Page 1
AN2492
Application note
Wide range 400W L6599-based
HB LLC resonant converter for PDP application
Introduction
This note describes the performances of a 400 W reference board, with wide-range mains
operation and power-factor-correction (PFC) and presents the results of its bench
evaluation. The electrical specification refers to a power supply for a typical high-end PDP
application.
The main features of this design are the very low no-load input consumption (<0.5 W) and
the very high global efficiency, better than 90% at full load and nominal mains voltage (115 230 V
The circuit consists of three main blocks. The first is a front-end PFC pre-regulator based on
the L6563 PFC controller. The second stage is a multi-resonant half-bridge converter with
an output voltage of +200 V/400 W, whose control is implemented through the L6599
resonant controller. A further auxiliary flyback converter based on the VIPer12A off-line
primary switcher completes the architecture. This third block, delivering a total power of 7 W
on two output voltages (+3.3 V and +5 V), is mainly intended for microprocessor supply and
display power management operations.
AC
).
L6599 & L6563 400W demo board (EVAL6599-400W-S)
June 2007 Rev 3 1/35
www.st.com
Page 2
Contents AN2492
Contents
1 Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 4
2 Electrical test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Resonant stage operating waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Stand-by and no-load power consumption . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Thermal tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 20
5 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 PFC coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7 Resonant power transformer specification . . . . . . . . . . . . . . . . . . . . . 29
7.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Auxiliary flyback power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
11 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2/35
Page 3
AN2492 List of figures
List of figures
Figure 1. PFC pre-regulator electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2. Resonant converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3. Auxiliary converter electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4. Compliance to EN61000-3-2 for harmonic reduction: full load . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5. Compliance to EN EN61000-3-2 for harmonic reduction: 70 W load . . . . . . . . . . . . . . . . . . 9
Figure 6. Compliance to JEIDA-MITI standard for harmonic reduction: full load . . . . . . . . . . . . . . . . . 9
Figure 7. Compliance to JEIDA-MITI standard for harmonic reduction: 70 W load . . . . . . . . . . . . . . . 9
Figure 8. Power factor vs. Vin & load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9. Total harmonic distortion vs. Vin & load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10. Overall efficiency versus output power at nominal mains voltages. . . . . . . . . . . . . . . . . . . 10
Figure 11. Overall efficiency versus input mains voltage at various output power levels . . . . . . . . . . 12
Figure 12. Resonant circuit primary side waveforms at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 13. Resonant circuit primary side waveforms at light load (about 30 W output power) . . . . . . 13
Figure 14. Resonant circuit primary side waveforms at no load condition . . . . . . . . . . . . . . . . . . . . . . 14
Figure 15. Resonant circuit secondary side waveforms: +200 V output . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 16. Low frequency (100 Hz) ripple voltage on the +200 V output . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 17. Load transition (0.4 A - 2 A) on +200 V output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 18. +200 V output short-circuit waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 19. Thermal map @115 V
Figure 20. Thermal map at 230 V
Figure 21. Peak measurement on LINE at 115 V
Figure 22. Peak measurement on NEUTRAL at 115 V
Figure 23. Peak measurement on LINE at 230 V
Figure 24. Peak measurement on NEUTRAL at 230 V
Figure 25. Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 26. Pin side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 27. Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 28. Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 29. Winding position on coil former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 30. Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 31. Auxiliary transformer winding position on coil former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 32. Copper tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 33. Thru-hole component placing and top silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 34. SMT component placing and bottom silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AC
- full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AC
and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AC
AC
and full load . . . . . . . . . . . . . . . . . . . . . . . . 20
AC
and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
and full load . . . . . . . . . . . . . . . . . . . . . . . . 21
AC
3/35
Page 4
Main characteristics and circuit description AN2492
1 Main characteristics and circuit description
The main characteristics of the SMPS are listed below:
● Universal input mains range: 90 to 264 V
● Output voltages: 200 V @ 2 A - 3.3 V @ 0.7 A - 5 V @ 1 A
● Mains harmonics: Compliance with EN61000-3-2 specifications
● Stand-by mains consumption: Typical 0.5 W @230 V
●
Overall efficiency: better than 88% at full load, 90-264 V
●
EMI: Compliance with EN55022-class B specifications
● Safety: Compliance with EN60950 specifications
● PCB single layer: 132x265 mm, mixed PTH/SMT technologies
The circuit consists of three stages. A front-end PFC pre-regulator implemented by the
controller L6563 (Figure 1), a half-bridge resonant DC/DC converter based on the resonant
controller L6599 (Figure 2) and a 7 W flyback converter intended for stand-by management
(Figure 3) utilizing the VIPer12A off-line primary switcher.
The PFC stage delivers a stable 400 VDC supply to the downstream converters (resonant +
flyback) and provides for the reduction of the current harmonics drawn from the mains, in
order to meet the requirements of the European norm EN61000-3-2 and the JEIDA-MITI
norm for Japan.
- 45 to 65 Hz
AC
AC
AC
The PFC controller is the L6563 (U1), integrating all functions needed to operate the PFC
and interface the downstream resonant converter. Though this controller chip is designed for
Transition-Mode (TM) operation, where the boost inductor works next to the boundary
between Continuous (CCM) and Discontinuous Conduction Mode (DCM), by adding a
simple external circuit, it can be operated in LM-FOT (line-modulated fixed off-time) mode,
allowing Continuous Conduction Mode operation, normally achievable with more expensive
control chips and more complex architectures. This operative mode allows the use of this
device at a high power level, usually covered by CCM topologies. For a detailed and
complete description of the LM-FOT operating mode, see the application note AN1792. The
external components to configure the circuit in LM-FOT mode are: C15, C17, D5, Q3, R14,
R17 and R29.
The power stage of the PFC is a conventional boost converter, connected to the output of
the rectifier bridge through a differential mode filtering cell (C5, C6 and L3) for EMI
reduction. It includes a coil (L4), a diode (D3), and two capacitors (C7 and C8). The boost
switch consists of two Power MOSFETs (Q1 and Q2), connected in parallel, which are
directly driven by the L6563 output drive thanks to the high current capability of the IC. The
divider (R30, R31 and R32) connected to MULT pin 3 brings the information of the
instantaneous voltage that is used to modulate the boost current and to derive further
information like the average value of the AC line used by the VFF (voltage feed-forward)
function. This function is used to keep the output voltage almost independent of the mains.
The divider (R3, R6, R8, R10 and R11) is dedicated to detecting the output voltage while a
further divider (R5, R7, R9, R16 and R25) is used to protect the circuit in case of voltage
loop failure.
The second stage is an LLC resonant converter, with half-bridge topology implementation,
working in ZVS (zero voltage switching) mode. The controller is the L6599 integrated circuit
that incorporates the necessary functions to properly drive the two half-bridge MOSFETs by
a 50% fixed duty cycle with fixed dead-time, changing the frequency according to the
4/35
Page 5
AN2492 Main characteristics and circuit description
feedback signal in order to regulate the output voltages against load and input voltage
variations.
The main features of the L6599 are a non-linear soft-start, a current protection mode used
to program the hiccup mode timing, a dedicated pin for sequencing or brown-out (LINE) and
a stand-by pin (STBY) for burst mode operation at light loads (not used in this design).
The transformer (T1) uses the magnetic integration approach, incorporating the resonant
series and shunt inductances of the LLC resonant tank. Thus, no additional external coils
are needed for the resonance. For a detailed analysis of the LLC resonant converter, please
refer to the application note AN2450.
The secondary side power circuit is configured with a single-ended transformer winding and
full-bridge rectification (diodes D8A, D8B, D10A, D10B), which is more suitable for the
current design. In fact, with this configuration, the total junction capacitance of the output
diodes reflected at primary side is one half the capacitance in case of center-tap
transformer. This capacitance at transformer primary side may affect the behavior of the
resonant tank, changing the circuit from LLC to LLCC type, with the risk that the converter,
in light-load/no-load condition (when the feedback loop increases the operating frequency)
can no longer control the output voltage. If the converter has to operate down to zero load,
this capacitance needs to be minimized. An inherent advantage of the full-bridge
rectification is that the voltage rating of the output diodes in this configuration is one half the
rating necessary for center-tap and two diodes circuit, which translates into a lower junction
capacitance device, with consequent lower reflected capacitance at primary side.
The feedback loop is implemented by means of a classical configuration using a TL431 (U4)
to adjust the current in the optocoupler diode (U3). The optocoupler transistor modulates the
current from controller Pin 4, so the frequency will change accordingly, thus achieving the
output voltage regulation. Resistors R46 and R54 set the maximum operating frequency. In
case of a short circuit, the current entering the primary winding is detected by the lossless
circuit (C34, C39, D11, D12, R43, and R45) and the resulting signal is fed into L6599 Pin 6.
In case of overload, the voltage on Pin 6 will exceed an internal threshold that triggers a
protection sequence via Pin 2, keeping the current flowing in the circuit at a safe level.
The third stage is a small flyback converter based on the VIPer12A, a current mode
controller with integrated Power MOSFET, capable of delivering about 7 W total output
power on the output voltages (5 V and 3.3 V). The regulated output voltage is the 3.3 V
output and, also in this case, the feedback loop uses the TL431 (U7) and optocoupler (U6)
to control the output voltage. This converter is able to operate in the whole mains voltage
range, even when the PFC stage is not working. From the auxiliary winding on the primary
side of the flyback transformer (T2), a voltage Vs is available, intended to supply the other
controllers (L6563 and L6599) in addition to the VIPer12A itself.
The PFC stage and the resonant converter can be switched on and off through the circuit
based mainly on components Q7, Q8, D22 and U8, which, depending on the level of the
signal ST-BY, supplies or removes the auxiliary voltage (VAUX) necessary to start up the
controllers of the PFC and resonant stages. When the AC input voltage is applied to the
power supply, the small flyback converter switches on first. Then, when the ST-BY signal is
low, the PFC pre-regulator becomes operative, and the resonant converter can deliver the
output power to the load. Note that if Pin 9 of Connector J3 is left floating (no signal ST-BY
present), the PFC and resonant converter will not operate, and only +5 V and +3.3 V
supplies are available on the output. In order to enable the +200 V output, Pin 9 of
Connector J3 must be pulled down to ground.
5/35
Page 6
Main characteristics and circuit description AN2492
Figure 1. PFC pre-regulator electrical diagram
Vdc
+400V
C9
2nF2-Y1
330uF/450V
C8
R2
NTC 2R5-S237
C7
470nF/630V
D3
STTH8R0 6
1-2
D1
1N5406
L4
PQ40-500uH
5-6
D4
LL4148
Q2
STP12NM50FP
Q1
STP12NM50FP
D6
LL4148
R18
R15
6R8
6R8
R24
0R39
R23
0R39
R22
0R39
R21
0R39
R19
1k0
C18
330pF
Vrect
C6
470nF/630V
L3
DM-51uH-6A
C5
470nF/630V
Vaux
+
-
D2
D15XB60
~
~
C11
C4
L2
CM-10m H-5A
C3
L1
CM-1.5mH-5A
C2
R1
F1
8A/250V
1
J1
2nF2-Y2
680nF-X2
C10
2nF2-Y2
330nF-X2
470nF-X2
1M5
2
CON2-IN
R4
47
C13
10uF/50V
C12
100nF
R6
680kR8680k
R3
680k
R5
Vdc
2M2
R11
R10
R7
2M2
R9
D5
C15
100pF
R14
3k3
R17
C17
15k
U1
L6563
100k
R13
56k
C14
100nF
C16
1uF
2M2
CSCS
LL4148
15k
220pF
GD
VCC
INV
COMP
ZCD
GND
MULTCSVFF
PWM-Latch
R29
1k5
Q3
BC857C
R20
1k0
C21
2nF2
R28
RUN
PWM-STOP
TBO
PFC-OK PWM-LATCH
R16
5k1
LINE
240k
R26
150k
C20
470nF
C19
10nF
R25
30k
C22
10nF
R32
10k
R31
620k
R30
620k
Vrect
6/35
Page 7
AN2492 Main characteristics and circuit description
Figure 2. Resonant converter electrical diagram
1234567
J2
+200V
8
CON8
C59
47nF
R86
470R
R61
R53
75k
R58
75k
C38
C25
22uF/250V
C29
100uF/250V
100uF/250V
R51
330k
2k2
R60
12k
L5
10uH
C30
100uF/250V
D8A
D8B
D10A
STTH803
STTH803
T1
T-RES-ER49
C28
47nF/630V
Vdc
Q5
R33
D7
Q6
STP14NK50Z
0R
R35
47
LL4148
STP14NK50Z
R39
0R
R40
47
D9
LL4148
C37
100uF/250V
STTH803
D10B
STTH803
R43
150
C34
220pF/630V
Vaux
C32
100nF
R38
47
C31
10uF/50V
D11
LL4148
D12
LL4148
R45
75R
C39
1uF0
C41
R85
R50
R49
R48
10uF/50V
120k
D13
C-12V
330k
R59
R56
330k
R52
330k
1k0
3k3
U3A
SFH617A-2
1k0
C44
47nF
U4
TL431
C27 100nF
NC
LVG
OUT
VCC
HVG
VBOOT
U2
L6599
CSS
DELAYCFRFMIN
STBY
ISEN
LINE GND
R36
0R
R34
3k9
C23
4uF7
C24
470nF
C26
270pF
R37
1M0
R41
DIS PFC-STOP
C33
4nF7
R42
10
16k
LINE
C40
10nF
R47
10k
R46
1k5
PWM-Latch
U3B
SFH617A-2
C60
470nF
R87
220R
R54
1k5
7/35
Page 8
Main characteristics and circuit description AN2492
Figure 3. Auxiliary converter electrical diagram
J3
+5Vst-by
L7
T2
123456789
+5Vst-by
T-FLY -AUX-E20
+3V3
C46
100uF/10V
33uH
C45
1000uF/10V
D15
1N5822
D14
10
CON10
St-By
C49
100uF/10V
L8
33uH
C47
1000uF/10V
D16
1N5821
D20
PKC-136
Vs
C51
100nF
R77
R64
1k6
C54
100nF
R67
1k0
C53
2nF2
R73
8k2
R62
47
U6A
SFH617A-2
+5Vst-by
R68
BAV103
C50
10uF/50V
R66
1k0
St-By
22k
R71
10k
Q8
BC847C
R69
0R
4k7
U7
TL431
+200V
R76
150k
R75
150k
D21
B-15V
R80
30k
R79
2k2
Vdc
+400V
D19
C-30V
D
D
D
SSFB
U5
VIPER-12A
U6B
SFH617A-2
Vdd D
D17
LL4148
D18
B-10V
C52
C48
10uF/50V
8/35
47nF
Q9
BC857C
U8A
R72
22R
10k
R74
C55
10uF/50V
Vdc
+400V
R83
Q11
BC557C
SFH617A-2
1M0
R84
C58
10nF
150k
Vs
Q7
BC547C
R70
Vaux
C56
100nF
Q10
BC847C
U8B
SFH617A-2
10k
D22
C-15V
C57
1nF0
Page 9
AN2492 Electrical test results
2 Electrical test results
2.1 Harmonic content measurement
The current harmonics drawn from the mains have been measured according to the
European rule EN61000-3-2 Class-D and Japanese rule JEIDA-MITI Class-D, at full load
and 70 W output power, at both nominal input voltages (230 V
in Figure 4., Figure 5., Figure 6. and Figure 7. show that the measured current harmonics
are well below the limits imposed by the regulations, both at full load and at 70 W load.
and 100 VAC). The pictures
AC
Figure 4. Compliance to EN61000-3-2 for
10
1
0.1
0.01
0.001
0.0001
harmonic reduction: full load
Measurements @ 230Vac Full load EN61000-3-2 class D limit s
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 5 16 17 18 19 20
Harmoni c Orde r ( n)
Figure 6. Compliance to JEIDA-MITI standard
10
1
0.1
0.01
0.001
for harmonic reduction: full load
Measurements @ 100Vac Full load JEI DA- M ITI c l ass D l im it s
Figure 5. Compliance to EN EN61000-3-2 for
harmonic reduction: 70 W load
Measurement s @ 230Vac 70W EN61 00 0-3-2 class D limits
1
0.1
0.01
0.001
0.0001
1234567891011121314151617181920
Harmoni c Order (n)
Figure 7. Compliance to JEIDA-MITI standard
for harmonic reduction: 70 W load
Measurement s @ 100V ac 70W JEI DA -MI TI cla s s D limits
1
0.1
0.01
0.001
0.0001
1234567891011121314151617181920
Harmoni c Orde r (n )
The Power Factor (PF) and the Total Harmonic Distortion (THD) are reported in Figure 8.
and Figure 9. It is evident from the picture that the PF stays close to unity in the whole mains
voltage range at full load and at half load, while it decreases at high mains at low load
(70W). The THD has similar behavior, remaining within 25% overall the mains voltage range
and increasing at low load (70 W) at high mains voltage.
0.0001
1234567891011121314151617181920
Harmoni c Orde r ( n)
9/35
Page 10
Electrical test results AN2492
60%
65%
70%
75%
80%
85%
90%
95%
100%
0 50 100 150 200 250 300 350 400 450
Output Power (W)
Eff. (%)
@230Vac @115Vac
Figure 8. Power factor vs. Vin & load Figure 9. Total harmonic distortion vs. Vin &
PF
1.00
0.98
0.95
0.93
0.90
0.88
0.85
80 120 160 200 240 280
400W
200W
70W
Vin [Vrms]
THD [%]
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
80 120 160 200 240 280
load
400W
200W
70W
Vin [Vrms]
2.2 Efficiency measurements
Table 1. and Tab l e 2 . show the output voltage measurements at the nominal mains voltages
of 115 V
load and at light load operations, the input power is measured using a Yokogawa WT-210
digital power meter. Particular attention has to be paid when measuring input power at full
load in order to avoid measurement errors due to the voltage drop on cables and
connections.
and 230 VAC, with different load conditions. For all measurements, both at full
AC
Figure 10. shows the overall circuit efficiency, measured at each load condition, at both
nominal input mains voltages of 115 V
and 230 VAC. The values were measured after 30
AC
minutes of warm-up at maximum load. The high efficiency of the PFC pre-regulator working
in FOT mode and the very high efficiency of the resonant stage working in ZVS (i.e. with
negligible switching losses), provides for an overall efficiency better than 88% at full load in
the complete mains voltage range. This is a significant high value for a two-stage converter,
especially at low input mains voltage where PFC conduction losses increase. Even at lower
loads, the efficiency still remains high.
Figure 10. Overall efficiency versus output power at nominal mains voltages
10/35
Page 11
AN2492 Electrical test results
The global efficiency at full load has been measured even at the limits of the input voltage
range, with good results:
At VIN = 90 V
At VIN = 264 V
- full load, the efficiency is 88.48%
AC
- full load, the efficiency is 93.70%
AC
Also at light load, at an output power of about 10% of the maximum level, the overall
efficiency is very good, reaching a value better than 79% over the entire input mains voltage
range. Figure 11. shows the efficiency measured at various output power levels versus input
mains voltage.
Table 1. Efficiency measurements @V
+200 V@load(A) +5 V @load(A) +3.3 V @load(A) POUT(W) PIN(W) Efficiency
202.50 1.989 4.84 0.968 3.33 0.695 409.77 451.38 90.78%
202.50 1.751 4.84 0.968 3.33 0.695 361.58 397.70 90.92%
202.50 1.501 4.84 0.968 3.33 0.695 310.95 341.39 91.08%
202.50 1.251 4.84 0.968 3.33 0.695 260.33 285.86 91.07%
202.50 1.000 4.84 0.968 3.33 0.695 209.50 230.96 90.71%
202.53 0.751 4.84 0.968 3.33 0.695 159.10 176.63 90.08%
202.53 0.500 4.84 0.968 3.33 0.695 108.26 122.62 88.29%
202.53 0.250 4.84 0.968 3.33 0.695 57.63 69.04 83.48%
202.56 0.150 4.84 0.293 3.33 0.309 32.83 41.14 79.80%
202.67 0.051 4.84 0.293 3.33 0.309 12.78 20.34 62.85%
= 115 V
IN
AC
Table 2. Efficiency measurements @VIN = 230 V
+200 V@load(A) +5 V @load(A) +3.3 V @load(A) POUT(W) PIN(W) Efficiency
202.50 1.987 4.84 0.968 3.33 0.695 409.37 437.79 93.51%
202.50 1.750 4.84 0.968 3.33 0.695 361.37 386.90 93.40%
202.50 1.500 4.84 0.968 3.33 0.695 310.75 333.33 93.23%
202.50 1.250 4.84 0.968 3.33 0.695 260.12 279.65 93.02%
202.50 1.000 4.84 0.968 3.33 0.695 209.50 226.68 92.42%
202.50 0.750 4.84 0.968 3.33 0.695 158.87 174.10 91.25%
202.53 0.500 4.84 0.968 3.33 0.695 108.26 121.54 89.08%
202.53 0.250 4.84 0.968 3.33 0.695 57.63 68.96 83.57%
202.54 0.150 4.84 0.293 3.33 0.309 32.83 41.80 78.54%
202.67 0.050 4.84 0.293 3.33 0.309 12.58 19.86 63.35%
AC
11/35
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Electrical test results AN2492
Figure 11. Overall efficiency versus input mains voltage at various output power
levels
400W 200W 70W
Eff[%]
94%
93%
92%
91%
90%
89%
88%
87%
86%
85%
80 120 160 200 240 280
Vin [Vrms]
2.3 Resonant stage operating waveforms
Figure 12. shows some waveforms during steady state operation of the resonant circuit at
full load. The Ch1 waveform is the half-bridge square voltage on Pin 14 of L6599, driving the
resonant circuit. In the picture it is not evident, but the switching frequency is normally
slightly modulated following the PFC pre-regulator 100-Hz ripple that is rejected by the
resonant control circuitry. The Ch2 waveform represents the transformer primary current
flowing into the resonant tank. As shown, it has almost a sinusoidal shape. The resonant
tank has been designed (following the procedure presented in the application note AN2450)
to operate at a resonance frequency of about 120 kHz when the dc input voltage of the halfbridge circuit is at 390 V (that is the nominal output voltage of the PFC stage).
The resonant frequency has been selected at approximately 120 kHz in order to have a
good trade off between transformer losses and dimensions.
The resonant tank circuit has been designed in order to have a good margin for ZVS
operation, providing good efficiency, while the almost sinusoidal current waveform allows for
an extremely low EMI generation.
Figure 13. and Figure 14. shows the same waveforms as Figure 12, when the +200 V output
is at a light load (about 30 W) or not loaded at all. These two graphics demonstrate the
ability of the converter to operate down to zero load, with the output voltage still within the
regulation range. The resonant tank current has a triangular shape and represents the
magnetizing current flowing into the transformer primary side. The oscillation superimposed
on the tank current depends on the occurrence of a further resonance due to the parallel of
the inductances at primary side (the series and shunt inductances in the APR (all primary
referred) transformer model presented in AN2450) and the undesired secondary side
capacitance reflected at the transformer primary side.
12/35
Page 13
AN2492 Electrical test results
Figure 12. Resonant circuit primary side waveforms at full load
Ch1: half-bridge square
voltage on pin 14 of L6599
Ch2: resonant tank current
Ch3: low side MOSFET
drive signal
Figure 13. Resonant circuit primary side waveforms at light load (about 30 W output
power)
Ch1: half-bridge square
voltage on pin 14 of L6599
Ch2: resonant tank current
Ch3: low side MOSFET
drive signal
13/35
Page 14
Electrical test results AN2492
Figure 14. Resonant circuit primary side waveforms at no load condition
Ch1: half-bridge square
voltage on pin 14 of L6599
Ch2: resonant tank current
Ch3: low side MOSFET
drive signal
In Figure 15., waveforms relevant to the secondary side are represented. In particular, the
waveform Ch1 is the voltage of D8A anode referenced to the secondary ground potential,
while the waveform CH3 shows the current flowing into D8A-D10B diodes. Also this current
waveform (like the one flowing into the resonant tank at the transformer primary side) has
almost a sine shape, and its average value is one half the output average current.
Thanks to the advantages of the resonant converter, the high frequency noise on the output
voltages is less than 50 mV, while the residual ripple at twice the mains frequency (100 Hz)
is about 150 mV at maximum load and worse line condition (90 V
), as shown in Figure 16.
AC
Figure 15. Resonant circuit secondary side waveforms: +200 V output
Ch1: anode voltage of diode D8A
Ch2: current into diode D8A
14/35
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AN2492 Electrical test results
Figure 16. Low frequency (100 Hz) ripple voltage on the +200 V output
Ch2: resonant tank current
envelope
Ch3: +200 V output voltage
ripple at 100 Hz
Figure 17. shows the dynamic behavior of the converter during a load variation from 20% to
100% on the +200 V output. This figure also highlights the induced effect of this load change
on the PFC pre-regulator output voltage (+400 V on Ch1 track). Both the transitions (from
20% to 100% and from 100% to 20%) are clean and do not show any problem for the output
voltage regulation.
This shows that the proposed architecture is also highly suitable for power supplies
operating with strong load variation without any problems related to the load regulation.
Figure 17. Load transition (0.4 A - 2 A) on +200 V output voltage
Ch1: PFC output voltage
Ch2: resonant tank current
envelope
Ch3: +200 V output voltage
ripple
2.4 Stand-by and no-load power consumption
The board is specifically designed for light load and zero load operations, typical conditions
occurring during Stand-by or Power-off operations, when no power is requested from the
15/35
Page 16
Electrical test results AN2492
+200 V output. Though the resonant converter can operate down to zero load, some actions
are required to keep the input power drawn from the mains very low when the complete
system is in this load condition. Thus, when entering this power management mode, the STBY signal needs to be set high (by the microcontroller of the system). This forces the PFC
pre-regulator and the resonant stage to switch off, because the supply voltage of the two
control ICs is no longer present (Figure 3) and only the auxiliary flyback converter continues
working just to supply the microprocessor circuitry.
Table 3. and Table 4. show the measurements of the input power in several light load
conditions at 115 and 230 V
. These tables show that at no-load the input power is about
AC
0.5 W.
Table 3. Stand-by consumption at VIN = 115 V
+5 V @load(A) +3.3 V @load(A) POUT(W) PIN(W)
5.06 - 0.017 3.33 - 0.102 0.425 0.860
5.04 - 0.017 3.33 - 0.079 0.349 0.750
4.98 - 0.017 3.33 - 0.046 0.238 0.581
4.90 - 0.017 3.33 - 0.024 0.163 0.475
4.47 - 0.000 3.33 - 0.000 0.00 0.245
Table 4. Stand-by consumption at VIN = 230 V
+5 V @load(A) +3.3 V @load(A) POUT(W) PIN(W)
5.06 - 0.017 3.33 - 0.102 0.425 1.156
5.04 - 0.017 3.33 - 0.079 0.349 1.044
4.98 - 0.017 3.33 - 0.046 0.238 0.870
4.90 - 0.017 3.33 - 0.024 0.163 0.755
4.47 - 0.000 3.33 - 0.000 0.00 0.510
2.5 Short-circuit protection
AC
AC
The L6599 is equipped with a current sensing input (pin 6, ISEN) and a dedicated
overcurrent management system. The current flowing in the circuit is detected (through the
not dissipative sensing circuit already mentioned in Chapter 1, mainly based on a capacitive
divider formed by the resonant capacitor C28 and the capacitor C34, followed by an
integration cell D12, R45, C39) and the signal is fed into the ISEN pin. This is internally
connected to the input of a first comparator, referenced to 0.8 V, and to that of a second
comparator referenced to 1.5 V. If the voltage externally applied to the ISEN pin exceeds 0.8
V, the first comparator is tripped causing an internal switch to be turned on discharging the
soft-start capacitor CSS.
For output short-circuits, this operation results in a nearly constant peak primary current.
The designer can externally program the maximum time (t
to run overloaded or under short-circuit conditions. Overloads or shortcircuits lasting less
than t
duration phenomena. If, instead, t
16/35
will not cause any other action, hence providing the system with immunity to short
SH
is exceeded, an overload protection (OLP) procedure is
SH
) that the converter is allowed
SH
Page 17
AN2492 Electrical test results
activated that shuts down the device and, in case of continuous overload/short circuit,
results in continuous intermittent operation with a user-defined duty cycle. This function is
accomplished by the DELAY pin 2 of the resonant controller, by means of the capacitor C24
and the parallel resistor R37 connected to ground. As the voltage on the ISEN pin exceeds
0.8V, the first OCP comparator, in addition to discharging CSS, turns on an internal current
generator that via the DELAY pin charges C24. As the voltage on C24 reaches 3.5 V, the
L6599 stops switching and the internal generator is turned off, so that C24 will now be slowly
discharged by R37. The IC will restart when the voltage on C24 becomes 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 will be triggered, the device will shut down and the
operation will be resumed after an on-off cycle. Figure 18. illustrates the short-circuit
protection sequence described above. The on-off operation is controlled by the voltage on
pin 2 (DELAY), providing for the hiccup mode of the circuit. Thanks to this control pin, the
designer can select the hiccup mode timing and thus keep the average output current at a
safe level.
Figure 18. +200 V output short-circuit waveforms
2.6 Overvoltage protection
Both the PFC pre-regulator and the resonant converter are equipped with their own
overvoltage protection circuit. The PFC controller is internally equipped with a dynamic and
a static overvoltage protection circuit sensing the current flowing through the error amplifier
compensation network and entering in the COMP pin (#2). When this current reaches about
18 µA, the output voltage of the multiplier is forced to decrease, thus reducing the energy
drawn from the mains. If the current exceeds 20 µA, the OVP is triggered (Dynamic OVP),
and the external power transistor is switched off until the current falls approximately below 5
µA. However, if the overvoltage persists (e.g. in case the load is completely disconnected),
the error amplifier will eventually saturate low, triggering an internal comparator (Static OVP)
that will keep the external power switch turned off until the output voltage comes back close
to the regulated value. Moreover, in the L6563 there is additional protection against loop
failures using an additional divider (R5, R7, R9, R16 and R25) connected to a dedicated pin
(PFC_OK, Pin 7) protecting the circuit in case of loop failures, disconnection, or deviation
from the nominal value of the feedback loop divider. Hence the PFC output voltage is always
Ch1: half-bridge voltage on pin
14
Ch2: + 200 V output current
Ch3: pin 6 (ISEN)
Ch4: pin 2 (DELAY)
17/35
Page 18
Thermal tests AN2492
under control and if a fault condition is detected, the PFC_OK circuitry will latch the PFC
operation and, by means of the PWM_LATCH pin 8 it will also latch the L6599 via the DIS
pin of the resonant controller.
The OVP circuit (see Figure 3) for the output voltages of the resonant converter uses a
resistive divider (R75, R76, R80) and the zener diode D21 to sense the +200 V output: if the
sensed voltage exceeds the threshold imposed by the zener diode plus the VBE of Q10, the
transistor Q9 starts conducting and the optocoupler U8 opens Q7, so that the VAUX supply
voltage of the controller ICs L6563 and L6599 is no longer available. This state is latched
until a mains voltage recycle occurs.
3 Thermal tests
In order to check design reliability, a thermal mapping by an IR Camera was performed.
Figure 19. and Figure 20. show the thermal measurements of the board, component side, at
nominal input voltage. The correlation between measurement points and components is
indicated for both diagrams in Table 5.
All other board components work well within the temperature limits, assuring a reliable long
term operation of the power supply.
Note that the temperatures of L4 and T1 have been measured both on the ferrite core (Fe)
and on the copper winding (Cu).
Table 5. Key components temperature at nominal voltages and full load
Point Item 230 V
A D2 40,3°C 47,6°C
B L4-(FE) 44,2°C 50,5°C
C L4-(CU) 46,0°C 55,5°C
D Q1 44,5°C 53,4°C
E R2 63,5°C 73,0°C
F D3 46,1°C 51,0°C
G C8 39,3°C 40,1°C
H Q6 51,4°C 52,8°C
I T1-(CU) 63,7°C 62,6°C
J T1-(FE) 51,3°C 49,6°C
K U5 53,2°C 53,4°C
L D14 51,8°C 52,3°C
M C38 39,4°C 38,5°C
N C45 36,1°C 35,7°C
AC
115 V
AC
O D8A 44,5°C 44,9°C
P R22 41,4°C 55,6°C
18/35
Page 19
AN2492 Thermal tests
Table 5. Key components temperature at nominal voltages and full load
Point Item 230 V
Q D15 43,3°C 43,5°C
R D16 42,6°C 42,1°C
S T2 43,3°C 43,6°C
Figure 19. Thermal map @115 VAC - full load
Figure 20. Thermal map at 230 V
- full load
AC
AC
115 V
AC
19/35
Page 20
Conducted emission pre-compliance test AN2492
4 Conducted emission pre-compliance test
The measurements have been taken in peak detection mode, both on LINE and on Neutral
at nominal input mains and at full load. The limits indicated on the following diagrams refer
to the EN55022 Class- B specifications (the higher limit curve is the quasi-peak limit while
the lower curve is the average limit) and the measurements show that the PSU emission is
well below the maximum allowed limit.
Figure 21. Peak measurement on LINE at 115 V
Figure 22. Peak measurement on NEUTRAL at 115 V
and full load
AC
and full load
AC
20/35
Page 21
AN2492 Conducted emission pre-compliance test
Figure 23. Peak measurement on LINE at 230 VAC and full load
Figure 24. Peak measurement on NEUTRAL at 230 V
and full load
AC
21/35
Page 22
Bill of materials AN2492
5 Bill of materials
Table 6. Bill of materials
Item Part Description Supplier
C2 470 nF-X2 275
C3 330 nF-X2 275
C4 680 nF-X2 27 5
C5 470 nF/630 V POLYPROPYLENE CAPACITOR HIGH RIPPLE MKP R71 ARCOTRONICS - EPCOS
C6 470 nF/630 V POLYPROPYLENE CAPACITOR HIGH RIPPLE MKP R71 ARCOTRONICS - EPCOS
C7 470 nF/630 V POLYPROPYLENE CAPACITOR HIGH RIPPLE MKP R71 ARCOTRONICS - EPCOS
C8 330 µF/450 V ALUMINIUM ELCAP USC SERIES 85 DEG SNAP-IN RUBYCON
C9 2 nF2-Y1 400
C10 2 nF2-Y1 250
C11 2 nF2-Y1 250
C12 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C13 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C14 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C15 100 pF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C16 1 µF 25 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C17 220 pF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C18 330 pF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C19 10 nF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C20 470 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
V
X2 SAFETY CAPACITOR MKP R46 ARCOTRONICS
AC
V
X2 SAFETY CAPACITOR MKP R46 ARCOTRONICS
AC
V
X2 SAFETY CAPACITOR MKP R46 ARCOTRONICS
AC
V
Y1 SAFETY CERAMIC DISK CAPACITOR MURATA
AC
V
Y1 SAFETY CERAMIC DISK CAPACITOR MURATA
AC
V
Y1 SAFETY CERAMIC DISK CAPACITOR MURATA
AC
C21 2 nF2 100 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C22 10 nF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C23 4 µF7 16 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C24 470 nF 25 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C25 22 µF/250 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C26 270 pF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C27 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C28 47 nF/630 V POLYPROPYLENE CAPACITOR HIGH RIPPLE PHE450 RIFA-EVOX
C29 100 µF/250 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C30 100 µF/250 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C31 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C32 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C33 4 nF7 100 V 1206 SMD CERCAP GENERAL PURPOSE AVX
22/35
Page 23
AN2492 Bill of materials
Table 6. Bill of materials (continued)
Item Part Description Supplier
C34 220 pF/630 V POLYPROPYLENE CAPACITOR HIGH RIPPLE PFR RIFA-EVOX
C37 100 µF/250 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C38 100 µF/250 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C39 1 µF0 25 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C40 10 nF 100 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C41 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C44 47 nF 100 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C45 1000 µF/10 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C46 100 µF/10 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C47 1000 µF/10 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C48 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C49 100 µF/10 V ALUMINIUM ELCAP YXF SERIES 105 DEG RUBYCON
C50 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C51 100 nF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C52 47 nF 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C53 2 nF2 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C54 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C55 10 µF/50 V ALUMINIUM ELCAP GENERAL PURPOSE 85 DEG RUBYCON
C56 100 nF 50 V 1206 SMD CERCAP GENERAL PURPOSE AVX
C57 1 nF0 100 V 0805 SMD CERCAP GENERAL PURPOSE AVX
C58 10 nF 50 V X7R STANDARD CERAMIC CAPACITOR AVX
C59 47 nF/250 V POLCAP PHE426 SERIES RIFA-EVOX
C60 470 nF 25 V 1206 SMD CERCAP GENERAL PURPOSE VISHAY
D1 1N5406 GENERAL PURPOSE RECTIFIER VISHAY
D2 D15XB60 SINGLE PHASE BRIDGE RECTIFIER SHINDENGEN
D3 STTH8R06 TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER STMicroelectronics
D4 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D5 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D6 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D7 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D8A STTH803 TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER STMicroelectronics
D8B STTH803 TO220FP ULTRAFAST HIGH VOLTAGE RECTIFIER STMicroelectronics
D9 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D10A STTH803 TO220FP ULTRAFAST MEDIUM VOLTAGE RECTIFIER STMicroelectronics
D10B STTH803 TO220FP ULTRAFAST MEDIUM VOLTAGE RECTIFIER STMicroelectronics
23/35
Page 24
Bill of materials AN2492
Table 6. Bill of materials (continued)
Item Part Description Supplier
D11 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D12 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D13 C-12 V BZV55-C SERIES ZENER DIODE VISHAY
D14 PKC-136 PEAK CLAMP TRANSIL STMicroelectronics
D15 1N5822 POWER SCHOTTKY RECTIFIER STMicroelectronics
D16 1N5821 POWER SCHOTTKY RECTIFIER STMicroelectronics
D17 LL4148 MINIMELF FAST SWITCHING DIODE VISHAY
D18 B-10 V BZV55-B SERIES ZENER DIODE VISHAY
D19 C-30 V BZV55-C SERIES ZENER DIODE VISHAY
D20 BAV103 GENERAL PURPOSE DIODE VISHAY
D22 C-15 V BZV55-C SERIES ZENER DIODE VISHAY
F1 8 A/250 V T TYPE FUSE 5 X 20 HIGH CAPABILITY & FUSEHOLDER WICKMANN
J1 CON2-IN 3 PINS CONN. (CENTRAL REMOVED) P 3.96 KK SERIES MOLEX
J2 CON8 8 PINS CONNECTOR P 3.96 KK SERIES MOLEX
J3 CON10 10 PINS CONNECTOR P 2.54 MTA SERIES AMP
L1 CM-1.5 mH-5 A LFR2205B SERIES COMMON MODE INDUCTOR DELTA
L2 CM-10 mH-5 A TF3524 SERIES COMMON MODE TOROIDAL INDUCTOR TDK
L3 DM-51 µH-6 A
L4 PQ40-500 µH 86H-5410B BOOST INDUCTOR DELTA
L5 10 µH ELC08 DRUM CORE INDUCTOR PANASONIC
L7 33 µH ELC08 DRUM CORE INDUCTOR PANASONIC
L8 33 µH ELC08 DRUM CORE INDUCTOR PANASONIC
Q1 STP12NM50FP TO220FP N-CHANNEL Power MOSFET STMicroelectronics
Q2 STP12NM50FP TO220FP N-CHANNEL Power MOSFET STMicroelectronics
Q3 BC857C SOT23 SMALL SIGNAL PNP TRANSISTOR STMicroelectronics
Q5 STP14NK50Z TO220FP N-CHANNEL Power MOSFET STMicroelectronics
Q6 STP14NK50Z TO220FP N-CHANNEL Power MOSFET STMicroelectronics
Q7 BC547C TO92 SMALL SIGNAL PNP TRANSISTOR STMicroelectronics
Q8 BC847C SOT23 SMALL SIGNAL PNP TRANSISTOR STMicroelectronics
Q9 BC857C SOT23 SMALL SIGNAL PNP TRANSISTOR STMicroelectronics
Q10 BC847C SOT23 SMALL SIGNAL NPN TRANSISTOR STMicroelectronics
Q11 BC547C TO92 SMALL SIGNAL PNP TRANSISTOR STMicroelectronics
LSR2306-1 DIFFERENTIAL MODE TOROIDAL
INDUCTOR
DELTA
R1 1M5 VR25 TYPE HIGH VOLTAGE RESISTOR BC COMPONENTS
R2 NTC 2R5-S237 NTC RESISTOR 2R5 S237 SERIES EPCOS
24/35
Page 25
AN2492 Bill of materials
Table 6. Bill of materials (continued)
Item Part Description Supplier
R3 680 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R4 47 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R5 2M2 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R6 680 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R7 2M2 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R8 680 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R9 2M2 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R10 100 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R11 15 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R13 56 k 1206 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R14 3k3 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R15 6R8 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R16 5k1 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R17 15 k 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R18 6R8 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R19 1k0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R20 1k0 STANDARD METAL FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R21 0R39 PR02 POWER RESISTOR BC COMPONENTS
R22 0R39 PR02 POWER RESISTOR BC COMPONENTS
R23 0R39 PR02 POWER RESISTOR BC COMPONENTS
R24 0R39 PR02 POWER RESISTOR BC COMPONENTS
R25 30 k 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R26 150 k 1206 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R28 240 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R29 1k5 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R30 620 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R31 620 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R32 10 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R33 0R 0805 SMD STANDARD FILM RES 1/8 W BC COMPONENTS
R34 3k9 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R35 47 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R36 0R 0805 SMD STANDARD FILM RES 1/8 W BC COMPONENTS
R37 1M0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R38 47 STANDARD METAL FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R39 0R 0805 SMD STANDARD FILM RES 1/8 W BC COMPONENTS
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Page 26
Bill of materials AN2492
Table 6. Bill of materials (continued)
Item Part Description Supplier
R40 47 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R41 16 k 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R42 10 1206 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R43 150 1206 SMD STANDARD FILM RES 1/4 W 5% 200ppm/°C BC COMPONENTS
R45 75R 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R46 1k5 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R47 10 k 1206 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R48 330 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R49 330 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R50 330 k 1206 SMD STANDARD FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R51 330 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R52 3k3 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R53 75 k 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R54 1k5 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R56 1k0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R58 75k 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R59 1k0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R60 12 k 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R61 2k2 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R62 47 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R64 1k6 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R66 1k0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R67 1k0 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R68 22 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R69 0R 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R70 22R 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R71 10 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R72 10 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R73 8k2 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R74 10 k 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R75 150 k 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R76 150 k 1206 SMD STANDARD FILM RES 1/4 W 1% 100 ppm/°C BC COMPONENTS
R77 4k7 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
R79 2k2 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R80 30 k 0805 SMD STANDARD FILM RES 1/8 W 1% 100 ppm/°C BC COMPONENTS
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Page 27
AN2492 Bill of materials
Table 6. Bill of materials (continued)
Item Part Description Supplier
R83 1M0 VR25 TYPE HIGH VOLTAGE RESISTOR BC COMPONENTS
R84 150 k STANDARD METAL FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R85 120 k STANDARD METAL FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
R86 470R 0805 SMD STANDARD FILM RES 1/8 W 5% 200 ppm/°C BC COMPONENTS
R87 220R STANDARD METAL FILM RES 1/4 W 5% 200 ppm/°C BC COMPONENTS
T1
T2 T-FLY-AUX-E20 86A-6079-R TYPE FLYBACK TRANSFORMER E20 CORE DELTA
U1 L6563 ADVANCED TRANSITION MODE PFC CONTROLLER STMicroelectronics
U2 L6599 HIGH VOLTAGE RESONANT CONTROLLER STMicroelectronics
U3 SFH617A-2 63-125% CTR SELECTION OPTOCOUPLER INFINEON
U4 TL431 TO92 PROGRAMMABLE SHUNT VOLTAGE REGULATOR STMicroelectronics
U5 VIPer12A LOW POWER OFF LINE SMPS PRIMARY SWITCHER STMicroelectronics
U6 SFH617A-2 63-125% CTR SELECTION OPTOCOUPLER INFINEON
U7 TL431 TO92 PROGRAMMABLE SHUNT VOLTAGE REGULATOR STMicroelectronics
T- R E S - E R 4 9 -
400 W
86H-6412 TYPE RESONANT TRANSFORMER ER49 DELTA
U8 SFH617A-2 63-125% CTR SELECTION OPTOCOUPLER INFINEON
Note: Q9 and R72: mounted by reworking on PCB
Q11, R83, R84, R85, R86, R87, C58, C59 and C60: added by reworking on PCB
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Page 28
PFC coil specification AN2492
6 PFC coil specification
● Application type: consumer, home appliance
● Inductor type: open
● Coil former: vertical type, 6+6 pins
● Max. temp. rise: 45 °C
● Max. operating ambient temp.: 60 °C
6.1 Electrical characteristics
● Converter topology: FOT PFC Preregulator
● Core type: PQ40-30 material grade PC44 or equivalent
● Max operating freq: 100 KHz
● Primary inductance: 500 µH ±10% @1 KHz-0.25 V (see Note: 1)
● Primary RMS current: 4.75 A
Note: 1 Measured between pins 2-3 and 10-11
Figure 25. Electrical diagram
2 The auxiliary winding is not used in this design, but is foreseen for another application
Table 7. Winding characteristics
Start PINS End PINS
11 8 5 (spaced) Single Ø 0.28 mm Bottom
5 - 6 1 - 2 65 Multistrand – G2 Litz Ø 0.2 mm x 30 Top
Number
of turns
Wire type
6.2 Mechanical aspect and pin numbering
● Maximum height from PCB: 45 mm
● Cut pins: 9-12
● Pin distance: 5 mm
● Row distance: 45.5 mm
● External copper shield 15 x 0.05 (mm) connected to pin 11 by tinned wire
Wire
diameter
Notes
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Page 29
AN2492 Resonant power transformer specification
Figure 26. Pin side view
● Manufacturer: DELTA ELECTRONICS
● P/N: 86H-5410
7 Resonant power transformer specification
● Application type: consumer, home appliance
● Transformer type: open
● Coil former: horizontal type, 7+7 pins, 2 slots
● Max. temp. rise: 45 °C
● Max. operating ambient temp.: 60 °C
● Mains insulation: ACC. with EN60065
7.1 Electrical characteristics
● Converter topology: half-bridge, resonant
● Core type: ER49 - PC44 or equivalent
● Min. operating frequency: 75 Khz
● Typical operating freq: 120 KHz
● Primary inductance: 240 µH ±10% @1 KHz - 0.25 V [see Note 1]
● Leakage inductance: 40 µH ±10% @1 KHz - 0.25 V [see Note 1] - [see Note 2]
Note: 1 Measured between pins 1-3
2 Measured between pins 1-3 with the secondary winding shorted
Figure 27. Electrical diagram
PRIM.
1
14
SEC.
3
12
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Page 30
Resonant power transformer specification AN2492
SECONDARY
COIL FORMER
PRIMARY
Table 8. Winding characteristics
Pins Winding RMS current N° turns
1 - 3 PRIMARY 2.90 A
14 - 12 SECONDARY 2.25 A
Figure 28. Mechanical aspect and pin numbering
Note: Cut PIN 7
● Manufacturer: DELTA ELECTRONICS
● P/N: 86H-6412
RMS
RMS
Wire
type
19 Litz Ø 0.2 mm x 20
18 Litz Ø 0.2 mm x 20
Table 9. Mechanical dimensions
ABCDEF
Dimensions
(mm)
39.0 max 3.5 ± 0.5 41.6 ± 0.4 51 max 7.0 ± 0.2 51.5 max
Figure 29. Winding position on coil former
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Page 31
AN2492 Auxiliary flyback power transformer
8 Auxiliary flyback power transformer
● Application type: consumer, home appliance
● Transformer type: open
● Winding type: layer
● Coil former: horizontal type, 4+5 pins
● Max. temp. rise: 45 °C
● Max. operating ambient temp.: 60 °C
● Mains insulation: ACC. with EN60065
8.1 Electrical characteristics
● Converter topology: flyback, DCM/CCM mode
● Core type: E20 - N67 or equivalent
● Operating frequency: 60 Khz
● Primary inductance: 4.20 mH ±10% @1 KHz - 0.25 V [see Note 1]
● Leakage inductance: 50 µH MAX @100 KHz - 0.25 V [see Note 2]
Note: 1 Measured between pins 4-5
2 Measured between pins 4-5 with the secondary windings shorted
Figure 30. Electrical diagram
● Manufacturer: DELTA ELECTRONICS
● P/N: 86A - 6079 - R
Table 10. Winding characteristics
Pins: start - end Winding RMS current N° turns Wire type
4 - 5 PRIMARY 0.2 A
2 - 1 AUX 0.05 A
8- 10 3.3 V 0.2 A
6 - 7 5 V 1 A
RMS
RMS
RMS
RMS
140 G2 - Ø 0.25 mm
29 G2 - Ø 0.25 mm
7 TIW Ø 0.75 mm
3 TIW Ø 0.75 mm
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Page 32
Board layout AN2492
Figure 31. Auxiliary transformer winding position on coil former
COIL FORMER
9 Board layout
Figure 32. Copper tracks
3.3V / 5V
AUX
PRIMARY
INSULATING TAPE
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Page 33
AN2492 Board layout
Figure 33. Thru-hole component placing and top silk screen
Figure 34. SMT component placing and bottom silk screen
33/35
Page 34
References AN2492
10 References
1. "L6563/L6563A advanced transition-mode PFC controller" Datasheet
2. "Design of Fixed-Off-Time-Controlled PFC Pre-regulators with the L6562", AN1792
3. "L6599 high-voltage resonant controller" Datasheet
4. "LLC resonant half-bridge converter design guideline", AN2450
11 Revision history
Table 11. Revision history
Date Revision Changes
28-Feb-2007 1 First issue
23-Apr-2007 2
12-Jun-2007 3 Figure 2 modified
– Cross references updated
– Table 6: Bill of materials modified
34/35
Page 35
AN2492
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