AN3233
Application note
12 V - 150 W resonant converter with synchronous rectification
using L6563H, L6599A, and SRK2000A
Claudio Spini
Introduction
This application note describes the characteristics and features of a 150 W SMPS
demonstration board (EVL150W-ADP-SR), tailored to all-in-one computer power supply
(PS) specifications.
The characteristics of this design are the very high efficiency and low consumption at light
load which make it a viable solution for applications compliant with ENERGY STAR®
eligibility criteria (EPA rev. 5.0 computer and EPA rev. 2.0 EPS). One of the key factors to
achieving high efficiency at heavy load is the SRK2000A. This synchronous rectification
(SR) driver for LLC resonant converters allows a significant decrease in secondary side
losses.
Standby consumption is very low thanks to the sleep function embedded in the SRK2000A
and the high voltage start-up circuit integrated in the L6563H. The possibility of driving the
PFC burst mode via the L6599A PFC_STOP pin dramatically boosts light load efficiency.
Additionally, a secondary sensing circuit, dedicated to driving the primary controller into
burst mode, reduces deviation of light load efficiency against resonant circuit parameter
spread, improving the repeatability of design in production volumes.
Figure 1. EVL150W-ADP-SR: 150 W SMPS demonstration board
June 2017
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32
Contents
AN3233
Contents
1
Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 5
2
Efficiency measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4
Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5
Thermal map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6
Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 21
7
Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8
PFC coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9
Transformer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2/32
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AN3233
List of figures
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.
EVL150W-ADP-SR: 150 W SMPS demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Burst mode circuit block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Light load efficiency diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compliance with EN61000-3-2 at 230 Vac – 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . 13
Compliance with JEITA-MITI at 100 Vac – 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . 13
Resonant stage waveforms at 115 V – 60 Hz – full load . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SRK2000A key signals at 115 V – 60 Hz – full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High-side MOSFET ZV turn-on at 115 V – 60 Hz – full load. . . . . . . . . . . . . . . . . . . . . . . 15
Low-side MOSFET ZV turn-on at 115 V – 60 Hz – full load . . . . . . . . . . . . . . . . . . . . . . . . 15
Converter startup at 115 Vac full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Converter shutdown at 115 Vac full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Startup resonant current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shutdown resonant current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
No-load operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
No-load operation – detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transition full load to no load at 115 Vac – 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transition no load to full load at 115 Vac – 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Short-circuit at full load and 115 Vac – 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Thermal map at 115 Vac – 60 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Thermal map at 230 Vac – 50 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Thermal map SR daughterboard - full load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CE average measurement at 115 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CE average measurement at 230 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PFC coil electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PFC coil mechanical aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transformer overall drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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32
Main characteristics and circuit description
1
AN3233
Main characteristics and circuit description
The main features of the SMPS are:
Input mains range: 90 ÷ 264 Vac - frequency 45 65 Hz
Output voltage: 12 V at 12.5 A continuous operation
Mains harmonics: acc. to EN61000-3-2 Class-D or JEITA-MITI Class-D
Standby mains consumption: < 0.2 W at 230 Vac
Efficiency at nominal load: > 91 % at 115 Vac
EMI: according to EN55022-Class-B
Safety: according to EN60950
Dimensions: 65 x 154 mm, 28 mm component maximum height
PCB: double side, 70 µm, FR-4, mixed PTH/SMT.
The circuit is composed of two stages: a front-end PFC using the L6563H and an LLC
resonant converter based on the L6599A and the SRK2000A, controlling the SR MOSFETs
on the secondary side. The SR driver and the rectifier MOSFETs are mounted on a
daughterboard.
The L6563H is a current mode PFC controller operating in transition mode and implements
a high voltage start-up source to power on the converter.
The L6599A integrates all the functions necessary to properly control the resonant converter
with a 50 % fixed duty cycle and working with variable frequency.
The output rectification is managed by the SRK2000A, an SR driver dedicated to LLC
resonant topology.
The PFC stage works as the pre-regulator and powers the resonant stage with a constant
voltage of 400 V. The downstream converter operates only if the PFC is on and regulating.
In this way, the resonant stage can be optimized for a narrow input voltage range.
The L6599A's LINE pin (pin 7) is dedicated to this function. It is used to prevent the resonant
converter from working with an input voltage that is too low which can cause incorrect
capacitive mode operation. If the bulk voltage (PFC output) is below 380 V, the resonant
start-up is not allowed. The L6599A LINE pin internal comparator has a hysteresis allowing
to set the turn-on and turn-off voltage independently. The turn-off threshold has been set to
300 V in order to avoid capacitive mode operation but allow the resonant stage to operate
even in the case of mains sag and consequent PFC output dip.
The transformer uses the integrated magnetic approach, incorporating the resonant series
inductance. Therefore, no external, additional coil is needed for the resonance. The
transformer configuration chosen for the secondary winding is center-tap.
On the secondary side, the SRK2000A core function is to switch on each synchronous
rectifier MOSFET whenever the corresponding transformer half-winding starts conducting
(i.e. when the MOSFET body diode starts conducting) and then switching it off when the
flowing current approaches zero. For this purpose, the IC is provided with two pins (DVS1
and DVS2) sensing the MOSFET drain voltage level.
One of the SRK2000A’s main characteristics is the ability to automatically detect light load
operation and enter sleep mode, disabling MOSFET driving and decreasing its
consumption. This function allows great power saving at light load with respect to
benchmark SR solutions.
4/32
DocID17595 Rev 2
AN3233
Main characteristics and circuit description
In order to decrease the output capacitors size, aluminium solid capacitors with very low
ESR were preferred to standard electrolytic ones. Therefore, high frequency output voltage
ripple is limited and output LC filter is not required. This choice allows a saving of output
inductor power dissipation which can be significant in the case of high output current
applications like this.
Start-up sequence
The PFC acts as master and the resonant stage can operate only if the PFC output is
delivering the nominal output voltage. Therefore, the PFC starts first and then the
downstream converter turns on. At the beginning, the L6563H is supplied by the integrated
high voltage start-up circuit; as soon as the PFC starts switching, a charging pump
connected to the PFC inductor supplies both PFC and resonant controllers and the HV
internal current source is disabled. Once both stages have been activated, the controllers
are supplied also by the auxiliary winding of the resonant transformer, assuring correct
supply voltage even during standby operation.
As the L6563H integrated HV start-up circuit is turned off, and therefore is not dissipative
during the normal operation, it gives a significant contribution to power consumption
reduction when the power supply operates at light load, in accordance with worldwide
standby standards currently required.
Standby power saving
The board has a burst mode function implemented which allows power saving during light
load operation.
The L6599A's STBY pin (pin 5) senses the optocoupler’s collector voltage (U3), which is
related to the feedback control. This signal is compared to an internal reference (1.24 V). If
the voltage on the pin is lower than the reference, the IC enters an idle state and its
quiescent current is reduced. When the voltage exceeds the reference by 50 mV, the
controller restarts the switching.
The burst mode operation load threshold can be programmed by properly choosing the
resistor connecting the optocoupler to pin RFMIN (R34). Basically, R34 sets the switching
frequency at which the controller enters burst mode.
As the power at which the converter enters burst mode operation heavily influences
converter efficiency at light load, it must be properly set. Anyhow, despite this threshold
being well set, if its tolerance is too wide, the light load efficiency of mass production
converters has a considerable spread.
The main factors affecting the burst mode threshold tolerance are the control circuitry
tolerances and, even more influential, the tolerances of resonant inductance and the
resonant capacitor. Slight changes of resonance frequency can affect the switching
frequency and, consequently, notably change the burst mode threshold.
Typical production spread of these parameters, which fits the requirements of many
applications, are no longer acceptable if very low power consumption in standby must be
guaranteed.
As reducing production tolerance of resonant components causes cost increases, a new
cost-effective solution is required.
The key point of the proposed solution is to directly sense the output load to set the burst
mode threshold. In this way the resonant elements parameters no longer affect this
threshold. The implemented circuit block diagram is shown in Figure 2.
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32
Main characteristics and circuit description
AN3233
Figure 2. Burst mode circuit block diagram
to power transformer
RCS
to load
to FB optocoupler
L6599A
RFMIN
2V
TSC101
TSM1014
Rlim
RFB
CC-
OUT
V_REF
Standby
Comp.
+
1.24V
STBY
CC_OUT
Comp.
+
RH
1.25V
+
E/A.
100
VP
VM
CC+
RL
RBM RBM
RHts
The output current is sensed by a resistor (RCS); the voltage drop across this resistor is
amplified by TSC101, a dedicated high side current sense amplifier; its output is compared
to a set reference by the TSM1014; if the output load is high, the signal fed into the CC- pin
is above the reference voltage, CC_OUT stays down and the optocoupler transistor pulls up
the L6599A’s STBY pin to the RFMIN voltage (2 V), setting continuous switching operation
(no burst mode); if load decreases, the voltage on CC- falls below the set threshold,
CC_OUT goes high opening the connection between RFMIN and STBY and so allowing
burst mode operation by the L6599A.
RCS is dimensioned considering two constraints. The first is the maximum power dissipation
allowed, based on the efficiency goal. The second limitation is imposed by the necessity to
feed a reasonable voltage signal into the TSM1014A inverting input. In fact, signals which
are too small would affect system accuracy.
On this board, the maximum acceptable power dissipation has been set to:
Ploss,MAX = 500 mW. RCS maximum value is calculated as follows:
Equation 1
R CS,MAX
Ploss,MAX
2
Iout,
MAX
3.2mΩ
The burst mode threshold is set at 5 W corresponding to CBM = 417 mA output current at 1
2 V.
Choosing VCC+,min = 50 mV as the minimum reference of the TSM1014A, which allows
a good signal-to-noise ratio, the RCS minimum value is calculated as follows:
Equation 2
R CS,min
VCC+,min
100 CBM
1.2mΩ
The actual value of the mounted resistor is 2 mΩ, corresponding to Ploss = 312 mW power
losses at full load. The actual resistor value at burst mode threshold current provides an
output voltage by TSC101 of 83 mV. The reference voltage of TSM1014 VCC+ must be set at
6/32
DocID17595 Rev 2
AN3233
Main characteristics and circuit description
this level. The resistor divider setting the TSM1014 threshold RH and RL should be in the
range of kilo-ohms to minimize dissipation. By selecting RL = 22 kΩ, the right RH value is
obtained as follows:
Equation 3
RH
RL 1.25V VBM
309kΩ
VBM
The value of the mounted resistor is 330 kΩ.
RHts sets a small de-bouncing hysteresis and is in the range of mega-ohms. Rlim is in the
range of tens of kilo-ohms and limits the current flowing through the optocoupler’s diode.
Both L6599A and L6563H implement their own burst mode function but, in order to improve
the overall power supply efficiency, at light load the L6599A drives the L6563H via the
PFC_STOP pin and enables the PFC burst mode: as soon as the L6599A stops switching
due to load drops, its PFC_STOP pin pulls down the L6563H’s PFC_OK pin disabling PFC
switching. Thanks to this simple circuit, the PFC is forced into idle state when the resonant
stage is not switching and rapidly wakes up when the downstream converter restarts
switching.
Fast voltage feedforward
The voltage on the L6563H VFF pin (pin 5) is the peak value of the voltage on the MULT pin
(pin 3). The RC network (R15 + R26, C12) connected to VFF completes a peak-holding
circuit. This signal is necessary to derive information of the RMS input voltage to
compensate the loop gain that is mains voltage dependent.
Generally speaking, if the time constant is too small, the voltage generated is affected by a
considerable amount of ripple at twice the mains frequency causing distortion of the current
reference (resulting in higher THD and lower PF). If the time constant is too large, there is a
considerable delay in setting the right amount of feed-forward, resulting in excessive
overshoot or undershoot of the pre-regulator’s output voltage in response to large line
voltage changes.
To overcome this issue, the L6563H implements the fast voltage feedforward function. As
soon as the voltage on the VFF pin decreases by a set threshold (40 mV typically), a mains
dip is assumed and an internal switch rapidly discharges the VFF capacitor via a 10 k
resistor. Thanks to this feature, it is possible to set an RC circuit with a long time constant,
assuring a low THD, keeping a fast response to mains dip.
Brownout protection
Brownout protection prevents the circuit from working with abnormal mains levels. It is easily
achieved using the RUN pin (pin 12) of the L6563H: this pin is connected through a resistor
divider to the VFF pin (pin 5), which provides the information of the mains voltage peak
value. An internal comparator enables the IC operations if the mains level is correct, within
the nominal limits. At startup, if the input voltage is below 90 Vac (typ.), circuit operations are
inhibited.
Output voltage feedback loop
The feedback loop is implemented by means of a typical circuit using the dedicated
operational amplifier of TSM1014A modulating the current in the optocoupler’s diode. The
DocID17595 Rev 2
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32
Main characteristics and circuit description
AN3233
second comparator embedded in the TSM1014A - usually dedicated to constant current
regulation - is here utilized for burst mode as previously described.
On the primary side, R34 and D17 connect the RFMIN pin (pin 4) to the optocoupler’s
phototransistor closing the feedback loop. R31, which connects the same pin to ground,
sets the minimum switching frequency. The R-C series R44 and C18 sets both soft-start
maximum frequency and duration.
L6599A overload and short-circuit protection
The current into the primary winding is sensed by the loss-less circuit R41, C27, D11, D10,
R39, and C25 and it is fed into the ISEN pin (pin 6). In the case of overcurrent, the voltage
on the pin overpasses an internal threshold (0.8 V) that triggers a protection sequence. The
capacitor (C45) connected to the DELAY pin (pin 2) is charged by an internal 150 µA current
generator and is slowly discharged by the external resistor (R24). If the voltage on the pin
reaches 2 V, the soft-start capacitor is completely discharged so that the switching
frequency is pushed to its maximum value. As the voltage on the pin exceeds 3.5 V the IC
stops switching and the internal generator is turned off, so that the voltage on the pin decays
because of the external resistor. The IC is soft-restarted as the voltage drops below 0.3 V. In
this way, under short-circuit conditions, the converter works intermittently with very low input
average power.
Open loop protection
Both circuit stages, PFC and resonant, are equipped with their own overvoltage protections.
The PFC controller L6563H monitors its output voltage via the resistor divider connected to
a dedicated pin (PFC_OK, pin 7) protecting the circuit in case of loop failures or
disconnection. If a fault condition is detected, the internal circuitry latches the L6563H
operations and, by means of the PWM_LATCH pin (pin 8), it also latches the L6599A via the
DIS pin (pin 8). The converter is kept latched by the L6563H internal HV start-up circuit that
supplies the IC by charging the Vcc capacitor periodically. To resume converter operation,
a mains restart is necessary.
The output voltage is monitored by sensing the Vcc voltage. If Vcc voltage overrides the
D12 breakdown voltage, Q9 pulls down the L6563H INV pin latching the converter.
8/32
DocID17595 Rev 2
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AN3233
Main characteristics and circuit description
Figure 3. Electrical diagram
9/32
32
Efficiency measurement
2
AN3233
Efficiency measurement
EPA rev. 2.0 external power supply compliance verification
Table 1 shows the no-load consumption and the overall efficiency, measured at the nominal
mains voltages. At 115 Vac the average efficiency is 90.6 %, while at 230 Vac it is 91.8 %.
Both values are much higher than the 87 % required by EPA rev 2.0 external power supply
(EPS) limits.
The efficiency at nominal load, 230 Vac, is 94 %, which is a very high efficiency for a double
stage converter and confirms the benefit of implemented SR.
Also at no load the board performances are superior: maximum no-load consumption at
nominal mains voltage is 200 mW; this value is significantly lower than the limit imposed by
the ENERGY STAR program which is 500 mW.
Table 1. Overall efficiency
230 V - 50 Hz
Test
Vout
Iout
Pout
Pin
Eff.
Vout
Iout
Pout
Pin
Eff.
[V]
[A]
[W]
[W]
[%]
[V]
[A]
[W]
[W]
[%]
12.10
0.00
0.00
0.20
-
12.10
0.00
0.00
0.20
-
25 % load eff. 12.14
3.10
37.63
43.15
87.2 %
12.13
3.10
37.60
43.08
87.3 %
50 % load eff. 12.14
6.19
75.15
81.30
92.4 %
12.12
6.19
75.02
82.34
91.1 %
75 % load eff. 12.08
9.37
113.19 120.81
93.7 %
12.07
9.38
113.22 123.00
92.0 %
100 % load eff. 12.04 12.47 150.14 159.79
94.0 %
12.04 12.50 150.50 163.90
91.8 %
91.8 %
-
90.6 %
No load
Average eff.
10/32
115 V - 60 Hz
-
DocID17595 Rev 2
AN3233
Efficiency measurement
Light load operation efficiency
Measurement results are reported in Table 2 and plotted in Figure 4. As can be seen,
efficiency is better than 50 % even for very light loads such as 500 mW.
Table 2. Light load efficiency
230 V - 50 Hz
Test
115 V - 60 Hz
Vout
Iout
Pout
Pin
Eff.
Vout
Iout
Pout
Pin
Eff.
[V]
[mA]
[W]
[W]
[%]
[V]
[mA]
[W]
[W]
[%]
0.25 W
12.12
20.84
0.253
0.581
43.5 %
12.12
20.84
0.253
0.565
44.7 %
0.5 W
12.12
41.34
0.501
0.931
53.8 %
12.12
41.34
0.501
0.912
55.0 %
1.0 W
12.12
82.65
1.002
1.553
64.5 %
12.12
82.65
1.002
1.552
64.5 %
1.5 W
12.12
123.93
1.502
2.203
68.2 %
12.12
123.93
1.502
2.211
67.9 %
2.0 W
12.12
164.93
1.999
2.797
71.5 %
12.12
164.93
1.999
2.828
70.7 %
2.5 W
12.12
206.75
2.506
3.392
73.9 %
12.12
206.75
2.506
3.439
72.9 %
3.0 W
12.11
248.00
3.003
3.979
75.5 %
12.11
248.00
3.003
4.040
74.3 %
3.5 W
12.11
288.25
3.491
4.560
76.6 %
12.11
288.25
3.491
4.644
75.2 %
4.0 W
12.11
330.06
3.997
5.155
77.5 %
12.11
330.06
3.997
5.258
76.0 %
4.5 W
12.11
372.31
4.509
5.748
78.4 %
12.11
372.31
4.509
5.874
76.8 %
5.0 W
12.11
413.34
5.006
6.327
79.1 %
12.11
413.34
5.006
6.474
77.3 %
Figure 4. Light load efficiency diagram
80%
75%
Efficiency [%]
70%
65%
60%
230V-50Hz
55%
115V-60Hz
50%
45%
40%
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Pout [W]
DocID17595 Rev 2
11/32
32
Harmonic content measurement
3
AN3233
Harmonic content measurement
The board has been tested according to the European standard EN61000-3-2 Class-D and
the Japanese standard JEITA-MITI Class-D, at both the nominal input voltage mains. As
shown in the following images, the circuit is able to reduce the harmonics well below the
limits of both regulations.
Figure 5. Compliance with EN61000-3-2 at 230 Vac – 50 Hz, full load
Measured Value
Harmonic Current [A]
EN610003 2 ClassD Limits
1
0.1
0.01
0.001
0.0001
1
3
5
7
9
11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic Order [n]
THD = 14.70 % - PF = 0.978
Figure 6. Compliance with JEITA-MITI at 100 Vac – 50 Hz, full load
Measured Value
JEITAMITI Class D Limits
Harmonic Current [A]
1
0.1
0.01
0.001
0.0001
1
3
5
7
9
11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic Order [n]
THD = 5.20 % - PF = 0.995
On the bottom side of the diagrams the total harmonic distortion (THD) and power factor
(PF) have been measured too. The values in all conditions give a clear idea regarding the
correct functioning of the PFC.
12/32
DocID17595 Rev 2
AN3233
4
Functional check
Functional check
Steady-state operation
In Figure 7 some waveforms relevant to the resonant stage during steady-state operation
are given. The selected switching frequency is about 120 kHz, in order to have a good trade
off between transformer losses and dimensions. The converter operates slightly above the
resonance frequency.
Figure 8 shows the key signals of the SRK2000A: each rectifier MOSFET is switched on
and off according to its drain-source voltage which, during conduction time, is the voltage
image of the current flowing through the MOSFET.
Figure 7. Resonant stage waveforms
at 115 V – 60 Hz – full load
CH1: HB voltage
-
CH2: CF pin voltage
CH4: Res. tank current
Figure 8. SRK2000A key signals
at 115 V – 60 Hz – full load
CH1: GD1 pin voltage
CH3: GD2 pin voltage
DocID17595 Rev 2
CH2: DVS1 pin
CH4: DVS2 pin
13/32
32
Functional check
AN3233
Zero voltage switching
Figure 9 and 10 show details of ZVS operation. Both MOSFETs turn on when current is
flowing through their body diodes and drain-source voltage is zero.
Figure 9. High-side MOSFET ZV turn-on
at 115 V – 60 Hz – full load
CH1: HB voltage
CH3: LVG pin voltage
CH2: HVG pin voltage
-
Figure 10. Low-side MOSFET ZV turn-on
at 115 V – 60 Hz – full load
CH1: HB voltage
CH3: LVG pin voltage
CH2: HVG pin voltage
-
Startup and shutdown
Figure 11 and 12 show the start-up and shut-down sequence of the two converter stages:
The PFC starts first and the LLC only starts after the PFC achieves regulation. In the same
way the PFC stops first and the LLC shuts down as its input voltage falls below the allowed
voltage.
Figure 11. Converter startup
at 115 Vac full load
CH1: half-bridge node
CH3: output voltage
Figure 12. Converter shutdown
at 115 Vac full load
CH2: PFC drain
CH4: LINE pin
CH1: half-bridge node
CH3: output voltage
CH2: PFC drain
CH4: LINE pin
Figure 13 and 14 again show startup and shutdown but highlighting the current flowing
through the resonant tank.
14/32
DocID17595 Rev 2
AN3233
Functional check
In Figure 13 it can be noted that the resonant current at turn-on has some oscillations due to
the charging of the resonant elements. However, current zero-crossing always lags the HB
commutations and, consequently, MOSFETs are soft switched.
Figure 14 shows the resonance current at shutdown. Due to input voltage dip, the LLC
stage operates below resonance, but current still lags the HB voltage.
Avoiding hard switching also during transitions like startup and shutdown is a must for a
reliable design, because some hard switching commutations could also damage the
converter.
Figure 13. Startup resonant current
CH1: half-bridge
-
CH3 C6 voltage
CH4: res. tank current
Figure 14. Shutdown resonant current
CH1: half-bridge
-
CH4: res. tank current
No-load operation
In Figure 15 and 16, some burst mode waveforms are captured. As seen, both L6599A and
L6563H operate in burst mode. In Figure 16, it is possible to see that PFC and LLC bursts
are synchronized.
Figure 15. No-load operation
CH1: LVG pin
CH3: output voltage
Figure 16. No-load operation – detail
CH2: PFC gate
CH4: STBY pin
CH1: half-bridge
CH3: PFC-STOP pin
DocID17595 Rev 2
CH2: PFC drain
CH4: STBY pin
15/32
32
Functional check
AN3233
In Figure 17 and 18 the transitions from full load to no load and vice versa have been
checked. As seen in the images, both transitions are clean and there isn’t any output
voltage dip.
Figure 17. Transition full load to no load
at 115 Vac – 60 Hz
Figure 18. Transition no load to full load
at 115 Vac – 60 Hz
CH1: LVG pin
CH3: output voltage
CH1: LVG pin
CH3: output voltage
CH2: PFC gate
CH4: output current
CH2: PFC gate
CH4: output current
Overcurrent and short-circuit protection
The L6599A is equipped with a current sensing input (pin 6, ISEN) and a dedicated
overcurrent management system. The current flowing in the resonant tank is detected and
the signal is fed into the ISEN pin. It 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 the soft-start capacitor CSS to be discharged.
Under output short-circuit, this operation results in an almost constant peak primary current.
With the L6599A, the board designer can externally program the maximum time that the
converter is allowed to run overloaded or under short-circuit conditions. Overloads or shortcircuits lasting less than the set time do not cause any other action, therefore providing the
system with immunity to short duration phenomena. If, instead, the overload condition
continues, a protection procedure is activated that shuts down the L6599A and, in case of
continuous overload/short-circuit, results in continuous intermittent operation with a user
defined duty cycle. This function is realized with the DELAY pin (pin 2), by means of a
capacitor C45 and the parallel resistor R24 connected to ground. As the voltage on the
ISEN pin exceeds 0.8 V, the first OCP comparator, in addition to discharging CSS, turns on
an internal 150 µA current generator that, via the DELAY pin, charges C45. As the voltage
on C45 is 3.5 V, the L6599A stops switching and the PFC_STOP pin is pulled low. Also the
internal generator is turned off, so that C45 is now slowly discharged by R24. The IC restarts
when the voltage on C45 is less than 0.3 V. Additionally, if the voltage on the ISEN pin
reaches 1.5 V for any reason (e.g. transformer saturation), the second comparator is
triggered, the L6599A shuts down and the operation is resumed after an off-on cycle.
Figure 19 shows intermittent operations caused by an output short-circuit: average output
current is limited, preventing the converter from overheating and consequent failure.
16/32
DocID17595 Rev 2
AN3233
Functional check
Figure 19. Short-circuit at full load and 115 Vac – 60 Hz
CH1: LVG pin
CH3: DELAY pin
CH2: output voltage
CH4: output current
DocID17595 Rev 2
17/32
32
Thermal map
5
AN3233
Thermal map
In order to check the design reliability, a thermal mapping by means of an IR camera was
done. In Figure 20 and 21 the thermal measurements of the board, component side, at
nominal input voltage, are shown. Some pointers, visible in the images, have been placed
across key components or components showing high temperature. The ambient
temperature during both measurements was 27 °C.
Figure 20. Thermal map at 115 Vac – 60 Hz - full load
Figure 21. Thermal map at 230 Vac – 50 Hz - full load
Table 3. Thermal maps reference points
18/32
Point
Reference
Description
A
D1
Bridge rectifier
B
L1
EMI filtering inductor
C
L2
PFC inductor
D
Q8
ICs supply regulator
E
D4
PFC output diode
F
R6
Inrush limiting NTC resistor
G
Q4
Resonant low side MOSFET
H
T1
Resonant power transformer
DocID17595 Rev 2
AN3233
Thermal map
To directly check the efficiency of the SR stage, a thermal map of the SR daughterboard has
also been taken. As seen, the temperature of both rectifier MOSFETs is below 70 °C,
confirming that heatsinking is not required and confirming that the SR solution implemented
allows a significant secondary side board dimension squeezing.
Figure 22. Thermal map SR daughterboard - full load
Table 4. Daughterboard thermal map reference points
Point
Reference
Description
SP1
Q501
SR MOSFET
SP2
Q502
SR MOSFET
DocID17595 Rev 2
19/32
32
Conducted emission pre-compliance test
6
AN3233
Conducted emission pre-compliance test
Figure 23 and 24 represent the average measurement of the conducted emission at full load
and nominal mains voltages. The limit indicated in red on the diagrams is relevant to
average measurements and is the EN55022 Class-B one, which has more severe limits
compared to Class-A, dedicated to IT technology equipment. As can be seen, in all test
conditions the measurements are significantly below the limits.
Figure 23. CE average measurement at 115 Vac and full load
Figure 24. CE average measurement at 230 Vac and full load
20/32
DocID17595 Rev 2
AN3233
7
Bill of material
Bill of material
Table 5. EVL150W-ADP-SR demonstration board: motherboard bill of materials
Des.
Part type/
part value
Description
Supplier
Case
C1
470 NF
X2 - film cap. - B32922C3474K
EPCOS
9.0 x 18.0 p. 15 mm
C2
2.2 NF
Y1 safety cap. DE1E3KX222M
MURATA
P. 10 mm
C3
2.2 NF
Y1 safety cap. DE1E3KX222M
MURATA
P. 10 mm
C4
470 NF
X2 - film cap. - B32922C3474K
EPCOS
9.0 x 18.0 p. 15 mm
C5
470 NF
520 V - film cap. - B32673Z5474K
EPCOS
7.0 x 26.5 p. 22.5 mm
C6
4.7 NF
50 V cercap - general purpose
AVX
0805
C7
100 NF
100 V cercap - general purpose
AVX
PTH
C8
10 F - 50 V
Aluminium elcap - YXF series - 105 °C
RUBYCON
Dia. 5.0 x 11 p. 2 mm
C9
100 F - 450 V
Aluminium elcap - UPZ2W101MHD
NICHICON
Dia. 18 x 32 mm
C10
1 NF
50 V cercap - general purpose
AVX
0805
C11
2.2 NF
50 V cercap - general purpose
AVX
0805
C12
1 F
25 V cercap - general purpose
AVX
0805
C13
680 NF
25 V cercap - general purpose
AVX
1206
C14
68 NF
50 V cercap - general purpose
AVX
0805
C15
47 F - 50 V
Aluminium elcap - YXF series - 105 °C
RUBYCON
Dia. 6.3 x 11
p. 2.5 mm
C16
2.2 NF
50 V cercap - general purpose
AVX
1206
C17
330 PF
50 V - 5 % - C0G - cercap
AVX
0805
C18
4.7 F
25 V cercap - general purpose
MURATA
1206
C19
100 NF
50 V cercap - general purpose
AVX
1206
C20
2.2 NF
Y1 safety cap. DE1E3KX222M
MURATA
P. 10 mm
C21
2.2 NF
Y1 safety cap. DE1E3KX222M
MURATA
P. 10 mm
C22
220 PF
50 V cercap - general purpose
AVX
0805
C23
10 NF
50 V cercap - general purpose
AVX
0805
C24
220 F - 50 V
Aluminium elcap - YXF series - 105 °C
RUBYCON
Dia.10 x 16 p. 5 mm
C25
2.2 F
50 V cercap - general purpose
AVX
0805
C26
10 F - 50 V
Aluminium elcap - YXF series - 105 °C
RUBYCON
Dia. 5.0 x 11 p. 2 mm
630 V cercap - GRM31A7U2J220JW31
MURATA
1206
C27 220 pF - 630 V
C28
22 NF
1 KV - film cap - B32652A223K
EPCOS
5.0 x 18.0 p15 mm
C29
470 F - 16 V
16 V aluminium solid capacitor
SANYO
Dia. 10 X 13 p5 mm
C30
470 F - 16 V
16 V aluminium solid capacitor
SANYO
Dia. 10 x 13 p5 mm
C32
1 F
50 V cercap - general purpose
AVX
0805
DocID17595 Rev 2
21/32
32
Bill of material
AN3233
Table 5. EVL150W-ADP-SR demonstration board: motherboard bill of materials (continued)
Des.
Part type/
part value
Description
Supplier
Case
C33
1 NF
50 V cercap - general purpose
AVX
0805
C34
100 NF
50 V cercap - general purpose
AVX
0805
C36
1 F - 350 V
50 V cercap - general purpose
AVX
1206
C37
470 F - 16 V
16 V aluminium solid capacitor
SANYO
Dia. 10 x 13 p. 5 mm
C38
100 NF
50 V cercap - general purpose
AVX
0805
C39
100 NF
50 V cercap - general purpose
AVX
0805
C40
100 NF
50 V cercap - general purpose
AVX
1206
C41
22 NF
50 V cercap - general purpose
AVX
0805
C42
100 NF
50 V cercap - general purpose
AVX
0805
C43
4.7 NF
50 V cercap - general purpose
AVX
0805
C44
3.3 NF
50 V cercap - general purpose
AVX
0805
C45
220 NF
25 V cercap - general purpose
AVX
0805
C47
1 NF
50 V cercap - general purpose
AVX
0805
C48
1 NF
50 V cercap - general purpose
AVX
0805
C49
470 F
16 V aluminium solid capacitor
SANYO
Dia. 10 x 13 p. 5 mm
C50
470 F
16 V aluminium solid capacitor
SANYO
Dia. 10 x 13 p. 5 mm
C51
100 NF
50 V cercap - general purpose
AVX
0805
C52
1 NF
25 V cercap - general purpose
AVX
0805
D1
GBU8J
Single phase bridge rectifier
VISHAY
STYLE GBU
D2
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D3
1N4005
General purpose rectifier
VISHAY
DO-41 DO - 41
D4
STTH5L06
Ultrafast high voltage rectifier
STMicroelectronics
DO-201
D5
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D6
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D7
STPS140Z
Power Schottky rectifier
STMicroelectronics
SOD-123
D9
STPS1L60A
Power Schottky diode
STMicroelectronics
SMA
D10
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D11
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D12
BZV55-C43
Zener diode
VISHAY
Minimelf SOD-80
D14
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D16
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D17
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D18
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
D19
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
22/32
DocID17595 Rev 2
AN3233
Bill of material
Table 5. EVL150W-ADP-SR demonstration board: motherboard bill of materials (continued)
Des.
Part type/
part value
Description
Supplier
Case
D20
BZV55-B15
Zener diode
VISHAY
Minimelf SOD-80
D21
LL4148
High speed signal diode
VISHAY
Minimelf SOD-80
F1
FUSE T4A
Fuse 4 A - time lag - 3921400
LITTLEFUSE
8.5 x 4 p. 5.08 mm
HS1
HEATSINK
Heatsink for D1, Q1, Q3, Q4
-
DWG
J1
MKDS 1,5/
3-5,08
PCB term. block, screw conn., pitch 5 mm - 3 W
PHOENIX
CONTACT
DWG
J2
FASTON
Faston - connector
-
DWG
J3
FASTON
Faston - connector
-
DWG
L1
2019.0002
Common mode choke - EMI filter
MAGNETICA
DWG
L2
1975.0004
PFC inductor - 0.31 mH - PQ26/25
MAGNETICA
DWG
Q1
STF19NM50N
N-channel power MOSFET
STMicroelectronics
TO-220FP
Q2
BC857
PNP small signal BJT
VISHAY
SOT-23
Q3
STF8NM50N
N-channel power MOSFET
STMicroelectronics
TO-220FP
Q4
STF8NM50N
N-channel power MOSFET
STMicroelectronics
TO-220FP
Q8
BC847C
NPN small signal BJT
VISHAY
SOT-23
Q9
BC847C
NPN small signal BJT
VISHAY
SOT-23
R1
3.3 M
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R2
3.3 M
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R3
1 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R5
10
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R6
NTC 2R5-S237
NTC resistor P/N B57237S0259M000
EPCOS
DWG
R7
1 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R8
1 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R9
62 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R10
27 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R11
2.2 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R12
2.2 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R13
8.2 K
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R14
51 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R15
56 K
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R16
4.7 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R17
2.2 M
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R18
82 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R19
56 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
DocID17595 Rev 2
23/32
32
Bill of material
AN3233
Table 5. EVL150W-ADP-SR demonstration board: motherboard bill of materials (continued)
Des.
Part type/
part value
Description
Supplier
Case
R20
33
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R21
22
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R22
0.27
SFR25 axial stand. film res. - 0.4 W - 5 % - 250
ppm/°C
VISHAY
PTH
R23
0.47
SFR25 axial stand. film res. - 0.4 W - 5 % - 250
ppm/°C
VISHAY
PTH
R24
1 M
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R25
56
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R26
1 M
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R27
470 R
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R28
33 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R29
1 K
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R30
10
SMD film res .- 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R31
12 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R32
47
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R34
27 K
SMD film res .- 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R35
180 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R36
1.8 M
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R37
220 K
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R38
56
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R39
160
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R40
33
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R41
100
SFR25 axial stand. film res. - 0.4 W - 5 % 250 ppm/°C
VISHAY
PTH
R42
1 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R43
51
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R44
6.2 K
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R45
3.3
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R46
100 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R48
47 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R49
91 K
SMD film res. - 1/4 W - 1 % - 100 ppm/°C
VISHAY
1206
R50
12 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R51
82 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R52
1.5 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R53
2.2 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
24/32
DocID17595 Rev 2
AN3233
Bill of material
Table 5. EVL150W-ADP-SR demonstration board: motherboard bill of materials (continued)
Des.
Part type/
part value
Description
Supplier
Case
R54
0
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R55
2.7 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R57
0.02
SMD shunt resistor - RL3264-9V-R002-FNH-11
CYNTEC
2512
R58
100 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R59
100 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R60
10 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R63
0
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R64
10 M
SMD film res.- 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R68
39 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R69
4.7 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R70
22 k
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R71
1 K
SMD film res. - 1/4 W - 5 % - 250 ppm/°C
VISHAY
1206
R72
330 K
SMD film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R73
22
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R75
0
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R76
33 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R77
1 K
SMD film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
T1
1860.0034
Resonant power transformer
MAGNETICA
ETD34
U1
L6563H
High voltage start-up TM PFC controller
STMicroelectronics
SO-16
U2
L6599AD
Improved HV resonant controller
STMicroelectronics
SO-16
U3
SFH617A-2
Optocoupler
INFINEON
DIP-4 - 10.16 mm
U4
SFH617A-2
Optocoupler
INFINEON
DIP-4 - 10.16 mm
U5
TSM1014AIST
Low consumption CV/CC controller
STMicroelectronics
MINI SO-8
U6
TSC101C
High side current sense amplifier
STMicroelectronics
SOT23-5
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Bill of material
AN3233
Table 6. EVL150W-ADP-SR evaluation board: daughterboard bill of material
Des.
Part type/
part value
Description
Supplier
Case
C501
4.7 nF
50 V cercap - general purpose
VISHAY
0805
C502
100 nF
50 V cercap - general purpose
VISHAY
0805
C503
1 F
50 V cercap - general purpose
VISHAY
0805
D501
BAS316
Fast switching signal diode
STMicroelectronics
SOD-123
D502
BAS316
Fast switching signal diode
STMicroelectronics
SOD-123
JP501
HEADER 13
13-pin connector
-
-
Q501
STL140N4LLF5
N-channel power MOSFET
STMicroelectronics POWER FLAT
Q502
STL140N4LLF5
N-channel power MOSFET
STMicroelectronics POWER FLAT
R501
10
SMD standard film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R502
10
SMD standard film res .- 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R503
10
SMD standard film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R504
150 k
SMD standard film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R505
33 k
SMD standard film res. - 1/8 W - 1 % - 100 ppm/°C
VISHAY
0805
R506
330
SMD standard film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
R507
330
SMD standard film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
RX1
0
SMD standard film res. - 1/8 W - 5 % - 250 ppm/°C
VISHAY
0805
U501
SRK2000A
SR smart driver for LLC resonant converter
STMicroelectronics
SO8
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8
PFC coil specification
PFC coil specification
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: PQ26/25-PC44 or equivalent
Min. operating frequency: 40 kHz
Typical operating frequency: 120 kHz
Primary inductance: 310 µH ± 10% at 1 kHz-0.25 V(a)
Peak current: 5.6 Apk
Electrical diagram and winding characteristics
Figure 25. PFC coil electrical diagram
5
11
9
3
Table 7. PFC coil winding data
a.
Pins
Windings
RMS current
Number of turns
Wire type
11 - 3
AUX
0.05 ARMS
5
0.28 mm – G2
5-9
PRIMARY
2.3 ARMS
50
50 x 0.1 mm – G1
Measured between pins #5 and #9.
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PFC coil specification
AN3233
Mechanical aspects and pin numbering
Maximum height from PCB: 30 mm
Coil former type: vertical, 6 + 6 pins (pins 1, 2, 4, 6, 7, 10, 12 are removed)
Pin distance: 3.81 mm
Row distance: 25.4 mm
External copper shield: not insulated, wound around the ferrite core and including the
coil former. Height is 8 mm. Connected to pin #3 by a soldered solid wire.
Figure 26. PFC coil mechanical aspect
28 MAX
30 MAX
30 MAX
11
3
3
9 5
25.40
11
3
11.43
3.81
3.81
11.43
9
5
8
BOTTOM VIEW (PIN SIDE)
22.86
3.81
∅ 0.9 (X5)
RECOMMENDED PCB HOLE ∅1.3
DIMENSIONS IN MILLIMETERS, DRAWING NOT IN SCALE
Manufacturer
28/32
Magnetica - Italy
Inductor P/N: 1975.0004
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AN3233
9
Transformer specifications
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: 60 kHz
Typical operating frequency: 100 kHz
Primary inductance: 800 µH ± 10% at 1 kHz-0.25 V(b)
Leakage inductance: 100 µH ± 10% at 100 kHz-0.25 V(c).
Electrical diagram and winding characteristics
Figure 27. Transformer electrical diagram
2
8
9
10
11
12
4
6
7
13
14
b.
Measured between pins 2 - 4.
c.
Measured between pins 2 - 4 with only half secondary winding shorted at time.
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32
Transformer specifications
AN3233
Table 8. Transformer winding data
Pins
Winding
RMS current
Number of turns
Wire type
2-4
PRIMARY
1.2 ARMS
34
30 x 0.1 mm – G1
8 - 11
4
5 ARMS
2
90 x 0.1 mm – G1
4
5 ARMS
2
90 x 0.1 mm – G1
5 ARMS
2
90 x 0.1 mm – G1
5 ARMS
2
90 x 0.1 mm – G1
0.05 ARMS
3
0.28 mm– G2
SEC-1A
9 -10
SEC-1B
10 - 13
SEC-2A(1)
12 - 14
6-7
SEC-2B
4
(2)
AUX
1.
Secondary windings A and B are in parallel.
2.
Aux winding is wound on top of primary winding.
Mechanical aspect and pin numbering
Maximum height from PCB: 30 mm
Coil former type: horizontal, 7 + 7 pins (pins #3 and #5 are removed)
Pin distance: 5.08 mm
Row distance: 25.4 mm
Figure 28. Transformer overall drawing
39 MAX
30 MAX
25.4
3 MIN
39 MAX
LABEL
5.08
Ø1.1 (x12) / PCB hole Ø1.6
MISSING PIN 3 AND 5
AS PCB REFERENCE
PIN SIDE VIEW
1
2
6
7
14 13 12 11 10 9
8
QUOTES IN MILLIMETERS, DRAWING NOT IN SCALE
Manufacturer
30/32
Magnetica - Italy
Transformer P/N: 1860.0034
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10
Revision history
Revision history
Table 9. Document revision history
Date
Revision
Changes
13-Jan-2011
1
Initial release
20-Jun-2017
2
Replaced “SRK2000” by “SRK2000A” in the whole document.
Replaced Figure 3 on page 9 by new figure.
Minor modifications throughout document.
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AN3233
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