STM green model SMPS solution for high power SLIM adaptor

John LU APM Technical Marketing, Shanghai 2009-MAR-18th

Agenda
Current Power Adapter status and challenges Energy Star v2.0 specification for PC external power ST Proposal for the Slim Adapter(90W+)
Proposal (i) base on L6563+L6591@AHB Proposal (ii) base on L6563+L6599A@LLC AHB@L6591, LLC@L6599A features comparison

Conclusions ST Power contact window (GC) Q&A

Current Power Adapter status and challenges

Power rating

Typical Solution

Typ. full-load efficiency >85 % >82 % >85 % >85 %

Typ. no-load consumption 0.3 W

<75 W Input <90 W Output

Flyback (FF or QR) TM PFC + Flyback (FF or QR)

<150 W Output TM PFC + Forward or ZVS HB >150 W Output TM or FF PFC + Forward or ZVS HB

0.5 W 0.8 W 1W

Market Demands is changing

.Efficiency .Power Density .Standby .Space/Thickness .cost

Traditional Solution can not meet market demands any more?? Opportunity for new Solution !! Where is ST..?
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Energy Star v2.0 Final Specification

(Standard Models)

Effective November 1, 2008 for External Power Supplies

87%

Energy Star v2.0 Final Specification

(Low voltage products, <6V & >=550mA)

Effective November1, 2008 for External Power Supplies

Energy Star v2.0 Final Specification

(No Load Specification)

Effective November1, 2008 for External Power Supplies

International Efficiency Marking Protocol

Example:
. Any external power supply Meeting the performance Requirements for level V and Above would qualify as ENERGY STAR(v2.0) . Power suppliers with Performance Levels of I IV would NOT qualify under the v2.0 Specification. Format: Font: Size: Color: Placement: Roman numeral: I, II, III, IV, V, or VI. Times Roman preferred (or other plain serif fonts). Legible and indelible. Text to contrast with the nameplate background. On the power supply nameplate; however, the exact location is at the discretion of the manufacturer. The text Efficiency Level shown above is optional.
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ST Proposal for Slim Adapter (90W+)

Proposal (i) (A.H/B)

PFC : L6563 PWM: L6591 A.H/B Syn-Rectification: IC(STSR2) or non-ICs driver

Proposal (ii) (LLC Resonant H/B)

PFC: L6563 PWM: L6599A Syn-Rectification: IC driver Available now !!

High-power Adapter (90W+) System Architecture (i) @ AHB/L6591

PFC PRE-REGULATOR (BOOST) DC-DC CONVERTER (ZVS HALF-BRIDGE)

HG

Vinac

EMI Filter

LG

CV/CC CTL

Voutdc

PWM is turned off in case of PFC's anomalous operation, for safety

PFC: L6563
PFC can be turned off at light load to ease compliance with energy saving requirements.

PWM L6591

Option: synchronous Rectification STSR2

L6563 : Advanced TM PFC controller

TBO
PFC_OK AC_OK VFF

PWM_LATCH

TRACKING BOOST

FEEDBACK DISCONNECT. DETECTION

AC BROWNOUT

VOLTAGE FEED FORWARD

INTERFACE WITH PWM

PWM_STOP

L6563
Vcc

L6562 CORE

LEB + INDUCTOR SATURATION DETECTOR

GD

GND

ZCD

MULT

INV

COMP

ISEN

MAIN APPLICATIONS:
1. Hi-end AC-DC Adapter/Charger 2. SMPS for Desktop PC's, Entry-level Servers 3. IEC61000-3-2 Compliant SMPS, up to 700W(FOT)
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L6591: AHB ZVS PWM Primary Controller

POWER DENSITY
S S O S W S O FF W II T T T H TH C II C N N G G

HALF BRIDGE TOPOLOGY ZERO VOLTAGE SWITCHING

NO SWITCHING LOSSES @ TURN ON

UP TO 500KHz OPER. FREQ.

SMALL MAGNETICS AND CAP, SHORT RESPONSE TIMES, SMALL FILTERS, LOW NOISE LEVELS

ON-BOARD HV START-UP GEN. LOW QUIESCENT CURRENT (<3mA) BURST MODE @ LIGHT LOAD INTERFACE PIN WITH PFC PULSE-BY-PULSE OCP TRANSFORMER SAT. DETECTION LATCHED OR AUTORESTART OVP BROWNOUT PROTECTION ADAPTIVE UVLO

LOW POWER CONSUMPTION

PROTECTIONS

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L6591: HB ZVS PWM Primary Controller

Typical Applications:
LINE DIS ISEN SS OSC VREF COMP PFC_STOP 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 HVSTART BOOT HVG FGND N.C. GND LVG Vcc

High Power AC-DC Adapters > 90W ATX Desktop PCs (85+ initiative) Servers (90+ initiative) Telecom SMPS Audio Systems

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Asymmetrical Half Bridge Waveforms

Q1 current 0

Hysteresis loop

ASIMMETRIC

HB midpoint voltage Vin Iload

D1 current

0 0 Lout current Iload

L6591
Tank circuit current Iload 0 0 D2 current

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AHB 2nd side Waveforms

Vrect Vin(1-D)/n1 VinD/n2 Vrect D1 Iout

ILout

Iout

ID1 = ISEC1 D2

ID2 = ISEC2

Rectifiers reverse voltages

1 1 VD1 = Vin D n + n 2 1 1 1 VD 2 = Vin (1 D ) n + n 2 1

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AHB Topology Key Features

CONTROL
PWM fixed frequency (Dmax = 50%) Dead time between HG and LG to allow ZVS

HALF BRIDGE
ZVS operation: Soft Switching - No switching losses @ turnon

SECONDARY SIDE
Balanced or unbalanced (Ns1Ns2) transformer Output inductor needed
Can be coupled for multiple outputs

TRANSFORMER
Unbalanced transformer: no need of high Llk to obtain ZVS

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L6591 Promotional Tools

SAMPLES: AVAILABLE NOW (PRODUCTION PHASE)

DATASHEETs: AVAILABLE ON ST WEB SITE DEMO BOARDS:

EVL6591-90WADP (AVAILABLE AN2842)
12V/90W AC-DC Adapter with PFC using L6563 + L6591

Energy Star 2.0 compliant EVL6591-250WATX (IN PROGRESS PRELIMINARY DATA

AND DEMO AVAILABLE UPON REQUEST)

12V, 5V and 3.3V outputs 250W ATX, based on L6591 ZVS AHB

and L6563 PFC 85+ Compliant

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90w_12v demo@L6563+L6591, schematic

AHB STAGE

Options: Synchronous Rectifications

PFC STAGE
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90w_12v demo@L6563+L6591, Data (Schottky)

Table 1. Efficiency@115Vrms Load( %) 25% 50% 75% 100% Iout (A) Vout (V) 1.8787 3.7537 5.6287 7.5037 12.09 12.08 12.07 12.06 Pout (W) 22.71 45.34 67.94 90.49 Pin (W) 26.83 51.41 76.67 102.48 Eff (%) 84.66% 88.20% 88.61% 88.30% 87.44%

Average Eff for EPA Table 2. Efficiency@230Vrms Load( %) 25% Table 3. No Load Power Consumption (W) 90Vac 0.215 115Vac 0.225 135Vac 0.235 180Vac 0.255 230Vac 0.290 264Vac 0.315 50% 75% 100% Iout (A) Vout (V) 1.8787 3.7537 5.6287 7.5037 12.09 12.08 12.07 12.06 Pout (W) 22.71 45.34 67.94 90.49 Pin (W) 27.02 51.05 75.60 100.55

Eff (%) 84.06% 88.82% 89.87% 90.00% 88.19%

Average Eff for EPA

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90w_12v demo@L6563+L6591, Data (Syn-Rect)

Syn- Recti IC or Non-ICs

in cc re a in ss e re d a e d

+ 2 + 2% ff %ee fifi

Table 1. Efficiency@115Vrms Load( %) 25% 50% 75% 100% Iout (A) Vout (V) 1.8787 3.7537 5.6287 7.5037 12.09 12.08 12.07 12.06 Pout (W) 22.71 45.34 67.94 90.49 Pin (W) 26.34 50.22 74.89 100.26 Eff (%) 86.21% 90.28% 90.97% 90.25% 89.43%

Table 2. Efficiency@230Vrms Load( %) 25% 50% 75% 100% Iout (A) Vout (V) 1.8787 3.7537 5.6287 7.5037 12.09 12.08 12.07 12.06 Pout (W) 22.71 45.34 67.94 90.49 Pin (W) 26.55 49.86 73,82 98.33 Eff (%) 85.53% 90.93% 92.03% 92.02% 90.13% 18

Average Eff for EPA

Average Eff for EPA

High-power Adapter (90W+) System Architecture (ii) @ LLC/L6599A

PFC PRE-REGULATOR (BOOST) DC-DC CONVERTER (LLC RESONANT HALF-BRIDGE)

HG

Vinac

EMI Filter

LG

CV/CC CTL

Voutdc

PWM is turned off in case of PFC's anomalous operation, for safety

Option: synchronous rectification

PFC L6563

RESONANT L6599A

PFC can be turned off at light load to ease compliance with energy saving requirements.

Syn-Re cti driver I C Availab s le !!

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L6599A: HV Resonant Controller

HALF BRIDGE TOPOLOGY ZERO CURRENT & ZERO VOLTAGE SWITCHING

POWER DENSITY

S O S F O T S F W T S II W T H TH C II N C G N G

LOSSLESS I/O TRANSFER OF ENERGY - REDUCED CONDUCTION AND RADIATED NOISE

UP TO 500KHz OPER. FREQ.

SMALL MAGNETICS AND CAP, SHORT RESPONSE TIMES, SMALL FILTERS, LOW NOISE LEVELS

LOW QUIESCENT CURRENT (<2mA) BURST MODE @ LIGHT LOAD INTERFACE PIN WITH PFC

LOW POWER CONSUMPTION

TWO-LEVEL OCP: FREQ. SHIFT and LATCHED SHUTDOWN BROWNOUT PROTECTION SAFETY LATCHED DISABLE INPUT
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Typical Resonant LLC Architecture

Td between LG and HG To allow ZVS Operation @ Turn-on No Output Choke

fsw fr sinusoidal waveforms low turn-off losses low EMI

Out

Auxiliary Stage: VIPer15/16/17 for std-by up to 5W Extremely low consumption VIPer25/27/28 for std-by from 5W to 10W L6566A/B with external Mosfet for higher power levels

ZCS Operation No recovery losses

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Typical Resonant LLC Architecture with Synchronous Rectification

STD MOSFETs! (not logic)

Supporting also Housekeeping function on secondary side with TSM104

Higher Efficiency Improved Form Factor

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L6599A vs. L6599

In L6599A, both DIP-16 and SO16N are from now on always Halogen-Free A thermal extended (-40 to 125 deg) version can be derived. It is named L6599AT (L6599ATD, L6599ATDTR, L6599ATN) Improved spread of electrical parameters (see other doc.) Improved PFC_STOP function when used with L6563x. It possible to connect PFC stop pin (L6599A) directly with RUN pin (L6563x)

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L6599A: Promotional tools

DATA SHEET: AVAILABLE ON THE WEB APPLICATION NOTES:
LLC RESONANT HALF-BRIDGE CONVERTER DESIGN GUIDELINE (AN2450) 19V-90W ADAPTER BOARD WITH PFC USING L6599 AND L6563 (AN2321) 400W L6599-BASED HB LLC RESONANT CONVERTER FOR PDP (AN2492) 400W L6599-BASED HB LLC RESONANT CONVERTER (AN2509) 200W L6599-BASED HB LLC RESONANT CONVERTER FOR LCD TV & FLAT PANELS (AN2393)

DEMO BOARDS:
19V-90W BOARD WITH PFC USING L6599 AND L6563 (EVAL6599-90W) 200W SMPS FOR LCD TV, USING L6599, L6563 and VIPer12A (EVAL6599-200W) 400W SMPS FOR PDP USING L6599, L6563 and VIPer12A (EVAL6599-400W-S) 400W GENERIC SMPS USING L6599, L6563 and VIPer12A (EVAL6599-400W-T) 350W 80+ DESKTOP SMPS (IN DESIGN)

DESIGN SOFTWARE:
L6599 RESONANT CONVERTER DESIGN WORKBOOK (EXCEL SPREADSHEET, AVAILABLE ON REQUEST)

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90w_19v demo@L6563+L6599/A, schematic

Options: Synchronous Rectifications
SGND EN DVS1 DVS2 1 2 3 4 8 7 6 5 Vcc GD1 PGND GD2

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90w_19v demo@L6563+L6599/A, Data (schottky)

Average efficiency (%) : 115Vac @ 89.73 & 230Vac @ 91.16

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SR vs Schottky in Adapter Application

Due to the high current requirement, Synchronous Rectification is a must:

Adaptor Output Power

120W

It allows space saving, cost reduction, reliability and performance improvement with respect to discrete solution

90W

STSR3/30 STSR2 SRK2000

60W

Schottky diode solution is preferable: simpler and cost effective

45W 3.3V 5V 12V 16V 19V Adapter Output Voltage

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SRK2000: Synchronous Rectification controller for LLC resonant topology Main Features:
Synchronous rectification for LLC resonant topology allows to have an highest efficiency & power density All synchronization signals from secondary side: simple design implementation Capability to work in CCM and DCM and manage all current/voltage waveforms typical of LLC topology Light load detection and automatic sleep mode enter/exit: better standby and efficiency Very low component count 8 pins package, SO8 Current drive capability for rectification Mosfet (standard and logic level) in power supply up to 12V/50A

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SRK2000: Typical application schematic

The typical application are SMPS

Adapter from 90 W (Space shrunk/slim form factor) PC (ATX) (high efficiency/ smaller heat sink) Sever (high efficiency) Console games (high efficiency) LCDTV (space shrunk/slim form factor)
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SRK2000: Efficiency results

Efficiency with synchronous rectifiers: 2 X STP270N4F3 (2.5 mOhm) (one for each center tap winding) +
@ 390 Vdc input voltage: Vout = 11.98V Pout = 230.37W Iout = 19.23A Pin = 242.50W Vout = 11.99V Pout = 119.90W Iout = 10.00A Pin = 127.10W
(two for each center tap winding)
n cc re in a ss re e d a e d

+ 2 .5 + % 2 .5 %ee ff fifi in

eff% = 95.00% eff% = 94.33%

Efficiency with schottky diodes: 4 X STPS20L40CFP

@ 390 Vdc input voltage: Vout = 11.98V Pout = 230.37W Iout = 19.23A Pin = 249.70W Vout = 11.99V Pout = 119.90W Iout = 10.00A Pin = 130.45W

eff% = 92.26% eff% = 91.91%

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AHB, LLC Features Comparison

Features A.H/B@L6591 LLC Res. H/B@L6599A
able to reach 95~96% thanks to Q1/Q2 easier to realize ZVS, D=50% (Max) Variable freq, voltage mode, Dynamic = poor

Efficiency able to reach 94~95% thanks to the ZVS on (DC/DC block) main Sw Q1 and reset Sw Q2, D<=50% Dynamic side syncrectification Output Ripple Volt Burst Mode EMI Transformer usage factor Protection 2nd
Fixed Freq, pulse by pulse current mode, dynamic = perfect

A bit difficult to do syn- rectification due Easily to do Synchronous rectification thanks to variable freq, however ST dedicated to fixed freq operation IC driver is simple design implemented with very low component count If for Dual output (CCM) Ripple < 1% Vo Available on L6591, Stand by performance is Perfect Good 80% Thermal: Perfect Pulse by Pulse Good. If for Dual output (DCM) Ripple < 3% Vo Available on L6599A, Stand by performance is Perfect Perfect 100% Thermal: Poor Voltage mode Poor.
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Conclusion:
Both L6563+L6591@AHB and L6563+L6599A@LLC which we proposed two platforms are suitable for the application of high-end adapter(90W+)(like Slim adapter) However, the features of AHB and LLC topology is somehow different. Which platform is better depends on exactly application specification The 2nd side synchronous rectification is available for both proposal, when/where to be use depends on exactly application specification SRK2000, dedicated synchronous rectification controller for LLC resonant topology, samples is available upon your requests.

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Function Location
Marketing
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Name
David HUANG John LU Polly YANG Tom HE Jerry SHEN Allan LAGASCA Sam GUO

Email @
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Q&A Thanks!!!
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