STMicroelectronics EVL170W-FTV 170W Power Supply Application note
إعلان
إعلان
AN3329
Application note
170 W power supply with PFC and standby supply for flat TV using the L6564, L6599A, and Viper27LN
Introduction
This application note describes the characteristics and features of a 170 W, wide input mains range, power-factor-corrected, demonstration board for flat TVs or industrial applications. The electrical specifications are tailored to a typical flat TV.
The architecture is made up of three stages: a front-end PFC pre-regulator based on the
L6564 TM (transition mode) boost PFC controller and a downstream LLC resonant half bridge converter stage, built around the new L6599A resonant controller, which provides two regulated output voltages at 12 V and 24 V. In addition, a flyback-based standby supply delivers 10 W to a 5 V output. Thanks to the chipset used, this design achieves very high efficiency, compliant with ENERGY STAR
®
eligibility criteria (EPA rev. 2.0 EPS), as well as very low input consumption during standby operation.
Figure 1.
EVL170W-FTV: 170 W demonstration board
February 2011 Doc ID 18376 Rev 1 1/47 www.st.com
Contents
Contents
AN3329
Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 6
Efficiency measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 29
Resonant power transformer specifications . . . . . . . . . . . . . . . . . . . . 41
Auxiliary flyback transformer specifications . . . . . . . . . . . . . . . . . . . . 43
2/47 Doc ID 18376 Rev 1
AN3329
List of tables
List of tables
Doc ID 18376 Rev 1 3/47
List of figures
List of figures
AN3329
Standby supply burst mode operation at 230 Vac - 50 Hz - 10 mA load . . . . . . . . . . . . . . 15
Standby supply burst mode operation at 230 Vac - 50 Hz - 10 mA load-detail . . . . . . . . . 15
4/47 Doc ID 18376 Rev 1
AN3329 List of figures
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Main characteristics and circuit description
1 Main characteristics and circuit description
6/47
AN3329
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The main features of the SMPS are:
● Universal input mains range: 90
÷
264 Vac - frequency 45
÷
65 Hz
● Output voltage 1: 24 V ± 5 % at 6 A for backlight and audio supply
Output voltage 2: 12 V ± 3 % at 2 A for TV panel supply
Output voltage 3: 5 V ± 2 % at 2 A for microprocessor supply
Mains harmonics: acc. to EN61000-3-2 Class-D or JEITA-MITI Class-D
Standby mains consumption: at 230 Vac <150 mW with 50 mW load
Overall efficiency at full load: above 90 %
EMI: according to EN55022-Class-B
Safety: according to EN60065
Dimensions: 197x115 mm, 25 mm maximum component height from PCB
PCB: single side, 70 µm, CEM-1, mixed PTH/SMT.
The circuit is made up of two sections; a 10 W supply generating 5 V standby output, dedicated to supplying the TV microprocessor and the logic circuitry, and a larger section made up of a PFC front-end and an LLC resonant converter which provides two output voltages, one dedicated to supplying the TV panel, and one for the backlight and audio power amplifiers. The PFC stage delivers 400 V constant voltage and acts as a preregulator for both the LLC stage and the standby supply. An external signal, referred to as secondary ground, turns the PFC and LLC stages on and off.
Startup
At turn-on the standby supply starts up and delivers 5 V dedicated to the TV microprocessor and other logic circuitry. It also generates the auxiliary supply voltage for the PFC and LLC controllers at primary side via the linear regulator Q7. Q7 is activated by the optocoupler U5, that is driven by the logic signal on/off (active high). At startup, the on/off signal (delivered by the microprocessor) is supposed to be low, so the PFC and the LLC are off. Once the on/off signal is asserted high, the regulator Q7 provides 14 V to the L6564 PFC controller and the
L6599A LLC controller; to always ensure proper operation of the LLC, the circuit is designed so that the PFC starts first, then the downstream converter. The LINE pin of L6599A allows the resonant stage to operate only if the PFC output is delivering its rated output voltage. It prevents the resonant converter from working with an input voltage that is too low which may cause the undesirable capacitive-mode operation. The L6599A LINE pin internal comparator has a hysteresis allowing to set the turn-on and turn-off thresholds independently. The LLC turn-on voltage (PFC output) and the turn-off threshold are set to
380 V and 300 V respectively. This last value prevents the LLC stage operating in capacitive-mode but allows the resonant stage to operate even in the case of mains sag or dips lowering the PFC output voltage.
Brownout protection
Brownout protection prevents the circuit from working with abnormal mains levels. It is accomplished by both the Viper, through the brownout pin, and the L6564, through an internal comparator internally connected to the VFF pin (#5), which detects the mains voltage peak value. The internal comparators allow the IC operation with proper mains level only, as defined by power supply specifications, therefore, if the input voltage is below around 80 Vac (typ.), the circuit is not allowed to start up.
Doc ID 18376 Rev 1
AN3329 Main characteristics and circuit description
Resonant power stage
The downstream converter features the ST L6599A, which embeds all the functions needed to drive properly the resonant converter with 50 % fixed duty cycle and variable frequency.
The converter makes use of a transformer designed with the integrated magnetic approach, using the primary leakage as the resonant series inductance and the magnetizing inductance as the resonant shunt inductance. The transformer secondary-side is centertapped and power Schottky diodes are used as output rectifiers. Additional LC filter stages have been added on each output to minimize high-frequency ripple.
Output voltage feedback loop
The regulation feedback loop is implemented through a typical circuit using a TL431, which modulates the current through the optocoupler diode. In order to improve the cross regulation, the two resonant stage output voltages are regulated by a weighted feedback control, that is using a single rail to regulate multiple outputs. The feedback loop is closed to the primary side by R37, which connects the RFMIN (#4) pin of the resonant controller
L6599A to the optocoupler phototransistor and sets the maximum switching frequency at around 130 kHz. This value has been chosen to limit the switching losses at light load operation. On the same pin, R36 connected to ground, sets the minimum switching frequency. The RC series R22 and C21 sets both soft-start maximum frequency as well as duration.
L6599A overload and short-circuit protection
Half bridge primary-side current is sensed by the lossless circuit consisting of R53, C36,
D14, D12, R55, and C38 and is fed into the ISEN pin (#6). During an overcurrent event, the pin voltage rises to the internal comparator threshold (0.8 V), triggering the following protection sequence: the soft-start capacitor (C10) connected to the DELAY pin (#2) is charged by an internal 150 µA current generator and is slowly discharged by the resistor
R12. This pin is connected to the DIS (#8) pin and, if the voltage reaches 1.85 V, the IC stops switching, being latched off. Once latched, an on/off signal recycle is needed to restart the converter.
Overvoltage and open loop protection
Both PFC and resonant stages are provided with their own overvoltage protections. The
PFC controller L6564 monitors its output voltage through the resistor divider connected to the PFC_OK pin (#6) protecting the circuit in case of loop failure, disconnection, or deviation from the nominal value of the feedback loop divider. When a fault condition is detected, the
L6564 is shut down and latched off by an internal circuit monitoring the voltage on the
PFC_OK and INV pins, until the mains voltage is recycled. Upon the occurrence of an overvoltage condition, of either the 24 V or 12 V output of the resonant stage, the Zener diodes D16 and D17 conduct, respectively, forcing Q10 to be turned on by the resulting base current, which causes Q9 to conduct. These two transistors form a pnp-npn SCR (silicon controlled rectifier) structure that shorts to ground the anode of the U5 optocoupler in such a way that the IC supply voltage Vcc cannot be delivered to controllers by Q7, forcing them to be latched off until the mains voltage is recycled.
Doc ID 18376 Rev 1 7/47
Main characteristics and circuit description
Figure 2.
Electrical diagram
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AN3329
8/47 Doc ID 18376 Rev 1
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AN3329 Efficiency measurement
Table 1.
Table 1 shows the overall efficiency, measured at different mains voltages. The full load
efficiency is 90.09 % at 115 Vac, and 91.85 % at 230 Vac. Both values are considerably high
and maintained high even decreasing the load as reported in Table 1
. Measurements are also reported in the graph of
Overall efficiency measured at different AC input voltages
Load = 100 %
5 V 12 V 24 V Pout
Vin [Vrms] Vout [V] Iout [A] Vout [V] Iout [A] Vout [V] Iout [A]
90
115
230
265
5.01
5.01
5.01
5.01
1.99
1.99
1.99
1.99
11.69
11.69
11.69
11.69
2.01
2.01
2.01
2.01
23.47
23.48
23.48
23.48
5.98
5.98
5.98
5.98
Load = 75 %
5 V 12 V 24 V
Vin [Vrms] Vout [V] Iout [A] Vout [V] Iout [A] Vout [V] Iout [A]
90
115
230
265
5.01
5.01
5.01
5.01
1.51
1.51
1.51
1.51
11.70
11.70
11.70
11.70
1.51
1.51
1.51
1.51
23.49
23.49
23.49
23.49
Load = 50 %
4.50
4.50
4.50
4.50
5 V 12 V 24 V
Vin [Vrms] Vout [V] Iout [A] Vout [V] Iout [A] Vout [V] Iout [A]
90
115
230
265
5.01
5.01
5.01
5.01
1.00
1.00
1.00
1.00
11.71
11.72
11.71
11.71
1.01
1.01
1.01
1.01
23.51
23.51
23.51
23.51
3.00
3.00
3.00
3.00
Load = 25 %
5 V 12 V 24 V
Vin [Vrms] Vout [V] Iout [A] Vout [V] Iout [A] Vout [V] Iout [A]
90
115
230
265
5.02
5.02
5.02
5.02
0.49
0.49
0.49
0.49
11.72
11.72
11.72
11.72
0.50
0.50
0.50
0.50
23.53
23.53
23.53
23.53
1.51
1.51
1.51
1.51
Pout
[W]
87.5
87.5
87.5
87.5
Pout
[W]
43.83
43.83
43.83
43.83
Pout
[W]
130.9
130.9
130.9
130.9
[W]
173.8
173.9
173.8
173.8
Pin
[W]
98.6
97.7
96.6
96.5
Pin
[W]
50.82
50.57
50.47
50.29
Pin
[W]
147.5
145.5
143.0
142.7
Pin
[W]
197.5
193.6
189.3
188.9
Eff.
[%]
88.00 %
90.09 %
91.85 %
91.98 %
Eff.
[%]
88.78 %
89.96 %
91.56 %
91.73 %
Eff.
[%]
88.67 %
89.54 %
90.53 %
90.64 %
Eff.
[%]
86.25 %
86.67 %
86.85 %
87.16 %
Doc ID 18376 Rev 1 9/47
Efficiency measurement AN3329
The average efficiency has been calculated according to ENERGY STAR 2.0 criteria.
Results are summarized in
.
Figure 3.
Overall efficiency vs. output power Figure 4.
Average efficiency acc. ES-2
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Standby supply efficiency
Standby supply efficiency has been measured and the results are plotted in Figure 5
. As shown, the efficiency during rated load operation is above 82 %, over the whole input mains voltage range, from 50 % to full load.
Efficiency during standby operation at very light load, like microprocessor and wake-up circuitry, is plotted in
Figure 6 . As shown, in this condition it is higher than 35 % at 230 Vac,
therefore, it allows to supply the microprocessor with a significant low consumption from the mains. It should be mentioned that the standby supply efficiency has been calculated measuring the input power at the input connector, including power loss contribution due to all residual loads connected to mains before and after the input bridge rectifier, like the EMI filter and PFC resistor dividers.
Figure 5.
Standby supply efficiency vs. output power
Figure 6.
Standby supply efficiency vs. light load output power
10/47
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Doc ID 18376 Rev 1
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AN3329
3 Harmonic content measurement
Harmonic content measurement
The main purpose of a PFC pre-regulator is the input current shaping to reduce the harmonic content below the limits of the relevant regulations. This demonstration board has been tested according to the European standard EN61000-3-2 Class-D and Japanese standard JEITA-MITI Class-D, at full load and 75 W input power, at both the nominal input voltage mains.
Figure 7 to Figure 10 show the test results. Note that the PFC stage operates
properly as it effectively reduces harmonics well below the limits of both regulations in all conditions. Total harmonic distortion and power factor values are reported below in each diagram.
Figure 7.
EN61000-3-2 compliance at 230 Vac
- 50 Hz, full load
Figure 8.
JEITA-MITI compliance at
100 Vac - 50 Hz, full load
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Vin=230 Vac - 50 Hz, Pin=191 W
THD=4.52 %, PF=0.982
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Vin=100 Vac - 50 Hz, Pin=191 W
THD=3.97 %, PF=0.999
Figure 9.
EN61000-3-2 compliance at
230 Vac - 50 Hz, 75 W
Figure 10.
JEITA-MITI compliance at
100 Vac - 50 Hz, 75 W
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Vin=230 Vac - 50 Hz, Pin=75 W
THD=7.15 %, PF=0.867
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Vin=100 Vac - 50 Hz, Pin=75 W
THD=5.66 %, PF=0.999
Doc ID 18376 Rev 1 11/47
Harmonic content measurement AN3329
In Figure 11 and 12 the AC input voltage and current waveform at nominal input mains and
full load are reported for reference.
Figure 11.
Input voltage and current at 100
Vac, full load
Figure 12.
Input voltage and current at 230
Vac, full load
CH3: AC input voltage
CH4: input current
CH3: AC input voltage
CH4: input current
12/47 Doc ID 18376 Rev 1
AN3329 Functional check
Standby supply
Some salient waveforms of the standby supply during full load operation are reported in
and
. This converter is based on the Viper27LN, a device integrating the controller and the MOSFET in a single DIP-7 package. The Viper27LN version operates in fixed frequency mode at about 60 kHz, and frequency jitter technique is implemented to reduce EMI noise. In order to obtain good efficiency as well as reduced transformer size the converter has been designed to operate at full load in continuous conduction mode at low
mains voltage ( Figure 13 ) and discontinuous conduction mode at high mains voltage
(
), once the PFC and resonant stages are off. It can be noted from the drain waveforms that the typical ringing at turn-off is limited, thanks to the small value of the transformer's primary leakage inductance, allowing limited power dissipation on the Transil diode D19 and therefore enhancing the efficiency at rated load. D19 acts as a clamper and allows to limit the drain peak voltage below the Viper27LN maximum rating even with maximum input voltage and full load operation.
Figure 13.
Standby supply waveforms at
115 Vac - 60 Hz, full load
Figure 14.
Standby supply waveforms at
230 Vac - 50 Hz, full load
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: V
DD
(pin #2)
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: V
DD
(pin #2)
CH4: FB (pin #4)
In
Figure 15 the converter waveforms are captured while the PFC is working and the
standby supply is powered with 400 V. The margin with respect to the Viper27LN maximum drain voltage can be noted on the sidebar on the right.
In
Figure 16 typical waveforms relevant to the secondary side have been captured; the
maximum reverse voltages applied to the rectifier at 400 V during full load operation with
PFC working are, even in this case, well below the component's maximum ratings, ensuring long term reliability.
Doc ID 18376 Rev 1 13/47
Functional check AN3329
Figure 15.
Standby supply waveforms at
400 Vdc, full load
Figure 16.
Standby supply output rectifiers
PIV at 400 Vdc, full load
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: V
DD
(pin #2)
CH4: FB (pin #4)
CH3: PIV D22 CH4: PIV D18
In
Figure 17 the 5 V standby output voltage ripple has been captured during operation at
115 Vac of the standby converter only. Ripple and noise measured at full load are very limited.
shows the waveforms during the startup of the standby converter only, at 115 Vac and full load. At Viper27LN power-on the Vcc capacitor is charged by the internal startup current source until its voltage reaches the turn-on threshold. At this point the Viper27LN starts operating and the output voltage rises to reach the nominal value. During the converter startup, the Viper27LN internal digital fixed time-based (8.5 ms) soft-start gradually increases the drain current to its maximum value. In this way the stress on the secondary diode is considerably reduced and transformer saturation is prevented. The brownout circuit prevents the Viper27LN from starting up during abnormal mains conditions.
Figure 17.
Standby supply 5 V ripple at
115 Vac - 60 Hz, full load
Figure 18.
Standby supply startup at 115 Vac -
60 Hz, full load
CH3: + 5 V standby ripple voltage
14/47
CH1: DRAIN (pin #8)
CH3: BO (pin #5)
CH2: +5 V standby
CH4: V
DD
(pin #2)
Doc ID 18376 Rev 1
AN3329 Functional check
and
Figure 20 illustrate the waveforms during light load operation. Viper27LN
operates in burst-mode, with just a few pulses per burst, minimizing switching losses and therefore improving efficiency under light load operation, making it suitable for equipment with low standby consumption requirements.
Figure 19.
Standby supply burst mode operation at 230 Vac - 50 Hz - 10 mA load
Figure 20.
Standby supply burst mode operation at 230 Vac - 50 Hz - 10 mA load-detail
CH1: DRAIN (pin #8)
CH3: +5 V standby
CH2: V
DD
(pin #2)
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: +5 V standby
CH2: V
DD
(pin #2)
CH4: FB (pin #4)
Figure 21.
Standby supply OVP at 115 Vac -
60 Hz, full load
Figure 22.
Standby supply OVP at 230 Vac -
50 Hz - 0.5 A
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: +5 V standby
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: +5 V standby
CH2: V
DD
(pin #2)
shows the OVP response, observed opening the Viper27LN feedback loop. If the output voltage value exceeds the internal threshold set by the resistor divider connected to the CONT pin (#3), the Viper27LN stops working, providing protection against dangerous voltages which may damage the system. It remains latched until the V
DD
has dropped down to V
DD_RESTART
(4.5 V). At this point the auto-restart process takes place like any startup; the internal current source charges the V
DD
capacitor until it reaches the V
DDon
threshold
Doc ID 18376 Rev 1 15/47
Functional check AN3329 and switching starts again. This protection and restart sequence lasts as long as the OVP condition is removed. It is important to highlight that the Viper27LN OVP protection, thanks to the internal logic, ensures a stable OVP intervention point, independent of the output load, even if the voltage sensing is done on auxiliary winding at primary side. It can be noted, by comparing
which report some OVP intervention with different loads and input voltage conditions, that the maximum output voltage peak has a negligible variation.
Figure 23.
Standby supply OVP at 115 Vac -
60 Hz - PFC on - 1 A
Figure 24.
Standby supply OVP at 115 Vac -
60 Hz - PFC on - 1 A
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: +5 V standby
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: 5 V standby
CH4: FB (pin #4)
Figure 25.
Standby supply output short-circuit at 230 Vac - 50 Hz, full load
Figure 26.
Standby supply output short-circuit at 230 Vac - 50 Hz, full load - detail
CH1: DRAIN (pin #8)
CH3: V
DD
(pin #2)
CH2: +5 V standby
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: V
DD
(pin #2)
CH2: 5 V standby
CH4: FB (pin #4)
Figure 24 shows, in detail, the OVP intervention at 115 Vac. In Figure 25 a short-circuit
event on the standby supply output has been captured. In this situation the Viper27LN enters a safe hiccup mode, providing protection against overheating of the auxiliary converter power components.
16/47 Doc ID 18376 Rev 1
AN3329 Functional check
In
details of Viper27LN operation at short detection is captured; once an output short-circuit is detected, an internal current source charges the device internal circuitry and stops the auxiliary converter operation until the V
DD
voltage drops down to V
DD_RESTART
(4.5 V). At that time the internal HV current source is activated and charges the V
DD capacitor until it reaches the V
DDon
threshold, then the Viper27LN restarts switching via a soft-start cycle. Hiccup cycles are repeated as long as the short-circuit condition lasts.
Viper27LN is resumed back to normal operation only when the short-circuit condition is removed.
and
show the load regulation for the 5 V standby output. The standby supply has been tested in the most critical situation, the transition from full load to no load and vice versa. In fact, when a flyback converter is operating at full load, typically the self supply voltage V
DD
spike is quite high, due to the effect of the leakage inductance. Once the load is decreased or removed, V
DD
tends to reduce. Since the circuit works in burst-mode during no load operation, at high mains the burst pulses have a low repetition rate due to the almost negligible residual load. In this condition the V
DD
might drop below V
DD_RESTART
(4.5 V), causing the auto-restart cycles activation by the controller and consequent reset by the microprocessor powered by the 5 V standby. As can be seen in
transitions are clean and there is no output voltage or Vcc dip.
Figure 27.
Standby supply dynamic load at
115 Vac - 60 Hz - PFC off
Figure 28.
Standby supply dynamic load at
115 Vac - 60 Hz - PFC on
CH1: FB (pin #4)
CH3: +5 V standby
CH2: V
DD
(pin #2)
CH4: 5 V stby current
CH1: FB (pin #4)
CH3: 5 V standby
CH2: V
DD
(pin #2)
CH4: 5 V stby current
Doc ID 18376 Rev 1 17/47
Functional check AN3329
Power factor corrector stage
shows the PFC MOSFET's drain voltage, inductor current, and voltages on the
CS (#4) and MULT (#3) pins along a line half-period at 115Vac. Low current distortion and high power factor are achieved as the peak inductor current waveform follows the MULT pin.
THD (total harmonic distortion) is considerably reduced by the L6564 THD optimizer.
In
Figure 30 the same signals are captured at the top of the input sine wave. Transition
mode control makes the inductor work on the boundary between continuous and discontinuous conduction mode. When the PFC MOSFET turns on, the inductor current ramps up, until the voltage on the current sense input reaches the reference level programmed by the internal multiplier block. At that point, the PWM comparator changes state, turning off the power switch. During the MOSFET off-time, the current ramps down until it reaches zero, so the inductor is demagnetized. The zero current detection (ZCD) circuit detects that point by monitoring the voltage across the inductor auxiliary winding, which falls to zero when the current reaches zero, due to the resonance between the inductor and the drain capacitance. Once the demagnetization point is detected by the
L6564 internal logic, the signal on ZCD drives the MOSFET on again and another switching cycle begins. A significant advantage of TM operation is the possibility to work in ZVS: if the instantaneous input voltage of the converter is lower than the inductor voltage, the ZVS
(zero voltage switching) condition is achieved, decreasing MOSFET commutation losses.
However, if the instantaneous input voltage is higher than the inductor voltage the MOSFET is turned on at the minimum voltage, on the valley point of the resonance, still minimizing the transition losses, as seen in
.
Figure 29.
PFC Vds and inductor current at
115 Vac - 60 Hz, full load
Figure 30.
PFC Vds and inductor current at
115 Vac - 60 Hz, full load - detail
CH1: Q1 drain voltage
CH3: CS (pin #4)
CH2: MULT (pin #3)
CH4: L1 inductor current
CH1: Q1 drain voltage CH2: MULT (pin #3)
CH3: CS (pin #4) CH4: L1 inductor current
and
Figure 32 show the same waveforms at 230 Vac. As the input voltage is
higher than the inductor voltage, it is possible to observe the boost inductor resonating with the total drain capacitance with an amplitude of twice the inductor voltage on the offset of the input voltage. In order to maximize efficiency the RC network connected to the ZCD (#7) pin is tuned to make the turn-on of the MOSFET occur just on the valley of the drain voltage.
18/47 Doc ID 18376 Rev 1
AN3329 Functional check
Figure 31.
PFC Vds and inductor current at
230 Vac - 50 Hz, full load
Figure 32.
PFC Vds and inductor current at
230 Vac - 50 Hz, full load - detail
CH1: Q1 drain voltage
CH3: CS (pin #4)
CH2: MULT (pin #3)
CH4: L1 inductor current
CH1: Q1 drain voltage CH2: MULT (pin #3)
CH3: CS (pin #4) CH4: L1 inductor current
L6564 signals are shown in
Figure 33 and 34 for reference.
Figure 33.
L6564 signals-1 at 115 Vac - 60 Hz, full load
Figure 34.
L6564 signals-2 at 115 Vac - 60 Hz, full load
CH1: GD (pin #9)
CH3: MULT (pin #3)
CH2: ZCD (pin #7)
CH4: CS (pin #4)
CH1: GD (pin #9)
CH3: MULT (pin #3)
CH2: ZCD (pin #7)
CH4: CS (pin #4)
shows voltages on the VFF (#5), CS (#4), COMP (#2), and MULT (#3) pins along a line half-period at 115 Vac and 230 Vac respectively. Voltage feed-forward compensates for the gain and crossover frequency variation with the line voltage, since the power stage gain of PFC pre-regulators varies with the square of the RMS input voltage. Therefore, a DC voltage equal to the peak of the MULT (#3) pin is derived on the VFF (#5) pin and fed into a square/divider circuit making the COMP signal almost line-independent and improving the
dynamic behavior. That is emphasized in Figure 36 , which illustrates voltage on the MULT
(#3) pin at the peak of the line voltage matching that on the VFF pin.
Doc ID 18376 Rev 1 19/47
Functional check AN3329
Figure 35.
PFC signals-1 at 115 Vac - 60 Hz, full load
Figure 36.
PFC signals-2 at 115 Vac - 60 Hz, full load
CH1: COMP (pin #9)
CH3: MULT (pin #3)
CH2: VFF (pin #7)
CH4: CS (pin #4)
CH1: COMP (pin #9)
CH3: MULT (pin #3)
CH2: VFF (pin #7)
CH4: CS (pin #4)
20/47 Doc ID 18376 Rev 1
AN3329 Functional check
Resonant stage
Some waveforms relevant to the resonant stage during steady-state operation are reported in
, and
. The switching frequency at full load and nominal input voltage is around 75 kHz, in order to achieve a good trade-off between transformer losses and size.
shows the resonant ZVS operation. The converter operates slightly below resonance, therefore, the resonant current lags the voltage applied, as input impedance of the resonant network is inductive. The current is negative during the rising edge of half bridge voltage and positive during the falling-edge, providing, in both cases, the energy to allow the node HB swinging. Because of the dead time, the MOSFETs are turned on when resonant current is flowing through their body diodes and drain-source voltage is almost zero. In
Figure 38 voltages on the L6599A LINE (#7), RFmin (#4), CF (#3), and LVG
(#11) pins are observed. The switching frequency is programmed by the resistors connected to the RFmin (#4) pin, which provides an accurate 2 V reference. The current flowing out from the RFmin (#4) pin is internally mirrored and alternately charges and discharges the capacitor connected to CF (#3). LINE (#7) pin voltage enables and disables the resonant stage, preventing operation in capacitive mode.
Figure 37.
Resonant stage waveforms at 115 V
- 60 Hz, full load
Figure 38.
Resonant stage waveforms at 115 V
- 60 Hz, full load
CH1: HB voltage
CH3: HVG
CH2: LVG
CH4: C39 current
CH1: LVG (pin #11)
CH3: RFmin (pin #4)
CH2: CF (pin #3)
CH4: LINE (pin #7)
In
Figure 39 the reverse voltages across secondary rectifiers are represented. The system
operates slightly below resonance and therefore the output rectifiers are working in discontinuous conduction mode, as energy transfer ends before each node HB voltage swinging. Therefore, at primary side there are some short intervals where both diodes are reverse-biased and the magnetizing inductance Lp, being no longer shunted by the output capacitance reflected to the primary, becomes part of resonance. This corresponds to the primary side current waveform to the portion circled in blue.
In the same image, it can be noted that the rectifiers PIV are operating within their voltage rating and well below the BV, so ensuring long term reliability.
Doc ID 18376 Rev 1 21/47
Functional check
Figure 39.
Output rectifiers PIV waveforms
AN3329
CH1: D4 anode voltage
CH3: D9A anode voltage
CH2: D11 anode voltage
CH4: D9B anode voltage
No load operation
In
Figure 40 and 41 operation at no load is shown. This check has been done for reference
only, as typically a TV SMPS never works in such conditions. As seen, PFC is working in burst-mode, while the resonant stage is operating in continuous switching. This is possible by connecting the standby pin to the RFmin pin and it has been done to avoid any possible interference between the resonant stage and the TV circuitry. In
the half bridge maximum operating switching frequency is measured.
Figure 40.
No load operation at 115 Vac - 60 Hz Figure 41.
No load operation at 115 Vac - 60 Hz
- L6599A signals
CH1: HB voltage CH4: PFC drain voltage CH1: HB voltage
CH3: Standby (pin #5)
CH2: CF (pin #3)
22/47 Doc ID 18376 Rev 1
AN3329 Functional check
Dynamic load operation and output voltage regulation
and
show the output voltage regulation in the case of load transients on both the resonant stage outputs. The waveforms have been captured applying a load transient from 0 to full load to one output while the other is delivering full load. The period of load steps has been selected very long (1 s), to allow the output voltage to reach the steady-state condition and output voltage waveforms have been captured using the DC coupling of the scope to avoid waveform distortions caused by the AC coupling. A suitable offset has been also added to waveforms in order to get the maximum resolution.
reports the output voltage regulation with a dynamic load on 24 V output while the 12 V output is delivering the 2 A rated load. It can be noted that the 24 V output voltage has a tight variation, because even considering the spikes at the current edges, it is within
+/- 4 %.
it is possible to see the output voltage regulation with a dynamic load on the 12 V output, while the 24 V output is delivering the 6 A rated load. It can be noted that the 12 V output has a very tight variation - within +/- 3 %.
Figure 42.
12 V - 2 A; 24 V 0 ÷ 6 A transition at
115 Vac - 60 Hz
Figure 43.
24 V - 6 A; 12 V 0 ÷ 2 A transition at
115 Vac - 60 Hz
CH1: +24 V O/P voltage CH2: +24 V O/P current CH1: +12 V O/P voltage CH2: +12 V O/P current
Cross regulation
and
show the output voltage cross regulation similar to previous tests but at
300 Hz load step frequency on one output, with the other delivering the rated load.
shows the simulation of the backlight and audio amplifier connected to the 24 V output. Load is varying from minimum to maximum and vice versa, as typically happens in a flat-TV because of backlight dimming and audio power amplifiers. Even in this condition, the
24 V output has a maximum deviation of
±
4 %, mainly due to the series filter inductor L4.
The 12 V output variation due to the dynamic load on 24 V (cross-regulation) is
±
2 %, therefore very tight and suitable to power properly the internal logic of the LCD panel.
In Figure 45 cross regulation between the 12 V and 24 V has been measured. In this image
the 12 V load is changing from 1 to 2 A, as may happen when powering the LCD panel, and the variation of 24 V at rated load is measured. It can be noted in the image that the 12 V output has a deviation less than
± load on 12 V (cross-regulation) is
1.2 %, while the 24 V output variation due to the dynamic
±
0.5 %.
Doc ID 18376 Rev 1 23/47
Functional check
Figure 44.
12 V - 2 A; 24 V 0 ÷ 6 A - 300 Hz transition at 115 Vac - 60 Hz
AN3329
Figure 45.
24 V - 6 A; 12 V 1 ÷ 2 A - 300 Hz transition at 115 Vac - 60 Hz
CH2: +12 V O/P voltage CH3: +24 V O/P voltage
CH4: +24 V O/P current
CH2: +12 V O/P voltage CH3: +24 V O/P voltage
CH4: +12 V O/P current
24/47
Overcurrent and short-circuit protection
The L6599A is provided with a current sensing input (pin #6, ISEN) and a dedicated overcurrent management system. Current flowing in the resonant tank is detected and the signal is fed into the ISEN pin, which is internally connected to a first comparator, referenced to 0.8 V, and to 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 and discharge the soft-start capacitor CSS, increasing the switching frequency and so limiting the output power, while the second, referenced to 1.5 V, latches the L6599A, protecting the circuit against dead short-circuit. These two comparators, together with the
DELAY pin (#2) are dedicated to offering the possibility of implementing the overload protection in either auto-restart or latch mode, according to the whole equipment needs. In this case, being a flat TV, the final application to which this demonstration board is dedicated, the desired overload and short protection is latched.
If the 12 V output is failing short-circuit as in Figure 46 , the ISEN pin (#6) voltage rapidly
rises over 1.5 V, triggering the second comparator of the overcurrent protection. In this case, as shown, the protection intervention is very quick, protecting properly the circuit. Then, the
L6599A shuts down and operation can be resumed after an off-on signal or a mains voltage
details of half bridge voltage and current during the higher current peaks have been captured, showing the correct ZVS operation by the circuit.
If the 24 V output is failing shorts (
), the L6599A ISEN pin reaches 0.8 V, triggers the first comparator, and the capacitor C10 connected to the DELAY and DIS pins, starts being charged by an internal 150 µA current generator while the soft-start capacitor C21 is discharged, increasing the switching frequency to limit the output power. When the voltage on the DELAY and DIS pins reaches 1.85 V, an internal comparator is triggered, then the
L6599A is shut down and its consumption is reduced. The PFC_STOP pin is pulled down.
The capacitor C10 is discharged by the external resistor R12. The latch condition is kept until the L6599A Vcc drops below the UVLO. Therefore, to resume the operation an off-on
signal or a mains voltage recycling is necessary. Figure 48
details HB switching transitions as soon as the short is detected, where the borderline between inductive and capacitive mode could be critical. As can be seen, the resonant current has the correct polarity during both HB transitions and the converter is properly working in the inductive region even in this case.
Doc ID 18376 Rev 1
AN3329 Functional check
Figure 46.
12 V short-circuit at full load and
115 Vac - 60 Hz
Figure 47.
12 V short-circuit at full load and
115 Vac - 60 Hz - detail
CH1: HB voltage
CH3: ISEN (pin #6)
CH2: DELAY (pin #2)
CH4: 12 V O/P current
CH1: HB voltage
CH4: C39 current
CH3: ISEN (pin #6)
Figure 48.
24 V short-circuit at full load and
115 Vac - 60 Hz
Figure 49.
24 V short-circuit at full load and
115 Vac - 60 Hz - detail
CH1: HB voltage
CH3: ISEN (pin #6)
CH2: DELAY (pin #2)
CH4: 12 V O/P current
CH1: HB voltage
CH4: C39 current
CH3: ISEN (pin #6)
Doc ID 18376 Rev 1 25/47
Functional check AN3329
Startup
shows waveforms during startup at 115 Vac and full load of PFC and resonant stages. It is possible to note the sequence of the two stages; once the on/off signal is asserted high, voltage on C44 increases up to the Vcc turn-on thresholds of the L6564 and
L6599A. The PFC starts first and its output voltage starts increasing from the mains rectified voltage to its nominal value. In the meantime, the L6599A is kept inactive by the LINE pin
(#7) until the PFC voltage reaches the nominal output voltage, corresponding to 1.24 V on
the LINE pin, then the resonant converter is enabled and starts switching. Figure 53 reports
details of initial operation by the half bridge. It can be noted that the initial HB pulses are shorter than the following ones, and the resonant tank current has the correct polarity. This is achieved by means of the circuit R29, D8, C23, and R23, connected to the L6599A CF pin
(#3). The purpose of this circuit is to provide an asymmetric operation by the half bridge
MOSFETs during the initial pulses to prevent hard switching operation that may occur because the resonant capacitor C39 is discharged, and could damage the half bridge
MOSFETs.
Figure 50.
Startup by on-off signal at full load and 115 Vac - 60 Hz
Figure 51.
Startup by on-off signal at full load and 115 Vac - 60 Hz - L6599A signals
CH1: HB voltage
CH3: V_C44
CH2: PFC drain
CH4: On/off signal
CH1: HB voltage
CH3: LVG (pin #11)
CH2: LINE (pin #7)
CH4: C39 current
In
Figure 52 the rising of the output voltages at startup has been captured. Note that the
output voltages are reaching the steady-state level after ~90 ms when the on/off signal has been asserted high. The rising of the output voltages, controlled by C21 (CSS capacitor), is monotonic, regular, and without overshoots.
details the PFC and resonant converter turn-off. Note that after the on/off signal has been asserted low, the V_C44 decreases down to the L6564 and L6599A respective
Vcc UVLO voltages and both converters stops switching correctly, without restarting attempts.
26/47 Doc ID 18376 Rev 1
AN3329 Functional check
Figure 52.
Startup by on/off signal at full load and 115 Vac - 60 Hz O/P voltage rising
Figure 53.
Turn-off at full load and 115 Vac - 60
Hz by on/off signal
CH1: On/off signal
CH3: 24 V output
CH2: CSS (pin #1)
CH4: 12 V output
CH1: HB voltage
CH3: V_C44
CH2: PFC drain
CH4: On/off signal
Overvoltage protection
and
show the OVP response, observed opening the resonant stage feedback loop. Upon an overvoltage condition of either 24 V or 12 V output, the Zener diodes D16 and
D17 are reverse-biased and conduct respectively, forcing Q10 on by the resulting base current, which causes Q9 to conduct shorting to ground the anode of the U5 optocoupler and the disappearance of V_C44. Therefore, the L6564 and the L6599A are not powered.
The two transistors mentioned form a pnp-npn SCR structure that force the PFC and resonant converter to be latched off until the 5 V standby is removed by a mains voltage recycling. In the case of an open loop event, the 12 V and 24 V outputs reach 14.16 V and
28.26 V respectively.
Figure 54.
OVP at full load and 115 Vac - 60 Hz on 12 V - 24 V
Figure 55.
OVP at full load and 115 Vac - 60 Hz on 12 V - 24 V - outputs detail
CH1: HB voltage
CH3: V_C53
CH2: PFC drain
CH4: V_C44
CH1: 24 V output
CH3: V_C53
CH2: 12 V output
CH4: V_C44
Doc ID 18376 Rev 1 27/47
Functional check AN3329
Mains sags/dips
and
show the converter behavior in the case of half-cycle (8.3 ms) or a complete cycle (16.6 ms) mains dip. As can be noted, in both cases the PFC output voltage drops but the L6599A still works correctly, and output voltages do not show any disturbance, therefore demonstrating a good immunity of the circuit against mains dips.
Figure 56.
Half cycle mains dip at full load and
115 Vac - 60 Hz
Figure 57.
Full cycle mains dip at full load and
115 Vac - 60 Hz
CH1: HB voltage
CH3: 24 V output
CH2: PFC drain
CH4: PFC gate
CH1: HB voltage
CH3: 24 V output
CH2: PFC drain
CH4: PFC gate
28/47 Doc ID 18376 Rev 1
AN3329
5
Conducted emission pre-compliance test
Conducted emission pre-compliance test
,
,
, and
61 are the peak measurements of the conducted emission noise at
full load and nominal mains voltages. The limits shown in the diagrams are EN55022 Class-
B, which is the most popular norm for domestic equipment and has more severe limits compared to Class-A, dedicated to IT technology equipment. As visible in the diagrams, in all test conditions the measurements are far below the limits.
Figure 58.
CE peak measurement at 115 V - 60 Hz and full load - phase wire
Figure 59.
CE peak measurement at 115 V - 60 Hz and full load - neutral wire
Doc ID 18376 Rev 1 29/47
Conducted emission pre-compliance test
Figure 60.
CE peak measurement at 230 V - 50 Hz and full load - phase wire
AN3329
Figure 61.
CE peak measurement at 230 V - 50 Hz and full load - neutral wire
30/47 Doc ID 18376 Rev 1
AN3329 Bill of materials
Table 2.
Des.
C1
C10
C12
C13
C14 1000 µF - 35 V
C15 1000 µF - 35 V
C16
C17
C18
C19
C2
C20
C21
C23
C24
C25
100 nF
470 nF
100 nF
470 nF
4.7 µF - 6.3 V
4.7 nF
470 pF
2.2 nF
C26 1000 µF - 25 V
C27
C28
C29
C3
C30
C31
C32
C33
Bill of materials
Part type / part value
Case style
/ package
2.2 nF
100 nF
100 nF
47 nF
100 µF - 50 V
1 µF - X2
100 µF - 50 V
100 nF
N.M.
1 µF - X2
470 nF
2.2 nF
1 µF
10 µF - 50 V
0805
11x26.5 mm p. 22.5
0805
0805
0805
0805
0805
Dia.12x20 p. 5 mm
Dia. 8x11 p. 3.5 mm
0805
0805
11x26.5 mm p. 22.5
1206
0805
1206
Dia. 6.3x11
(MM) p. 2.5 mm
DWG
0805
1206
0805
Dia.12x25 p. 5 mm
Dia.12x25 p. 5 mm
Dia.8x11 p. 3.5 mm
0805
1206
Description
Y1 - safety cap. DE1E3KX222M
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
Aluminium ELCAP - YXF series - 105 °C
Aluminium ELCAP - YXF series - 105 °C
Aluminium ELCAP - YXF series - 105 °C
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - Y5V - 20 %
50 V Cercap - general purpose - X7R - 10 %
FLM CAP - B32923C3105K
16 V Cercap - general purpose - X7R - 10 %
6.3 V Cercap - general purpose - X5R - 15 %
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - C0G - 5 %
50 V Cercap - general purpose - X7R - 10 %
Aluminium ELCAP - YXF series - 105 °C
Aluminium ELCAP - YXF series - 105 °C
50 V Cercap - general purpose - X7R - 10 %
Not mounted
FLM CAP - B32923C3105K
50 V Cercap - general purpose - Y5 V - 20 %
50 V Cercap - general purpose - X7R - 10 %
16 V Cercap - general purpose - X7R - 10 %
Aluminium ELCAP - YXF series - 105 °C
Doc ID 18376 Rev 1
Supplier
MURATA
KEMET
KEMET
KEMET
Rubycon
Rubycon
Rubycon
KEMET
KEMET
KEMET
EPCOS
KEMET
KEMET
KEMET
KEMET
KEMET
RUBYCON
RUBYCON
KEMET
EPCOS
KEMET
KEMET
KEMET
Rubycon
31/47
Bill of materials AN3329
Table 2.
Des.
Bill of materials (continued)
Part type / part value
Case style
/ package
Description Supplier
C39
C4
C40
C42
C44
C45
C46
C47
47 nF
2.2 nF
C49 1000 µF - 10 V
C5
C50 1000 µF - 10 V
C51
C52
C53
C54
C55
C56
C59
C34
C35
C36
C38
C6
C60
C61
220 pF
4.7 nF
220 pF
220 nF
33 nF
470 nF - 630 V
47 µF - 50 V
10 nF
47 µF - 50 V
10 µF - 450 V
470 nF - 630 V
220 µF - 16 V
100 nF
22 µF - 50 V
100 nF
2.2 nF
100 nF
10 nF
100 µF - 450 V
100 nF
10 nF
0805
1206
1206
50 V Cercap - general purpose - COG - 5 %
50 V Cercap - general purpose - X7R - 10 %
500 V Cercap - 12067A221JAT2A - C0G - 5 %
16 V Cercap - general purpose - X7R - 10 % 0805
5.0 x 18.0 p. 15 mm
11x26.5 mm p. 22.5
Dia. 6.3x11 mm p. 2.5
0805
Dia. 6.3x11 mm p. 2.5 mm
0805
1 kV - MKP film capacitor B32652A0333J
630 V - FLM CAP - B32613A6474K***
Aluminium ELCAP - YXF series - 105 °C
50 V Cercap - general purpose - X7R - 10 %
Aluminium ELCAP - YXF series - 105 °C
DWG
Dia. 10 p. 5 mm
Dia.10x16 p. 5 mm
25 V Cercap - general purpose - X7R - 10 %
Y1 - Safety CAP. DE1E3KX222M
450 V - Aluminium ELCAP - VY series - 105 °C
Aluminium ELCAP - YXF series - 105 °C
KEMET
KEMET
AVX
KEMET
EPCOS
EPCOS
Rubycon
KEMET
Rubycon
KEMET
MURATA
Nichicon
Rubycon
11x26.5 mm p. 22.5
Dia.10x16 p. 5 mm
Dia.8x11 p. 2 mm
0805
Dia. 5X11 p. 2 mm
0805
630 V - FLM CAP - B32613A6474K***
Aluminium ELCAP - YXF series - 105 °C
Aluminium ELCAP - YXF series - 105 °C
50 V Cercap - general purpose - X7R - 10 %
Aluminium ELCAP - YXF series - 105°C
EPCOS
Rubycon
Rubycon
KEMET
Rubycon
0805
0805
0805
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
KEMET
KEMET
KEMET
KEMET
Dia. 18x35 mm p.10
0805
0805
450 V - aluminium ELCAP - KXG series - 105 °C Nippon Chemi-con
50 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - X7R - 10 %
KEMET
KEMET
32/47 Doc ID 18376 Rev 1
AN3329 Bill of materials
Table 2.
Des.
Bill of materials (continued)
Part type / part value
Case style
/ package
Description Supplier
C62
C63
C64
C65
C7
C8
C9
D1
D10
D11
10 µF - 50 V
10 nF
1 nF
220 pF
100 µF - 450 V
2.2 nF
2.2 nF
1N5406
1N4148WS
STPS20H100C
FP
Dia 6.3X11
(MM) p. 2.5 mm
0805
1206
DWG
DO-201
SOD323
Aluminium ELCAP - YXF series - 105°C
50 V Cercap - general purpose - X7R - 10 %
100 V Cercap - general purpose - X7R - 10 %
50 V Cercap - general purpose - COG - 5 %
Rubycon
KEMET
KEMET
KEMET 0805
Dia. 18x35 mm p.10
DWG
450 V - aluminium ELCAP - KXG series - 105 °C Nippon Chemi-con
Y1 - Safety cap. DE1E3KX222M
Y1 - Safety cap. DE1E3KX222M
Rectifier - general purpose
High speed signal diode
MURATA
MURATA
VISHAY
VISHAY
TO-220FP Power Schottky rectifier STMicroelectronics
D12
D14
D15
1N4148WS
1N4148WS
BZV55-C15
SOD323
SOD323
MINIMELF
D16
D17
MMSZ4711-V
MMSZ4702-V
SOD123
SOD123
D18 STPS20L45CFP TO-220FP
D19
D2
D20
P6KE250A
STTH5L06
STTH108A
DO-15
DO-201
SMA
High speed signal diode
High speed signal diode
Zener diode
27 V Zener diode
15 V Zener diode
Power Schottky rectifier
Transil
Ultrafast high voltage rectifier
HV ultrafast rectifier
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
STMicroelectronics
STMicroelectronics
STMicroelectronics
STMicroelectronics
D21
D22
D3
D4
BAV103
STTH102A
D10XB60H
STPS20H100C
FP
1N4148WS
MINIMELF
SMA
DWG
TO-220FP
D5
D6
D7
D8
1N4148WS
1N4148WS
1N4148WS
SOD323
SOD323
SOD323
SOD323
D9 STPS20L45CFP TO-220FP
F1 Fuse T4A
8.5x4 p.5.08 mm
HS1 Heatsink DWG
High speed signal diode
High efficiency ultrafast diode
Single-phase bridge rectifier
HV power Schottky rectifier
High speed signal diode
High speed signal diode
High speed signal diode
High speed signal diode
Power Schottky rectifier
Fuse 4 A - Time LAG - 3921400
Heatsink for D3 and Q5
VISHAY
STMicroelectronics
SHINDENGEN
STMicroelectronics
VISHAY
VISHAY
VISHAY
VISHAY
STMicroelectronics
Littelfuse
Doc ID 18376 Rev 1 33/47
Bill of materials AN3329
JPX23
JPX24
JPX25
JPX3
JPX4
JPX5
JPX6
JPX7
JPX8
JPX9
L1
JPX18
JPX19
JPX2
JPX20
JPX21
JPX22
J2
J3
JPX1
JPX10
JPX11
JPX12
JPX13
JPX14
JPX15
JPX16
JPX17
Table 2.
Des.
HS2
HS3
HS4
HS5
J1
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
240 µH
280385-2
280384-2
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Shorted
Bill of materials (continued)
Part type / part value
Case style
/ package
Heatsink
Heatsink
Heatsink
Heatsink
DWG
DWG
DWG
DWG
09-65-2038 DWG
DWG
DWG
DWG
Description
Heatsink for Q3 and Q6
Heatsink for D4 and D11
Heatsink for D18
Heatsink for D9
Connector-pitch 3.96 mm - 2 pins (1 removed) -
KK
Connector - p. 2.54 mm - 8 x 2 rows - MODU-II
Connector - p. 2.54 mm - 4 x 2 rows - MODU-II
Wire jumper
Wire jumper
Wire jumper - insulated
Wire jumper
Wire jumper - insulated
Wire jumper
Wire jumper
Wire jumper - insulated
Wire jumper
Wire jumper - insulated
Wire jumper
Wire jumper - insulated
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper
Wire jumper - insulated
Wire jumper - insulated
Wire jumper
Wire jumper
2086.0001 - PFC inductor
Supplier
Molex
AMP
AMP
MAGNETICA
34/47 Doc ID 18376 Rev 1
AN3329 Bill of materials
R2
R20
R21
R22
R23
R24
R12
R13
R15
R16
R17
R18
R25
R27
R29
R3
R31
Q11
Q3
Q5
Q6
Q7
Q8
Q9
R1
R10
R11
L2
L3
L4
L5
L6
PCB
Q10
Table 2.
Des.
Bill of materials (continued)
Part type / part value
Case style
/ package
Description Supplier
3 mH
70 µH
2.2 µH
1 µH
1 µH
PCB rev. 2
BC847C
BC847C
STF12NM50N
STF14NM50N
STF12NM50N
BC847C
BC847C
BC857C
NTC 2R5-S237
51 k
Ω
3.9 M
Ω
470 k
Ω
130 k
Ω
2.2 M
Ω
3.9 M
Ω
200 k
Ω
56
Ω
2.2 M
Ω
100 k
Ω
10
Ω
3.9 k
Ω
4.7 M
Ω
3.3 k
Ω
10
Ω
2.2
Ω
4.7 k
Ω
27 k
Ω
100 k
Ω
0805
0805
1206
0805
0805
1206
0805
0805
1206
0805
1206
SOT-23
SOT-23
TO-220FP
TO-220FP
TO-220FP
SOT-23
SOT-23
SOT-23
DWG
0805
1206
DWG
26x13 mm
DIA12 p. 5 mm
DIA8 p. 5 mm
DIA8 p. 5 mm
1606.0007 EMI filter
2190.0001 DM inductor
10610041 - 3 µH - 11 A inductor
10710083 - 1 µ - 5 A inductor
10710083 - 1 µ - 5 A inductor
Single Layer - 2 OZ. - CEM-1
NPN small signal BJT
MAGNETICA
MAGNETICA
MAGNETICA
MAGNETICA
MAGNETICA
NPN small signal BJT
N-channel Power MOSFET
N-channel Power MOSFET
N-channel Power MOSFET
NPN small signal BJT
NPN small signal BJT
PNP small signal BJT
NTC resistor P/N B57237S0259M000
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4W - 1 % - 100 ppm/°C
VISHAY
VISHAY
STMicroelectronics
STMicroelectronics
STMicroelectronics
VISHAY
VISHAY
VISHAY
EPCOS
VISHAY
VISHAY
0805
0805
1206
1206
1206
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
Doc ID 18376 Rev 1 35/47
Bill of materials
R57
R59
R6
R60
R61
R62
R50
R51
R52
R53
R55
R56
R64
R65
R67
R68
R69
R4
R40
R41
R43
R44
R45
R46
R47
R49
R5
R32
R33
R34
R36
R37
R38
R39
Table 2.
Des.
Bill of materials (continued)
Part type / part value
22
Ω
200 k
Ω
10
Ω
13 k
Ω
6.2 k
Ω
0
3.9 k
Ω
2.2 M
Ω
1 k
Ω
56
Ω
1 M
Ω
100 k
Ω
10 k
Ω
220
Ω
0
33 k
Ω
2.2 M
Ω
180 k
Ω
0.47
Ω
0.47
Ω
100
Ω
150
Ω
5.6 k
Ω
51
Ω
1 k
Ω
4.7 M
Ω
47 k
Ω
180 k
Ω
75 k
Ω
1 k
Ω
180 k
Ω
10 k
Ω
1 k
Ω
4.7 k
Ω
Case style
/ package
0805
0805
0805
0805
1206
0805
1206
1206
0805
0805
0805
0805
0805
1206
1206
0805
1206
0805
PTH
PTH
1206
0805
0805
0805
0805
1206
0805
0805
0805
0805
0805
0805
0805
0805
Description
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8W - 5% - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
AN3329
Supplier
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
36/47 Doc ID 18376 Rev 1
AN3329
R7
R70
R71
R72
R73
R74
R84
R86
R87
R88
R89
R9
R8
R80
R81
R82
R83
R90
R91
R92
Table 2.
Des.
R75
R78
R79
R93
R94
R95
R96
RV1
RX2
39 k
Ω
47 k
Ω
220 k
Ω
10
Ω
220 k
Ω
2.7 k
Ω
2.2 M
Ω
82 k
Ω
27 k
Ω
1 k
Ω
27 k
Ω
12 k
Ω
120 k
Ω
270 k
Ω
Bill of materials (continued)
Part type / part value
2.2 M
Ω
10 k
Ω
4.7 k
Ω
1 k
Ω
1 k
Ω
2.7 k
Ω
Case style
/ package
1206
0805
0805
0805
0805
0805
Description
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
1
Ω
3.9
Ω
PTH
1206
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
NFR25H - axial fusible res - 1/2 W - 5 % - 100 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
390 k
Ω
AXIAL
Dia.1.6x3.6 mm
1206
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
0805
0805
0805
0805
0805
0805
0805
0805
0805
0805
1206
1206
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
2.2
Ω
AXIAL
Dia.1.6x3.6 mm
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
22 k
Ω
1 k
Ω
0.47
Ω
300 Vac
0
AXIAL
Dia.1.6x3.6 mm
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
0805
PTH
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
Dia. 15x5 p. 7.5 mm
1206
300 V metal oxide varistor - B72214S0301K101
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
Bill of materials
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
Supplier
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
VISHAY
EPCOS
VISHAY
Doc ID 18376 Rev 1 37/47
Bill of materials
Table 2.
Des.
T1
T2
U1
U2
U3
U4
U5
U6
U7
U8
Bill of materials (continued)
Part type / part value
Case style
/ package
1860.0014
Rev. 0.1
1715.0059
L6564D
L6599AD
SFH610A-2
TL431ACZ
SFH610A-2
VIPER27LN
SFH610A-2
TS431AZ
SSOP10
SO-16
DIP-4 -
10.16MM
TO-92
DIP-4 -
10.16MM
DIP8
DIP-4 -
10.16MM
TO-92
Description
Resonant transformer
Standby flyback TRAFO
10-pin transition mode PFC controller
Improved HV resonant controller
Optocoupler
Programmable shunt voltage reference
Optocoupler
Offline HV converter
Optocoupler
Programmable shunt voltage reference
AN3329
Supplier
MAGNETICA
MAGNETICA
STMicroelectronics
STMicroelectronics
Infineon
STMicroelectronics
Infineon
STMicroelectronics
Infineon
STMicroelectronics
38/47 Doc ID 18376 Rev 1
AN3329
7 PFC coil specifications
General description and characteristics
●
●
●
●
●
●
●
Application type: consumer, home appliance
Transformer type: open
Coil former: vertical type, 6+6 pins
Max. temp. rise: 45 ºC
Max. operating ambient temperature: 60 ºC
Mains insulation: n.a.
Unit finishing: varnished
Electrical characteristics
●
●
●
●
●
Converter topology: boost, transition mode
Core type: PQ32/20-PC44 or equivalent
Min. operating frequency: 30 kHz
Typical operating frequency: 120 kHz
Primary inductance: 240 µH ± 15 % at 1 kHz - 0.25 V
(a)
Electrical diagram and winding characteristics
Figure 62.
PFC coil electrical diagram
PFC coil specifications
!-V
Table 3.
Pins
PFC coil winding data
Windings RMS current Number of turns
8 - 11
1,2 - 5,6
AUX
Primary
0.05 Arms
2.65 Arms
3
28
Wire type
φ
0.3 mm - G2
2x40
φ
0.1 mm - G2 a.
Measured between pins 1,2 and 5,6.
Doc ID 18376 Rev 1 39/47
PFC coil specifications
Mechanical aspect and pin numbering
●
●
●
●
Maximum height from PCB: 22 mm
Coil former type: vertical, 6+6 pins (pins #3, 4, 7, 12 are removed)
Pin distance: 5.08 mm
Row distance: 30.5 mm
Figure 63.
PFC coil mechanical aspect
33
MAX
3 5
MAX
21 MAX
6 8 1 2 9 5 6
3 0.5
11
9
8
5.0
8
Dimen s ion s millimeter s , dr a wing not in s c a le
Manufacturer
●
●
MAGNETICA
Inductor P/N: 2086.0001
BOTTOM VIEW ( PIN S IDE )
1
2
∅ 0.
8 (X7)
R
ECOMMENDED
PCB
HOLE
∅ 1.2
(X7)
5
6
AN3329
AM0 83 76v1
40/47 Doc ID 18376 Rev 1
AN3329
8
Resonant power transformer specifications
Resonant power transformer specifications
General description and characteristics
●
●
●
●
●
●
Application type: consumer, home appliance
Transformer type: open
Coil former: horizontal type, 7+7 pins, two slots
Max. temp. rise: 45 ºC
Max. operating ambient temperature: 60 ºC
Mains insulation: acc. to EN60065
Electrical characteristics
●
●
●
●
●
●
Converter topology: half bridge, resonant
Core type: ETD34-PC44 or equivalent
Min. operating frequency: 70 kHz
Typical operating frequency: 90 kHz
Primary inductance: 660 µH ± 8 % at 1 kHz - 0.25 V
(b)
Leakage inductance: 112 µH at 100 kHz - 0.25 V
(c)
Figure 64.
Transformer overall drawing
!-V
Table 4.
Pins
2-4
6 - 7
Resonant transformer winding data
Winding
Primary
AUX
DC resistance Number of turns
158 m
Ω
94 m
Ω
36
3
Wire type
30x
φ
0.1 mm – G1
φ
0.28 mm – G2 b.
Measured between pins 2-4.
c.
Measured between pins 2-4 with secondary windings with same polarity shorted at time.
Doc ID 18376 Rev 1 41/47
Resonant power transformer specifications AN3329
Table 4.
Pins
8 - 11
9 - 10
10 - 13
12 - 14
Resonant transformer winding data (continued)
Winding
SEC - A
SEC - B
SEC - C
SEC - D
DC resistance Number of turns
4.4 m
Ω
4.4 m
Ω
4.4 m
Ω
4.4 m
Ω
2
2
2
2
Wire type
90x
φ
0.1 mm – G1
90x
φ
0.1 mm – G1
90x
φ
0.1 mm – G1
90x
φ
0.1 mm – G1
Mechanical aspect and pin numbering
●
●
●
●
Maximum height from PCB: 30 mm
Coil former type: horizontal, 7+7 pins (pins #1 and 7 are removed)
Pin distance: 5.08 mm
Row distance: 25.4 mm
Figure 65.
Transformer electrical diagram
PD[
PD[
PLQ
PD[
ARKINGS
[ERUH3&%
2EFERENCE
3IDEVIEWOFTERMINALS
$IMENSIONSMILLIMETERSDRAWINGNOTINSCALE
Manufacturer
●
●
MAGNETICA
Transformer P/N: 1860.0014 Rev. 0.1
!-V
42/47 Doc ID 18376 Rev 1
AN3329
9
Auxiliary flyback transformer specifications
Auxiliary flyback transformer specifications
General description and characteristics
●
●
●
●
●
●
●
●
Application type: consumer, home appliance
Transformer type: open
Winding type: layer
Coil former: horizontal type, 4+5 pins, two slots
Max. temp. rise: 45 ºC
Max. operating ambient temperature: 60 ºC
Mains insulation: acc. to EN60950
Unit finishing: varnished
Electrical characteristics
●
●
●
●
●
●
●
Converter topology: flyback, CCM/DCM mode
Core type: E20-PC44 or equivalent
Typical operating frequency: 60 kHz
Primary inductance: 2.380 mH ± 10 % at 1 kHz - 0.25 V
(d)
Leakage inductance: 30 µH at 50 kHz - 0.25 V
(e)
Max. peak primary current: 0.5 Apk
RMS primary current: 0.17 Arms
DC output characteristics
● Converter topology: flyback, CCM/DCM mode
Table 5.
DC output voltage and load
DC output voltage
5 V
16 V
DC load
2 A
DC
0.05 A
DC d.
Measured between pins 4-5.
e.
Measured between pins 2-4 with secondary windings with same polarity shorted at time.
Doc ID 18376 Rev 1 43/47
Auxiliary flyback transformer specifications
Figure 66.
Transformer construction
0RIMAR
6
AN3329
S
ECONDARY
AUXILIARY
PRIMARY
6
!UX
!-V
Winding characteristics
Table 6.
Pins
4 - 5
2 - 1
6 - 8
7 - 9
Standby transformer winding data
Winding
O/P rms current
Number of turns
Number of layers
Primary
Aux
5 V
0.17 A
RMS
0.05 A
RMS
2.6 A
RMS
(TOTAL)
93
18 spaced
6
2
1
1
Wire type
G2 -
φ
0.224 mm
G2 -
φ
0.224 mm
TIW - 2 x
φ
0.7 mm in parallel
Figure 67.
Mechanical aspect and pin numbering
2 LAYER S POLYE S TER TAPE
COIL FORMER
FERRITE CORE
AM0 838 0v1
44/47 Doc ID 18376 Rev 1
AN3329 Auxiliary flyback transformer specifications
Figure 68.
Mechanical aspect and pin numbering
0$;
0,1
0$;
0$;
0$;
3LQLVPLVVLQJ
%277209,(: 3,16,'(
Manufacturer
●
●
MAGNETICA
Inductor P/N: 1715.0059
;
5 (&200(1'(' 3&% +2/( ;
!-V
Doc ID 18376 Rev 1 45/47
Revision history
Table 7.
Date
Document revision history
Revision
25-Feb-2011 1 Initial release.
Changes
AN3329
46/47 Doc ID 18376 Rev 1
AN3329
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Doc ID 18376 Rev 1 47/47
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