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january 2009 rev 1 1/35 an2852 application note EVL6591-90WADP: 90 w ac-dc asymmetrical half-bridge adapter using l6591 and l6563 introduction this document describes the characteristics and performance of a 90 w wide range input ac-dc adapter based on asymmetrical half-bridge topology (ahb). the converter comprises a two-stage approach: a pfc front-end stage using the l6563 tm pfc controller and a dc-dc stage that implements the asymmetrical half-bridge (ahb) topology driven by the l6591, the new pwm controller dedicated to this architecture. thanks to the ahb topology, the system offe rs good electrical performance (epa 2.0 compliant) with a low-voltage and high-current output (12 v - 7.5 a). the order code for this demonstration board is EVL6591-90WADP. figure 1. EVL6591-90WADP demonstration board am01816v1 www.st.com
contents an2852 2/35 contents 1 main characteristics and cir cuit description . . . . . . . . . . . . . . . . . . . . . 4 2 operating waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 asymmetrical half-bridge (ahb) typical wave forms . . . . . . . . . . . . . . . . . . 7 2.2 low-load operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3 short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.4 overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.5 startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 electrical performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.1 efficiency measurement and no-load consumpt ion . . . . . . . . . . . . . . . . . 17 3.2 harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4 thermal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5 conducted noise measur ements (pre-compliance test) . . . . . . . . . . . 24 6 bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 7 pfc coil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7.1 electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7.2 mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 8 ahb transformer specificatio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8 .1 electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8 .2 mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9 pcb layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 10 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
an2852 list of figures 3/35 list of figures figure 1. EVL6591-90WADP demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 figure 2. EVL6591-90WADP schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 figure 3. ahb primary side key waveforms at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 figure 4. detailed ahb zero-voltage switching at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 figure 5. detailed ahb zero-voltage switching at half load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 6. ahb secondary side key waveforms at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 7. burst mode at no load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 figure 8 . detailed burst mode at no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 figure 9. load transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 figure 10. detailed short-circuit behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 11. hiccup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 12. detailed ovp intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 13. ovp intervention: system is latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 14. complete startup sequence at 115vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 15. detailed startup sequence at 115vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 16. efficiency vs. o/p power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 figure 17. no-load consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 figure 1 8 . en61000-3-2 measurements at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 figure 19. jeida-miti measurements at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 figure 20. en61000-3-2 measurements at 75 w input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 figure 21. jeida-miti measurements at 75 w input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 figure 22. pf vs. input voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 23. thd vs. input voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 24. thermal map at 115vac - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 25. thermal map at 230vac - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 26. ce peak measure at 115vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 figure 27. ce peak measure at 230vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 figure 2 8 . electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 figure 29. bottom view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 figure 30. electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 figure 31. windings position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 figure 32. top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 figure 33. topside silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 figure 34. bottomside silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 figure 35. copper traces (bottomside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
main characteristics and circuit description an2852 4/35 1 main characteristics and circuit description the main characteristics of the smps adapter are as follows: input mains range ?vin: 88 ~ 264 vrms ? f: 45 ~ 66 hz output: 12vdc 2% - 7.5 a no-load: pin below 0.35 w protections ? short-circuit ?overload ? ouput overvoltage ? brownout pcb type and size ?cem-1 ? single-side 70 m ? 174 x 7 8 mm safety: according to en60065 emi: according to en50022 - class b the adapter implements a two-stage solution. the front-end pfc uses a boost topology working in transition mode (tm). the ic used is the l6563, advanced tm pfc controller, which integrates all the functions and protection needed to control the stage and an interface with the downstream dc-dc converter. the power stage of the pfc comprises inductor l2, mosfet q1, diode d4 and capacitor c9. the pfc circuit is quite standard and already well described in previous st application notes. therefore this note will focus on the ahb stage and its c ontroller, the l6591. this dc- dc converter comprises a half-bridge (mosfet q3 and q4) connected to the output voltage of the pfc stage that drives the series connection of a dc blocking capacitor (c44) and the primary of the transformer (t1). the transformer has two secondary windings with a center tap connection tied to ground. the other ends are connected to the output diodes d12 and d13. the output inductor is between the common cathode of diodes d12 and d13 and the output. the l6591 includes a current mode pwm controller (fixed-frequency solution), gate drivers for both low and high-side mosfets with integrated bootstrap diode and all the functions and protections tailored for this topology. the device is housed in an so-16 narrow package. this adapter uses the magnetizing current and the output inductor current ripple to obtain the correct primary current direction to achieve zero-voltage switching (zvs) at turn-on of both mosfets. the transformer construction is quite simple as it is a layer type with the primary winding split in two parts (sandwich configuration) and two secondary windings. the primary leakage inductance is about 3% of the magnetizing inductance. the half-bridge is operated at fixed frequency with complementary duty cycles on the two mosfets. the high-side fet is on during the d time and the low-side fet is on for the 1-d time. c44 is calculated in order to have a resonance frequency due to lm and c44 well below the switching frequency (that, in this application, has been set at about 100 khz). in this way the voltage on c44 is nearly constant and equal to vin x d where vin is the high-voltage input
an2852 main characteristics and circuit description 5/35 bus and d is the duty cycle. for stability reason s related to the topolo gy, the ic limits the maximum duty cycle at 50%. the current in the primary tank circuit is read by the controller thanks to the se nse resistors r 8 1 and r 8 2. the self supply is ba sically obtained thanks to an auxiliary winding on the ahb transformer. a small charge pump on t he auxiliary windings of the pfc inductor helps during the startup phase. a pin dedicated to startup sequencing, a spare latched protection (dedicated here to output overvoltage protection), the soft-start function, the overload protection, an interface with the pfc controller and the integrated high-voltage startup generator complete the features of the l6591. all the functions and protections are detailed in the following sections.
main characteristics and circuit description an2852 6/35 figure 2. EVL6591-90WADP schematic am01817v1 r54 0r0 r87 n.m. 1 2 3 j1 inp u t connector f1 t4a c1 470nf c2 2n2 c 3 2n2 c4 470nf -+ d1 gbu6j r91 75k + c17 n.m. 2 4 9 10 12 14 5 6 t1 ahb tr a fo d21 1n4148 r95 47r c50 100nf 1 5 4 8 l1 86a-516 3 + c51 22 u f r55 0r0 1 2 u 3 a pc817 jp9 n.m. 1 2 j2 o u tp u t connector r97 n.m. c5 470nf 400v r101 0r0 88 - 264v a c d29 ll4148 r8 3 6k8 c45 220pf d24 ll4148 c16 1n0 inv 1 comp 2 mult 3 c s 4 vff 5 tbo 6 pfc_ok 7 pwm_latch 8 pwm_ s to p 9 run 10 zcd 11 gnd 12 gd 1 3 vcc 14 u1 l656 3 d27 ll4148 r75 56r line 1 di s 2 i s en 3 ss 4 o s c 5 vref 6 comp 7 pfc_ s to p 8 vcc 9 lvg 10 gnd 11 n.c. 12 fgnd 1 3 hvg 14 boot 15 hv s ta r t 16 u2 l6591 d28 bzv55-b11 2 3 1 q10 bc847c 2 3 1 q11 bc847c r24 1.8k r25 4.7k 4 3 u5b pc817 r29 100k r 3 0 2k2 c 3 9 100nf c4 3 10nf r96 470 r99 15k + c15 22 u f c21 2n2 4 3 u 3 b pc817 r85 220k + c46 1000 u f 25v c56 100nf r1 1m0 r2 1m2 r86 33 k q1 s tp12nm50fp r74 10r c11 10nf r9 3 3 k 3 + c9 47 u f 450v + c57 100 u f r17 0r0 r90 0r0 r14 18k c49 33 0pf c59 470pf r21 27r d12 s tp s 16l40ct r84 220r d1 3 s tp s3 0100 s t c54 1 u f r18 56k 8 5 10 3 l2 700 u h c14 100nf c1 3 1 u f r89 100k c52 100nf r7 680k r27 470 r8 680k l 3 3 . 3u h r10 15k r46 100k r9 82k r22 0r47 r 3 680k r2 3 0r47 r5 3 0r0 1 2 u5a pc817 r82 0r82 d20 n.m. c10 1n0 c22 220pf d26 s tp s 1l60a c48 6.8nf 2 3 1 q9 nm c40 10nf 3 2 1 u4 t s3 4 3 1 r81 0r82 r72 10r c20 2n2 r77 56r + c61 n.m. r15 150k r26 240k r79 100k d 3 1n4005 + c62 n.m. r71 10r r88 2k2 r94 12r d25 bzv55-b1 3 q 3 s tp12nm50fp d4 s tth 2l06 d2 3 ll4148 q4 s tp12n m50fp c41 4n7 r20 0r0 c47 2.2nf r6 2r5 c42 100nf c12 470nf c58 1n8 r100 0r0 c5 3 n.m. r19 56k r11 3 m0 c55 n.m. r69 n.m. r7 3 100k r12 3 m0 r1 3 8.2k r98 220k r70 33 r r28 24k9 r78 19k6 c44 220nf 250v 12v-7.5a r80 1k0 d22 ll4148
an2852 operating waveforms 7/35 2 operating waveforms 2.1 asymmetrical half-bridge (ahb) typical waveforms as mentioned before, this application note focuses on the ahb stage. this dc-dc converter has the 400 v pfc bus as input and delivers 12 v at the output. in figure 3 the primary side key waveforms with full load applied are shown. figure 4 shows the detail of the two transitions during one switching cycle. when the lvg signal goes down, the current is negative and so the half-bridge node (that has a certain capacitance value due to the coss of the mosfets and the stray capacitance of the circuit) is charged up to 400 v. after the deadtime has elapsed the high-side driver is turned on with zero volts across the high-side mosfet drain-source pins. the driver activation is visible on the hvg signal when there is the small voltage step on the high part of the waveform. when the high-side driver is turned off, the primary current is positive, so the half-bridge node is discharged down to zero volts and t he body diode of q4 is activated. after the deadtime the lvg turns on in zvs condition. figure 3. ahb primary side ke y waveforms at full load typically, in the ahb topology, the most critical transition is the one between lvg turn-off and hvg turn-on. in fact it is visible that the current available to move the half-bridge point is less with respect to the other transition. this is due to the magnetizing current that is not symmetrical with an average value of zero amps but has a certain offset due to the asymmetrical driving of the tank circuit. the fast current variation during transitions is due to the reversal of the current direction in the secondary windings. the effort in this design was to maintain a negative current after am01818v1 ch1: lvg pin volt a ge (yellow) ch 3 : hvg pin volt a ge (p u rple) ch4: prim a ry winding c u rrent (green)
operating waveforms an2852 8 /35 the positive variation at lvg turn-off. this was done by a correct design of the magnetizing current, output inductor current ripple and choice of turns ratio. figure 4. detailed ahb zero-voltage switching at full load the zvs condition is harder to meet as the load increases, so full load is the worst condition to have for a correct zvs operation. in figure 5 the same waveforms are shown with half load. since the output current is reduced, the fast primary side current variations are also reduced and so the magnetizing current (that remains basically the same if the load changes) becomes proportionally higher. the result is that there is more current available for moving the half-bridge node. am01819v1 ch1: lvg pin volt a ge (yellow) ch 3 : hvg pin volt a ge (p u rple) ch4: prim a ry winding c u rrent (green)
an2852 operating waveforms 9/35 figure 5. detailed ahb zero-voltage switching at half load the key waveforms at the secondary side are shown in figure 6 . it is interesting to note that, while the current is swapped between the two diodes, the voltage at their cathode is nearly zero. figure 6. ahb seconda ry side key waveforms at full load am01820v1 ch1: lvg pin volt a ge (yellow) ch 3 : hvg pin volt a ge (p u rple) ch4: prim a ry winding c u rrent (green) am01821v1 ch1: d12 a nd d1 3 common c a thode volt a ge (yellow) ch 3 : fgnd pin volt a ge (p u rple) ch4: diode d1 3 c u rrent (green) ch2: diode d12 c u rrent ( b l u e)
operating waveforms an2852 10/35 another peculiarity of this topology is that, since it is asymmetrical, the diode d13 has to carry higher average and rms current and sustain higher reverse voltage with respect to diode d12. this implies that d13 dissipates a lot more than d12 and makes sense, in order to improve efficiency and save money, to have a synchronous rectification only on d13. 2.2 low-load operation at light loads (and no-load) cond itions the system enters a cont rolled burst mode operation, allowing input power reduction. the burst mode is activated according to the comp pin level. in figure 7 and figure 8 the burst mode operation with no load is shown. under a certain load also the pfc stage works in burst mode operation (specifically the pfc enters in burst mode for a load value higher than the one for the ahb). using the pfc_stop pin of the l6591 and the pfc_ok pin of the l6563, a simple interface is built in order to keep the burst modes of the two ics synchronized. this operation allows fast response to a heavy load transition since the pfc is already on wh en the power is needed. this avoids output voltage dips. the load transition from 0 to 100% and vice versa can be seen in figure 9 . figure 7. burst mode at no load am01822v1 ch1: lvg pin volt a ge (yellow) ch 3 :pfc o u tp u t volt a ge ch4: comp pin volt a ge (green) ch2: q1 (pfc mo s fet) g a te ( b l u e)
an2852 operating waveforms 11/35 figure 8. detailed burst mode at no load figure 9. load transitions am0182 3 v1 ch1: lvg pin volt a ge (yellow) ch 3 :pfc o u tp u t volt a ge ch4: l656 3 pfc_ok pin volt a ge (green) ch2: q1 (pfc mo s fet) g a te ( b l u e) am01824v1 ch4: o u tp u t c u rrent (green) ch2: o u tp u t volt a ge ( b l u e)
operating waveforms an2852 12/35 2.3 short-circuit protection a short-circuit at the output activates the overload protection (olp). figure 10 shows the pins involved in this function. when the short-circuit is applied, the comp pin saturates high. the ic detects this condition and starts charging the ss capacitor. when the ss voltage reaches 5 v, the system shuts down . diode d29 allows the ss voltage to be clamped at about 5.4 v and the protection has an auto-restart behavior. if the short circuit is not removed, the ic enters the hiccup mode ( figure 11 ). when the ic is stopped by the olp, the high-voltage startup generator is invoked only when vcc falls to 5 v (v ccrestart ). thanks to this approach, the period between two restart trials is quite long which reduces the stress on power components. figure 10. detailed short-circuit behavior am01825v1 ch1: ss pin volt a ge (yellow) ch2: comp pin volt a ge ( b l u e) ch 3 : fgnd pin volt a ge (p u rple) ch4: pfc_ s top pin volt a ge (green)
an2852 operating waveforms 13/35 figure 11. hiccup mode 2.4 overvoltage protection since it is impossible to sense the output voltage from the primary side in all load conditions, the ovp senses such voltage directly on the output. a zener diode (d25) is used as the threshold to activate the protection. the information is passed to the controller using optocoupler u5 that increases the disable pin voltage over the intervention threshold of 4.5 v. in figure 12 a loop failure is simulated by shorting r93. the overvoltage protection is invoked and the output voltage reaches a maximum voltage of 14. 8 v. since this protection uses the disable pin, it is latched. hence, after pwm is stopped, the hv generator is invoked to keep vcc voltage between 14 v and 13.5 v. diode d27 brings the pfc_ok pin voltage over 2.5 v, so the l6563 is also shut down and its consumption goes almost to the startup level. the pwm_latch goes high which also keeps the disable pin high. the latched operation is shown in figure 13 . am01826v1 ch1: ss pin volt a ge (yellow) ch2: comp pin volt a ge ( b l u e) ch 3 : fgnd pin volt a ge (p u rple) ch4: pfc_ s top pin volt a ge (green)
operating waveforms an2852 14/35 figure 12. detailed ovp intervention figure 13. ovp intervention: system is latched am01827v1 ch1: o u tp u t volt a ge (yellow) ch2: vcc pin volt a ge ( b l u e) ch 3 : fgnd pin volt a ge (p u rple) ch4: di s able pin volt a ge (green) am01828v1 ch2: vcc pin volt a ge ( b l u e) ch4: di s able pin volt a ge (green)
an2852 operating waveforms 15/35 2.5 startup sequence in this converter the startup sequence is quit e particular and merits a detailed explanation. when the mains is plugged in, the rectified input voltage is present on bulk capacitor c9. since this value is greater than 8 0 v, the hv startup generator of the l6591 is turned on and vcc capacitors are charged with a constant current of about 0.75 ma. this charge time is therefore independent of input voltage level. the l6563 has a turn-on threshold lower than that of l6591, so the pfc controller starts first. the hv startup current is insufficient to power the l6563, so a small charge pump (r70, c40, d21 and d22) is connected to the pfc inductor auxiliary winding. with this circuit, when the l6563 starts, both vcc voltage and pfc output voltage increase. once vcc > 14 v and line pin voltage is greater than 1.25 v, the l6591 also turns on. at this point the charge pump is insuffi cient to sustain vcc current of both ics and so an auxiliary winding on the ahb transformer is used to provide, together with the charge pump, the power requested by the devices. the complete sequence is shown in figure 14 , while the details of the turn-on of both ics are shown in figure 15 . both figures show the startup at 115vac mains input. the startup at 230vac is very similar, the only difference is that the vcc voltage during steady state operation is a little higher since the charge pump delivers more current. figure 14. complete startup sequence at 115vac and full load am01829v1 ch1: lvg volt a ge (yellow) ch2: vcc pin volt a ge ( b l u e) ch 3 : pfc o u tp u t volt a ge (p u rple) ch4: o u tp u t volt a ge (green)
operating waveforms an2852 16/35 figure 15. detailed startup sequence at 115vac and full load am018 3 0v1 ch1: lvg volt a ge (yellow) ch2: vcc pin volt a ge ( b l u e) ch 3 : pfc o u tp u t volt a ge (p u rple) ch4: o u tp u t volt a ge (green)
an2852 electrical performance 17/35 3 electrical performance 3.1 efficiency measurement and no-load consumption ta bl e 1 and 2 give the efficiency measurements taken at the two nominal voltages. table 1. efficiency at 115vrms load [%] iout [a] vout [v ] pout [w] pin [w] eff [%] 5% 0.3746 12.12 4.54 6. 8 0 66.77% 10% 0.7507 12.11 9.09 12.10 75.13% 20% 1.5037 12.10 1 8 .19 21.9 88 2.7 8 % 25% 1. 8 7 8 7 12.09 22.71 26. 8 3 8 4.66% 40% 3.0037 12.09 36.31 41.49 8 7.53% 50% 3.7537 12.0 8 45.34 51.41 88 .20% 60% 4.5037 12.0 8 54.40 61.44 88 .55% 75% 5.62 8 7 12.07 67.94 76.67 88 .61% 8 0% 6.0037 12.07 72.46 8 1.77 88 .62% 100% 7.5037 12.06 90.49 102.4 888 .30% table 2. efficiency at 230vrms load [%] iout [a] vout [v ] pout [w] pin [w] eff [%] 5% 0.3746 12.12 4.54 6.5 8 6 8 .97% 10% 0.7507 12.11 9.09 12.41 73.26% 20% 1.5037 12.10 1 8 .19 22.30 8 1.59% 25% 1. 8 7 8 7 12.09 22.71 27.02 8 4.06% 40% 3.0037 12.0 8 36.2 8 41.37 8 7.71% 50% 3.7537 12.0 8 45.34 51.05 88 . 8 2% 60% 4.5037 12.07 54.36 60. 8 3 8 9.36% 75% 5.62 8 7 12.07 67.94 75.60 8 9. 8 7% 8 0% 6.0037 12.07 72.46 8 0.56 8 9.95% 100% 7.5037 12.06 90.49 100.55 90.00%
electrical performance an2852 1 8 /35 the efficiency taken at 25%, 50%, 75% and 100% of rated load allows calculating the average efficiency required by the energy star ? specification. ta bl e 4 shows the no-load consumption. the adapter has good values (about 300 mw at 230vac), considering that it is a two-stage system with the pfc stage always on. this adapter meets the two conditions required by energy star ? specification version 2.0 (average efficiency > 8 7% and no-load input power < 0.5 w) for an external power supply (eps). theref ore this smps is epa 2.0 compliant. figure 16 shows the graph of the efficiency vs. output power while figure 17 shows the graph of the input power vs. input voltage with no load applied. figure 16. efficiency vs. o/p power table 3. average efficiency for epa vin [vrms] average efficiency for epa 115 8 7.44% 230 88 .19% table 4. no-load consumption vin [vac] 90 115 135 1 8 0 230 264 pin [w] 0.215 0.225 0.235 0.255 0.290 0.315 am018 3 1v1 efficiency 66.00 % 68.00 % 70.00 % 72.00 % 74.00 % 76.00 % 78.00 % 80.00 % 82.00 % 84.00 % 86.00 % 88.00 % 90.00 % 92.00 % 020406080100 o u tp u t power [w] 115v a c 2 3 0v a c
an2852 electrical performance 19/35 figure 17. no-load consumption some measurements with low output loads were also taken, refer to ta bl e 5 and ta b l e 6 . table 5. low-load efficiency at 115vrms pout [w] iout [ma] vout [v] pin [w] eff [%] 1.50 124.50 12.12 2.696 55.97% 1.00 8 2.50 12.12 1. 88 3 53.10% 0.50 42.02 12.12 1.076 47.31% 0.25 21.05 12.11 0.654 3 8 .9 8 % table 6. low-load efficiency at 230vrms pout [w] iout [ma] vout [v] pin [w] eff [%] 1.50 124.50 12.12 2.59 8 5 8 .0 8 % 1.00 8 2.50 12.12 1. 8 02 55.49% 0.50 42.02 12.12 1.0 8 746. 8 3% 0.25 21.05 12.11 0.704 36.21% am018 3 2v1 0.000 0.050 0.100 0.150 0.200 0.250 0. 3 00 0. 3 50 50 100 150 200 250 3 00 inp u t volt a ge [v a c] inp u t power [w]
electrical performance an2852 20/35 3.2 harmonic content measurement the front-end pfc stage provides the reduction of the mains harmonic, allowing meeting european en61000-3-2 and japanese jeida-miti standards for class d equipment. figure 18 and 19 show the harmonic contents of the mains current at full load. a measure has been done also with 75 w input power which is the lower limit for using harmonic reduction techniques. figure 18. en61000-3-2 measurements at full load figure 19. jeida-miti measurements at full load am018 33 v1 0.0001 0.001 0.01 0.1 1 1 3 579111 3 15 17 19 21 2 3 25 27 29 3 1 33 3 5 3 7 3 9 h a rmonic order (n) h a rmonic c u rrent (a) me asu rement s @ 2 3 0v a c f u ll lo a d en61000- 3 -2 cl ass d limit s am018 3 4v1 0.0001 0.001 0.01 0.1 1 10 1 3 579111 3 15 17 19 21 2 3 25 27 29 3 1 33 3 5 3 7 3 9 h a rmonic order (n) h a rmonic c u rrent (a) me asu rement s @ 100v a c f u ll lo a d jeida-miti cl ass d limit s figure 20. en61000-3-2 measurements at 75 w input figure 21. jeida-miti measurements at 75 w input am018 3 5v1 0.0001 0.001 0.01 0.1 1 1 3 579111 3 15 17 19 21 2 3 25 27 29 3 1 33 3 5 3 7 3 9 h a rmonic order (n) h a rmonic c u rrent (a) me asu rement s @ 2 3 0v a c 75w in en61000- 3 -2 cl ass d limit s am018 3 6v1 0.0001 0.001 0.01 0.1 1 1 3 579111 3 15 17 19 21 2 3 25 27 29 3 1 33 3 5 3 7 3 9 h a rmonic order (n) h a rmonic c u rrent (a) me asu rement s @ 100v a c 75w in jeida-miti cl ass d limit s
an2852 electrical performance 21/35 to evaluate the performance of the pfc stage also, the pf and thd vs. input voltage graphs are shown in figure 22 and 23 at full load and 75 w input power. figure 22. pf vs. input voltage figure 23. thd vs. input voltage am018 3 7v1 0.850 0.875 0.900 0.925 0.950 0.975 1.000 80 120 160 200 240 280 vin [vrm s ] pf f u ll lo a d 75 w in am018 3 8v1 0.00 1.00 2.00 3 .00 4.00 5.00 6.00 7.00 8.00 9.00 80 120 160 200 240 280 vin [vrm s ] thd [ % ] f u ll lo a d 75 w in
thermal measurements an2852 22/35 4 thermal measurements a thermal analysis of the board was performed using an ir camera, refer to figure 24 and 25 . figure 24. thermal map at 115vac - full load figure 25. thermal map at 230vac - full load table 7. temperature of key components (t amb = 25 c, emissivity = 0.95 for all points) point reference t [c] at 115vac t [c] at 230vac a d1 (input bridge) 49.5 39.5 b q1 (pfc mosfet) 46.4 37.9 c d4 (pfc diode) 56. 8 49.1 d r6 (ntc) 55.9 47.1 e l2 (pfc coil) 3 8 .1 35.7 f q4 (ahb low-side mosfet) 43. 8 39.2 am018 3 9v1 c 90.0 81.9 7 3 .8 65.6 57.5 49.4 41. 3 33 .1 25.0 am01840v1 c 90.0 81.9 7 3 .8 65.6 57.5 49.4 41. 3 33 .1 25.0
an2852 thermal measurements 23/35 g q3 (ahb high side mosfet) 40.2 39.3 h t1 (ahb transformer ferrite) 64. 8 63.4 i t1 (ahb transformer winding) 8 1.2 8 0.1 j d13 (ahb output diode) 8 3.1 8 1. 8 k d12 (ahb output diode) 73.7 72. 8 l l3 (output inductor) 5 8 .7 57.9 table 7. temperature of key components (t amb = 25 c, emissivity = 0.95 for all points) (continued) point reference t [c] at 115vac t [c] at 230vac
conducted noise measurements (pre-compliance test) an2852 24/35 5 conducted noise measurements (pre-compliance test) figure 26 and 27 show the conducted noise measurements performed at the two nominal voltages with peak detection and considering only the worst phase. both measures are well below the average limit (taken from en55022 class b norm). figure 26. ce peak measure at 115vac and full load figure 27. ce peak measure at 230vac and full load am01841v1 am01842v1
an2852 bill of material 25/35 6 bill of material table 8. EVL6591-90WADP bill of materials ref value description manufacturer c1 470 nf polypropylene x2 capacitor - r46 ki 3470--02 m arcotronics c10 1n0 smd ceramic capacitor x7r - 50 v avx c11 10 nf smd ceramic capacitor x7r - 50 v avx c12 470 nf smd ceramic capacitor x7r - 25 v avx c13 1 f smd ceramic capacitor x7r - 25 v avx c14 100 nf smd ceramic capacitor x7r - 50 v avx c15 22 f electrolytic capa citor yxf - 50 v rubycon c16 1n0 smd ceramic capacitor x7r - 50 v avx c17 n.m. electroly tic capacitor c2 2n2 ceramic y1 capacitor - de1e3kx222m murata c20 2n2 ceramic y1 capacitor - de1e3kx222m murata c21 2n2 ceramic y1 capacitor - de1e3kx222m murata c22 220 pf smd ceramic capacitor np0 - 50 v avx c3 2n2 ceramic y1 capacitor - de1e3kx222m murata c39 100 nf smd ceramic capacitor x7r - 50 v avx c4 470 nf polypropylene x2 capacitor - r46 ki 3470--02 m arcotronics c40 10 nf ceramic capacitor x7r - 50 v avx c41 4n7 smd ceramic capacitor x7r - 50 v avx c42 100 nf smd ceramic capacitor x7r - 50 v avx c43 10 nf smd ceramic capacitor x7r - 50 v avx c44 220 nf polypropylene capacitor - b32652a3224j epcos c45 220 pf smd ceramic capacitor np0 - 50 v avx c46 1000 f electrolytic capacitor zl - 25 v rubycon c47 2.2 nf smd ceramic capacitor x7r - 50 v avx c4 8 6. 8 nf smd ceramic capacitor x7r - 50 v avx c49 330 pf smd ceramic capacitor np0 - 50 v - 2% avx c5 470 nf polypropylene capacitor - phe426kd6470jr06l2 evox-rifa c50 100 nf smd ceramic capacitor x7r - 50 v avx c51 22 uf electrolytic capa citor yxf - 50 v rubycon c52 100 nf smd ceramic capacitor x7r - 50 v avx c53 n.m. smd ceramic capacitor x7r - 50 v c54 1 uf smd ceramic capacitor x7r - 25 v avx
bill of material an2852 26/35 c55 n.m. smd ceramic capacitor x7r - 50 v c56 100 nf smd ceramic capacitor x7r - 50 v avx c57 100 f electrolytic ca pacitor yxf - 35 v rubycon c5 8 1n 8 smd ceramic capacitor x7r - 50 v avx c59 470 pf smd ceramic capacitor x7r - 50 v avx c61 n.m. electroly tic capacitor c62 n.m. electroly tic capacitor c9 47 f electrolytic capacitor - 450 v - eeued2w470 panasonic d1 gbu6j bridge rectifier vishay d12 stps16l40ct power schottky rectifier stmicroelectronics d13 stps30100st power schottky rectifier stmicroelectronics d20 n.m. zener diode d21 1n414 8 diode d22 ll414 8 smd diode d23 ll414 8 smd diode d24 ll414 8 smd diode d25 bzv55-b13 zener diode - 2% vishay d26 stps1l60a smd schottky diode stmicroelectronics d27 ll414 8 smd diode d2 8 bzv55-b11 zener diode - 2% vishay d29 ll414 8 smd diode d3 1n4005 diode vishay d4 stth2l06 ultrafast diode stmicroelectronics f1 t4 a pcb fuse tr5 wickmann j1 in connector screw connector - mkds 1,5/3-5.0 8 phoenix contact j2 out connector screw connector - mkds 1,5/2-5.0 8 phoenix contact jp9 n.m. wire jumper l1 2x25 mh input em i filter - hf2 8 26-253y1r2-t01 tdk l2 700 h pfc inductor - 1 8 25.0001 magnetica l3 3.3 h power inductor - pcv-0-332-10l coilcraft q1 stp12nm50fp power mosfet stmicroelectronics q10 bc 8 47c small signal bjt q11 bc 8 47c small signal bjt q3 stp12nm50fp power mosfet stmicroelectronics q4 stp12nm50fp power mosfet stmicroelectronics table 8. EVL6591-90WADP bill of materials (continued) ref value description manufacturer
an2852 bill of material 27/35 q9 n.m. small signal bjt r1 1m0 smd film resistor - 5% - 250 ppm/c - 1206 vishay r10 15 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r100 0r0 smd film resistor - 1206 vishay r101 0r0 smd film resistor - 1206 vishay r11 3m0 film resistor - 1% - 100 ppm/c - 0.4w vishay r12 3m0 film resistor - 1% - 100 ppm/c - 0.4w vishay r13 8 .2 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r14 1 8 k ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r15 150 k ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r17 0r0 smd film resistor - 1206 vishay r1 8 56 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r19 56 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r2 1m2 smd film resistor - 5% - 250 ppm/c - 1206 vishay r20 0r0 smd film resistor - 1206 vishay r21 27 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r22 0r47 film resistor ? 5% ? 250 ppm/c - 0.4w vishay r23 0r47 film resistor ? 5% ? 250 ppm/c - 0.4w vishay r24 1. 8 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r25 4.7 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r26 240 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r27 470 smd film resistor - 5% - 250 ppm/c - 1206 vishay r2 8 24k9 smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r29 100 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r3 6 8 0 k ? film resistor - 1% - 100 ppm/c - 1206 vishay r30 2k2 smd film resistor - 1% - 100 ppm/c - 1206 vishay r46 100 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r53 0r0 smd film resistor - 1206 vishay r54 0r0 smd film resistor - 1206 vishay r55 0r0 smd film resistor - 1206 vishay r6 2r5 ntc resistor s237 - b57237s0259m000 epcos r69 n.m. smd resistor - 0 8 05 vishay r7 6 8 0 k ? film resistor - 1% - 100 ppm/c - 0.4 w vishay r70 33 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r71 10 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay table 8. EVL6591-90WADP bill of materials (continued) ref value description manufacturer
bill of material an2852 2 8 /35 r72 10 ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r73 100 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r74 10 ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r75 56 ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r77 56 ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r7 8 19k6 smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r79 100 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r 8 6 8 0 k ? film resistor - 1% - 100 ppm/c - 0.4 w vishay r 8 0 1k0 smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r 8 10r 8 2 smd film resistor - 5% - 250 ppm/c - 1206 vishay r 8 20r 8 2 smd film resistor - 5% - 250 ppm/c - 1206 vishay r 8 36k 8 smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r 8 4 220 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r 8 5220 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r 8 6 33 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r 8 7 n.m. smd resistor - 0 8 05 vishay r 88 2k2 smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r 8 9100 k ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r9 8 2 k ? smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r90 0r0 smd film resistor ? 0 8 05 vishay r91 75 k ? smd film resistor - 5% - 250 ppm/c - 0 8 05 vishay r93 3k3 smd film resistor - 1% - 100 ppm/c - 0 8 05 vishay r94 12 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r95 47 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r96 470 smd film resistor - 1% - 100 ppm/c - 1206 vishay r97 n.m. smd resistor - 1206 vishay r9 8 220 ? smd film resistor - 5% - 250 ppm/c - 1206 vishay r99 15 k ? smd film resistor - 5% - 250 ppm/c - 1206 vishay t1 transformer ahb transformer 1754.0004 magnetica u1 l6563 advanced tm pfc cont roller stmicroelectronics u2 l6591 pwm controller for zvs half-bridge stmicroelectronics u3 pc 8 17 optocoupler - pc 8 17x1j000f sharp u4 ts3431ailt smd voltage reference - 1% stmicroelectronics u5 pc 8 17 optocoupler - pc 8 17x1j000f sharp table 8. EVL6591-90WADP bill of materials (continued) ref value description manufacturer
an2852 pfc coil specifications 29/35 7 pfc coil specifications application type: consumer, it transformer type: open coil former: vertical type, 6+6 pins max. temp. rise: 45c max. operating ambient temp.: 60c mains insulation: n.a. 7.1 electrical characteristics converter topology: boost, transition mode core type: rm14 - n 8 7 or equivalent min. operating frequency: 20 khz primary inductance: 700 h 10% at 1 khz - 0.25 v (see note 1 ) peak primary current: 3.5 a pk rms primary current: 1.25 a rms . note: 1 measured between pins 3-5 figure 28. electrical diagram table 9. winding characteristics pins winding rms current nr. of turns wire type 3 ? 5 primary 1.25 a rms 53 stranded 7 x ? 0.2 8 mm ? g2 8 ? 10 aux (1) 1. auxiliary winding is w ound on top of primary winding 0.05 a rms 4 spaced ? 0.2 8 mm ? g2 am0184 3 v1 aux prim 5 3 8 10
pfc coil specifications an2852 30/35 7.2 mechanical aspect and pin numbering maximum height from pcb: 22 mm coil former type: vertical, 6+6 pins pin distance: 5.0 8 mm row distance: 35.56 mm pins removed: # 1, 4, 6, 7, 9, 11, 12 external copper shield: bare, wound around the ferrite core including the windings and coil former. height is 7 mm. connected by a solid wire soldered to pin 10 manufacturer: magnetica p/n: 1 8 25.0001. figure 29. bottom view am01844v1 1 6 12 7
an2852 ahb transformer specifications 31/35 8 ahb transformer specifications application type: consumer, it transformer type: open coil former: horizontal type, 7+7 pins max. temp. rise: 45c max. operating ambient temp.: 60c mains insulation: compliance with en60950. 8.1 electrical characteristics converter topology: asymmetrical half - bridge core type: etd34 - n 8 7 or equivalent operating frequency: 100 khz primary inductance: 400 h 10% at 1 khz - 0.25 v (see note 1 ) air gap: 2.32 mm on central leg leakage inductance: 10 h max. at 100 khz - 0.25 v (see note 2 ) primary capacitance: 6 pf typ. (see note 3 ) max. peak primary current: 1.93 a pk rms primary current: 0.75 a rms note: 1 measured between pins 2-4 2 measured between pins 2-4 with seco ndaries and auxiliary windings shorted 3 calculated considering primary inductance and resonance frequency figure 30. electrical diagram am01845v1 6 5 2 4 14 12 9 10 prim. aux s ec. s ec.
ahb transformer specifications an2852 32/35 note: primaries a and b are in series cover wires ends with silicon sleeve figure 31. windings position 8.2 mechanical aspect and pin numbering maximum height from pcb: 30 mm coil former type: vertical, low profile , 7+7 pins, norwe etd34lr/h14/-1/rtg pin distance: 5.0 8 mm row distance: 25.4 mm pin removed: # 7 manufacturer: magnetica p/n: 1754.0004 figure 32. top view table 10. winding characteristics pins winding rms current n r. of turns wire type 2 ? 3 primary a 0.75 a rms 35 ? 0.355 mm ? g2 9 ? 10 secondary 1 3. 8 1 a rms 4 stranded 90 x ? 0.1 mm ? g1 12 ? 14 secondary 2 6.57 a rms 7 stranded 135 x ? 0.1 mm ? g1 3 ? 4 primary b 0.75 a rms 35 ? 0.355 mm ? g2 5 ? 6 auxiliary 0.05 a rms 3 spaced ? 0.355 mm ? g2 am01846v1 coil former 3 mm 3 mm s econdary 1 primary - a s econdary 2 primary - b aux in s ulating tape am01847v1 1 7 14 8
an2852 pcb layout 33/35 9 pcb layout figure 33. topside silk screen figure 34. bottomside silk screen figure 35. copper traces (bottomside) am01848v1 am01849v1 am01850v1
revision history an2852 34/35 10 revision history table 11. document revision history date revision changes 2 8 -jan-2009 1 initial release
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