STEVAL-ISA031V1

UM0584 User manual STEVAL-ISA031V1: 40 W SMPS with HV MOSFET and L6565 for three-phase industrial applications Introduction This document introduces a solution for industrial power supplies fed by a three-phase mains. It employs a high voltage (1500 V breakdown voltage) power MOSFET to optimize the operation of a quasi-resonant flyback converter based on the primary controller L6565. The demonstration board has been designed and developed specifically for low power applications. The board features two outputs, 24 V and 5 V, and is capable of delivering more than 40 W of output power. The 5 V output is obtained by means of an integrated DCDC converter based on the L5970AD 1.5 A switch step-down switching regulator, connected to the 24 V output. The demonstration board is available through order code STEVALISA031V1. Figure 1. STEVAL-ISA031V1 demonstration board - top side AM01306v1 Figure 2. STEVAL-ISA031V1 demonstration board - bottom side AM01307v1 September 2009 Doc ID 14974 Rev 1 1/9 www.st.com Contents UM0584 Contents 1 Demonstration board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 2 2/9 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Doc ID 14974 Rev 1 UM0584 1 Demonstration board description Demonstration board description The STEVAL-ISA031V1 demonstration board is based on a quasi resonant flyback converter and employs the STW4N150 power MOSFET as the primary switch. The STW4N150 is a 5 Ω 1500 V power MOSFET designed with STMicroelectronics’ proprietary high voltage "Mesh Overlay" technology, which gives the switch very low RDS(on) per area, low gate charge and high switching performance. The STW4N150 device is available in the TO-220, TO-247 and TO-220FH packages. The main specifications of the demonstration board are provided in table below. Table 1. STEVAL-ISA031V1 main specifications Parameter Value Input voltage range 185 to 460 Vac Input frequency range 50/60 Hz Output 1 24 V @ 1.7 A Output 2 5V@1A Output power 40 W Safety EN60950 EMI EN55014 The input section features two connectors: CON1 for 400 Vac input voltage and CON2 for 230 Vac input voltage. The output voltages are available on CON3, with a shared ground between the two outputs. The converter is controlled by the L6565, a primary controller for quasi resonant ZVS (zero voltage switching) flyback converters. The IC controls the power capability variations with the mains voltage by means of line voltage feed-forward. In addition to the very low startup and quiescent currents, the device manages light load conditions with optimized consumption thanks to a special function which automatically lowers the operating frequency while maintaining operation as close to ZVS as possible. The IC also includes a disable function, an on-chip filter on current sense, an error amplifier with a precise reference voltage for primary regulation and effective two-level overcurrent protection. The transformer reflected voltage is set to 400 V, providing sufficient margin for the leakage inductance voltage spike, and a small RCD clamper circuit is used to limit excess voltage on the drain of the MOSFET. During normal operation, the IC is powered by the auxiliary winding of the transformer via diode D7. A spike killer circuit for auxiliary voltage fluctuations is provided but not connected (Q11, C13, R13). The primary current is measured using external sensing resistors (R20, R21) for current mode operation. Output voltage regulation is performed via a secondary feedback on the 24 V output. The feedback network consists of a programmable voltage reference, TL431, driving an optocoupler which ensures the required insulation between the primary and secondary sections. The optotransistor drives the feedback pin (COMP) which controls the operation of the IC. Doc ID 14974 Rev 1 3/9 4/9 CON1 CON2 2 1 230Vac L3 2.2mH L2 2.2mH L1 2.2mH D3 1N4007 D1 1N4007 D4 1N4007 D2 1N4007 22n-X2 C3 33 mH L4 22n-X2 C4 5O NTC1 C1 C2 22uF + 22uF + R4 1M R3 1M R2 1M R1 1M Doc ID 14974 Rev 1 R15 15k 2.2n 1n C7 R14 15k C6 C9 2.2n 4 3 2 1 U1 LL4148 D8 5 6 7 8 C8 100n ZCD GND GD VCC L6565 120k R16 CS VFF COMP INV R7 1.8M 1.8M R6 R5 1.8M C10 47u R17 56k R9 330k R8 330k D7 2.2n - Y1 C14 LL4148 C11 470p R11 150K/2W R10 150K/2W Q11 2.2 1k R19 HS 6.8n - nc C13 R13 2.2k - nc nc R12 16R R18 D5 STTH108 STTH108 D6 3.3n/2kV C5 M1 R20 2R2 U2 T1 14 8 C12 nc R27 3k3 R26 2k2 + C16 22u/35V 3k9 R24 R23 12k 5k6 n.c. C23 C22 C21 L6 15uH R29 U5 TL431 L5 10uH C17 220uF/10V 220u/35V C15 D9 STPS5H100 Lp=3.5mH Np/Ns=12.17 Np=185T-AWG34 Ns=15T-AWG23 Naux=10T-AWG32 Core material N67(CF138) COre shape ETD29 g=1.32mm TRANSFORMER R21 2R2 PC817 STW4N150 2 1 3 7 22n nc 4 3 2 1 R30 1.2k - 1% R28 10k - 1% 4k7 R25 22n C18 STPS2L25U D10 R22 5.6k 220p C19 COMP INH SYNC OUT U4 FB VREF GND VCC L5970A 8 7 5 6 1 2 3 CON3 J6 10uF/35V C20 24V/1.7A 5V/1A Figure 3. 2 1 400Vac F1 1A 480-650VDC Demonstration board description UM0584 LC filters have been added on both outputs to reduce high frequency ripple, with moderate output capacitor values. The flyback transformer is a layer-type based on an ETD29 core and N67 ferrite, manufactured by Tronic, with insulation meeting EN60950 safety standards. Circuit schematic AM01308v1 UM0584 Demonstration board description The 5 V output is obtained from the 24 V output by means of an integrated power IC, the L5970AD. The L5970AD is a step-down monolithic power switching regulator with a switch current limit of 1.5 A, capable of delivering more than 1 A of DC current to the load depending on application conditions. The output voltage can be adjusted down to 1.235 V by a voltage divider. The device uses an internal P-channel DMOS transistor, with a typical RDS(on) of 200 mΩ as a switching element to avoid the need for a bootstrap capacitor and to guarantee high efficiency. An internal oscillator sets the switching frequency at 500 kHz to minimize the size of external components. The power IC features several protection functions, such as pulse-by-pulse current limiting, with the internal frequency modulation aimed at effective constant current short-circuit protection, feedback disconnection and thermal shutdown. Finally, the device can be synchronized using a dedicated pin, and also inhibited for reduced standby power consumption and time sequence operations. The schematic of the board is shown in Figure 3. The complete power supply is built on a double-sided 35 µm PCB in FR-4, sized 130 x 66 mm. The bill of materials is given in table below. 1.1 Bill of materials Table 2. STEVAL-ISA031V1 bill of materials Reference Value Description C1 22 µF - 450 V Elect. capacitor – 85 °C C2 22 µF - 450 V Elect. capacitor – 85 °C C3 22 nF - 660 Vac Polip. capacitor X2 C4 22 nF - 660 Vac Polip. capacitor X2 C5 4.7 nF - 2 kV Polip. capacitor FKP1 - WIMA C6 1 nF Elect. capacitor C7 2.2 nF Ceramic capacitor C8 100 nF Ceramic capacitor C9 2.2 nF Ceramic capacitor C10 47 µF Ceramic capacitor C11 470 pF Ceramic capacitor C12 n.m. Ceramic capacitor C13 6.8 nF (n.m.) Ceramic capacitor C14 2.2 nF Polip. capacitor X1 Y1 C15 220 µF – 35 V Elect. capacitor C16 22 µF – 35 V Elect. capacitor C17 220 µF – 10 V Elect. capacitor C18 22 nF Ceramic capacitor C19 220 pF Ceramic capacitor Doc ID 14974 Rev 1 5/9 Demonstration board description Table 2. UM0584 STEVAL-ISA031V1 bill of materials (continued) Reference Value Description C20 10 µF- 35 V Elect capacitor C21 n.m. C22 22 nF C23 n.m. D1, D2, D3, D4 1N4007 Rectifier 1000 V 1 A D5 STTH108 STMicroelectronics turboswitch diode 1 A - 800 V D6 STTH108 STMicroelectronics turboswitch diode 1 A - 800 V D7 LL4148 SOD-80 general purpose rectifier 75 V 200 mA D8 LL4148 SOD-80 general purpose rectifier 75 V 200 mA D9 STPS5H100 Schottky rectifier 5 A - 100 V D10 STPS2L25U Schottky rectifier 2 A - 25 V L1, L2, L3 2.2 mH Inductor - TDK SL1720-222KR60 L4 33 mH Common mode choke - TDK 333Y0R0 L5 10 µH Inductor - TDK SLF7045T - 100M1R3 L6 15 µH Inductor - TDK SLF7045T - 150M1R1 NTC1 5Ω NTC inrush current suppressor - EPCOS 0544 F1 1A Fuse R1 1 mΩ Resistor R2 1 mΩ Resistor R3 1 mΩ Resistor R4 1 mΩ Resistor R5 1.8 mΩ Resistor R6 1.8 mΩ Resistor R7 1.8 mΩ Resistor R8 330 kΩ Resistor R9 330 kΩ Resistor R10 150 kΩ Resistor, 2 W R11 150 kΩ Resistor, 2 W R12 22 Ω Resistor, SMD-1206 R13 2.2 kΩ (n.m) Resistor R14 15 kΩ Resistor, SMD-0805 R15 15 kΩ Resistor, SMD-0805 R16 120 kΩ Resistor R17 56 kΩ Resistor R18 2.2 Ω Resistor 6/9 Ceramic capacitor Doc ID 14974 Rev 1 UM0584 Table 2. Demonstration board description STEVAL-ISA031V1 bill of materials (continued) Reference Value Description R19 1 kΩ Resistor R20 2.2 Ω Resistor R21 2.2 Ω Resistor R22 4.7 kΩ Resistor, 0.25 W TRH R23 12 kΩ Resistor R24 3.9 kΩ Resistor R25 4.7 kΩ Resistor R26 2.2 kΩ Resistor R27 3.3 kΩ Resistor R28 10 kΩ Resistor, 0.25 W 1% R29 5.6 kΩ Resistor R30 1.2 kΩ Resistor, 0.25 W 1% T1 0603261 Switch mode transformer - Tronic U1 L6565 STMicroelectronics quasi resonant controller U2 PC817 Optocoupler - Sharp U4 L5970AD STMicroelectronics - 1.5 A switch step-down switching regulator U5 TL431 STMicroelectronics programmable shunt voltage reference 1% M1 STW4N150 STMicroelectronics MOSFET 1500 V - 5 Ω - 4 A Q11 BC547 (n.m.) Small signal PNP transistor Doc ID 14974 Rev 1 7/9 Revision history 2 UM0584 Revision history Table 3. 8/9 Document revision history Date Revision 24-Sep-2009 1 Changes Initial release. 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