march 2009 rev 1 1/10 AN2936 application note 10 w smps with hv power mosfet and the l6565 for three-phase industrial applications introduction this document introduces a solution for industrial power supplies fed by a three-phase mains. it uses a high voltage power mosfet with 1500 v breakdown voltage to optimize the operation of a quasi-resonant flyback converter based on the primary controller l6565. the steval-isa034v1 demonstration board has been designed and developed for low power applications. the board features two isolated outputs, 12 v and 5 v, and is capable of delivering up to 10 w. the board can be ordered through order code steval-isa034v1. figure 1. 10 w board prototype am01 33 2v1 www.st.com
contents AN2936 2/10 contents 1 demonstration board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AN2936 demonstration board description 3/10 1 demonstration board description the steval-isa034v1 demonstration board is based on a quasi-resonant flyback converter topology and uses the stp3n150 1500 v power mosfet as the primary switch. the stp3n150 employs stmicroelectronics? proprietary high voltage mesh overlay technology. characteristic of this technology, the switch features very low r ds(on) per area, low gate charge and high switching performance. the device is available in the to-220, to- 247 and to-220fh packages. the demonstration board is designed in accordance with the specifications in ta b l e 1 . the input section is equipped with two connectors: con1 for 400 vac input voltage, and con2 for 230 vac input voltage. the output voltages are available on con3, with a shared ground between the two outputs. the converter is controlled by the l6565, a primary controller for quasi-resonant zvs (zero- voltage switching) flyback conv erters. the device is capable of controlling power variations in the mains voltage by means of line voltage feed-forward. in light load conditions the device features a special function which automatically lowers the operating frequency while maintaining operation as close to zvs as possible. in addition to very low startup and quiescent currents, this feature helps to main tain low consumption fr om the mains in light load conditions. the device also includes a disable function, an on-chip filter on current sense, an error amplifier with a precise reference voltage for primary regulation and effective two-level overcurrent protection. the transformer reflected voltage is set to 400 v, providing enough margin for leakage inductance voltage spikes. a small rcd clamper circuit is used to limit excess voltage on the drain of the power mosfet. during normal operation, the l6565 is powered by the auxiliary winding of the transform er, via diode d7. a spike killer circuit for the auxiliary voltage fluctuations is present, bu t not connected (q2, c1 2, r15). the primary current is measured using an external sensing resistor (r21) for current mode operation. output voltage regulation is performed using secondary feedback on the 5 v output. the feedback network consists of a programmable voltage reference, tl431, driving an optocoupler which ensures the required insulation between the primary and secondary sections. the optotransistor drives the feedback pin (comp), which controls the operation of the device. lc filters have been added on both of the outputs to reduce the high frequency ripple, using moderate output capacitor values. table 1. main specifications parameter value input voltage range 185 to 460 vac input frequency range 50/60 hz output 1 12 v @ 0.6 a output 2 5 v @ 0.55 a output power 10 w safety en60950 emi en55014
demonstration board description AN2936 4/10 the flyback transformer is a layer-type based on an e25/13/7 core and n27 ferrite, manufactured by tronic, and ensures safety insulation in accordance with standard en60950. the schematic of the board is shown in figure 2 . the power supply has been built on a double-sided 35 m pcb in fr-4, size 120 x 68 mm. the bill of material is provided in ta bl e 3 .
AN2936 demonstration board description 5/10 figure 2. circuit schematic am01 33 1v1 r5 1.8m lp=15mh 5v @ 550 ma 12v @ 600 ma n1/n5v=87 r24 nc n1/n12v=38 n1/naux=30 r25 nc core material n67 core shape e20 (e25) l8 1mh d10 1n4007 a c l9 1mh c20 10n-x2 400vac con1 1 2 c21 10n-x2 r26 1m r27 1m r28 1m r29 1m ntc2 50e + c22 4.7uf 230vac con2 1 2 + c23 4.7uf f4 1a l10 1mh l11 27 mh 1 2 3 4 d11 1n4007 a c d12 1n4007 a c d13 1n4007 a c 480-650vdc 10u l7 10u l6 q11 nc r12 2.2k - nc co4 22u - 10v c16 nc r11 10 u1 l6565 vff 3 zcd 5 inv 1 gnd 6 gd 7 comp 2 cs 4 vcc 8 r7 330k r13 27k c11 2.2n r15 15k r12 12k c10 1n c19 2.2n - y1 r17 1k m1 stp4n150 3 1 2 r18 3.5 r16 2.2 c12 220p r19 2.2k c17 330n r22 10k c9 47u r21 10k u3 tl431 2 3 1 r23 560 r20 1k c18 n.c. pc817 u2 c13 100n c14 100p d6 1n4148 r6 1.8m co3 22u - 25v c15 6.8n - nc d5 stth108 r9 150k c8 1n/2kv d7 1n4148 r14 120k r8 330k r10 150k co1 220u - 25v d8 stps3l40s d9 stps3l25s co2 220u - 10v t1 transformer 1 2 5 4 3 6 7 8 d4 stth108 j6 con2 1 2 3
demonstration board description AN2936 6/10 1.1 bill of materials table 2. bill of materials reference value description c1 4.7 f - 450 v elect. capacitor c2 4.7 f - 450 v elect. capacitor c3 10 nf - 660 v polip. capacitor x2 c4 10 nf - 660 v polip. capacitor x2 c5 1 nf - 2 kv polip. capacitor fkp c6 47 f - 50 v e lec. capacitor c7 1 nf - 50 v ceramic capacitor c8 2.2 nf ceramic capacitor c9 220 pf ceramic capacitor c10 100 nf ceramic capacitor c11 100 pf ceramic capacitor c12 n.m. ceramic capacitor c13 n.m. ceramic capacitor c14 330 nf ceramic capacitor c15 n.m. ceramic capacitor c16 2.2 nf ceramic capacitor y1 c17 220 f ? 25 v elec. capacitor 85 c c18 220 f ? 16 v elec. capacitor 85 c c19 22 f- 25 v elec. capacitor c20 22 f- 25 v elec. capacitor d1, d2, d3, d4 1n4007 rectifier 1000 v 1 a d5 stth108 turboswitch diode 1 a-800 v - stmicroelectronics d6 stth108 turboswitch diode 1 a-800 v - stmicroelectronics d7 ll4148/sod-80 sod-80 general-pur pose rectifier 75 v 200 ma d8 ll4148/sod-80 sod-80 general-pur pose rectifier 75 v 200 ma d9 stps3l40s schottky rectifier 3 a-40 v d10 stps3l25s schottky rectifier 3 a-25 v l1, l2, l3 1 mh l4 33 mh common mode choke l5 10 h inductor l6 10 h inductor ntc1 50 ? ntc inrush current suppressor f1 1 a fuse
AN2936 demonstration board description 7/10 r1 1 m ? resistor, metal film 0.25 w 5%, smd r2 1 m ? resistor, metal film 0.25 w 5%, smd r3 1 m ? resistor, metal film 0.25 w 5%, smd r4 1 m ? resistor, metal film 0.25 w 5%, smd r5 1.8 m ? resistor, metal film 0.25 w 5%, smd r6 1.8 m ? resistor, metal film 0.25 w 5%, smd r7 1.8 m ? resistor, metal film 0.25 w 5%, smd r8 1.8 m ? resistor, metal film 0.25 w 5%, smd r9 330 k ? resistor, metal film 0.25 w 5%, smd r10 330 k ? resistor, metal film 0.25 w 5%, smd r11 150 k ? resistor, metal film 0.25 w 5%, smd r12 150 k ? resistor, metal film 0.25 w 5%, smd r13 10 ? r14 12 k ? resistor, metal film 0.25 w 5%, smd r15 2.2 k ? ? n.m. resistor, metal film 0.25 w 5%, smd r16 18 k ? resistor, metal film 0.25 w 5%, smd r17 120 k ? resistor, metal film 0.25 w 5%, smd r18 15 k ? r19 2.2 ? r20 1 k ? r21 3.5 ? r22 2.2 k ? r23 1 k ? r24 10 k ? r25 10 k ? r26 560 ? r27 n.m. r28 n.m. r29 150 k ? resistor, metal film 0.25 w 5%, smd r30 1.2 k ? t1 0603261 switch mode transformer - tronic u1 l6565 quasi resonant controller - stmicroelectronics u2 pc817 optocoupler u3 tl431 programmable shunt voltage reference 1% - stmicroelectronics table 2. bill of materials (continued) reference value description
demonstration board description AN2936 8/10 q1 stp3n150 power mosfet 1500 v - 3 a - stmicroelectronics q2 bc547 small signal pnp transistor table 2. bill of materials (continued) reference value description
AN2936 related documents 9/10 2 related documents 1. an1326: l6565 quasi-resonant controller 3 revision history table 3. document revision history date revision changes 16-mar-2009 1 initial release.
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