ST AN2321 Application note
Contents
1. z 8 lt 8 sz g PESE 519 7 a ge Hie gt gt 12 55 7 EF 8 88 Tum 1 i amp 5 B ze 3 PLI LE EE ru 43 s 58 m gt g 7 E r 8 z3 88 2z 5K J 1 8 PE sy 4 li 29 m m C3 i 4 FF 8 6 1 1 8 E SB y ez E ER ab T 5 3 83 z 88 z ge 34 dH s 2 al ab a i l t g 88 42 E 4 toe se of ag 88 HI 7g p 5 adosiNc as 8 a li T4 X PE E 8 5 8 eu B ne E Lc 4 WO9NNHITOLS 8 T T En I E ee i 1 92. 2 14 PRIM SEC A 4 13 12 5 e AUX Table 9 Winding characteristics Pins Winding RMS current Number of turns Wire type 2 4 PRIMARY 1 ARMS 60 MULTISTRAND 0 12x12 G2 14 13 SEC A 4 Anus 6 MULTISTRAND 0 20x20 G2 12 11 SEC B 4 ARMS 6 MULTISTRAND 0 20x20 G2 5 6 AUX 2 0 05 5 SPACED 0 22 G2 1 Secondary windings A and B must be wound in parallel 2 Auxiliary winding is wound on top of primary winding 25 29 Resonant power transformer specification AN2321 7 2 26 29 Mechanical aspect and Pin numbering Maximum height from PCB 22 mm Coil former type horizontal 7 7 Pins Pins 1 and 7 are removed Pin distance 5 mm Row distance 30 mm Manufacturer DELTA ELECTRONICS P N 86A 5166A Figure 21 Pin lay out top view AN2321 PCB lay out 8 PCB lay out Figure 22 Thru hole component placing and top silk screen 1 1 I TL le E 4 m 11 L R t I I Al te P d 4 2 Figure 23 5 component placing and bottom silk screen n H 4 s EL l Uih mE ia zd EXC ees rt LL I T I Tes CSDL Eu y A Id i mn Figure 24 Copper tracks ky 27 29 Revi
3. 7 Efficiency measurements Vin 230 7 Stand by consumption Vin 115 11 Stand by consumption Vin 230 11 Temperature of measured points 9115 Vac full load 15 Temperature of measured points 0230 Vac full load 16 Bill of material eer eem e cere e Dk Ne iR e Wot ace 18 Winding 23 Winding 25 ReVISION NISLOLY 28 3 29 List of figures AN2321 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 4 29 Electrical diagram e npa y soportes Hon peter deed 6 Efficiency POUL wx RUE ERR xx RR Rcx De d So ed 8 Resonant circuit primary side 8 Resonant circuit secondary side waveforms 9 Input power without load vs mains voltage 10 Wave
4. 7 2321 Application note Reference design high performance L6599 based HB LLC adapter with PFC for laptop computers Introduction This note describes the performances of a 90 W wide range mains power factor corrected AC DC adapter reference board Its electrical specification is tailored on a typical hi end portable computer power adapter The peculiarities of this design are the very low no load input consumption 0 4 W and the very high global efficiency The architecture is based on a two stage approach a front end PFC pre regulator based on the L6563 TM PFC controller and a downstream multi resonant half bridge converter that makes use of the new L6599 resonant controller The Standby function of the L6599 pushing the DCDC converter upon recognition of a light load to work in burst mode and the logic dedicated to stop the PFC stage allows meeting the severe no load consumption requirement The PFC TM operation and the top level efficiency performance of the HB LLC topology provide also a very good overall efficiency of the circuit L6599 amp L6563 90W adapter demo board EVAL6599 90W m 1 E DANGER MAN Lud 2 gt POTENTIAL E May 2007 Rev 2 1 29 www st com Contents AN2321 Contents 1 Main characteristics and circuit description 5 2 Test TesullS u ue o RC RU
5. 115Vac FULL LOAD Start 158 kHz Stop 38 HHz 9 kHz UBH 38 kHz Sweep 881 3 ms 1515 pts Figure 17 CE peak measure at 230 Vac and full load Mkrl 15 38 MHz Ref 75 dB Rtten 18 dB 25 85 dBpV FULL LOAD Start 158 kHz Stop 38 HHz BH 9 kHz VBH 38 kHz Sweep 861 3 ms 1515 pts 17 29 Bill of material AN2321 5 Bill of material Table 7 Bill of material Res Part type De des part value Description Supplier C1 470N X2 X2 FILM CAPACITOR 46 1 3470 M1 RUBYCON C1 470N X2 X2 FILM CAPACITOR 46 1 3470 M1 ARCOTRONICS C10 22N 50 V CERCAP GENERAL PURPOSE AVX C11 10N 50 V CERCAP GENERAL PURPOSE AVX C12 470N 25 V CERCAP GENERAL PURPOSE AVX C13 1uF 25 V CERCAP GENERAL PURPOSE AVX C14 100N 50 V CERCAP GENERAL PURPOSE AVX C15 10uF 50V ALUMINIUM ELCAP YXF SERIES 105 C RUBYCON C16 2N2 50 V CERCAP GENERAL PURPOSE AVX C17 470PF 50 V 5 COG CERCAP AVX C18 2 2 6 3 V 25 V CERCAP GENERAL PURPOSE AVX C19 100N 50 V CERCAP GENERAL PURPOSE AVX C2 2N2 Y1 SAFETY CAP MURATA C20 2N2 Y1 DE1E3KX222M Y1 SAFETY CAP MURATA C21 2N2 Y1 DE1E3KX222M Y1 SAFETY CAP MURATA C22 220PF 50 V CERCAP GENERAL PURPOSE AVX C23 10N 50 V CERCAP GENERAL PURPOSE AVX C24 220 uF 35 V ALUMINIUM ELCAP
6. OF Ma 08 17 67 55 q 3 Jan 05 155 CY un LL 06 17 575 tera hz 20 ow 504 Q tw CH1 L6599 Vpiy 14 HB voltage CH2 L6599 2 DELAY CH2 L6599 Vpini 2 DELAY CH3 16599 6 ISEN CH3 16599 6 ISEN 4 Output current bu M 100r 1 0 45 Oh2 20 oy 10 100654 504 4 Output current 12 29 The L6599 short circuit protection sequence described above is visible in the Figure 10 The on off operation is controlled by the voltage on pin 2 DELAY providing for the hiccup mode of the circuit Thanks to this control pin the designer can select the hiccup mode timing and thus keep the average output current at a safe level Please note on the picture left side the very low mean current flowing in the shorted output less than 0 3 A A better detail of the waveforms can ky 2321 Test results 2 5 2 6 be appreciated in Figure 1 1 where it is possible to recognize the operation phases described above Over voltage protections Both circuit stages PFC and resonant are equipped with their own over voltage protection The PFC controller L6563 is internally equipped with a dynamic and a static over voltage protection circuit detecting the error amplifier via the voltage divider dedicated to the feedback loop to detect the PFC output voltage In case the internal threshold is exc
7. YXF SERIES 105 C RUBYCON C25 100N 50 V CERCAP GENERAL PURPOSE AVX C26 10 50 V ALUMINIUM ELCAP YXF SERIES 105 C RUBYCON C27 220PF 500 V CERCAP 5MQ221KAAAA AVX C28 22N 630 V PHE450MA5220JR05 EVOX RIFA C29 470 uF 35 V YXF ALUMINIUM YXF SERIES 105 C RUBYCON C3 2N2 Y1 SAFETY CAP MURATA C30 470 35 V YXF ALUMINIUM YXF SERIES 105 C RUBYCON C31 100 uF 35 V YXF ALUMINIUM YXF SERIES 105 C RUBYCON C32 100N 50 V CERCAP GENERAL PURPOSE AVX C34 220N 50 V CERCAP GENERAL PURPOSE AVX C36 1 50 V ALUMINIUM ELCAP YXF SERIES 105 C RUBYCON C39 100N 50 V CERCAP GENERAL PURPOSE AVX C4 470N X2 X2 FILM CAPACITOR 46 1 3470 M1 ARCOTRONICS C40 100N 50 V CERCAP GENERAL PURPOSE AVX 18 29 2321 Bill of material Table 7 Bill of material continued Description Supplier C43 4N7 50V CERCAP GENERAL PURPOSE AVX C44 3N9 50V CERCAP GENERAL PURPOSE AVX C45 220NF 25V CERCAP GENERAL PURPOSE AVX C5 470N 400 V PHE426KD6470JRO6L2 POLYPROP FILM CAP EVOX RIFA C9 47 450 V ALUMINIUM ELCAP ED SERIES 105 C PANASONIC D1 GBU4J SINGLE PHASE BRIDGE RECTIFIER VISHAY D10 LL4148 FAST SWITCHING DIODE VISHAY D11 LL4148 FAST SWITCHING DIODE VISHAY D12 STPS10L60FP POWER SCHOTTKY RECTIFIER STMicroelectronics D13 STPS10L60FP POWER SCHO
8. provides for an almost constant wake up time of the circuit In Figure 13 the L6599 start up sequence is analyzed as soon as the LINE pin 7 enables the operation of the L6599 converter s soft start up sequence is triggered therefore initially the capacitor C18 is totally discharged and the resistor R44 is effectively in parallel to R24 thus the resulting initial frequency is determined by Rss and Rgmin only since the optocoupler s phototransistor is off as long as the output voltage is not too far away from the regulated value C18 is progressively charged until its voltage reaches the reference voltage 2 V and consequently the current through R44 goes to zero During this frequency sweep the operating frequency will decrease following the exponential charge of C18 that will count balance the non linear frequency dependence of the tank circuit As a result the average input current will smoothly increase without the peaking that occurs with linear frequency sweep and the output voltage will reach the regulated value with almost no overshoot as the waveforms in the picture AN2321 Thermal tests 3 Thermal tests In order to check the design reliability a thermal mapping by means of an IR Camera was done Here below the thermal measures of the board component side at nominal input voltage are shown Some pointers visible on the pictures have been placed across key components or components showing high temperature The correl
9. Red QUK Rc ea 7 2 1 Efficiency measurements 7 2 2 Resonant stage operating waveforms 8 2 3 Stand by amp no load power consumption 9 24 Short circuit protection 12 2 5 Over voltage protections 13 210 Start Up SequUencE unu cage wee 13 3 Thermal testS i sr rua na eR ds dws EUR E RB 15 4 Conducted emission pre compliance test 17 5 Billof material 444 RRRRRR 18 6 coil specification 23 6 1 Electrical characteristics 23 6 2 Mechanical aspect and pin numbering 24 7 Resonant power transformer specification 25 7 1 Electrical 25 7 2 Mechanical aspect and Pin numbering 26 8 lay OUl wise eden dang eee eS EAE fca 27 9 Revision history 28 2 29 Ti 2321 List of tables List of tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Efficiency measurements Vin 115
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11. et A addc 2 a 5 x 8 amp 5 2 6 2 E 5 4 EP ELE n d Ee J 2 4 s c a 2 ze 22 g amp la amp 4 2 a 5 Ir 4 54 3 LEAL i T 6 29 3 AN2321 Test results 2 2 1 Test results Efficiency measurements Table 1 and Table 2 show the output voltage measurements at nominal mains with different load conditions Efficiency is then calculated For all measurements both at full load and no load operation the input power has been measured by a digital power meter Yokogawa WT 210 Particular attention has to be paid when measuring input power at full load in order to avoid measurement errors due to the voltage drop on cables and connections Therefore please connect the WT210 voltmeter termination to the board input connector For the same reason please measure the output voltage at the output connector or use the remote detect option of your active load for a correct voltage measurement Table 1 Efficiency measurements Vinz115 Vac Vout V lout A Pout W Pin W Efficiency 96 18 95 4 71 89 25 99 13 90 04 18 95 3 72 70 49 78 00 90 38 18 97 2 7 51 22 56 55 90 57 18 98 1 71 32 46 36 00 90 16 18 99 1 0 18 99 21 70 87 51 18 99 0 5 9 50 11 30 84 03 19 00 0 25 4 75 5 86 81 06 Table 2 Efficiency measurements Vin 230 Vac Vout V lout A Pout W Pin W Efficie
12. waveforms Figure 3 Resonant circuit primary side waveforms Tek Run Pe Detect 1450 Arg 0 Mar 06 174636 era Length Scale CH1 L6599 HB voltage CH3 400 V PFC Output voltage CH2 L6599 Vping CF 4 T1 primary winding current In Figure 3 are reported some waveforms during steady state operation of the circuit at full load The CH2 waveform is the oscillator signal at pin 3 of the L6599 while the CH3 waveform is the PFC output voltage powering the resonant stage The CH1 trace is the half bridge waveform driving the resonant circuit In the picture it is not obvious but the switching frequency is normally slightly modulated following the PFC 100 Hz ripple that is rejected by the resonant control circuitry The switching frequency has been chosen around 90 kHz in order to have a good trade off between transformer losses and its dimensions ky AN2321 Test results 2 3 The transformer primary current wave shape is the CH4 trace As shown it is almost sinusoidal because the operating frequency is slightly above the resonance of the leakage inductance and the resonant capacitor C28 In this condition the circuit has a good margin for ZVS operations providing good efficiency and the almost sinusoidal wave shape provides for an extremely low EMI generation Figure 4 Resonant circuit secondary side waveforms Tek Preview 1655 Aces 13 Mar 06 184042 Mead Ch2 Po
13. 0 V PFC Output voltage CH4 Resonant capacitor C28 current TA 201500519292 Tek Saq rera Pos Position Ch4 Scale 104 real 20 te M2 Ores 25 58 n SO gt 2008 1009 ow 100 ow Q A Oh 284 Figure 12 shows the waveforms during the start at 90 Vac and full load It is possible to note the sequence of the two stages at power on the L6563 and L6599 Vcc voltages increase up to the turn on thresholds of the two ICs The PFC starts and its output voltage increases from the mains rectified voltage to its nominal value with a small overshoot In the meantime the L6599 is kept inactive by the LINE pin 7 until the PFC voltage reaches the threshold 13 29 Test results AN2321 14 29 set by the divider R11 R12 R13 R28 As soon as it reaches the L6599 LINE pin threshold the resonant starts to operate Hence the output voltage rises according to the soft start and reaches the nominal level This sequence provides for the advantages of a perfect sequencing of the circuit at start up with the PFC acting as master and avoids complex additional circuitry for the correct start up of the circuit in all conditions The circuit has been tested in all line and load conditions showing a correct start up sequence The used high voltage start up circuit used avoids useless power dissipation during light load operation and
14. 63 the information about the PFC coil core demagnetization necessary to the controller for the TM operation The divider R1 R2 and R14 provides to the L6563 the information of the instantaneous voltage that is used to modulate the boost current and to derive some further information like the average value of the AC line used by the Ver voltage feed forward function This function keeps the output voltage almost independent of the mains one The divider R7 R8 R9 R10 detects the output voltage The second divider R11 R12 R13 and R28 protects the circuit in case of voltage loop fail The second stage is a resonant converter half bridge topology working in ZVS The controller is the new L6599 incorporating the necessary functions to drive properly the Half bridge by a 50 percent fixed duty cycle with dead time working with variable frequency The main features of the L6599 are a non linear soft start a new current protection pin ISEN pin 6 that programs the hiccup mode timing a dedicated pin for sequencing or brown out LINE and a stand by pin STBY for burst mode operation at light load The transformer uses the integrated magnetic approach incorporating the resonant series inductance Thus no any external additional coil is needed for the resonance The transformer configuration chosen for the secondary winding is centre tap using two Schottky rectifiers type STPS10L60FP The feedback loop is implemented by means of a typical circui
15. AL FILM RES 0 4 W 1 50ppm C BC COMPONENTS R9 82K SMD STANDARD FILM RES 1 8 W 195 100 9 COMPONENTS 21 29 Bill of material AN2321 Table 7 Bill of material continued 2 eh Description Supplier R101 0 39R SMD STANDARD FILM RES 1 8 W 595 250 COMPONENTS T1 86A 5166A RESONANT POWER TRANSFORMER DELTA ELECTRONICS U1 L6563 TRANSITION MODE PFC CONTROLLER STMicroelectronics U2 L6599D HIGH VOLTAGE RESONANT CONTROLLER STMicroelectronics U3 SFH617A 2 OPTOCOUPLER INFINEON U4 TL431AIZ PROGRAMMABLE SHUNT VOLTAGE REFERENCE STMicroelectronics 1 R101 mounted by reworking on PCB 22 29 Ti AN2321 PFC coil specification 6 PFC coil specification Application type consumer IT Transformer type open Coil former vertical type 6 6 pins Max temp rise 45 C Max operating ambient temp 60 C Mains insulation N A 6 1 Electrical characteristics Converter topology boost transition mode Core type RM14 PC40 or equivalent Min operating frequency 20 kHz Primary inductance 700 uH 10 1 kHz 0 25 V see Note 1 Peak primary current 5 Apk RMS primary current 1 8 A rms Note 1 Measured between pins 2 amp 5 Figure 18 Electrical diagram 5 8 e e PRIM AUX 2 11 Table 8 Winding characteristics Pins Winding RMS current Number of turns Wire type 5 2 PRIMAR
16. Figure 7 Waveforms at no load operation T Ren Hi 11 23 Dec 05 12 44 28 PR 122 23 OF Ma 06 13 1629 L e Ch Position 2 oS DL T 2 SaaS CH1 116599 Vpini4 HB voltage Ch2 Scale CH1 L6599 Vpini4 HB voltage CH2 19 V Output voltage CH2 L6563 RUN CH3 400 V PFC Output voltage CH3 400 V PCF Output voltage CH4 Q1 Drain voltage CH4 Q1 Drain voltage 10 29 Table 3 and Table 4 report the measurements of the input power during operation as a function of the output power Even with reduced load operation the burst mode functionality allows to work with good circuit efficiency ky AN2321 Test results Table 3 Stand by consumption Vinz115 Vac Vout V lout mA Pout W Pin W 19 01 80 1 5 3 19 01 53 1 2 19 01 27 0 5 1 08 19 01 13 0 25 0 66 Table 4 Stand by consumption Vinz230 Vac Vout V lout mA Pout W Pin W 19 01 80 1 5 2 4 19 01 53 1 19 01 27 0 5 1 19 01 13 0 25 0 67 Figure 8 shows the waveforms of the output voltage and current during load variation from 0 to 100 During operation at zero load the circuit is working in burst mode as described before then as soon as the load increases it works in continuous switching operation As shown due to the fact that the PFC is always o
17. M RES 1 8 W 1 100ppm C BC COMPONENTS R29 1K0 SMD STANDARD FILM RES 1 4 W 595 250 COMPONENTS R3 2M4 SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R30 10R SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R31 15K SMD STANDARD FILM RES 1 8 W 1 100ppm C BC COMPONENTS R32 47R SMD STANDARD FILM RES 1 4 W 5 250ppm C BC COMPONENTS R34 3K3 SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R35 SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R37 100K SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R38 56R SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS 20 29 ky AN2321 Bill of material Table 7 Bill of material continued 2 Description Supplier R39 130R SMD STANDARD FILM RES 1 4 W 595 250ppm C BC COMPONENTS R4 2M4 SMD STANDARD FILM RES 1 4 W 5 250ppm C BC COMPONENTS R40 688 5 STAND FILM RES 0 4 W 526 BC COMPONENTS R41 100R 2 STAND FILM RES 0 4 W 5 BC COMPONENTS R42 5K6 SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R43 51R SMD STANDARD FILM RES 1 8 W 595 250ppm C BC COMPONENTS R44 2K7 SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R46 100K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R47 1K0 SMD STANDA
18. RD FILM RES 1 8 W 5 250 BC COMPONENTS R48 47K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R49 39K SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R50 6K2 SMD STANDARD FILM RES 1 8 W 1 100ppm C COMPONENTS R51 120K SMD STANDARD FILM RES 1 8 W 1 100ppm C BC COMPONENTS R52 6K8 SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R53 ORO ORO JUMPER BC COMPONENTS R54 ORO ORO JUMPER BC COMPONENTS R55 ORO ORO JUMPER BC COMPONENTS R56 1K8 SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R57 ORO ORO JUMPER BC COMPONENTS R58 100K SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R59 100K SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R6 NTC 10R 5236 RESISTOR P N 5723650100 000 EPCOS R60 10K SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R62 4K7 SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R65 47K SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R66 2K2 SMD STANDARD FILM RES 1 4 W 5 250ppm C BC COMPONENTS R69 4K7 SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R7 1 0 MBB0207 AXIAL FILM RES 0 4 W 1 50ppm C BC COMPONENTS R70 100K SMD STANDARD FILM RES 1 8 W 5 250 BC COMPONENTS R71 12K SMD STANDARD FILM RES 1 4 W 1 100ppm C BC COMPONENTS R72 ORO ORO JUMPER BC COMPONENTS R8 1 0 MBB0207 AXI
19. TTKY RECTIFIER STMicroelectronics D15 BZV55 C18 ZENER DIODE VISHAY D16 LL4148 FAST SWITCHING DIODE VISHAY D17 BZV55 C12 ZENER DIODE VISHAY D18 LL4148 FAST SWITCHING DIODE VISHAY D19 LL4148 FAST SWITCHING DIODE VISHAY D20 BZV55 B15 ZENER DIODE VISHAY D3 1N4005 GENERAL PURPOSE RECTIFIER VISHAY D4 STTH2L06 ULTRAFAST HIGH VOLTAGE RECTIFIER STMicroelectronics D7 LL4148 FAST SWITCHING DIODE VISHAY D8 BZV55 B24 ZENER DIODE VISHAY D9 LL4148 FAST SWITCHING DIODE VISHAY F1 FUSE 4A FUSE TIME DELAY WICHMANN HS1 HEAT SINK FOR D1 amp Q1 DWG HS2 HEAT SINK FOR Q3 amp Q4 DWG 53 HEAT SINK FOR D12 amp D13 DWG J1 MKDS 1 5 3 5 08 PCB TERM BLOCK SCREW CONN 3 W PHOENIX CONTACT J2 MKDS 1 5 2 5 08 PCB TERM BLOCK SCREW CONN 2 W PHOENIX CONTACT L1 86A 5163 INPUT EMI FILTER DELTA ELECTRONICS L2 86A 5158C PFC INDUCTOR DELTA ELECTRONICS L3 RFB0807 2R2 2u2 RADIAL INDUCTOR COILCRAFT Q1 STP12NM50FP N CHANNEL POWER MOSFET STMicroelectronics Q10 BC847C NPN SMALL SIGNAL BJT STMicroelectronics Q2 BC847C NPN SMALL SIGNAL BJT STMicroelectronics Q3 STPSNK50ZFP POWER MOSFET STMicroelectronics 19 29 Bill of material AN2321 Table 7 Bill of material continued pa eh Description Supplier Q4 STPSNK50ZFP N CHANNEL POWER MOSFET STMicroelectronics Q5 BC847C NPN SMALL SIGNAL BJT STMicroele
20. Y 1 8 Anus 53 STRANDED 7 x 0 28 mm G2 8 11 AUX 0 05 Anus 4 SPACED 0 28 mm G2 1 Auxiliary winding is wound on top of primary winding ky 23 29 PFC coil specification AN2321 6 2 24 29 Mechanical aspect and pin numbering Maximum height from PCB 22 mm Coil former type vertical 6 6 pins Pin distance 5 08 mm Pins 41 3 4 6 7 10 12 are removed Pin 9 is for polarity key External copper shield Bare wound around the ferrite core and including the winding and coil former Height is 7 mm Connected by a solid wire soldered to pin 11 Manufacturer DELTA ELECTRONICS P N 86A 5158C Figure 19 Bottom view 2321 Resonant power transformer specification 7 7 1 Note Resonant power transformer specification Application type consumer IT 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 Compliance with EN60950 Electrical characteristics Converter topology half bridge resonant Core type ER35 PC40 or equivalent Min operating frequency 60 kHz Typical operating frequency 100 kHz Primary inductance 810 UH 10 91 kHz 0 25 V see Note 1 Leakage inductance 200 1H 10 91 kHz 0 25 V see Note 1 and Note 2 Measured between pins 1 4 Measured between pins 1 4 with ONLY a secondary winding shorted Figure 20 Electrical diagram
21. ation between measurement points and components is indicated below for both diagrams Figure 14 Thermal map 2115 Vac full load Table 5 Temperature of measured points 2115 Vac full load Points ref Temp A D1 59 1 C B Q1 54 0 C D4 67 6 C D R6 85 8 C E L2 45 7 C G Q3 46 5 61 8 C Tipp 67 2 J T1sec 67 4 C K D12 62 8 C L D13 62 8 C ky 15 29 Thermal tests AN2321 Figure 15 Thermal map 2230 Vac full load 250 27 Table 6 Temperature of measured points 2230Vac full load Points ref Temp A D1 45 9 C B Q1 44 3 C C D4 59 0 D R6 72 4 C E L2 43 7 C F Q4 46 8 G Q3 46 5 63 7 C I Tipn 67 9 J 1 69 5 K 012 64 8 L D13 64 9 C All other components of the board are working within the temperature limits assuring a reliable long term operation of the power supply 16 29 ky 2321 Conducted emission pre compliance test 4 Conducted emission pre compliance test The limits indicated on both diagrams at 115 Vac and 230 Vac comply with EN55022 Class B specifications The values are measured in peak detection mode Figure 16 CE peak measure at 115 Vac and full load Mkr1 15 38 MHz Ref 75 dp Rtten 18 dB 28 18 dBpV
22. ctronics Q6 BC847C NPN SMALL SIGNAL BJT STMicroelectronics Q8 STQ1HNK60R N CHANNEL POWER MOSFET STMicroelectronics Q9 BC847C NPN SMALL SIGNAL BJT STMicroelectronics R1 1 0 SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R10 15K SMD STANDARD FILM RES 1 8 W 1 100ppm C BC COMPONENTS R11 3MO MBB0207 AXIAL FILM RES 0 4 W 1 50ppm C BC COMPONENTS R12 3MO MBB0207 AXIAL FILM RES 0 4 W 1 50ppm C BC COMPONENTS R13 8K2 SMD STANDARD FILM RES 1 8 W 1 100ppm C COMPONENTS R14 18K SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R15 150K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R18 56K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R19 56K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R2 1M2 SMD STANDARD FILM RES 1 4 W 5 250ppm C COMPONENTS R20 10K SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R21 39R SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R22 0R47 2 STAND FILM RES 0 4 W 5 BC COMPONENTS R23 0R47 STAND FILM RES 0 4 W 5 BC COMPONENTS R24 1 0 SMD STANDARD FILM RES 1 4 W 5 250 COMPONENTS R25 56R SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R26 240K SMD STANDARD FILM RES 1 8 W 5 250ppm C BC COMPONENTS R27 470R SMD STANDARD FILM RES 1 4 W 5 250 BC COMPONENTS R28 24K9 SMD STANDARD FIL
23. e a RR De RR aC RC RR 27 2321 Main characteristics and circuit description Main characteristics and circuit description The main characteristics of the SMPS are listed here below Universal input mains range 90 264 Vac frequency 45 to 65 Hz Output voltage 19 V 4 7 A continuous operation Mains harmonics Compliance with EN61000 3 2 specifications Standby mains consumption 0 4 W 230 Vac Max 0 5 W 2265 Vac Overall efficiency better than 9096 EMI Compliance with EN55022 class B specifications Safety Compliance with EN60950 specifications Low profile design 25 mm maximum height PCB single layer 78x174 mm mixed PTH SMT technologies The circuit consists of two stages a front end PFC implementing the L6563 and a resonant DC DC converter based on the new resonant controller the L6599 The Power Factor Corrected PFC stage delivers a stable 400 VDC and provides for the reduction of the mains harmonic allowing to meet European standard EN61000 3 2 The controller is the L6563 U1 working in transition mode and integrating all functions needed to control the and interface the downstream resonant converter The power stage of the PFC is a conventional boost converter connected to the output of the rectifier bridge It includes coil L2 diode D4 and capacitor C9 The boost switch is represented by the power MOSFET Q1 The L2 secondary winding pins 8 10 is dedicated to provide to the L65
24. eeded the IC limits the voltage to a programmable safe value Moreover in the L6563 there is an additional protection against loop failures using an additional divider R11 R12 R13 R28 connected to a dedicated pin OK 47 protecting the circuit in case of loop failures disconnection or deviation from the nominal value of the feedback loop divider Hence the PFC output voltage is always under control and in case a fault condition is detected the circuitry will latch the L6563 operations and by means of the PWM LATCH pin 8 it will latch the L6599 as well via the pin 8 DIS The pin DIS is also used to protect the resonant stage against over voltage or loop disconnections In fact the zener diode D8 connected to pin DIS detects the voltage and in case of open loop it will conduct and voltage on pin DIS will exceed the internal threshold Then the IC will be immediately shut down and its consumption reduced at a low value This state will be latched and will be necessary to let the voltage on the Vcc pin go below the UVLO threshold to reset the latch and restart the IC operation Start up sequence Figure 12 Start up 2115 Vac full load Figure 13 Start up 2115 Vac full load TW Butt 0 13 Jan 06 13 17 43 CH1 L6599 Vpini4 HB voltage 1 16599 VpiN14 HB voltage 2 Vcc voltage CH2 L6599 Vpn2 SS CH3 19 V Output voltage CH3 19 V Output voltage CH4 40
25. forms at no load 10 Waveforms at no load 10 Load transition 0 100 11 Load transition 10096 0 2 eee eee 11 O P short circuit waveforms 12 O P short circuit waveforms 2 0 12 Start up 9115 Vac 13 Start up 115 Vac 13 Thermal map 9115 15 Thermal 230 16 CE peak measure at 115 Vac and full load 17 peak measure at 230 Vac and full load 17 Electricaldiagralm uoces acne REE a e RE a ee be ee a RU 23 Bottom VIEW e RE cee ce 24 2 mese REC VERS ERU NA 25 Pirilay out VIEW coh eis kee Los egeat 26 Thru hole component placing and top silk screen 27 SMT component placing and bottom silk screen 27 Copper Tacks css ea eta ac ce a a
26. n program externally the maximum time TSH that the converter is allowed to run overloaded or under short circuit conditions Overloads or short circuits lasting less than TSH will not cause any other action hence providing the system with immunity to short duration phenomena If instead TSH is exceeded an overload protection OLP procedure is activated that shuts down the L6599 and in case of continuous overload short circuit results in continuous intermittent operation with a user defined duty cycle This function is realized with the pin DELAY 2 by means of a capacitor C45 and the parallel resistor R24 connected to ground As the voltage on the ISEN pin exceeds 0 8V the first OCP comparator in addition to discharging CSS turns on an internal current generator that via the DELAY pin charges C45 As the voltage on C45 is 3 5 V the L6599 stops switching and the STOP pin is pulled low Also the internal generator is turned off so that C45 will now be slowly discharged by R24 The IC will restart when the voltage on C45 will be less than 0 3 V Additionally if the voltage on the ISEN pin reaches 1 5 V for any reason e g transformer saturation the second comparator will be triggered the L6599 will shutdown and the operation will be resumed after an on off cycle Figure 10 O P short circuit waveforms Figure 11 O P short circuit waveforms zoomed Ci 200 10 5 Arg 13 Jan 05 155022 Fes
27. ncy 18 95 4 71 89 25 97 23 91 80 18 96 3 72 70 53 76 74 91 91 18 97 2 7 51 22 55 85 91 71 18 98 1 71 32 46 35 57 91 24 18 99 1 0 18 99 21 30 89 15 19 00 0 5 9 50 10 87 87 40 19 00 0 25 4 75 5 77 82 32 In Table 1 Table 2 and Figure 2 the overall circuit efficiency is measured at different loads powering the board at the two nominal input mains voltages The measures have been done after 30 minutes of warm up at maximum load The high efficiency of the PFC working in transition mode and the very high efficiency of the resonant stage working in ZVS provides for an overall efficiency better than 9096 This is a significant high number for a two stage converter delivering an output current of 4 7 amps especially at low input mains voltage where the PFC conduction losses increase Even at lower loads the efficiency remains still high 7 29 Test results AN2321 2 2 8 29 Figure 2 Efficiency vs Pout Efficiency vs Pout 94 00 92 00 90 00 88 00 86 00 84 00 82 00 80 00 78 00 76 00 74 00 115Vac 230Vac Efficiency 89 71 51 32 19 10 5 O P Power The global efficiency at full load has been measured with good results even at the limits of the input voltage range Vin 90Vac full load Vin 264 Vac Full load Pin 100 5 W Pin 96 3 W Efficiency 88 9 Efficiency 92 6 Resonant stage operating
28. perating the circuit response is fast enough to avoid output voltage dips In Figure 9 the opposite load transition is checked 100 to 0 Even in this case the transition in clean and doesn t show any problem for the output voltage regulation Thus it is clear that the proposed architecture is the most suitable for power supply operating with strong load variation without any problem related to the load regulation Figure 8 Load transition 0 100 Figure 9 Load transition 100 0 d 2490 Ag 13 OF 15 57 48 fue Tes Ru Hi Pes 912 Aes 13 War OF 15 50 26 1 T C duse WE CH3 19 V Output voltage CH3 419 V Output voltage CH4 19 V Output current CH4 19 V ky 11 29 Test results AN2321 2 4 Short circuit protection The L6599 is equipped with a current sensing input pin 46 ISEN and a dedicated over current management system The current flowing in the circuit is detected and the signal is fed into the ISEN pin It is internally connected to the input of a first comparator referenced to 0 8 V and to that of a second comparator referenced to 1 5 V If the voltage externally applied to the pin by either circuit in Figure 8 exceeds 0 8 V the first comparator is tripped causing an internal switch to be turned on and discharging the soft start capacitor CSS Under output short circuit this operation results in a nearly constant peak primary current With the L6599 the designer ca
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30. sion history AN2321 9 28 29 Revision history Table 10 Revision history Date Revision Changes 01 Aug 2006 1 Initial release Fi 1 changed 15 May 2007 2 M Minor text changes AN2321 Please Read Carefully Information in this document is provided solely in connection with ST products STMicroelectronics NV and its subsidiaries ST reserve the right to make changes corrections modifications or improvements to this document and the products and services described herein at any time without notice All ST products are sold pursuant to ST s terms and conditions of sale Purchasers are solely responsible for the choice selection and use of the ST products and services described herein and ST assumes no liability whatsoever relating to the choice selection or use of the ST products and services described herein No license express or implied by estoppel or otherwise to any intellectual property rights is granted under this document If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein UNLESS OTHERWISE SET FORTH IN ST S TERMS AND CONDITIONS OF SALE
31. sition 319v Ch Scale 50 EPC Y T 7 083 1007 t OQ Q w AGS CH2 19V Output voltage ripple and noise CH3 D12 rectifiers anode voltage 4 D12 rectifiers current In Figure 4 are represented some waveforms relevant to the secondary side the rectifiers reverse voltage is measured by CH3 and the peak to peak value is indicated on the right of the picture It is a bit higher than the theoretical value that would be 2 Vour Vg hence about 40 V It is possible to observe a small ringing on the bottom side of the waveform responsible for this difference The channel CH4 green in the picture shows the current in the diode D12 equal to that one flowing in D13 Even this current shape is almost a sine wave its average value is half of the output current The ripple and noise on the output voltage is measured by CH2 Thanks to the advantages of the resonant converter the high frequency ripple and noise of the output voltage is only 100mV 0 52 including spikes while the residual ripple at mains frequency is 130 mV at maximum load and any line condition Stand by amp no load power consumption The board is specifically designed for light load and zero load operation like during operation with load disconnected The results are reported in the diagram of Figure 5 here following As highlighted in the diagram of Figure 4 the input power at no load is always below 0 4 W for any inp
32. t using a TL431 modifying the current in the optocoupler diode The optocoupler transistor modulates the current from pin 4 so the frequency will change accordingly thus achieving the output voltage regulation Resistor R34 sets the maximum operating frequency and the load at which the controller starts to work in Burst mode In case of a short circuit the current into the primary winding is detected by the lossless circuit R41 C27 D11 D10 R39 and C25 and it is fed into the pin 6 In case of overload the voltage on pin 6 will overpass an internal threshold that will trigger a protection sequence via pin 2 keeping the current flowing in the circuit at a safe level In case of output voltage loop failure the intervention of the zener diode connected to pin 48 DIS will activate the latched protection of the L6599 The DIS pin can be also activated by the L6563 via the PWM LATCH pin in case of PFC loop failure 5 29 Main characteristics and circuit description AN2321 Figure 1 Electrical diagram
33. ut mains voltage Thanks to the L6599 stand by function at light load conditions both the resonant converter and the PFC work skipping switching cycles according to the load In fact the L6599 via the STOP pin 9 stops the operation of the L6563 during the burst mode off time 9 29 Test results AN2321 Figure 5 Input power without load vs mains voltage Pin vs Vac no load 0 5 i dcc e 5 2 0 3 2 0 2 0 1 0 90Vac 115Vac 230Vac 265Vac Pin W 0 4 0 28 0 34 0 37 Mains voltage The result is visible in Figure 6 the two converters are now working for a very short time the output voltage is perfectly regulated at its nominal value with just a negligible residual ripple over imposed 140mV Thanks to the burst mode and the reduced number of switching cycles the relevant losses are drastically reduced therefore input power drawn from the mains is very low However if the output voltage has a sudden load change both converters are ready to react immediately thus avoiding output voltage drops In Figure 7 the details of the waveforms captured in Figure 6 show some details during the switching period and additionally the L6563 RUN pin 10 signal is captured This pin is connected to the PFC_STOP pin 9 of the L6599 and enables the operation of the PFC during the burst pulse of the resonant Figure 6 Waveforms at no load operation
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ST AN2321 Application note application note an-ss1