AN3172
Application note
19 V - 90 W adapter with PFC for laptop computers
using the L6563H and L6599A
Introduction
This application note describes the performance of a 90 W, wide-range mains, power-factor-
corrected, AC-DC adapter demonstration board. Its electrical specification is tailored on a
typical hi-end portable computer power adapter.
The architecture is based on a two-stage approach; a front-end PFC pre-regulator based on
the L6563H TM PFC controller and a downstream LLC resonant half-bridge converter using
the new L6599A resonant controller. Thanks to the chipset used, the main aspects of this
design are very high efficiency, compliance with ENERGY STAR
®
Eligibility Criteria (EPA
rev. 2.0 EPS), and very low input consumption at no-load (<0.3 W).
Figure 1.
EVL6599A-90WADP: 90 W adapter demonstration board
December 2010
Doc ID 17230 Rev 1
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www.st.com
Contents
AN3172
Contents
1
Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 5
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brownout protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fast voltage feed forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Resonant power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Output voltage feedback loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
L6599A overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . 8
PFC overvoltage and open-loop protection . . . . . . . . . . . . . . . . . . . . . . . . 8
Standby power saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2
Efficiency measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1
Light-load operation efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3
4
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1
4.2
Standby and no-load operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overcurrent and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5
6
7
8
Thermal map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 20
BOM list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PFC coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.1
Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9
Transformer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.1
Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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AN3172
List of figures
List of figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
Figure 22.
Figure 23.
EVL6599A-90WADP: 90 W adapter demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Efficiency vs. output power diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Light-load efficiency diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compliance to EN61000-3-2 at 230 Vac - 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compliance to JEITA-MITI at 100 Vac - 50 Hz, full load. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Resonant stage waveforms at 115 V - 60 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resonant stage waveforms at 230 V - 50 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rectifier waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Startup waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
No-load operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
No-load operation - detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transition full load to no-load at 265 Vac - 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transition no-load to full load at 265 Vac - 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Short-circuit at full load and 115 Vac - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Thermal map at 115 Vac - 60 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Thermal map at 230 Vac - 50 Hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CE Peak measurement at 115 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CE peak measurement at 230 Vac and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PFC coil electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PFC coil mechanical aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transformer overall drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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List of tables
AN3172
List of tables
Table 1.
Table 2.
Table 3.
Table 4.
Table 5.
Table 6.
Table 7.
Overall efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Light-load efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermal maps reference points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EVL6599A-90WADP demonstration board: BOM list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PFC coil winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Transformer winding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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AN3172
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
÷
65 Hz
Output voltage: 19 V at 4.75 A continuous operation
Mains harmonics: Acc. to EN61000-3-2 Class-D or JEITA-MITI Class-D
Standby mains consumption: <0.3 W at 230 Vac
Efficiency at nominal load: Better than 90 % at full load
EMI: According to EN55022-Class-B
Safety: According to EN60950
Dimensions: 65x151 mm, 25 mm component maximum height
PCB: Double side, 70 µm, FR-4, Mixed PTH/SMT
The circuit is composed of two stages; a front-end PFC using the L6563H and an LLC
resonant converter based on the L6599A.
The PFC stage works as the pre-regulator and powers the resonant stage with a constant
voltage of 400 V. The downstream converter operates only if the PFC is on and regulating its
output voltage. In this way, the resonant stage can be optimized for a narrow input voltage
range, improving the efficiency and the primary side power components.
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