NXP Semiconductors UM10972 User Manual

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UM10972

TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

Rev. 1.1 — 8 June 2018 User manual

COMPANY PUBLIC

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Keywords TEA1916DB1262, TEA19161T, TEA19162T TEA1995T 240 W, LLC,

resonant, half-bridge, PFC, controller, converter, burst mode, power supply, demo board, high efficiency, 80+ certification

Abstract The TEA19161T is a digital LLC controller. It is used in combination with the

PFC controller TEA19162T.Combining these two ICs with the SR controller TEA1995T at the secondary side results in a high-efficient resonant converter over the whole output power range. This document describes such a resonant power supply design with a 240 W (12 V/20 A) typical output power. It operates in normal mode for high and medium power levels, in low-power mode at medium and low power levels, and in burst mode at (very) low power levels. Low-power mode and burst mode operation provide a reduction of power losses, resulting in a higher efficiency at lower output power levels. Power levels for switching over from one mode to another mode can be selected by adjusting component values. The efficiency at high power levels is well above 90 %. No-load power consumption is well below 100 mW. At 250 mW output power, the input power is well below the 500 mW (complies easily with EUP lot6).

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 2 / 38

Table 1. Revision history

Rev Date Description

v.1.1 20180608 second, updated issue

Modifications: • Section 7 "Bill of Materials" has been updated.

• Section 9.2 "PFC coil" has been updated.

v.1 20171201 first issue

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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1 Introduction

Warning

The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/or ignition of fire.

This product is intended for evaluation purposes only. It shall be operated in a designated test area by personnel qualified according to local requirements and labor laws to work with non-insulated mains voltages and high-voltage circuits. This product shall never be operated unattended.

This user manual describes the TEA1916DB1262 240 W power supply board using the TEA19161T, TEA19162T, and TEA1995T. The user manual contains a functional description and a set of preliminary measurements to show the main characteristics.

1.1 TEA19161T and TEA19162T

The TEA19161T is a Half-Bridge Converter (HBC). The TEA19162T is a controller for Power Factor Correction (PFC). Both ICs provide drive functionality for the related discrete MOSFETs.

The resonant controller part (TEA19161T) is a high-voltage controller for a zero voltage switching LLC resonant converter. The resonant controller includes:

• A high-voltage shift circuit

• A high-voltage internal start-up switch

• Several protection features, like OverCurrent Protection (OCP), Open-Loop Protection

(OLP), Capacitive Mode Protection (CMP), and a general purpose latched protection input

The TEA19162T is a PFC controller. To ensure efficient operation of the PFC, the TEA19162T incorporates quasi-resonant operation at high power levels and quasiresonant operation with valley skipping at lower power levels. OCP, OverVoltage Protection (OVP), and demagnetization sensing ensure safe operation under all conditions. To improve the overall performance significantly, the TEA19161T and TEA19162T work together.

With the TEA1995T as a synchronized rectifier controller at the secondary side, MOSFETs can be used instead of rectifying diodes, improving the overall efficiency of the complete system even more.

The combination of PFC, resonant controller, and SR controller makes these devices suitable for all kinds of applications. Especially for application requiring high efficiency over the whole power range from no load to maximum output load.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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1.1.1 Pinning

SUPIC SNSBOOST

SNSFB SNSCAP

SNSOUT SNSCUR

GND

SNSSET

SUPREG n.c.

GATELS HB

n.c. SUPHS

SUPHV GATEHS

aaa-017286

GATEPFC SNSAUX

GND PFCCOMP

SNSCUR SNSMAINS

SUPIC SNSBOOST

aaa-017287

a. TEA19161T b. TEA19162T

Figure 1. Pinning diagrams

1.2 TEA1995T

The TEA1995T is the first product of a new generation of Synchronous Rectifier (SR) controller ICs for switched-mode power supplies. It incorporates an adaptive gate drive method for maximum efficiency at any load.

The TEA1995T is a dedicated controller IC for synchronous rectification on the secondary side of resonant converters. It includes two driver stages for driving the SR MOSFETs, which rectify the outputs of the central tap secondary transformer windings. The two-gate driver stages have their own sensing inputs and operate independently.

GDB GDA

GND V

DSB DSA

SSB SSA

aaa-016990

Figure 2. TEA1995T pinning diagram

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 5 / 38

2 Safety warning

The board must be connected to mains voltage. Avoid touching the demo board while it is connected to the mains voltage. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. Galvanic isolation of the mains phase using a variable transformer is always recommended. Figure 3 shows the symbols that identify the isolated and non-isolated devices.

019aab173

019aab174

a. Isolated b. Not isolated

Figure 3. Isolation symbols

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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3 Specifications

Table 2. Specifications

Symbol Description Value Conditions

Input

input voltage 90 V (RMS) to

264 V (RMS)

input frequency 47 Hz to 63 Hz

i(noload)

no-load input power < 100 mW at 230 V/50 Hz

i(load=250mW)

standby power consumption

< 450 mW at 230 V/50 Hz

Output

output voltage 12 V

output current 0 A to 20 A continuous

o(max)

maximum output current

25 A with OPP

o(peak)max

maximum peak output current

30 A t < 50 ms

hold

hold time > 10 ms at 115 V/60 Hz;

full load

start

start time ≤ 0.5 s at 115 V/60 Hz

η efficiency ≥ 89 % average according to

CoC

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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4 Board photographs

a. Top view

b. Bottom view

Figure 4. TEA1916DB1262 prototype 240 W demo board

The board can operate at a mains input voltage between 90 V (RMS) and 264 V (RMS; universal mains).

The TEA1916DB1262demo board contains two subcircuits:

• A BCM-type PFC converter

• A resonant LLC-type HBC converter

To achieve an optimized resonant power board, the converters are working together.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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The purpose of the TEA1916DB1262 prototype demo board is to evaluate the operation of the combination of converters (TEA19161T, TEA19162T, and TEA1995T) in a single output supply, which includes all modes. The performance passes general standards, including the EuP lot6 requirements. It can be used as a starting point for further development.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 9 / 38

5 Performance measurements

5.1 Test facilities

• Oscilloscope: Yokogawa DL9140L

• AC Power Source: Agilent 6812B

• Electronic load: Agilent 6063B

• Digital power meter: Yokogawa WT210

5.2 Start-up behavior

The rise time of the output voltage (measured from 10 % to 90 % point of the nominal output) is between 6 ms and 10 ms. The rise time depends on the output current load.

a. Start-up at 230 V mains and no load (0 A) b. Start-up at 115 V mains and nominal load (20 A)

(1) PFC (2) HBC (3) V

out

(4) I

out

Figure 5. Start-up behavior

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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a. Start-up time = 381 ms at V

mains

= 230 V (RMS) mains

out

= 20 A)

b. Start-up time = 495 ms at V

mains

= 115 V (RMS) mains

out

= 20 A)

(1) V

SUPIC

(2) V

out

(3) V

bulk

(4) I

out

Figure 6. Start-up time at different mains voltages

Table 3. Start-up time

Condition Start-up time (ms)

115 V/60 Hz 470

230 V/50 Hz 380

requirement < 500

5.3 Efficiency

5.3.1 Efficiency characteristics

To determine the efficiency, the output voltage (not taking into account the losses in an output connection cable) on the TEA1916DB1262 demo board was measured.

Table 4. Efficiency results

Condition CoC efficiency

average requirement (%)

Average 25 % load 50 % load 75 % load 100 % load

115 V/60 Hz > 89 91.17 90.12 91.97 91.84 90.77

230 V/50 Hz > 89 92.6 91.06 93.29 93.2 92.71

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 11 / 38

aaa-022160

10 25 40 55 70 85 100

Load (%)

ηη

(%)(%)

(1)(1)

(2)(2)

1. V

mains

= 230 V (RMS)

2. V

mains

= 115 V (RMS)

Figure 7. Efficiency curve

aaa-022161

0 50 100 150 200 250

125

175

225

275

out

(W)

PinP

(W)(W)

(2)(2)

(1)(1)

1. V

mains

= 230 V (RMS)

2. V

mains

= 115 V (RMS)

Figure 8. Power consumption

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 12 / 38

5.3.2 No-load power consumption

Power consumption performance of the total application board at no load was measured with a Yokogawa WT210 digital power meter. To measure the power consumption over a long time, the integration time function was used.

Table 5. Output voltage and power consumption at no load

Condition ENERGY STAR 2.0

requirement

Output voltage Power consumption

115 V/60 Hz ≤ 500 mW 12.2 V 46 mW

230 V/50 Hz ≤ 500 mW 12.2 V 51 mW

5.3.3 Standby load power consumption

Power consumption performance of the total application board at standby load was measured with a Yokogawa WT210 digital power meter. To measure the power consumption over a long time, the integration time function was used.

Table 6. Output voltage and power consumption at no load

Condition ENERGY STAR 2.0

requirement

Output voltage Power consumption

115 V/60 Hz 250 mW 12.2 V 356 mW

230 V/50 Hz 250 mW 12.2 V 357 mW

Requirement < 500 mW

5.3.4 Power factor correction

Table 7. Output voltage and power consumption at no load

Condition ENERGY STAR 2.0

requirement

Output power Power factor

115 V/60 Hz ≥ 0.9 mW 240 W 0.992

115 V/60 Hz - 120 W 0.976

230 V/50 Hz - 240 W 0.945

230 V/50 Hz - 120 W 0.911

5.4 Low-power mode and burst mode operation

To reach a high efficiency at medium/low and standby output power, the low-power mode and burst mode are introduced.

In low-power mode, the behavior of the half-bridge converter is changed compared to the standard behavior at maximum output power. The result is a higher efficiency that is close to the expected efficiency at maximum load.

The power level for leaving the high-power mode and entering the low-power mode can be adjusted. Here the power level is set at 53.4 W.

Below 21.3 W, the HBC converter enters burst mode, which improves the overall efficiency at lower output loads.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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Finally, when the output power level is further reduced, the PFC converter enters burst mode.

The power supply consumes more power without low-power mode and burst mode.

a. PFC continues switching until regulation level is reached, swaps after that to normal mode when P

out

is low. The

measurement example shows the result at Pout = 13.8 W.

b. FC continues switching until regulation level is reached, then swaps to burst mode when P

out

is very low. The

measurement example shows the result at P

out

= 6.6 W.

(1) PFC (2) HBC (3) V

out

Figure 9. HBC burst mode operation after initial start-up

a. The “wait” time increases at lower output power when the HBC operates in low-power mode. The measurement example shows the result at P

out

= 22.5 W.

b. The “wait” time decreases at higher output power when the HBC operates in low-power mode. The measurement example shows the result at P

out

= 39.7 W.

(1) PFC (2) HBC (3) V

out

(4) I

out

Figure 10. HBC low-power mode operation

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.5 Operation mode transitions

(1) GATELS (2) GATEPFC (3) HBC (4) V

out(ripple)

(5) I

out

Figure 11. Transitions HP - LP - BM

Table 8. Mode transitions

Transition Power level

HP - LP 53.4 W

LP - BM 21.3 W

BM - LP 21.3 W

LP - HP 60.2 W

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.6 Output voltage ripple

(1) V

out

(AC)

(2) I

out

Figure 12. Maximum output voltage ripple in burst mode at 50 % duty cycle

The maximum output voltage ripple is 114 mV (peak-to-peak).

5.7 Dynamic load response

The dynamic load response test shows the result of constant load steps across the output. Output current of the converter is changed in steps of between 0 A and 20 A at a repetition frequency of 1 Hz, 10 Hz, 100 Hz, and 1000 Hz.

Table 9. Minimum and maximum output voltage at minimum-maximum load steps

Condition Load Minimum to maximum output

voltage

115 V/60 Hz Io: 0 % to 100 % 11.48 V to 12.47 V

230 V/50 Hz Io: 0 % to 100 % 11.48 V to 12.47 V

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 16 / 38

a. Basic sequential load step test is done at 1 Hz b. Basic sequential load step test is done at 10 Hz

c. Basic sequential load step test is done at 100 Hz d. Basic sequential load step test is done at 1 kHz

(1) V

out

(2) I

out

Figure 13. Output voltage during dynamic load test

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.8 OverPower Protection (OPP)

Tested with a higher current (dynamic overload) on the output voltage, OPP is activated when the current exceeds 25 A (300 W). This current corresponds with a load condition that is 25 % higher than the rated power for continuous use.

OPP allows a typical continuously maximum output current of 25 A during 50 ms. Any higher current, intended to run longer than 50 ms, triggers an OPP. After the 50 ms, a safe restart follows (OPP protection is reset).

The SNSCAP function of the TEA19161 detects OPP. This function monitors the voltage across the series capacitor (C211) of the half bridge.

The power capability limitation protection limits the maximum power to 360 W as long as the time is shorter than 50 ms.

a. OPP protection is triggered at I

out

≈ 27 A (output power is

lost during a safe restart)

b. OPP is not triggered at I

out

≈ 26 A

(1) V

out

(2) GATELS (3) HBC (4) I

out

Figure 14. Overpower protection

The power capability limitation level limits the maximum output power to typically 360 W as long as the time fits within the selected OPP timer. In this example, the time is shorter than 50 ms. So, when more output current is requested than accepted by the power capability limitation level, the output voltage drops.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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(1) V

out

(2) HBC (3) I

out

(4) GATELS

Figure 15. Power capability level

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.9 Hold time

The output was set to full load and the mains supply voltage of 115 V disconnected. The time that passes before the output voltage falls below 90 % of its initial value was measured. The hold time is 29 ms.

(1) V

line

(2) V

out

(3) I

out

(4) HBC

Figure 16. Hold time at V

MAINS

= 115 V and nominal load

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.10 Short-Circuit Protection (SCP)

The output was shorted before the resonant converter was connected to the mains. A short circuit across the output of the resonant converter increases primary current. The SNSCUR pin detects the increase. When this voltage exceeds ±1.5 V, the safe-restart protection is triggered. Approximately 4 ms after the HBC is started, the protection level is reached. Removing the short across the output resets the protection.

(1) SUPIC (2) HBC (3) SNSCUR

Figure 17. Safe-restart protection during shorted output

Table 10 shows the input power when the output is shorted.

Table 10. Input power when output power is shorted

Condition Pin (W)

115 V; 60 Hz 1.75

230 V; 50 Hz 1.70

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.11 OverVoltage Protection (OVP)

(1) V

out

(2) I

out

(3) SNSOUT

Figure 18. Overvoltage protection at V

out

= 14.1 V (SNSOUT triggers latched protection)

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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5.12 X-capacitor discharge time

The power line was unplugged at no-load. The discharge time was measured at the Xcapacitor (470 nF + 470 nF).

Table 11. X-capacitor discharge time test results

Condition From 264 * √2 to 135 V

X-capacitor discharge time 505 ms

(1) V

xcap

(2) V

out

(3) GATEPFC

Figure 19. X-capacitor discharge at 264 V (RMS)/50 Hz and no load

5.13 ElectroMagnetic Compatibility (EMC)

The conducted ElectroMagnetic Interference (EMI) of the TEA1916DB1262 prototype demo board was measured under the following conditions:

• Load resistor: 0.6 Ω; V

out

= 12.1 V; I

out

=20.1 A

• V

line

= 230 V/50 Hz or 120 V/50 Hz

The conducted EMI was measured both in the Line and Neutral. The product complies with the EMC standard.

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

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a. Line b. Neutral

Figure 20. Conducted EMI at V

line

= 230 V

RMS

a. Line b. Neutral

Figure 21. Conducted EMI at V

line

= 120 V

RMS

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 24 / 38

6 Schematic

aaa-022069

GATEPFC

GND

SUPREG

R101 10 MΩ 1 %

C104 470 nF 450 V

C103

1 µF

450 V

n.m.

C105 470 nF 450 V n.m.

C106 1 µF 450 V

CX101 470 nF

310 VAC

CX102 470 nF 310 VAC

LF102

6.8 mH

GDT4 n.m. 2051-20

GDT3 n.m. DSP-201M

GDT2 2051-20

BD101 GBU806

BD101

on heatsink

L103

100 µH, 5 A

GDT5 n.m. DSP-201M

GDT6 2051-20

GDT1 n.m. DSP-201M

431

R121

R102 10 MΩ 1 %

SNSCUR

SUPIC

SNSAUX

U101

TEA19162

PFCCOMP

SNSMAINS

SNSBOOST

360 kΩ

n.m.

F101

SS-5H-4A-APH

R198

0 Ω

D104

BAS416

R110

5.1 kΩ

R107

0.05 Ω

C107 47 pF 1 kV

R114 750 kΩ 1 %

C115 180 µF 450 V

R115

7.5 MΩ 1 %

R116

7.5 MΩ 1 %

C114 1 nF 50 V

R118 100 kΩ 1 %

C116 47 nF 630 V

C117 47 nF 630 V

on heat sink Q101 IPA60R190P6

R108

0.2 Ω

SNSBOOST

VBOOST

PG3

PG1 PG1

PG1

R120

3.9 kΩ 1 %

R113 100 kΩ

C110 470 nF 50 V

C109 150 nF 50 V

C111 10 pF 50 V n.m.

C112 10 nF 50 V

C113 100 nF 50 V

R112 33 kΩ

R111

3.6 kΩ n.m.

C108 100 pF 50 V

R103

4.7 Ω

D105

1N5408

WB102

923345-10

923345-04

WB101

L104

PQ32/20

PG3

PG1

PG3

R106

1 kΩ

R104

20 Ω

R196

0 Ω

D103

BAS316

D102

MURS360T3G

R197

0 Ω

R199

0 Ω

earth wire

E101 AWG18 earth

E103

AWG15

E104

AWG15

E102 mounting hole earth casing earth

PG3

PG3 PG3 PG1

Figure 22. Schematic TEA1916DB1262 240 W prototype demo board (PFC)

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 25 / 38

aaa-022070

VBOOST

SNSBOOST

WB201

WB202

C216 10 nF 500 V

923345-10 923345-03

R214

6.2 kΩ

R213

6.2 kΩ

WB208

923345-03

R231

6.2 kΩ

R202

10 Ω

R201

22 Ω

D201

BAS316

R232

6.2 kΩ CY201

2.2 nF 250 V

SUPHV

TEA1916T

NC1

GATELS

SUPREG

GND

SNSOUT

SNSFB

SUPIC

U201

GATEHS

PG1

D206

C213

330 nF

50 V

C218 680 pF 50 V

WB206

923345-05

R209 R208

WB205

923345-10

2.7 MΩ 2.2 MΩ

C222

R298

0 Ω

R206

56 kΩ, 1 %

R296

0 Ω

R299

0 Ω

120 pF

50 V n.m.

C209

1 nF 1 kV

R208

33 pF

1 kV

WB209

923345-05

n.m.

C210

2.2 nF 50 V

R229

Q203 BS170

R212

61.9 kΩ 1 %C212

33 nF

50 V

R211

6.8 kΩ 1 %

WB207

U202B VOL618A-3X001T

U203A VOL618A-3X001T

923345-05

SUPREG

0 Ω

R230

27 kΩ

MURS160

SUPHS

NC2

SNSSET

SNSCUR

SNSCAP

SNSBOOST

PG1

C207

5.1 nF 50 V

PG1

C219 680 pF 100 V

PG1

C203 47 pF

50 V

C204 470 nF 50 V

C214 1 µF 50 V

C215 10 µF 63 V

923345-06

WB203

R297 0 Ω

R207 10 kΩ 1 %

C206 47 µF 35 V

D203

BAS316

T1A

1 2

T1B D204 ES1D

D205 ES1D

PG1

SUPIC

PG1 PG1

SUPREG

PG1PG1

C221 10 nF 50 V

C211 33 nF 1 kV

C220 47 nF 1 kV n.m.

PG1

D208 BAS316 n.m.

PG1

R215 20 kΩ 1 %

PG2

PG1

R210

5.6 Ω

D207 BAS316 n.m.

PG1

0 Ω

n.m.

R234

180 kΩ

n.m.

R233

R204

10 Ω

R203

22 Ω

R205 180 kΩ 1 %

C201 330 pF 1 kV

Q201 and Q202

on heat sink

SG1

sparkgap

6.0 mm

HS for BD101, Q101, Q201 and Q202 TEA1916DB1252-PRI HS101

Lp = 600 µH Ls = 100 µH 35:3:3:2:2 prim: aux 1: aux 2: sec 1: sec 2

750315374 ETD34

Q201 SPA12N50C3

PG1

PG2 PG1

PG2

D202

923345-04

WB204

C202 330 pF 1 kV

Q202 SPA12N50C3

PG1

Figure 23. Schematic TEA1916DB1262 240 W prototype demo board (LLC)

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TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 26 / 38

aaa-022072

T1C

GATEB

GND DSB SSB

GATEA

U301

R302

C302 2200 µF 16 V

WB301 923345-03

WB302 923345-04

mounting hole for wire; 20 A

AWG16 Vo

AWG16 GND

WB303 923345-03

C303 2200 µF 16 V

L302

Option:

replace coil by wire

L301

900 nH

R304

0 Ω

TEA1995T

VCC DSA SSA

1 2 3 4

8 7 6 5

R301

R303

0 Ω

C301

100 nF, 50 V

0 Ω

R306

20-2137

D301

BZX384-C3V3

U202B VOL618A-3X001T

U202A VOL618A-3X001T

D302 BAS316

Q301

PSMN1R8-40YLC

Q306 n.m.

PSMN2R2-40PS

Q302 PSMN1R8-40YLC Q307 n.m. PSMN2R2-40PS

R305

1.8 kΩ

AWG18

earth

wire

100 kΩ

C304 2200 µF 16 V

R307 39 kΩ

R309 51 Ω

C305

1.5 nF,50 V

R308

47 kΩ

C306

47 nF 50 V

R310 47 Ω

U302

AS431IBNTR-G1

R311 10 kΩ

Vout

mounting hole for wire; 20 A

CN302

22-23-2021

fan

Vout

Figure 24. Schematic TEA1916DB1262 240 W prototype demo board (synchronous rectifier)

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User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 27 / 38

7 Bill Of Materials (BOM)

Table 12. Bill Of Materials (BOM)

Reference Description and values Part number Manufacturer

BD101 bridge rectifier; 600 V; 8 A - -

C103 capacitor; not mounted; 1 μF; 10 %;

450 V; PET; THT

- -

C104 capacitor; 470 nF; 10 %; 450 V; PET;

THT

- -

C105 capacitor; not mounted; 470 nF; 10 %;

450 V; PET; THT

- -

C106 capacitor; 1 μF; 10 %; 450 V; PET;

THT

- -

C107 capacitor; 47 pF; 5 %; 1 kV; C0G;

1206

- -

C108 capacitor; 100 pF; 10 %; 50 V; X7R;

0603

- -

C109 capacitor; 150 nF; 10 %; 50 V; X7R;

0603

- -

C110 capacitor; 470 nF; 10 %; 50 V; X7R;

0805

- -

C111 capacitor; not mounted; 10 pF; 10 %;

50 V; X7R; 0603

- -

C112 capacitor; 10 nF; 10 %; 50 V; X7R;

0603

- -

C113 capacitor; 100 nF; 10 %; 50 V; X7R;

0603

- -

C114 capacitor; 1 nF; 10 %; 50 V; X7R;

0603

- -

C115 capacitor; 180 μF; 20 %; 450 V; ALU;

THT

- -

C116; C117 capacitor; 47 nF; 10 %; 630 V; X7R;

1210

- -

C201; C202 capacitor; 330 pF; 5 %; 1 kV; C0G;

1206

- -

C203 capacitor; 47 pF; 10 %; 50 V; X7R;

0805

- -

C204 capacitor; 470 nF; 10 %; 50 V; X7R;

0805

- -

C206 capacitor; 47 μF; 20 %; 35 V; ALU;

THT

- -

C207 capacitor; 5.1 nF; 5 %; 50 V; COG;

0603

- -

C208 capacitor; 33 pF; 5 %; 1 kV; C0G;

1206

- -

C209 capacitor; 1 nF; 5 %; 1 kV; C0G; 1812 - -

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Reference Description and values Part number Manufacturer

C210 capacitor; 2.2 nF; 10 %; 50 V; X7R;

0603

- -

C211 capacitor; 33 nF; 20 %; 1 kV; MKP - -

C212 capacitor; 33 nF; 10 %; 50 V; X7R;

0603

- -

C213 capacitor; 330 nF; 10 %; 50 V; X7R;

0805

- -

C214 capacitor; 1 μF; 10 %; 50 V; X7R;

0805

- -

C215 capacitor; 10 μF; 20 %; 63 V; ALU;

THT

- -

C216 capacitor; 10 nF; 10 %; 500 V; X7R;

1812

- -

C218 capacitor; 680 pF; 10 %; 50 V; X7R;

0603

- -

C219 capacitor; 680 pF; 5 %; 50 V; COG;

0603

- -

C220 capacitor; not mounted; 47 nF; 5 %;

1 kV; MKP

- -

C221 capacitor; 10 nF; 10 %; 50 V; X7R;

0805

- -

C222 capacitor; not mounted; 120 pF; 5 %;

50 V; COG; 0603

- -

C301 capacitor; 100 nF; 10 %; 50 V; X7R;

0603

- -

C302; C303; C304

capacitor; 2200 μF; 20 %; 16 V; ALU; THT

- -

C305 capacitor; 1.5 nF; 10 %; 50 V; X7R;

0603

- -

C306 capacitor; 47 nF; 10 %; 50 V; X7R;

0603

- -

CN302 header; straight; 2-way - -

CX101; CX102 capacitor; 470 nF; 20 %; 310 V (AC);

MKP; THT

- -

CY201 capacitor; 2.2 nF; 20 %; 250 V; CER;

THT

- -

D102 diode; 600 V; 3 A - -

D103; D201; D202; D203; D302

diode; 100 V; 250 mA - -

D104 diode; 85 V; 200 mA - -

D105 diode; 1 kV; 3 A - -

D204; D205 diode; 140 V; 1 A - -

D206 diode; 600 V; 1 A - -

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Reference Description and values Part number Manufacturer

D207; D208 diode; not mounted; 100 V; 250 mA - -

D301 diode; Zener; 3.3 V; 250 mA - -

F101 fuse; slow blow; 300 V (AC); 4 A - -

GDT2; GDT6 gas discharge tube; 200 V; THT - -

GDT4 gas discharge tube; not mounted - -

HS101 heat sink; primary - -

L103 inductor; 100 μH; 5 A 7447070 Würth Elektronik

L104 coil former; PQ32/20 750315487 Würth Elektronik

L301; L302 inductor; 900 nH - -

LF102 inductor; common mode; 6.8 mH;

3.2 A

- -

Q101 MOSFET-N; 600 V; 20.2 A - -

Q201; Q202 MOSFET-N; 560 V; 11.6 A - -

Q203 MOSFET-N; 60 V; 500 mA - -

Q301; Q302 MOSFET-N; 40 V; 100 A - -

Q306; Q307 MOSFET-N; not mounted; 40 V;

100 A

- -

R101; R102 resistor; 10 MΩ; 1 %; 250 mW; 1206 - -

R103 resistor; 4.7 Ω; 1 %; 63 mW; 0603 - -

R104 resistor; 20 Ω; 1 %; 63 mW; 0603 - -

R106 resistor; 1 kΩ; 1 %; 63 mW; 0603 - -

R107 resistor; 0.05 Ω; 1 %; 1 W; 2512 - -

R108 resistor; 0.2 Ω; 1 %; 1 W; 2512 - -

R110 resistor; 5.1 kΩ; 1 %; 63 mW; 0603 - -

R111 resistor; not mounted; 3.6 kΩ; 1 %;

63 mW; 0603

- -

R112 resistor; 33 kΩ; 1 %; 63 mW; 0603 - -

R113 resistor; NTC; 100 kΩ; 5 %; 500 mW - -

R114 resistor; 750 kΩ; 1 %; 250 mW; 1206 - -

R115; R116 resistor; 7.5 MΩ; 1 %; 250 mW; 1206 - -

R118 resistor; 100 kΩ; 1 %; 63 mW; 0603 - -

R120 resistor; 3.9 kΩ; 1 %; 63 mW; 0603 - -

R121 resistor; not mounted; 360 kΩ; 1 %;

63 mW; 0603

- -

R196; R197; R198; R199

resistor; jumper; 0 Ω; 250 mW; 1206 - -

R201; R203 resistor; 22 Ω; 1 %; 63 mW; 0603 - -

R202; R204 resistor; 10 Ω; 1 %; 63 mW; 0603 - -

R205 resistor; 180 kΩ; 1 %; 63 mW; 0603 - -

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Reference Description and values Part number Manufacturer

R206 resistor; 56 kΩ; 1 %; 63 mW; 0603 - -

R207 resistor; 10 kΩ; 1 %; 63 mW; 0603 - -

R208 resistor; 2.2 MΩ; 1 %; 250 mW; 1206 - -

R209 resistor; 2.7 MΩ; 1 %; 250 mW; 1206 - -

R210 resistor; 5.6 Ω; 1 %; 63 mW; 0603 - -

R211 resistor; 6.8 kΩ; 1 %; 63 mW; 0603 - -

R212 resistor; 61.9 kΩ; 1 %; 63 mW; 0603 - -

R213; R214; R231; R232

resistor; 6.2 kΩ; 1 %; 250 mW; 1206 - -

R215 resistor; 20 kΩ; 1 %; 63 mW; 0603 - -

R229 resistor; jumper; 0 Ω; 63 mW; 0603 - -

R230 resistor; 27 kΩ; 1 %; 63 mW; 0603 - -

R233 resistor; not mounted; 180 kΩ;

63 mW; 0603

- -

R234 resistor; jumper; not mounted; 0 Ω;

250 mW; 1206

- -

R296; R297; R298; R299

resistor; jumper; 0 Ω; 250 mW; 1206 - -

R301; R302; R303; R304

resistor; jumper; 0 Ω; 63 mW; 0603 - -

R305 resistor; 1.8 kΩ; 1 %; 63 mW; 0603 - -

R306 resistor; 100 kΩ; 1 %; 63 mW; 0603 - -

R307 resistor; 39 kΩ; 1 %; 63 mW; 0603 - -

R308 resistor; 47 kΩ; 1 %; 100 mW; 0603 - -

R309 resistor; 51 Ω; 1 %; 63 mW; 0603 - -

R310 resistor; 47 Ω; 1 %; 63 mW; 0603 - -

R311 resistor; 10 kΩ; 1 %; 63 mW; 0603 - -

SG1 spark gap; 6.0 mm - -

T1 transformer; ETD3 750315374 Würth Elektronik

U101 PFC driver; TEA19162T; SO8 - NXP Semiconductors

U201 LLC controller; TEA19161T; SO16 - NXP Semiconductors

U202; U203 optocoupler; NPN; 80 V; 60 mA - -

U301 synchronous rectifier controller; dual;

TEA1995T; SO8

- NXP Semiconductors

U302 Regulator; AS431 - -

WB102; WB201; WB205

wire bridge; 0.8 mm; P = 25.40 mm - -

WB101; WB204; WB302

wire bridge; 0.8 mm; P = 10.16 mm - -

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Reference Description and values Part number Manufacturer

WB202; WB208; WB301; WB303

wire bridge; 0.8 mm; P = 7.62 mm - -

WB203 wire bridge; 0.8 mm; P = 15.24 mm - -

WB206; WB207 wire bridge; 0.8 mm; P = 12.10 mm - -

WB209 wire bridge; not mounted; 0.8 mm;

P = 12.10 mm

- -

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8 Layout

a. Layout

b. Components

Figure 25. Demo board layout and components (copper tracks and areas)

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9 Transformer specifications

9.1 Resonant transformer

term numbers for reference only

36 max

dot locates term #1

26.5 max

2.5 min

36 max

lot code and date code

12 V, 10 A

dimensions in mm

70-120 kHz,

360-400 V

18 V, 30 mA

aaa-022216

Ø 0.8 (x12) part must insert fully to surface A in recommended grid

5.5

Ø 1.6 (x12)

Figure 26. Resonant transformer

Table 13. Resonant transformer specifications

Parameter Values Test conditions

DC resistance; 3-1 0.152 Ω; ±10 % at 20 °C

DC resistance; 8-10 maximum 0.005 Ω at 20 °C

DC resistance; 9-11 maximum 0.005 Ω at 20 °C

DC resistance; 6-5 0.122 Ω; ±10 % at 20 °C

DC resistance; 5-4 0.122 Ω; ±10 % at 20 °C

inductance; 3-1 600 μH; ±10 % 10 kHz; 100 mV; L

saturation current; 3-1 1.7 A 20 % roll-off from initial

leakage inductance; 3-1 100 μH; ±10 % tie(4+5+6, 8+9+10+11);

100 kHz; 100 mV; L

dielectric; 1-11 3200 V (AC); 1 minute tie(3+4, 10+11); 4000 V (AC);

1 s

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Parameter Values Test conditions

(3-1):(9-11)turns ratio 17.5:1; ±1 %

(3-1):(8-10)

(3-1):(6-5)turns ratio 11.67:1; ±1 %

(3-1):(5-4)

9.2 PFC coil

dimensions in mm

aaa-022217

dot locates term #1

lot code and date code

Ø 0.8 (x12) part must insert fully to surface A in recommended grid

term numbers for reference only

30.48

5.08

7.62

Ø 1.6 (x12)

auxiliaryprimary

recommended

P.C. pattern component side

37.34 max

35.56 max

24.13 max

2.8 min

Note: Pin 4 is connected to the core. Marking PFC: "750315487"

Figure 27. PFC coil

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Table 14. PFC coil specifications

Parameter Value Condition

Electric specifications

DC resistance; 3-4 0.048 Ω; ±20 % at 20 °C

DC resistance; 9-10 0.060 Ω; ±20 % at 20 °C

inductance; 9-10 130 μH; ±5 % 10 kHz; 100 mV; L

saturation current; 9-10 13 A 20 % roll-off from initial

leakage inductance; 9-10 52 μH (typical);

maximum 75 μH

tie(3+4); 100 kHz; 100 mV; L

dielectric; 3-10 1500 V (AC); 1 s

turns ratio 30:1; ±1 % (9-10):(4-3)

General specifications

operating temperature −40 °C to +125 °C including temperature rise

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10 Abbreviations

Table 15. Abbreviations

Acronym Description

BCM Boundary Conduction Mode

CMP Capacitive Mode Protection

EMC ElectroMagnetic Compatibility

EMI ElectroMagnetic Interference

HBC Half-Bridge Converter

MOSFET Metal-Oxide Semiconductor Field-Effect Transistor

OCP OverCurrent Protection

OPP OverPower Protection

OVP OverVoltage Protection

OLP Open-Loop Protection

PCB Printed-Circuit Board

PFC Power Factor Correction

RMS Root Mean Square

SOI Silicon-On Insulator

ZVS Zero-Voltage Switching

11 References

1 TEA19161T data sheet Digital controller for high-efficiency resonant power supply; 2016,

NXP Semiconductors

2 TEA19162T data sheet PFC controller; 2016, NXP Semiconductors 3 TEA1995T data sheet GreenChip dual synchronous rectifier controller; 2015, NXP

Semiconductors

NXP Semiconductors

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12 Legal information

12.1 Definitions

Draft — The document is a draft version only. The content is still under

internal review and subject to formal approval, which may result in modifications or additions. NXP Semiconductors does not give any representations or warranties as to the accuracy or completeness of information included herein and shall have no liability for the consequences of use of such information.

12.2 Disclaimers

Limited warranty and liability — Information in this document is believed

to be accurate and reliable. However, NXP Semiconductors does not give any representations or warranties, expressed or implied, as to the accuracy or completeness of such information and shall have no liability for the consequences of use of such information. NXP Semiconductors takes no responsibility for the content in this document if provided by an information source outside of NXP Semiconductors. In no event shall NXP Semiconductors be liable for any indirect, incidental, punitive, special or consequential damages (including - without limitation - lost profits, lost savings, business interruption, costs related to the removal or replacement of any products or rework charges) whether or not such damages are based on tort (including negligence), warranty, breach of contract or any other legal theory. Notwithstanding any damages that customer might incur for any reason whatsoever, NXP Semiconductors’ aggregate and cumulative liability towards customer for the products described herein shall be limited in accordance with the Terms and conditions of commercial sale of NXP Semiconductors.

Right to make changes — NXP Semiconductors reserves the right to make changes to information published in this document, including without limitation specifications and product descriptions, at any time and without notice. This document supersedes and replaces all information supplied prior to the publication hereof.

Suitability for use — NXP Semiconductors products are not designed, authorized or warranted to be suitable for use in life support, life-critical or safety-critical systems or equipment, nor in applications where failure or malfunction of an NXP Semiconductors product can reasonably be expected to result in personal injury, death or severe property or environmental damage. NXP Semiconductors and its suppliers accept no liability for inclusion and/or use of NXP Semiconductors products in such equipment or applications and therefore such inclusion and/or use is at the customer’s own risk.

Applications — Applications that are described herein for any of these products are for illustrative purposes only. NXP Semiconductors makes no representation or warranty that such applications will be suitable for the specified use without further testing or modification. Customers are responsible for the design and operation of their applications and products using NXP Semiconductors products, and NXP Semiconductors accepts no liability for any assistance with applications or customer product design. It is customer’s sole responsibility to determine whether the NXP Semiconductors product is suitable and fit for the customer’s applications and products planned, as well as for the planned application and use of customer’s third party customer(s). Customers should provide appropriate design and operating safeguards to minimize the risks associated with their applications and products. NXP Semiconductors does not accept any liability related to any default, damage, costs or problem which is based

on any weakness or default in the customer’s applications or products, or the application or use by customer’s third party customer(s). Customer is responsible for doing all necessary testing for the customer’s applications and products using NXP Semiconductors products in order to avoid a default of the applications and the products or of the application or use by customer’s third party customer(s). NXP does not accept any liability in this respect.

Export control — This document as well as the item(s) described herein may be subject to export control regulations. Export might require a prior authorization from competent authorities.

Evaluation products — This product is provided on an “as is” and “with all faults” basis for evaluation purposes only. NXP Semiconductors, its affiliates and their suppliers expressly disclaim all warranties, whether express, implied or statutory, including but not limited to the implied warranties of non-infringement, merchantability and fitness for a particular purpose. The entire risk as to the quality, or arising out of the use or performance, of this product remains with customer. In no event shall NXP Semiconductors, its affiliates or their suppliers be liable to customer for any special, indirect, consequential, punitive or incidental damages (including without limitation damages for loss of business, business interruption, loss of use, loss of data or information, and the like) arising out the use of or inability to use the product, whether or not based on tort (including negligence), strict liability, breach of contract, breach of warranty or any other theory, even if advised of the possibility of such damages. Notwithstanding any damages that customer might incur for any reason whatsoever (including without limitation, all damages referenced above and all direct or general damages), the entire liability of NXP Semiconductors, its affiliates and their suppliers and customer’s exclusive remedy for all of the foregoing shall be limited to actual damages incurred by customer based on reasonable reliance up to the greater of the amount actually paid by customer for the product or five dollars (US$5.00). The foregoing limitations, exclusions and disclaimers shall apply to the maximum extent permitted by applicable law, even if any remedy fails of its essential purpose.

Safety of high-voltage evaluation products — The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/or ignition of fire. This product is intended for evaluation purposes only. It shall be operated in a designated test area by personnel that is qualified according to local requirements and labor laws to work with non-insulated mains voltages and high-voltage circuits. The product does not comply with IEC 60950 based national or regional safety standards. NXP Semiconductors does not accept any liability for damages incurred due to inappropriate use of this product or related to non-insulated high voltages. Any use of this product is at customer’s own risk and liability. The customer shall fully indemnify and hold harmless NXP Semiconductors from any liability, damages and claims resulting from the use of the product.

Translations — A non-English (translated) version of a document is for reference only. The English version shall prevail in case of any discrepancy between the translated and English versions.

12.3 Trademarks

Notice: All referenced brands, product names, service names and trademarks are the property of their respective owners.

GreenChip — is a trademark of NXP B.V.

NXP Semiconductors

UM10972

TEA1916DB1262 digital resonant 240 W/12 V power supply demo board

Please be aware that important notices concerning this document and the product(s) described herein, have been included in section 'Legal information'.

For more information, please visit: http://www.nxp.com For sales office addresses, please send an email to: salesaddresses@nxp.com

Date of release: 8 June 2018

Document identifier: UM10972

Contents

1 Introduction ......................................................... 3

1.1 TEA19161T and TEA19162T ............................ 3

1.1.1 Pinning ............................................................... 4

1.2 TEA1995T .......................................................... 4

2 Safety warning .................................................... 5

3 Specifications ...................................................... 6

4 Board photographs .............................................7

5 Performance measurements .............................. 9

5.1 Test facilities ...................................................... 9

5.2 Start-up behavior ............................................... 9

5.3 Efficiency ..........................................................10

5.3.1 Efficiency characteristics ................................. 10

5.3.2 No-load power consumption ............................ 12

5.3.3 Standby load power consumption ....................12

5.3.4 Power factor correction ....................................12

5.4 Low-power mode and burst mode operation ....12

5.5 Operation mode transitions ............................. 14

5.6 Output voltage ripple ....................................... 15

5.7 Dynamic load response ................................... 15

5.8 OverPower Protection (OPP) ...........................17

5.9 Hold time ......................................................... 19

5.10 Short-Circuit Protection (SCP) ......................... 20

5.11 OverVoltage Protection (OVP) .........................21

5.12 X-capacitor discharge time .............................. 22

5.13 ElectroMagnetic Compatibility (EMC) .............. 22

6 Schematic .......................................................... 24

7 Bill Of Materials (BOM) .....................................27

8 Layout .................................................................32

9 Transformer specifications .............................. 33

9.1 Resonant transformer ...................................... 33

9.2 PFC coil ...........................................................34

10 Abbreviations .................................................... 36

11 References ......................................................... 36

12 Legal information ..............................................37

NXP Semiconductors UM10972 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual