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december 2010 doc id 16064 rev 2 1/29 AN3014 application note 19 v, 90 w resonant converter with synchronous rectification using the l6563h, l6599a and srk2000 introduction this application note describes the characteristics and the features of a 90 w demonstration board (evl90wadp-llcsr), tailored to specifications for a typical high-end portable computer power supply. a peculiarity of this smps design is the very high efficiency compliant with energy star ? eligibility criteria (epa rev. 2.0 eps). one of the key factors in achieving this result is the srk2000. th is synchronous rectific ation driver for llc resonant converters allows significantly reduced secondary-side losses. thanks to this improvement, secondary-side heatsinks, which are typically needed for this power range, can be dramatically reduced or even removed. figure 1. evl90wadp-llcsr: 90 w adapter demonstration board !-v www.st.com
contents AN3014 2/29 doc id 16064 rev 2 contents 1 main characteristics and cir cuit description . . . . . . . . . . . . . . . . . . . . . 5 2 efficiency measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4 functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5 thermal map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6 conducted emission pre-compli ance test . . . . . . . . . . . . . . . . . . . . . . 18 7 bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 8 pfc coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 9 transformer specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 10 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AN3014 list of tables doc id 16064 rev 2 3/29 list of tables table 1. overall efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 table 2. efficiency comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 table 3. light load efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 table 4. thermal map reference points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 table 5. evl90wadp-llcsr demonstration bo ard bill of material . . . . . . . . . . . . . . . . . . . . . . . . 19 table 6. pfc coil winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 table 7. transformer winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 table 8. document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
list of figures AN3014 4/29 doc id 16064 rev 2 list of figures figure 1. evl90wadp-llcsr: 90 w adapter demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . 1 figure 2. electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 3. light load efficiency diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 figure 4. compliance to en61000-3-2 at 230 vac - 50 hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 5. compliance to jeita-miti at 100 vac - 50 hz, full load. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 6. resonant stage oscillator at 230 v - 50 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 7. resonant stage waveforms at 230 v - 50 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 8. secondary waveforms at 230 v - 50 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 9. startup sequencing at 230 v - 50 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 10. no load operation at 230 v - 50 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 11. no load operation - detail at 230 v - 50 hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 12. transition full load to no load at 265 vac - 50 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 13. transition no load to full load at 265 vac - 50 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 14. short-circuit at full load and 115 vac - 60 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 figure 15. short-circuit detail at full load and 115 vac - 60 hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 16. thermal map at 115 vac - 60 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 figure 17. thermal map at 230 vac - 50 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 figure 18. ce average measurement at 115 vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 figure 19. ce average measurement at 230 vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 figure 20. pfc coil electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 figure 21. pfc coil mechanical aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 figure 22. transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 figure 23. transformer overall drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AN3014 main characteristics and circuit description doc id 16064 rev 2 5/29 1 main characteristics and circuit description the main features of the smps are: universal input mains range: 90 ? 264 vac, frequency 45 ? 65 hz output voltage: 19 v at 4.75 a continuous operation mains harmonics: according to en61000-3-2 class-d or jeita-miti class-d standby mains consumption: < 0.26 w at 230 vac efficiency at nominal load: > 92% at 115 vac emi: according to en55022-class-b safety: according to en60950 dimensions: 65 x 155 mm, 25 mm maximum component height pcb: double-sided, 70 m, fr-4, mixed pth/smt the circuit is composed of two stages: a front-end pfc using the l6563h, and a llc resonant converter based on the l6599a. the srk2000 controls the synchronous rectification on the secondary side. the pfc stage works as a preregulator and powers the resonant stage with a constant voltage of 400 v. the downstream converter operates only if the pfc is on and regulating. in this way, the resonant stage can be optimized for a narrow input voltage range. startup sequence as indicated previously, the pfc acts as master and the resonant stage can operate only if the pfc output is delivering the nominal output voltage. therefore the circuit is designed so that at startup the pfc starts first, then the downstream converter turns on. initially, the l6563h is supplied by the integrated high voltage startup circuit, but as soon as the pfc starts switching, a charge pump connected to the pfc inductor supplies both the pfc and resonant controllers. once both stages have been activated, the controllers are supplied also by the auxiliary winding of the resonant transformer, as suring correct supply voltage even during standby operation. because the l6563h integrated hv startup circuit is turned off and therefore is not dissipative during normal operation, it significantly contributes to the reduction of power consumption when the power supply operates at light load, in accordance with current world-wide standby consumption standards. brownout protection brownout protection prevents the circuit from working with abnormal mains levels. it is easily achieved using the run pin (pin12) of the l6563h. this pin is connected through a resistor divider to the vff pin (pin 5), which provides the mains voltage peak value information. an internal comparator enables the ic operations if the mains level is correct, within the nominal limits. at startup, if the input voltage is below 90 vac (typ), circuit operations are inhibited. the l6599a has similar protection on the line pin (pin 7). it is used to prevent the resonant converter from working with too low an input voltage, which can cause incorrect capacitive mode operation. if the bulk voltage (pfc output) is below 380 v, the resonant startup is not allowed. the l6599a internal comparator has a hysteresis which allows the turn-on and turn-off voltage to be set independently. the turn-off threshold has been set to 300 v in
main characteristics and circuit description AN3014 6/29 doc id 16064 rev 2 order to avoid capacitive mode operation, but to allow the resonant stage to operate even in case of mains sag and consequent pfc output dip. fast voltage feed-forward the voltage on the l6563h vff pin (pin 5) is the peak value of the voltage on the mult pin (pin 3). the rc network (r15+r26, c12) connected to vff completes the peak-holding circuit. this signal is necessary to derive rms input voltage information to compensate the loop gain, which is mains voltage dependent. generally speaking, if the time constant is too small, the voltage generated is affected by a considerable amount of ripple at twice the mains frequency, thus causing distortion of the current reference (resulting in high thd and poor pf). if the time constant is too large, there is a considerable delay in setting the right amount of feed-forward, resulting in excessive overshoot or undershoot of the preregulator's output voltage in response to large line voltage changes. to overcome this issue, the l6563h implements the new fast voltage feed-forward function. as soon as the voltage on the vff pin decreases to a set threshold (40 mv typically), a mains dip is assumed and an internal switch rapidly discharges the vff capacitor via a 10- k resistor. thanks to this feature, it is possible to set an rc circuit with a long time constant, assuring a low thd and maintaining a fast response to mains dip. resonant power stage the downstream converter employs st?s l6599a, which incorporates all the functions necessary to properly control the resonant converter with a 50% fixed duty cycle and works with a variable frequency. the transformer uses the integrated magnetic approach, incorporating a resonant series inductor. thus, no additional external coil is needed for the resonance. the transformer configuration chosen for the secondary winding is center tap. on the secondary side, the output rectification is controlled by the srk2000, an sr driver dedicated to llc resonant topology. a small lc filter has been added on the output, filtering the high-frequency ripple. d15, r56, r62, r65, r66, q5 and q6 implement an output voltage ?fast discharge? circuit which quickly discharges the output capacitors when the converter is turned off. it has been implemented to quickly decrease the residual output voltage after the converter is turned off at no load. output voltage feedback loop the feedback loop is implemented by means of a typical circuit using a tl431 to modulate the current in the optocoupler diode. on the primary side, r34 - connecting the rfmin pin (pin 4) to the optocoupler phototransistor - closes the feedback loop and its value sets the maximum switching frequency at about 130 khz. this value has been chosen to limit the switching losses at light load operation. r31, which connects the same pin to ground, sets the minimum switching frequency. the r-c series (r44 and c18) sets both the soft-start maximum frequency and duration.
AN3014 main characteristics and circuit description doc id 16064 rev 2 7/29 l6599a overload and short-circuit protection the current into the primary winding is sensed by the lossless circuit r41, c27, d11, d10, r39, and c25 and is fed to the isen pin (pin 6). in case of overcurrent, the voltage on the pin passes an internal threshold (0.8 v), triggering a protection sequence. the capacitor (c45) connected to the delay pin (pin 2) is charged by an internal 150-a current generator and is slowly discharged by the external resistor (r24). if the voltage on the pin reaches 2 v, the soft-start capacitor is completely discharged so that the switching frequency is pushed to its maximum value. as the voltage on the pin exceeds 3.5 v, the ic stops switching and the internal generator is turned off, so that the voltage on the pin decays due to the external resistor. the ic is soft-restarted as the voltage drops below 0.3 v. in this way, under short-circuit conditions, the converter works intermittently with very low input average power. overvoltage and open loop protection both the pfc and resonant circuit stages are equipped with their own overvoltage protection. the pfc controller l6563h monitors its output vo ltage via the resistor divider connected to a dedicated pin (pfc_ok, pin 7), protecting the circuit in case of loop failures, disconnection or deviation from the nominal value of the feedback loop divider. if the voltage on pin #7 exceeds 2.5 v the ic stops switching and restarts as the voltage on the pin falls below 2.4 v, preventing the output voltage becoming excessive in case of transient due to the slow response of the error amplifier. however, if contemporaneously the voltage of the inv pin falls below 1.66 v (typ.), a feedback fa ilure is assumed. in this case the pfc_ok circuitry latches the l6563h operations and, by means of the pwm_latch pin (pin 8) it latches the l6599a as well, via the dis pin (pin 8). the converter is kept latched by the l6563h hv circuit which supplies the ic, charging the v cc capacitor periodically. to resume converter operation, mains restart is necessary. the dis pin is used to protect also the resonant stage against overvoltage. the zener diode d8 detects the auxiliary voltage, which is proportional to the output voltage. in case of loop failure it conducts and voltage on the dis pin exceeds the internal threshold, and latches off the device. l6563h operation is also stopped by the pfc_stop pin. secondary-side synchronous rectification with the srk2000 the srk2000 core function is to switch on each synchronous rectifier mosfet whenever the corresponding transformer half-winding starts conducting (i.e. when the mosfet body diode starts conducting), and then to switch it off when the current flowing through it approaches zero. for this purpose, the ic is equipped with two pins (dvs1 and dvs2) capable of sensing the mosfet drain voltage level. standby power saving the board has a burst-mode function implemented, allowing power saving during light load operation. the l6599a stby pin (pin 5) senses the optocoupler?s collector voltage, which is related to the feedback control. this signal is compared to an internal reference (1.24 v). if the voltage on the pin is lower than the reference, the ic enters an idle state and its quiescent current is reduced. as the voltage exceeds the reference by 50 mv, the controller restarts the switching. the burst-mode operation load threshold can be programmed by properly choosing the resistor connecting the optocoupler to the rfmin pin (r34). on this board, the controller operates in burst-mode if the load falls below ~10 w.
main characteristics and circuit description AN3014 8/29 doc id 16064 rev 2 the l6563h implements its own burst-mode function. if the comp voltage falls below 2.5 v, the ic stops switching, causing an output voltage drop. as a consequence, the comp voltage rise again and the ic starts switching again. in order to achieve better load transient response, the pfc burst-mode operation is partially forced by the resonant converter: as soon as the l6599a stops switching due to load drops, its pfc_stop pin pulls down the l6563h's pfc_ok pin, disabling pfc switching. thanks to this simple circuit, the pfc is forced into an idle state when the resonant stage is not switching, and rapidly wakes up when the down stream converter restar ts switching. this solution prevents significant drop of the bulk voltage in case of abrupt load rising.
AN3014 main characteristics and circuit description doc id 16064 rev 2 9/29 figure 2. electrical diagram !-v 9df ,19 &203 08/7 &6 9)) 7%2 3)&2. 3:0/$7&+ 3:06723 581 =&' *1' *' 9&& +96 1& 8 /+ 8 /+ & q) & q) 8 7/$,= 8 7/$,= & q) & q) 5 . 5 . & x) & x) 4 67)1) 4 67)1) 5 . 5 . 5 . 5 . 4 %&& 4 %&& 5 . 5 . & q) & q) 5 5 5 5 & x) & x) - 0.'6 - 0.'6 5 . 5 . 5 . 5 . 5 5 5 5 ' // ' // & q) & q) & q) & q) 5 5 5 5 5 . 5 . 5 5 5 5 5 . 5 . & s) & s) & x) & x) 5 5 5 5 5 . 5 . 6*1' (1 '96 '96 *' 3*1' *' 9&& 8 65. 8 65. 5 5 5 5 & s) & s) 5 0 5 0 5 . 5 . 5 17&56 5 17&56 & q) & q) ' 1 ' 1 5 . 5 . 5 . 5 . & x) & x) ' 677+/ ' 677+/ 5 5 5 5 & x) & x) ' // ' // & q) & q) ' // ' // & q) & q) 5 . 5 . 5 0hj 5 0hj & q) & q) 5 . 5 . 4 67)101 4 67)101 & q) & q) ' // ' // & q) & q) 5 . 5 . & q) & q) 5 0 5 0 5 . 5 . & x) & x) 7 7 & q) & q) 5 5 5 5 & q) & q) 5 . 5 . 5 . 5 . 5 0hj 5 0hj ' %=9% ' %=9% 5 . 5 . & x) & x) 5 0hj 5 0hj ' // ' // 5 . 5 . & q) & q) 5 . 5 . ' // ' // ' // ' // ) )86(7$ ) )86(7$ 5 . 5 . & q) & q) 5 . 5 . & q) & q) 4 67310)3 4 67310)3 +6 +($76,1. +6 +($76,1. 5 . 5 . 4 %&& 4 %&& / / 5 5 5 5 5 0hj 5 0hj & q) & q) 4 67310)3 4 67310)3 5 5 5 5 & x) & x) 5 . 5 . & q) & q) & q) & q) & x) & x) 4 67)1) 4 67)1) ' %=9& ' %=9& ' %=9% ' %=9% 5 5 5 5 5 0 5 0 5 . 5 . & q) & q) & q) & q) 5 . 5 . & s) & s) b a a ' *%8- b a a ' *%8- 5 5 5 5 5 . 5 . 5 . 5 . 4 %&& 4 %&& 5 . 5 . 5 . 5 . 5 0 5 0 ' 6736/$ ' 6736/$ & x) & x) 5 0hj 5 0hj - 0.'6 - 0.'6 5 . 5 . 5 0 5 0 & q) & q) & q) & q) / +)<57 / +)<57 / x+ / x+ & q) & q) & q) & q) 5 . 5 . 5 0 5 0 &66 '(/$< &) 5)0,1 67%< ,6(1 /,1( *1' /9* 9&& 1& 287 +9* 9%227 ',6 3)&6723 8 /$ 8 /$ & x) & x) 8 6)+$ 8 6)+$ & x) & x) ' // ' // 5 . 5 . ' // ' // 5 5 5 5 5 . 5 . 5 5 5 5 5 . 5 . & q) & q)
efficiency measurement AN3014 10/29 doc id 16064 rev 2 2 efficiency measurement epa rev. 2.0 external power supply compliance verification ta bl e 1 shows the no-load consumption and overall efficiency, measured at the nominal mains voltages. at 115 vac the average efficiency is 91.27%, while at 230 vac it is 92.22%. both values are much higher than the 87% required by the epa rev 2.0 external power supply limits. even at no-load, the board performances are superior: maximum no-load consumption at nominal mains voltage is 260 mw only. this value is significantly lower than the limit imposed by the energy star ? program, which is 500 mw. efficiency comparison between diode rectification and synchronous rectification in ta b l e 2 , the efficiency of two different designs are compared. one is the evl90wadp- llcsr board, and the other is an identical board but with diode rectification (two stps10l60 devices). in this way, a direct indication of the efficiency improvement obtained with the new synchronous rectific ation solution is obtained. table 1. overall efficiency test 230 v-50 hz 115 v-60 hz vout [v] iout [ma] pout [w] pin [w] eff. [%] vout [v] iout [ma] pout [w] pin [w] eff. [%] no load 18.98 0.00 0.00 0.26 - 18.98 0.00 0.00 0.23 - 25% load eff. 18.97 1187 22.52 25.46 88.45% 18.97 1187 22.51 25.41 88.57% 50% load eff. 18.95 2375 45.01 48.70 92.42% 18.95 2374 44.99 49.03 91.77% 75% load eff. 18.94 3565 67.52 71.96 93.82% 18.94 3565 67.50 73.06 92.38% 100% load eff. 18.92 4756 89.99 95.54 94.19% 18.92 4758 90.02 97.48 92.34% average eff. 92.22% 91.27% table 2. efficiency comparison test 230 v-50 hz 115 v-60 hz eff. with diodes eff. with srk2000 variation eff. with diodes eff. with srk2000 variation 25% load eff. 87.49% 88.45% 0.96% 88.24% 88.57% 0.33% 50% load eff. 91.52% 92.42% 0.90% 90.85% 91.77% 0.91% 75% load eff. 92.58% 93.82% 1.24% 91.16% 92.38% 1.23% 100% load eff. 92.84% 94.19% 1.35% 91.00% 92.34% 1.34% average eff. 91.11% 92.22% 1.11% 90.31% 91.27% 0.95%
AN3014 efficiency measurement doc id 16064 rev 2 11/29 light load operation efficiency measurement results are reported in ta b l e 3 below and plotted in figure 3 . as shown, efficiency is better than 68% even for very light loads, such as 1 w. figure 3. light load efficiency diagram table 3. light load efficiency test 230 v - 50 hz 115 v - 60 hz vout [v] iout [ma] pout [w] pin [w] eff. [%] vout [v] iout [ma] pout [w] pin [w] eff. [%] 0.25 w 18.97 13.2 0.250 0.610 41. 05% 18.97 13.2 0.250 0.590 42.45% 0.5 w 18.97 26.4 0.501 0.877 57. 18% 18.97 26.4 0.501 0.870 57.57% 1.0 w 18.97 52.7 0.999 1.467 68. 13% 18.97 52.7 0.999 1.457 68.60% 1.5 w 18.98 79.0 1.499 2.160 69. 41% 18.97 79.2 1.503 2.134 70.41% 2.0 w 18.97 105.5 2.002 2.822 70. 93% 18.97 105.5 2.002 2.895 69.15% 2.5 w 18.97 131.8 2.500 3.558 70. 27% 18.98 131.8 2.501 3.711 67.38% 3.0w 18.98 158.3 3.004 4.110 73.09 % 18.97 158.3 3.002 4.230 70.97% 3.5 w 18.97 184.5 3.501 4.660 75. 13% 18.97 184.5 3.501 4.637 75.49% 4.0 w 18.97 210.8 3.999 5.256 76. 08% 18.97 210.8 3.999 5.234 76.40% 4.5 w 18.97 237.3 4.502 5.840 77. 08% 18.97 237.3 4.502 5.830 77.22% 5.0 w 18.97 263.6 5.000 6.450 77. 52% 18.97 263.6 5.001 6.420 77.89% !-v /utputpower;7= %fficiency 9+] 9+]
harmonic content measurement AN3014 12/29 doc id 16064 rev 2 3 harmonic content measurement the board has been tested according to the european standard en61000-3-2 class-d and japanese standard jeita-miti class-d, at both nominal input voltage mains. as reported in graphs that follow, the circuit is capable of reducing the harmonics well below the limits of both regulations. at the bottom of the diagrams, the total harmonic distortion and power factor measurements are also reported. the values in all conditions provide a clear overview of the correct functionality of the pfc. figure 4. compliance to en61000-3-2 at 230 vac - 50 hz, full load figure 5. compliance to jeita-miti at 100 vac - 50 hz, full load !-v +duprqlf2ughu>q@ +duprqlf&xuuhqw>$@ 0hdvxuhgydoxh (1&odvv'olplwv 4($ 0& !-v +duprqlf2ughu>q@ +duprqlf&xuuhqw>$@ 0hdvxuhgydoxh -(,7$0,7,&odvv'olplwv 7+' 3)
AN3014 functional check doc id 16064 rev 2 13/29 4 functional check figure 6 and figure 7 are waveforms relevant to the resonant stage during steady state operation. the selected switching frequency is approximately 100 khz in order to achieve a good trade-off between transformer losses and dimensions. the converter operates above the resonance frequency. figure 7 shows the resonant zvs operation. both mosfets are turned on when resonant current is flowing through their body diodes and the drain-source voltage is zero. in figure 8 , typical waveforms relevant to the secondary side are shown. it can be noted that the rectifier mosfets are switched on and off according to the current flowing through them. figure 9 shows the waveforms during startup at 90 vac and full load. here, the sequence of the two stages can be noted: at power-on the l6563h and l6599a v cc 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. in the meantime, the l6599a is kept inactive by the line pin (pin 7) until the pfc voltage reaches the set threshold. then the resonant starts operating and the output voltage reaches the nominal level. figure 6. resonant stage oscillator at 230 v - 50 hz - full load figure 7. resonant stage waveforms at 230 v - 50 hz - full load !-v #( ("voltage #( #&pinvoltage #( 6cc #( 2estankcurrent !-v #( ("voltage #( (6&%4gate #( ,6 &%4gate #( 2estankcurrent
functional check AN3014 14/29 doc id 16064 rev 2 standby and no-load operation in figure 10 and figure 11 , some burst-mode waveforms are displayed. as illustrated, both the l6599a and l6563h operate in burst-mode. in figure 11 it can be observed that the pfc and llc bursts are synchronized. in figure 12 and figure 13 the transitions from full load to no load and vice-versa at maximum input voltage have been checked. the maximum input voltage has been chosen because it is the most critical input voltage for transition; in fact, at no load the burst pulses have the lower repetition frequency and the v cc could drop, causing restart cycles of the controller. as visible in the images, both transitions are clean and there is no output voltage or v cc dip. figure 8. secondary waveforms at 230 v - 50 hz figure 9. startup sequencing at 230 v - 50 hz !-v #( 1gate #( 1gate #( 1current #( 1current !-v #( 1gate #( 1gate #( 1current #( 1current figure 10. no load operation at 230 v - 50 hz figure 11. no load operation - detail at 230 v - 50 hz !-v #( ("voltage #( 34"9pin #( outputvoltage #( 0&#gatevoltage !-v #( ("voltage #( 34"9pin #( outputvoltage #( 0&#gatevoltage
AN3014 functional check doc id 16064 rev 2 15/29 overcurrent and short-circuit protection the l6599a is equipped with a current sensing input (pin 6, isen) and a dedicated overcurrent management system. the current flowing in the resonant tank is detected and the signal is fed to the isen pin. it is interna lly 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 discharging the soft-start capacitor css. under output short-circuit, this operation results in a nearly constant peak primary current. with the l6599a, designers can externally program the maximum time that the converter is allowed to run in overload or short-circuit conditions. overloads or short-circuits lasting less than the set time do not cause any protective action, thus providing the system with immunity to short-duration phenomena. if, instead, an overload condition continues, a protection procedure is activated that shuts down the l6599a 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 delay pin (pin 2) by means of a capacitor (c45) and the parallel resistor r24 connected to ground. if the voltage on the isen pin exceeds 0.8 v, the first ocp comparator, in addition to discharging css, turns on an internal 150 a current generator which, via the delay pin, charges c45. if the voltage on c45 is 3.5 v, the l6599a stops switching and the pfc_stop pin is pulled low. also, the internal generator is turned off, so that c45 is now slowly discharged by r24. the ic restarts when the voltage on c45 is less than 0.3 v. additionally, if the voltage on the isen pin reaches 1.5 v for any reason (e.g. transformer saturation), the second comparator is triggered, the l6599a shuts down, and operation resumes after an off-on cycle. figure 12. transition full load to no load at 265 vac - 50 hz figure 13. transition no load to full load at 265 vac - 50 hz !-v #( ("voltage #( 32+gate #( outputcurrent #( 6 ## !-v #( ("voltage #( 32+gate #( outputcurrent #( 6 ##
functional check AN3014 16/29 doc id 16064 rev 2 in the graphs above it can be noted that the average output current as well as the average primary current are limited, preventing converter over-heating and consequent failure. figure 14. short-circuit at full load and 115 vac - 60 hz figure 15. short-circuit detail at full load and 115 vac - 60 hz !-v #( ("voltage #( $%,!9pin #( outputcurrent #( )3%.pin !-v #( ("voltage #( $%,!9pin #( outputcurrent #( )3%.pin
AN3014 thermal map doc id 16064 rev 2 17/29 5 thermal map in order to check design reliability, thermal ma pping by means of an ir camera was done. below, thermal measurements of the component side of the board at nominal input voltage are shown. the pointers on the images have been placed across key components. the ambient temperature during both measurements was 27 c. figure 16. thermal map at 115 vac - 60 hz - full load figure 17. thermal map at 230 vac - 50 hz - full load the pictures highlight that although both the synchronous rectifier mosfets at secondary side are working without a heatsink, their operating case temperature is lower than 60 c. table 4. thermal map reference points point reference description a l1 emi filtering inductor b d1 bridge rectifier c l2 pfc inductor d d4 pfc output diode e q3 resonant high-side mosfet f t1 resonant power transformer g q11 output rectifier mo sfets (hottest spot) !-v !-v
conducted emission pre-compliance test AN3014 18/29 doc id 16064 rev 2 6 conducted emission pre-compliance test the following figures represent the average measurement of the conducted noise at full load and nominal mains voltages. the limits shown on the diagrams are those of the en55022 class-b standard, which is most popular standard for domestic equipment, and sets more severe limits compared to class-a, dedicated to it technology equipment. as visible in the diagrams, under all test conditions the measurements are well below the limits. figure 18. ce average measurement at 115 vac and full load figure 19. ce average measurement at 230 vac and full load !-v !-v
AN3014 bill of material doc id 16064 rev 2 19/29 7 bill of material table 5. evl90wadp-llcsr demonstration board bill of material des. part type/part value description supplier case c1 470 nf x2 - flm cap - r46-i 3470--m1- arcotronics 918 mm p15 mm c2 2.2 nf y1 safety cap. de1e3kx222m murata dwg c3 2.2 nf y1 safety cap. de1e3kx222m murata dwg c4 470 nf x2 - flm cap - r46-i 3470--m1- arcotronics 918 mm p15 mm c5 470 nf 400 v - film cap - b32653a4474 epcos dwg c6 4.7 nf 50 v cercap - general purpose avx 0805 c7 100 nf 100 v cercap - general purpose avx pth c8 10 f aluminum elcap - yxf series rubycon dia. 6.3x11 mm c9 47 f 450 v aluminum elcap - ed series panasonic dia. 18x32 mm c10 1 nf 50 v cercap - general purpose avx 0805 c11 2.2 nf 50 v cercap - general purpose avx 0805 c12 1 f 25 v cercap - general purpose avx 0805 c13 680 nf 25 v cercap - general purpose avx 1206 c14 68 nf 50 v cercap - general purpose avx 0805 c15 47 f 50 v aluminum elcap - yxf series rubycon dia. 6.3x11 mm c16 2.2 nf 50 v cercap - general purpose avx 1206 c17 470 pf 50 v - 5% - c0g - cercap avx 0805 c18 2.2 f 6.3 v cercap - general purpose avx 1206 c19 100 nf 50 v cercap - general purpose avx 1206 c20 2.2 nf y1 safety cap. de1e3kx222m murata dwg c21 2.2 nf y1 safety cap. de1e3kx222m murata dwg c22 220 pf 50 v cercap - general purpose avx 0805 c23 10 nf 50 v cercap - general purpose avx 0805 c24 100 f 50 v aluminum elcap-yxf series rubycon dia. 10x12.5 mm c25 330 nf 50 v cercap - general purpose avx 0805 c26 10 f 50 v aluminum elcap - yxf series rubycon dia. 6.3x11 mm c27 220 pf 500 v cercap - 5mq221kaaaa avx 5x3 mm c28 22 nf 630 v - phe450ma5220jr05 kemet 16x8 mm c29 470 f 35 v aluminum elcap - yxf series rubycon dia. 12.5x20 mm c30 470 f 35 v aluminum elcap - yxf series rubycon dia. 12.5x20 mm c31 220 f 35 v aluminum elcap - fm series panasonic d8x16 c32 100 nf 50 v cercap - general purpose avx 0805
bill of material AN3014 20/29 doc id 16064 rev 2 c34 220 nf 50 v cercap - general purpose avx 0805 c36 1 f 50 v aluminum elcap - yxf series rubycon dia. 6.3x11 mm c39 100 nf 50 v cercap - general purpose avx 0805 c40 100 nf 50 v cercap - general purpose avx 1206 c41 100 nf 50 v cercap - general purpose avx 0805 c42 100 nf 50 v cercap - general purpose avx 1206 c43 4.7 nf 50 v cercap - general purpose avx 1206 c44 10 nf 50 v cercap - general purpose avx 1206 c45 220 nf 25 v cercap - general purpose avx 0805 c48 10 f 50 v aluminum elcap - yxf series rubycon dia. 6.3x11 mm d1 gbu4j single-phase bridge rectifier vishay gbu d2 ll4148 high-speed signal diode vishay sod-80 d3 1n4005 general purpose rectifier vishay do-41 d4 stth2l06 ultrafast high-voltage rectifier stmicroelectronics do-41 d5 ll4148 high-speed signal diode vishay sod-80 d7 ll4148 high-speed signal diode vishay sod-80 d8 bzv55-b27 zener diode vishay sod-80 d9 stps1l60a power schottky rectifier stmicroelectronics sma d10 ll4148 high-speed signal diode vishay sod-80 d11 ll4148 high-speed signal diode vishay sod-80 d15 bzv55-c15 zener diode vishay sod-80 d16 ll4148 high-speed signal diode vishay sod-80 d18 ll4148 high-speed signal diode vishay sod-80 d19 ll4148 high-speed signal diode vishay sod-80 d20 bzv55-b15 zener diode vishay sod-80 d22 ll4148 fast switching diode vishay sod-80 f1 fuse t4a fuse 4 a - time lag - 3921400 littelfuse p 5.08 mm hs1 heatsink heatsink for d1, q1, q3, q4 dwg j1 mkds 1,5/ 3-5,08 pcb term. block, screw conn., - 3 wires phoenix contact p 5.08 mm j2 mkds 1,5/ 2-5,08 pcb term. block, screw conn., - 2 wires phoenix contact p 5.08 mm l1 hf2826-123y1r8-t01 input emi filter tdk dwg l2 1974.0002 pfc inductor - 0.52 mh magnetica dwg l3 1073.0083 1 h - 5 a inductor magnetica dwg q1 stf12nm50n n-channel power mo sfet stmicroelectronics to-220fp q3 stp8nm50fp n-channel power mosf et stmicroelectronics to-220fp table 5. evl90wadp-llcsr demonstration board bill of material (continued) des. part type/part value description supplier case
AN3014 bill of material doc id 16064 rev 2 21/29 q4 stp8nm50fp n-channel power mosf et stmicroelectronics to-220fp q5 bc847c npn small signal bjt vishay sot-23 q6 bc847c npn small signal bjt vishay sot-23 q9 bc847c npn small signal bjt vishay sot-23 q11 stf60n55f3 n-channel power mosfet stmicroelectronics to-220fp q12 stf60n55f3 n-channel power mosfet stmicroelectronics to-220fp r1 3.3 m smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r2 3.3 m smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r3 1 m smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r4 2.2 m smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r5 10 smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r6 ntc 2r5-s237 ntc resistor p/n b57237s0259m000 epcos dwg r7 1 m smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r8 1 m smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r9 62 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r10 27 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r11 2.2 m smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r12 2.2 m smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r13 10 k smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r14 51 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r15 56 k smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r16 4.7 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r17 2.2 k smd film res - 1/4 w - 1% - 100 ppm/c vishay 1206 r18 82 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r19 56 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r21 39 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r22 0.47 axial film res - 0.4 w - 5% - 250 ppm/c vishay pth r23 0.82 axial film res - 0.4 w - 5% - 250 ppm/c vishay pth r24 1 m smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r25 56 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r26 1 m smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r27 470 smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r28 33 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r29 1.0 k smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r30 10 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 table 5. evl90wadp-llcsr demonstration board bill of material (continued) des. part type/part value description supplier case
bill of material AN3014 22/29 doc id 16064 rev 2 r31 15 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r32 47 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r34 3.3 k smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r35 180 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r37 220 k smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r38 56 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r39 130 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r40 0.0 smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r41 100 axial film res-0.4 w - 5% - 250 ppm/c vishay pth r42 4.7 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r43 51 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r44 4.3 k smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r46 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r47 1.0 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r48 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r49 39 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r50 6.2 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r51 120 k smd film res - 1/8 w - 1% - 100 ppm/c vishay 0805 r53 0.0 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r54 0.0 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r56 18 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r58 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r59 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r60 10 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r62 4.7 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r63 27 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r64 27 smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r65 47 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r66 2.2 k smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 r68 7.5 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r69 4.7 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r74 3.9 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r75 3.9 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r76 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r77 100 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 table 5. evl90wadp-llcsr demonstration board bill of material (continued) des. part type/part value description supplier case
AN3014 bill of material doc id 16064 rev 2 23/29 r78 33 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r79 150 k smd film res - 1/8 w - 5% - 250 ppm/c vishay 0805 r80 0.0 smd film res - 1/4 w - 5% - 250 ppm/c vishay 1206 t1 1860.0025 resonant power transformer magnetica dwg u1 l6563h high voltage startup tm pfc controller stmicroelectronics so-16 u3 sfh617a-2 optocoupler infineon dip-4 u4 tl431aiz programmable shunt voltag e reference stmicroelectronics to-92 u5 srk2000 synch. rect. driver for llc res conv stmicroelectronics so-8 u6 l6599a improved hv resonant co ntroller stmicroelectronics so-16 table 5. evl90wadp-llcsr demonstration board bill of material (continued) des. part type/part value description supplier case
pfc coil specification AN3014 24/29 doc id 16064 rev 2 8 pfc coil specification general description and characteristics application type: consumer, home appliance transformer type: open coil former: vertical type, 6+6 pins max. temperature rise: 45 c max. operating ambient temperature: 60 c mains insulation: n.a. unit finishing: varnished electrical characteristics converter topology: boost, transition mode core type: pq26/20-pc44 or equivalent min. operating frequency: 40 khz typical operating frequency: 120 khz primary inductance: 520 h 10% at 1 khz - 0.25 v (see note below) peak primary current: 4.2 apk note: measured between pins 5 and 9. electrical diagram and winding characteristics figure 20. pfc coil electrical table 6. pfc coil winding data pins windings rms current number of turns wire type 11 - 3 aux 0.05 a rms 5.5 0.28 mm ? g2 5 - 9 primary 1.4 a rms 57.5 30x 0.1 mm ? g1 !-v
AN3014 pfc coil specification doc id 16064 rev 2 25/29 mechanical aspect and pin numbering maximum height from pcb: 22 mm coil former type: vertical, 6+6 pins (pins 1, 2, 4, 6, 7, 10, 12 are removed) pin distance: 3.81 mm row distance: 25 mm external copper shield: not insulated, wound around the ferrite core and including the coil former. height is 8 mm. connected to pin 3 by a soldered solid wire. figure 21. pfc coil mechanical aspect manufacturer magnetica - italy inductor p/n: 1974.0002 !-v
transformer specification AN3014 26/29 doc id 16064 rev 2 9 transformer specification general description and characteristics application type: consumer, home appliance transformer type: open coil former: horizontal type, 7+7 pins, two slots max. temperature rise: 45 c max. operating ambient temperature: 60 c mains insulation: in accordance with en60950 electrical characteristics converter topology: half bridge, resonant core type: etd34-pc44 or equivalent min. operating frequency: 60 khz typical operating frequency: 100 khz primary inductance: 1200 h 10% at 1 khz - 0.25 v (see note 1 ) leakage inductance: 200 h 10% at 100 khz - 0.25 v (see note 2 ) note: 1 measured between pins 2-4 2 measured between pins 2-4 with only one secondary winding shorted electrical diagram and winding characteristics figure 22. transforme r electrical diagram table 7. transformer winding data pins winding rms current number of turns wire type 2-4 primary 1 a rms 50 30 x 0.1 mm ? g1 14-13 sec - a (1) 1. secondary windings a and b are in parallel 4 a rms 590 x 0.1 mm ? g1 12-11 sec ? b (1) 4 a rms 590 x 0.1 mm ? g1 5-6 aux (2) 0.05 a rms 4 0.28 mm ? g2 !-v 35,0 $8; 6(&% 6(&$
AN3014 transformer specification doc id 16064 rev 2 27/29 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 23. transformer overall drawing manufacturer magnetica - italy transformer p/n: 1860.0025 2. aux winding is wound on top of primary winding !-v
revision history AN3014 28/29 doc id 16064 rev 2 10 revision history table 8. document revision history date revision changes 22-mar-2010 1 initial release. 13-dec-2010 2 updated chapter 1
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