NXP Semiconductors UM10972 User Manual
NXP Semiconductors UM10972 User Manual

NXP Semiconductors UM10972 User Manual

Tea1916db1262 digital resonant 240 w/12 v power supply demo board

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UM10972
TEA1916DB1262 digital resonant 240 W/12 V power supply
demo board
Rev. 1.1 — 8 June 2018
Document information
Information
Content
Keywords
TEA1916DB1262, TEA19161T, TEA19162T TEA1995T 240 W, LLC,
resonant, half-bridge, PFC, controller, converter, burst mode, power supply,
demo board, high efficiency, 80+ certification
Abstract
The TEA19161T is a digital LLC controller. It is used in combination with the
PFC controller TEA19162T.Combining these two ICs with the SR controller
TEA1995T at the secondary side results in a high-efficient resonant converter
over the whole output power range.
This document describes such a resonant power supply design with a 240 W
(12 V/20 A) typical output power.
It operates in normal mode for high and medium power levels, in low-power
mode at medium and low power levels, and in burst mode at (very) low power
levels.
Low-power mode and burst mode operation provide a reduction of power
losses, resulting in a higher efficiency at lower output power levels. Power
levels for switching over from one mode to another mode can be selected by
adjusting component values.
The efficiency at high power levels is well above 90 %.
No-load power consumption is well below 100 mW.
At 250 mW output power, the input power is well below the 500 mW (complies
easily with EUP lot6).
User manual
COMPANY PUBLIC

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Summary of Contents for NXP Semiconductors UM10972

  • Page 1 UM10972 TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Rev. 1.1 — 8 June 2018 User manual COMPANY PUBLIC Document information Information Content Keywords TEA1916DB1262, TEA19161T, TEA19162T TEA1995T 240 W, LLC, resonant, half-bridge, PFC, controller, converter, burst mode, power supply,...
  • Page 2 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Table 1. Revision history Date Description v.1.1 20180608 second, updated issue Modifications: • Section 7 "Bill of Materials" has been updated. • Section 9.2 "PFC coil" has been updated.
  • Page 3: Introduction

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Introduction Warning The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/or ignition of fire. This product is intended for evaluation purposes only. It shall be...
  • Page 4: Pinning

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 1.1.1 Pinning SUPIC SNSBOOST SNSFB SNSCAP SNSOUT SNSCUR SNSSET SUPREG n.c. GATEPFC SNSAUX GATELS PFCCOMP n.c. SUPHS SNSCUR SNSMAINS SUPIC SNSBOOST SUPHV GATEHS aaa-017286 aaa-017287 a. TEA19161T b.
  • Page 5: Safety Warning

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Safety warning The board must be connected to mains voltage. Avoid touching the demo board while it is connected to the mains voltage. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments.
  • Page 6: Specifications

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Specifications Table 2. Specifications Symbol Description Value Conditions Input input voltage 90 V (RMS) to 264 V (RMS) input frequency 47 Hz to 63 Hz no-load input power <...
  • Page 7: Board Photographs

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Board photographs a. Top view b. Bottom view Figure 4.  TEA1916DB1262 prototype 240 W demo board The board can operate at a mains input voltage between 90 V (RMS) and 264 V (RMS;...
  • Page 8 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board The purpose of the TEA1916DB1262 prototype demo board is to evaluate the operation of the combination of converters (TEA19161T, TEA19162T, and TEA1995T) in a single output supply, which includes all modes. The performance passes general standards, including the EuP lot6 requirements.
  • Page 9: Performance Measurements

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Performance measurements 5.1 Test facilities • Oscilloscope: Yokogawa DL9140L • AC Power Source: Agilent 6812B • Electronic load: Agilent 6063B • Digital power meter: Yokogawa WT210 5.2 Start-up behavior The rise time of the output voltage (measured from 10 % to 90 % point of the nominal output) is between 6 ms and 10 ms.
  • Page 10: Efficiency

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board a. Start-up time = 381 ms at V = 230 V (RMS) mains b. Start-up time = 495 ms at V = 115 V (RMS) mains mains...
  • Page 11 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board aaa-022160 η η Load (%) 1. V = 230 V (RMS) mains 2. V = 115 V (RMS) mains Figure 7. Efficiency curve aaa-022161 1. V = 230 V (RMS) mains 2.
  • Page 12: No-Load Power Consumption

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.3.2 No-load power consumption Power consumption performance of the total application board at no load was measured with a Yokogawa WT210 digital power meter. To measure the power consumption over a long time, the integration time function was used.
  • Page 13 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Finally, when the output power level is further reduced, the PFC converter enters burst mode. The power supply consumes more power without low-power mode and burst mode.
  • Page 14: Operation Mode Transitions

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.5 Operation mode transitions (1) GATELS (2) GATEPFC (3) HBC (4) V out(ripple) (5) I Figure 11. Transitions HP - LP - BM Table 8. Mode transitions Transition Power level HP - LP 53.4 W...
  • Page 15: Output Voltage Ripple

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.6 Output voltage ripple (1) V (AC) (2) I Figure 12. Maximum output voltage ripple in burst mode at 50 % duty cycle The maximum output voltage ripple is 114 mV (peak-to-peak).
  • Page 16 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board a. Basic sequential load step test is done at 1 Hz b. Basic sequential load step test is done at 10 Hz c. Basic sequential load step test is done at 100 Hz d.
  • Page 17: Overpower Protection (Opp)

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.8 OverPower Protection (OPP) Tested with a higher current (dynamic overload) on the output voltage, OPP is activated when the current exceeds 25 A (300 W). This current corresponds with a load condition that is 25 % higher than the rated power for continuous use.
  • Page 18 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board (1) V (2) HBC (3) I (4) GATELS Figure 15. Power capability level UM10972 All information provided in this document is subject to legal disclaimers. © NXP B.V. 2018. All rights reserved.
  • Page 19: Hold Time

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.9 Hold time The output was set to full load and the mains supply voltage of 115 V disconnected. The time that passes before the output voltage falls below 90 % of its initial value was measured.
  • Page 20: Short-Circuit Protection (Scp)

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.10 Short-Circuit Protection (SCP) The output was shorted before the resonant converter was connected to the mains. A short circuit across the output of the resonant converter increases primary current. The SNSCUR pin detects the increase.
  • Page 21: Overvoltage Protection (Ovp)

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.11 OverVoltage Protection (OVP) (1) V (2) I (3) SNSOUT Figure 18. Overvoltage protection at V = 14.1 V (SNSOUT triggers latched protection) UM10972 All information provided in this document is subject to legal disclaimers.
  • Page 22: X-Capacitor Discharge Time

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board 5.12 X-capacitor discharge time The power line was unplugged at no-load. The discharge time was measured at the X- capacitor (470 nF + 470 nF). Table 11. X-capacitor discharge time test results Condition From 264 * √2 to 135 V...
  • Page 23 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board a. Line b. Neutral Figure 20. Conducted EMI at V = 230 V line a. Line b. Neutral Figure 21. Conducted EMI at V = 120 V line UM10972 All information provided in this document is subject to legal disclaimers.
  • Page 24: Schematic

    NXP Semiconductors UM10972 TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Schematic WB102 D105 earth wire BD101 GDT1 n.m. GDT2 923345-10 1N5408 on heatsink F101 DSP-201M 2051-20 GDT5 n.m. GDT6 E103 BD101 DSP-201M 2051-20 SS-5H-4A-APH AWG15 GBU806 L103...
  • Page 25 NXP Semiconductors UM10972 TEA1916DB1262 digital resonant 240 W/12 V power supply demo board WB201 WB202 VBOOST HS for BD101, Q101, Q201 and Q202 WB208 923345-10 923345-03 R214 R213 R231 R232 TEA1916DB1252-PRI C216 HS101 Q201 and Q202 6.2 kΩ 923345-03 6.2 kΩ...
  • Page 26 NXP Semiconductors UM10972 TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Option: replace coil by wire WB301 mounting hole for wire; 20 A L302 923345-03 WB302 mounting hole for wire; 20 A 900 nH 923345-04 Vout L301 WB303...
  • Page 27: Bill Of Materials (Bom)

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Bill Of Materials (BOM) Table 12. Bill Of Materials (BOM) Reference Description and values Part number Manufacturer BD101 bridge rectifier; 600 V; 8 A C103 capacitor; not mounted; 1 μF; 10 %;...
  • Page 28 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Reference Description and values Part number Manufacturer C210 capacitor; 2.2 nF; 10 %; 50 V; X7R; 0603 C211 capacitor; 33 nF; 20 %; 1 kV; MKP C212 capacitor;...
  • Page 29 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Reference Description and values Part number Manufacturer D207; D208 diode; not mounted; 100 V; 250 mA D301 diode; Zener; 3.3 V; 250 mA F101 fuse; slow blow; 300 V (AC); 4 A GDT2;...
  • Page 30 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Reference Description and values Part number Manufacturer R206 resistor; 56 kΩ; 1 %; 63 mW; 0603 R207 resistor; 10 kΩ; 1 %; 63 mW; 0603 R208 resistor; 2.2 MΩ; 1 %; 250 mW; 1206 R209 resistor;...
  • Page 31 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Reference Description and values Part number Manufacturer WB202; WB208; wire bridge; 0.8 mm; P = 7.62 mm WB301; WB303 WB203 wire bridge; 0.8 mm; P = 15.24 mm WB206;...
  • Page 32: Layout

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Layout a. Layout b. Components Figure 25. Demo board layout and components (copper tracks and areas) UM10972 All information provided in this document is subject to legal disclaimers.
  • Page 33: Transformer Specifications

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Transformer specifications 9.1 Resonant transformer term numbers dot locates term #1 2.5 min for reference only 26.5 max 36 max 36 max Ø 0.8 (x12) lot code...
  • Page 34: Pfc Coil

    UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Parameter Values Test conditions turns ratio 17.5:1; ±1 % (3-1):(9-11) (3-1):(8-10) turns ratio 11.67:1; ±1 % (3-1):(6-5) (3-1):(5-4) 9.2 PFC coil term numbers 2.8 min for reference only dot locates term #1 24.13 max...
  • Page 35 UM10972 NXP Semiconductors TEA1916DB1262 digital resonant 240 W/12 V power supply demo board Table 14. PFC coil specifications Parameter Value Condition Electric specifications DC resistance; 3-4 0.048 Ω; ±20 % at 20 °C DC resistance; 9-10 0.060 Ω; ±20 % at 20 °C inductance;...
  • Page 36: Abbreviations

    11 References TEA19161T data sheet Digital controller for high-efficiency resonant power supply; 2016, NXP Semiconductors TEA19162T data sheet PFC controller; 2016, NXP Semiconductors TEA1995T data sheet GreenChip dual synchronous rectifier controller; 2015, NXP Semiconductors UM10972 All information provided in this document is subject to legal disclaimers.
  • Page 37: Legal Information

    12.1 Definitions responsible for doing all necessary testing for the customer’s applications and products using NXP Semiconductors products in order to avoid a default of the applications and the products or of the application or use by Draft — The document is a draft version only. The content is still under customer’s third party customer(s).
  • Page 38: Table Of Contents

    'Legal information'. © NXP B.V. 2018. All rights reserved. For more information, please visit: http://www.nxp.com For sales office addresses, please send an email to: salesaddresses@nxp.com Date of release: 8 June 2018 Document identifier: UM10972...

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