This note describes performances reference board, with wide-range main

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Reference design: wide range 200W L6599-based resonant converter flat panels
This note describes performances reference board, with wide-range mains operation power-factor-correction (PFC). electrical specification tailored typical high-end application monitor applications. main features this design very no-load input consumption (<0.5 very high global efficiency, better than full load nominal mains voltage (115 Vac). circuit consists three main blocks; first front-end pre-regulator based L6563 controller. second stage multi-resonant half-bridge converter whose control implemented through STMicroelectronics L6599 resonant controller. further auxiliary flyback converter based VIPer12A-E off-line primary switcher completes architecture. This third block mainly intended microprocessor supply display power management operations. Figure L6599 L6563 200W evaluation board (EVAL6599-200W)
October 2007
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www.st.com
Contents
AN2393
Contents
Main characteristics circuit description Electrical test results
Efficiency measurements Resonant stage operating waveforms Stand-by load power consumption Short-circuit protection Overvoltage protection
Thermal tests Conducted emission pre-compliance test Bill materials coil specification
Electrical characteristics Mechanical aspect numbering
Resonant power transformer specification
Electrical characteristics mechanical aspect
Auxiliary flyback power transformer
Electrical characteristics
Reference design board layout Revision history
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AN2393
List figures
List figures
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure L6599 L6563 200W evaluation board (EVAL6599-200W). pre-regulator electrical diagram Resonant converter electrical diagram Auxiliary converter electrical diagram Overall efficiency versus output power nominal mains voltages. Overall efficiency versus output power several input voltage values Resonant circuit primary side waveforms full load Resonant circuit primary side waveforms no-load condition. Resonant circuit secondary side waveforms: output Resonant circuit secondary side waveforms: output frequency (100 ripple voltage output voltages Load transition 100%) output voltage Load transition 100%) output voltage output short-circuit waveforms output short-circuit waveforms Thermal @115 full load Thermal full load quasi peak measurement full load quasi peak measurement full load coil electrical diagram coil side view. Mechanical aspect numbering resonant transformer Resonant transformer electrical diagram Resonant transformer winding position coil former Auxiliary transformer electrical diagram Auxiliary transformer winding position coil former Copper tracks Thru-hole component placing silk screen component placing bottom silk screen
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Main characteristics circuit description
AN2393
Main characteristics circuit description
main characteristics SMPS listed below:
Universal input mains range: frequencies between Output voltages: continuous operation continuous operation continuous operation continuous operation
Mains harmonics: Compliance with EN61000-3-2 specifications St-by mains consumption: Typical @230 Overall efficiency: better than full load EMI: Compliance with EN55022-class specifications Safety: Compliance with EN60950 specifications single layer: 132x265 mixed PTH/SMT technologies
circuit consists three stages. front-end pre-regulator implemented controller L6563 (Figure half-bridge resonant DC/DC converter based resonant controller L6599 (Figure flyback converter intended stand-by management (Figure utilizing VIPer12A-E off-line primary switcher. stage delivers stable supply provides reduction mains harmonics, order meet requirements European norm EN61000-3-2 JEIDA-MITI norm Japan. controller L6563 (U1), working (fixed off-time) mode integrating functions needed operate interface downstream resonant converter. Note: control implemented through components C15, C17, R14, (see AN1792 complete description pre-regulator). power stage conventional boost converter, connected output rectifier bridge through differential mode filtering cell (C5, reduction. includes coil (L4), diode (D3) capacitors C8). boost switch represented Power MOSFET (Q2) which directly driven L6563 output drive thanks high current capability divider (R30, R32) provides L6563 (MULT with information instantaneous voltage that used modulate boost current derive some further information like average value line used (voltage feed-forward) function. This function used keep output voltage almost independent mains one. first divider (R3, R11) dedicated detecting output voltage while second divider (R5, R25) used protect circuit case voltage loop fail. second stage resonant converter, with half bridge topology, working (zero voltage switching) mode. controller L6599 integrated circuit that incorporates necessary functions drive properly half-bridge MOSFETs percent fixed duty cycle with dead-time,
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AN2393
Main characteristics circuit description changing frequency according feedback signal order regulate output voltages against load input voltage variations. main features L6599 non-linear soft-start, current protection mode used program hiccup mode timing, dedicated sequencing brown-out (LINE) stand-by (STBY) burst mode operation light loads (not used this design). transformer uses magnetic integration approach, incorporating resonant series shunt inductances. Thus, additional external coils needed resonance. transformer configuration chosen secondary winding center-tap, output rectifiers Schottky type diodes, order limit power dissipation. feedback loop implemented means classical configuration using TL431 (U4) adjust current optocoupler diode (U3). weighted resistive divider (R53, R57, R58, R61) used detect both output voltages order better overall voltage regulation. optocoupler transistor modulates current from frequency will change accordingly, thus achieving output voltage regulation. Resistors maximum operating frequency. case short circuit, current entering primary winding detected lossless circuit (C34, C39, D11, D12, R43, R45) resulting signal into case overload, voltage will overpass internal threshold that triggers protection sequence keeping current flowing circuit safe level. third stage small flyback converter based VIPer12A-E, current mode controller with integrated Power MOSFET, capable delivering (approximately) output power output voltages regulated output voltage output and, also this case, feedback loop bases TL431 (U7) optocoupler (U6) control output voltage. This converter able operate whole mains voltage range, even when stage working. From auxiliary winding primary side flyback transformer (T2), voltage available, intended supply other controllers (L6563 L6599) addition VIPer12A-E itself. stage resonant converter switched through circuit based mainly components which, depending level signal ST-BY, supplies removes auxiliary voltage (VAUX) necessary start-up controllers resonant stages. this way, when input voltage applied power supply, small flyback converter switches first; then, when ST-BY signal low, pre-regulator becomes operative, last resonant converter deliver output power load. Note that Connector left floating signal ST-BY present), resonant converter will operating, only +3.3V supplies available output. order enable outputs, Connector must pulled down ground.
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Vrect 1N5406 D15XB60 STTH8R06 470nF/630V 220uF/450V 2R5-S237 +400V DM-LSR-72uH-3A 100nF-X2 Jumper 330nF-X2 680nF-X2 330nF/630V 680nF/630V PQ35-900uH Jumper
Figure
CM-TF2628V-5mH-3A
6.3A/250V
CON2-IN
2nF2-Y 2nF2-Y2
2nF2-Y1
Vaux 680k 680k 100nF 10uF/50V
Main characteristics circuit description
680k
100k 100nF COMP MULT PWM-Latch 150k 470nF 240k 2nF2 330pF 0R68 0R68 0R68 PFC-OK PWM-LATCH PWM-STOP 220pF LL4148 LL4148 STP12NM50FP L6563 100pF
pre-regulator electrical diagram
LINE
10nF
BC857C
Vrect
620k 10nF
620k
AN2393
AN2393 Figure
LL4148 STP14NK50Z 2uH2 LL4148 VBOOT 2200uF/35V Vaux 2uH2 220pF/630V 10uF/50V LL4148 220nF LL4148 2200uF/25V 2200uF/25V 100nF D10B STPS20L40CF 470uF/25V D10A STPS20L40CF 2200uF/35V PFC-STOP STP14NK50Z 22nF/630V 100nF L6599 STPS20H100CF 470uF/35V STPS20H100CF
+24V
2uF2
T-RES-ER49
470nF
CON8
DELAY
270pF
RFMIN
rework
STBY
LINE
ISEN
+12V
LINE
4nF7
Resonant converter electrical diagram
PWM-Latch
C-12V 10uF/50V
10nF
SFH617A-2 SFH617A-2
47nF TL431
Main characteristics circuit description
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+5Vst-by 1N5822 33uH 100uF/10V +3V3 PKC-136 1000uF/10V 100uF/10V BAV103 B-10V C-30V 10uF/50V 47nF 100nF 1N5821 33uH St-By 1000uF/10V +5Vst-by T-FLY -AUX-E20 CON10
Figure
+400V
VIPER-12A
LL4148 SFH617A-2
Main characteristics circuit description
10uF/50V
+400V 150k SFH617A-2 BC847C BC857C B-27V BC847C 100nF SFH617A-2 B-15V +12V +24V St-By +5Vst-by
BC557C
SFH617A-2
Auxiliary converter electrical diagram
10nF
2nF2 TL431 100nF
Vaux
BC547C
10uF/50V
1nF0
C-15V
AN2393
AN2393
Electrical test results
Electrical test results
Efficiency measurements
Table Table show output voltage measurements nominal mains voltages Vac, with different load conditions. measurements, both full load light load operation, input power measured using Yokogawa WT-210 digital power meter. Particular attention paid when measuring input power full load order avoid measurement errors voltage drop cables connections. Therefore please connect WT210 voltmeter termination board input connector. same reason please measure output voltage output connector remote sense option your active load correct output voltage measurement.
Table
Efficiency measurements @VIN
V(V) @load(A) V(V) @load(A) V(V) @load(A) +3.3 V(V) @load(A) POUT Efficiency 23.81 6.00 24.04 3.04 23.84 3.02 23.79 2.01 23.94 0.53 11.86 4.94 11.80 4.91 11.91 1.98 11.96 0.49 11.92 0.49 4.93 0.98 4.93 0.98 4.93 0.98 4.96 0.31 4.97 0.31 3.35 0.71 3.35 0.71 3.35 0.71 3.35 0.31 3.35 0.31 208.66 138.23 102.79 56.25 21.11 235.00 155.50 115.47 63.55 25.56 88.79% 88.89% 89.02% 88.52% 82.58%
Table
Efficiency measurements @VIN
V(V) @load(A) V(V) @load(A) V(V) @load(A) +3.3 V(V) @load(A) POUT Efficiency 23.82 6.00 24.05 3.04 23.85 3.02 23.80 2.01 23.94 0.53 11.86 4.94 11.80 4.91 11.91 1.98 11.96 0.49 11.92 0.49 4.94 0.98 4.94 0.98 4.94 0.98 4.96 0.31 4.96 0.31 3.35 0.71 3.35 0.71 3.35 0.71 3.35 0.31 3.35 0.31 208.73 138.27 102.83 56.27 21.11 229.96 152.85 114.05 63.47 26.47 90.77% 90.46% 90.16% 88.66% 79.73%
Table Table Figure overall circuit efficiency measured each load condition, both nominal input mains voltages Vac. values were measured after minutes warm-up maximum load. high efficiency pre-regulator working mode very high efficiency resonant stage working (i.e. with negligible switching losses), provides overall efficiency better than 88%. This significant high value two-stage converter with output voltages delivering output current excess amps, especially input mains voltage where conduction losses increase. Even lower loads, efficiency still remains high. global efficiency full load been measured even limits input voltage range, with good results:
full load, efficiency 86.88% (POUT 208.8 240.3 full load, efficiency 90.90% (POUT 208.7 229.6
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Electrical test results
AN2393
Also light load, output power about maximum level, overall efficiency very good, reaching value better than over entire input mains voltage range. Figure shows efficiency measured various input voltages versus output power. Figure
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% Output power eff% eff%
Overall efficiency versus output power nominal mains voltages
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AN2393 Figure
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00%
Electrical test results Overall efficiency versus output power several input voltage values
eff% eff% eff% eff%
utput power
95.00% 94.00% 93.00% 92.00% 91.00% 90.00% 89.00% 88.00% efficiency 87.00% 86.00% 85.00% 84.00% 83.00% 82.00% 81.00% 80.00% 79.00% 78.00% 77.00% 76.00% 75.00% Output power eff% eff% eff% eff%
Resonant stage operating waveforms
Figure shows some waveforms during steady state operation resonant circuit full load. waveform half-bridge square voltage L6599, driving resonant circuit. picture evident, switching frequency normally slightly modulated following pre-regulator 100-Hz ripple that rejected resonant control circuitry. switching frequency been selected approximately 95-kHz order have good trade between transformer losses dimensions. waveform represents transformer primary current flowing into resonant tank. shown, almost sinusoidal because operating frequency close resonance leakage inductance transformer resonant capacitor (C28). this condition, circuit good margin operation, providing good efficiency,
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Electrical test results while almost sinusoidal current waveform just allows extremely generation.
AN2393
Figure shows same waveforms previous figure, when both outputs loaded. This picture demonstrates ability converter operate down zero load, with output voltages still within regulation. resonant tank current obviously triangular shape represents magnetizing current flowing into transformer primary side. Figure Resonant circuit primary side waveforms full load
Ch3: half-bridge square voltage Ch4: resonant tank current
Figure
Resonant circuit primary side waveforms no-load condition
Ch1: +12V output voltage Ch2: +24V output voltage Ch3: half-bridge square voltage Ch4: resonant tank current
Figure Figure waveforms relevant secondary side represented: rectifiers reverse voltage measured (for both outputs) peak peak value indicated right side figure. higher than theoretical value that would 2(VOUT+VF): possible observe small ringing bottom side waveform, responsible this difference.
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AN2393
Electrical test results Waveform shows current flowing into output diodes each output voltage (respectively D10A). Also this current shape almost sine wave, whose average value half output current. ripple noise output voltage shown CH2. Thanks advantages resonant converter, high frequency noise output voltages less than while residual ripple twice mains frequency lower than maximum load line condition, shown Figure
Figure
Resonant circuit secondary side waveforms: output
Figure Resonant circuit secondary side waveforms: output
output waveforms: Ch1: diode reverse voltage Ch2: high freq. ripple output voltage Ch3: diode current
output waveforms: Ch1: +12V diode reverse voltage Ch2: high freq. ripple output voltage Ch3: diode D10A current
Figure frequency (100 ripple voltage output voltages
Ch1: ripple voltage Ch2: ripple voltage
Figure shows dynamic behavior converter during load variation from 100% output, with other output maximum load. This figure also highlights induced effect this load change pre-regulator output voltage (+400 track). Both transitions (from 100% from 100% clean show problem output voltage regulation.
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Electrical test results
AN2393
Thus, clear that proposed architecture really suitable power supplies operating with strong load variation without problem related load regulation. Figure Load transition 100%) Figure Load transition 100%) output voltage output voltage
Dynamic load @0-6 load Ch1: output voltage Ch2: output current Ch3: output voltage (400 Ch4: output current
Dynamic load @0-5 load Ch1: output voltage Ch2: output current Ch3: output voltage (400 Ch4: output current
Stand-by load power consumption
board specifically designed light load zero load operation, during Stand-by Power-off operation, when power requested from outputs. Though resonant converter operate down zero load, some tricks required keep very input power drawn from mains when system this load condition. Thus, when entering this power management mode, ST-BY signal needs high microcontroller system). This forces pre-regulator resonant stage switch (because supply voltage control longer present (Figure only auxiliary flyback converter continues working just supply microprocessor circuitry. Table Table show measurements input power several light load conditions Vac. These tables show that load input power lower than
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AN2393 Table Stand-by consumption
+3.3 V(V) @load(A) 3.35 0.102 3.35 0.079 3.35 0.046 3.35 0.023 3.35 0.000
Electrical test results
V(V) @load(A) 5.08 0.018 5.04 0.018 4.98 0.018 4.92 0.018 4.47 0.000
POUT 0.43 0.36 0.24 0.17 0.00
0.863 0.751 0.582 0.445 0.221
Table
Stand-by consumption
+3.3 V(V) @load(A) 3.35 0.102 3.35 0.079 3.35 0.046 3.35 0.023 3.35 0.000 POUT 0.43 0.36 0.24 0.17 0.00 1.138 1.022 0.857 0.740 0.470
V(V) @load(A) 5.08 0.018 5.04 0.018 4.98 0.018 4.92 0.018 4.47 0.000
Short-circuit protection
L6599 equipped with current sensing input (pin ISEN) dedicated overcurrent management system. current flowing circuit detected (through dissipative sensing circuit already mentioned Section signal into ISEN pin. internally connected input first comparator, referenced that second comparator referenced voltage externally applied exceeds first comparator tripped causing internal switch turned discharging soft-start capacitor CSS. output short-circuits, this operation results nearly constant peak primary current. Using L6599, designer externally program maximum time (tSH) that converter allowed overloaded under short-circuit conditions. Overloads shortcircuits lasting less than will cause other action, hence providing system with immunity short duration phenomena. instead, exceeded, overload protection (OLP) procedure activated that shuts down L6599 and, case continuous overload/short circuit, results continuous intermittent operation with user-defined duty cycle. This function realized with DELAY (#2), means capacitor parallel resistor connected ground. voltage ISEN exceeds first comparator, addition discharging CSS, turns internal current generator that DELAY charges C24. voltage reaches L6599 stops switching PFC_STOP pulled low. Also internal generator turned off, that will slowly discharged R37. will restart when voltage becomes less than Additionally, voltage ISEN reaches reason (e.g. transformer saturation), second comparator will triggered, L6599 will shutdown operation will resumed after on-off cycle. Figure Figure illustrate L6599 short-circuit protection sequence described above. on-off operation controlled voltage (DELAY), providing hiccup mode circuit. Thanks this control pin, designer select hiccup mode timing thus keep average output current safe level. Please note left
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Electrical test results
AN2393
side figure very mean current flowing shorted output which less than Figure output short-circuit waveforms Figure output short-circuit waveforms
Short circuit output voltage
Ch1: output voltage Ch2: L6599 (ISEN) Ch3: L6599 (DELAY) Ch4: output current
Short circuit output voltage
Ch1: output voltage Ch2: L6599 (ISEN) Ch3: L6599 (DELAY) Ch4: output current
Overvoltage protection
Both pre-regulator resonant converter equipped with their overvoltage protection circuit. controller L6563 internally equipped with dynamic static overvoltage protection circuit sensing error amplifier voltage divider dedicated feedback loop sense output voltage. internal threshold exceeded, limits output voltage programmable, safe value. Moreover, L6563 there additional protection against loop failures using additional divider (R5, R25) connected dedicated (PFC_OK, protecting circuit case loop failures disconnection deviation from nominal value feedback loop divider. Hence output voltage always under control case fault condition detected PFC_OK circuitry will latch L6563 operations and, means PWM_LATCH (Pin will latch L6599 well (Pin circuit (see Figure output voltages resonant converter uses zener diodes (D21 D23) sense and+12 output voltages exceeds threshold imposed these zener diodes plus Q10, transistor starts conducting optocoupler opens that VAUX supply voltage controller L6563 L6599 longer available. This state latched until mains voltage recycle occurs.
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AN2393
Thermal tests
Thermal tests
order check design reliability, thermal mapping means Camera performed. Figure Figure show thermal measurements board, component side, nominal input voltage. correlation between measurement points components indicated both diagrams. Figure Thermal @115 full load
Figure Thermal full load
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Thermal tests Table components temperature full load
Ambient temperature: Item (Fe) (Cu) D10A D10B Temp (°C) 44.9 53.7 50.3 47.0 46.0 45.8 49.2 37.3 78.0 40.2 46.7 56.2 56.7 42.1 42.7 45.1 46.1 42.0 41.6 71.2 56.0 51.7 56.8 81.4 74.2 57.6 55.3 56.4
AN2393
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AN2393 Table components temperature full load
Ambient temperature: Item (Fe) (Cu) D10A D10B (Fe) (Cu) Temp (°C) 37.1 46.6 44.0 33.6 34.9 39.1 41.2 37.1 65.8 38.3 43.7 56.4 55.6 42.1 43.8 48.2 47.4 44.3 44.5 73.6 57.3 51.3 58.8 81.8 74.4 59.4 56.3 56.8
Thermal tests
other board components work within temperature limits, assuring reliable long term operation power supply. Note that temperatures have been measured both ferrite core (Fe) copper (Cu).
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Conducted emission pre-compliance test
AN2393
Conducted emission pre-compliance test
limits indicated both diagrams comply with EN55022 Class-B specifications. measurements have been taken Quasi Peak detection mode. Figure quasi peak measurement full load
Figure quasi peak measurement full load
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AN2393
Bill materials
Table
Item
Bill materials
Bill materials
Part type/value nF-X2 nF-X2 nF-X2 nF/630 nF/630 nF/630 µF/450 2nF2-Y1 2nF2-Y1 2nF2-Y1 µF/50 2nF2 µF/35 nF/630 V/400 2200 µF/35 2200 µF/35 µF/50 Description Safety Capacitor Safety Capacitor Safety Capacitor Polypropylene Capacitor High Ripple Polypropylene Capacitor High Ripple Polypropylene Capacitor High Ripple Aluminium ELCAP Series SNAP-IN Safety Ceramic Disk Capacitor Safety Ceramic Disk Capacitor Safety Ceramic Disk Capacitor 1206 Cercap General Purpose Aluminium ELCAP General Purpose 1206 Cercap General Purpose 0805 Cercap General Purpose 1206 Cercap General Purpose 0805 Cercap General Purpose 0805 Cercap General Purpose 0805 Cercap General Purpose 1206 Cercap General Purpose 1206 Cercap General Purpose 0805 Cercap General Purpose 1206 Cercap General Purpose 1206 Cercap General Purpose Aluminium ELCAP Series 0805 Cercap General Purpose 1206 Cercap General Purpose Polypropylene Capacitor High Ripple PHE450 Aluminium ELCAP Series Aluminium ELCAP Series Aluminium ELCAP General Purpose 1206 Cercap General Purpose 1206 Cercap General Purpose Supplier Arcotronics Arcotronics Arcotronics Arcotronics Epcos Arcotronics Epcos Arcotronics Epcos Rubycon Murata Murata Murata Components Rubycon Components Components Components Components Components Components Components Components Components Components Components Rubycon Components Components RIFA-EVOX Rubycon Rubycon Rubycon Components Components
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Bill materials Table
Item D8A-B D10A-B
AN2393
Bill materials (continued)
Part type/value pF/630 µF/25 2200 µF/25 2200 µF/25 µF/50 1000 µF/10 µF/10 1000 µF/10 µF/50 µF/10 µF/50 µF/50 1nF0 1N5406 D15XB60 STTH8R06 LL4148 LL4148 LL4148 STPS20H100CF LL4148 STPS20L40CF LL4148 LL4148 C-12 PKC-136 Description Polypropylene Capacitor High Ripple Aluminium ELCAP Series Aluminium ELCAP Series Aluminium ELCAP Series 1206 Cercap General Purpose 1206 Cercap General Purpose Aluminium ELCAP General Purpose 1206 Cercap General Purpose Aluminium ELCAP Series Aluminium ELCAP Series Aluminium ELCAP Series Aluminium ELCAP General Purpose Aluminium ELCAP Series Aluminium ELCAP General Purpose 0805 Cercap General Purpose 0805 Cercap General Purpose 0805 Cercap General Purpose 1206 Cercap General Purpose Aluminium ELCAP General Purpose 1206 Cercap General Purpose 0805 Cercap General Purpose Standard Ceramic Capacitor General Purpose Rectifier Single Phase Bridge Rectifier TO220FP Ultrafast High Voltage Rectifier MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode TO220FP Power Schottky Rectifier MINIMELF Fast Switching Diode TO220FP Power Schottky Rectifier MINIMELF Fast Switching Diode MINIMELF Fast Switching Diode BZV55-C Series Zener Diode Peak Clamp Transil Supplier RIFA-EVOX Rubycon Rubycon Rubycon Components Components Rubycon Components Rubycon Rubycon Rubycon Rubycon Rubycon Rubycon Components Components Components Components Rubycon Components Components Components Vishay Shindengen STMicroelectronics Vishay Vishay Vishay STMicroelectronics Vishay STMicroelectronics Vishay Vishay Vishay STMicroelectronics
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AN2393 Table
Item
Bill materials Bill materials (continued)
Part type/value 1N5822 1N5821 LL4148 B-10 C-30 BAV103 B-27 C-15 B-15 6.3A/250 CON2-IN CON8 CON10 CM-TF2628V-5 mH-3 DM-LSR-72 µH-3 PQ35-900 STP12NM50FP BC857C STP14NK50Z STP14NK50Z BC547C BC847C BC857C BC847C BC547C 2R5-S237 Description Power Schottky Rectifier Power Schottky Rectifier MINIMELF Fast Switching Diode BZV55-B Series Zener Diode BZV55-C Series Zener Diode General Purpose Diode BZV55-B Series Zener Diode BZV55-C Series Zener Diode BZV55-B Series ZENER DIODE Type Fuse High Capability Fuseholder 3-Pin Connector (Central Removed) 3.96 Series 8-Pin Connector 3.96 Series 10-Pin Connector 2.54 Series TF2628 Series Common Mode Toroidal Inductor LSR1803-2 Differential Mode Toroidal Inductor 86H-5409 Boost Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor RFB0807 Drum Core Inductor TO220FP N-Channel Power MOSFET SOT23 Small Signal Transistor TO220FP N-Channel Power MOSFET TO220FP N-Channel Power MOSFET TO92 Small Signal Transistor SOT23 Small Signal Transistor SOT23 Small Signal Transistor SOT23 Small Signal Transistor TO92 Small Signal Transistor VR25 Type High Voltage Resistor RESISTOR S237 Series 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film 0ppm/°C Supplier STMicroelectronics STMicroelectronics Vishay Vishay Vishay Vishay Vishay Vishay Vishay Wickmann Molex Molex Delta Delta Coilcraft Coilcraft Coilcraft Coilcraft STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Components Epcos Components Components Components Components
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Bill materials Table
Item
AN2393
Bill materials (continued)
Part type/value 0R68 0R68 0R68 Description 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film 1/8W 200ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C Standard Metal Film ppm/°C Standard Metal Film ppm/°C PR01 Power Resistor PR01 Power Resistor PR01 Power Resistor 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film 0805 Standard Film ppm/°C Standard Metal Film 1/4W 200ppm/°C 0805 Standard Film 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C Supplier Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components
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AN2393 Table
Item
Bill materials Bill materials (continued)
Part type/value T-RES-ER49 T-FLY-AUX-E20 L6563 L6599 SFH617A-2 Description 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C 1206 Standard Film 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film 1/8W 200ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film 200ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film 1206 Standard Film ppm/°C 0805 Standard Film ppm/°C 0805 Standard Film ppm/°C 1206 Standard Film ppm/°C VR25 Type High Voltage Resistor Standard Metal Film ppm/°C 86H-5411 Type Resonant Transformer ER49-27-17 86A-6079-R Type Flyback Transformer Core Advanced Transition Mode Controller High Voltage Resonant Controller 63-125% Selection Optocoupler Supplier Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Components Delta Delta STMicroelectronics STMicroelectronics Infineon
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coil specification Table
Item
AN2393
Bill materials (continued)
Part type/value TL431 VIPer12A-E SFH617A-2 TL431 SFH617A-2 Description TO92 Programmable Shunt Voltage Regulator Power Line SMPS Primary Switcher 63-125% Selection Optocoupler TO92 Programmable Shunt Voltage Regulator 63-125% Selection Optocoupler Supplier STMicroelectronics STMicroelectronics Infineon STMicroelectronics Infineon
Note:
R72: Mounted reworking Q11, R83, C58: Added reworking
coil specification
Application type: Consumer, home appliance Transformer type: Open Coil former: vertical type, pins Maximum temperature rise: Maximum operating ambient temperature:
Electrical characteristics
Converter topology: FOT-PFC Pre-regulator Core type: PQ35-35 material grade PC44 equivalent Maximum operating frequency: Primary inductance: ±10% 0.25 (see Note Primary current: 2.65
Note:
Measured between Pins Pins Figure coil electrical diagram
Primary Auxiliary
Note:
auxiliary winding used this design, foreseen another application
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AN2393 Table
Start pins
Resonant power transformer specification coil winding characteristics
pins Turn number (spaced) Wire type Single Multistrand Wire diameter (mm) 0.28 Litz Notes Bottom
Mechanical aspect numbering
Maximum height from PCB: pins: distance: 5.08 distance: 35.5
Figure coil side view
30.5 35.5
Note:
External copper shield 0.05 (mm) connected tinned wire Manufacturer: DELTA ELECTRONICS Part number: 86H-5409
Resonant power transformer specification
Application type: Consumer, home appliance Transformer type: Open Coil former: Horizontal type, pins, Slots Maximum temperature rise: Maximum operating ambient temperature: Mains insulation: Compliance with EN60065 specifications
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Resonant power transformer specification
AN2393
Electrical characteristics mechanical aspect
Converter topology: half-bridge, resonant Core type: ER49 PC44 equivalent Typical operating frequency: Primary inductance: ±10% 0.25 (see Note Leakage inductance: ±10% 0.25 (see Note Note
Note:
Measured between Pins Measured between Pins with ONLY secondary winding shorted Figure Mechanical aspect numbering resonant transformer
Table
Resonant transformer dimensions
3.5±0.5 41.6±0.4 7.0±0.2 51.5
Dimensions (mm)
39.0
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AN2393
Resonant power transformer specification Figure Resonant transformer electrical diagram
SEC. SEC. PRIM. SEC. SEC.
Table
Pins
Resonant transformer winding characteristics
Winding Primary Sec. Sec. Sec.
current ARMS ARMS ARMS ARMS ARMS
Turn number
Wire type [mm] LITZ dia. 0.15x20 LITZ dia. 0.20x30 LITZ dia. 0.20x30 LITZ dia. 0.20x30 LITZ dia. 0.20x30
Sec.
Secondary windings must wound parallel winding wound primary winding
Figure Resonant transformer winding position coil former
Note:
Manufacturer: DELTA ELECTRONICS Part number: 86H-5411
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Auxiliary flyback power transformer
AN2393
Auxiliary flyback power transformer
Application type: Consumer, home appliance Transformer type: Open Winding type: Layer Coil former: Horizontal type, pins Maximum temperature rise: Maximum operating ambient temperature: Mains insulation: Complies with EN60065 specifications
Electrical characteristics
Converter topology: Flyback, DCM/CCM mode Core type: E20-N67 equivalent Operating frequency: Primary inductance: 4.20 ±10% 0.25 (see Note Leakage inductance: @100 0.25 (see Note Maximum peak primary current: 0.38 primary current: ARMS
Note:
Measured between Pins Measured between Pins with secondary windings shorted Figure Auxiliary transformer electrical diagram
Primary Auxliary +3.3V
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AN2393
Auxiliary flyback power transformer Figure Auxiliary transformer winding position coil former Insulating Coil Former Auxiliary Primary
Table
Pins Start 8-10
Auxiliary transformer winding characteristics
Winding PRIMARY current ARMS 0.05 ARMS ARMS ARMS Number turns Wire type 0.25 0.25 0.75 0.75
Note:
Manufacturer: DELTA ELECTRONICS Part number: 86A-6079-R
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Reference design board layout
AN2393
Reference design board layout
Figure Copper tracks
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AN2393
Reference design board layout Figure Thru-hole component placing silk screen
Figure component placing bottom silk screen
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Revision history
AN2393
Revision history
Table
Date 02-Aug-2006 08-Sep-2006 25-Jan-2007 23-Apr-2007 25-Oct-2007
Document revision history
Revision Initial release Figure modified Minor text change Cross references updated Table Bill materials modified Modified: Section 8.1: Electrical characteristics VIPer12A replaced VIPer12A-E Changes
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AN2393
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This note describes performances reference board, with wide-range main

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