TEA1721 Isolated 3-phase universal mains flyback converter demo board

UM10520
TEA1721 isolated 3-phase universal mains flyback converter
demo board
Rev. 1.2 — 15 May 2013
User manual
Document information
Info
Content
Keywords
TEA1721, isolated, 3-phase universal mains, AC/DC conversion, flyback
converter, Switched Mode Power Supply (SMPS)
Abstract
This user manual describes the application of the TEA1721ADB1062
demo board. The demo board is designed as an isolated 24 V, 5 V and
3.3 V AC/DC SMPS for supplying up to 5 W into a load.
UM10520
NXP Semiconductors
Isolated 3-phase universal mains flyback converter demo board
Revision history
Rev
Date
Description
v.1.2
20130515
updated issue
Modifications:
Figure 5 “TEA1721 3-phase SMPS circuit diagram” has been updated.
v.1.1
20130501
updated issue
v.1
20120123
first issue
Contact information
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
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1. Introduction
WARNING
Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present when operating this product, constitute a
risk of electric shock, personal injury, death and/or ignition of fire.
This product is intended for evaluation purposes only. It shall be operated in a designated test
area by personnel qualified according to local requirements and labor laws to work with
non-insulated mains voltages and high-voltage circuits. This product shall never be operated
unattended.
This user manual describes the application of the TEA1721ADB1062 demo board. The
demo board is designed as an isolated 24 V, 5 V and 3.3 V AC/DC SMPS for supplying up
to 5 W to a load.
On the input side, single phase, 2-phase or 3-phase Universal Mains power can be
connected. The switch-mode converter operates in flyback mode at a maximum
frequency of around 50 kHz. Overcurrent and short-circuit protection are built in. The
power consumption is below 50 mW under no-load conditions.
EMI filtering and surge protection using TVS diodes is implemented in this circuit. This
application is intended as a 3-phase low-power SMPS which is especially suited for
3-phase industrial and multi-phase e-metering SMPS applications.
Do not exceed an RMS input voltage of 560 V (AC) across any combination of the J1.x
connectors. 560 V (AC) corresponds to a maximum instantaneous voltage difference of
800 V.
An additional high surge protection using MOVs can be implemented if necessary.
1.1 Features and benefits
•
•
•
•
•
•
•
UM10520
User manual
Compatible with 3-phase universal mains
Tolerant with respect to “missing neutral”
Inrush current limitation
EMI filtering to meet EMC requirements of EN55022
ESD protection on the TEA1721
Optional high-surge protection companion circuit option
Power Line Communication (PLC) decoupling extension
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2. Safety warning
The demo board is powered by AC mains voltage. Avoid touching the board when power
is applied. An isolated housing is obligatory when used in uncontrolled, non-laboratory
environments. Always provide galvanic isolation of the mains phase using a variable
transformer. The following symbols identify isolated and non-isolated devices.
019aab174
019aab173
a. Isolated
Fig 1.
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b. Non-isolated
Isolated and non-isolated symbols
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3. Specification
Table 1.
Demo board specification
Parameter
Value
Comment
AC line input voltage
single-phase:
85 V (AC) to 560 V (AC)
supplied to any pair of the J1.x terminals
2-phase or 3-phase:
output voltage
50 V (AC) to 320 V (AC)[1]
assuming 120 phase angle. The Phase and the Neutral
wires from the mains utility system can be connected
randomly to the J1.x terminals.
24 V (DC), 5 V (DC) and
3.3 V (DC)
supplied from connectors:
J2.1 = 24 V, GND
J2.2 = 5 V
J2.3 = 3.3 V
J2.4 = 0 V, GND
maximum output current
24 V = 200 mA
5 V = 300 mA
3.3 V = 300 mA
maximum output power
5W
output voltage accuracy
5 %
depends primarily on the accuracy of the secondary
winding construction of transformer T1
output voltage stability
5 %
strongly depends on the magnetic coupling of the
secondary and auxiliary winding of transformer T1
efficiency
76.7 % at 115 V/60 Hz
79.6 % 230 V/50 Hz
operating temperature
40 C to 85 C
EMC Compliance
EN 55022
board dimensions
82 mm  62 mm  35 mm
[1]
LBH
Each phase, measured between the neutral and the phase wire
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a. Front view.
b. Back view.
Fig 2.
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Photographs of the board
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4. Demo board connections
The isolated 3-phase flyback demo board has an input and an output terminal block.
The input terminal block (left on the picture) is connected to the utility mains. Either 1, 2 or
3 phases can be connected using 2, 3 or 4 wires respectively. The input wires (L1, L2, L3
and N) can be connected to the terminals of the left terminal block randomly.
The output terminal block provides the 24 V (DC), 5 V (DC) and 3.3 V (DC) output
voltages, all referenced to a common ground (GND).
Remark: Mount the board in a shielded or isolated box for demonstration purposes.
Fig 3.
UM10520
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TEA1721 demo board connections
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5. Operation and performance
Basic operation of the IC is described in the NXP Semiconductors TEA1721 data sheets.
5.1 No-load power consumption
Table 2.
Typical no-load power consumption
Power supply
Energy Star 2.0 requirement
No-load power consumption
115 V (AC)/60 Hz
< 300 mW
36 mW
230 V (AC)/50 Hz
< 300 mW
38 mW
The typical no-load power consumption of the TEA1721 3-phase SMPS exceeds the
Energy Star 2.0 level V requirement by nearly a factor of 10.
5.2 Efficiency
Table 3.
Typical efficiency data
Parameter
Energy Star
Efficiency (%)
2.0 level V (%) average 25 % load 50 % load 75 % load 100 % load
115 V (AC)/60 Hz
72.3
76.7
77.6
78.5
76.7
74.1
230 V (AC)/50 Hz
72.3
79.6
79.1
80.7
79.9
78.7
The typical efficiency of the TEA1721 3-phase SMPS exceeds the Energy Star 2.0 level V
requirement by more than 5 % on average. Efficiency was measured by having a load on
the 24 V output only.
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6. Test results
6.1 ElectroMagnetic Interference
EMI was measured with 4 W load (80 % load) on the joint outputs of the TEA1721
3-phase SMPS. Measurement results are shown in Figure 4. The TEA1721 3-phase
SMPS is EMC compliant according to EN55022 and the margin with respect to the limits
is more than 10 dB.
a. 115 V (AC) input voltage.
b. 230 V (AC) input voltage.
Fig 4.
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Typical EMI pattern measured at 4 W load
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7. Demo board schematic
'
/
-
5
&
5
'
'
7
5
'
5
'
5
&
&
5
&
'
'
-
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&
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5
-
5
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5
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4
-
&
5
/
'
&
&
-
5
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5
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5
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&
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,&
5
*1'
'5$,1
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6285&(
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5
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-
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9&&
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5
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-
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5
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5
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DDD
Fig 5.
TEA1721 3-phase SMPS circuit diagram
to PLC transceiver module
L1.4
J1.4
J1.4’
to PLC transceiver module
L1.3
J1.3’
J1.3
to PLC transceiver module
L1.2
J1.2’
J1.2
to PLC transceiver module
L1.1
J1.1’
J1.1
aaa-002099
a. PLC decoupling stage extension
F4
J1.4’
J1.4
F3
J1.3’
J1.3
F2
J1.2’
J1.2
F1
J1.1’
J1.1
V1
V2
V3
V4
aaa-002100
b. High-surge protection extension
Fig 6.
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Optional extensions
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8. PCB components
Table 4.
Demo board components
Reference
Description and value
Part number
Manufacturer
C1
100 nF; 1 kV
-
-
C2
10 nF; 1 kV
-
-
C3
electrolytic capacitor; 22 F; 400 V
-
-
C4
electrolytic capacitor; 22 F; 400 V
-
-
C5
100 nF; 500 V; 1812
-
-
C6
100 nF; 500 V; 1812
-
-
C7
10 pF; 25 V; 0805
-
-
C8
220 pF; 500 V; 1206
-
-
C9
ceramic capacitor; 1 F; 50 V; 1206
-
-
C10
electrolytic capacitor; 1 mF; 6.3 V
-
-
C11
100 nF; 25 V; 0805
-
-
C12
electrolytic capacitor; 470 F; 10 V
-
-
C13
100 nF; 25 V; 0805
-
-
C14
electrolytic capacitor; 100 F; 35 V
-
-
C15
100 nF; 50 V; 0805
-
-
C16
Y-capacitor; 2.2 nF; 1 kV
-
-
D1
S1M; SMA
S1M (or equivalent)
-
D2
S1M; SMA
S1M (or equivalent)
-
D3
S1M; SMA
S1M (or equivalent)
-
D4
S1M; SMA
S1M (or equivalent)
-
D5
S1M; SMA
S1M (or equivalent)
-
D6
S1M; SMA
S1M (or equivalent)
-
D7
S1M; SMA
S1M (or equivalent)
-
D8
S1M; SMA
S1M (or equivalent)
-
D9
BZG03-C200; SMA
BZG03-C200
-
D10
BZG03-C200; SMA
BZG03-C200
NXP Semiconductors
D11
BZG03-C200; SMA
BZG03-C200
NXP Semiconductors
D12
BZG03-C200; SMA
BZG03-C200
NXP Semiconductors
D13
BZG03-C240; SMA
BZG03-C240
NXP Semiconductors
D14
BZG03-C240; SMA
BZG03-C240
NXP Semiconductors
D15
BZX384-C13; SOD323
BZX384-C13
NXP Semiconductors
D16
S1M; SMA
S1M
-
D17
BAS316; SOD323
BAS316
NXP Semiconductors
D18
BYG22D; SMA
BYG22D
-
D19
PMEG4050EP; SOD128
PMEG4050EP
NXP Semiconductors
D20
PMEG3050EP; SOD128
PMEG3050EP
NXP Semiconductors
D21
BZX384-C3V6; SOD323
BZX384-C3V6
NXP Semiconductors
D22
BZX384-C5V6; SOD323
BZX384-C5V6
NXP Semiconductors
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Table 4.
Demo board components …continued
Reference
Description and value
Part number
Manufacturer
D23
BZX384-C30; SOD323
BZX384-C30
NXP Semiconductors
IC1
TEA1721; SO7
TEA1721AT
NXP Semiconductors
L1
2  25 mH; 80 mA; 500 V (AC)
744862250
Würth Elektronik
L2
1 mH; 80 mA
-
-
Q1
STD3NK60Z; IPAK
STD3NK60Z
-
R1
carbon resistor; 33 Ω
-
-
R2
carbon resistor; 33 
-
-
R3
carbon resistor; 33 
-
-
R4
carbon resistor; 33 
-
-
R5
10 ; 0.25 W; 1206
-
-
R6
10 ; 0.25 W; 1206
-
-
R7
680 k; 0.125 W; 1206
-
-
R8
680k; 0.125 W; 1206
-
-
R9
680k; 0.125 W; 1206
-
-
R10
100 ; 0805
-
-
R11
4.7 k; 1 %; 0805
-
-
R12
100 k; 0.5 W; 1206
-
-
R13
470 ; 0805
-
-
R14
1.8 ; 0.25 W; 1206
-
-
R15
25.5 k; 1 %; 1206
[2]
-
R16
10 ; 0805
-
-
R17
5.6 k; 0805
-
-
R18
12 k; 0805
-
-
R19
270 k; 0805
-
-
750817841
Würth Elektronik
T1
custom
transformer[1]
[1]
Custom transformer: primary winding inductance 2.4 mH; turns ratio Primary: Secondary: Auxiliary = 10 : 3 : 2. The secondary winding
must have a tap for the 5 V and the 3.3 V output voltage. The magnetic coupling between the secondary and the auxiliary winding must
be optimal.
[2]
To set the output voltage with greater accuracy, fine-tuning is required.
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9. Optional modifications implementation guidelines
• The output voltages are adjusted using resistors R11 and R15. The secondary
winding on transformer T1 turns ratio defines the ratio between the three output
voltages. Using a different transformer makes other output voltages and/or other
output voltage ratios available.
• To achieve good voltage regulation, the secondary winding and the auxiliary winding
of the transformer must have a tight magnetic coupling.
• The maximum output power and output current levels are adjusted using resistor R14.
The maximum current allowed in the TEA1721 IC switching MOSFET is 700 mA. Take
care that under no circumstances, the peak current in the primary winding of the T1
transformer exceeds 700 mA.
• Resistors R1, R2, R3 and R4 limit the inrush current. The resistor must be a carbon
resistor because metal film resistors can act as a fuse in this position. If no inrush
current limiting is required, the resistor can be replaced with a short-circuit.
• EMI-filtering is implemented using separate stages for common mode (L1) and
differential mode (L2). Depending on the requirements, the filtering stage can be
adapted. For example, inductor L1 can be chosen to ensure that its leakage
inductance takes care of differential filtering. As a consequence L2 can be omitted.
• Surge voltage protection is implemented using TVS diodes D9, D10, D11, D12 and
capacitors C5/C6. The surge protection limits the DC bus voltage to 800 V. The TVS
diodes choice determines the maximum allowable surge pulse energy.
• Resistors R17, R18 and R19 form small pre-loads for the converter. When the output
voltages are adjusted, also adjust the pre-load resistors to ensure that they consume
roughly the same amount of power. Depending on the connected load, eliminate the
resistors.
• Zener diodes D21, D22 and D23 are an elementary output OverVoltage Protection
(OVP). When OVP is not needed, eliminate the diodes.
• Capacitors C11, C13 and C15 are used to obtain additional (HF) voltage stability and
noise suppression. Eliminate the capacitors when the feature is not needed.
• Capacitor C16 is a Y-capacitor. If theT1 transformer construction provides the
required EMI performance without the use of capacitor C16, omit the capacitor.
• Additional high surge protection using MOVs (V1 to V4) is implemented using the
dedicated companion circuit in the front end. Depending on the application
requirements, fuses (F1 to F4) can be included in the circuit as required. The MOVs
must be DC rated at approximately 400 V. For example, S10K320.
• Additional Power Line Communication (PLC) decoupling can be implemented when
the SMPS is used in combination with a PLC transceiver module. For example in
e-metering applications. Depending on the frequency band, choose the value for L1.1
to L1.4. Typically, the inductor values range between a few hundred µH up to several
mH.
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10. Board layout
A 61 mm  59.7 mm sized evaluation PCB was created that accommodates an
implementation of the TEA1721 3-phase SMPS.
aaa-002101
a. Top silk screen plus top component placement and drill pattern
aaa-002102
b. Bottom copper and bottom silk screen plus component placement
Fig 7.
PCB layout
The bottom silk screen is normally not used in PCB production. Merged with the bottom
copper, it is shown here as a component placement reference only. See Table 4 for a list
of components.
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Table 5.
Drill tool table
Drill tool code
Drill diameter
C
1 mm
D
0.9 mm
E
1.3 mm
M
0.8 mm
Gerber files are available from your local NXP Semiconductor sales representative, on
request.
11. Abbreviations
Table 6.
Abbreviations
Acronym
Description
EMC
ElectroMagnetic Compatibility
EMI
ElectroMagnetic Interference
MOSFET
Metal-Oxide Semiconductor Field-Effect Transistor
OCP
OverCurrent Protection
OPP
OverPower Protection
OVP
OverVoltage Protection
OLP
Open-Loop Protection
PCB
Printed-Circuit Board
PFC
Power Factor Correction
SMPS
Switched Mode Power Supply
ZVS
Zero Voltage Switching
12. References
UM10520
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[1]
TEA1721XT - Ultra-low standby SMPS controller with integrated power switch
[2]
AN11060 - TEA172X 5 W to 11 W power supply/USB charger
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13. Legal information
13.1 Definitions
Draft — The document is a draft version only. The content is still under
internal review and subject to formal approval, which may result in
modifications or additions. NXP Semiconductors does not give any
representations or warranties as to the accuracy or completeness of
information included herein and shall have no liability for the consequences of
use of such information.
Export control — This document as well as the item(s) described herein
may be subject to export control regulations. Export might require a prior
authorization from competent authorities.
13.2 Disclaimers
Limited warranty and liability — Information in this document is believed to
be accurate and reliable. However, NXP Semiconductors does not give any
representations or warranties, expressed or implied, as to the accuracy or
completeness of such information and shall have no liability for the
consequences of use of such information. NXP Semiconductors takes no
responsibility for the content in this document if provided by an information
source outside of NXP Semiconductors.
In no event shall NXP Semiconductors be liable for any indirect, incidental,
punitive, special or consequential damages (including - without limitation - lost
profits, lost savings, business interruption, costs related to the removal or
replacement of any products or rework charges) whether or not such
damages are based on tort (including negligence), warranty, breach of
contract or any other legal theory.
Notwithstanding any damages that customer might incur for any reason
whatsoever, NXP Semiconductors’ aggregate and cumulative liability towards
customer for the products described herein shall be limited in accordance
with the Terms and conditions of commercial sale of NXP Semiconductors.
Right to make changes — NXP Semiconductors reserves the right to make
changes to information published in this document, including without
limitation specifications and product descriptions, at any time and without
notice. This document supersedes and replaces all information supplied prior
to the publication hereof.
Suitability for use — NXP Semiconductors products are not designed,
authorized or warranted to be suitable for use in life support, life-critical or
safety-critical systems or equipment, nor in applications where failure or
malfunction of an NXP Semiconductors product can reasonably be expected
to result in personal injury, death or severe property or environmental
damage. NXP Semiconductors and its suppliers accept no liability for
inclusion and/or use of NXP Semiconductors products in such equipment or
applications and therefore such inclusion and/or use is at the customer’s own
risk.
Applications — Applications that are described herein for any of these
products are for illustrative purposes only. NXP Semiconductors makes no
representation or warranty that such applications will be suitable for the
specified use without further testing or modification.
Customers are responsible for the design and operation of their applications
and products using NXP Semiconductors products, and NXP Semiconductors
accepts no liability for any assistance with applications or customer product
design. It is customer’s sole responsibility to determine whether the NXP
Semiconductors product is suitable and fit for the customer’s applications and
products planned, as well as for the planned application and use of
customer’s third party customer(s). Customers should provide appropriate
design and operating safeguards to minimize the risks associated with their
applications and products.
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NXP Semiconductors does not accept any liability related to any default,
damage, costs or problem which is based on any weakness or default in the
customer’s applications or products, or the application or use by customer’s
third party customer(s). Customer is responsible for doing all necessary
testing for the customer’s applications and products using NXP
Semiconductors products in order to avoid a default of the applications and
the products or of the application or use by customer’s third party
customer(s). NXP does not accept any liability in this respect.
Evaluation products — This product is provided on an “as is” and “with all
faults” basis for evaluation purposes only. NXP Semiconductors, its affiliates
and their suppliers expressly disclaim all warranties, whether express, implied
or statutory, including but not limited to the implied warranties of
non-infringement, merchantability and fitness for a particular purpose. The
entire risk as to the quality, or arising out of the use or performance, of this
product remains with customer.
In no event shall NXP Semiconductors, its affiliates or their suppliers be liable
to customer for any special, indirect, consequential, punitive or incidental
damages (including without limitation damages for loss of business, business
interruption, loss of use, loss of data or information, and the like) arising out
the use of or inability to use the product, whether or not based on tort
(including negligence), strict liability, breach of contract, breach of warranty or
any other theory, even if advised of the possibility of such damages.
Notwithstanding any damages that customer might incur for any reason
whatsoever (including without limitation, all damages referenced above and
all direct or general damages), the entire liability of NXP Semiconductors, its
affiliates and their suppliers and customer’s exclusive remedy for all of the
foregoing shall be limited to actual damages incurred by customer based on
reasonable reliance up to the greater of the amount actually paid by customer
for the product or five dollars (US$5.00). The foregoing limitations, exclusions
and disclaimers shall apply to the maximum extent permitted by applicable
law, even if any remedy fails of its essential purpose.
Safety of high-voltage evaluation products — The non-insulated high
voltages that are present when operating this product, constitute a risk of
electric shock, personal injury, death and/or ignition of fire. This product is
intended for evaluation purposes only. It shall be operated in a designated
test area by personnel that is qualified according to local requirements and
labor laws to work with non-insulated mains voltages and high-voltage
circuits.
The product does not comply with IEC 60950 based national or regional
safety standards. NXP Semiconductors does not accept any liability for
damages incurred due to inappropriate use of this product or related to
non-insulated high voltages. Any use of this product is at customer’s own risk
and liability. The customer shall fully indemnify and hold harmless NXP
Semiconductors from any liability, damages and claims resulting from the use
of the product.
Translations — A non-English (translated) version of a document is for
reference only. The English version shall prevail in case of any discrepancy
between the translated and English versions.
13.3 Trademarks
Notice: All referenced brands, product names, service names and trademarks
are the property of their respective owners.
All information provided in this document is subject to legal disclaimers.
Rev. 1.2 — 15 May 2013
© NXP B.V. 2013. All rights reserved.
16 of 17
UM10520
NXP Semiconductors
Isolated 3-phase universal mains flyback converter demo board
14. Contents
1
1.1
2
3
4
5
5.1
5.2
6
6.1
7
8
9
10
11
12
13
13.1
13.2
13.3
14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features and benefits . . . . . . . . . . . . . . . . . . . . 3
Safety warning . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Demo board connections . . . . . . . . . . . . . . . . . 7
Operation and performance . . . . . . . . . . . . . . . 8
No-load power consumption . . . . . . . . . . . . . . . 8
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ElectroMagnetic Interference . . . . . . . . . . . . . . 9
Demo board schematic . . . . . . . . . . . . . . . . . . 10
PCB components . . . . . . . . . . . . . . . . . . . . . . . 11
Optional modifications implementation
guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . 15
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Legal information. . . . . . . . . . . . . . . . . . . . . . . 16
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Please be aware that important notices concerning this document and the product(s)
described herein, have been included in section ‘Legal information’.
© NXP B.V. 2013.
All rights reserved.
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
Date of release: 15 May 2013
Document identifier: UM10520