STEVAL-ISA018V1

UM0727 User manual IV E STEVAL-ISA018V1 demonstration board based on resonant half-bridge SMPS for industrial applications Introduction NA CT This user manual describes a high efficiency solution for industrial power supplies with a continuous output power of 150 W and peak power up to 240 W. It takes advantage of the resonant approach to minimize switching losses, resulting in higher than 90% efficiency. The topology is based on half-bridge and operated in a resonant fashion by means of a resonant LC tank, driven by the L6599 dedicated controller. -I The board provides one regulated output, VO=24 V with IO=6 A, and an overload capability of up to IO=10 A. Output voltage and current are controlled by the TSM1011 constant voltage and constant current controller, providing square output regulation, while the overload is managed by thermal protection (PTC) on the output rectifiers. STEVAL-ISA018V1 board prototype IN AC TI VE -I NA CT IV Figure 1. E The board, shown in Figure 1, is obtainable using the order code STEVAL-ISA018V1. May 2010 Doc ID 15906 Rev 1 1/18 www.st.com Contents UM0727 Contents Demonstration board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Experimental waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3 EMI measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 IN AC TI VE -I NA CT IV E -I NA CT IV E 1 2/18 Doc ID 15906 Rev 1 UM0727 List of figures List of figures Figure 8. Figure 9. Figure 10. IV E IN AC TI VE -I NA CT IV E Figure 11. Figure 12. NA CT Figure 7. STEVAL-ISA018V1 board prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Resonant transformer: pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Resonant transformer: mechanical drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STEVAL-ISA018V1 board layout with tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) . . . . . . . . . . . . . . . . . . . 12 Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) . . . . . . . . . . . . . . . . . . . 12 Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) . . . . . . . . . . . . . . . . . . . 13 Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) . . . . . . . . . . . . . . . . . . . 13 Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) . . . . . . . . . . . . . . . . . . . 14 Conducted emissions - phase - Vin = 230 Vac, Iout = 6 A . . . . . . . . . . . . . . . . . . . . . . . . . 15 Conducted emissions - neutral - Vin = 230 Vac, Iout = 6 A . . . . . . . . . . . . . . . . . . . . . . . . 15 -I Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Doc ID 15906 Rev 1 3/18 Demonstration board description 1 UM0727 Demonstration board description IV E The STEVAL-ISA018V1 board is based on an LLC resonant converter, and employs the 5 Ω, 500 V STF21NM50N power MOSFET as the primary switches in the half-bridge. The STF21NM50N is produced using STMicroelectronics’ proprietary high voltage MDmesh™ II technology. Thanks to this technology, the switch features a very low RDS(on) per area, low gate charge and high switching performance. The device is available in different packages, i.e. the TO-220, TO-247 and TO-220FH. Table 1. NA CT The demonstration board has been designed based on the specifications listed in Table 1. Main specifications Parameter Value Input voltage range a. 185 to 265 Vac - b. 85 to 185 Vac (with voltage double) Input frequency range 50/60 Hz 24 V ± 2% -I Output voltage Output power 150 W (240Wpk) EN60950 E Safety EN55014 IV EMI CT The electrical schematic of the board is shown in Figure 2. The input section is provided with a connector for line input and a jumper for voltage double operation for a 110 Vac input voltage. -I NA The output voltage is available on the CN3 connector. The converter is controlled by the L6599, a double ended primary controller for resonant half-bridge ZVS (zero voltage switching). The IC controls the output power, changing the switching frequency and controlling the half-bridge with a constant 50% duty cycle by means of a dedicated pin, connected to the output feedback through an optocoupler. Light load conditions are managed, with optimized consumption, thanks to burst mode operation. The IC also includes a disable function and two-level over-current protection with programmable delay. TI VE In order to properly run the half-bridge devices and guarantee high efficiency, the IC features an internal P- channel D-MOS transistor with a typical RDS(on) of 200 mΩ as a switching element to avoid the use of a bootstrap capacitor. IN AC During normal operation the IC is powered by the auxiliary winding of the transformer via the D9 diode. A discrete linear voltage regulator is connected in order to stabilize the auxiliary voltage fluctuations. The circuit consists of Q4, C42, R38, D3, D12, C32 and C33. 4/18 Doc ID 15906 Rev 1 /,1( &1 Doc ID 15906 Rev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igure 2.  IN AC UM0727 Demonstration board description Schematic !-V 5/18 Demonstration board description UM0727 Regulation of the output voltage is performed by secondary feedback on the 24 V output. The feedback network consists of a programmable voltage reference, TSM1011, driving an optocoupler which ensures the required insulation between the primary and secondary sections. The optotransistor drives the feedback pin (RFMIN) which controls the operation of the IC. IV E The resonant transformer is based on a two-slot coil former and an EER39-PC40 ferrite core, manufactured by TDK. The transformer ensures safety insulation in accordance with EN60950. Table 2. Resonant transformer specifications Parameter Value Core EER39 – PC40 Coil former 2 slot -I Primary inductance, Lp Leakage inductance, Llk 450 µH ± 10% 150 µH ± 10% 32 (0.15x20) – 220 mΩ (DC) Secondary turns, Ns 2x7 (0.2x30) (bifilar) – 40 mΩ (DC) 8 (on primary winding) CT Auxiliary turns, Naux IV E Primary turns, Np Resonant transformer: pinout TI VE -I NA Figure 3. NA CT In Table 2 the main features of the transformer are listed and in Figure 3 and 4 the pinout and the geometrical characteristics are shown respectively. IN AC !-V 6/18 Doc ID 15906 Rev 1 UM0727 Demonstration board description Figure 4. Resonant transformer: mechanical drawing NA CT IV E  !-V IV E -I The output voltage can be adjusted down to 1.235 V by a voltage divider. An internal oscillator fixes the switching frequency up to 500 kHz to minimize the size of external components. The power IC features several layers of protection, such as pulse by pulse current limit with internal frequency modulation aimed at an effective constant current short circuit protection, feedback disconnection and thermal shutdown. Finally, it can be synchronized using a dedicated pin as well as inhibited for reduced standby power consumption and time sequence operations. STEVAL-ISA018V1 board layout with tracks IN AC TI VE -I NA Figure 5. CT The board layout is shown in Figure 5. The whole power supply is produced on a double side 35 µm PCB FR-4 (130 x 66 mm). AM04390v1 Doc ID 15906 Rev 1 7/18 Demonstration board description Table 3. UM0727 STEVAL-ISA018V1 BOM list Value Description C1 220 nF Polyester X2 – 275 Vac C2 100 nF Polyester X2 – 275 Vac C3 680 µF Elect. capacitor 200 V C4 220 pF Ceramic capacitor NPO C5 100 nF Ceramic capacitor Y5 V C6 100 nF Ceramic capacitor Y5 V C7 4.7 nF Ceramic capacitor Y5 V C8 10 nF Ceramic capacitor Z5U C9 47 nF Ceramic capacitor Y5 V C10 100 pF Ceramic capacitor NPO C12 470 pF Ceramic capacitor Y5 V C14 470 pF Ceramic capacitor Y5 V C15 220 pF Polip. capacitor 630 V C16 22 nF Ceramic capacitor 630 V C17 4.7 µF C18 47 nF C19 100 nF C20 470 µF C21 470 µF C22 470 µF C23 470 µF C24 220 nF C25 100 µF C26 2.2 nF C27 22 nF Ceramic capacitor 630 V C28 100 nF Ceramic capacitor Y5 V C29 100 nF Ceramic capacitor Y5 V C30 100 nF Ceramic capacitor Y5 V C32 100 µF Elect. capacitor 25 V C33 100 nF Ceramic capacitor Y5 V C35 47 nF Ceramic capacitor Y5 V C36 100 nF Ceramic capacitor Y5 V C37 680 µF Elect. capacitor 200 V C39 4.7 nF Ceramic capacitor Y2 – 250 Vac C40 4.7 nF Ceramic capacitor Y2 – 250 Vac NA CT -I E IV Elect. capacitor -I NA CT Elect. capacitor Y5 V TI VE IN AC 8/18 IV E Reference Ceramic capacitor Y5 V Elect. capacitor 35 V Elect. capacitor 35 V Elect. capacitor 35 V Elect. capacitor 35 V Ceramic capacitor Y5 V Elect. capacitor 50 V Polyester capacitor Y1 - 300 Vac Doc ID 15906 Rev 1 UM0727 STEVAL-ISA018V1 BOM list (continued) Reference Value Description C42 1 µF Elect. capacitor 160 V CN1 3 pos Connector - pitch 3.96 mm CN2 2 pos Connector - pitch 3.96 mm CN3 4 pos Connector - pitch 3.96 mm DP1 S1M/11T Rectifier 1 A - 1000 V - DO214AC NA CT D1 Bridge rectifier 8 A - 600 V IV E Table 3. Demonstration board description D2 Zener diode 24 V - 1 W LS4148 Ultrafast diode 200 mA - 75 V - SOD80 D4 LS4148 Ultrafast diode 200 mA - 75 V - SOD80 D5 LS4148 Ultrafast diode 200 mA - 75 V - SOD80 D6 LS4148 Ultrafast diode 200 mA - 75 V - SOD80 D7 LS4148 Ultrafast diode 200 mA - 75 V - SOD80 D8 STPS20H100 STMicroelectronics - Schottky rectifier 2x10A - 100 V D9 BAV23C Fast rectifier 2x400 mA - 250 V - SOT23 D11 LS4148 Ultrafast diode 200 mA - 75 V - SOD80 IV E -I D3 STPS20H100 STMIcroelectronics - Schottky rectifier 2x10 A - 100 V DL1 LED LED red 0805 L1 2x25 mH NTC1 2Ω-4A NTC2 10 kΩ F1 3.15 A R1 100 kΩ R2 470 kΩ R3 10 kΩ Resistor, 5% - SMD 0603 R4 10 kΩ Resistor, 5% - SMD 0603 R5 1 MΩ Resistor, 5% - SMD 0603 R6 56 kΩ Resistor, 5% - SMD 0603 R8 10 Ω Resistor, 5% - SMD 0603 10 Ω Resistor, 5% - SMD 0603 R10 100 Ω Resistor, 5% - SMD 0603 R11 10 Ω Resistor, 5% - SMD 0603 R12 100 Ω Resistor, 5% - SMD 0603 R13 100 Ω Resistor, 5% - SMD 1206 R14 100 Ω Resistor, 5% - SMD 0603 R9 CT D13 TI VE Zener diode 12 V - 1 W IN AC D12 -I NA CM choke - TDK HF2836 - 1.2 A NTC Inrush current suppressor NTC -40 °C to 125 °C Fuse 250 V delayed Resistor, 5% - SMD 1206 Resistor, 5% - SMD 1206 Doc ID 15906 Rev 1 9/18 Demonstration board description STEVAL-ISA018V1 BOM list (continued) Value Description R15 10 kΩ Resistor, 5% - SMD 0603 R16 220 Ω Resistor, 5% - SMD 0603 R17 1 kΩ Resistor, 5% - SMD 0603 R18 470 Ω Resistor, 5% - SMD 0603 R19 10 Ω Resistor, 5% - SMD 0603 R20 1 kΩ Resistor, 5% - SMD 0603 R21 15 kΩ Resistor, 5% - SMD 0603 R22 1 kΩ Resistor, 5% - SMD 0603 R23 1 kΩ Resistor, 5% - SMD 0603 R24 22 kΩ Resistor, 5% - SMD 0603 R25 10 kΩ Resistor, 5% - SMD 0603 R26 0.1 Ω Shunt resistor 3 W R27 1 kΩ Resistor, 5% - SMD 0603 R28 22 kΩ Resistor, 1% - SMD 0603 R29 2.2 kΩ Resistor, 5% - SMD 0603 R30 4.7 kΩ R31 10 Ω R32 1 kΩ R34 220 kΩ R35 470 kΩ R36 100 kΩ R37 1 kΩ R38 4.7 kΩ R40 100 Ω R41 5.6 kΩ Resistor, 1% - SMD 0603 R43 3.3 kΩ Resistor, 5% - SMD 0603 R45 22 kΩ Resistor, 5% - SMD 0603 R46 1 kΩ Resistor, 5% - SMD 0603 R47 10 kΩ Resistor, 5% - SMD 0603 R48 100 kΩ Resistor, 5% - SMD 0603 R49 10 kΩ Resistor, 5% - SMD 0603 R50 0Ω Resistor, - SMD 0603 R51 1 kΩ Resistor, 5% - 1W R52 220 kΩ Resistor, 5% - SMD 1206 R53 220 kΩ Resistor, 5% - SMD 1206 -I E IV Resistor, 5% - SMD 0603 CT Resistor, 5% - SMD 0603 Resistor, 5% - SMD 0603 -I NA Resistor, 5% - SMD 0603 TI VE IN AC 10/18 NA CT Reference IV E Table 3. UM0727 Resistor, 5% - SMD 1206 Resistor, 5% - SMD 1206 Resistor, 5% - SMD 0603 Resistor, 5% - SMD 1206 Resistor, 5% - SMD 0603 Doc ID 15906 Rev 1 UM0727 Table 3. Demonstration board description STEVAL-ISA018V1 BOM list (continued) Value Description R54 0Ω Resistor, - SMD 0603 R55 47 Ω Resistor, 5% - SMD 1206 T1 SRW40EC2-E01 Switch mode transformer - TDK U1 L6599 STMicroelectronics - high voltage resonant controller U2 TCET1101 Optocoupler - Vishay U3 TS321 STMicroelectronics - low power single operational amplifier - SOT 23-5 U4 TSM1011 STMicroelectronics constant voltage and constant current controller - SO-8 Q1 STB21NM50N STMicroelectronics - MOSFET MDmesh II 500 V -0.15 Ω - 18 A - D2PAK Q2 STB21NM50N STMicroelectronics - MOSFET MDmesh II 500 V -0.15 Ω - 18 A - D2PAK Q3 BC817 STMicroelectronics - small signal NPN transistor 50 V 1 A SOT-23 Q4 STN715 Z1 VK300 NA CT IV E Reference -I STMicroelectronics - NPN medium power transistor 140 V - 1 A SOT-223 IN AC TI VE -I NA CT IV E Varistor 300 V Doc ID 15906 Rev 1 11/18 Experimental waveforms 2 UM0727 Experimental waveforms Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) AM04391v1 CT Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) IN AC TI VE -I NA Figure 7. IV E -I NA CT Figure 6. IV E In this section some experimental waveforms are given. The contents of the following images show the output ripple, both at low frequency and high frequency, the short circuit protection operations and the startup and shutdown waveforms. 12/18 AM04392v1 Doc ID 15906 Rev 1 UM0727 Experimental waveforms Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) AM04394v1 IN AC TI VE -I NA CT IV E Figure 9. AM04393v1 -I NA CT IV E Figure 8. Doc ID 15906 Rev 1 13/18 Experimental waveforms UM0727 IN AC TI VE -I NA CT IV E -I NA CT IV E Figure 10. Midpoint voltage and transformer current - Vin = 230 Vac, Vout=24.6 V, Iout = 2 A (CH1: HB midpoint voltage; CH2: transformer current) 14/18 Doc ID 15906 Rev 1 AM04395v1 UM0727 EMI measurements IV E EMI behavior has been evaluated, as shown in Figure 11 and 12, and measurements have been obtained using the standard settings with a 50 Ω LISN and a spectrum analyzer using the peak detector. The emissions are below the limit of the quasi-peak mask although the peak detector has been used, confirming the suitability of the topology with “light” EMI filters. IV E -I NA CT Figure 11. Conducted emissions - phase - Vin = 230 Vac, Iout = 6 A !-V TI VE -I NA CT Figure 12. Conducted emissions - neutral - Vin = 230 Vac, Iout = 6 A !-V IN AC 3 EMI measurements Doc ID 15906 Rev 1 15/18 Conclusions 4 UM0727 Conclusions IN AC TI VE -I NA CT IV E -I NA CT IV E This document describes the STEVAL-ISA018V1 demonstration board which implements a single output SMPS for industrial applications. The power supply is based on the L6599 resonant controller and uses the latest MDmesh II power MOSFET technology in order to achieve very high efficiency in all the operating range. 16/18 Doc ID 15906 Rev 1 UM0727 Revision history Document revision history Date Revision 18-May-2010 1 Changes Initial release TI VE -I NA CT IV E -I NA CT IV E Table 4. IN AC 5 Revision history Doc ID 15906 Rev 1 17/18 NA CT IV E UM0727 Please Read Carefully: Information in this document is provided solely in connection with ST products. STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, modifications or improvements, to this document, and the products and services described herein at any time, without notice. -I All ST products are sold pursuant to ST’s terms and conditions of sale. Purchasers are solely responsible for the choice, selection and use of the ST products and services described herein, and ST assumes no liability whatsoever relating to the choice, selection or use of the ST products and services described herein. CT IV E No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein. NA UNLESS OTHERWISE SET FORTH IN ST’S TERMS AND CONDITIONS OF SALE ST DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE USE AND/OR SALE OF ST PRODUCTS INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION), OR INFRINGEMENT OF ANY PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT. -I UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED ST REPRESENTATIVE, ST PRODUCTS ARE NOT RECOMMENDED, AUTHORIZED OR WARRANTED FOR USE IN MILITARY, AIR CRAFT, SPACE, LIFE SAVING, OR LIFE SUSTAINING APPLICATIONS, NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY, DEATH, OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE. ST PRODUCTS WHICH ARE NOT SPECIFIED AS "AUTOMOTIVE GRADE" MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT USER’S OWN RISK. TI VE Resale of ST products with provisions different from the statements and/or technical features set forth in this document shall immediately void any warranty granted by ST for the ST product or service described herein and shall not create or extend in any manner whatsoever, any liability of ST. ST and the ST logo are trademarks or registered trademarks of ST in various countries. Information in this document supersedes and replaces all information previously supplied. IN AC The ST logo is a registered trademark of STMicroelectronics. All other names are the property of their respective owners. © 2010 STMicroelectronics - All rights reserved STMicroelectronics group of companies Australia - Belgium - Brazil - Canada - China - Czech Republic - Finland - France - Germany - Hong Kong - India - Israel - Italy - Japan Malaysia - Malta - Morocco - Philippines - Singapore - Spain - Sweden - Switzerland - United Kingdom - United States of America www.st.com 18/18 Doc ID 15906 Rev 1