmax cos(t )
dt
dt
dt
Thus, smaller, lighter circuits.
N = number of turns, = magnetic flux,

B = magnetic field, A = x-sectional area
Fast Switching Frequencies

Previous slide was just to illustrate how, with increased
switching frequency, one can reduce the size of AC
transformer cores needed:
d Bmax sin(t )
d
dB
v (t ) N
NA
NA
NABmax cos(t )
dt
dt
dt
Thus, smaller, lighter circuits.
N = number of turns, = magnetic flux,

B = magnetic field, A = x-sectional area
The drawback, of course, to high frequency switching is

increased power loss, since:
PTotal (loss) = Pswitching loss x number of switching events
(or, the switching frequency)
This is the downside of high-frequency switching. Thus,

one must work to ensure overall losses are reduced by
working to reduce the individual switching transition time.
+12V
10
Dual Op Amp
+12V
VPWM
Buffer
SPDT
Dcont,ext
+
220k
B10k
15 turn
+12V
14, 13, 12, 11, 10, 9, 8
Buffer
B10k
15 turn
+
LED
8, 7, 6, 5
Driver
1, 2, 3, 4, 5 , 6, 7
Dcont
1, 2, 3, 4
+
LED
100k
D
S
1k
MOSFET
VGS, VDS
C
B10k
C1
6.8nF
Dcont,man
symbol shows direction of
resistance change for
clockwise turn
220k
PWM Modulator
1k
Dcont,limiter
+12V
All caps in this figure are ceramic.

Unlabeled Cs are 0.01uF.
470
CF
Switching
frequency control
RF
+12V
Dual Op Amp
+12V
Buffer
SPDT
Dcont,ext
+
220k
+12V
B10k
15 turn
Dcont
+
LED
B10k
15 turn
Dcont,man
+12V
220k
+
LED
100k
8, 7, 6, 5
Driver
1, 2, 3, 4
1k
MOSFET
C
B10k
C1
6.8nF
All caps in this figure are ceramic.

Unlabeled Cs are 0.01uF.
470
symbol shows direction

of resistance change for
clockwise turn
MC34060A, Fixed Frequency, PWM,

Voltage Mode Single Ended Controller
VGS, VDS
C
1k
Dcont,limiter
VPWM
14, 13, 12, 11, 10, 9, 8

PWM Modulator
1, 2, 3, 4, 5 , 6, 7
Buffer
10
C
CF
RF
TLE2072CP, Texas Instruments,

Dual Low Noise Op Amp
Switching
frequency control
Microchip Technology, TC1426CPA,

MOSFET & Power Driver, Inverting,
1.2A Dual
Fairchild FQA62N25C, 250V N-Channel MOSFET, 62A

Gate capacitance 10 nF
TLE2072CP, Texas Instruments,

Dual Low Noise Op Amp
Microchip Technology, TC1426CPA,

MOSFET & Power Driver, Inverting,
1.2A Dual
MC34060A, Fixed Frequency, PWM,

Voltage Mode Single Ended Controller
1.2
RT CT
10
The PWM chip has an internal sawtooth wave generator, whose

frequency is controlled by an external R and C
Internal sawtooth
3.5V
0-3.5V adjustable
analog input (duty
cycle control)
Linear portions of sawtooth allows to directly translate

voltage levels into time intervals (on-times)
12V
In essence, the PWM process involves

comparing a sawtooth (or any other periodic
function with linear transitions) with a voltage
level. If the voltage level is constant, it will
tend to produce a constant (dc) output.
Duty cycle
control
sawtooth
+
-
PWM
signal
11
The PWM chip has an internal sawtooth wave generator, whose

frequency is controlled by an external R and C
Internal sawtooth
3.5V
0-3.5V adjustable
analog input
Output of PWM chip
5V
Comparison yields 0-5V

control input to driver chip
Output of inverting driver chip goes to MOSFET gate

12V
So, raising the 0-3.5V analog input raises the duty cycle of the
MOSFET 12V gate signal
12
To control the duty cycle and provide fast turnon and turn-off, we use
A 0-12V signal from a MOSFET driver chip to very
quickly turn the MOSFET on and off at 20kHz-100kHz
by charging and discharging the MOSFET gate
capacitance (nano Farads)
A pulse-width modulator (PWM) chip to provide a 05V control input to the MOSFET driver chip
A 0-3.5V analog voltage to control the duty cycle of
the PWM chip
13
14
Some PCB Electronics suppliers
Digikey
Mouser
Arrow
Allied
Newark
http://www.digikey.com
http://www.mouser.com/
http://www.arrow.com/
http://www.alliedelec.com
http://www.newark.com/
(Note: Digikey & Mouser will let one purchase smaller

quantities, although it will cost more per component.)
To look up a part numbers spec sheet, go to a suppliers website,
type in the part number, and they should have a link to the actual
spec sheet of the part in question.
15
Keep in mind that your CT may be 20%

higher than labeled
16
17
18
One can see that from Pin 6, RT = 10k potentiometer + 470 (in series)
And from Pin 5, CT = two, 6.9 nF capacitors in parallel = 13.8 nF
Since the 470 resistor and the C values are fixed,
adjusting the 10k pot will then control fOSC.
R
T
CT
19
What About the Other Potentiometer?

The D Limiter; Whats Its Function?
D Limiter - UCL
Acts as an Upper Bounds to limit the
maximum range of D
D Limiter
(UCL)
75%
0%
Restricting the duty cycles (D) range will become
very important later, for certain DC-DC converters
100%
Restricted Range of D
20
MOSFET Gate Driver

Assures Rapid Turn On
and Off
21
MOSFET Gate Driver

Assures Rapid Turn On
and Off
Note:
For mounting your ICs, look for this
dot. This dot designates which pin
is Pin 1
Aside:
N.C. = No Connect
22
Power Section
100uF, 50V low ESR

electrolytics,
1.
power plane to
ground plane,
2.
power traces to
ground plane,
3.
across wall wart.
NMH1212SC, Murata Power Solutions, DC/DC

Converter & Regulator 2W, +12,-12V Dual Output
Converter input
Plug in 12V regulated

wall wart (marked
with red 12R)
Converter 12V feeds power traces

Converter 0V to ground plane
Converter +12V to power plane
Wall wart
+12V
Wall wart
0V
23
Buck Converter Firing Circuit
Less steep at high voltages
24
Construction Tips
Use #8 nylon half-inch threaded
spacers as feet, with #8 nylon
screws on top
All soldering is done on the bottom
side of the PCB
Double-socket the chips one
socket stays attached to the chip for
re-use each semester. The other
socket is soldered to the PCB.
Solder the shortest components
first, and the tallest components last
The soldering iron tip should be
held firmly on the solder pad, and
slightly touching the component
Use wood props to hold
components flat on the top surface
while you solder the bottom side
Traces are rated 4A per 0.1 of

width. The thin ones here are 0.05,
and the wide one is 0.20.
It is time to memorize the color
code. Ask around for a jingle.
B, B, R, O, Y, G, B, V, G, W
0, 1, 2, 3, 4, 5, 6, 7, 8, 9
25
Resistor Color Code
26
Construction Tips, cont.

Orient the resistors so the color code reads left to right, or top to bottom
BEFORE SOLDERING, make sure that the green plugs point in the
desired direction
The long lead on LEDs is +
Do not solder the MOSFET it will be screwed to a green plug
27
MOSFETS are Very Static Sensitive

Touching the gate lead before the MOSFET is properly mounted
with a 100k gate-to-source resistor will likely ruin the MOSFET
But it may not fail right away. Instead, the failure may be
gradual. Your circuit will work, but not correctly. Performance
gradually deteriorates.
When that happens, you can spend unnecessary hours
debugging
Key indicators of a failed MOSFET are
Failed or burning hot driver chip
Burning hot gate driver resistor (discolored, or bubbled up)
Board scorches or melts underneath the driver chip or gate driver
resistor
Avoid these problems by mounting the MOSFET last, by using an

antistatic wristband, and by not touching the gate lead
28
The 100k gate-to-source

resistor is soldered onto the
PCB.
A 3-pin header strip (under the
green plug) is soldered to the
PCB, with the black plastic strip
of the header on top of the PCB.
After that, mount the heat sink

assembly with nylon hardware
and tighten the MOSFET firmly
to the heat sink.
S: Source
G: Gate
Then, using an antistatic

wristband, and without
touching the gate lead, insert
the MOSFET into the green
plug and tighten the three
screws.
D: Drain
Before taking the MOSFET out

of the pink zip bag, push the
green plug down (hard) onto
the header strip.
29
Initial Checkout. Use 20kHz, with MOSFET Mounted,

But No DBR Power to MOSFET
With Dcont fully counter-clockwise, D should be about 0.05
Rotate Dcont fully clockwise, and adjust D limiter until D is about 0.90
Then, capture the waveforms shown below
VPWM
D 0.5
VGS
VPWM
D 0.2
VGS
30
VPWM
With MOSFET, No DBR

Power to MOSFET
20kHz
VGS
VPWM
100kHz
VGS
VPWM
200kHz
VGS
31
200kHz, No DBR Power to MOSFET

With MOSFET
VPWM
VGS
VPWM
5sec
Without MOSFET
VGS
32
200kHz, No DBR Power to MOSFET

VPWM
With MOSFET
VGS
(1 e-1) = 0.632, tau 140nsec = 0.14sec

Check 10nF 10 =
100nsec = 0.1 sec
VPWM
Without MOSFET
VGS
Fall times are about the same as rise times

33
Hard Switching Load Tests (i.e., full interruption of load

current with parasitic line inductance). Start with 100kHz.
Before turning on the variac/transformer/DBR, connect scope leads to simultaneously
view VGS and VDS.
Set the D control to zero. Raise Vdc (i.e., the DBR voltage) to about 20V.
While viewing VGS and VDS, slowly raise D to about 0.5. Observe and measure the
peak value and frequency of the ringing overvoltage in VDS.
Sweep D over the entire range. Does the ringing overvoltage increase with D?
If no sign of trouble, repeat the above with the Vdc about 35 to 40V. Take a screen
snapshot of VDS. Measure the peak value and frequency of the ringing overvoltage.
If no sign of trouble, repeat with 200kHz.
+
Variac
120/25V
Transformer
DBR
10, 100W
power
resistor
60W light
bulb
If peak ringing
overvoltage reaches 200V,
back off on Vdc
34
34
Controlling the Ringing Overvoltage

Ringing overvoltage is due to the MOSFET capacitance in series
with the load circuits parasitic inductance (including DBR, wires,
and resistor)
Obviously, in the hard switching case, the ringing overvoltage
can be greater than the acceptable twice Vdc.
High ringing overvoltage uses up the MOSFETs voltage rating
To reduce ringing overvoltage, slow it down by placing a 0.022
F ceramic disk capacitor (a.k,a snubber capacitor) between the
MOSFETs drain and source terminals.
Then, repeat the hard switching load test with 35-40 Vdc, D = 0.5,
and re-measure the frequency and peak value of the ringing
overvoltage.
35
200kHz, MOSFET Switching a 35V, 5 Resistive Load
230V
VDS
35V
OFF
ON
VGS
36
MOSFET Switch Turn-Off

Overshoot. MOSFET in series with
DBR and (5 || with 60W light bulb)
200kHz, 0.01F snubber
Note you will use 10. Parallel

light bulb optional.
200kHz, no snubber
37
MOSFET Safe Operating Area (SOA)

Pulsed drain current
must never be exceed
Operation naturally
limited by RDS,on (Ohms
law)
Maximum
continuous drain
current can be
exceeded but only
for a brief time
Thermal limit (power

limit) can be exceeded
but only for a brief time
Breakdown voltage
must never be
exceeded
38
MOSFET Datasheet
39
Large 10 , 225W Resistor. 5.3Vdc. Vpeak = 200V.
MOSFET
opens
40
Small 10 , 100W Resistor. 22Vdc. Vpeak = 240V.
MOSFET
opens
VDS
ON
VGS
OFF
D
Note: Due to ringing, you may have to measure D manually on the O-scope
41
MOSFET
opens
VDS
ON
VGS
OFF
t
Measure t to determine ringing Turn OFF
42

0.022F Snubber Cap
MOSFET
opens
43
Small 10 , 100W Resistor. 22Vdc. Vpeak = 60V

0.0068F Snubber Cap
MOSFET
opens
44

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EE462L, Spring 2014

MOSFET Firing Circuit

Switch closes when

N channel MOSFET equivalent circuit

Controlled turn on, controlled turn off

We Avoid the Linear (Lossy) Region, Using

when VGS = 12V

We Want to Switch Quickly to Minimize Switching Losses

Energy lost per

Energy lost per

Consider, for example, the turn off

The more often we switch, the more

Thus, switching losses (average W)

Energy lost per turn off is

Energy lost per

frequency f, V, I, toff, and ton.

And, of course, there are conduction losses that are

Advantages of Operating Above 20kHz

Thus, smaller, lighter circuits.

N = number of turns, = magnetic flux,

Fast Switching Frequencies

N = number of turns, = magnetic flux,

The drawback, of course, to high frequency switching is

This is the downside of high-frequency switching. Thus,

14, 13, 12, 11, 10, 9, 8

All caps in this figure are ceramic.

All caps in this figure are ceramic.

symbol shows direction

MC34060A, Fixed Frequency, PWM,

14, 13, 12, 11, 10, 9, 8

TLE2072CP, Texas Instruments,

Microchip Technology, TC1426CPA,

Fairchild FQA62N25C, 250V N-Channel MOSFET, 62A

TLE2072CP, Texas Instruments,

Microchip Technology, TC1426CPA,

MC34060A, Fixed Frequency, PWM,

The PWM chip has an internal sawtooth wave generator, whose

Linear portions of sawtooth allows to directly translate

In essence, the PWM process involves

The PWM chip has an internal sawtooth wave generator, whose

Comparison yields 0-5V

Output of inverting driver chip goes to MOSFET gate

Some PCB Electronics suppliers

(Note: Digikey & Mouser will let one purchase smaller

Keep in mind that your CT may be 20%

What About the Other Potentiometer?

MOSFET Gate Driver

MOSFET Gate Driver

100uF, 50V low ESR

across wall wart.

NMH1212SC, Murata Power Solutions, DC/DC

Plug in 12V regulated

Converter 12V feeds power traces

Buck Converter Firing Circuit

Less steep at high voltages

Traces are rated 4A per 0.1 of

Resistor Color Code

Construction Tips, cont.

MOSFETS are Very Static Sensitive