NXP Semiconductors UM10972 User Manual

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).

NXP Semiconductors

UM10972

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

NXP Semiconductors

UM10972

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

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 3 / 38

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.

NXP Semiconductors

UM10972

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

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 4 / 38

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

NXP Semiconductors

UM10972

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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UM10972

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

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 6 / 38

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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UM10972

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

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 7 / 38

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.

NXP Semiconductors

UM10972

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

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

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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UM10972

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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UM10972

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

User manual Rev. 1.1 — 8 June 2018 COMPANY PUBLIC 10 / 38

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

NXP Semiconductors

UM10972

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

NXP Semiconductors

UM10972

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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