MP44010+HR1000A+MP6922(A) PFC+Half Bridge LLC+SR 220W AC-DC Power Supply for Servers Design Concept Report 220W AC-DC Resonant Power Supply Design Specs Input Voltage Input Frequency Output Voltage Output Current Isolation MPS IC Value 90-265 47-63 12 18.3 Unit VAC Hz VDC A Yes MP44010, HR1000A, MP6922(A) Server Power Supply AC-DC Power Supply Application Document Number DCXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary MP44010+HR1000A + MP6922(A) is a design concept for a universal offline isolated power supply with 12V, 18.3A output. It contains the estimated specification of the power supply, a detailed circuit diagram, drawing of the power inductors and transformers. Such information would be useful to the customer to create a similar design with less effort. There is no physical PCB that can be ordered for MPS’s design concepts, however schematics and further support is available upon request. For ordering reference designs that include an assembled PCB and more detailed spec, please refer to MPS website for more information. EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 MP44010+HR1000A+MP6922(A) PFC+Half Bridge LLC+SR 220W AC-DC Power Supply for Servers ELECTRICAL SPECIFICATIONS DESCRIPTION Here introduces a design concept for a 220W AC-DC power supply, it is primary for server applications but also applies to other general AC-DC applications. This design includes a boost PFC pre-regulator using MP44010. This design concept also utilizes MPS’s state-of-art half bridge LLC resonant controller HR1000A and dual fast synchronous rectifier MP6922(A) to realize very high overall efficiency. MP44010 is a boundary conduction mode PFC controller which can provide simple and high performance active power factor correction using minimum external components. HR1000A is a controller designed specifically for the resonant half-bridge ZVS. It controls the output power by changing the switching frequency and controlling the half-bridge with a constant 50% duty cycle. And HR1000A can optimize the light load consumption for the burst mode operation. Parameter Input AC Voltage Input Frequency Output Voltage Output Current Power Factor THD Active Mode Efficiency Symbol VAC F VOUT IOUT PF Value 90 to 265 47 to 63 12 18.3 >0.9* <20%* Eff >90%* Units VAC Hz VDC A *By estimate FEATURES High Efficiency Active PFC Very Low No-Load Power Consumption Output Short Circuit Protection Over Voltage Protection All MPS parts are lead-free and adhere to the RoHS directive. For MPS green status, please visit MPS website under Products, Quality Assurance page. “MPS” and “The Future of Analog IC Technology” are registered trademarks of Monolithic Power Systems, Inc. Warning: Although this board is designed to satisfy safety requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 MP44010+HR1000A+MP6922(A) – 220W SERVER POWER SUPPLY DESIGN CONCEPT MP44010+HR1000A + MP6922(A) DESIGN CONCEPT SCHEMATICS EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 MP44010+HR1000A+MP6922(A) – 220W SERVER POWER SUPPLY DESIGN CONCEPT EV44010HS+4688DN-00A Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 4 MP44010+HR1000A+MP6922(A) – 220W SERVER POWER SUPPLY DESIGN CONCEPT Design Number MPS IC Number HR1000A MP44010+HR1000A + MP6922(A) MP44010 MP6922, MP6922A Disclaimer Monolithic Power Systems (MPS) reserves the right to make changes to its products and to discontinue products without notice. The applications information, schematic diagrams, and other reference information included herein is provided as a design aid only and are therefore provided as-is. MPS makes no warranties with respect to this information and disclaims any implied warranties of merchantability or non-infringement of third-party intellectual property rights. MPS cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a MPS product. No circuit patent licenses are implied. Certain applications using semiconductor products may involve potential risks of death, personal injury, or severe property or environmental damage (“Critical Applications”). MPS PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE SUITABLE FOR USE IN LIFE‑SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER CRITICALAPPLICATIONS. Inclusion of MPS products in critical applications is understood to be fully at the risk of the customer. Questions concerning potential risk applications should be directed to MPS. MPS semiconductors are typically used in power supplies in which high voltages are present during operation. High voltage safety precautions should be observed in design and operation to minimize the chance of injury. EV44010HS+4688DN-00A Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. Preliminary Specifications Subject to Change © 2015 MPS. All Rights Reserved. 5 MP44010+HR1000A+MP6922(A) – 220W SERVER POWER SUPPLY DESIGN CONCEPT APPENDIX: PFC INDUCTOR SPECIFICATION Electrical Diagram Winding Diagram Primary Winding 1 N1 6 5 N2 7 Auxiliary Winding Electrical Characteristic Parameter Value Inductance 170μH±5% Core PQ3220 Bobbin PQ3220 Core Material PC40 Turns Ratio 26:3 Winding Specification Pin Number Wire Winding Order Start Finish N1 N2 6 5 1 Type (Φ) 0.1mm*100 7 0.2 Number of Turns Tube 26 3 Matching Wire Matching Wire EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 MP44010+HR1000A+MP6922(A) – 220W SERVER POWER SUPPLY DESIGN CONCEPT APPENDIX: LLC TRANSFORMER SPECIFICATION Electrical Diagram Winding Diagram Electrical Characteristic Parameter Primary Inductance Leakage Inductance Condition Value 1.2mH±5% 135uH (Max) Core ETD34 Bobbin ETD34 Core Material PC40 Turn Ratio N1:N2:N3:N4 47:5:3:3 Winding Specification Winding Order N1 N2 N3 N4 Pin Number Finish Start 1 2 5 6 Wire 3 Type (Φ) 0.1mm*40 4 6 7 0.2mm 0.1mm*200 0.1mm*200 Number of Turns Tube 47 5 3 3 Matching with Wire Matching with Wire Matching with Wire Matching with Wire EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 8/26/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7