description: a design review of a full-featured 350w ... · a design review of a full-featured ......

Power Supply Design Seminar

Topic 2 Presentation:

A Design Review of a Full-Featured 350-W Offline Power Converter

Reproduced from 2012 Texas Instruments Power Supply Design Seminar

SEM2000, Topic 2 TI Literature Number: SLUP301

© 2012, 2013 Texas Instruments Incorporated

Power Seminar topics and online power training modules are available at:

ti.com/psds

Topic 2

A Design Review of a Full-Featured 350-W Offline Power Converter

Milan Marjanovic and Matthias Ulmann

SLUP301

Agenda

1.   Specification and Overview

2.  Power Board

3.  ADC Card

4.  MCU Card

5.  Conclusion

Texas Instruments – 2012 Power Supply Design Seminar 2-2 SLUP301

Specification and Overview Input • Universal AC input voltage range 85- to 265-VAC, 50/60 Hz

Output • 12- to 14-V DC adjustable

• 25-A continuous, 30-A peak

• Ripple < 12 mVpp (at 20-MHz BW measured)

• Load step 2% to 100% with voltage deviation < 1%

Mechanics •  Silent power = no forced air → Efficiency > 90%

•  Slim line, maximum height < 2 in./50 mm Extras •  Hold-up time > 20 ms for harsh environments

•  All converters synchronized to the same switching frequency → Switching frequency is selectable (170 kHz ±10%)

•  Full monitoring with a microcontroller → Analog design with digital monitoring


Universal Input85- to 265-VAC, 50/60 Hz

12- to14-V DC25-A/30-A peak

L

N

+

-

Primary Secondary

PFCInputEMI

Filter

OutputEMI

Filter

ACRectifier Isolated

DC/DCConverter

Analog

VoltageCurrent

Temperature Man-MachineInterface

CLK Microcontroller

forMonitoring

Vout Setting

Digital

(fswitch)

Aux.PowerSupply

Specification and Overview


Agenda

1.  Specification and Overview

2.   Power Board

3.  ADC Card

4.  MCU Card

5.  Conclusion


Power Board – AC Input EMI Filter

Texas Instruments – 2012 Power Supply Design Seminar 2-6

Common-Mode Filter L2, C1, C5 and L3, C2, C6

Differential-Mode Filter L1, L4, C3, C4 for low frequency FB1-FB6 for high frequency

Y-Capacitors C1, C2, C5, C6

Main Switch

LineNeutral

Earth

85..265-VAC

CT1

J1

CT2

F15 A

FB1

FB2

FB3

FB4

FB5

FB6

LNG

L2400 µH C3

C1 L32.6 mH

L14.7 µH

R1open

C2RT1

275 VRT2

275 V

C6

4.7 nF

4.7 nF

C4

0.68 µFR2open

4.7 µHL4

C5

0.68 µF1 nF

1 nF

L_OUT

N_OUT

SLUP301

Texas Instruments – 2012 Power Supply Design Seminar

[V]

[A]

Forward Voltage

VThreshold

Dio

de C

urre

nt

ǻI

ǻV

+

-

OUT

~

~

IN

Power Board – AC/DC Rectification – Diode Losses 1

2-7

RDiode =

ΔVΔI

PDiode = VForward×IDiode,avg + RDiode×IDiode, rms2

PDiode,n = VForward×IDiode, avg + RDiode×

IDiode, rms2

n

Single Diode

n Diodes in Parallel

Diode Losses = Static Losses + Dynamic Losses

Forward Voltage Dynamic Resistance

SLUP301

Power Board – AC/DC Rectification – Diode Losses 2


Input Voltage • 110-V AC/60 Hz, 13.8 V at 25-A load, 90% efficiency and Current: • 1.7-A rms/1.6-A avg/4.9-A peak per diode

Diode 1N5406: • 600-V, 3 A • 0.8-V voltage drop at 1.6-A average • 40-mΩ dynamic resistance

PDiode = VForward × IDiode,avg + RDiode × IDiode,rms2

PDiode = 0.6 V×1.6 A+80 mΩ× (1.7 A)2 = 1.0 W+0.2 W = 1.2 WPBridge rectifier = 4 × PDiode = 4 × 1.2 W = 4.8 W

Result: • Diode losses mainly due to static losses • Paralleling diodes provides little improvement • Losses can only be reduced by using an element with a lower voltage drop or by eliminating the need for a diode

SLUP301

IDiode

IMOSFET

Power Board – AC/DC Rectification – FET and Diode Parallel


FET IPW60R041C6: •  600 V, 49 A •  41-mΩ on-resistance •  290-nC gate charge

Solution: MOSFET in parallel with the diodes

PFET = RDS×I2FET, rms

PFET = 41mΩ× 1.7 A( )2 = 0.1W

PFET rectifier = 4×PFET = 4×0.1W = 0.4 W

Result: •  Losses reduced by 93% •  Switching and driving losses are negligible at line

frequency •  If optimized for 110-V grid (15-A fused):

−  GSIB2040: 400 V, 20 A, 0.6-V threshold, 20 mΩ 4x 5.2 W = 20.8 W (equals 1.3%) −  IPP200N25N3G: 250 V, 20 mΩ, 64 A

4x 1.1 W = 4.4 W (equals 0.3%)

SLUP301

High-Side DriverCarrying

Gate DriverUCC27324

High-Side DriverCarrying

Gate DriverUCC27324

InputEMI

Filter

Phase

Neutral

AC

Low-SideGate Driver

½ UCC27323

Low-SideGate Driver

½ UCC27323

Q1D1

Q2D2

Q4D4

Q3D3R2 R3

R1 R4

OperationalAmplifierOPA333

RShunt

-DC

+DC

InterleavedCCM PFC

ILoad

MicrocontrollerMPS430F2012

Power Board – AC/DC Rectification – Block Diagram


N/C N/C

INA OUTAGND VDD

INB OUIB

+12V_PAC

12

3

4

87

665

U1UCC27324D

C2

100 nF

1

5

2

4

3

T1980 µHC1 10 µF

D5BZX84C15

D41N4148

D2BAT54

R412.1 k

D3BAT54C

D11N4148

R227.4

Q2MMBT2907

Q1MMBT2907

C4

1 nF

R1

33

C3

100 nFR310.0 k

Source

Gate

Power Board – AC/DC Rectification – High-Side Gate Driver


•  INA/INB: 200-kHz PWM generated by MSP430™ microcontroller •  Open-loop configuration

FET Switch Off Time Base: 500 µs/div FET Switch On

SLUP301

Start

Load Current > 0 A

Voltage Phase = 1

Voltage Neutral = 0

Voltage Phase = 1

Voltage Neutral = 0

Switch OFF Q1, Q3

Switch OFF Q2, Q4

Switch OFF Q1, Q3

Switch OFF Q2, Q4

Switch OFF Q2, Q4

Switch ON Q1, Q3

Switch OFF Q1, Q3

Switch ON Q2, Q4

NO

NONO

YES YES

Power Board – AC/DC Rectification – Software


Switching of MOSFET needs to behave like a diode rectifier: •  Energy flows in one direction only •  The MOSFET only conducts if the

voltage and current on the switch are positive at the same time

•  The MOSFET must not switch under any other circumstances

SLUP301

Power Board – PFC Considerations


Continuous conduction mode interleaved PFC with UCC28070

Advantages: •  Reduced high-frequency current ripple •  Easier EMI filtering •  Easier scalability to higher power levels

(multiphase systems possible) •  Low profile possible (<50 mm needed) Disadvantages: •  Hard switching topology (needs fast reverse recovery diode) •  Higher EMI issues at higher frequency range (50-200 MHz)

SLUP301

390-V DC @ 0.9-A nom. / 1.15-A max.

Bulk

Capacitor

Mains Voltage PFC Voltage

PWM 1 Current Sense 2

PWM 2Current

Sense 1

AC/DC

Rectifier

Full

Bridge

Active

In-Rush

Control

Interleaved CCM

PFC Controller

UCC28070

CLK

350 kHz

Gate Driver

UCC27324

Gate Driver

UCC27324

Power Board – PFC – Block Diagram


Power Board – PFC – Component Selection


Results in a power stage efficiency of 97% at high line.

Key points for maximum efficiency:

•  Interconnects as short as possible with sufficient copper cross section (4 A/mm²)

•  Fast switching MOSFETs with low gate charge:

– Rule of thumb: 50% switching losses, 50% conduction losses

•  Fast switching MOSFET → Fast recovery diode needed SiC technology boosts efficiency by more than 2%

•  Toroid core (high flux, MPP) for PFC choke with single-layer winding: –  Low distributed capacitance –  Low conduction losses

SLUP301

0.75

0.80

0.85

0.90

0.95

1.00

0 5 10 15 20 25 30

Output C urrent [A]

Po

we

r F

ac

tor

110 VAC 230 VAC

Power Board – PFC – Power Factor


80

70

60

50

40

30

20

10

0

-10

-20

A

SGL

1AP

Center 2.121320344 MHz

F1

Span 29.85 MHz

67DB

Max/Ref Lv1

80 dBµV

0 dBµV

Marker 1 (T1)

48.87 dBµV

8.75411965 MHz

RBW

VBW

SWT

10 kHz

100 kHz

60 s

RF Att

Unit

10 dB

dBµV

Limit check:

Passed

1 MHz 10 MHz

1

Power Board – PFC – Conducted Emission


•  230-VAC in, 390-VDC at 0.9-A load •  PFC and auxiliary supply running

SLUP301

(A,B)

(C,D)

(A,B)-(C,D)

VIN

0 V

VIN

0 V

0 V

+VIN

-VIN

0°

(A,B)

(C,D)

(A,B)-(C,D)

VIN

0 V

VIN

0 V

0 V

+VIN

-VIN

90 °Phase-Shifted Full Bridge

(A,B)

(C,D)

(A,B)-(C,D)

VIN

0 V

VIN

0 V

0 V

+VIN

-VIN

180°

Phase D

Phase C

Phase B

Phase A

VIN

VOUT

(A,B) (C,D)

Power Board – Full Bridge – Functionality


Gate Drive

Transformers

Current Sense

Transformer

Full Bridge

Transformer

Interleaved

CCM PFC

Gate Signals

Phase A, B, C, D

12-14 VDC

25-A cont./30-A peak

Phase E Phase F

Phase D

Phase C

Phase B

Phase A

+

-

Gate Driver

UCC27324

Gate Driver

UCC27324

Phase-Shifted

Full Bridge

Controller

UCC28950

+12-V

Sec.

CLK

350 kHz

PWM

Vout

Power Board – Full Bridge


+12 V_S

High Side

Low Side

Low Drive H-OUT2

H-OUT1

U1UCC27324D

1234

8765

1

2

3 4

6

5N/C N/CINA OUTAGND VDDINB OUIB

C3100 nF D6

BAT54A

D2BAT54C

D1 HRW0202A

C2

D5

C4

100 nF

100 nF

HRW0202A

T1450 µH1

1034

87

D3BAT54S

C6

C7

22 nF

100

R3

100

R1

100100 nF

R4

Q1PMD3001D C2

22 nF

C1

100 nF

R2

10.0

Q2IRFB9N65A

D4MURS360T3G

Power Board – Full Bridge – Gate Driver


Controller on secondary side needs MOSFET driver with galvanic isolation: •  Low-side gate driver UCC27324 on secondary side drives single-ended transformer •  Npn-pnp pair placed close to power MOSFET, eliminating influence of interconnect inductance and

enabling fast switching •  Cost-effective, simple, reliable •  High gate capacitance also applicable (higher power level)

SLUP301

Power Board – Full Bridge – Component Selection


Key points for maximum efficiency:

•  Transformer: –  Highest possible cross-section with the lowest possible core volume –  Pot cores (RM and P) are well-suited and generate low EMI –  Litz wire and single layer to minimize skin and proximity effect –  Rule of thumb: 50% copper losses, 50% core losses –  Epcos N97 RM core

•  MOSFETs with moderate switching speed for primary side to prevent extremely high dV/dt (self-destruction, EMI) •  Fast-switching MOSFETs for synchronous rectification

Infineon OptiMOS 3

•  High-current storage choke with lowest DCR (flat wire) Coilcraft SERxxxx series

SLUP301

Channel 2: Leg (A,B), 200 V/divChannel 3: Leg (C,D), 200 V/divChannel F1: (A,B)-(C,D), 220 V/divTime Base: 2 µs/div

Leg CD Leg AB

AB-CD

C3

F1

Power Board – Full Bridge – Switching Waveforms


Channel 2: Output voltage AC coupled, 200 mV/div

250 mV peak-peak

Channel 4: Output current, 5 A/div

Time Base: 1 ms/div

Output Current

Vout AC

C4

C2

Power Board – Full Bridge – Transient Response


Power Board – Full Bridge – Control Loop


•  Bandwidth: 25.2 kHz •  Phase margin: 61 degrees •  Gain margin: 15 dB

Frequency (k)300 300 k

1 k

Hz

Gain

(d

B)

-20

60

Ph

ase (

deg

)-1

80°

180°

-10 dB

-5 dB

0 dB

5 dB

10 dB

15 dB

20 dB

25 dB

30 dB

35 dB

50 dB

55 dB

-135 deg

-112.5 deg

-90 deg

-67.5 deg

-45 deg

-22.5 deg

0 deg

22.5 deg

45 deg

67.5 deg

90 deg

112.5 deg

135 deg

157.5 deg

5-Phase

5-Gain

10 k

Hz

100 k

Hz

SLUP301

Agenda


2.  Power Board

3.   ADC Card

4.  MCU Card

5.  Conclusion


ADC Card – Specification


Task: •  Sense mains and PFC voltage and transfer to MCU card •  Transfer CLK signal from MCU card to PFC controller Solution: •  I2C for data transfer:

-  Better noise and EMI immunity compared to an analog signal - ADC with I2C interface placed on primary side

•  ISO7520/1 for galvanic isolation instead of optocoupler: - Speed (1 Mbps) - Aging - Thresholds - Isolation (5-kV rms reinforced)

SLUP301

PFC Voltage

Mains Voltage

CLK PFC

85-265 VAC

390 VDC

12- BitǻȈ ADC

350-W Power Supply

MCU

Card

Co

mm

on

-Mo

de F

ilte

r

ADC Card

SA74LVC1G17

OPA 2335

ADS 1015

ISO 7520

ISO 7521

SCL

SDA

Primary Secondary

CLK

I2C

Common-Mode Filter

370 at 100 MHz, 450-m DCR

ADC

Card

CLK

SCL (I2C)

SDA (I2C)

VCC

MCU

Card

ADC Card – Block Diagram


Agenda


2.  Power Board

3.  ADC Card

4.   MCU Card

5.  Conclusion


MCU Card – Human-Machine Interface


•  Display: –  Mains and PFC voltage –  Output voltage and current –  Heat sink and chassis temperature

•  Control: –  CLK for synchronization: PFC, full bridge, auxiliary supply

(Dithering with an MSP430™ MCU with higher PWM resolution possible) –  PWM for setting the output voltage –  Enabling of the full bridge

•  Monitoring: –  Disable output when a parameter is out of range

(Mains/PFC voltage, output voltage/current, temperature)

SLUP301

V

I

10 Bit

ADC

V

V 350-W Power Supply

ADC Card

Mains Voltage

PFC Voltage

Enable

PWM 1

Vout Adjustment

PWM 2

CLK

µController

MSP430F2252

USCI

JTAG

Digital I/ODigital I/O

Timer_A

Timer_B

Spy-Bi-Wire

DebuggingI2C Bus

Output Voltage

Output Current

LCD

2x 16

Push-Buttons

4x

Temperature

Chassis

Temperature

PFC, Full Bridge

MCU Card

MCU Card – Block Diagram


YES NO

Initialization

Read-Out

ADC Card

Analog Inputs

Push-Buttons

Check

Parameters

User Inputs? Update Display

Update Outputs

(PWM, Enable)

Process Input

Start

Update Display

Read-Out

Read-Out

MCU Card – Software




2.  Power Board

3.  ADC Card

4.  MCU Card

5.   Conclusion

Agenda

SLUP301

92.5

92.0

91.5

91.0

90.5

90.0

89.5

89.090 130 170 210 250

Effic

ienc

y (%

)AC Input Voltage (V)

FET AC Recifier Diode AC Rectifier

Eff

icie

ncy (

%)

230-VAC 110-VAC

Output Current (A)

94

90

86

82

78

74

70

66

62

0 5 10 15 20 25 30


Conclusion – Efficiency Plug-to-Plug

•  13.8 V at 25.0 A •  0.9% difference at 110-VAC operation •  0.3% difference at 230-VAC operation

•  13.8-V output voltage •  90.4% peak efficiency at 110-VAC •  92.2% peak efficiency at 230-VAC

SLUP301

80

70

60

50

40

30

20

10

0

-10

-20

Max/Ref Lv1

80 dBµV

0 dBµV

Marker 1 (T1)

51.00 dBµV

1.24704133 MHz

RBW

VBW

SWT

10 kHz

100 kHz

30 s

RF Att

Unit

10 dB

dBµV

Limit check:

Passed

1 MHz 10 MHz

1

A

SGL

1AP

F1

67DB

Center 2.121320344 MHz Span 29.85 MHz


Conclusion – Conducted Emission

•  230-VAC in, 13.8-VDC at 25-A load •  PFC, full bridge and auxiliary supply running

SLUP301

+

-

OutputEMIF ilter

Universal Input85-265 VAC, 50/60 Hz

InputEMI

Filter

AC Rectifierwith

MOSFETs

InterleavedCCM PFCUCC28070

390 VDC Phase-ShiftedFull BridgePowerstage

Primary Secondary

L

N

PWM PWM PWM

PWM

PWM

High-SideGate Drive

Full Bridge

Current Sense

Gate Drive

Flyback Transformer

I2C

Synchronization

SEC AUX

Synchronization

AC AUX

PRI AUX

12-14 VDC25-A/30-A peak

SynchronousRectification

Phase-ShiftedFull BridgeControllerUCC28950

Out

put V

olta

ge S

ettin

g

Out

put V

olta

ge

Out

put C

urre

nt

MCU CardMSP430F2252

AuxiliaryPower Supply

UCC2813AC RectifierControl CircuitMSP430F2012

ADCCard

ISO7520ISO7521


Conclusion – System Block Diagram

SLUP301

Conclusion – System Block Overview

Au

x.

Su

pp

ly

Input EMI Filter

Phase-Shifted

Full Bridge

MCU Card

AC Rectifier

Interleaved CCM PFC

ADC Card

Output

EMI Filter


9.1 in. 230 mm

10.8 in. 275 mm

SLUP301

Conclusion – Summary


Input •  Universal AC input voltage range 85-265-VAC, 50/60 Hz

Output •  12-14-VDC adjustable

•  25-A continuous, 30-A peak

•  Ripple < 12 mVpp (at 20-MHz BW measured)

•  Load step 2% to 100% with voltage deviation < 1%

Mechanics •  Silent power = no forced air → Efficiency > 90%

•  Slim line, maximum height < 2 in./50 mm

Extras •  Hold-up time > 20 ms for harsh environments

•  All converters synchronized to the same switching frequency → Switching frequency is selectable (170 kHz ± 10%)

•  Full monitoring with MSP430™ microcontroller → Analog design with digital monitoring

SLUP301

Conclusion


Additional Resources


Interleaved PFC Topology •  http://focus.ti.com/download/trng/docs/seminar/Topic5MO.pdf •  http://www.ti.com/lit/an/slua479b/slua479b.pdf •  http://www.ti.com/lit/an/slua369b/slua369b.pdf Phase-Shifted Full Bridge •  http://www.ti.com/lit/an/slua560c/slua560c.pdf •  http://www.ti.com/lit/an/slyt378/slyt378.pdf •  http://www.ti.com/lit/an/slua107a/slua107a.pdf •  http://www.ti.com/lit/ml/slup102/slup102.pdf Dithering •  http://focus.ti.com/download/trng/docs/seminar/Topic_2_Rice_Gehrke_Segal.pdf Isolated I2C •  http://www.ti.com/lit/an/slyt403/slyt403.pdf

Complete System •  Search for “PMP5568” on TI.com (schematics, layout, software)

SLUP301

TI Worldwide Technical SupportInternetTI Semiconductor Product Information Center Home Pagesupport.ti.comTI E2E™ Community Home Pagee2e.ti.com

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