AN2393 Application note
Reference design: wide range 200W L6599-based HB LLC resonant converter for LCD TV & flat panels
Introduction
This note describes the performances of a 200 W reference board, with wide-range mains operation and power-factor-correction (PFC). Its electrical specification is tailored to a typical high-end application for LCD TV or monitor applications. The main features of this design are the very low no-load input consumption (<0.5 W) and the very high global efficiency, better than 87% at full load and nominal mains voltage (115 230 Vac). The circuit consists of three main blocks; the first is a front-end PFC pre-regulator based on the L6563 PFC controller. The second stage is a multi-resonant half-bridge converter whose control is implemented through the STMicroelectronics L6599 resonant controller. A further auxiliary flyback converter based on the VIPer12A-E off-line primary switcher completes the architecture. This third block is mainly intended for microprocessor supply and display power management operations. Figure 1. L6599 and L6563 200W evaluation board (EVAL6599-200W)
October 2007
Rev 5
1/35
www.st.com
Contents
AN2393
Contents
1 2 Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 4 Electrical test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 2.2 2.3 2.4 2.5 Efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Resonant stage operating waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stand-by and no load power consumption . . . . . . . . . . . . . . . . . . . . . . . . 14 Shor t-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 4 5 6
Thermal tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 20 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PFC coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 6.2 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7
Resonant power transformer specification . . . . . . . . . . . . . . . . . . . . . 27
7.1 Electrical characteristics and mechanical aspect . . . . . . . . . . . . . . . . . . . 28
8
Auxiliary flyback power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9 10
Reference design board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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AN2393
List of figures
List of figures
Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. L6599 and L6563 200W evaluation board (EVAL6599-200W). . . . . . . . . . . . . . . . . . . . . . . 1 PFC pre-regulator electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Resonant converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Auxiliary converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overall efficiency versus output power at nominal mains voltages. . . . . . . . . . . . . . . . . . . 10 Overall efficiency versus output power at several input voltage values . . . . . . . . . . . . . . . 11 Resonant circuit primary side waveforms at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Resonant circuit primary side waveforms at no-load condition. . . . . . . . . . . . . . . . . . . . . . 12 Resonant circuit secondary side waveforms: +24 V output . . . . . . . . . . . . . . . . . . . . . . . . 13 Resonant circuit secondary side waveforms: +12 V output . . . . . . . . . . . . . . . . . . . . . . . . 13 Low frequency (100 Hz) ripple voltage on the output voltages . . . . . . . . . . . . . . . . . . . . . . 13 Load transition (0 - 100%) on +24 V output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Load transition (0 - 100%) on +12 V output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 +24 V output short-circuit waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 +12 V output short-circuit waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Thermal map @115 Vac - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Thermal map at 230 Vac - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CE quasi peak measurement at 115 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CE quasi peak measurement at 230 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PFC coil electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PFC coil pin side view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Mechanical aspect and pin numbering of resonant transformer . . . . . . . . . . . . . . . . . . . . . 28 Resonant transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Resonant transformer winding position on coil former . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Auxiliary transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Auxiliary transformer winding position on coil former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Copper tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Thru-hole component placing and top silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 SMT component placing and bottom silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Main characteristics and circuit description
AN2393
1
Main characteristics and circuit description
The main characteristics of the SMPS are listed below:
Universal input mains range: 90 to 264 Vac and frequencies between 45 and 65 Hz Output voltages: 24 V@6 A continuous operation 12 V@ 5 A continuous operation 3.3 V@ 0.7 A continuous operation 5 V@ 1 A continuous operation
Mains harmonics: Compliance with EN61000-3-2 specifications St-by mains consumption: Typical 0.5 W @230 Vac Overall efficiency: better than 88% at full load EMI: Compliance with EN55022-class B specifications Safety: Compliance with EN60950 specifications PCB single layer: 132x265 mm, mixed PTH/SMT technologies
The circuit consists of three stages. A front-end PFC pre-regulator implemented by the controller L6563 (Figure 2), a half-bridge resonant DC/DC converter based on the resonant controller L6599 (Figure 3) and a 7 W flyback converter intended for stand-by management (Figure 4) utilizing the VIPer12A-E off-line primary switcher. The PFC stage delivers a stable 400 VDC supply and provides for the reduction of the mains harmonics, in order to meet the requirements of the European norm EN61000-3-2 and the JEIDA-MITI norm for Japan. The PFC controller is the L6563 (U1), working in FOT (fixed off-time) mode and integrating all functions needed to operate the PFC and interface the downstream resonant converter. Note: The FOT control is implemented through components C15, C17, D5, Q3, R14, R17 and R29 (see AN1792 for a complete description of a FOT PFC pre-regulator). The power stage of the PFC is a conventional boost converter, connected to the output of the rectifier bridge through a differential mode filtering cell (C5, C6 and L3) for EMI reduction. It includes a coil (L4), diode (D3) and two capacitors (C7 and C8). The boost switch is represented by the Power MOSFET (Q2) which is directly driven by the L6563 output drive thanks to the high current capability of the IC. The divider (R30, R31 and R32) provides the L6563 (MULT Pin 3) with the information of the instantaneous voltage that is used to modulate the boost current and to derive some further information like the average value of the AC line used by the VFF (voltage feed-forward) function. This function is used to keep the output voltage almost independent of the mains one. The first divider (R3, R6, R8, R10 and R11) is dedicated to detecting the output voltage while the second divider (R5, R7, R9, R16 and R25) is used to protect the circuit in case of voltage loop fail. The second stage is an LLC resonant converter, with half bridge topology, working in ZVS (zero voltage switching) mode. The controller is the L6599 integrated circuit that incorporates the necessary functions to drive properly the two half-bridge MOSFETs by a 50 percent fixed duty cycle with dead-time,
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AN2393
Main characteristics and circuit description changing the frequency according to the feedback signal in order to regulate the output voltages against load and input voltage variations. The main features of the L6599 are a non-linear soft-start, a current protection mode used to program the hiccup mode timing, a dedicated pin for sequencing or brown-out (LINE) and a stand-by pin (STBY) for burst mode operation at light loads (not used in this design). The transformer uses the magnetic integration approach, incorporating the resonant series and shunt inductances. Thus, no additional external coils are needed for the resonance. The transformer configuration chosen for the secondary winding is center-tap, and the output rectifiers are Schottky type diodes, in order to limit the power dissipation. The feedback loop is implemented by means of a classical configuration using a TL431 (U4) to adjust the current in the optocoupler diode (U3). A weighted resistive divider (R53, R57, R58, R60 and R61) is used to detect both output voltages in order to get a better overall voltage regulation. The optocoupler transistor modulates the current from Pin 4, so the frequency will change accordingly, thus achieving the output voltage regulation. Resistors R46 and R54 set the maximum operating frequency. In case of a short circuit, the current entering the primary winding is detected by the lossless circuit (C34, C39, D11, D12, R43, and R45) and the resulting signal is fed into Pin 6. In case of overload, the voltage on Pin 6 will overpass an internal threshold that triggers a protection sequence via Pin 2, keeping the current flowing in the circuit at a safe level. The third stage is a small flyback converter based on the VIPer12A-E, a current mode controller with integrated Power MOSFET, capable of delivering (approximately) 7 W output power on the output voltages (5 V and 3.3 V). The regulated output voltage is the 3.3 V output and, also in this case, the feedback loop bases on the TL431 (U7) and optocoupler (U6) to control the output voltage. This converter is able to operate in the whole mains voltage range, even when the PFC stage is not working. From the auxiliary winding on the primary side of the flyback transformer (T2), a voltage Vs is available, intended to supply the other controllers (L6563 and L6599) in addition to the VIPer12A-E itself. The PFC stage and the resonant converter can be switched on and off through the circuit based mainly on components Q7, Q8, D22 and U8, which, depending on the level of the signal ST-BY, supplies or removes the auxiliary voltage (VAUX) necessary to start-up the controllers of the PFC and resonant stages. In this way, when the AC input voltage is applied to the power supply, the small flyback converter switches on first; then, when the ST-BY signal is low, the PFC pre-regulator becomes operative, and last the resonant converter can deliver the output power to the load. Note that if Pin 9 of Connector J3 is left floating (no signal ST-BY present), the PFC and resonant converter will be not operating, and only +5V and +3.3V supplies are available on the output. In order to enable the +24 V and +12 V outputs, Pin 9 of Connector J3 must be pulled down to ground.
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4-5
1-2
6/35
Vrec t D1 1N 5406 D2 D 15XB60 L3 D3 STTH 8R 06 C7 470nF / 630V C8 220uF / 450V C9 R2 Vdc N TC 2R5-S237 +400V + D M-LSR -72uH -3A C2 100nF -X2 Jumper ~ 330nF -X2 680nF -X2 330nF / 630V 680nF / 630V C3 C4 C5 C6 PQ35-900uH L4 Jumper ~
Figure 2.
F1 L1
C M-TF 2628V-5m H -3A
J1
1
6. 3A/ 250V
R1
2
1M5
C ON 2-I N
C 10 2nF 2-Y 2 2nF 2-Y 2
C 11 2nF 2-Y 1
Vdc
R4 R3 Vaux 47 680k R6 680k 100nF 10uF / 50V C 12 C 13
Main characteristics and circuit description
R5
2M2
R7 680k
R8
2M2
R9 R 10 C 14 100k 100nF R 14 C 16 1k 5 R 17 C 17 15k I NV C OMP MU LT CS VF F TBO R 20 PW M-Lat c h 1k 0 R 26 150k C 20 470nF 240k 2nF 2 1k 5 R 28 C 21 R 29 C 18 R 21 330pF 2R 2 0R 68 0R 68 0R 68 R 22 R 23 R 24 PF C -OK PW M-LATC H PW M-STOP R UN 1k CS Z CD GN D CS GD 6R 8 R 19 VC C 220pF LL4148 LL4148 R 18 Q2 STP12N M50F P D5 D6 U1 L6563 1uF 56k R 13 100pF 15k C 15 R 11
PFC pre-regulator electrical diagram
2M2
R 16
5k 1
LI N E
C 19
R 25
10nF
30k
R 30
R 31
Q3 BC 857C
Vrec t
620k R 32 10k 10nF C 22
620k
AN2393
AN2393 Figure 3.
Vdc
C 23 Q5 LL4148 47 STP14N K50Z 16 2uH 2 Q6 4 LL4148 C 28 C 27 VBOOT 13 C 29 2200uF / 35V R 38 Vaux 47 12 2uH 2 C 34 C 31 220pF / 630V 10uF / 50V R 43 9 150 D 12 LL4148 C 39 220nF 75R LL4148 R 45 D 11 C 37 2200uF / 25V C 38 2200uF / 25V 100nF 10 C 32 11 D 10B STPS20L40C F C 35 470uF / 25V L6 D 10A STPS20L40C F C 30 2200uF / 35V H VG OU T NC VC C LVG GN D PF C -STOP 47 STP14N K50Z 22nF / 630V 100nF 14 R 40 0R 15 U2 L6599 D 8B STPS20H 100C F C 25 470uF / 35V L5 R 35 0R D 8A STPS20H 100C F
D7
R 33 +24V
2uF 2
R 34 J2 T1 T-R ES-ER 49 2 D9 R 39
2k 7
R 36
C 24
0R
470nF
R 37
1 2 3 4 5 6 7 8 C ON 8
1M0
C 26
C SS
D ELAY
270pF
R 41
CF
R F MI N
16k
CC by rework
STBY
LI N E
R 42
I SEN
+12V
LI N E
10
C 33
DI S
4nF 7
Resonant converter electrical diagram
PW M-Lat c h
R 46
R 47
C 40 R 51 2k 2 R 52 5k 6 D 13 C -12V C 41 R 53 10uF / 50V 33k
5k 6
10k
10nF
R 54 U 3B SF H 617A-2 U 3A SF H 617A-2 R 56 1k 0 R 57 15k R 58 0R
5k 6
R 60 C 44 47nF U4 TL431 R 59 3k 9 27k
R 61 3k 9
Main characteristics and circuit description
7/35
8/35
+5Vs t -by L7 D 15 1N 5822 C 45 33uH 100uF / 10V +3V3 PKC -136 L8 D 16 4 8 Vs 9 - 10 1000uF / 10V 100uF / 10V D 20 2 BAV103 D 18 1 B-10V C -30V 10uF / 50V R 62 47 C 52 47nF R 64 1k 6 C 51 100nF D 19 C 50 1N 5821 C 47 33uH C 49 St -By 1000uF / 10V C 46 S D 14 7 S FB Vdd D D D D +5Vst-by T2 T-F LY -AU X-E20 5 6 J3 1 2 3 4 5 6 7 8 9 10 C ON 10
Figure 4.
Vdc +400V
U5 VI PER -12A
C 48 LL4148 U 6B D 17 SF H 617A-2
Main characteristics and circuit description
10uF / 50V
R 83 Vdc +400V 1M0 R 84 150k U 8A SF H 617A-2 R 68 Vs R 69 0R Q8 BC 847C 10k R 72 10k D 21 Q9 BC 857C B-27V D 23 Q10 BC 847C C 56 R 79 100nF 1k 0 U 8B SF H 617A-2 B-15V 1k 5 0R 1k 5 R 82 +12V R 75 R 76 +24V R 71 St -By 22k 1k 0 R 66 +5Vs t -by
Q11 BC 557C
U 6A SF H 617A-2
R 67 1k 0
C 58
Auxiliary converter electrical diagram
10nF
C 53 2nF 2 R 73 8k 2 U7 TL431 R 77 4k 7 C 54 100nF
Vaux
R 70
Q7 BC 547C
22R
C 55
10uF / 50V
R 74
10k
C 57
D 22
1nF 0
C -15V
AN2393
AN2393
Electrical test results
2
2.1
Electrical test results
Efficiency measurements
Table 1 and Table 2 show the output voltage measurements at the nominal mains voltages of 115 Vac and 230 Vac, with different load conditions. For all measurements, both at full load and at light load operation, the input power is measured using a Yokogawa WT-210 digital power meter. Particular attention has to be paid when measuring input power at full load in order to avoid measurement errors due to the voltage drop on cables and connections. Therefore please connect the WT210 voltmeter termination to the board input connector. For the same reason please measure the output voltage at the output connector or use the remote sense option of your active load for a correct output voltage measurement.
Table 1.
Efficiency measurements @VIN = 115 Vac
+24 V(V) @load(A) +12 V(V) @load(A) +5 V(V) @load(A) +3.3 V(V) @load(A) POUT (W) PIN (W) Efficiency 23.81 - 6.00 24.04 - 3.04 23.84 - 3.02 23.79 - 2.01 23.94 - 0.53 11.86 - 4.94 11.80 - 4.91 11.91 - 1.98 11.96 - 0.49 11.92 - 0.49 4.93 - 0.98 4.93 - 0.98 4.93 - 0.98 4.96 - 0.31 4.97 - 0.31 3.35 - 0.71 3.35 - 0.71 3.35 - 0.71 3.35 - 0.31 3.35 - 0.31 208.66 138.23 102.79 56.25 21.11 235.00 155.50 115.47 63.55 25.56 88.79% 88.89% 89.02% 88.52% 82.58%
Table 2.
Efficiency measurements @VIN = 230 Vac
+24 V(V) @load(A) +12 V(V) @load(A) +5 V(V) @load(A) +3.3 V(V) @load(A) POUT (W) PIN (W) Efficiency 23.82 - 6.00 24.05 - 3.04 23.85 - 3.02 23.80 - 2.01 23.94 - 0.53 11.86 - 4.94 11.80 - 4.91 11.91 - 1.98 11.96 - 0.49 11.92 - 0.49 4.94 - 0.98 4.94 - 0.98 4.94 - 0.98 4.96 - 0.31 4.96 - 0.31 3.35 - 0.71 3.35 - 0.71 3.35 - 0.71 3.35 - 0.31 3.35 - 0.31 208.73 138.27 102.83 56.27 21.11 229.96 152.85 114.05 63.47 26.47 90.77% 90.46% 90.16% 88.66% 79.73%
In Table 1, Table 2 and Figure 5 the overall circuit efficiency is measured at each load condition, at both nominal input mains voltages of 115 Vac and 230 Vac. The values were measured after 30 minutes of warm-up at maximum load. The high efficiency of the PFC pre-regulator working in FOT mode and the very high efficiency of the resonant stage working in ZVS (i.e. with negligible switching losses), provides for an overall efficiency better than 88%. This is a significant high value for a two-stage converter with two output voltages delivering an output current in excess of 5 amps, especially at low input mains voltage where the PFC conduction losses increase. Even at lower loads, the efficiency still remains high. The global efficiency at full load has been measured even at the limits of the input voltage range, with good results:
At VIN = 90 Vac - full load, the efficiency is 86.88% (POUT = 208.8 W and PIN = 240.3 W) At VIN = 264 Vac - full load, the efficiency is 90.90% (POUT = 208.7 W and PIN = 229.6 W)
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Electrical test results
AN2393
Also at light load, at an output power of about 10% of the maximum level, the overall efficiency is very good, reaching a value better than 79% over the entire input mains voltage range. Figure 6 shows the efficiency measured at various input voltages versus output power. Figure 5.
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency (% 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 Output power (W ) eff% @ 115 Vac eff% @ 230 Vac
Overall efficiency versus output power at nominal mains voltages
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AN2393 Figure 6.
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency (% 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% 0 10 20 30 40 50 60 70 80 90
Electrical test results Overall efficiency versus output power at several input voltage values
eff% @ 90 Vac eff% @ 100 Vac eff% @ 115 Vac eff% @ 135 Vac
100 110 120 130 140 150 160 170 180 190 200 210
O tput power (W u )
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency (% 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 Output power (W ) eff% @ 170 Vac eff% @ 200 Vac eff% @ 230 Vac eff% @ 264 Vac
2.2
Resonant stage operating waveforms
Figure 7 shows some waveforms during steady state operation of the resonant circuit at full load. The Ch3 waveform is the half-bridge square voltage on Pin 14 of L6599, driving the resonant circuit. In the picture it is not evident, but the switching frequency is normally slightly modulated following the PFC pre-regulator 100-Hz ripple that is rejected by the resonant control circuitry. The switching frequency has been selected approximately at 95-kHz in order to have a good trade off between transformer losses and dimensions. The Ch4 waveform represents the transformer primary current flowing into the resonant tank. As shown, it is almost sinusoidal because the operating frequency is close to the resonance of the leakage inductance of the transformer and the resonant capacitor (C28). In this condition, the circuit has a good margin for ZVS operation, providing good efficiency,
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Electrical test results while the almost sinusoidal current waveform just allows for an extremely low EMI generation.
AN2393
Figure 8 shows the same waveforms of previous figure, when both the outputs are not loaded. This picture demonstrates the ability of the converter to operate down to zero load, with the output voltages still within regulation. The resonant tank current has obviously a triangular shape and represents the magnetizing current flowing into the transformer primary side. Figure 7. Resonant circuit primary side waveforms at full load
Ch3: half-bridge square voltage Ch4: resonant tank current
Figure 8.
Resonant circuit primary side waveforms at no-load condition
Ch1: +12V output voltage Ch2: +24V output voltage Ch3: half-bridge square voltage Ch4: resonant tank current
In Figure 9 and Figure 10, waveforms relevant to the secondary side are represented: the rectifiers reverse voltage is measured by CH1 (for both +24 V and +12 V outputs) and the peak to peak value is indicated on the right side of the figure. It is a bit higher than the theoretical value that would be 2(VOUT+VF): it is possible to observe a small ringing on the bottom side of the waveform, responsible for this difference.
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AN2393
Electrical test results Waveform CH3 shows the current flowing into one of the two output diodes for each output voltage (respectively D8A and D10A). Also this current shape is almost a sine wave, whose average value is one half the output current. The ripple and noise on the output voltage is shown on CH2. Thanks to the advantages of the resonant converter, the high frequency noise of the output voltages is less than 50 mV, while the residual ripple at twice the mains frequency is lower than 75 mV at maximum load and any line condition, as shown in Figure 11.
Figure 9.
Resonant circuit secondary side waveforms: +24 V output
Figure 10. Resonant circuit secondary side waveforms: +12 V output
+24 V output waveforms: Ch1: +24 V diode reverse voltage Ch2: high freq. ripple on +24 V output voltage Ch3: diode D8A current
+12 V output waveforms: Ch1: +12V diode reverse voltage Ch2: high freq. ripple on +12 V output voltage Ch3: diode D10A current
Figure 11. Low frequency (100 Hz) ripple voltage on the output voltages
Ch1: 100 Hz ripple voltage on +12 V Ch2: 100 Hz ripple voltage on +24 V
Figure 12 shows the dynamic behavior of the converter during a load variation from 0 to 100% on one output, with the other output at maximum load. This figure also highlights the induced effect of this load change on the PFC pre-regulator output voltage (+400 V on Ch3 track). Both the transitions (from 0 to 100% and from 100% to 0) are clean and do not show any problem for the output voltage regulation.
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Electrical test results
AN2393
Thus, it is clear that the proposed architecture is really suitable for power supplies operating with strong load variation without any problem related to the load regulation. Figure 12. Load transition (0 - 100%) on +24 V Figure 13. Load transition (0 - 100%) on +12 V output voltage output voltage
Dynamic load +24 V @0-6 A - 12 V @ max load (5 A) Ch1: +24 V output voltage Ch2: +12 V output current Ch3: PFC output voltage (400 V) Ch4: + 24 V output current
Dynamic load +12 V @0-5 A - 24 V @ max load (6 A) Ch1: +24 V output voltage Ch2: +12 V output current Ch3: PFC output voltage (400 V) Ch4: + 12 V output current
2.3
Stand-by and no load power consumption
The board is specifically designed for light load and zero load operation, as during Stand-by or Power-off operation, when no power is requested from the +24 V and +12 V outputs. Though the resonant converter can operate down to zero load, some tricks are required to keep very low the input power drawn from the mains when the system is in this load condition. Thus, when entering this power management mode, the ST-BY signal needs to be set high (by the microcontroller of the system). This forces the PFC pre-regulator and the resonant stage to switch off (because the supply voltage of the two control ICs is no longer present (Figure 4) and only the auxiliary flyback converter continues working just to supply the microprocessor circuitry. Table 3 and Table 4 show the measurements of the input power in several light load conditions at 115 and 230 Vac. These tables show that at no load the input power is lower than 0.5 W.
14/35
AN2393 Table 3. Stand-by consumption at VIN = 115 Vac
+3.3 V(V) @load(A) 3.35 - 0.102 3.35 - 0.079 3.35 - 0.046 3.35 - 0.023 3.35 - 0.000
Electrical test results
+5 V(V) @load(A) 5.08 - 0.018 5.04 - 0.018 4.98 - 0.018 4.92 - 0.018 4.47 - 0.000
POUT (W) 0.43 0.36 0.24 0.17 0.00
PIN (W) 0.863 0.751 0.582 0.445 0.221
Table 4.
Stand-by consumption at VIN = 230 Vac
+3.3 V(V) @load(A) 3.35 - 0.102 3.35 - 0.079 3.35 - 0.046 3.35 - 0.023 3.35 - 0.000 POUT (W) 0.43 0.36 0.24 0.17 0.00 PIN (W) 1.138 1.022 0.857 0.740 0.470
+5 V(V) @load(A) 5.08 - 0.018 5.04 - 0.018 4.98 - 0.018 4.92 - 0.018 4.47 - 0.000
2.4
Short-circuit protection
The L6599 is equipped with a current sensing input (pin #6, ISEN) and a dedicated overcurrent management system. The current flowing in the circuit is detected (through the not dissipative sensing circuit already mentioned in Section 1 and the signal is fed into the ISEN pin. It is internally connected to the input of a first comparator, referenced to 0.8 V, and to that of a second comparator referenced to 1.5 V. If the voltage externally applied to the pin exceeds 0.8 V, the first comparator is tripped causing an internal switch to be turned on discharging the soft-start capacitor CSS. For output short-circuits, this operation results in a nearly constant peak primary current. Using the L6599, the designer can externally program the maximum time (tSH) that the converter is allowed to run overloaded or under short-circuit conditions. Overloads or shortcircuits lasting less than tSH will not cause any other action, hence providing the system with immunity to short duration phenomena. If, instead, tSH is exceeded, an overload protection (OLP) procedure is activated that shuts down the L6599 and, in case of continuous overload/short circuit, results in continuous intermittent operation with a user-defined duty cycle. This function is realized with the pin DELAY (#2), by means of a capacitor C24 and the parallel resistor R37 connected to ground. As the voltage on the ISEN pin exceeds 0.8 V, the first OCP comparator, in addition to discharging CSS, turns on an internal current generator that via the DELAY pin charges C24. As the voltage on C24 reaches 3.5 V, the L6599 stops switching and the PFC_STOP pin is pulled low. Also the internal generator is turned off, so that C24 will now be slowly discharged by R37. The IC will restart when the voltage on C24 becomes less than 0.3 V. Additionally, if the voltage on the ISEN pin reaches 1.5 V for any reason (e.g. transformer saturation), the second comparator will be triggered, the L6599 will shutdown and the operation will be resumed after an on-off cycle. Figure 14 and Figure 15 illustrate the L6599 short-circuit protection sequence described above. The on-off operation is controlled by the voltage on pin #2 (DELAY), providing for the hiccup mode of the circuit. Thanks to this control pin, the designer can select the hiccup mode timing and thus keep the average output current at a safe level. Please note on the left
15/35
Electrical test results
AN2393
side of the figure the very low mean current flowing in the shorted output which is less than 0.3 A. Figure 14. +24 V output short-circuit waveforms Figure 15. +12 V output short-circuit waveforms
Shor t circuit on +24 V output voltage
Ch1: +24 V output voltage Ch2: L6599 pin 6 (ISEN) Ch3: L6599 pin 2 (DELAY) Ch4: +24 V output current
Shor t circuit on +12 V output voltage
Ch1: +12 V output voltage Ch2: L6599 pin 6 (ISEN) Ch3: L6599 pin 2 (DELAY) Ch4: +12 V output current
2.5
Overvoltage protection
Both the PFC pre-regulator and the resonant converter are equipped with their own overvoltage protection circuit. The PFC controller L6563 is internally equipped with a dynamic and a static overvoltage protection circuit sensing the error amplifier via the voltage divider dedicated to the feedback loop to sense the PFC output voltage. If an internal threshold is exceeded, the IC limits the PFC output voltage to a programmable, safe value. Moreover, in the L6563 there is an additional protection against loop failures using an additional divider (R5, R7, R9, R16 and R25) connected to a dedicated pin (PFC_OK, Pin 7) protecting the circuit in case of loop failures or disconnection or deviation from the nominal value of the feedback loop divider. Hence the PFC output voltage is always under control and in case a fault condition is detected the PFC_OK circuitry will latch the L6563 operations and, by means of the PWM_LATCH pin (Pin 8) it will latch the L6599 as well via the DIS pin (Pin 8). The OVP circuit (see Figure 4) for the output voltages of the resonant converter uses two zener diodes (D21 and D23) to sense the +24 V and+12 V. If one of the output voltages exceeds the threshold imposed by these zener diodes plus the VBE of Q10, the transistor Q9 starts conducting and the optocoupler U8 opens Q7, so that the VAUX supply voltage of the controller ICs L6563 and L6599 is no longer available. This state is latched until a mains voltage recycle occurs.
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AN2393
Thermal tests
3
Thermal tests
In order to check the design reliability, a thermal mapping by means of an IR Camera was performed. Figure 16 and Figure 17 show the thermal measurements of the board, component side, at nominal input voltage. The correlation between measurement points and components is indicated for both diagrams. Figure 16. Thermal map @115 Vac - full load
Figure 17. Thermal map at 230 Vac - full load
17/35
Thermal tests Table 5. Key components temperature at 115 Vac - full load
Ambient temperature: 25 C Item D2 Q2 D3 L1 L3 L4 (Fe) L4 (Cu) C8 R2 Q5 Q6 D8A D8B D10A D10B C29 C30 C37 C38 L5 L6 T1 T1 U5 D14 D15 D16 T2 Temp (C) 44.9 53.7 50.3 47.0 46.0 45.8 49.2 37.3 78.0 40.2 46.7 56.2 56.7 42.1 42.7 45.1 46.1 42.0 41.6 71.2 56.0 51.7 56.8 81.4 74.2 57.6 55.3 56.4
AN2393
18/35
AN2393 Table 6. Key components temperature at 230 VAC - full load
Ambient temperature: 25 C Item D2 Q2 D3 L1 L3 L4 (Fe) L4 (Cu) C8 R2 Q5 Q6 D8A D8B D10A D10B C29 C30 C37 C38 L5 L6 T1 (Fe) T1 (Cu) U5 D14 D15 D16 T2 Temp (C) 37.1 46.6 44.0 33.6 34.9 39.1 41.2 37.1 65.8 38.3 43.7 56.4 55.6 42.1 43.8 48.2 47.4 44.3 44.5 73.6 57.3 51.3 58.8 81.8 74.4 59.4 56.3 56.8
Thermal tests
All other board components work within the temperature limits, assuring a reliable long term operation of the power supply. Note that the temperatures of L4 and T1 have been measured both on the ferrite core (Fe) and on the copper (Cu).
19/35
Conducted emission pre-compliance test
AN2393
4
Conducted emission pre-compliance test
The limits indicated on both diagrams at 115 Vac and 230 Vac comply with EN55022 Class-B specifications. The measurements have been taken in Quasi Peak detection mode. Figure 18. CE quasi peak measurement at 115 Vac and full load
Figure 19. CE quasi peak measurement at 230 Vac and full load
20/35
AN2393
Bill of materials
5
Table 7.
Item C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33
Bill of materials
Bill of materials
Part type/value 100 nF-X2 330 nF-X2 680 nF-X2 330 nF/630 V 680 nF/630 V 470 nF/630 V 220 F/450 V 2nF2-Y1 2nF2-Y1 2nF2-Y1 100 nF 10 F/50 V 100 nF 100 pF 1 F 220 pF 330 pF 10 nF 470 nF 2nF2 10 nF 2 F2 470 nF 470 F/35 V 270 pF 100 nF 22 nF/630 V/400 Vac 2200 F/35 V 2200 F/35 V 10 F/50 V 100 nF 4 nF7 Description 275 Vac X2 Safety Capacitor MKP R46 275 Vac X2 Safety Capacitor MKP R46 275 Vac X2 Safety Capacitor MKP R46 Polypropylene Capacitor High Ripple MKP R71 Polypropylene Capacitor High Ripple MKP R71 Polypropylene Capacitor High Ripple MKP R71 Aluminium ELCAP USC Series 85 DEG SNAP-IN 400 Vac Y1 Safety Ceramic Disk Capacitor 250 Vac Y1 Safety Ceramic Disk Capacitor 250 Vac Y1 Safety Ceramic Disk Capacitor 50 V 1206 SMD Cercap General Purpose Aluminium ELCAP General Purpose 85 DEG 50 V 1206 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 25 V 1206 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 50 V 1206 SMD Cercap General Purpose 100 V 1206 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 25 V 1206 SMD Cercap General Purpose 25 V 1206 SMD Cercap General Purpose Aluminium ELCAP YXF Series 105 DEG 100 V 0805 SMD Cercap General Purpose 50 V 1206 SMD Cercap General Purpose Polypropylene Capacitor High Ripple PHE450 Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP General Purpose 85 DEG 50 V 1206 SMD Cercap General Purpose 100 V 1206 SMD Cercap General Purpose Supplier Arcotronics Arcotronics Arcotronics Arcotronics - Epcos Arcotronics - Epcos Arcotronics - Epcos Rubycon Murata Murata Murata BC Components Rubycon BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components Rubycon BC Components BC Components RIFA-EVOX Rubycon Rubycon Rubycon BC Components BC Components
21/35
Bill of materials Table 7.
Item C34 C35 C37 C38 C39 C40 C41 C44 C45 C46 C47 C48 C49 C50 C51 C52 C53 C54 C55 C56 C57 C58 D1 D2 D3 D5 D6 D7 D8A-B D9 D10A-B D11 D12 D13 D14
AN2393
Bill of materials (continued)
Part type/value 220 pF/630 V 470 F/25 V 2200 F/25 V 2200 F/25 V 220 nF 10 nF 10 F/50 V 47 nF 1000 F/10 V 100 F/10 V 1000 F/10 V 10 F/50 V 100 F/10 V 10 F/50 V 100 nF 47 nF 2 nF2 100 nF 10 F/50 V 100 nF 1nF0 10 nF 1N5406 D15XB60 STTH8R06 LL4148 LL4148 LL4148 STPS20H100CF LL4148 STPS20L40CF LL4148 LL4148 C-12 V PKC-136 Description Polypropylene Capacitor High Ripple PFR Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP YXF Series 105 DEG 50 V 1206 SMD Cercap General Purpose 100 V 1206 SMD Cercap General Purpose Aluminium ELCAP General Purpose 85 DEG 100 V 1206 SMD Cercap General Purpose Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP General Purpose 85 DEG Aluminium ELCAP YXF Series 105 DEG Aluminium ELCAP General Purpose 85 DEG 100 V 0805 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 50 V 1206 SMD Cercap General Purpose Aluminium ELCAP General Purpose 85 DEG 50 V 1206 SMD Cercap General Purpose 100 V 0805 SMD Cercap General Purpose 50 V X7R Standard Ceramic Capacitor General Purpose Rectifier Single Phase Bridge Rectifier TO220FP Ultrafast High Voltage Rectifier MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode TO220FP Power Schottky Rectifier MINIMELF Fast Switching Diode TO220FP Power Schottky Rectifier MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode BZV55-C Series Zener Diode Peak Clamp Transil Supplier RIFA-EVOX Rubycon Rubycon Rubycon BC Components BC Components Rubycon BC Components Rubycon Rubycon Rubycon Rubycon Rubycon Rubycon BC Components BC Components BC Components BC Components Rubycon BC Components BC Components BC Components Vishay Shindengen STMicroelectronics Vishay Vishay Vishay STMicroelectronics Vishay STMicroelectronics Vishay Vishay Vishay STMicroelectronics
22/35
AN2393 Table 7.
Item D15 D16 D17 D18 D19 D20 D21 D22 D23 F1 J1 J2 J3 L1 L3 L4 L5 L6 L7 L8 Q2 Q3 Q5 Q6 Q7 Q8 Q9 Q10 Q11 R1 R2 R3 R4 R5 R6
Bill of materials Bill of materials (continued)
Part type/value 1N5822 1N5821 LL4148 B-10 V C-30 V BAV103 B-27 V C-15 V B-15 V 6.3A/250 V CON2-IN CON8 CON10 CM-TF2628V-5 mH-3 A DM-LSR-72 H-3 A PQ35-900 H 2 H2 2 H2 33 H 33 H STP12NM50FP BC857C STP14NK50Z STP14NK50Z BC547C BC847C BC857C BC847C BC547C 1M5 NTC 2R5-S237 680 k 47 2M2 680 k Description Power Schottky Rectifier Power Schottky Rectifier MINIMELF Fast Switching Diode BZV55-B Series Zener Diode BZV55-C Series Zener Diode General Purpose Diode BZV55-B Series Zener Diode BZV55-C Series Zener Diode BZV55-B Series ZENER DIODE T Type Fuse 5 X 20 High Capability & Fuseholder 3-Pin Connector (Central Removed) P 3.96 KK Series 8-Pin Connector P 3.96 KK Series 10-Pin Connector P 2.54 MTA Series TF2628 Series Common Mode Toroidal Inductor LSR1803-2 Differential Mode Toroidal Inductor 86H-5409 Boost Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor TO220FP N-Channel Power MOSFET SOT23 Small Signal PNP Transistor TO220FP N-Channel Power MOSFET TO220FP N-Channel Power MOSFET TO92 Small Signal PNP Transistor SOT23 Small Signal PNP Transistor SOT23 Small Signal PNP Transistor SOT23 Small Signal NPN Transistor TO92 Small Signal PNP Transistor VR25 Type High Voltage Resistor NTC RESISTOR 2R5 S237 Series 1206 SMD Standard Film RES 1/4 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/4 W 5% 20 0ppm/C Supplier STMicroelectronics STMicroelectronics Vishay Vishay Vishay Vishay Vishay Vishay Vishay Wickmann Molex Molex AMP TDK Delta Delta Coilcraft Coilcraft Coilcraft Coilcraft STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics BC Components Epcos BC Components BC Components BC Components BC Components
23/35
Bill of materials Table 7.
Item R7 R8 R9 R10 R11 R13 R14 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R45
AN2393
Bill of materials (continued)
Part type/value 2M2 680 k 2M2 100 k 15 k 56 k 1k5 5k1 15 k 6R8 1K0 1k0 2R2 0R68 0R68 0R68 30 k 150 k 240 k 1k5 620 k 620 k 10 k 0R 2k7 47 0R 1M0 47 0R 47 16 k 10 150 75R Description 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/4 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8W 5% 200ppm/C 1206 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C Standard Metal Film RES 1/4 W 5% 200 ppm/C Standard Metal Film RES 1/4 W 5% 200 ppm/C PR01 Power Resistor PR01 Power Resistor PR01 Power Resistor 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C Standard Metal Film RES 1/4W 5% 200ppm/C 0805 SMD Standard Film RES 1/8 W 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C Supplier BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components
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AN2393 Table 7.
Item R46 R47 R51 R52 R53 R54 R56 R57 R58 R59 R60 R61 R62 R64 R66 R67 R68 R69 R70 R71 R72 R73 R74 R75 R76 R77 R79 R82 R83 R84 T1 T2 U1 U2 U3
Bill of materials Bill of materials (continued)
Part type/value 5k6 10 k 2k2 5k6 33 k 5k6 1k0 15 k 0R 27 k 3k9 3k9 47 1k6 1k0 1k0 22 k 0R 22R 10 k 10 k 8k2 10 k 0R 1k5 4k7 1k0 1k5 1M0 15 0k T-RES-ER49 T-FLY-AUX-E20 L6563 L6599 SFH617A-2 Description 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 1206 SMD Standard Film RES 1/4 W 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8W 5% 200ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 1% 100 ppm/C 0805 SMD Standard Film RES 1/8 W 5% 200 ppm/C 1206 SMD Standard Film RES 1/4 W 1% 100 ppm/C VR25 Type High Voltage Resistor Standard Metal Film RES 1/4 W 5% 200 ppm/C 86H-5411 Type Resonant Transformer ER49-27-17 86A-6079-R Type Flyback Transformer E20 Core Advanced Transition Mode PFC Controller High Voltage Resonant Controller 63-125% CTR Selection Optocoupler Supplier BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components BC Components Delta Delta STMicroelectronics STMicroelectronics Infineon
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PFC coil specification Table 7.
Item U4 U5 U6 U7 U8
AN2393
Bill of materials (continued)
Part type/value TL431 VIPer12A-E SFH617A-2 TL431 SFH617A-2 Description TO92 Programmable Shunt Voltage Regulator Low Power Off Line SMPS Primary Switcher 63-125% CTR Selection Optocoupler TO92 Programmable Shunt Voltage Regulator 63-125% CTR Selection Optocoupler Supplier STMicroelectronics STMicroelectronics Infineon STMicroelectronics Infineon
Note:
Q9 and R72: Mounted by reworking on PCB Q11, R83, R84 and C58: Added by reworking on PCB
6
PFC coil specification
Application type: Consumer, home appliance Transformer type: Open Coil former: vertical type, 6+6 pins Maximum temperature rise: 45 C Maximum operating ambient temperature: 60 C
6.1
Electrical characteristics
Conver ter topology: FOT-PFC Pre-regulator Core type: PQ35-35 material grade PC44 or equivalent Maximum operating frequency: 100 kHz Primary inductance: 900 H 10% @1 kHz - 0.25 V (see Note 1) Primary RMS current: 2.65 A
Note:
1
Measured between Pins 2 and 3 and Pins 10 and 11 Figure 20. PFC coil electrical diagram
4-5 Primar y 1-2 12 Auxiliary 8
Note:
The auxiliary winding is not used in this design, but is foreseen for another application
26/35
AN2393 Table 8.
Start pins 12 4 and 5
Resonant power transformer specification PFC coil winding characteristics
End pins 8 1 and 2 Turn number 5 (spaced) 70 Wire type Single Multistrand - G2 Wire diameter (mm) 0.28 Litz 0.2 x 20 Notes Bottom Top
6.2
Mechanical aspect and pin numbering
Maximum height from PCB: 38 mm Cut pins: 7, 10 and 11 Pin distance: 5.08 mm Row distance: 35.5 mm
Figure 21. PFC coil pin side view
6 5 4 30.5 mm 3 2 1 39 mm 10 11 12 7 8 9 35.5 mm
Note:
External copper shield 15 x 0.05 (mm) connected to pin 12 by tinned wire Manufacturer: DELTA ELECTRONICS - Part number: 86H-5409
7
Resonant power transformer specification
Application type: Consumer, home appliance Transformer type: Open Coil former: Horizontal type, 7+7 pins, 2 Slots Maximum temperature rise: 45 C Maximum operating ambient temperature: 60 C Mains insulation: Compliance with EN60065 specifications
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Resonant power transformer specification
AN2393
7.1
Electrical characteristics and mechanical aspect
Conver ter topology: half-bridge, resonant Core type: ER49 - PC44 or equivalent Typical operating frequency: 100 kHz Primary inductance: 585 H 10% @1 kHz - 0.25 V (see Note 1) Leakage inductance: 110 H 10% @1 kHz - 0.25 V (see Note 1 and Note 2)
Note:
1 2
Measured between Pins 1 and 3 Measured between Pins 1 and 3 with ONLY a secondary winding shorted Figure 22. Mechanical aspect and pin numbering of resonant transformer
Table 9.
Resonant transformer dimensions
A B 3.50.5 C 41.60.4 D 51 MAX E 7.00.2 F 51.5 MAX
Dimensions (mm)
39.0 MAX
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AN2393
Resonant power transformer specification Figure 23. Resonant transformer electrical diagram
14 SEC. A 13 SEC. B 1 PRIM. 3 11 SEC. C 10 9 SEC. D 8 12
Table 10.
Pins 1-3 14 - 13 13 - 12 11 - 10 9-8
Resonant transformer winding characteristics
Winding Primary Sec. A Sec. B Sec. C
(1) (1) (2)
RMS current 1.5 ARMS 6.7 ARMS 6.7 ARMS 5.6 ARMS 5.6 ARMS
Turn number 36 4 4 2 2
Wire type [mm] LITZ - dia. 0.15x20 LITZ - dia. 0.20x30 LITZ - dia. 0.20x30 LITZ - dia. 0.20x30 LITZ - dia. 0.20x30
Sec. D (2)
1. Secondary windings A and B must be wound in parallel 2. Aux winding is wound on top of primary winding
Figure 24. Resonant transformer winding position on coil former
Note:
Manufacturer: DELTA ELECTRONICS - Part number: 86H-5411
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Auxiliary flyback power transformer
A N23 9 3
8
Auxiliary flyback power transformer
Application type: Consumer, home appliance Transformer type: Open Winding type: Layer Coil former: Horizontal type, 4+5 pins Maximum temperature rise: 45 C Maximum operating ambient temperature: 60 C Mains insulation: Complies with EN60065 specifications
8.1
Electrical characteristics
Conver ter topology: Flyback, DCM/CCM mode Core type: E20-N67 or equivalent Operating frequency: 60 kHz Primary inductance: 4.20 mH 10% @1 kHz - 0.25 V (see Note 1) Leakage inductance: 50 H MAX @100 kHz - 0.25 V (see Note 2) Maximum peak primary current: 0.38 Apk RMS primary current: 0.2 ARMS
Note:
1 2
Measured between Pins 4 and 5 Measured between Pins 4 and 5 with all secondary windings shorted Figure 25. Auxiliary transformer electrical diagram
5 Primary 4 2 Auxliary 1 6 +5V 7 8 +3.3V 10
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AN2393
Auxiliary flyback power transformer Figure 26. Auxiliary transformer winding position on coil former Insulating Coil Former 3.3 V/5 V Auxiliary Primary
Table 11.
Pins Start - End 4-5 2-1 8-10 6-7
Auxiliary transformer winding characteristics
Winding PRIMARY AUX 3.3 V 5V RMS current 0.2 ARMS 0.05 ARMS 1.2 ARMS 1 A RMS Number of turns 140 29 7 3 Wire type G2 - 0.25 mm G2 - 0.25 mm TIW - 0.75 mm TIW - 0.75 mm
Note:
Manufacturer: DELTA ELECTRONICS - Part number: 86A-6079-R
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Reference design board layout
AN2393
9
Reference design board layout
Figure 27. Copper tracks
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AN2393
Reference design board layout Figure 28. Thru-hole component placing and top silk screen
Figure 29. SMT component placing and bottom silk screen
33/35
Revision history
AN2393
10
Revision history
Table 12.
Date 02-Aug-2006 08-Sep-2006 25-Jan-2007 23-Apr-2007 25-Oct-2007
Document revision history
Revision 1 2 3 4 5 Initial release Figure 2. modified Minor text change Cross references updated Table 7: Bill of materials modified Modified: Section 8.1: Electrical characteristics VIPer12A replaced by VIPer12A-E Changes
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AN2393
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