Application Note

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.
February 2011
EVL170W-FTV: 170 W demonstration board
Doc ID 18376 Rev 1
1/47
www.st.com
Contents
AN3329
Contents
1
Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 6
2
Efficiency measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4
Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5
Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 29
6
Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7
PFC coil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8
Resonant power transformer specifications . . . . . . . . . . . . . . . . . . . . 41
9
Auxiliary flyback transformer specifications . . . . . . . . . . . . . . . . . . . . 43
10
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2/47
Doc ID 18376 Rev 1
AN3329
List of tables
List of tables
Table 1.
Table 2.
Table 3.
Table 4.
Table 5.
Table 6.
Table 7.
Overall efficiency measured at different AC input voltages . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PFC coil winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Resonant transformer winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DC output voltage and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Standby transformer winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Doc ID 18376 Rev 1
3/47
List of figures
AN3329
List of figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
Figure 22.
Figure 23.
Figure 24.
Figure 25.
Figure 26.
Figure 27.
Figure 28.
Figure 29.
Figure 30.
Figure 31.
Figure 32.
Figure 33.
Figure 34.
Figure 35.
Figure 36.
Figure 37.
Figure 38.
Figure 39.
Figure 40.
Figure 41.
Figure 42.
Figure 43.
Figure 44.
Figure 45.
Figure 46.
Figure 47.
Figure 48.
Figure 49.
4/47
EVL170W-FTV: 170 W demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overall efficiency vs. output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Average efficiency acc. ES-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Standby supply efficiency vs. output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Standby supply efficiency vs. light load output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EN61000-3-2 compliance at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
JEITA-MITI compliance at 100 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EN61000-3-2 compliance at 230 Vac - 50 Hz, 75 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
JEITA-MITI compliance at 100 Vac - 50 Hz, 75 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Input voltage and current at 100 Vac, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Input voltage and current at 230 Vac, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standby supply waveforms at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standby supply waveforms at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standby supply waveforms at 400 Vdc, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standby supply output rectifiers PIV at 400 Vdc, full load . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standby supply 5 V ripple at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standby supply startup at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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
Standby supply OVP at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Standby supply OVP at 230 Vac - 50 Hz - 0.5 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Standby supply OVP at 115 Vac - 60 Hz - PFC on - 1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Standby supply OVP at 115 Vac - 60 Hz - PFC on - 1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Standby supply output short-circuit at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . 16
Standby supply output short-circuit at 230 Vac - 50 Hz, full load - detail . . . . . . . . . . . . . . 16
Standby supply dynamic load at 115 Vac - 60 Hz - PFC off . . . . . . . . . . . . . . . . . . . . . . . . 17
Standby supply dynamic load at 115 Vac - 60 Hz - PFC on . . . . . . . . . . . . . . . . . . . . . . . . 17
PFC Vds and inductor current at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . 18
PFC Vds and inductor current at 115 Vac - 60 Hz, full load - detail . . . . . . . . . . . . . . . . . . 18
PFC Vds and inductor current at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . 19
PFC Vds and inductor current at 230 Vac - 50 Hz, full load - detail . . . . . . . . . . . . . . . . . . 19
L6564 signals-1 at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
L6564 signals-2 at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PFC signals-1 at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PFC signals-2 at 115 Vac - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Resonant stage waveforms at 115 V - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Resonant stage waveforms at 115 V - 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Output rectifiers PIV waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
No load operation at 115 Vac - 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
No load operation at 115 Vac - 60 Hz - L6599A signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12 V - 2 A; 24 V 0 ÷ 6 A transition at 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
24 V - 6 A; 12 V 0 ÷ 2 A transition at 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12 V - 2 A; 24 V 0 ÷ 6 A - 300 Hz transition at 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . 24
24 V - 6 A; 12 V 1 ÷ 2 A - 300 Hz transition at 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . 24
12 V short-circuit at full load and 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12 V short-circuit at full load and 115 Vac - 60 Hz - detail . . . . . . . . . . . . . . . . . . . . . . . . . 25
24 V short-circuit at full load and 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
24 V short-circuit at full load and 115 Vac - 60 Hz - detail . . . . . . . . . . . . . . . . . . . . . . . . . 25
Doc ID 18376 Rev 1
AN3329
Figure 50.
Figure 51.
Figure 52.
Figure 53.
Figure 54.
Figure 55.
Figure 56.
Figure 57.
Figure 58.
Figure 59.
Figure 60.
Figure 61.
Figure 62.
Figure 63.
Figure 64.
Figure 65.
Figure 66.
Figure 67.
Figure 68.
List of figures
Startup by on-off signal at full load and 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Startup by on-off signal at full load and 115 Vac - 60 Hz - L6599A signals . . . . . . . . . . . . 26
Startup by on/off signal at full load and 115 Vac - 60 Hz O/P voltage rising . . . . . . . . . . . 27
Turn-off at full load and 115 Vac - 60 Hz by on/off signal . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OVP at full load and 115 Vac - 60 Hz on 12 V - 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OVP at full load and 115 Vac - 60 Hz on 12 V - 24 V - outputs detail . . . . . . . . . . . . . . . . 27
Half cycle mains dip at full load and 115 Vac - 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Full cycle mains dip at full load and 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CE peak measurement at 115 V - 60 Hz and full load - phase wire . . . . . . . . . . . . . . . . . . 29
CE peak measurement at 115 V - 60 Hz and full load - neutral wire . . . . . . . . . . . . . . . . . 29
CE peak measurement at 230 V - 50 Hz and full load - phase wire . . . . . . . . . . . . . . . . . . 30
CE peak measurement at 230 V - 50 Hz and full load - neutral wire . . . . . . . . . . . . . . . . . 30
PFC coil electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PFC coil mechanical aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Transformer overall drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Transformer construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Doc ID 18376 Rev 1
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Main characteristics and circuit description
1
AN3329
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 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.
6/47
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
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Figure 2.
Main characteristics and circuit description
AN3329
Electrical diagram
!-V
AN3329
2
Efficiency measurement
Efficiency measurement
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 Figure 3.
Table 1.
Overall efficiency measured at different AC input voltages
Load = 100 %
5V
12 V
24 V
Pout
Pin
Eff.
Vin [Vrms]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
[W]
[W]
[%]
90
5.01
1.99
11.69
2.01
23.47
5.98
173.8
197.5
88.00 %
115
5.01
1.99
11.69
2.01
23.48
5.98
173.9
193.6
90.09 %
230
5.01
1.99
11.69
2.01
23.48
5.98
173.8
189.3
91.85 %
265
5.01
1.99
11.69
2.01
23.48
5.98
173.8
188.9
91.98 %
Pout
Pin
Eff.
Load = 75 %
5V
12 V
24 V
Vin [Vrms]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
[W]
[W]
[%]
90
5.01
1.51
11.70
1.51
23.49
4.50
130.9
147.5
88.78 %
115
5.01
1.51
11.70
1.51
23.49
4.50
130.9
145.5
89.96 %
230
5.01
1.51
11.70
1.51
23.49
4.50
130.9
143.0
91.56 %
265
5.01
1.51
11.70
1.51
23.49
4.50
130.9
142.7
91.73 %
Pout
Pin
Eff.
Load = 50 %
5V
12 V
24 V
Vin [Vrms]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
[W]
[W]
[%]
90
5.01
1.00
11.71
1.01
23.51
3.00
87.5
98.6
88.67 %
115
5.01
1.00
11.72
1.01
23.51
3.00
87.5
97.7
89.54 %
230
5.01
1.00
11.71
1.01
23.51
3.00
87.5
96.6
90.53 %
265
5.01
1.00
11.71
1.01
23.51
3.00
87.5
96.5
90.64 %
Pout
Pin
Eff.
Load = 25 %
5V
12 V
24 V
Vin [Vrms]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
Vout [V]
Iout [A]
[W]
[W]
[%]
90
5.02
0.49
11.72
0.50
23.53
1.51
43.83
50.82
86.25 %
115
5.02
0.49
11.72
0.50
23.53
1.51
43.83
50.57
86.67 %
230
5.02
0.49
11.72
0.50
23.53
1.51
43.83
50.47
86.85 %
265
5.02
0.49
11.72
0.50
23.53
1.51
43.83
50.29
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 and 4.
Figure 3.
Overall efficiency vs. output power Figure 4.
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Average efficiency acc. ES-2
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!-V
!-V
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.
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Standby supply efficiency vs. light
load output power
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!-V
10/47
Doc ID 18376 Rev 1
!-V
AN3329
Harmonic content measurement
3
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 Figure 8.
- 50 Hz, full load
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(1&ODVV'OLPLWV
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-(,7$0,7,&ODVV'OLPLWV
+DUPRQLF&XUUHQW>[email protected]
+DUPRQLF&XUUHQW>[email protected]
JEITA-MITI compliance at
100 Vac - 50 Hz, full load
+DUPRQLF2UGHU>[email protected]
+DUPRQLF2UGHU>[email protected]
!-V
!-V
Vin=100 Vac - 50 Hz, Pin=191 W
THD=3.97 %, PF=0.999
Vin=230 Vac - 50 Hz, Pin=191 W
THD=4.52 %, PF=0.982
Figure 9.
EN61000-3-2 compliance at
230 Vac - 50 Hz, 75 W
0HD VXUHGYDOXH
Figure 10. JEITA-MITI compliance at
100 Vac - 50 Hz, 75 W
0HDVXUHGYDOXH
(1&ODVV'OLPLWV
+DUPRQLF&XUUHQW>[email protected]
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+DUPRQLF2UGHU>[email protected]
+DUPRQLF2UGHU>[email protected]
!-V
!-V
Vin=230 Vac - 50 Hz, Pin=75 W
THD=7.15 %, PF=0.867
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
InFigure 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
CH3: AC input voltage
CH4: input current
12/47
Figure 12. Input voltage and current at 230
Vac, full load
CH3: AC input voltage
CH4: input current
Doc ID 18376 Rev 1
AN3329
4
Functional check
Functional check
Standby supply
Some salient waveforms of the standby supply during full load operation are reported in
Figure 13 and 14. 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
(Figure 14), 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
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: VDD (pin #2)
CH4: FB (pin #4)
Figure 14. Standby supply waveforms at
230 Vac - 50 Hz, full load
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: VDD (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.
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Functional check
AN3329
Figure 15. Standby supply waveforms at
400 Vdc, full load
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: VDD (pin #2)
CH4: FB (pin #4)
Figure 16. Standby supply output rectifiers
PIV at 400 Vdc, full load
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.
Figure 18 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
CH3: + 5 V standby ripple voltage
14/47
Figure 18. Standby supply startup at 115 Vac 60 Hz, full load
CH1: DRAIN (pin #8)
CH3: BO (pin #5)
Doc ID 18376 Rev 1
CH2: +5 V standby
CH4: VDD (pin #2)
AN3329
Functional check
Figure 19 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
Figure 20. Standby supply burst mode
operation at 230 Vac - 50 Hz - 10 mA
operation at 230 Vac - 50 Hz - 10 mA
load
load-detail
CH1: DRAIN (pin #8)
CH3: +5 V standby
CH2: VDD (pin #2)
CH4: FB (pin #4)
Figure 21. Standby supply OVP at 115 Vac 60 Hz, full load
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: VDD (pin #2)
CH4: FB (pin #4)
Figure 22. Standby supply OVP at 230 Vac 50 Hz - 0.5 A
CH1: DRAIN (pin #8)
CH3: +5 V standby
CH2: VDD (pin #2)
Figure 21 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 VDD has dropped down
to VDD_RESTART (4.5 V). At this point the auto-restart process takes place like any startup;
the internal current source charges the VDD capacitor until it reaches the VDDon threshold
Doc ID 18376 Rev 1
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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 Figure 21 to Figure 23 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
CH1: DRAIN (pin #8)
CH3: CONT (pin #3)
CH2: +5 V standby
CH4: FB (pin #4)
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)
Figure 25. Standby supply output short-circuit Figure 26. Standby supply output short-circuit
at 230 Vac - 50 Hz, full load
at 230 Vac - 50 Hz, full load - detail
CH1: DRAIN (pin #8)
CH3: VDD (pin #2)
CH2: +5 V standby
CH4: FB (pin #4)
CH1: DRAIN (pin #8)
CH3: VDD (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 Figure 26 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 VDD voltage drops down to VDD_RESTART
(4.5 V). At that time the internal HV current source is activated and charges the VDD
capacitor until it reaches the VDDon 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.
Figure 27 and 28 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 VDD spike is quite high, due to the effect of the leakage inductance. Once the load is
decreased or removed, VDD 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 VDD might drop below VDD_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 Figure 27 and 28, both
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
CH1: FB (pin #4)
CH3: +5 V standby
CH2: VDD (pin #2)
CH4: 5 V stby current
Figure 28. Standby supply dynamic load at
115 Vac - 60 Hz - PFC on
CH1: FB (pin #4)
CH3: 5 V standby
Doc ID 18376 Rev 1
CH2: VDD (pin #2)
CH4: 5 V stby current
17/47
Functional check
AN3329
Power factor corrector stage
Figure 29 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 32.
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)
CH1: Q1 drain voltage
CH3: CS (pin #4)
CH2: MULT (pin #3)
CH4: L1 inductor current
CH2: MULT (pin #3)
CH4: L1 inductor current
Figure 31 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)
CH1: Q1 drain voltage
CH3: CS (pin #4)
CH2: MULT (pin #3)
CH4: L1 inductor current
CH2: MULT (pin #3)
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)
CH1: GD (pin #9)
CH3: MULT (pin #3)
CH2: ZCD (pin #7)
CH4: CS (pin #4)
CH2: ZCD (pin #7)
CH4: CS (pin #4)
Figure 35 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
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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)
CH1: COMP (pin #9)
CH3: MULT (pin #3)
20/47
CH2: VFF (pin #7)
CH4: CS (pin #4)
Doc ID 18376 Rev 1
CH2: VFF (pin #7)
CH4: CS (pin #4)
AN3329
Functional check
Resonant stage
Some waveforms relevant to the resonant stage during steady-state operation are reported
in Figure 37, 38, 39, 40, and 41. 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. Figure 37 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 Figure 38. Resonant stage waveforms at 115 V
- 60 Hz, full load
- 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
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Functional check
AN3329
Figure 39. Output rectifiers PIV waveforms
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 Figure 41 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
22/47
CH4: PFC drain voltage
CH1: HB voltage
CH3: Standby (pin #5)
Doc ID 18376 Rev 1
CH2: CF (pin #3)
AN3329
Functional check
Dynamic load operation and output voltage regulation
Figure 42 and 43 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.
Figure 42 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 %.
In the same way, in Figure 43 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 Figure 43. 24 V - 6 A; 12 V 0 ÷ 2 A transition at
115 Vac - 60 Hz
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
Figure 44 and 45 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.
Figure 44 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 ± 1.2 %, while the 24 V output variation due to the dynamic
load on 12 V (cross-regulation) is ± 0.5 %.
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Functional check
AN3329
Figure 44. 12 V - 2 A; 24 V 0 ÷ 6 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
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: +12 V O/P current
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
recycling. In Figure 47 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 (Figure 48), 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.
24/47
Doc ID 18376 Rev 1
AN3329
Functional check
Figure 46. 12 V short-circuit at full load and
115 Vac - 60 Hz
CH1: HB voltage
CH3: ISEN (pin #6)
CH2: DELAY (pin #2)
CH4: 12 V O/P current
Figure 48. 24 V short-circuit at full load and
115 Vac - 60 Hz
CH1: HB voltage
CH3: ISEN (pin #6)
CH2: DELAY (pin #2)
CH4: 12 V O/P current
Figure 47. 12 V short-circuit at full load and
115 Vac - 60 Hz - detail
CH1: HB voltage
CH4: C39 current
CH3: ISEN (pin #6)
Figure 49. 24 V short-circuit at full load and
115 Vac - 60 Hz - detail
CH1: HB voltage
CH4: C39 current
Doc ID 18376 Rev 1
CH3: ISEN (pin #6)
25/47
Functional check
AN3329
Startup
Figure 50 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 Figure 51. Startup by on-off signal at full load
and 115 Vac - 60 Hz
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.
Figure 53 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 Figure 53. Turn-off at full load and 115 Vac - 60
and 115 Vac - 60 Hz O/P voltage
Hz by on/off signal
rising
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
Figure 54 and 55 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 Figure 55. OVP at full load and 115 Vac - 60 Hz
on 12 V - 24 V
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
Doc ID 18376 Rev 1
CH2: 12 V output
CH4: V_C44
27/47
Functional check
AN3329
Mains sags/dips
Figure 56 and 57 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 Figure 57. Full cycle mains dip at full load and
115 Vac - 60 Hz
115 Vac - 60 Hz
CH1: HB voltage
CH3: 24 V output
28/47
CH2: PFC drain
CH4: PFC gate
CH1: HB voltage
CH3: 24 V output
Doc ID 18376 Rev 1
CH2: PFC drain
CH4: PFC gate
AN3329
5
Conducted emission pre-compliance test
Conducted emission pre-compliance test
Figure 58, 59, 60, 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 ClassB, 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
Figure 61. CE peak measurement at 230 V - 50 Hz and full load - neutral wire
30/47
Doc ID 18376 Rev 1
AN3329
AN3329
Bill of materials
6
Bill of materials
Table 2.
Bill of materials
Part type /
Case style
part value
/ package
C1
2.2 nF
C10
Des.
Description
Supplier
DWG
Y1 - safety cap. DE1E3KX222M
MURATA
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C12
100 nF
1206
50 V Cercap - general purpose - X7R - 10 %
KEMET
C13
47 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C14
1000 µF - 35 V
Dia.12x25
p. 5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C15
1000 µF - 35 V
Dia.12x25
p. 5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C16
100 µF - 50 V
Dia.8x11
p. 3.5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C17
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C18
470 nF
1206
50 V Cercap - general purpose - Y5V - 20 %
KEMET
C19
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C2
1 µF - X2
11x26.5 mm
p. 22.5
FLM CAP - B32923C3105K
EPCOS
C20
470 nF
0805
16 V Cercap - general purpose - X7R - 10 %
KEMET
C21
4.7 µF - 6.3 V
0805
6.3 V Cercap - general purpose - X5R - 15 %
KEMET
C23
4.7 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C24
470 pF
0805
50 V Cercap - general purpose - C0G - 5 %
KEMET
C25
2.2 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C26
1000 µF - 25 V
Dia.12x20
p. 5 mm
Aluminium ELCAP - YXF series - 105 °C
RUBYCON
C27
100 µF - 50 V
Dia. 8x11
p. 3.5 mm
Aluminium ELCAP - YXF series - 105 °C
RUBYCON
C28
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C29
N.M.
0805
Not mounted
C3
1 µF - X2
11x26.5 mm
p. 22.5
FLM CAP - B32923C3105K
EPCOS
C30
470 nF
1206
50 V Cercap - general purpose - Y5 V - 20 %
KEMET
C31
2.2 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C32
1 µF
1206
16 V Cercap - general purpose - X7R - 10 %
KEMET
C33
10 µF - 50 V
Dia. 6.3x11
(MM) p. 2.5
mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
Doc ID 18376 Rev 1
31/47
Bill of materials
Table 2.
AN3329
Bill of materials (continued)
Part type /
Case style
part value
/ package
C34
220 pF
C35
Des.
Description
Supplier
0805
50 V Cercap - general purpose - COG - 5 %
KEMET
4.7 nF
1206
50 V Cercap - general purpose - X7R - 10 %
KEMET
C36
220 pF
1206
500 V Cercap - 12067A221JAT2A - C0G - 5 %
AVX
C38
220 nF
0805
16 V Cercap - general purpose - X7R - 10 %
KEMET
C39
33 nF
5.0 x 18.0
p. 15 mm
1 kV - MKP film capacitor B32652A0333J
EPCOS
C4
470 nF - 630 V
11x26.5 mm
p. 22.5
630 V - FLM CAP - B32613A6474K***
EPCOS
C40
47 µF - 50 V
Dia. 6.3x11
mm p. 2.5
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C42
10 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C44
47 µF - 50 V
Dia. 6.3x11
mm p. 2.5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C45
47 nF
0805
25 V Cercap - general purpose - X7R - 10 %
KEMET
C46
2.2 nF
DWG
Y1 - Safety CAP. DE1E3KX222M
MURATA
C47
10 µF - 450 V
Dia. 10 p. 5
mm
450 V - Aluminium ELCAP - VY series - 105 °C
Nichicon
C49
1000 µF - 10 V
Dia.10x16
p. 5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C5
470 nF - 630 V
11x26.5 mm
p. 22.5
630 V - FLM CAP - B32613A6474K***
EPCOS
C50
1000 µF - 10 V
Dia.10x16
p. 5 mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C51
220 µF - 16 V
Dia.8x11 p. 2
mm
Aluminium ELCAP - YXF series - 105 °C
Rubycon
C52
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C53
22 µF - 50 V
Dia. 5X11
p. 2 mm
Aluminium ELCAP - YXF series - 105°C
Rubycon
C54
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C55
2.2 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C56
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C59
10 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C6
100 µF - 450 V
Dia. 18x35 mm
p.10
450 V - aluminium ELCAP - KXG series - 105 °C
Nippon Chemi-con
C60
100 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C61
10 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
32/47
Doc ID 18376 Rev 1
AN3329
Table 2.
Bill of materials
Bill of materials (continued)
Part type /
Case style
part value
/ package
C62
10 µF - 50 V
C63
Des.
Description
Supplier
Dia 6.3X11
(MM) p. 2.5
mm
Aluminium ELCAP - YXF series - 105°C
Rubycon
10 nF
0805
50 V Cercap - general purpose - X7R - 10 %
KEMET
C64
1 nF
1206
100 V Cercap - general purpose - X7R - 10 %
KEMET
C65
220 pF
0805
50 V Cercap - general purpose - COG - 5 %
KEMET
C7
100 µF - 450 V
Dia. 18x35 mm
p.10
450 V - aluminium ELCAP - KXG series - 105 °C
Nippon Chemi-con
C8
2.2 nF
DWG
Y1 - Safety cap. DE1E3KX222M
MURATA
C9
2.2 nF
DWG
Y1 - Safety cap. DE1E3KX222M
MURATA
D1
1N5406
DO-201
Rectifier - general purpose
VISHAY
D10
1N4148WS
SOD323
High speed signal diode
VISHAY
D11
STPS20H100C
FP
TO-220FP
Power Schottky rectifier
STMicroelectronics
D12
1N4148WS
SOD323
High speed signal diode
VISHAY
D14
1N4148WS
SOD323
High speed signal diode
VISHAY
D15
BZV55-C15
MINIMELF
Zener diode
VISHAY
D16
MMSZ4711-V
SOD123
27 V Zener diode
VISHAY
D17
MMSZ4702-V
SOD123
15 V Zener diode
VISHAY
D18
STPS20L45CFP
TO-220FP
Power Schottky rectifier
STMicroelectronics
D19
P6KE250A
DO-15
Transil
STMicroelectronics
D2
STTH5L06
DO-201
Ultrafast high voltage rectifier
STMicroelectronics
D20
STTH108A
SMA
HV ultrafast rectifier
STMicroelectronics
D21
BAV103
MINIMELF
High speed signal diode
VISHAY
D22
STTH102A
SMA
High efficiency ultrafast diode
STMicroelectronics
D3
D10XB60H
DWG
Single-phase bridge rectifier
SHINDENGEN
D4
STPS20H100C
FP
TO-220FP
HV power Schottky rectifier
STMicroelectronics
D5
1N4148WS
SOD323
High speed signal diode
VISHAY
D6
1N4148WS
SOD323
High speed signal diode
VISHAY
D7
1N4148WS
SOD323
High speed signal diode
VISHAY
D8
1N4148WS
SOD323
High speed signal diode
VISHAY
D9
STPS20L45CFP
TO-220FP
Power Schottky rectifier
STMicroelectronics
F1
Fuse T4A
8.5x4
p.5.08 mm
Fuse 4 A - Time LAG - 3921400
Littelfuse
HS1
Heatsink
DWG
Heatsink for D3 and Q5
Doc ID 18376 Rev 1
33/47
Bill of materials
Table 2.
AN3329
Bill of materials (continued)
Part type /
Case style
part value
/ package
HS2
Heatsink
DWG
Heatsink for Q3 and Q6
HS3
Heatsink
DWG
Heatsink for D4 and D11
HS4
Heatsink
DWG
Heatsink for D18
HS5
Heatsink
DWG
Heatsink for D9
J1
09-65-2038
DWG
Connector-pitch 3.96 mm - 2 pins (1 removed) KK
Molex
J2
280385-2
DWG
Connector - p. 2.54 mm - 8 x 2 rows - MODU-II
AMP
J3
280384-2
DWG
Connector - p. 2.54 mm - 4 x 2 rows - MODU-II
AMP
JPX1
Shorted
Wire jumper
JPX10
Shorted
Wire jumper
JPX11
Shorted
Wire jumper - insulated
JPX12
Shorted
Wire jumper
JPX13
Shorted
Wire jumper - insulated
JPX14
Shorted
Wire jumper
JPX15
Shorted
Wire jumper
JPX16
Shorted
Wire jumper - insulated
JPX17
Shorted
Wire jumper
JPX18
Shorted
Wire jumper - insulated
JPX19
Shorted
Wire jumper
JPX2
Shorted
Wire jumper - insulated
JPX20
Shorted
Wire jumper
JPX21
Shorted
Wire jumper
JPX22
Shorted
Wire jumper
JPX23
Shorted
Wire jumper
JPX24
Shorted
Wire jumper
JPX25
Shorted
Wire jumper
JPX3
Shorted
Wire jumper
JPX4
Shorted
Wire jumper
JPX5
Shorted
Wire jumper
JPX6
Shorted
Wire jumper - insulated
JPX7
Shorted
Wire jumper - insulated
JPX8
Shorted
Wire jumper
JPX9
Shorted
Wire jumper
L1
240 µH
Des.
34/47
DWG
Description
2086.0001 - PFC inductor
Doc ID 18376 Rev 1
Supplier
MAGNETICA
AN3329
Table 2.
Bill of materials
Bill of materials (continued)
Part type /
Case style
part value
/ package
L2
3 mH
L3
Des.
Description
Supplier
DWG
1606.0007 EMI filter
MAGNETICA
70 µH
26x13 mm
2190.0001 DM inductor
MAGNETICA
L4
2.2 µH
DIA12 p. 5 mm
10610041 - 3 µH - 11 A inductor
MAGNETICA
L5
1 µH
DIA8 p. 5 mm
10710083 - 1 µ - 5 A inductor
MAGNETICA
L6
1 µH
DIA8 p. 5 mm
10710083 - 1 µ - 5 A inductor
MAGNETICA
PCB
PCB rev. 2
Q10
BC847C
SOT-23
NPN small signal BJT
VISHAY
Q11
BC847C
SOT-23
NPN small signal BJT
VISHAY
Q3
STF12NM50N
TO-220FP
N-channel Power MOSFET
STMicroelectronics
Q5
STF14NM50N
TO-220FP
N-channel Power MOSFET
STMicroelectronics
Q6
STF12NM50N
TO-220FP
N-channel Power MOSFET
STMicroelectronics
Q7
BC847C
SOT-23
NPN small signal BJT
VISHAY
Q8
BC847C
SOT-23
NPN small signal BJT
VISHAY
Q9
BC857C
SOT-23
PNP small signal BJT
VISHAY
R1
NTC 2R5-S237
DWG
NTC resistor P/N B57237S0259M000
EPCOS
R10
51 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R11
3.9 MΩ
1206
SMD standard film res - 1/4W - 1 % - 100 ppm/°C
VISHAY
R12
470 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R13
130 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R15
2.2 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R16
3.9 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R17
200 kΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R18
56 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R2
2.2 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R20
100 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R21
10 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R22
3.9 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R23
4.7 MΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R24
3.3 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R25
10 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R27
2.2 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R29
4.7 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R3
27 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R31
100 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
Single Layer - 2 OZ. - CEM-1
Doc ID 18376 Rev 1
35/47
Bill of materials
Table 2.
AN3329
Bill of materials (continued)
Part type /
Case style
part value
/ package
R32
22 Ω
R33
Des.
Description
Supplier
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
200 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R34
10 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R36
13 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R37
6.2 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R38
0
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R39
3.9 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R4
2.2 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R40
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R41
56 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R43
1 MΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R44
100 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R45
10 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R46
220 Ω
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R47
0
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R49
33 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R5
2.2 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R50
180 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R51
0.47 Ω
PTH
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
VISHAY
R52
0.47 Ω
PTH
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
VISHAY
R53
100 Ω
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R55
150 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R56
5.6 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R57
51 Ω
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R59
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R6
4.7 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R60
47 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R61
180 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R62
75 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R64
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R65
180 kΩ
0805
SMD standard film res - 1/8W - 5% - 250 ppm/°C
VISHAY
R67
10 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R68
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R69
4.7 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
36/47
Doc ID 18376 Rev 1
AN3329
Table 2.
Bill of materials
Bill of materials (continued)
Part type /
Case style
part value
/ package
R7
2.2 MΩ
R70
Des.
Description
Supplier
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
10 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R71
4.7 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R72
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R73
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R74
2.7 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R75
1Ω
PTH
NFR25H - axial fusible res - 1/2 W - 5 % - 100
ppm/°C
VISHAY
R78
3.9 Ω
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R79
390 kΩ
AXIAL
Dia.1.6x3.6
mm
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
VISHAY
R8
2.2 MΩ
1206
SMD standard film res - 1/4 W - 1 % - 100 ppm/°C
VISHAY
R80
82 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R81
27 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R82
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R83
27 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R84
12 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R86
120 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R87
270 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R88
39 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R89
47 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R9
220 kΩ
0805
SMD standard film res - 1/8 W - 1 % - 100 ppm/°C
VISHAY
R90
10 Ω
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R91
220 kΩ
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
R92
2.7 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R93
2.2 Ω
AXIAL
Dia.1.6x3.6
mm
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
VISHAY
R94
22 kΩ
AXIAL
Dia.1.6x3.6
mm
Axial STD film res - 1/8 W - 5 % - 100 ppm/°C
VISHAY
R95
1 kΩ
0805
SMD standard film res - 1/8 W - 5 % - 250 ppm/°C
VISHAY
R96
0.47 Ω
PTH
PR01 - metal film res - 1 W - 5 % - 250 ppm/°C
VISHAY
RV1
300 Vac
Dia. 15x5
p. 7.5 mm
300 V metal oxide varistor - B72214S0301K101
EPCOS
RX2
0
1206
SMD standard film res - 1/4 W - 5 % - 250 ppm/°C
VISHAY
Doc ID 18376 Rev 1
37/47
Bill of materials
Table 2.
Des.
AN3329
Bill of materials (continued)
Part type /
Case style
part value
/ package
Description
Supplier
T1
1860.0014
Rev. 0.1
Resonant transformer
MAGNETICA
T2
1715.0059
Standby flyback TRAFO
MAGNETICA
U1
L6564D
SSOP10
10-pin transition mode PFC controller
STMicroelectronics
U2
L6599AD
SO-16
Improved HV resonant controller
STMicroelectronics
U3
SFH610A-2
DIP-4 10.16MM
Optocoupler
Infineon
U4
TL431ACZ
TO-92
Programmable shunt voltage reference
STMicroelectronics
U5
SFH610A-2
DIP-4 10.16MM
Optocoupler
Infineon
U6
VIPER27LN
DIP8
Offline HV converter
STMicroelectronics
U7
SFH610A-2
DIP-4 10.16MM
Optocoupler
Infineon
U8
TS431AZ
TO-92
Programmable shunt voltage reference
STMicroelectronics
38/47
Doc ID 18376 Rev 1
AN3329
7
PFC coil specifications
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
!-V
Table 3.
PFC coil winding data
Pins
Windings
RMS current
Number of turns
Wire type
8 - 11
AUX
0.05 Arms
3
φ 0.3 mm - G2
1,2 - 5,6
Primary
2.65 Arms
28
2x40φ 0.1 mm - G2
a. Measured between pins 1,2 and 5,6.
Doc ID 18376 Rev 1
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PFC coil specifications
AN3329
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
35 MAX
21 MAX
6
8
1
30.5
2
9 5 6
∅ 0.8 (X7)
RECOMMENDED PCB HOLE ∅1.2 (X7)
1
2
11
9
8
5
5.08
6
BOTTOM VIEW (PIN SIDE)
AM08376v1
Dimensions millimeters, drawing not in scale
Manufacturer
40/47
●
MAGNETICA
●
Inductor P/N: 2086.0001
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.
Resonant transformer winding data
Pins
Winding
DC resistance
Number of turns
Wire type
2-4
Primary
158 mΩ
36
30xφ 0.1 mm – G1
6-7
AUX
94 mΩ
3
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
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Resonant power transformer specifications
Table 4.
AN3329
Resonant transformer winding data (continued)
Pins
Winding
DC resistance
Number of turns
Wire type
8 - 11
SEC - A
4.4 mΩ
2
90xφ 0.1 mm – G1
9 - 10
SEC - B
4.4 mΩ
2
90xφ 0.1 mm – G1
10 - 13
SEC - C
4.4 mΩ
2
90xφ 0.1 mm – G1
12 - 14
SEC - D
4.4 mΩ
2
90xφ 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&%‘ 3IDEVIEWOFTERMINALS
2EFERENCE
$IMENSIONSMILLIMETERSDRAWINGNOTINSCALE
Manufacturer
42/47
●
MAGNETICA
●
Transformer P/N: 1860.0014 Rev. 0.1
Doc ID 18376 Rev 1
!-V
AN3329
9
Auxiliary flyback transformer specifications
Auxiliary flyback transformer specifications
General description and characteristics
●
Application type: consumer, home appliance
●
Transformer type: open
●
Winding type: layer
●
Coil former: horizontal type, 4+5 pins, two slots
●
Max. temp. rise: 45 ºC
●
Max. operating ambient temperature: 60 ºC
●
Mains insulation: acc. to EN60950
●
Unit finishing: varnished
Electrical characteristics
●
Converter topology: flyback, CCM/DCM mode
●
Core type: E20-PC44 or equivalent
●
Typical operating frequency: 60 kHz
●
Primary inductance: 2.380 mH ± 10 % at 1 kHz - 0.25 V(d)
●
Leakage inductance: 30 µH at 50 kHz - 0.25 V(e)
●
Max. peak primary current: 0.5 Apk
●
RMS primary current: 0.17 Arms
DC output characteristics
●
Converter topology: flyback, CCM/DCM mode
Table 5.
DC output voltage and load
DC output voltage
DC load
5V
2 ADC
16 V
0.05 ADC
d. Measured between pins 4-5.
e. Measured between pins 2-4 with secondary windings with same polarity shorted at time.
Doc ID 18376 Rev 1
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Auxiliary flyback transformer specifications
AN3329
Figure 66. Transformer construction
0RIMAR
6
6
!UX
!-V
Winding characteristics
Table 6.
Standby transformer winding data
Pins
Winding
O/P rms
current
Number of
turns
Number of
layers
Wire type
4-5
Primary
0.17 ARMS
93
2
G2 - φ 0.224 mm
2-1
Aux
0.05 ARMS
18 spaced
1
G2 - φ 0.224 mm
6-8
7-9
5V
2.6 ARMS
(TOTAL)
6
1
TIW - 2 x φ 0.7 mm in parallel
Figure 67. Mechanical aspect and pin numbering
2 LAYERS POLYESTER TAPE
SECONDARY
AUXILIARY
COIL FORMER
FERRITE CORE
PRIMARY
AM08380v1
44/47
Doc ID 18376 Rev 1
AN3329
Auxiliary flyback transformer specifications
Figure 68. Mechanical aspect and pin numbering
0$;
0,1
0$;
0$;
0$;
3LQLVPLVVLQJ
‘ ;
5(&200(1'('3&%+2/(‘ ;
%277209,(:3,16,'(
!-V
Manufacturer
●
MAGNETICA
●
Inductor P/N: 1715.0059
Doc ID 18376 Rev 1
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Revision history
10
AN3329
Revision history
Table 7.
46/47
Document revision history
Date
Revision
25-Feb-2011
1
Changes
Initial release.
Doc ID 18376 Rev 1
AN3329
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