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Satoshi Okamoto
MR4000/5000 Series Partial Resonance Power Supply IC Modules
Supporting Standby Mode Operation
Ju|v.2005
Vo|.05-07-e
Ju|v.2005
Vo|.05-07-e
F/SSWCFD Vc|.05-07-e
MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
01
De vi c e De s i gn De pa r t me nt , Adva nc e d Powe r Pr oduc t s
Division (joined Shindengen in 2002)
1
As digital home appliances such as plasma TVs, LCD TVs, and digital audio components increase
i n performance and si ze, power out put capaci t y i s i ncreasi ng. At t he same t i me, envi ronment al
concerns are creat i ng more demand for di gi t al home appl i ances and ot her el ect roni c devi ces wi t h
lower power consumption during standby, and higher efficiency during steady operation.
The previously released models in Shindengen` s MR Series of partial resonance power supply IC
modul es have a funct i on for swi t chi ng t o st andby mode duri ng mi cro-l oads. Thi s paper descri bes
t he r ecent l y compl et ed MR4000/ 5000 Ser i es, desi gned f or hi gher eff i ci ency and hi gher power
output capacity. (A model with a CoolMOS device is under development.)
Introduction
2
The MR Seri es are part i al resonance power suppl y IC modul es wi t h a funct i on for swi t chi ng t o
st andby mode dur i ng mi cr o- l oads. They ar e compr i sed of a swi t chi ng el ement and cont r ol I C
optimized to 100 V class, 200 V class, and worldwide input power supplies.
The MR4000/ 5000 Ser i es r educe t he cont r ol I C l os s mor e t han convent i onal pr oduct s , and
incorporate high-performance switching elements such as Shindengen` s original second-generation
hi gh- speed I GBTs ( i nsul at ed gat e bi pol ar t r ansi st or s) and Cool MOS* devi ces. These f eat ur es
reduce power consumption during micro-loads, and increase efficiency and power output capacity
during heavy loads. (* The model with a CoolMOS device is under development.)
Product Overview (see Figure 1)
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F/SSWCFD Vc|.05-07-e
MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
02
2002
MOSFET
FTO-5P
FTO-7P
MZIP-7
2005
50
100
150
200
250
300
MIH-7
MR2000
MR4000
MR1000
MR5000
Products in MR Series
Figure 1. Products in MR Series
Higher capacity
Lower cost
More compact
CoolMOS, second-generation
high-speed IGBT
High withstand voltage elements
create optimum partial resonance.
High radiant heat package
increases capacity.
MOSFET, CoolMOS,
second-generation high-speed IGBT
FTO package creates long pin
interval, higher capacity.
High withstand voltage elements
create optimum partial resonance.
Higher capacity
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First-generation high-speed IGBT
The MR4000/5000 Series incorporate the following main features.
Use of second-generation high-speed IGBTs and CoolMOS devices improves efficiency.
- Reduction of control IC loss improves standby characteristic.
- Same control functions as predecessor MR2000 Series, enabling simple device design.
- Higher efficiency, low noise
The high-speed IGBTs developed by Shindengen are elements with an original patented structure.
The first-generation high-speed IGBT was released in the MR2000 Series. The second-generation
hi gh- speed I GBT al t er ed t he i nt er nal st r uct ur e of t he f i r st - gener at i on model , i mpr ovi ng on i t s
saturation characteristic and tail loss tradeoff characteristic. These improvements further reduced
t he t ai l l oss of t he second- gener at i on hi gh- speed I GBT whi l e mai nt ai ni ng t he same sat ur at i on
characteristic as the first-generation model.
Fi gure 2 compares t he t ai l l oss waveform of t he fi rst - and second-generat i on hi gh-speed IGBTs.
After subtracting a 10 J loss (corresponding to the junction capacitance), the tail loss is reduced
by roughly half, from 77 to 39 J.
2-1 MR4000/5000 Series features
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
03
Next , we compar ed t he t emper at ur e r i se ver sus i nput vol t age char act er i st i cs of t he f i r st - and
second-generation high-speed IGBTs, with a worldwide input (Po = 100 W) power supply, and the
same chip size and package (see Figure 3). The second-generation model reduces the temperature
rise by at least 8C when Vin is 276 VAC.
Thi s i mprovement i ncreases t he capaci t y t o a val ue much hi gher t han t he MR1000/ 2000 Seri es.
The MR4000 Seri es has a Po val ue of 180 W wi t h an FTO-7P package, and t he MR5000 Seri es a
Po val ue of 320 W wi t h an MZI P- 7 package. ( Ref er ence: Maxi mum out put capaci t y val ues of
previous models are Po = 80 W for the MR1000 Series (FTO-5P package), and Po = 250 W for the
MR2000 Series (MIH-7 package). )
First-generation high-speed IGBT Second-generation high-speed IGBT
100ns/div
Figure 2 Tail loss waveforms of first- and second-generation high-speed IGBTs
Figure 3 Temperature rise vs. input voltage
Po = 100 W, worldwide power supply
Temperature rise vs. AC input voltage
AC input voltage (V)
First-generation
high-speed IGBT
Second-generation
high-speed IGBT
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100ns/div
Gate Gate
Loss is reduced.
Tail current is halved.
Loss Loss
Current Current
Voltage Voltage
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
04
Standby power has been reduced by optimizing the startup circuit` s bias current. We compared the
st andby mode i nput power of MR4010 and MR1722 wi t h a worl dwi de i nput (Po = 25 W) power
supply. When Vin was 100 VAC, the no-load input power (Pin) was 74 mW (MR1722) and 62 mW
( MR4010) ( see Fi gur e 4- 1) . When Vi n was 230 VAC, Pi n was 120 mW ( MR1722) and 85 mW
(MR4010) (see Figure 4-2). The improvement in input power was particularly significant with 200
V AC class input, where there was a 35 mW reduction during no load.
[ Power suppl y speci f i cat i ons f or compar i son: Vi n = 85 t o 276 VAC; 5/ 12 V out put ( Po = 25 W
(peak 45 W)) power supply]
Note: Only 5 V output was used for output power in standby mode (12 V output 0 A).
Standby mode input power comparison for MR 4010 and MR1722
Figure 4-1 Standby mode input power comparison for MR 4010 and MR1722 (1) (Vin = 100 VAC)
Figure 4-2 Standby mode input power comparison for MR 4010 and MR1722 (2) (Vin = 230 VAC)
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Output power Po (W)
Vin=AC100V
Standby mode input power comparison for MR 4010 and MR1722
Vin=AC230V
Output power Po (W)
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
05
Table 1 shows the MR4000/5000 Series products. The maximum output capacity and input voltage
ranges differ according to the design conditions.
Table 1. MR4000/5000 Series products
Model name
Main switching element
Second
-generation
high-speed
IGBT
Second
-generation
high-speed
IGBT
Maximum output capacity Po (W) (reference value)
Input voltage ranges
Withstand
voltage (V)
2-2 Product range
The main features of products in the MR4000/5000 Series are described below.
MR4000 Series features
(1) Higher output capacity with FTO package
(Po for MR1531 [FTO-5P] = up to 80 W MR4040 [FTO-7P] = up to 180 W)
(2) FTO package 7-pin configuration allows for distance between high-voltage pins.
(3) Use of second-generation high-speed IGBT with 900 V withstand voltage improves efficiency.
(4) Supports standby mode (Pin at no load is about 60 mW).
Appl i cat i ons: DVD r ecor der s, LCD TVs, di gi t al set t op boxes, mul t i f unct i on pr i nt er s, whi t e
goods, other
MR5000 Series features
(1) Achieves higher output capacity with new MZIP-7 package.
(Po for MR5060 [MZIP-7] = up to 320 W)
(2) New high radiant heat package allows for distance between high-voltage pins.
(3) Use of CoolMOS and second-generation high-speed IGBT improves efficiency.
(4) Supports standby mode (Pin at no load is about 100 mW).
Applications: Plasma TVs, LCD TVs, digital audio, other
2-3 Individual product features
AC90 132V AC180 276V AC90 276V
MR4500 12 - -
MR4510 25 - -
MR4520 50 - -
MR4530
500
80 - -
MR4710 - 25 12
MR4720
MOSFET
700
- 50 25
MR4010 - 70 45
MR4020 - 105 70
MR4030 - 135 90
MR4040
900
- 180 120
MR5540 MOSFET 500 150 - -
MR5650
Under development
CoolMOS 600 200 - -
MR5040 - 270 150
MR5060
900
- 320 180
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
0
We compared the efficiency of MR4030 and MR2920 in a worldwide input 24 V single output (Po
= 90 W) power supply. Figure 5 shows the efficiency data when Vin is 220 and 276 VAC.
The peak effi ci ency val ue when Vi n was 220 VAC was 90. 1%. MR4030 i mproved effi ci ency by a
maximum of about 1. 7% over MR2920. (Note: MR2920 uses the first-generation high-speed IGBT
and MI H- 7 package, and has a maxi mum out put capaci t y ( Po) of up t o 100 W f or wor l dwi de
input. )
3-1 MR4030
3
This section presents efficiency data for power supplies with MR4030/5060.
Efficiency comparison of MR4000 and MR2000 (1)
Figure 5 Efficiency comparisons of MR4000 and MR2000
Efficiency comparison of MR4000 and MR2000 (2)
Output power Po (W)
Output power Po (W)
Vin = AC 220 V
Vin = AC 276 V
Experimental Data (Power Supply Efficiency)
95
90
20 40 60 80 100
85
95
90
20 40 60 80 100
85
80
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
07
Fi gur e 6 shows t he eff i ci ency dat a of a power suppl y usi ng MR5060. Despi t e bei ng a par t i al
resonance power supply using RCC, it had a peak efficiency value of 94.9%.
[Power suppl y speci fi cat i ons: 390 VDC i nput (model i ng st age aft er power fact or correct i on i n a
power supply with PFC), 87 V single-output, 320 W power supply]
Figure 6 MR5060 power supply efficiency
Figure 7 Photo of MR4000 Series model and its equivalent circuit
MR5060 power supply efficiency
Output power Po (W)
Vin = DC 390 V
3-2 MR5060
100
90
92. 2
90.0
93. 8 94. 2 94.6 94. 6 94. 9
80
70
60
50
40
0 100 300 400 200
4
Figures 7 and 8 show photographs of MR4000/5000 Series models and their equivalent circuits.
Product Photographs, Equivalent Circuits
1
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4
5
7
IC1
Vin
Vcc
GND
F/B
Z/C
Q1
Drain
(Collector)
Source/OCL
(Emitter/OCL)
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MR4000/5000 Series Partial Resonance Power Supply IC Modules Supporting Standby Mode Operation
08
Figure 8 Photo of MR5000 Series model and its equivalent circuit
5
The MR4000/ 5000 Seri es have bet t er swi t chi ng el ement s and cont rol ICs t han previ ous model s
(MR1000/2000 Series), and package changes have enabled higher efficiency and higher capacity.
Switching power supplies will always demand lower power consumption during standby and more
compact models (fewer parts). Customer demands are also becoming more diverse as applications
such as digital home appliances and white goods expand. In the years ahead, Shindengen plans to
cr eat e cont r ol I Cs wi t h mor e advanced f unct i ons and expand our pr oduct s er i es t o pr ovi de
products more closely meeting customer needs.
Note: CoolMOS is a registered trademark of Infineon Technologies AG.
MR4000/5000 Series inquiries
Sales Planning Office, Sales Department
Tel: +81-3-3279-4464
The table below lists pin names and functions.
Items in parentheses () are for MR40xx and MR50xx models.
Pin name Function
Sets the ON timing.
Sets the signal from the control coil with the CR time constant.
Clamping the Z/C pin to 4.1 V (typical) or less with a
photocoupler, etc. selects standby mode.
Controls the ON width with the pin voltage.
The resistor setting the maximum ON width and the feedback
photocoupler are connected to this pin.
Conclusion
1
2
3
4
5
10
IC1
Vin
Vcc
GND
F/B
Z/C
Q1
15
Drain
(Collector)
Source/OCL
(Emitter/OCL)
Z/C
F/B
GND Ground pin
Vcc Supplies power from the control coil.
The drain (collector) pin for the main switch
The current detection resistor is connected to the source/OCL
(emitter/OCL) pin.
Vin
Directly inputs the AC voltage rectified by the startup circuit.
Suppl i es current t o Vcc onl y at st art up, and aut omat i cal l y shut s
off after startup.
Source/OCL
(Emitter/OCL)
Drain(Collector)