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L6599应用资料,参考设计:基于L6599 的LCD TV200W平板电源,ST应用资料,设计实例
AN2393 List of tables List of tables Table 1. Efficiency measurements @VIN=115 VAC 10 Table 2. Efficiency measurements @VIN=230 VAC Table 3. Stand-by consumption at VIN=115 VAC ,16 Table 4 Stand-by consumption at vin= 230 Vac 16 Table 5. Key components temperature at 1 15 VAC-full load Table 6. Key components temperature at 230 VAC-full load 20 Table7. Bill of materials 22 Table 8 PFC coil winding characteristics ,,,28 Table 9. Resonant transformer dimensions :.··.······::··· 30 Table 10. Resonant transformer winding characteristics Table 11. Auxiliary transformer winding characteristics 33 T able 12. Revision history 36 3/37 List of figures AN2393 List of figures Figure 1. Auxiliary converter electrical diagram Figure 2. PFC pre-regulator electrical diagram Figure 3. Resonant converter electrical diagram Figure 4. Overall efficiency versus output power at nominal mains voltages Figure 5. Overall efficiency versus output power at several input voltage values 12 Figure 6. Resonant circuit primary side waveforms at full load Figure 7. Resonant circuit primary side waveforms at no-load condition 13 Figure 8. Resonant circuit secondary side waveforms: +24V output ,,14 Figure 9. Resonant circuit secondary side waveforms: + 12V output 14 Figure 10. Low frequency(100Hz) ripple voltage on the output voltages 4 Figure 11. Load transition(0-100%)on +24V output voltage 15 Figure 12. Load transition(0-100%)on +12V output voltage ....15 Figure 13. +24V output short-circuit waveforms Figure 14. +12V output short-circuit waveforms Figure 15. Thermal map @115Vac-full load Figure 16. Thermal map at 230 Vac -full load 18 Figure 17. CE quasi peak measurement at 115 VAC and full load 21 Figure 18. CE quasi peak measurement at 230 VAC and full load 21 Figure 19. PFC coil electrical diagram 28 Figure 20. PFC coil pin side view ,,,,,,,,,,,,,,,,29 Figure 21. Mechanical aspect and pin numbering of resonant transformer ...30 Figure 22. Resonant transformer electrical diagram 31 Figure 23. Resonant transformer winding position on coil former Figure 24. Auxiliary transformer electrical diagram 2 Figure 25. Auxiliary transformer winding position on coil former .33 Figure 26. Copper tracks 34 Figure 27. Thru-hole component placing and top silk screen 35 Figure 28. SMT component placing and bottom silk screen 35 4/37 AN2393 Main characteristics and circuit description Main characteristics and circuit description The main characteristics of the smPs are listed below: Universal input mains range: 90 to 264 VAc and frequencies between 45 and 65 Hz ● Output voltages 24V@6A continuous operation 12V@ 5A continuous operation 3. 3V@0.7A continuous operation 5V@1A continuous operation Mains harmonics: Compliance with EN61000-3-2 specifications e St-by mains consumption: Typical 0. 5W@230 VAC Overall efficiency: better than 88% at full load O EMI: Compliance with EN55022-class B specifications e Safety: Compliance with EN60950 specifications o PCB single layer: 132X265 mm, mixed PTH/SMT technologies The circuit consists of three stages. A front-end PFC pre-regulator implemented by the ontroller L6563(Figure 1), a half-bridge resonant DC/dC converter based on the resonant controller L6599(Figure 2)and a 7W flyback converter intended for stand-by management Figure 3)utilizing the viPer 12A off-line primary switcher The PFG stage delivers a stable 400 V pC supply and provides for the reduction of the mains harmonics, in order to meet the requirements of the European norm EN61000-3-2 and the JEIDA-MITI norm for Japan The PFc controller is the L6563(U1), working in FoT(fixed off-time)mode and integrating all functions needed to operate the PFc and interface the downstream resonant converter Note The FoT control is implemented through components C15, C17, D5, Q3, R14, R17 and R2 9 (see AN1792 for a complete description of a FOT PFC pre-regulator) The power stage of the PFC is a conventional boost converter, connected to the output of the rectifier bridge through a differential mode filtering cell (C5, c6 and L3) for EM reduction. It includes a coil (L4), diode(D3)and two capacitors( c7 and c8) The boost switch is represented by the power MOSFET(Q2)which is directly driven by the L6563 output drive thanks to the high current capability of the IC The divider(R30, R31 and R32) provides the L6563(MULT Pin 3)with the information of the instantaneous voltage that is used to modulate the boost current and to derive some further information like the average value of the ac line used by the vFF(voltage feed-forward) function. This function is used to keep the output voltage almost independent of the mains one The first divider(R3, R6 R8, R10 and R1 1)is dedicated to detecting the output voltage while the second divider(R5, R7, R9, R16 and R25) is used to protect the circuit in case of voltage loop fail The second stage is an LLC resonant converter, with half bridge topology, working in ZVS (zero voltage switching) mode The controller is the L6599 integrated circuit that incorporates the necessary functions to drive properly the two half-bridge MOSFETs by a 50 percent fixed duty cycle with dead-time, 5/37 Main characteristics and circuit description AN2393 changing the frequency according to the feedback signal in order to regulate the output voltages against load and input voltage variations The main features of the L6599 are a non-linear soft-start, a current protection mode used to program the hiccup mode timing a dedicated pin for sequencing or brown-out(LINE) and a stand-by pin(STBY for burst mode operation at light loads(not used in this design) The transformer uses the magnetic integration approach, incorporating the resonant series transformer configuration chosen for the secondary winding is center-tap and the output o and shunt inductances. Thus, no additional external coils are needed for the resonance. th rectifiers are Schottky type diodes, in order to limit the power dissipation. The feedback loop is implemented by means of a classical configuration using a TL431(U4)to adjust the current in the optocoupler diode(U3). a weighted resistive divider(R53, R57, R58, R60 and R61)is used to detect both output voltages in order to get a better overall voltage regulation The optocoupler transistor modulates the current from Pin 4, so the frequency will change accordingly, thus achieving the output voltage regulation Resistors R46 and R54 set the maximum operating frequency In case of a short circuit, the current entering the primary winding is detected by the lossless circuit ( C34, C39, D11, D12, R43, and R45)and the resulting signal is fed into Pin 6 In case of overload, the voltage on Pin 6 will overpass an internal threshold that triggers a protection sequence via Pin 2, keeping the current flowing in the circuit at a safe level The third stage is a small flyback converter based on the VIPER12A a current mode controller with integrated power MOSFET, capable of delivering(approximately)7 W output power on the output voltages(5V and 3. 3V). The regulated output voltage is the 3.3V output and, also in this case, the feedback loop bases on the tL431(U7) and optocoupler(U6)to control the output voltage This converter is able to operate in the whole mains voltage range, even when the PFc stage is not working From the auxiliary winding on the primary side of the flyback transformer(T2), a voltage Vs is available, intended to supply the other controllers( L6563 and L6599) in addition to the viPEr12A itself The PFc stage and the resonant converter can be switched on and off through the circuit based mainly on components Q7, Q8, d22 and U8, which depending on the level of the signal ST-BY, supplies or removes the auxiliary voltage(VAUX) necessary to start-up the controllers of the PFC and resonant stages. In this way, when the aC input voltage is applied to the power supply the small flyback converter switches on first; then, when the ST-BY signal is high, the PFC pre- regulator becomes operative, and last the resonant converter can deliver the output power to the load Note that if Pin 9 of Connector J3 is left floating(no signal ST-BY present), the PFC and resonant converter will be not operating, and only +5V and +3. 3v supplies are available on the output. In order to enable the +24V and +12V outputs, Pin 9 of Connector J3 must be pulled down to ground 6/37 AN2393 Main characteristics and circuit description Figure 1. Auxiliary converter electrical diagram 十少 人凡A A少 7/37 Main characteristics and circuit description AN2393 Figure 2. PFC pre-regulator electrical diagram h 8/37 AN2393 Main characteristics and circuit description Figure 3. Resonant converter electrical diagram 9/37 Electrical test results AN2393 Electrical test results 2.1 Efficiency measurements Table 1 and Table 2 show the output voltage measurements at the nominal mains voltages of 115 Vac and 230 VAC, with different load conditions. For all measurements, both at full load and at light load operation, the input power is measured using a Yokogawa WT-210 digital power meter Particular attention has to be paid when measuring input power at full load in order to avoid measurement errors due to the voltage drop on cables and connections. Therefore please connect the Wt2 10 voltmeter termination to the board input connector. For the same reason please measure the output voltage at the output connector or use the remote sense option of your active load for a correct output voltage measurement Table 1. Efficiency measurements @VIN=115 VAC +24V(V)@load(A)+12v(V)@load(A)+5V(V)@load(A)+3.3V(V)@load(A)PouT(W) PIN(W) Efficiency 2381:600 11.86-4.94 4.93-0.98 3.35-0.71 2086235008879% 24.04-304 11.80-4.91 4.93-098 3.35-0.71 138.23155508889% 23.84-302 11.91-198 4.93-098 3.35-0.71 102791154789.02% 23.79-2.01 11.96-0.49 4.96-0.31 3.35-0.31 562563558852% 23.94-0.53 11920.49 4.97-0.31 3.35-0.31 21.1125.5682.58% Table 2 Efficiency measurements @ vIN= 230 VAC +24v(v)@load(A)+12v(V)@load(A)+5v(V)@load(A)+3. 3v(V)@ load(A)POUT(W) PIN(W)Efficiency 23.82-600 11.86-4.94 4.94-0.98 3.35-0.71 208732299690.7% 24.05-304 11.80-4.91 4.94-0.98 3.35-0.71 138271528590.46% 23.85-302 1191-1.98 4.94-0.98 3.35-0.71 102831140590.16% 2380-201 11.96-0.49 4.96-0.3 3.35-0.31 562763478866% 23.94-0.53 1192-0.49 4.96-0.31 3.35-0.31 21.1126477973% In Table 1, Table 2 and figure 4 the overall circuit efficiency is measured at each load condition, at both nominal input mains voltages of 115 VAc and 230 VAC. The values were measured after 30 minutes of warm-up at maximum load. The high efficiency of the PFC pre-regulator working in FoT mode and the very high efficiency of the resonant stage working in ZVs (i.e. with negligible switching losses), provides for an overall efficiency better than 88%. This is a significant high value for a two-stage converter with two output voltages delivering an output current in excess of 5 amps, especially at low input mains voltage where the PFC conduction losses increase. Even at lower loads, the efficiency still remains 10/37

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