AN2509 Application note
Wide range 400W (+200 V@1.6 A / +75 V@1 A) L6599-based HB LLC resonant converter
Introduction
This note describes the performances of a 400W reference board, with wide-range mains operation and power-factor-correction (PFC) and presents the results of its bench evaluation. The electrical specification refers to a power supply for general purpose application, with two main output voltages (200 V and 75 V). 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 90% 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 with two output voltages of +200 V/300 W and 75 V/75 W, whose control is implemented through the L6599 resonant controller. A further auxiliary flyback converter based on the VIPer12A off-line primary switcher completes the architecture. This third block, delivering a total power of 7 W on two output voltages (+3.3 V and +5 V), is mainly intended for microprocessor supply and display power management operations
L6599 & L6563 400W demonstration board
April 2007
Rev 3
1/37
www.st.com
Contents
AN2509
Contents
1 2 Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 4 Electrical test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 2.2 2.3 2.4 2.5 2.6 Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Resonant stage operating waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Standby and no-load power consumption . . . . . . . . . . . . . . . . . . . . . . . . 17 Shor t-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 4 5 6
Thermal tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 21 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PFC coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 6.2 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7
Resonant power transformer specification . . . . . . . . . . . . . . . . . . . . . 30
7.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8
Auxiliary flyback power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9 10 11
Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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AN2509
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. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. PFC pre-regulator electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Resonant converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Auxiliary converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compliance to EN61000-3-2 standard for harmonic reduction: full load . . . . . . . . . . . . . . . 9 Compliance to EN61000-3-2 standard for harmonic reduction: 70 W load. . . . . . . . . . . . . . 9 Compliance to JEIDA-MITI standard for harmonic reduction: full load . . . . . . . . . . . . . . . . . 9 Compliance to JEIDA-MITI standard for harmonic reduction: 70 W load . . . . . . . . . . . . . . . 9 Power factor vs. Vin & load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Total harmonic distortion vs. Vin & load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overall efficiency versus output power at nominal mains voltages. . . . . . . . . . . . . . . . . . . 12 Overall efficiency versus input mains voltage at various output power levels . . . . . . . . . . 12 Resonant circuit primary side waveforms at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Resonant circuit primary side waveforms at light load (about 45 W output power) . . . . . . 14 Resonant circuit primary side waveforms at no load condition . . . . . . . . . . . . . . . . . . . . . . 14 Resonant circuit secondary side waveforms: +200 V output . . . . . . . . . . . . . . . . . . . . . . . 15 Resonant circuit secondary side waveforms: +75 V output . . . . . . . . . . . . . . . . . . . . . . . . 15 Low frequency (100 Hz) ripple voltage on +200 V and + 75 V outputs . . . . . . . . . . . . . . . 16 Load transition (0.16 A - 1.6 A) on +200 V output voltage . . . . . . . . . . . . . . . . . . . . . . . . . 16 +200 V output short-circuit waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Thermal map @115 VAC - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Thermal map at 230 VAC - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Peak measurement on LINE at 115 VAC and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Peak measurement on Neutral at 115 VAC and full load. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Peak measurement on LINE at 230 VAC and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Peak measurement on Neutral at 230 VAC and full load. . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Pin side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Winding position on coil former. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Auxiliary transformer winding position on coil former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Copper tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Thru-hole component placing and top silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SMT component placing and bottom silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Main characteristics and circuit description
AN2509
1
Main characteristics and circuit description
The main characteristics of the SMPS are listed below: Universal input mains range: 90 to 264 VAC - 45 to 65 Hz: Output voltages: 200 V @ 1.5 A - 75 V @ 1 A - 3.3 V @ 0.7 A - 5 V @ 1 A Mains harmonics: compliance with EN61000-3-2 specifications Standby mains consumption: less than 0.5 W @230 VAC Overall efficiency: better than 87% at full load, 90-264 VAC 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 1), a half-bridge resonant DC/DC converter based on the resonant controller L6599 (Figure 2), and a 7 W flyback converter intended for standby management (Figure 3) utilizing the VIPer12A off-line primary switcher. The PFC stage delivers a stable 400 VDC supply to the downstream converters (resonant + flyback) and provides for the reduction of the current harmonics drawn from the mains, 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), integrating all functions needed to operate the PFC and interface the downstream resonant converter. Although this controller chip is designed for Transition-Mode (TM) operation, where the boost inductor works next to the boundary between Continuous (CCM) and Discontinuous Conduction Mode (DCM), by adding a simple external circuit, it can be operated in LM-FOT (line-modulated fixed off-time). This mode allows for CCM operation, normally achievable with more expensive control chips and more complex architectures. The LM-FOT mode allows the use of a low-cost device like the L6563 at a high power level, usually covered by CCM topologies. For a detailed and complete description of the LM-FOT operating mode see the application note AN1792. The external components to configure the circuit in LM-FOT mode are: C15, C17, D5, Q3, R14, R17 and R29. 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), a diode (D3) and two capacitors (C7 and C8). The boost switch consists of two power MOSFETs (Q1 and Q2), connected in parallel, which are directly driven by the L6563 output drive thanks to the high current capability of the IC. The divider (R30, R31 and R32), connected to MULT pin 3, provides the information of the instantaneous voltage that is used to modulate the boost current and to derive 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. The divider (R3, R6, R8, R10 and R11) is dedicated to detecting the output voltage while a further divider (R5, R7, R9, R16 and R25) is used to protect the circuit in case of voltage loop failure. The second stage is an LLC resonant converter, with half-bridge topology implementation, working in ZVS (zero voltage switching) mode.
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AN2509
Main characteristics and circuit description The controller is the L6599 integrated circuit that incorporates the necessary functions to properly drive the two half-bridge MOSFETs by a 50% fixed duty cycle with fixed dead-time, 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 standby pin (STBY) for burst mode operation at light loads (not used in this design). The transformer (T1) uses the magnetic integration approach, incorporating the resonant series and shunt inductances of the LLC resonant tank. Thus, no additional external coils are needed for the resonance. For a detailed analysis of the LLC resonant converter, please refer to the application note AN2450. The secondary side power circuit is configured with center-tap windings and two diodes rectification for each output (diodes D8A, D8B, D10A, D10B). The two center tap windings are connected in series on the DC side (refer to Figure 2). The +75 V rail is connected to the center tap of the higher voltage winding (the one connected to the anodes of D8A and D8B diodes). Therefore the higher voltage winding only has to provide a voltage equal to the difference of the two output voltages: 200 V - 75 V = 125 V. This winding arrangement has the advantage of a better cross regulation with respect to the case of two completely separated outputs. Furthermore, due to the fact that the +200 V diodes only have to withstand a voltage of about 250 V (2 x 125 V), instead of about 400 V in case of completely separated windings, the designer can select a diode with a lower junction capacitance minimizing the effect of this capacitance reflected at transformer primary side. This may affect the behavior of the resonant tank, changing the circuit from LLC to LLCC type, with the risk that the converter, in light-load/no-load condition (when the feedback loop increases the operating frequency), can no longer control the output voltage. The feedback loop is implemented by means of a classical configuration using a TL431 (U4) to adjust the current in the optocoupler diode (U3). The optocoupler transistor modulates the current from controller 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 L6599 Pin 6. In case of overload, the voltage on Pin 6 exceeds 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, a current mode controller with integrated power MOSFET, capable of delivering about 7 W total output power on the output voltages (5 V and 3.3 V). The regulated output voltage is the 3.3V output and, also in this case, the feedback loop uses 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 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. 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 asserted 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
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5-6
1-2
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Vrec t D1 1N 5406 D2 D 15XB60 L3 D3 STTH 8R 06 C7 470nF / 630V C8 330uF / 450V C9 N TC 2R5-S237 R2 Vdc +400V + D M-51uH -6A C4 Jumper 680nF -X2 ~ 470nF / 630V 470nF / 630V C5 C6 PQ40-500uH L4 ~ Jumper C3 330nF -X2
Figure 1.
F1
C M-1. 5m H -5A
J1
L1
1
8A/ 250V
R1
C2
2
1M5
470nF -X2
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 15 100k 100pF R 14 U1 L6563 3k 3 R 17 C 17 15k INV C OMP MU LT CS VF F TBO R 20 PW M-Lat c h 1k 0 R 26 150k C 20 R 29 470nF 1k 5 240k 2nF 2 R 28 C 21 C 18 R 21 330pF 0R 39 0R 39 0R 39 0R 39 R 22 R 23 R 24 PF C -OK PW M-LATC H PW M-STOP RUN 1k 0 ZCD GN D CS GD 6R 8 R 19 VC C 220pF LL4148 LL4148 R 18 Q2 STP12N M50F P D5 15k LL4148 R 15 6R 8 D6 Q1 STP12N M50F P R 11 D4
2M2
C 14
PFC pre-regulator electrical diagram
100nF
C 16
R 13
1uF
56k
CS
R 16
5k 1
LI N E
C 19
R 25
10nF
30k
R 30
R 31
Q3 BC 857C
Vrec t
620k C 22 10nF
620k
R 32
signal ST-BY present), the PFC and resonant converter will not operate, and only +5 V and +3.3 V supplies are available on the output. In order to enable the +200 V and +75 V outputs, Pin 9 of Connector J3 must be pulled down to ground.
10k
AN2509
AN2509 Figure 2.
C 61 Vdc
R 88
470nF D7 Q5 LL4148 47 STP14N K50Z D 8A BY T08P-400 Q6 10uH C 25 L5 T1 T-R ES-ER 49-400W R 35 0R R 33
560k
Q12 +200V
BC 557
C 23 J2
100nF D9 U2 L6599 LL4148 R 40 C 28 C 27 C SS D ELAY CF R F MI N R 38 Vaux 47 D 10A STTH 1002C STBY I SEN LI N E DI S C 34 C 31 220pF / 630V 10uF / 50V R 43 150 D 12 LL4148 C 39 1uF 0 100R R 45 D 11 LL4148 C 37 100nF STTH 1002C C 32 D 10B PF C -STOP GN D LVG VC C NC OU T H VG BY T08P-400 VBOOT 47 STP14N K50Z 47nF / 630V D 8B C 30 100nF 0R R 39
C 24
R 34 22uF / 250V
2k 7
R 36 0R
470nF
R 37
1 2 3 4 5 6 7 8 C ON 8 C 29 100uF / 250V JP 100uF / 250V
2M2
C 26
270pF
R 41
16k
L6 +75V 22uH C 35 47uF / 100V
LI N E
R 42
10
C 33
4nF 7
C 38 220uF / 100V 220uF / 100V
Resonant converter electrical diagram
PW M-Lat c h
R 46 10nF
R 47
C 40
R 48 56k
R 49 56k
R 50 56k
1k 5
10k
R 52 3k 3
D 13 C -12V
C 41 10uF / 50V
R 53 75k
C 59 47nF
R 54 U 3B SF H 617A-2 U 3A SF H 617A-2 R 56 1k 0 R 58 75k R 86 470R
1k 5
C 60
470nF C 44 47nF U4 6k 2 TL431 2k 7 R 59 1k 0 R 60 R 61
R 87
220R
Main characteristics and circuit description
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Figure 3.
+5Vs t -by L7 D 15 1N 5822 S D 14 1000uF / 10V L8 D 16 1N 5821 33uH 1000uF / 10V D 20 BAV103 D 18 B-10V C -30V 10uF / 50V R 62 47 C 52 47nF R 64 1k 6 C 51 100nF D 19 C 50 C 47 C 49 100uF / 10V 100uF / 10V +3V3 PKC -136 St -By S FB Vdd C 48 10uF / 50V LL4148 U 6B D 17 SF H 617A-2 Vs D D D D C 45 33uH C 46 +5Vst-by T2 T-F LY -AU X-E20 J3 1 2 3 4 5 6 7 8 9 10 C ON 10
Vdc +400V
Main characteristics and circuit description
U5 VI PER -12A
R 83 Vdc +400V C 58 1M0 R 84 10nF 150k 1k 0 U 8A SF H 617A-2 Vs R 69 0R Q8 BC 847C 10k R 72 10k R 74 Q9 BC 857C 10k B-15V D 23 Q10 BC 847C C 56 D 22 C -15V U 8B SF H 617A-2 100nF 2k 2 30k 30k R 79 B-15V R 80 R 81 100k 150k 150k R 82 D 21 R 75 R 76 R 71 R 68 22k R 66
Q11 BC 557C
U 6A SF H 617A-2
R 67 1k 0 +5Vs t -by C 53 2nF 2 R 73 St -By U7 TL431 R 77 +200V 4k 7 8k 2 C 54 100nF
Auxiliary converter electrical diagram
Vaux
R 70
Q7 BC 547C
22R
C 55
10uF / 50V
+75V
C 57
1nF 0
AN2509
AN2509
Electrical test results
2
2.1
Electrical test results
Harmonic content measurement
The current harmonics drawn from the mains have been measured according to the European rule EN61000-3-2 Class-D and Japanese rule JEIDA-MITI Class-D, at full load and 70 W output power, at both nominal input voltages (230 VAC and 100 VAC). The graphs in Figure 4 to Figure 7 show that the measured current harmonics are well below the limits imposed by the regulations, both at full-load and at 70 W load.
Figure 4.
Compliance to EN61000-3-2 standard for harmonic reduction: full load
Measur emen t s @ 230Vac Full load EN61000 - 3- 2 class D limit s
Figure 5.
Compliance to EN61000-3-2 standard for harmonic reduction: 70 W load
Measur ement s @ 230Vac 70W EN61000- 3- 2 class D limit s
10
1
1
0. 1
0.1
0 .0 1
0 .01
0. 00 1
0 .001
0.0001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0 .0 0 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H a r m o n i c Or d e r ( n )
H a r m o n i c Or d e r ( n )
Figure 6.
Compliance to JEIDA-MITI standard Figure 7. for harmonic reduction: full load
Measur ement s @ 100Vac Full load J EIDA - MITI class D limit s
Compliance to JEIDA-MITI standard for harmonic reduction: 70 W load
Measur ement s @ 100Vac 70W J EIDA - MITI class D limit s
10
1
1
0. 1
0.1
0 .0 1
0.01
0. 00 1
0.0 01
0.0001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0 .0 0 0 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H a r m o n i c Or d e r ( n )
H a r m o n i c Or d e r ( n )
The Power Factor (PF) and the Total Harmonic Distortion (THD) are reported in Figure 8 and Figure 9. It is evident from the graph that the PF stays close to unity in the whole mains voltage range at full load and at half load, while it decreases at high mains at low load (70 W). The THD has similar behavior, remaining within 25% overall the mains voltage range and increasing at low load (70 W) at high mains voltage.
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Electrical test results
AN2509
Figure 8.
PF 1.00
Power factor vs. Vin & load
Figure 9.
THD [%] 25.00
Total harmonic distortion vs. Vin & load
0.98
20.00
400W 200W
0.95 400W 0.93 200W 70W 0.90
5.00 10.00 15.00
70W
0.88
0.85 80 120 160 V in [Vrms] 200 240 280
0.00 80 120 160 V in [Vrms] 200 240 280
2.2
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 operations, 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. Figure 10 shows the overall circuit efficiency, 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 87% at full load in the complete mains voltage range. This is a significant high value for a two-stage converter, especially at low input mains voltage where the PFC conduction losses increase. Even at lower loads, the efficiency still remains high.
Table 1.
Efficiency measurements @VIN = 115 VAC
+75 V@load(A) 77.77 77.78 77.78 77.79 77.79 77.80 77.80 77.81 77.83 77.83 1.020 0.894 0.801 0.694 0.600 0.506 0.399 0.306 0.199 0.105 +5 V @load(A) 4.88 4.88 4.88 4.88 4.88 4.88 4.88 4.88 4.86 4.86 0.975 0.975 0.975 0.975 0.502 0.502 0.502 0.502 0.144 0.146 +3.3 V@load(A) 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 0.695 0.695 0.695 0.695 0.352 0.352 0.352 0.352 0.097 0.099 POUT(W) 405.06 365.23 325.97 285.41 243.00 203.66 163.28 123.80 80.84 41.48 PIN(W) 433.30 390.68 348.98 306.05 260.90 219.52 177.37 136.39 91.34 50.48 Eff. % 93.48% 93.48% 93.41% 93.25% 93.14% 92.78% 92.06% 90.77% 88.50% 82.17%
+200 V @load(A) 200.29 200.29 200.31 200.31 200.32 200.34 200.34 200.34 200.40 200.43 1.591 1.441 1.281 1.120 0.962 0.802 0.642 0.481 0.321 0.161
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AN2509
Electrical test results
Table 2.
Efficiency measurements @VIN = 230 VAC
+75 V @load(A) 77.78 77.79 77.80 77.80 77.80 77.79 77.79 77.80 77.83 77.84 1.022 0.896 0.802 0.694 0.600 0.508 0.399 0.305 0.197 0.050 +5 V @load(A) 4.88 4.88 4.88 4.88 4.88 4.88 4.88 4.88 4.86 4.86 0.977 0.977 0.977 0.977 0.502 0.502 0.503 0.503 0.144 0.146 +3.3 V @load(A) 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 0.695 0.695 0.695 0.695 0.351 0.351 0.351 0.351 0.097 0.099 POUT(W) 405.68 365.64 326.29 285.43 243.04 203.79 163.06 123.52 80.68 405.68 PIN(W) 449.65 404.46 360.10 314.90 267.18 224.33 180.53 138.06 91.83 49.72 Eff. % 90.22% 90.40% 90.61% 90.64% 90.96% 90.84% 90.32% 89.47% 87.86% 74.42%
+200 V @load(A) 200.32 200.32 200.32 200.32 200.35 200.32 200.31 200.34 200.40 200.43 1.593 1.442 1.282 1.120 0.962 0.802 0.641 0.480 0.321 0.160
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 87.27% At VIN = 264 VAC - full load, the efficiency is 93.49% Also at light load, at an output power of about 10% of the maximum level, the overall efficiency is very good, reaching a value of about 75% at nominal mains voltages. Figure 11 shows the efficiency measured at various output power levels versus input mains voltage. The cross regulation of the resonant converter stage is very good as shown in Table 3, where the +200 V and +75 V output voltages are measured in different load conditions, with minimum output current equal to 10% of maximum current for both the output voltages. Table 3. Cross regulation
230 VAC 200 V load max max min min no-load 75 V load max min max min no-load 200 V 200.26 200.35 200.35 200.42 200.76 75 V 77.77 77.92 77.58 77.82 77.66 200 V 200.32 200.35 200.35 200.45 200.76 115 VAC 75 V 77.78 77.94 77.58 77.84 77.65
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AN2509
Figure 10. Overall efficiency versus output power at nominal mains voltages
230Vac 95% 115Vac
90%
85% Eff. (%) 80% 75% 70% 0 50 100 150 200 250 300 350 400 450 Output Power (W)
Figure 11. Overall efficiency versus input mains voltage at various output power levels
400W 200W 70W
Ef f [%] 94% 93% 92% 91% 90% 89% 88% 87% 86% 85% 80 120 160 V in [Vrms] 200 240 280
2.3
Resonant stage operating waveforms
Figure 12 shows some waveforms during steady state operation of the resonant circuit at full load. The Ch1 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
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AN2509
Electrical test results resonant control circuitry. The Ch2 waveform represents the transformer primary current flowing into the resonant tank. As shown, it has almost a sinusoidal shape. The resonant tank has been designed (following the procedure presented in the application note AN2450) to operate at a resonance frequency of about 120 kHz when the dc input voltage of the halfbridge circuit is at 390 V (that is the nominal output voltage of the PFC stage). The resonant frequency has been selected at approximately 120 kHz in order to have a good trade-off between transformer losses and dimensions. The resonant tank circuit has been designed in order to have a good margin for ZVS operation, providing good efficiency, while the almost sinusoidal current waveform allows for an extremely low EMI generation. Figure 12. Resonant circuit primary side waveforms at full load
Ch1: half-bridge square voltage on pin 14 of L6599 Ch2: resonant tank current Ch3: low side MOSFET drive signal
Figure 13 and Figure 14 show the same waveforms as in Figure 12, when the resonant converter is light-loaded (about 45 W) or not loaded at all. These two graphs demonstrate the ability of the converter to operate down to zero load, with the output voltages still within the regulation range. The resonant tank current has obviously a triangular shape and represents the magnetizing current flowing into the transformer primary side. The oscillation superimposed on the tank current depends on the occurrence of a further resonance due to the parallel of the inductances at primary side (the series and shunt inductances in the APR (all primary referred) transformer model presented in AN2450) and the undesired secondary side capacitance reflected at transformer primary side.
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AN2509
Figure 13. Resonant circuit primary side waveforms at light load (about 45 W output power)
Ch1: half-bridge square voltage on pin 14 of L6599 Ch2: resonant tank current Ch3: low side MOSFET drive signal
Figure 14. Resonant circuit primary side waveforms at no load condition
Ch1: half-bridge square voltage on pin 14 of L6599 Ch2: resonant tank current Ch3: low side MOSFET drive signal
In Figure 15 and Figure 16, waveforms relevant to the secondary side are represented. For Figure 15, the waveform Ch1 is the voltage at the anode of D8B diode, referenced to secondary ground, while the waveforms CH2 and CH3 show the current flowing out of the cathode of D8B and D8A diodes. For Figure 16, the waveform Ch1 is the voltage at the anode of D10B diode, referenced to secondary ground, while the waveforms CH2 and CH3 show the current flowing out of the cathode of D10B and D10A diodes. Also these current waveforms, at secondary side, have almost a sine shape, and the total average value is the output average current.
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AN2509
Electrical test results Figure 15. Resonant circuit secondary side waveforms: +200 V output
Ch1: anode voltage of diode D8B Ch2: current flowing out of diode D8B cathode Ch3: current flowing out of diode D8A cathode
Figure 16. Resonant circuit secondary side waveforms: +75 V output
Ch1: anode voltage of diode D10B Ch2: current flowing out of diode D10B cathode Ch3: current flowing out of diode D10A cathode
Thanks to the advantages of the resonant converter, the high frequency noise on the output voltages is less than 50 mV, while the residual ripple at twice the mains frequency (100 Hz) is less than 200 mV on +200 V output and less than 100 mV on +75 V output, at maximum load and worse line condition (90 VAC), as shown in Figure 17.
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Electrical test results
AN2509
Figure 17. Low frequency (100 Hz) ripple voltage on +200 V and + 75 V outputs
Ch3: +75 V output voltage ripple at 100 Hz Ch4: +200 V output voltage ripple at 100 Hz
Figure 18 shows the dynamic behavior of the converter during a load variation from 10% to 100% on the +200 V output. This figure also highlights the induced effect of this load change on the PFC pre-regulator output voltage (+400 V on Ch1 track). Both the transitions (from 10% to 100% and from 100% to 10%) are clean and do not show any problem for the output voltage regulation. This shows that the proposed architecture is also highly suitable for power supplies operating with strong load variation without any problems related to the load regulation. Figure 18. Load transition (0.16 A - 1.6 A) on +200 V output voltage
Ch1: PFC output voltage Ch2: resonant tank current envelope Ch4: +200 V output voltage ripple
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AN2509
Electrical test results
2.4
Standby and no-load power consumption
The board is specifically designed for light load and zero load operations, typical conditions occurring during Standby or Power-off operations, when no power is requested from the +200 V and +75 V outputs. Though the resonant converter can operate down to zero load, some actions are required to keep the input power drawn from the mains very low when the complete 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 3) and only the auxiliary flyback converter continues working just to supply the microprocessor circuitry. Table 4 and Table 5 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 less than 0.5 W. Table 4. Standby consumption at VIN = 115 VAC
+3.3 V @load(A) 3.33 - 0.110 3.33 - 0.077 3.33 - 0.054 3.33 - 0.021 3.33 - 0.000 POUT(W) 0.447 0.336 0.259 0.148 0.000 PIN(W) 0.850 0.693 0.595 0.445 0.220
+5 V @load(A) 5.06 - 0.016 5.00 - 0.016 4.95 - 0.016 4.87 - 0.016 4.50 - 0.000
Table 5.
Standby consumption at VIN = 230 VAC
+3.3 V @load(A) 3.33 - 0.110 3.33 - 0.077 3.33 - 0.054 3.33 - 0.021 3.33 - 0.000 POUT(W) 0.081 0.080 0.079 0.078 0.000 PIN(W) 1.220 1.045 0.925 0.740 0.480
+5 V @load(A) 5.06 - 0.016 5.00 - 0.016 4.95 - 0.016 4.87 - 0.016 4.50 - 0.000
2.5
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, mainly based on a capacitive divider formed by the resonant capacitor C28 and the capacitor C34, followed by an integration cell D12, R45, C39) and the signal is fed into the ISEN pin. This 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 ISEN pin exceeds 0.8V, 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.
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Electrical test results
AN2509
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 device and, in case of continuous overload/short circuit, results in continuous intermittent operation with a user-defined duty cycle. This function is controlled by the DELAY pin 2 of the resonant controller, by means of the 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 internal generator is turned off, so that C24 is slowly discharged by R37. The IC restarts 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 is triggered, the device shuts down and the operation resumes after an on-off cycle. Figure 19 illustrates the 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. In order to allow a long soft-start time, that lets the tank current at start-up increase gradually, a high value capacitor should be connected on the CSS pin. Anyway, values above 1-2 F should not be used, otherwise, during short circuit, the CSS pin internal switch will not be able to properly discharge this capacitor and, therefore, the operating frequency will not increase quickly to the maximum value and the throughput power will not be reduced as desired. To resolve this problem, the circuit based on Q12, C61 and R88 can be used (see Figure 2) in addition to C23 and R34. The voltage increase across C23, and therefore the soft-start duration, mostly depends on the C61 capacitor value and on the high gain of transistor Q12, while, during short circuit, the small value capacitor C23 can be quickly discharged to push frequency to the maximum programmed value. Figure 19. +200 V output short-circuit waveforms
Ch1: L6599 pin 2 (DELAY) Ch2: resonant tank current Ch3: L6599 pin 6 (ISEN) Ch4: +200 V output voltage
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AN2509
Thermal tests
2.6
Overvoltage protection
Both the PFC pre-regulator and the resonant converter are equipped with their own overvoltage protection circuit. The PFC controller is internally equipped with a dynamic and a static overvoltage protection circuit sensing the current flowing through the error amplifier compensation network and entering in the COMP pin (#2). When this current reaches about 18 A, the output voltage of the multiplier is forced to decrease, thus reducing the energy drawn from the mains. If the current exceeds 20 A, the OVP is triggered (Dynamic OVP), and the external power transistor is switched off until the current falls approximately below 5 A. However, if the overvoltage persists (e.g. in case the load is completely disconnected), the error amplifier will eventually saturate low, triggering an internal comparator (Static OVP) that keeps the external power switch turned off until the output voltage comes back close to the regulated 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, disconnection or deviation from the nominal value of the feedback loop divider. The PFC output voltage is always under control and if a fault condition is detected, the PFC_OK circuitry latches the PFC operation and using the PWM_LATCH pin 8, it also latches the L6599 via the DIS pin of the resonant controller. The OVP circuit (see Figure 3) for the output voltages of the resonant converter uses resistive dividers (R75, R76, R80, R81, R82) and the zener diodes D21 and D23 to sense the +200 V and +75 V outputs. If the sensed voltage exceeds the threshold imposed by either 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.
3
Thermal tests
In order to check the design reliability, a thermal mapping by an IR Camera was performed. Figure 20 and Figure 21 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 in Table 6. All other board components work well 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 winding (Cu). Table 6. Key components temperature at nominal voltages and full load
Point A B C D E Item D2 L4-(FE) L4-(CU) Q1 R2 230 VAC 40,3C 44,2C 46,0C 44,5C 63,5C 115 VAC 47,6C 50,5C 55,5C 53,4C 73,0C
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Thermal tests Table 6. Key components temperature at nominal voltages and full load
Point F G H I J K L M N O P Q R S Item D3 C8 Q6 T1-(CU) T1-(FE) U5 D14 C38 C45 D8A R22 D15 D16 T2 230 VAC 46,1C 39,3C 51,4C 63,7C 51,3C 53,2C 51,8C 39,4C 36,1C 44,5C 41,4C 43,3C 42,6C 43,3C
AN2509
115 VAC 51,0C 40,1C 52,8C 62,6C 49,6C 53,4C 52,3C 38,5C 35,7C 44,9C 55,6C 43,5C 42,1C 43,6C
Figure 20. Thermal map @115 VAC - full load
Figure 21. Thermal map at 230 VAC - full load
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AN2509
Conducted emission pre-compliance test
4
Conducted emission pre-compliance test
The measurements have been taken in peak detection mode, both on LINE and on Neutral at nominal input mains and at full load. The limits indicated on the following diagrams refer to the EN55022 Class- B specifications (the higher limit curve is the quasi-peak limit while the lower curve is the average limit) and the measurements show that the PSU emission is well below the maximum allowed limit. Figure 22. Peak measurement on LINE at 115 VAC and full load
Figure 23. Peak measurement on Neutral at 115 VAC and full load
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Conducted emission pre-compliance test Figure 24. Peak measurement on LINE at 230 VAC and full load
AN2509
Figure 25. Peak measurement on Neutral at 230 VAC and full load
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AN2509
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 470 nF-X2 330 nF-X2 680 nF-X2 470 nF/630 V 470 nF/630 V 470 nF/630 V 330 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 100 nF 470 nF 22 F/250 V 270 pF 100 nF 47 nF/630 V 100 F/250 V 100 F/250 V 10 F/50 V 100 nF 4nF7 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 50 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
23/37
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 C59 C60 C61 D1 D2 D3 D4 D5 D6 D7 D8A D8B D9
AN2509
Bill of materials (continued)
Part 220 pF/630 V 47 F/100 V 220 F/100 V 220 F/100 V 1 F0 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 2nF2 100 nF 10 F/50 V 100 nF 1nF0 10 nF 47 nF/250 V 470 nF 470 nF 1N5406 D15XB60 STTH8R06 LL4148 LL4148 LL4148 LL4148 BYT08P-400 BYT08P-400 LL4148 Description POLYPROPYLENE CAPACITOR HIGH RIPPLE PFR ALUMINIUM ELCAP YXF SERIES 105 DEG ALUMINIUM ELCAP YXF SERIES 105 DEG ALUMINIUM ELCAP YXF SERIES 105 DEG 25 V 1206 SMD CERCAP GENERAL PURPOSE 100 V 1206 SMD CERCAP GENERAL PURPOSE ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG 100V 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 POLCAP PHE426 SERIES 25 V 1206 SMD CERCAP GENERAL PURPOSE 50 V CERCAP X7R GENERAL PURPOSE RECTIFIER SINGLE PHASE BRIDGE RECTIFIER TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER MINIMELF FAST SWITCHING DIODE MINIMELF FAST SWITCHING DIODE MINIMELF FAST SWITCHING DIODE MINIMELF FAST SWITCHING DIODE TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER MINIMELF FAST SWITCHING DIODE 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 RIFA-EVOX VISHAY BC COMPONENTS VISHAY SHINDENGEN STMicroelectronics VISHAY VISHAY VISHAY VISHAY STMicroelectronics STMicroelectronics VISHAY
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AN2509 Table 7.
Item D10A D10B D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 F1 J1 J2 J3 L1 L2 L3 L4 L5 L6 L7 L8 Q1 Q2 Q3 Q5 Q6 Q7 Q8
Bill of materials Bill of materials (continued)
Part STTH1002C STTH1002C LL4148 LL4148 C-12V PKC-136 1N5822 1N5821 LL4148 B-10 V C-30 V BAV103 B-15 V C-15 V B-15 V 8A/250 V CON2-IN CON8 CON10 Description TO220FP ULTRAFAST MEDIUM VOLTAGE RECTIFIER TO220FP ULTRAFAST MEDIUM VOLTAGE RECTIFIER MINIMELF FAST SWITCHING DIODE MINIMELF FAST SWITCHING DIODE BZV55-C SERIES ZENER DIODE PEAK CLAMP TRANSIL 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 5X20 HIGH CAPABILITY & FUSEHOLDER 3 PINS CONN. (CENTRAL REMOVE) P 3.96 KK SERIES 8 PINS CONNECTOR P 3.96 KK SERIES 10 PINS CONNECTOR P 2.54 MTA SERIES LFR2205B SERIES COMMON MODE INDUCTOR TF3524 SERIES COMMON MODE TOROIDAL INDUCTOR LSR2306-1 DIFF. MODE TOROIDAL INDUCTOR 86H-5410B BOOST INDUCTOR ELC08 DRUM CORE INDUCTOR ELC08 DRUM CORE INDUCTOR ELC08 DRUM CORE INDUCTOR ELC08 DRUM CORE INDUCTOR TO220FP N-CHANNEL POWER MOSFET 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 Supplier STMicroelectronics STMicroelectronics VISHAY VISHAY VISHAY STMicroelectronics STMicroelectronics STMicroelectronics VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY WICKMANN MOLEX MOLEX AMP DELTA TDK DELTA DELTA PANASONIC PANASONIC PANASONIC PANASONIC STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics
CM-1.5 mH-5 A CM-10 mH-5 A DM-51 H-6 A PQ40-500 H 10 H 22 H 33 H 33 H STP12NM50FP STP12NM50FP BC857C STP14NK50Z STP14NK50Z BC547C BC847C
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Bill of materials Table 7.
Item Q9 Q10 Q11 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R28 R29 R30 R31 R32 R33 R34
AN2509
Bill of materials (continued)
Part BC857C BC847C BC547C 1M5 Description 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% 200 ppm/C 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 1/8 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 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 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 PR02 POWER RESISTOR PR02 POWER RESISTOR PR02 POWER RESISTOR PR02 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 Supplier STMicroelectronics STMicroelectronics STMicroelectronics BC COMPONENTS EPCOS 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
NTC 2R5-S237 680 k 47 2M2 680 k 2M2 680 k 2M2 100 k 15 k 56 k 3k3 6R8 5k1 15 k 6R8 1K0 1k0 0R39 0R39 0R39 0R39 30 k 150 k 240 k 1k5 620 k 620 k 10 k 0R 2k7
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AN2509 Table 7.
Item R35 R36 R37 R38 R39 R40 R41 R42 R43 R45 R46 R47 R48 R49 R50 R52 R53 R54 R56 R58 R59 R60 R61 R62 R64 R66 R67 R68 R69 R70 R71 R72 R73 R74 R75
Bill of materials Bill of materials (continued)
Part 47 0R 2M2 47 0R 47 16 k 10 150 82R 1k5 10 k 56 k 56 k 56 k 3k3 75 k 1k5 1k0 75 k 1k0 6k2 2k7 47 1k6 1k0 1k0 22 k 0R 22R 10 k 10 k 8k2 10 k 150 k Description 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 1/4 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 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 0805 SMD STANDARD FILM RES 1/8 W 5% 200 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 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 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 1/8 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 1/8 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 1/8 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 1/8 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 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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Bill of materials Table 7.
Item R76 R77 R79 R80 R81 R82 R83 R84 R86 R87 R88 T1 T2 U1 U2 U3 U4 U5 U6 U7 U8
AN2509
Bill of materials (continued)
Part 150 k 4k7 2k2 30 k 30 k 100 k 1M0 150 k 470R 220R 560 K T-RES-ER49400W Description 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 1% 100 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 VR25 TYPE HIGH VOLTAGE RESISTOR STANDARD METAL FILM RES 1/4 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 STANDARD METAL FILM RES 1/4 W 5% 200 ppm/C 86H-5408B TYPE RESONANT TRANSFORMER ER49 86A-6079-R TYPE FLYBACK TRANSF. E20 CORE ADVANCED TRANSITION MODE PFC CONTROLLER HIGH VOLTAGE RESONANT CONTROLLER 63-125% CTR SELECTION OPTOCOUPLER TO92 PROGR. SHUNT VOLTAGE REGULATOR LOW POWER OFF LINE SMPS PRIMARY SWITCHER 63-125% CTR SELECTION OPTOCOUPLER TO92 PROGR. SHUNT VOLTAGE REGULATOR 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 DELTA DELTA STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics INFINEON STMicroelectronics INFINEON
T-FLY-AUX-E20 L6563 L6599 SFH617A-2 TL431 VIPER12A SFH617A-2 TL431 SFH617A-2
Note:
Q9 and R72: mounted by reworking on PCB Q11, Q12, R83, R84, R86, R87, R88, C58, C59, C60 and C61: added by reworking on PCB
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AN2509
PFC coil specification
6
PFC coil specification
Application type: consumer, home appliance Inductor type: open Coil former: vertical type, 6+6 pins Max. temp. rise: 45 C Max. operating ambient temp.: 60 C
6.1
Electrical characteristics
Conver ter topology: FOT PFC Preregulator Core type: PQ40-30 material grade PC44 or equivalent Max operating freq: 100 KHz Primary inductance: 500 H 10% @1 KHz-0.25 V (see Note: 1) Primary RMS current: 4.75 A
Note:
1
Measured between pins 2-3 and 10-11. Figure 26. Electrical diagram
2
The auxiliary winding is not used in this design, but is foreseen for another application. Table 8.
Start PINS 11 5-6
Winding characteristics
End PINS 8 1-2 Turn number 5 (spaced) 65 Wire type Single Multistrand G2 Wire diameter Ø 0.28 mm Litz Ø 0.2 mm x 30 Notes Bottom Top
6.2
Mechanical aspect and pin numbering
Maximum height from PCB: 45 mm Cut pins: 9-12 Pin distance: 5 mm Row distance: 45.5 mm External copper shield 15 x 0.05 (mm) connected to pin 11 by tinned wire
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Resonant power transformer specification Figure 27. Pin side view
AN2509
Manufacturer : DELTA ELECTRONICS P/N: 86H-5410
7
Resonant power transformer specification
Application type: consumer, home appliance Transformer type: open Coil former: horizontal type, 7+7 pins, 2 slots Max. temp. rise: 45 C Max. operating ambient temp.: 60 C Mains insulation: ACC. with EN60065
7.1
Electrical characteristics
Conver ter topology: half-bridge, resonant Core type: ER49 - PC44 or equivalent Min. operating frequency: 75 Khz Typical operating freq: 120 KHz Primary inductance: 240 H 10% @1 KHz - 0.25 V [see Note 1] Leakage inductance: 40 H 10% @1 KHz - 0.25 V [see Note 1] - [see Note 2]
Note:
1 2
Measured between pins 1-3 Measured between pins 1-3 with the secondary windings shorted
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AN2509 Figure 28. Electrical diagram
Resonant power transformer specification
14 SEC. A 13 SEC. B 1 PRIM. 3 11 SEC. C 10 9 SEC. D 8 12
Table 9.
Pins 1-3 14 - 13 13 - 12 11 - 10 9-8
Winding characteristics
Winding PRIMARY SEC. A SEC. B
(1) (1)
RMS current 2.90 ARMS 1.7 ARMS 1.7 ARMS 1.15 ARMS 1.15 ARMS
N turns 19 11 11 7 7
Wire type Litz Ø 0.2 mm x 20 Litz Ø 0.2 mm x 10 Litz Ø 0.2 mm x 10 Litz Ø 0.2 mm x 20 Litz Ø 0.2 mm x 20
SEC. C (2) SEC. D
(2)
1. Secondary windings A and B must be wound in parallel 2. Secondary windings C and D must be wound in parallel
Figure 29. Mechanical aspect and pin numbering
Note:
Cut PIN 7
Manufacturer : DELTA ELECTRONICS P/N: 86H-5408
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Auxiliary flyback power transformer
A N25 0 9
Table 10.
Mechanical dimensions
A B 3.5 0.5 C 41.6 0.4 D 51 max E 7.0 0.2 F 51.5 max
Dimensions (mm)
39.0 max
Figure 30. Winding position on coil former
COIL FORMER PRIMARY SECONDARY
8
Auxiliary flyback power transformer
Application type: consumer, home appliance Transformer type: open Winding type: layer Coil former: horizontal type, 4+5 pins Max. temp. rise: 45 C Max. operating ambient temp.: 60 C Mains insulation: ACC. with EN60065
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] Max. PEAK primary current: 0.38 Apk RMS primary current: 0.2 ARMS
Note:
1 2
Measured between pins 4-5 Measured between pins 4-5 with secondary windings shorted
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AN2509 Figure 31. Electrical diagram
5 PRIM 4 2 AUX 1
Auxiliary flyback power transformer
6 +5V 7 8 +3.3V 10
Manufacturer : DELTA ELECTRONICS P/N: 86A - 6079 - R Winding characteristics
Winding PRIMARY AUX 3.3 V 5V RMS current 0.2 ARMS 0.05 ARMS 1.2 ARMS 1 ARMS N turns 140 29 7 3 Wire type G2 - Ø 0.25 mm G2 - Ø 0.25 mm TIW Ø 0.75 mm TIW Ø 0.75 mm
Table 11.
Pins: start - end 4-5 2-1 8- 10 6-7
Figure 32. Auxiliary transformer winding position on coil former
COIL FORMER
3.3V / 5V AUX PRIMARY
INSULATING TAPE
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Board layout
AN2509
9
Board layout
Figure 33. Copper tracks
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AN2509 Figure 34. Thru-hole component placing and top silk screen
Board layout
Figure 35. SMT component placing and bottom silk screen
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References
AN2509
10
References
1. 2. 3. 4. "L6563/L6563A advanced transition-mode PFC controller" Datasheet "Design of Fixed-Off-Time-Controlled PFC Pre-regulators with the L6562", AN1792 "L6599 high-voltage resonant controller" Datasheet "LLC resonant half-bridge converter design guideline", AN2450
11
Revision history
Table 12.
Date 13-Mar-2007 20-Mar-2007 23-Apr-2007
Revision history
Revision 1 2 3 First issue Minor text changes Cross references updated Table 7: Bill of materials modified Changes
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AN2509
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