EVL185W-LEDTV STMicroelectronics, EVL185W-LEDTV Datasheet

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EVL185W-LEDTV

Manufacturer Part Number
EVL185W-LEDTV
Description
DEMO BOARD VIPER27L L6564 L6599A
Manufacturer
STMicroelectronics
Series
VIPER™r
Datasheets

Specifications of EVL185W-LEDTV

Design Resources
EVL185W-LED BOM EVL185W-LED Schematic
Main Purpose
Power Supply with PFC
Outputs And Type
4, Isolated
Power - Output
185W
Voltage - Output
130V, 24V, 12V, 5V
Current - Output
620mA,2A, 4A, 2A
Voltage - Input
90 ~ 264VAC
Regulator Topology
-
Frequency - Switching
-
Board Type
Fully Populated
Utilized Ic / Part
Viper27L, L6564, L6599A
Lead Free Status / Rohs Status
Lead free / RoHS Compliant
Other names
497-11255

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Part Number:
EVL185W-LEDTV
Manufacturer:
ST
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AN3339
Application note
185 W power supply with PFC and standby supply for LED TV
using the L6564, L6599A, and Viper27LN
Introduction
This document describes the characteristics and features of a 185 W, wide input mains
range, power-factor-corrected, demonstration board for LED TV.
The architecture is based on a three-stage approach: a front-end PFC pre-regulator based
on the L6564 TM PFC controller and a downstream LLC resonant half bridge converter
using the L6599A resonant controller, delivering 12 V, 24 V, and 130 V. A flyback-based
standby supply delivering 5 V, controlled by the Viper27LN, is also implemented. Thanks to
the chipset used, the principal factors of this design are the very high efficiency as well as
the very low input consumption during standby operation.
Figure 1.
EVL185W-LEDTV: 185 W demonstration board
February 2011
Doc ID 18449 Rev 1
1/43
www.st.com

Related parts for EVL185W-LEDTV

EVL185W-LEDTV Summary of contents

Page 1

... V, controlled by the Viper27LN, is also implemented. Thanks to the chipset used, the principal factors of this design are the very high efficiency as well as the very low input consumption during standby operation. Figure 1. EVL185W-LEDTV: 185 W demonstration board February 2011 using the L6564, L6599A, and Viper27LN Doc ID 18449 Rev 1 ...

Page 2

Contents Contents 1 Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 6 2 Efficiency measurement . . . . . . . ...

Page 3

AN3339 List of tables Table 1. Overall efficiency measured at 230 Vac and 115 Vac mains voltage . . . . . . . . . . . . . . . . . 10 Table 2. Thermal maps reference ...

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... List of figures List of figures Figure 1. EVL185W-LEDTV: 185 W demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Figure 2. Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Figure 3. Standby power supply efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 4. Standby consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 5. EN61000-3-2 compliance at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 6. JEITA-MITI compliance at 100 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 7. EN61000-3-2 compliance at 230 Vac - 50 Hz Figure 8 ...

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AN3339 Figure 50. Thermal map at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 6

Main characteristics and circuit description 1 Main characteristics and circuit description The main features of the SMPS are: Universal input mains range: 90 ÷ 264 Vac - frequency 45 ÷ ● ● Output voltage 1: 130 V ±8 ...

Page 7

AN3339 Brownout protection Brownout protection prevents the circuit from working with abnormal mains levels achieved by two separate circuits, one using the brownout pin of the Viper and a second using an internal comparator of the L6564 dedicated ...

Page 8

Main characteristics and circuit description also turns on. These two transistors form an SCR structure that shorts to ground the anode of the U5 optocoupler in case of an overvoltage event. In this way, Q7 cannot deliver supply voltage Vcc ...

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AN3339 Figure 2. Electrical diagram Main characteristics and circuit description Doc ID 18449 Rev 1 9/43 ...

Page 10

Efficiency measurement 2 Efficiency measurement Table 1 and 2 show the overall efficiency, measured at both nominal mains voltages. At 230 Vac the full load efficiency is 93.3 % and at 115 Vac it is 90.8 %. Average efficiency measured ...

Page 11

AN3339 Standby supply efficiency Standby power supply efficiency has been measured and the results are plotted in As shown, the efficiency during rated load operation is better than both nominal mains voltages from full ...

Page 12

Harmonic content measurement 3 Harmonic content measurement The main purpose of a PFC pre-regulator is the input current shaping to reduce the harmonic content below the limits of the relevant regulations. This demonstration board has been tested according to the ...

Page 13

AN3339 4 Functional check Standby supply In Figure 9 and 10 reported based on the Viper27LN, a device integrating the controller and MOSFET in a single DIP-7 package. The Viper27LN works with fixed switching frequency at about 60 ...

Page 14

Functional check Figure 11. Standby supply waveforms at 400 Vdc, full load CH1: DRAIN (pin #8) CH2: V CH3: CONT (pin #3) CH4: FB (pin #4) In Figure 13 the 5 V output voltage ripple has been captured during operation ...

Page 15

AN3339 In Figure 15 and operates in burst mode, with just a few pulses by each burst, minimizing switching losses and obtaining a significant efficiency, under light load operation, making it suitable for equipment with very low standby consumption requirements. ...

Page 16

Functional check Figure 17. Standby supply OVP at 115 Vac - 60 Hz, full load CH1: DRAIN (pin #8) CH2 stby CH3: CONT (pin #3) CH4: FB (pin #4) Figure 19. Standby supply OVP at 115 Vac - ...

Page 17

AN3339 Figure 21. Standby supply o/p short-circuit at 230 Vac - 50 Hz, full load CH1: DRAIN (pin #8) CH2 stby CH3: V (pin #2) CH4: FB (pin # Figure 23 and voltage have been checked. ...

Page 18

Functional check Power factor corrector stage Figure 25 and 26 considerably reduced due to the L6564 highly linear multiplier, along with a special correction circuit that reduces crossover distortion of the mains current. waveforms along a line half-period at 115 ...

Page 19

AN3339 Figure 27. PFC Vds and inductor current at 230 Vac - 50 Hz, full load CH1: Q1 drain voltage CH2: MULT (pin #3) CH3: CS (pin #4) CH4: L1 inductor current Figure 29 and 30 second input to the ...

Page 20

Functional check Resonant stage Figure 31 and 32 operation. The selected switching frequency is about 110 kHz, in order to have a good trade-off between transformer losses and size. The converter operates slightly below the resonance frequency. turned on when ...

Page 21

AN3339 Figure 33 and 24 V rectifier PIV CH1: D4-A anode CH2: D4-B anode CH3: D9-A anode CH4: D9-B anode Figure 35 shows the waveforms during startup at 115 Vac and full load. Note the sequence of the ...

Page 22

Functional check Figure 37. Startup at full load and 115 Vac by on/off signal - detail Output cross regulation has been checked. Resonant feedback signal is obtained by sensing all three outputs. Therefore, any load change relevant to any output ...

Page 23

AN3339 Figure 38 load transition CH1: +130 V CH2: +24 V CH3: +12 V CH4: +12 V o/p current Figure 40. 130 V load transition The L6599A is equipped with a current sensing input (pin #6, ISEN) and ...

Page 24

Functional check cause IC shutdown, therefore providing the system with immunity to short duration phenomena. If, instead, the overload condition continues, the mentioned procedure for shutting down the L6599A is activated and 130 V outputs respectively; the ...

Page 25

AN3339 Figure 45. OVP at full load and 115 Vac output CH1: LVG CH2: PFC_gate CH3 output CH4: Vcc Figure 47 and 48 input voltage via the resistor divider connected to the LINE pin. As ...

Page 26

Thermal map 5 Thermal map In order to check the design reliability, a thermal mapping by means camera was done. In Figure 49 nominal input voltage are shown. Some pointers, visible in the images, have been placed ...

Page 27

AN3339 Table 2. Thermal maps reference points Point Reference R51 D24 Description Temperature at 115 Vac ...

Page 28

Conducted emission pre-compliance test 6 Conducted emission pre-compliance test Figure 51 and 52 nominal mains voltages. The limits shown in the diagrams are EN55022 Class-B, which is the most popular rule for domestic equipment and has more severe limits compared ...

Page 29

AN3339 7 Bill of materials Table 3. Bill of materials Part type/ Des. part value C1 2 safety cap. DE1E3KX222M C2 1 µ µF C4 470 nF 630 V film cap-B32613A6474K C5 470 nF 630 V ...

Page 30

... KEMET 0805 KEMET 0805 KEMET 0805 KEMET 0805 KEMET 0805 Rubycon 6.3x11 mm P 2.5 mm KEMET 0805 KEMET 1206 KEMET 0805 Panasonic 12.5x20 8x11 mm P 3.5 mm KEMET 1206 Rubycon 12.5x20 VISHAY DO-201 STMicroelectronics DO-201 SHINDENGEN DWG STMicroelectronics TO-220FP VISHAY SOD323 AN3339 ...

Page 31

... SOD323 VISHAY MINIMELF VISHAY SOD323 VISHAY SOD123 STMicroelectronics TO-220FP STMicroelectronics DO-15 STMicroelectronics SMA VISHAY MINIMELF STMicroelectronics SMA STMicroelectronics DO-201 STMicroelectronics DO-201 STMicroelectronics DO-201 STMicroelectronics DO-201 VISHAY SOD323 VISHAY MINIMELF VISHAY MINIMELF Littelfuse 8.5x4 mm P 5.08 mm DWG DWG DWG DWG Molex DWG ...

Page 32

... NPN small signal BJT Doc ID 18449 Rev 1 Supplier Case style/package MAGNETICA 26x13 mm MAGNETICA 9x12 MAGNETICA 9x12 MAGNETICA 9x12 MAGNETICA 9x12 STMicroelectronics TO-220FP STMicroelectronics TO-220FP STMicroelectronics TO-220FP VISHAY SOT-23 VISHAY SOT-23 VISHAY SOT-23 VISHAY SOT-23 VISHAY SOT-23 EPCOS DWG VISHAY 1206 VISHAY 0805 ...

Page 33

AN3339 Table 3. Bill of materials (continued) Part type/ Des. part value 10 Ω R25 SMD film res-1/8 W-5 %-250 ppm/°C 2.2 Ω R27 SMD film res-1/8 W-5 %-250 ppm/°C R29 4.7 kΩ SMD film res-1/4 W-5 %-250 ppm/°C R31 ...

Page 34

Bill of materials Table 3. Bill of materials (continued) Part type/ Des. part value R68 1 kΩ SMD film res-1/8 W-5 %-250 ppm/°C R69 4.7 kΩ SMD film res-1/8 W-5 %-250 ppm/°C R70 10 kΩ SMD film res-1/8 W-5 %-250 ...

Page 35

... Standby flyback transformer Optocoupler Optocoupler Offline HV converter Optocoupler Doc ID 18449 Rev 1 Bill of materials Supplier Case style/package VISHAY 1206 MAGNETICA DWG MAGNETICA DWG STMicroelectronics SSOP10 STMicroelectronics SO-16 Infineon DIP-4 - 10.16 mm STMicroelectronics TO-92 Infineon DIP-4 - 10.16 mm STMicroelectronics DIP8 Infineon DIP-4 - 10.16 mm STMicroelectronics TO-92 35/43 ...

Page 36

PFC coil specification 8 PFC coil specification General description and characteristics ● Application type: consumer, home appliance ● Transformer type: open ● Coil former: vertical type, 6+6 pins ● Max. temp. rise: 45 °C ● Max. operating ambient temperature: 60 ...

Page 37

AN3339 Mechanical aspect and pin numbering ● Maximum height from PCB ● Coil former type: vertical, 6+6 pins (pins # and 12 are removed) ● Pin distance: 5.08 mm ● Row distance: 30.5 mm ● External ...

Page 38

Resonant power transformer specification 9 Resonant power transformer specification General description and characteristics ● Application type: consumer, home appliance ● Transformer type: open ● Coil former: horizontal type, 7+7 pins, two slots ● Max. temp. rise: 45 °C ● Max. ...

Page 39

AN3339 Table 5. Transformer winding data (continued) Pins Secondary windings A and B are in parallel. Mechanical aspect and pin numbering ● Maximum height from PCB: 30 ...

Page 40

Flyback transformer specification 10 Flyback transformer specification General description and characteristics ● Application type: consumer, home appliance ● Transformer type: open ● Coil former: horizontal type, 5+4 pins ● Max. temp. rise: 45 °C ● Max. operating ambient temperature: 60 ...

Page 41

AN3339 Mechanical aspect and pin numbering ● Maximum height from PCB ● Coil former type: horizontal, 5+4 pins (pin #3 missing) ● Primary pin distance: 3.81 mm ● Secondary pin distance: 5.08 mm ● Row distance: 19.05 mm ...

Page 42

Revision history 11 Revision history Table 7. Document revision history Date 23-Feb-2011 42/43 Revision 1 Initial release. Doc ID 18449 Rev 1 AN3339 Changes ...

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... AN3339 Information in this document is provided solely in connection with ST products. STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, modifications or improvements, to this document, and the products and services described herein at any time, without notice. All ST products are sold pursuant to ST’s terms and conditions of sale. ...

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