Power BJT Specification For RDFC Applications: Application Note AN-2276

Power BJT Specification for RDFC Applications
Application Note AN-2276
RDFC Circuit Description
ABSTRACT
This application note provides key parametric requirements of power BJTs suitable for Resonant Discontinuous Forward Converter (RDFC) applications. As the main power switch, the BJT will undergo different stresses in RDFC compared to hard switching topologies such as flyback. Selecting the correct BJT is vital to obtain optimal power supply performance and meet safety requirements. Further information on the RDFC topology and CamSemis advanced controller ICs is available at www.camsemi.com.
A typical RDFC application circuit is illustrated in Figure 1. The NPN power transistor, Q1, is the main power switching element. It switches in resonant / quasi-resonant mode at high frequency during the operation of the converter. The collector voltage waveform will depend on the converters operating mode. The RDFC IC controls Q1 through the BAS pin based on the information received through the COL and CS pins. Collector voltage of Q1 is sensed via the Ccol capacitor during both on and off states. On state voltage sensed via the COL pin is used to control the base current so the transistor is held in quasisaturation. Off state voltage sensed via the COL pin is used to identify the optimum turn-on timing for Q1 and to define the overall on time of the transistor. When the power supply is operating under load, the on time is fixed at of the off time. The CS pin is used to sense the Q1 emitter current, limit the current under overload conditions and reduce the switch duty cycle at light loads. During the on state, base current is supplied through the AUX pin to the BAS pin. Raux is used to limit the maximum base current.
INTRODUCTION
The Resonant Discontinuous Forward Converter (RDFC) topology with CamSemis controller IC offers a highly efficient and low cost solution for the replacement of linear power supplies. One of the most significant BOM cost advantages offered by the RDFC solution is the use of a low cost bipolar power transistor for the primary switch, rather than an expensive MOSFET. CamSemis RDFC controller ICs embody advanced patented techniques for bipolar transistor base drive control.
Figure 1: Typical RDFC Application Circuit
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Switching Waveforms Typical Q1 collector voltage and current waveforms in different operating modes are illustrated in Figure 2. In Normal mode, the collector voltage waveform is approximately a half sine wave. Q1 is turned on and off at minimum collector voltage to reduce switching losses. A notable collector voltage step is present during the turn off of Q1 due to the leakage inductance of the transformer. During Standby mode, Q1 turns on from HT (rectified mains) voltage and turns off at minimum collector voltage. Under Overload mode, the peak collector current is limited by the RDFC IC. The collector voltage waveform is non-sinusoidal. Turn-on and turn-off transients happen at higher collector voltages. Operating Temperature Range The following ratings and characteristics need to be maintained over the operating temperature range of TJ = -10oC to 125oC in order to guarantee reliable operation of the RDFC circuit. Collector Voltage Rating (VCE) Peak collector voltage during the off state in RDFC applications will be significantly higher than in flyback applications due to the resonant mode of operation. In order to select the correct collector voltage rating, the following breakdown voltage specifications should be taken into account: VCEO - Breakdown voltage under common emitter configuration (where emitter is grounded) with base open circuit VCBO - Breakdown voltage under common base configuration (where base is common/grounded) with emitter open circuit VCES - Breakdown voltage under common emitter configuration with base shorted to emitter. VCER - Breakdown voltage under common emitter configuration with a resistor between base and emitter Typically VCEO < VCER* VCES VCBO * For Rbe< 10k
Aux Supply Bypass transistor Raux
AUX Qon
PBD FON
BAS
Q1
TPBD
Qoff
Figure 2: Typical Q1 Collector Voltage (VCE) and Current (IC) waveforms
TRANSISTOR REQUIREMENTS
As illustrated in Figure 2 the main power switch (Q1) is operated in a significantly different way to a conventional flyback converter power switch. This results in different parametric requirements for suitable power transistors. These requirements are described in detail in the following sub-sections.
GND
0V
Figure 3: Q1 Base Drive Circuit The RDFC IC allows switch-off of the transistor with minimum collector voltage and uses a base turn off MOSFET (QOFF in Figure 3) with an RDSON of typically 5 . Therefore, VCER is the breakdown rating applied to Q1. As VCER is not normally specified in datasheets, the VCES or VCBO rating is used as the allowable worst-case peak collector voltage during the Q1 off state.
AN-2276-0904 07-Apr-2009

Collector Current Rating (IC-DC) The collector current rating of the transistor is selected based on the worst-case peak collector current possible in the target application. This peak collector current is then rounded up to the nearest 0.5 A (or 100 mA for 1 to 6 W RDFC applications) and selected as the collector current rating(IC-DC) of the transistor. Output Capacitance (COB) Low output capacitance of Q1 is essential for RDFC applications for two reasons. The resonant frequency of the converter is affected by the output capacitance of Q1. In order to control the resonant frequency tightly using an external capacitor, transistor output capacitance should be minimised. Minimising the output capacitance also allows Q1 to turn-on rapidly. Suitable COB values are in the 30 to 60 pF range (at VCB = 10 V). DC Current Gain (hFE) As seen in Figure 3, the Q1 base current will consist of two main parts. The base current is initially forced to a higher value (IFON) to turn-on Q1 rapidly. For the remainder of the on time, the base current (IPBD) is reduced to a lower value while maintaining the on-state collector voltage at a preset target voltage, minimizing turn-off time and consequent losses. It is essential that the minimum hFE is high enough to sustain the required collector current within the available base current from the controller (taking into account the effect of Raux). hFE is strongly dependant on the collector current, on-state collector voltage and temperature. Typically, hFE is lower at: High collector current Low collector voltage Low temperature VCE. For transistors with higher VCBO (e.g. 1.2 kV 1.5 kV) it is recommended to operate around 5 V on-state VCE. It is important to use hFE characteristics relevant to the on-state voltage. For higher power applications with 115 Vac input line voltage the hFE requirement will be quite demanding. RBSOA The Reverse Biased Safe Operating Area (RBSOA) of the transistor is mainly applicable to the Q1 turn off transient. To force turn-off of Q1, Qon is turned off and Qoff is turned on (Figure 3).The collector rises in a fast voltage step due to the leakage inductance of the transformer. There is a significant amount of collector current present during this voltage step as a result of the energy in the leakage inductance and charge storage in Q1. As the base drive is turned off through Qoff (Figure 3) there will be a negative base current present during the turn-off duration. Therefore RBSOA curves for Ib 0 or VBE 0 V are applicable to RDFC applications. In RDFC applications, turn-off conditions typically are different from those used to characterise RBSOA in transistor datasheets. Particularly, VBE is not negative during turn off, but also the transistor is operated with minimum excess base charge. It is important that the transformer leakage inductance and collector node capacitance are chosen to limit collector voltage until the transistor collector current has fallen to a low value. An applicable limit for Vce (with IC) can be judged from a family of RBSOA curves for varying reverse VBE. Where RBSOA data is not available, VCEO may be used as the VCE limit but a conservative margin should be applied. Storage Time (TSTG) Low storage time is required to achieve optimal turn-off switching operation and reduce peak collector voltages in RDFC applications. BJTs with storage times less than 0.5 us (measured under inductive load switching) are recommended for typical RDFC applications. Note that the switching specifications in transistor datasheets are normally under drive conditions and are very different to those used in RDFC applications. Particularly, datasheet tests are carried out under higher base currents and negative VBE at turn-off.
However, manufacturer datasheets usually dont characteristics. provide comprehensive hFE Therefore, extrapolation of available data may be required to predict minimum hFE over the operating range. The hFE characteristic of the transistor is selected based on the worst-case peak collector current and maximum base current limitation. This ensures BJT quasi-saturation under worst-case on-state conditions. Lower than rated hFE could cause inefficient power conversion and BJT overheating. The on-state collector voltage can be preset using the proportional base drive system in the controller. Setting a lower voltage improves efficiency but decreases the hFE of the transistor and increases storage time. For 700 V VCBO transistors it is normally best to operate around 2-3 V on-state
TRANSISTOR SELECTION
The following tables list suitable transistors with key parameters for 115 Vac and 230 Vac RDFC applications, based on the above requirements.
AN-2276-0904 07-Apr-2009

Notes: The IC-DC rating for suitable transistors should be higher than the IC-DCmin specification in order to achieve the target hFEmin specification at ICDCmin
hFEmin is calculated based on the minimum guaranteed IBASPBD specification of 100 mA for CamSemis C2472 and C2473 products and 22 mA for CamSemis C2471 product, [1] and [2]
RDFC Controller IC Product C2471
Application Power Range (W) 1-3 4-6 7-10 11-20 21-30 31-40
VCBO (V) 700 700 700 700 700 700
VCEO (V) 400 400 400 400 400 400
IC-DCmin (A) 0.15 0.30 0.50 1.00 1.50 2.00
hFEmin @ IC-DCmin & VCE = 2.5 V 8 15 5 10 15 20
Package TO-92 TO-92/TO-126 TO-92/TO-126 TO-126 TO-126/ TO-220 TO-220
C2472 / C2473
Table 1: BJT Specifications for 115 Vac RDFC Applications

RDFC Controller IC Product C2471 Application Power Range (W) 1-3 4-6 7-20 C2472 / C2473 21-40 41-60 VCBO (V) 1400 1400 1400 1400 1400 VCEO (V) 700 700 700 700 700 IC-DCmin (A) 0.10 0.15 0.50 1.00 1.50 hFEmin @ IC-DCmin & VCE = 5 V 6 8 5 10 15 Package TO-92 TO-92/TO-126 TO-126 TO-126 TO-126/ TO-220
Table 2: BJT Specifications for 230 Vac RDFC Applications
REFERENCES
[1] [2] [3] [4] RDFC C2472, C2473 Product Datasheet (DS-1423), www.camsemi.com/support/datasheets LPRDFC C2471 Product Datasheet (DS-1639), www.camsemi.com/support/datasheets RDFC Basic Design Guide (DG-1694), www.camsemi.com/support/designguides Low Power RDFC Basic Design Guide (DG-2128), www.camsemi.com/support/designguides
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CONTACT DETAILS
Cambridge Semiconductor Ltd St Andrews House St Andrews Road Cambridge CB4 1DL United Kingdom Phone: Fax: Email: Web: +44 (0)1223 446450 +44 (0)1223 446451 sales.enquiries@camsemi.com www.camsemi.com
DISCLAIMER
The product information provided herein is believed to be accurate and is provided on an as is basis. Cambridge Semiconductor Ltd (CamSemi) assumes no responsibility or liability for the direct or indirect consequences of use of the information in respect of any infringement of patents or other rights of third parties. Cambridge Semiconductor Ltd does not grant any licence under its patent or intellectual property rights or the rights of other parties. Any application circuits described herein are for illustrative purposes only. In respect of any application of the product described herein Cambridge Semiconductor Ltd expressly disclaims all warranties of any kind, whether express or implied, including, but not limited to, the implied warranties of merchantability, fitness for a particular purpose and non-infringement of third party rights. No advice or information, whether oral or written, obtained from Cambridge Semiconductor Ltd shall create any warranty of any kind. Cambridge Semiconductor Ltd shall not be liable for any direct, indirect, incidental, special, consequential or exemplary damages, howsoever caused including but not limited to, damages for loss of profits, goodwill, use, data or other intangible losses. The products and circuits described herein are subject to the usage conditions and end application exclusions as outlined in Cambridge Semiconductor Ltd Terms and Conditions of Sale which can be found at www.camsemi.com/legal . Cambridge Semiconductor Ltd reserves the right to change specifications without notice. To obtain the most current product information available visit www.camsemi.com or contact us at the address shown above
AN-2276-0904 07-Apr-2009

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Power BJT Specification for RDFC Applications

Application Note AN-2276

RDFC Circuit Description

Figure 1: Typical RDFC Application Circuit

Page 1 Cambridge Semiconductor Ltd 2008

Application Note AN-2276

Figure 2: Typical Q1 Collector Voltage (VCE) and Current (IC) waveforms

Page 2 Cambridge Semiconductor Ltd 2008

Application Note AN-2276

Page 3 Cambridge Semiconductor Ltd 2008

Application Note AN-2276

RDFC Controller IC Product C2471

VCBO (V) 700 700 700 700 700 700

VCEO (V) 400 400 400 400 400 400

IC-DCmin (A) 0.15 0.30 0.50 1.00 1.50 2.00

hFEmin @ IC-DCmin & VCE = 2.5 V 8 15 5 10 15 20

Package TO-92 TO-92/TO-126 TO-92/TO-126 TO-126 TO-126/ TO-220 TO-220

Table 1: BJT Specifications for 115 Vac RDFC Applications

Table 2: BJT Specifications for 230 Vac RDFC Applications

Page 4 Cambridge Semiconductor Ltd 2008

Application Note AN-2276

Page 5 Cambridge Semiconductor Ltd 2008

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