90W Resonant SMPS with TEA1610 SwingChip (tm)

APPLICATION NOTE
90W Resonant SMPS
with TEA1610 SwingChipTM
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
Abstract
This report describes a 90W Resonant Switched Mode Power Supply (ResSMPS) for a typical TV or monitor
application based upon the TEA1610 SwingChipTM resonant SMPS controller. The power supply is based on the
half bridge DC-to-DC resonant LLC converter with zero-voltage switching. The TEA1610 uses current driven
frequency control.
© Philips Electronics N.V. 1999
All rights are reserved. Reproduction in whole or in part is prohibited without the prior written consent of the copyright owner.
The information presented in this document does not form part of any quotation or contract, is believed to be
accurate and reliable and may be changed without notice. No liability will be accepted by the publisher for any
consequence of its use. Publication thereof does not convey nor imply any license under patent- or other industrial
or intellectual property rights.
2
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
APPLICATION NOTE
90W Resonant SMPS
with TEA1610 SwingChipTM
AN99011
Author:
R.Kennis
Philips Semiconductors Systems Laboratory Eindhoven,
The Netherlands
Approved by:
T. Mobers
E. Derckx
Keywords
TM
SwingChip
TEA1610
Resonant
SMPS
Zero-voltage-switching
Number of pages: 27
Date: 99-09-14
3
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
Summary
TM
The SwingChip TEA1610 controller is a monolithic integrated circuit and is implemented on the 650V BCD
power logic process. The IC provides the drive function for two discrete power MOSFETs in a half bridge
configuration and is a high voltage controller for a zero-voltage switching resonant converter. To guarantee an
accurate 50% duty cycle, the oscillator signal passes through a divider before being fed to the output drivers.
This application note briefly describes a 90W Resonant Converter for a typical TV or monitor application based
upon the TEA1610 controller. The converter is composed of two bi-directional switches and a resonant LLCcircuit. To limit the costs the two inductors are integrated in one transformer: a magnetising inductance and a
leakage inductance, which is cheaper than two separate coils. With a certain coupling of about 0.6 the leakage
inductance is given the required value. The outputs are mains isolated and the 80V is controlled secondary. The
converter has a high performance efficiency and a very good cross regulation
4
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
CONTENTS
1
INTRODUCTION ............................................................................................................................................. 7
2
FEATURES...................................................................................................................................................... 7
3
QUICK REFERENCE DATA ........................................................................................................................... 8
4
FUNCTIONAL BLOCK DIAGRAM.................................................................................................................. 9
5
CIRCUIT DESCRIPTION............................................................................................................................... 10
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
Mains input circuit...................................................................................................................................... 10
Half bridge switches .................................................................................................................................. 10
Transformer............................................................................................................................................... 10
Output section ........................................................................................................................................... 10
Regulation, opto coupler and controller..................................................................................................... 11
Start-up...................................................................................................................................................... 11
Protections................................................................................................................................................. 12
5.7.1Under Voltage Lock Out (UVLO) and Short Circuit Protection.......................................................... 12
5.7.2Over Voltage Protection (OVP) ......................................................................................................... 12
5.7.3Over Current Protection (OCP) ......................................................................................................... 12
MEASUREMENTS ........................................................................................................................................ 13
6.1
6.2
6.3
6.4
Static performance .................................................................................................................................... 13
Dynamic performance ............................................................................................................................... 16
Bode diagrams .......................................................................................................................................... 17
EMI results................................................................................................................................................. 18
7
CIRCUIT DIAGRAM ...................................................................................................................................... 19
8
LAYOUT CONSIDERATIONS....................................................................................................................... 21
9
PARTS LIST .................................................................................................................................................. 25
10
REFERENCES .............................................................................................................................................. 27
5
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
1
Application Note
AN99011
INTRODUCTION
The TV and monitor market demands more and
more high-quality, reliable, small, lightweight and
efficient power supplies. In principle the higher the
operating frequency the smaller and lighter the
transformers, filter inductors and capacitors can be.
A remark on this is that the core and winding losses
of the transformer will increase at higher
frequencies. and become dominant. This effect
reduces the efficiency at a high frequency, which
limits the minimum size of the transformer. The
corner frequency of the output filter usually
determines the band width of the control loop. A well
chosen corner frequency allows high operating
frequencies for achieving a fast dynamic response.
power applications. A disadvantage of these
converters is that the PWM rectangular voltage and
current waveforms cause turn-on and turn-off losses
that limit the operating frequency. The rectangular
waveforms
generate
also
broad
band
electromagnetic energy, what can produce
Electromagnetic Interference (EMI). A resonant DCDC converter produces sinusoidal waveforms and
reduces the switching losses, what gives the
possibility to operate at higher frequencies
The resonant converter can be separated into three
cascaded blocks: a AC-to-DC mains rectifier, a DCto-AC inverter and an AC-to-DC output rectifier
(figure 2 represents the last two blocks: the inverter
and the output rectifier).
At this moment the Pulse Width Modulated power
converters, such as the fly back, up and down
converter, are widely used in low and medium
2
FEATURES
•
•
•
•
•
•
Full mains input range 85-276VAC
Continuous Output Power 90W
Output voltages: 190V, 80V, +13V, +5V, -6.2V and -13V
Zero voltage switching
(EMI friendly)
Main output short circuit proof
7
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
3
Application Note
AN99011
QUICK REFERENCE DATA
SYMBOL
PARAMETER
CONDITIONS
MIN.
TYP.
MAX.
UNIT
Supply
Vline
mains voltage
nominal operation
85
276
VAC
fline
mains frequency
nominal operation
50 / 60
Hz
80.0
VDC
Output voltages
VOUT1
main output voltage
all conditions
VOUT1,fl
100Hz ripple
Vline= 230VAC, IOUT1=250 mA
75
mVACpp
VOUT1,fs
high frequency ripple
Vline= 230VAC, IOUT1=250 mA
50
mVACpp
∆VOUT1,line
line regulation
100
mVDC
∆VOUT1,load
load regulation
10
mVDC
IOUT1
main output current
135
225
mADC
VOUT2
output 2 voltage
193.0
193.9
VDC
IOUT2
output 2 current
190
243
mADC
VOUT3
output 3 voltage
12.4
13.0
VDC
IOUT3
output 3 current
670
890
mADC
VOUT4
output 4 voltage
-12.4
-11.7
VDC
IOUT4
output 4 current
240
890
mADC
VOUT5
output 5 voltage
-6.3
-6.4
VDC
IOUT5
output 5 current
650
mA
VOUT6
output 6 voltage
5.0
IOUT6
output 6 current
43
10 – 100% load
192.3
11.7
-12.9
-6.3
VDC
50
mA
Miscellaneous
tSTART
start-up time
η
efficiency
PMAX
maximum output
power
600
measured at maximum load,
spread over VOUT1 and VOUT2
89
91
90
VOUT5 and VOUT6 are post regulated.
8
msec
92
%
W
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
4
Application Note
AN99011
FUNCTIONAL BLOCK DIAGRAM
Figure 1 shows the functional block diagram of
the application. The topology which is used is
the half bridge resonant converter. A reduction
of EMI and especially self-pollution is achieved
by zero voltage switching (ZVS) in the
MOSFETs and output diodes. Another
advantage of ZVS are the lower switching
losses. Figure 2 shows the basic circuit of the
LLC-converter, which represents the blocks
‘Half bridge switches’, ‘Transformer’ and
‘Output section’. The DC-input voltage is
converted by the switches into a block voltage
with a duty cycle of 50%. The LLC circuit
converts this block voltage to a sinusoidal
current through its components and a
sinusoidal voltage across the resonant
capacitor Cr. This capacitor is acting at the
same time as blocking element for DC. The
transformer reflects (with winding ratio) the
voltage across Lp to the secondary, where it is
rectified and smoothed by the output capacitor.
Mains isolation
Mains input
circuit
Half bridge
switches
Transformer
Output
section
TEA1610
7[MRK'LMT
Optocoupler
Regulator
Controller
Figure 1 Functional block diagram
The auxiliary winding which supplies the
controller has a good coupling with the output
voltage and monitored by the controller. When
this voltage becomes too high the converter
will be switched off, this is called Over Voltage
Protection (OVP). The primary resonant
current is also guarded to protect the
MOSFETs in fault conditions, when the current
becomes too high, this is called Over Current
Protection (OCP). One of the output voltages,
the 80V-supply, is controlled by means of a
secondary regulator circuit that communicates
with the TEA1610 controller section by means
of an opto coupler, which is used for mains
isolation.
9
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
5
Application Note
AN99011
CIRCUIT DESCRIPTION
5.1
Mains input circuit
5.2
The input circuit is a conventional full bridge
rectifier. A common mode filter is included for
mains conducted EMI suppression.
A degaussing circuit is not included. A
standard PTC degaussing circuit can be
added. To gain full advantage in terms of
power consumption in the ‘OFF’ mode a circuit
to switch-off the degaussing PTC during these
modes should be added.
The body diodes D1 and D2 of the half bridge
MOSFETs are conducting during a part of the
primary resonant current. The capacitors C1
and C2 (see Figure 2) are the voltage resonant
capacitors which are reducing the TURN-OFF
dissipation and so the EMI produced by each
MOSFET by a proper dV/dt.
Inverter
C1
S1
Half bridge switches
Output rectifier
D1
Ct
Vin
DC
Lr
D
C2
S2
D2
Lp
D
Vout
Ls
D
D
Co
RL
Figure 2 Basic circuit LLC-converter
5.3
Transformer
5.4
The inductors Lr and Lp are combined on a
single mains-isolated transformer with a poor
coupling factor between primary and
secondary. In this case the transformer
behaves as an ideal transformer having a
magnetising inductance Lp with a primary
(Lr_p) and a secondary leakage inductance
(Lr_s) transferred to the primary (Lr = Lr_p
+Lr_s’). The transformer is designed to have
an output voltage of 6.67V per turn. The output
voltage can be chosen in 6.67V steps minus
one diode forward drop.
Output section
Three types of rectifiers are used. A bridge
rectifier for the 190V, a centre-tapped double
side rectifier for the 80V and single side
rectifiers for the +13 and –13V supplies. All
these voltage contains a π-output filter(C-L-C).
The 5V and –6.2V supply are derived out of
the +13V and –13V respectively.
10
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
5.5
Regulation,
controller
opto
coupler
Application Note
AN99011
Table 1 and figures 4 to 8 show the load
regulation of Vout1 and the (cross) load
regulation of the other outputs. With regard to
a comparable fly back converter this is a
extremely good cross regulation
and
The TEA1610 can be used either with primary
sensing as well as secondary sensing. Primary
sensing is cheaper but output regulation is less
accurate, especially in this application where
the coupling of the primary and secondary is
made purposely poor. Secondary sensing is
more expensive but has a higher performance.
For that reason this 90W application uses
secondary sensing. Component Z1 (see
chapter 7, page 19) is a TL431 voltage
regulator that feeds an error signal through
OC1 (CNX82A opto coupler) back to the
control input IRS of the TEA1610. The
TEA1610 uses this information to control an
internal frequency modulator (FM). The FM is
connected to the (high and low) output gate
drivers to control the MOSFETs. The supply is
designed to operate at a 50% duty cycle per
MOSFET. When less output power is required
or the input voltage is increased the frequency
will be made higher by the control loop to
maintain a constant output voltage. To
guarantee an accurate 50% duty cycle, the
oscillator signal inside the TEA1610 passes
through a divider before it is fed to the output
gate drivers.
5.6
Start-up
The TEA1610 is supplied by the applied
voltage on the Vdd pin. At a Vdd voltage of 4V
the low side MOSFET is conducting and the
high side MOSFET is does not conduct. This
start-up output state guarantees the initial
charging of the bootstrap capacitor which is
used for the floating supply of the high side
driver.
During start-up, the voltage across the
frequency capacitor C17 is zero to have a
defined start-up. The output voltage of the
error amplifier is kept on a constant voltage of
2.7V, which forces a current through R4 that
results in a maximum starting frequency
(fmax). The start-up state will be maintained
until the Vdd voltage reaches the start level of
13.5V, the oscillator is activated and the
converter starts operating
The total start-up time is low (less than approx.
600ms.) and no overshoots are presented on
Vout1 (80V) during start-up. The initial primary
start-up current is kept lower than the OCP
level. This is done via the soft start option of
the TEA1610 via soft start capacitor C31.
Soft start can also be done secondary with an
additional circuit R11, R18, C22 and D16. A
disadvantage of this circuit is that during the
first switching stage the primary current can
still be higher than the OCP level. With the
TEA1610 this circuit is not necessary and via
the soft start capacitor this disadvantage will
be avoided.
Figure 6 shows the load step response
(-49dB) of the supply. Output voltage Vout1
shows an overshoot of 260 mV during high
(100%) to low (10%) load step. During a low
(10%) to high (100%) load step an undershoot
of 288 mV occurs.
Figure 7 shows 100Hz line suppression
(-62dB) at main output voltage Vout1. Only
63.6 mV peak-peak ripple is present at the
output under worst case (low line voltage, high
output load) conditions.
Figure 8 shows the 77 kHz switching
frequency ripple (-65dB) present at the output
The switching frequency ripple is about 43 mV
under worst case conditions.
11
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
5.7
Protections
5.7.1 Under Voltage Lock Out (UVLO)
and Short Circuit Protection
When the voltage level Vaux becomes too low
the controller stops its operation (UVLO). This
feature enables the safe restart mode during
which the controller is alternately active and
not active.
When the main output (Vout1) gets short
circuited, the controller supply voltage Vaux
will drop because the transformer take-over
winding 1-2 fails to charge capacitors C17 and
C20. Vaux drops below UVLO and the
controller enters safe restart mode. This
situation persists until the short circuit is
removed.
5.7.2 Over Voltage Protection (OVP)
When the voltage level Vaux becomes too high
the controller also stops its operation (OVP).
Because Vaux is a reflection of the output
voltage, this feature limits the output voltage
level.
5.7.3 Over Current Protection (OCP)
When the (primary) resonant current becomes
too large the controller stops its operation
This protect the MOSFETs for failure due to
large currents. The current is measured by R35,
that converts it to a voltage, which can activate
the ShutDown (SD) via D14. During start-up the
first period of the resonant current contains an
amplitude that exceeds the OCP_level. To
avoid that the controller stops its operation the
SD is kept low during start-up for a short while
(about 600ms), with an additional circuit, see
chapter7, page 20.
12
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
6
Application Note
AN99011
MEASUREMENTS
6.1
Static performance
Output
Load
IOUT1=30mA
IOUT1=75mA
IOUT1=150mA
I OUT1=250mA
80.0 V
80.0 V
80.0 V
80.0 V
193.0 V
192.7 V
192.5 V
192.3 V
12.9 V
12.5 V
12.2 V
11.7 V
- 12.9 V
- 12.4 V
- 12.1 V
- 11.7 V
- 6.38 V
- 6.38 V
- 6.32 V
5.03 V
5.03 V
193.2 V
193.0 V
192.7 V
192.5 V
12.9 V
12.6 V
12.3 V
11.8 V
- 12.9 V
- 12.4 V
- 12.2 V
- 11.7 V
- 6.38 V
- 6.38 V
- 6.32 V
5.03 V
5.03 V
193.6 V
193.2 V
193.0 V
192.8 V
12.9 V
12.6 V
12.4 V
12.0 V
- 12.9 V
- 12.5 V
- 12.3 V
- 11.8 V
- 6.38 V
- 6.38 V
- 6.32 V
5.03 V
5.03 V
193.9 V
193.5 V
193.2 V
193.0 V
13.0 V
12.7 V
12.5 V
12.1 V
- 12.9 V
- 12.5V
- 12.3 V
- 11.9 V
- 6.38 V
- 6.38 V
- 6.32 V
5.03 V
5.03 V
VOUT1
80V
VOUT2
190V
VOUT3
13V
VOUT4
-13V
VOUT5
-6.2V
VOUT6
5V
30mA
75mA
150mA
250mA
0 mA
250 mA
500 mA
1.00 A
0 mA
250 mA
500 mA
1.00 A
0 mA
325mA
650mA
0 mA
50 mA
Table 1 Load and cross load regulation (@Vline=230VRMS), all measured values are in VDC, with –6.3V and 5.0V post
regulated.
Vline (VRMS)
POUT (W)
PIN(W)
Efficiency (%)
90
0
7.1
-
42.4
54.0
79
85.6
102.6
83
0
8.8
-
42.4
54.7
78
85.6
103.4
83
0
9.8
-
42.4
56.2
75
85.6
103.4
83
230
276
Table 2 Efficiency performance (@ load spread over all outputs), with –6.3V and 5.0V post regulated.
13
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
Vline (VRMS)
POUT (W)
PIN(W)
Efficiency (%)
90
0
6.8
-
44.3
53.7
82
89.3
102.3
87
0
6.7
-
44.3
52.6
84
89.3
101.3
88
0
6.8
-
44.3
53.2
83
89.3
100.4
89
230
276
Table 3 Efficiency performance (@ load spread over all outputs). minus the losses in start-up resistor and with the improved
transformer, which contains a separate winding for the –6.3V.
Measurements of table 2, and 3 are done with load spread over all outputs !!!!!!!!
14
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
100
90
80
70
60
η (%)
50
n 85Vac(%)
40
n 276Vac(%)
30
20
10
0
0
20
40
60
80
100
POUT (W)
Figure 3 Efficiency as function of the output power, measurement done with load spread over VOUT1 and VOUT2
NOTE: The load in the graph above is spread over two outputs. Because of that the diode losses are less and
the measured efficiency is better than that of table 2 and 3, where the load is spread over all outputs.
Temperature measurements @ Tambient=21°C:
TCORE = 46°C
→ ∆T = 25°C (near air gap)
TWIRE = 45°C
→ ∆T = 24°C
THEAT SINK = 43°C
→ ∆T = 22°C (near MOSFETs)
TBODY MOSFET = 42°C
→ ∆T = 21°C
TTIE POINT MOSFET = 46°C
→ ∆T = 25°C
TTIE POINT 190V DIODE = 46°C
→ ∆T = 25°C
TTIE POINT 80V DIODE = 41°C
→ ∆T = 20°C
15
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
6.2
Application Note
AN99011
Dynamic performance
600
100
600ms
Figure 4 Start-up behauviour(@Vline=230VAC, IOUT=250mA)
Figure 5 Start-up behauviour(@Vline=230VAC, IOUT=250mA)
PV
63.6mV
20.0
Figure 6
Load step response(@Vline=230VAC, IOUT=25 250mA)
Figure 7 VOUT1 100Hz ripple (@VLINE=90VAC, IOUT1=250mA)
Figure 6
→ 288mV load step response = -49dB
Figure 7
→ 63.6mV 100Hz ripple = -62dB
Figure 8
→ 43mV 77kHz ripple = -65dB
43mV
50.0
Figure 8 VOUT1 77kHz ripple (@VLINE=90VAC, IOUT1=250mA)
16
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
6.3
Bode diagrams
Figure 9 Bode plot control loop with Vin = 85V AC at full load
Figure 10 Bode plot control loop with Vin = 276VAC at full load
17
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
6.4
Application Note
AN99011
EMI results
Figure 11
CISPR13/22 measurement
ROUT2=659Ω, IOUT1=293mA, IOUT2=293mA
(150kHz-30MHz)
18
(@Vline=230VAC,
ROUT1=273Ω,
Philips Semiconductors
CIRCUIT DIAGRAM
7
A
B
C
D
E
F
85-270V
P1
value R34 is changed to 24k
1
C3
1
3
L1
CU20d3_4
4
470nF 2
**
C2
Cres
R1
3.9
AC07
2
**
C1
2.2nF
**
C4
2.2nF
2
D2
BYW54
D4
BYW54
D1
BYW54
D6
C5
220uF
400V
130k
R33
3
R2
47k
PR03
**
C15
R34
16k
100nF
R28
Vaux
BYW54
Vaux
R27
4.7M
VR25
** C28
2.2nF
**
C8
220nF
C17
1nF
**
C32
100pF
GND_AN
4.7M
VR25
3
R3
12k
R8
130k
9 SGND
10 GL
11 VDD
12 IFS
13 CF
14 IRS
15 SD
16 Vref
IC1
FVDD
GH
SH
GND
I-
4
8
7
6
5
4
3
1
2
GND_AN
1N4148
D14
I+
VCO
PGND
TEA1601
TEA1610
-13V
4
**
C9
220nF
Z3
BZX79C
6V8
R30
330
TR1
TR2
R4
39k
PR02
R39
3.9
C31
68nF
BD140
TR6
R31
6.8k
PHP8N50E
PHP8N50E
F1
2
Additional circuit for correct start-up with OCP:
Ra=33k Rb=68k TRa=BC548B Ca=10µF_16V
(see page 20)
2
1
1
2A
FUSE
components not visible in circuit diagram:
Za=BZX15V between pin11 and pin 9 of TEA1610
1
C10
470pF
C13
D15
1N4148
Vaux
470pF
C27
4.7uF
25V
5
Vres
C30
270pF
**
C14
22nF
D12
7
6
T1
ETD34
11
8
9
14
13
10
12
11
1
6
6
Monday, March 1, 1999
180V
7
L2
10uH
C7
C21
GND_AN
22uF
100V
GND_AN
R11
15k
**
C22
220nF
R18
1k
GND_AN
5V
Project:
GND_AN
GND_AN
5V
GND_AN
-6.2V
13V
8
8
1
2
3
4
5
6
7
8
9
P2
180V
GND_AN
80V
GND_AN
13V
5V
GND_AN
-6.2V
-13V
-13V
Size:
A3
Drwg: 130 - 1 / 1
80W Resonant SMPS
PR39461
Sheet Name:
Philips Semiconductors B.V.
Eindhoven The Netherlands
GND_AN
C12
GND_AN
C6
80V
GND_AN
22uF
250V
L3
10uH
C16
47uF
250V
L4
10uH
C40
1nF
D16
1N4148
C26
1uF
50V
Engineer:
Roger Kennis
Drawn by:
I.Lodema
Changed by:
7
12:35:44 pm
ilodema
22uF
100V
C11
13V
R17
3.3k
R10
120k
L5
-13V 10uH
22uF
200V
IC2
OUT
Time Changed:
GND_AN
GND_AN
R38
1k
** C24
47nF
100uF
160V
R7
330
GND_AN
C18
100uF
63V
R14
2.7k
GND_AN
GND
LM78L05AC
** C23
2.2nF
C19
63V
BYV27-100 100uF
D13
D11
BYV27-100
D8
D3
4 x BYV27-400V
D5
D7
D9
BYV27-200
R36
0
n.m.
R37
0
D17
BYV27-100
n.m.
GND_AN
GND_AN
** IN
C25
100nF
GND_AN
PHILIPS
10
R23
Z1
TL431C
D10
BYV27-200
GND_AN
SEMICONDUCTORS
PS-SLE CONSUMER2
13V
2
1
11
5
4
2
R13
1k
Date Changed:
PHILIPS
100nF
**
C29
CNX82A
OC1
47uF
63V
C20
BAV21
R35
68
R12
-6.2V
62k
5
A
B
C
D
E
F
19
Application Note
AN99011
90W Resonant SMPS with TEA1610 SwingChipTM
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Additional circuit for correct start-up with OCP:
Vaux
Ca
10uF/16V
TEA1610
Ra
33k
15
SD
TRa
BC548B
Rb
68k
20
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
8
Application Note
AN99011
LAYOUT CONSIDERATIONS
See next page for the implementation.
General guidelines:
q
q
q
q
Minimise area of loops that carry high dI/dt current transients (transformer in- and output loops)
Minimise area of traces and components with high dV/dt voltage excitation; reduce trace lengths and
component size
Keep functional circuit blocks close together
Keep transformer, resonance capacitor C14, TEA1610 and input capacitor C5 as close as possible to each
other such that the main current loop area is as small as possible
Layout flow:
1. Start layout with high current (large signal) primary circuit:
q Minimise high current AC-loop area (transformer, TEA1610, input capacitor C5)
q Minimise bridge traces (TEA1610 pin6, source TR1 and drain TR2) surface area
q Minimise dV/dt limiter loop areas (C10 and C13 close as possible to MOSFETs)
2. Continue with the output AC loops:
q Minimise AC loop areas (start with high current output)
3. Continue with the controller section:
q Compact set-up
q Keep Signal Ground (SGND) and Power Ground (PGND) separated on PCB, but short connection of pin4
to pin9
4. Continue with regulator section:
q Compact set-up
5. GND of input capacitor C5 with a short track via safety capacitor C28 to output capacitor C6 and C11
6. Avoid HF interference between mains filter section (C2, L1, C3) and connector P1 coming from circuits that
carry high dI/dt’s (magnetic interference)
21
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
22
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
23
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
24
Application Note
AN99011
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
9
Application Note
AN99011
PARTS LIST
REFERENCE
Capacitors
C1 C4 C28
C2
C3
C5
C6
C7
C8
C9
C10 C13
C11
C12
C14
C15 C25 C29
C16 C21
C17
C18 C19
C20
C22
C23
C24
C26
C27
C30
C31
C32
Diodes
D1 D2 D4 D6
D3 D5 D7 D8
VALUE
2.2nF
Cres
470nF
220uF
47uF
22uF
220nF
220nF
470pF
100uF
22uF
22nF
100nF
22uF
100pF
100uF
47uF
220nF
22nF
47nF
1uF
4.7uF
270pF
68nF
1nF
BYW54
BYV27400
D9 D10
BYV27200
D11 D13
BYV27100
D12
BAV21
D14 D15 D16 1N4148
D17
BYV27100
Fuse
F1
2A
Ics
IC1
TEA1610
IC2
LM78L05
AC
SERIES
MKP 336
MKT-P 330
MKP 336
PSM-SI 057
RLH 151
RLH 151
MKT 368
MKT 370
C655
RLH 151
RLH 151
KP/MMKP 376
MKT 370
RVI136
NP0
RVI136
RSM 037
MKT 465
MKT 370
MKT 370
RLP5 134
RLP5 134
C655
X7R
MKT 370
TOL RATING
20% 250V
20% 250V
20% 275V
20% 400V
20% 250V
20% 250V
10% 400V
10% 63V
10% 500V
20% 160V
20% 200V
5% 1000V
10% 63V
20% 100V
5% 50V
20% 63V
20% 63V
10% 100V
10% 100V
10% 100V
20% 50V
20% 25V
10% 500V
10% 50V
10% 400V
GEOMETRY
12NC_NO
C_B6_L12.5_P10mm
C_B10_L26_P22mm5
C_B10_L26_P22mm5
CASE_3050
CASE_R19
CASE_R19a
C368_I
C370_C
CER2_2A
CASE_R19
CASE_R16
C_B8.5_L26_P22mm5
C370_B
CASE_R14
C0805
CASE_R15
CASE_R13_m
C_B4.5_L8_P5mm
C370_A
C370_A
CASE_R51_CA
CASE_R52_CA
CER2_1
C0805
C370_A
2222-336-60222
2222-330-40334
2222-336-20474
2222-057-36221
2222-151-63479
2222-151-93229
2222-368-55224
2222-370-21224
2222-655-03471
2222-151-61101
2222-151-62229
2222-376-72223
2222-370-21104
2222-136-69229
2222-861-12101
2222-136-68101
2222-037-58479
2222-465-06224
2222-370-21223
2222-370-21473
2222-134-51108
2222-134-56478
2222-655-03271
2222-590-16638
2222-370-51102
Rectifier
Rectifier
600V
400V
SOD57
SOD57
9333-636-10153
9340-366-90133
Rectifier
200V
SOD57
9335-526-80112
Rectifier
100V
SOD57
9335-435-00133
100V
SOD27
SOD27
SOD57
9331-892-10153
9330-839-90153
9335-435-00133
SLOW
GLAS_HOLDER
2412-086-28239
IC_Universal
Stab_Pos
SOT38_s
TO92
Gen_Purpose
Gen_Purpose
Rectifier
25
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Inductors
L2 L3 L4 L5 10uH
TSL0709
Opto coupler
OC1
CNX82A CNX
Connectors
P1
MKS373 MKS3730
0_2p_22
0V
P2
MKS373 MKS3730
0_9p
Resistors
R1
3.3
AC07
R2
47k
PR03
R3
12k
RC01
R4
39k
RC01
R7
470 SFR25H
R8
130k
RC01
R10
120k
SFR25H
R11
15k
SFR25H
R12
62k
SFR25H
R13 R18
1k
SFR25H
R14
2.7k
SFR25H
R17
3.3k
SFR25H
R23
10 SFR25H
R27 R28
4.7M
VR25
R30
330 SFR25H
R31
6.8k
SFR25H
R33
120k
SFR25H
R34
24k
SFR25H
R35
68 SFR25H
R36
n.m.
SFR25H
R37
0 SFR25H
R38
1k
3296Y
R39
3.9
PR02
Transistors
TR1 TR2
PHP8N5 fets
0E
TR6
BD140 Pow_Low_Freq
Transformer
T1
ETD34 Switch_Mode
Zener diodes
Z1
X
Misc
Z3
BZX79C BZX79C
10%
Application Note
AN99011
TSL0707_2e
SOT231
9338-846-80127
MKS3730_2p_220V
MKS3730_9p
5% 7W
5% 3W
5% 0.25W
5% 0.25W
5% 0.5W
5% 0.25W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.25W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
5% 0.5W
10% 0.5W
5% 2W
6V8
26
AC07
PR03
R1206
R1206
SFR25H
R1206
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
VR25
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
SFR25H
BO3296Y
PR02
2322-329-07338
2322-195-13473
2322-711-61123
2322-711-61393
2322-186-16471
2322-711-61134
2322-186-16124
2322-186-16153
2322-186-16623
2322-186-16102
2322-186-16272
2322-186-16332
2322-186-16109
2322-241-13475
2322-186-16331
2322-186-16682
2322-186-16124
2322-186-16243
2322-186-16689
2322-181-90019
2322-181-90019
2122-362-00723
2322-194-13398
TO220
9340-438-80127
TO126
9330-912-30127
ETD34
8228-001-34471
TO226AA
SOD27
9331-177-50153
Philips Semiconductors
90W Resonant SMPS with TEA1610 SwingChipTM
Application Note
AN99011
10 REFERENCES
1
M.K. Kazimierczuk & D. Czarkowski, Resonant Power Converters, 1995 Wiley Intersience,
ISBN 0-471-04706-6
27
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