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Designing A Wide Input Range DCM Flyback Converter

Using the Si9108

FEATURES
D Wide 10-V to 100-V Input Voltage Range D 500-V Input/Output Isolation Minimum
D Enables Designs With Efficiency Above 80% D No Optocoupler Feedback Needed
D
12-V Outputs At 125 mA D Low Component Count, Low-cost Design
D Total 3-W Continuous Power D Complete Solution Occupies  2 In2 Of Board Space In
D Discontinuous Conduction Mode Flyback dc-to-dc A Single-Sided FR4 Board
Converter D Maximum Component Height Is  1/4 Inch.

INTRODUCTION
The Si9108 is a highly integrated, high-efficiency D eliminates the output rectifying diode reverse recovery
current-mode regulator designed for telecom dc-to-dc problem, hence there is no current shoot through in the
converters. Its wide operating duty cycle of up to 99.9% is main input power switching device
suitable for many power conversion applications, especially D higher efficiency, especially at high input voltage
those with a wide operating input voltage range. This D no right half plane zero in the control loop, simplifying
application note is intended to guide the user to design a very feedback compensation design, allowing a very stable
wide input voltage range, discontinuous conduction mode and wide-bandwidth feedback loop.
(DCM) flyback converter.
A DCM Flyback Design Has Some Limitations:
Why use a flyback converter? Because the flyback design D the peak primary current and output rectifying diode
combines simplicity, a low parts count, and affordability for current are large, although this is not a major concern for
low-power applications that require input/output isolation. low-power applications
D duty cycle varies with both the input voltage and output
Why use discontinuous conduction mode? Here are some of load, thus wide duty cycle operation is usually required.
the advantages:
The design of the Si9108 regulator helps to overcome this
D maximizes energy storage in the magnetic component (a limitation. Figure 1 illustrates a simplified flyback converter
smaller core is needed for a given output power) designed with the Si9108 regulator.

D1 IO1
VIN V1
ip iC1
+
iD1 C1
Np Ns1
D GND2
CIN
iC2
iD2 +
C2
S Ns2
IO2
SI9108 V2 (NEG)
Ris
D2
GND1

FIGURE 1. Simplified Flyback Converter Using Si9108 Regulator

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Discontinuous Flyback Converter Fundamentals Step one: converting all outputs into a single output. Let VO =
VO1, and PO = VO1  IO1 + VO2  IO2 ➔ IO = PO/VO

Figure 2 shows typical current waveforms of a DCM flyback Step two: reflecting the input voltage to the output side.VS =
converter in operation. Vi(Ns/Np)

To simplify circuit analysis, we can convert the flyback circuit Where Ns is the secondary number of turns and Np is the
to a basic buck-boost converter configuration. The conversion primary number of turns. Figure 3 shows the simplified
can be done in two steps: buck-boost converter.

Iprim–pk

ip

Ipk1

iD1
IO1
0

Ipk1 – IO1

iC1

0
–IO1

Ipk2

iD2
IO2
0

Ipk2 – IO2

iC2

0
–IO2

FIGURE 2. Typical Current Waveforms of DCM Flyback

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IO
Q
VD
+ VO (neg)
D

+
IL LO
VS +

QON QOFF

IL

0
D D2

1/f

FIGURE 3. Basic Buck-Boost Converter

DCM Buck-Boost Converter Analysis where D2 is the discharging cycle and Vo is the lump sum of
the output voltage plus the rectifying diode forward voltage
drop.
The inductor charging time interval is designated as t1. When
the power switch Q is on, VS is applied across the output After this time interval, all of the energy stored in Lo has been
inductor, Lo. The current in the inductor starts to ramp up from discharged to the output capacitor and load. The current in Lo
zero linearly, following the equation V = L(di/dt). By the end of has decreased to zero. The inductor current will remain at zero
this interval, when Q turns off, the inductor will have a peak until the next cycle start.
current of
For every switching cycle, a package of energy is transferred
to the output via Lo. The power associated with this energy
V SD transfer is:
Ipk  (1)
Lof
P  1 LoIpË2
2
or

where D is the duty cycle and f is the switching frequency. (3)
IpË  2P
Lof
Ipk indicates that a certain amount of energy has been stored
in the inductor. The inductor discharging time interval is Or
designated as t2. After Q turns off, the current in Lo forces Combining the above equations and solving for D and D2:
diode D to conduct. Lo sees the output voltage plus the diode
forward voltage drop across its terminal, but in the reverse D  1 2PLof (4)
Vs
direction. During this time, the inductor current decreases and and
the energy in Lo is discharged to the output capacitor and load.
D2  1 2PLof (5)
In DCM operation, all of the energy in Lo will discharge Vo
completely during this time interval. An equation similar to t1
Equation (4) shows the duty cycle as a function of the output
results:
power and input voltage, while equation (5) shows that D2 is
solely a function of the output power. The maximum duty cycle,
V OD2 DM, occurs at maximum output power, PM, and minimum input
Ipk  (2)
Lof voltage, Vsm. Maximum D2 occurs at maximum output power.

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To maintain DCM operation, the inductor current must Combining (9) and (10), we can now express the inductor peak
discharge completely before the next cycle start. In other current in terms of the maximum duty cycle chosen:
words, D + D2 must be equal or less than 1 under all conditions:
IpË  2PM (11)
Vo (1  DM)
DM  D2M  1 (6)
As DM increases, the required inductance decreases, while
where DM is the maximum duty cycle and D2M is the the inductor peak current increases. Since the energy storage
maximum discharging cycle. Substituting (4) and (5) into the in the inductor is proportional to LIpk2 while the inductor core
above equation and solving for Lo, we have: size is proportional only to LIpk, doubling Ipk will reduce the
required inductance to 1/4. and reduce the required core size
Lo  1
to 1/2. It is a good design practice to make D as large as
2PMf

2
1 1
Vsm
 Vo
possible. This minimizes inductance while keeping the peak
(7) current to a manageable value.
Locrit  1
2PMf Vsm 1

2
1
 Vo
Primary Side Calculations

where PM is the maximum output power and Vsm is the The primary inductance and peak current can be calculated by
minimum input voltage. reflecting the output inductance and its peak current to the
primary side via the flyback transformer turns ratio:
Equation (7) imposes a maximum value for the output inductor,
Np
Lo
2
Locrit, to maintain discontinuous conduction mode while Lp 
delivering the maximum output power at minimum input Ns
(12)
IipË  Ns 2P
voltage for a buck-boost converter. It is best to choose a Lo
value close to Locrit to maintain DCM while keeping the Np Lof
inductor peak current as low as possible.
where Lp is the primary inductance required and Iipk is the
primary peak current as a function of total output power. Since
Back to The Flyback Converter VS = Vi(Ns/Np) and from (4):
Np 
D 2PLof (13)
NsVi
In a flyback converter, the flyback transformer presents
designers with another choice, the secondary-to-primary turns As expected, the duty cycle D is a function of the input
ratio Ns/Np. The following equation was derived to assist the voltage,Vi, and the output power, P.
calculation of the turns ratio.
From (12) and (13), several equations can be derived to
Ns Vo (1  DM) support design calculation:
 (8)
Np Vim DM
Iiave  1 IipËD  P
where Vim is the minimum input voltage. Ns/Np determines a 2 vi
maximum duty cycle or in other words, allows designers to Iirms  IipË D3
choose a practical maximum duty cycle at the lowest operating
input voltage and then calculate the required transformer turns
ratio. It will be shown later that choosing DM is very important
to optimize the converter design.
Icirms  Iiave  D2 
6
2 6D
 D

3
 (1  D)
(14)

DVci  1 Iiave (2  D)
2
4 Cif
The following equations can be used to calculate the critical
output inductance once the maximum duty cycle is chosen. where
2
Vo 2 (1  DM) Iiave is the primary average current
Lo 
2PMf Iirms is the primary rms current
Or (9) Icirms is the input capacitor rms current
2 DVci is the input voltage ripple, excluding ESR effect
Vo 2(1 DM)
Locrit  Ci is the input bypass capacitor
2PMf

Again, choose Lo = Locrit, since Output Calculations

IpË  Lof
2P (10) Any output can be calculated referencing to the main output
using the following equations:

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Nsx  Vx Ns 1.0
Vo

Lo
2
Lx  Nx 0.8
Ns

Dx  1 2PxLxf
Lo Critical
Vx

2Px
0.6
IxpË 
Lxf (15)

Ixrms  IxpË Dx3 0.4

Ipk

Icxrms  Iox  DX2 

6
2 6Dx
 Dx

3
 (1  Dx)
0.2

Iox (
DVcx  1
2
2  Dx) 0.0
4 Cxf 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Maximum Duty Cycle Chosen

where:
FIGURE 4. Normalized Lo Critical and Ipk vs. Maximum Duty Cycle

X denotes the particular output of interest Figure 4 above shows the normalized critical output
Vx is the output voltage plus the rectifier forward voltage drop inductance and its peak current with respect to a maximum
Nsx is the winding number of turns duty cycle varying from 20% to 90%. From the graph, we can
Lx is the winding inductance see that Lo decreases significantly for DM >40% and its peak
Dx is the discharge duty cycle current decreases significantly for DM < 80%. This means that
Px is the output power it is desirable to choose DM anywhere in the 40% to 80%
Ixpk is the inductor, Lx, peak current region.
Ixrms is the inductor rms current
Icxrms is the output capacitor rms current Choose DM = 55% at full load and 24 V. Use Vo = 12 V as
Iox is the output average load current reference output plus 0.6 V for the rectifier forward voltage
DVcx is the output voltage ripple, excluding capacitor ESR and drop. We can now determine the required nominal output
ESL effects inductance. Notice that the inductor tolerance has already
Cx is the output capacitor been accounted for in the power calculation. The 55% DM was
chosen at a 24-V input so that at a 10-V input and with 1-W
output power, the duty cycle will be around 80%—still an
acceptable level.
Design Example
2
Vo 2 (1  DM)
Lo  
2PMf
This design example is based on the following specifications: (17)
2
12.62 (1  0.55)
 28.7mH
2x5.6x100Ë
Input voltage range: Vi from 10 V to 100 V
Next, calculate the transformer turns ratio:
Output voltages: +12 V and –12 V at 125 mA each
Total output power is 3 W Ns Vo (1  DM) 12.6 (1  0.55)
   0.4295 (18)
Output power is reduced to 1 W for Np Vim DM 24 0.55
input voltage <24 V
Switching frequency: 100 kHz Choose Ns = 40T and Np = 95T. Transformer specification
details will be covered later.

From this point on, the calculation of the rest of the circuit
Calculation parameters is relatively straightforward:

Transformer primary inductance:

Let us assume an efficiency of 75% and lump sum inductor
Np
95

2 2
tolerance of 20%, plus 20% for power limit headroom. In this
Lp  Lo  28.7mH  162 mH (19)
case, the total power processed by the flyback converter is: Ns 40

1 (1  40%)  5.6 W Duty cycle, primary maximum peak and rms currents at a 24-V
P3W (16)
input voltage
0.75

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Np  12-V output filter capacitor maximum ripple current and
D 2PLof  95 2x5.6x28.7mx100Ë  0.56
NsVi 40x24 maximum output ripple voltage, using 10-mF low ESR ceramic
IipË  Ns Lof
2P  40  2x5.6  0.832ApË
capacitor for output filtering.


Np 95 28.7m100Ë

2 6Dx
 Dx

(20) 3

Iirms  IipË D  0.832 

Icxrms  Iox Dx 2   (1  DX) 
0.56
 0.36Arms 6
3 3

Primary sense resistor, Ris, calculation:

125mA  0.232
6

2  0.28
6x0.28

3
 (1  0.28)  168 mArms
Ris  0.8V  0.8  0.96 Ohm (21) (27)
IipË 0.832
DVcx  1 Iox (2Dx)
2
where 0.8 V is the Si9108 current limit minimum threshold 4 Cxf
voltage. A 1-W sense resistor is used for this design.  1 125 m (20.28) 2  92.5 mVp_p
4 10 m 100 k

Output Calculation
Transformer Specifications
Since the +12 V and –12 V are identical, only one set of
calculations is needed. The following is the calculation for a The following parameters are needed to specify the DCM
12-V output. Since 12 V was used as the reference output flyback transformer:
voltage, its secondary winding number of turns and inductance
is the same as Ns and Lo calculated earlier. D Primary inductance, Lp = 162 mH
20%
D Secondary/primary turns ratio, Ns/Np = 0.43
0.01
12-V output maximum power, D Other winding turns ratio, referenced to the main output
turns ratio, if applicable
Px  VxIox  12x125 m  1.5 W (22)
D All winding maximum rms currents, Iirms = 0.36 Arms,
12-V secondary number of turns, Ixrms = 0.28 Arms, etc.
Nsx  40T (23) D The converter switching frequency, 100 kHz

12-V secondary winding inductance, An EFD10 core is recommended for this application, with 3F3
core material used for low core loss operation. The primary
Lx  28.7 mH (24)
number of turns is 95T which gives a maximum flux density of
12-V secondary maximum discharging duty cycle, 1000 Gauss (0.1 Testla). The secondary number of turns for
both the +12-V and –12-V outputs is 40T. A 34T auxiliary
Dx  1 2PxLxf  winding is used to power Vcc and for feedback regulation. The
Vx
(25) Vcc feedback voltage is designed at 10 V. The Vishay Dale
1 2x1.5x28.7m100Ë  0.23
12.6 part number for this transformer is LPE-4658-A409.

12-V secondary winding maximum peak and rms current,

Experimental Results and Other Design Considerations
Ixpk  2Px
Lxf
 
2x1.5
28.7 m
 1.02 Apk
(26) Figures 5 through 7 show the complete schematic of the
Ixrms  IxpË Dx  1.02 0.23  0.28 Arms design, together with its bill of materials and pcb layout
3 3 artworks.

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NOTE:
VIN 1. * OPTIONAL FEED BACK CONFIGURATION USING OP-TO.
P1 2. OUTPUT POWER DERATED FOR VIN <20V.

1 + C1 +12 V
+VIN 6.8 mF D1 P4
50V T1 V01
10V - 100V B160
LPE-4658-A409
+
1
C2
6.8 mF 8 5 +12V
50V R12 125 mA
30.1 kW C4
+ C5
C3 95T 10 mF
P2 6.8 mF 40T 0.1 mF
25V
1 50V
P5
1 4
GND 1
PGND

–12 V P6
D4 R9 D3 D2
VCC BYS10-25 10.0 W BYS10-45 B160 V02
1
R1 7 6 –12 V
R8
R7 C10 R13 125 mA
49.9 W D5 34T
C13 1.00 W 100 W 100 pF 30.1 kW C6
15V C7
0.1 mF 1% TP1 10 mF
ZMM 0.1 mF
5245BCT 40T 25 V

2 3

3
1
R10
10.0 kW
1

2 Q1
VN0605T
R11
1.00 kW
8

9 3 R5
VCC NC NC +VIN 15.0 kW
–VIN
R2
10 DRAIN 2
OSCOUT SOURCE BIAS
U1 TP2
11 1 R16*
330 kW
OSCIN SI9108DN02 NC 1
12 20 100 W
1 DISCHARGE FB
R14*
13 19 R4 C11 R17*
P3 NC NC 15.0 kW 16.9 kW
AGND VCC 1.00 kW
VREFN/C SD RESET
COMP U2*
14

15

16

17

18

0.01 mF CNY75B
C9 5
C12 0.1 mF C8*
VCC
C14 R3 100 pF R6 4 R15*
10.0 kW
0.1 mF 820 kW
100 W
6 0.1 mF
N/C 2 1
U3*
AS432AM
3 R18*
10.5 kW

SINGLE POINT CONNECTION

FIGURE 5. Complete Schematic

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TABLE 1 . BILL OF MATERIAL

Item Qty Designator Part Type Description Footprint Vendor Part# Manufacturer
1 1 R1 1.00 RES,1%, 1/8W 0805 CRCW08051R00FRT1 VISHAY DALE

2 1 R2 330K RES,1%, 1/8W 0805 CRCW08053303FRT1 VISHAY DALE

3 1 R3 820K RES,1%, 1/8W 0805 CRCW08058203FRT1 VISHAY DALE

4 2 R4, R5 15.0K RES,1%, 1/8W 0805 CRCW08051502FRT1 VISHAY DALE

5 2 R6, R10 10.0K RES,1%, 1/8W 0805 CRCW08051002FRT1 VISHAY DALE

6 1 R7, R15*, R16* 100 RES,1%, 1/8W 0805 CRCW08051000FRT1 VISHAY DALE

7 1 R8 49.9 RES,1%, 1/8W 0805 CRCW080549R9FRT1 VISHAY DALE

8 1 R9 10.0 RES,1%, 1/8W 0805 CRCW080510R0FRT1 VISHAY DALE

9 1 R11, R14* 1.00K RES,1%, 1/8W 0805 CRCW08051001FRT1 VISHAY DALE

10 2 R12, R13 30.1K RES,1%, 1/8W 0805 CRCW08053012FRT1 VISHAY DALE

11 0 R17* 16.9K RES,1%, 1/8W 0805 CRCW08051692FRT1 VISHAY DALE

12 1 R18 10.5K RES,1%, 1/8W 0805 CRCW08051052FRT1 VISHAY DALE

13 3 C1, C2, C3 6.8uF CAP, TAN, 50V, 20% 595D_C 595D685X0050C2T VISHAY SPRAGUE

14 2 C4, C6 10uF CAP, CER, X5R, 25V, 10% 1812 GRM43–2X5R106K25 MURATA

15 5 C5, C7, C8*, 0.1uF CAP, CER, Z5U, 50V, 10% 0805 VJ0805Y104KXAAT VISHAY VITRAMON
C9, C13, C14

16 2 C10, C12 100pF CAP, CER, X7R, 50V, 10% 0805 VJ0805Y101KXAAT VISHAY VITRAMON

17 1 C11 0.01uF CAP, CER, X7R, 50V, 10% 0805 VJ0805Y103KXAAT VISHAY VITRAMON

18 2 D1, D2 B160 SCHOTTKY DIODE, 35V SMA B160 LITEON

19 1 D3 BYS10–45 SCHOTTKY DIODE, 45V BYS10 BYS10–45 VISHAY TELEFUNKEN

20 1 D4 BYS10–25 SCHOTTKY DIODE, 25V BYS10 BYS10–25 VISHAY TELEFUNKEN

21 1 D5 ZMM5245BCT ZENER DIODE, 15V MiniMELF ZMM5245BCT LITEON

22 1 T1 LPE–4658–A409 TRANSFORMER XFMR_LPE4658 LPE–4658–A409 VISHAY DALE

23 1 U1 SI9108DN02 POWER IC PLCC–20 SI9108DN02 VISHAY SILICONIX

24 0 U2* CNY75B OPTOCOUPLER DIP6 CNY75B VISHAY TELEFUNKEN

25 0 U3* AS432AM ADJ SHUNT REGULATOR SOT–23 AS432AM ALPHA

SEMICONDUCTOR

26 1 Q1 VN0605T N–CHANNEL MOSFET SOT–23 VN0605T VISHAY SILICONIX

27 8 P1 TO P6, TP1, POWER, GND, TP 1 PIN HEADER TP1 MULTI–SOURCE

TP2

Note
* Optional Component, not needed unless opto-feedback is required.

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PCB LAYOUTSi9108DB

FIGURE 6. Layout Artwork

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feedback is not required. A special technique was used to wind

the transformer to ensure good coupling. U2, U3, R14 through
R18, and C8 are optional components for the optocoupler
feedback configuration and were not used on our test board.
For applications that need tight output voltage regulation,
optocoupler feedback circuitry should be used.

Leakage snubber: No matter how well the transformer is made,

a certain amount of leakage inductance is unavoidable in each
of the windings. The leakage inductance energy in the VCC
reference winding imposes a positive offset on to the VCC
regulation voltage level, thus lowering the voltage on other
outputs. A leakage snubbing circuit is employed (Q1, R8, R9,
R10, R11, C10, and D3) here to provide better output
regulation. For applications with an optocoupler feedback
configuration, the leakage snubbing circuit is not needed.

Preload: To reduce leakage inductance effects on the outputs,

FIGURE 7. Picture of Demoboard especially at light load conditions, pre-load resistors R12 and
R13 are used. The larger the pre-load (smaller resistance), the
better the voltage regulation at light loads, although this means
a trade off of more power losses. For applications where the
output current is maintained at a minimum of 10% of the full
Optocoupler Feedback
load current, these preload resistors are not needed.

This converter design obtains output regulation through Table 2 shows some typical efficiency and regulation
coupled windings between the VCC reference winding (T1 pin measurements. Efficiency above 80% is typical for most
7 to pin 2) and the output windings. As a result, optocoupler operating conditions.

TABLE 2 . EFFICIENCY AND REGULATION MEASUREMENT

+12 V I +12 V –12 V I –12 V Efficiency
VIN (V) IIN (A) (V) (A) (V) (A) PO (W) (%)
24.07 0.1500 11.85 0.1270 11.31 0.1256 2.93 81.0
23.94 0.0751 12.14 0.0627 11.56 0.0656 1.52 84.5
24.24 0.0240 12.33 0.0307 12.06 0.0107 0.51 87.3
23.82 0.0901 12.38 0.0300 11.16 0.1260 1.78 82.8

99.56 0.0330 11.86 0.1269 11.32 0.1374 3.06 93.1

99.72 0.0061 12.34 0.0312 12.14 0.0159 0.58 94.4

12.00 0.1437 12.17 0.0538 11.56 0.0580 1.32 76.8

12.07 0.0735 12.36 0.0261 11.70 0.0335 0.71 80.5
12.06 0.0190 12.68 0.0052 11.97 0.0061 0.14 60.8

VOUT(min) 11.850 11.160

VOUT(max) 12.680 12.140
VOUT(nom) 12.265 11.650
tol
3.38% 4.21%

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Figures 8, 9, and 10 show waveforms of the power switch
drain-to-source voltage, the primary current, and the ouput
voltage ripples. The minimum duty cycle occurs at light loads Primary Current
and high lines and is around 5% at a 100-V input and 30 mA .2A/div
at –12 V and 15 mA at +12 V. The worst-case maximum duty
cycle is at full load and low line and is around 52% at a 24-V
input and 125 mA on each of the outputs. The measured
primary peak current is 600 mA, which corresponds to
calculations using measurement data.

P = 2.92 W at 81% efficiency = 3.6 W

IipË 
Ns
Np
Lof
2P  40  2x3.6
95 28.7 m106 Ë
 648 mA (28)

CONCLUSION Drain-Source Voltage

A dual outputs, 3W, discontinuous conduction mode flyback

converter was designed, built and tested. The converter VIN = 24 V
features a very wide operating input voltage range with
12 V @ 125 mA
efficiency above 80%. Input output isolation is provided without FIGURE 9. Drain-Source Voltage and Primary Current
the use of opto-coupler feedback. Total components occupy
less than 2 in2 of board space in a single sided FR4 board. The
maximum component height is less than 1/4 of an inch.
C1 Pk–Pk
116 mV

C1 Freq
106.83 kHz
C3 Pk–Pk
C1 – Duty 130 mV
4.4%

VIN = 24 V

12 V @ 125 mA

VIN = 100 V FIGURE 10. Output Voltage Ripple

+12 V @ 15 mA
–12 V @ 30 mA
FIGURE 8. Drain-Source Voltage of Power Switch

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