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2 , March 2000
Application Note
AN-SMPS-1683X-1
CoolSET
TDA16831...-34 for OFF-Line Switch Mode Power Supplies
Author:
Harald Zllinger
Power Conversion
N e v e r
s t o p
t h i n k in g
Contents:
1 of 24
AN-SMPS-1683X-1
V1.2
Circuit description
The TDA 1683X is a current mode pulse width modulator with an integrated CoolMOS Transistor. It
meets the need for minimum external control circuitry for a flyback application.
Current mode control means that the current through the MOS transistor and flyback transformer is
compared with a feedback signal derived from the output voltage of the flyback application. The result
of that comparision determines the on time of the MOS transistor.
To minimize external circuitry the current sense circuitry is integrated within the CoolSET controller.
The oscillator resistor and capacitor which determine the switching frequency are also integrated,
reducing the external connections. Special efforts have been made to compensate temperature
dependancy and to minimize tolerances of the passive components.
Operating Principles
The TDA1683X is designed for a current mode flyback configuration in discontinous current mode.
The control circuit has a fixed frequency, and the duty cycle of integrated Cool-Mos switch is
controlled to maintain a constant output voltage.
The diagram below (Fig. 1) shows the input voltage and the primary and secondary transformer
current.
When the Cool-Mos transistor is turned on, the start of all windings on the transformer will go positive.
The rectifier diode on the secondary side will be reverse-biased and will not conduct. Therefore no
current will flow in the secondary while the Mosfet is turned on. During this phase energy is being
stored in the primary winding inductance and the transformer may be treated as a simple series
inductor. The diagram shows that there will be a linear increase of primary current (Ipri) while the
primary Cool-MOS switch is on.
When the Cool-MOS transistor is turned off, the voltage will reverse on all windings (flyback action)
until clamped by the secondary side widing through the secondary rectifier diode. Now the secondary
rectifier diode will conduct, and the magnetizing energy in the core will now transfer to the output
during the reset interval.
This current will decrease from its peak value to zero, as shown in the diagram (Isec). In this period the
complete stored energy in the primary inductance will be transferred to the secondary (neglecting
losses), before the next store cycle starts. The secondary voltage is reflected back through the
transformer turns ratio to the primary winding and added to the input voltage (VIN+VR). Additional
transient voltage may appear on the primary winding due to energy stored in uncoupled leakage
inductance in the primary winding which isnt clamped by the secondary side winding.
If the flyback current does not reach zero before the next on -cycle the converter is operating in
continous current mode. When this system reverts to the continous operation, the transfer function is
changed to a two pole system with low output impedance and additional design rules become
important.
2 of 24
AN-SMPS-1683X-1
V1.2
VIN = VINMIN
VINMIN + VR
VIN
VINMIN
IPRI
I PEAK
IPEAK
IPEAK
IPEAK
ISEC
tON
tOFF
Light load
IPRI
ISEC
tON
TOFF
full load
Fig. 1
3 of 24
AN-SMPS-1683X-1
V1.2
Circuit diagram:
Fig. 2
4 of 24
AN-SMPS-1683X-1
V1.2
Example
85V
270V
50Hz
40W
1W
12V
0,05V
100V
0,8
20V
12V
1
TDA16834 for 40W @ 25C
Vacmin
Vacmax
f ac
POmax
POmin
VOUT
VOripple
VR
Vripple
Vaux.
GC
POUT
(Eq 1)
PMAX =
40W
= 50W
0,8
(Eq 2)
I PRMS =
50W
= 0,98 A
85V 0,6
(Eq 3)
PMAX
V ac min cos
(Eq 4)
5 of 24
AN-SMPS-1683X-1
V1.2
(Eq 5)
arcsin dc min
V dc min pk
T D = 5ms 1 +
90
(Eq 6)
100V
arcsin
120V
T D = 5ms 1 +
90
(Eq 7)
(Eq 8)
CIN =
= 8,1ms
2 W IN
V dc2 min pk
V dc2 min
2 0,41Ws
14400V 2 10000V 2
= 186 F
CIN
2F/W
1F/W
2 ...3F/W....................
50W 3F = 150 F
2 WIN
C IN
(Eq 9)
V dc min = 14400V 2
2 0,41Ws
= 99, 2V
180 F
2000h lifetime
10000h lifetime
3000h lifetime
5000h lifetime
6 of 24
AN-SMPS-1683X-1
V1.2
Transformer Design:
2 PMAX
V dc min D max
I LRMS = I LPK
D max
3
2 50W
= 2,14 A
99V 0,47
(Eq 10)
I LPK =
(Eq 11)
I LRMS = 2,14 A
0,5
= 0,85 A
3
Dmax V dc min
I LPK f
(Eq 12)
0,47 99V
= 217 H
2,14 A 100kHz
LP =
LP
AL
(Eq 13)
NP =
217 H
= 29,85 turns
244nH
we choose Np = 30 turns
N P (VOUT + V FDIODE )
VR
(Eq 14)
Ns =
30 (12V + 0,7V )
= 3,81
100V
we choose Ns = 4 turns
7 of 24
AN-SMPS-1683X-1
V1.2
N aux =
(Eq 15)
N aux =
30 (12V + 0,7V )
= 3,81
100V
L P = N P2 Al
I Lpk =
V dc min D max
Lp f
B max =
L P I LPK
N P Ae
4 10 7 N P2 Ae
s=
LP
(Eq 16)
L P = 30 2 244nH = 220 H
(Eq 17)
I Lpk =
(Eq 18)
B max =
(Eq 19)
s=
99V 0,47
= 2,12 A
220 H 100kHz
220 H 2,12 A
30 83mm 2
= 187 mT
4 10 7 30 2 83mm 2
= 0,43mm
0,22mH
Winding design:
(see also page 20
Transformer Construction)
BWe = BW 2 M
ANe =
AN BWe
BW
(Eq 20)
(Eq 21)
8 of 24
AN-SMPS-1683X-1
V1.2
AP =
0,5 A N f Cu BWe
N P BW
As =
0,45 A N f Cu BWe
N s BW
Aaux =
0,05 AN f Cu BWe
N aux BW
(Eq 22)
AP =
(Eq 23)
(Eq 24)
As =
(Eq 25)
NP =
BWe
dP
(Eq 26)
Aaux =
Primary:
NP =
12,1mm
= 17 turns per layer
0,64 mm
2 layer needed
Secondary:
NS =
12,1mm
= 4 turns per layer
2 0,8mm
Aux.:
Can be neglected !
9 of 24
AN-SMPS-1683X-1
V1.2
Output Rectifier:
The output rectifier diodes in flyback converters are
subject to a large peak and rms current stress. The
values depend on the load, leakage inductance,
operating mode and output capacitor ESR.
Calculation of the maximum reverse voltage:
N
V RDIODE = VOUT + V dcinpk S
NP
(Eq 27)
(Eq 28)
I SPK = 2,81A
(Eq 29)
NP
NS
30
= 15,9 A
4
Output Capacitor:
VOUT = 0,5V
ncp = 5
C OUT =
I OUTMAX n cp
C OUT =
(Eq 30)
VOUT f
3,33 A 5
= 333F
0,5V 100kHz
B41826-A5477-M
4000h lifetime
2000h lifetime
10 of 24
AN-SMPS-1683X-1
V1.2
Output Filter:
The output filter consists of one capacitor and one
inductor in a L-C filter topology.
1
2 R ESR COUT
(Eq 31)
f ZCOUT =
1
= 5,6kHz
2 0,06 470F
R ESR
2 f ZCOUT
(Eq 32)
LOUT =
0,06
= 0,56 H
2 5,6kHz 3
VCC-Supply:
Start-up Resistor:
ICCLmax = max. Quiescent Current
ICCLmax = 80A
Il = VCC-Capacitor Load-Current
Il = 40A
CVCC = 22F
R start =
V dc min
I CCL max + I l
R start =
(Eq 33)
99V
= 827 k
80 + 40 A
CVCC VCCH
Il
Choose: 410k
(Eq 34)
t start =
22 F 12V
= 6,6s
40 A
11 of 24
AN-SMPS-1683X-1
V1.2
(Eq 35)
L LK = 220H 5% = 11H
2
C snub =
R snub =
I LPK L LK
(V R + Vsnub )V snub
(Vsnub + V R )2 V 2
R
0,5 L LK I LPK f
(Eq 36)
C snub =
(Eq 37)
R snub =
12 of 24
2,12 A 2 11H
= 1,9nF 2,2nF
(100V + 118V )118V
= 15,1k 15k
AN-SMPS-1683X-1
V1.2
Calculation of losses:
Input diode bridge:
PDIN = I PRMS V F 2
R PCu =
l N N P p100
AP
(Eq 38)
R PCu =
RSCu =
0,0644m 30 17,2mmm 2 / m
0,33mm 2
0,0644m 4 17,2mmm 2 / m
1,04 mm 2
(Eq 40)
= 116,3m
= 4,9m
PDDIODE = I SPK
1 D max
V FDIODE
3
Cu
(Eq 41)
PDDIODE = 15,9
1 0,47
0,7V = 5,36W
3
MOSFET :
TDA16834
COSS 40pF
RDSON = 1,6 (@ 150C)
Switching losses:
PSON = 1 C OSS V dc2 min f
2
(Eq 42)
(Eq 43)
(Eq 44)
Conduction losses:
2
PD = 1 R DSON I LPK
Dmax
3
13 of 24
AN-SMPS-1683X-1
V1.2
Reference: TL431
VREF =2,5V
IKAmin=1mA
3,7k
FB
VFB
Optocoupler: SFH617-3
Gc = 1 ...2 CTR 100% ...200%
VFD = 1,2V
IFmax =10mA (maximum current limit)
Fig. 3
Vout
Primary side:
R3
Feedback voltage:
Values from TDA16831...34 datasheet
Vrefint = 5.5V typ.
VFBmax = 4,8V
RFB = 3,7k typ.
R1
R4
R5
C1
C2
TL431
R2
Fig. 4
I FB max =
I FB min =
V ref int
R FB
(Eq 45)
I FB max =
5,5V
= 1,5mA
3,7k
(Eq 46)
I FB min =
5,5V 4,8V
= 0,19mA
3,7k
(Eq 47)
12V
R1 = 4,7k
1 = 17,86k
2
,
5
V
(Eq 48)
R3
(Eq 49)
0,2mA
1, 2V + 910 R
1
R4
= 1,4k 1,2k
1mA
Secondary side:
V
R1 = R2 OUT 1
V REF
the value of R2 can be fixed at 4,7k
R3
(VOUT (V FD + V REF ) )
I F max
V FD + R3 FB min
Gc
R4
I KA min
14 of 24
AN-SMPS-1683X-1
V1.2
Regulation loop:
FPWR(p)
VIN
Vout
FLC(p)
KVD
KFB
_
Fr(p)
+
Vref
Fig. 5
K FB =
G C 3k 7
R3
Feedback
GC= Optocoupler gain
K VD =
R2
Vref
=
R1 + R 2 Vout
FPWR ( p ) =
1
Z PWM
Voltage Divider
L P f R L (1 + p R ESR C 5 )
2 RL
RL
1 + p 2 + R ESR C 5
Power stage
FLC ( p) =
Fr ( p) =
1 + p R ESR C 9
Output filter
1 + p R ESR C 9 + p 2 L C 9
1 + p R 5 (C1 + C 2)
R1 R 2
p
C1 (1 + p R5 C 2)
R1 + R 2
Regulator
15 of 24
AN-SMPS-1683X-1
V1.2
R LH =
VOUT
12V 2
=
= 3,6
PO max
40W
R LL =
V OUT
12V 2
=
= 144
PO min
1W
foh =
1
R LH C 5
foh =
1
= 62,7 Hz
3,6 1410F
fol =
fol =
1
= 1,57 Hz
144 1410 F
R LL C 5
The gain of the optocoupler stage KFB and the voltage divider KVD we use as a constant.
K FB =
G C 3k 7
R3
KFB = 6,6
GFB = 16,4db
K VD =
R2
Vref
=
R1 + R 2 Vout
KVD = 0,208
GVD = -13,6db
With adjustment of the transfer characteristics of the regulator we want to have equal gain within the
operating range and to compensate the pole fo of the powerstage FPWR().
Because of the compensation of the output capacitors zero (see page 10 Eq31, Eq32) we neglect this zero
and the LC-Filter pole.
So the transfer characteristics of the power stage is reduced to a single pole response.
In order to calculate the gain of the open loop we have to select the crossover frequency.
We calculate the gain of the Power-Stage with max. output power at the selected crossover frequency
fg = 3kHz:
Z PWM (t ON ) = Z PWM
1
t ON
tON
t ON T1 + T 1 e T 1
tON
+ 0,6 1 e T 2
16 of 24
AN-SMPS-1683X-1
V1.2
4,7 s
4,7 s
1
V
V
FPWR ( fg ) =
1
Z PWM
R L L p f
1
2
2
fg
1
+
fo
1
3,6 R 220uH 100kHz 0,8
1
FPWR (3kHz ) =
2
1,8
2
1 + 3000
62,7
= 0,065
GPWR(3kHz) = -23,7db
Transfer characteristics:
50 50
Gr()
G
Gain
PWR ( )
GFB
[db]
Gr( )
G FB
GVD
G MOD
0
GPWR()
50
50
1
1
10
3
1 10
100
(i)
2.
4
1 10
1 10
5
1. 10
Fig. 6
17 of 24
AN-SMPS-1683X-1
V1.2
Gs () + Gr () = 0
Fr ( p) =
Gr = 0 (-20,9db) = 20,9db
1 + p R5 (C1 + C 2))
R1 R 2
p
C1 (1 + p R5 C 2)
R1 + R 2
Gr = 20 log
R5 (R1 + R 2)
R1 R 2
Gr
R5 = 10 20
R5 = 10
fp =
1
2 R5 C 2
C2 =
C2 =
20 ,9
20
R1 R 2
R1 + R 2
1
2 R5 2 fg
fp = 2*fg
1
= 617 pF 680pF
2 43k 6kHz
In order to have enough phase margin @ low load condition we select the zero frequency of compensation
network at the middle between min. and max. load pole of power stage.
f om = f oh 10
fz =
0,5log
f ol
f oh
1
2 R5 (C1 + C 2)
f om = 62,7 Hz 10
C1 =
C1 =
0,5log
1,57
62,7
= 9,92 Hz
1
C2
2 R5 fom
1
680 pF = 384nF 390nF
2 43k 9,92 Hz
18 of 24
AN-SMPS-1683X-1
V1.2
70
50
Gr( )
Gs( )
G( )
50
60
1
1
10
100
3
1 10
4
1 10
3
1 10
4
1 10
( i)
2.
1 10
5
.
1 10
Fig. 7
10
10
28
r( )
s( )
66
( )
104
0
142
180
180
1
1
10
100
( i)
2.
1 10
5
1. 10
Fig. 8
19 of 24
AN-SMPS-1683X-1
V1.2
Transformer Construction
The winding topology has a considerable influence on the performance and relaibility of the
transformer.
To reduce leakage inductance and proximity to acceptable limits, the use of a sandwich construction is
recommended.
In order to meet international safety requirements a transformer for off-line power supply must have
adequate insulation between primary and secondary winding.
This can be achived by using a margin wound construction or using triple insulated wire for the
secondary winding.
The creepage distance for universal input voltage range is typically 8mm. This sets a minimum margin
width as a half of the creepage distance to 4mm. Additional the neccesary insulation between primary
and secondary winding is provided using three layers of basic insulation tape.
BW*
BWe
Primary
second half
Creepage
distance
Secondary
Triple insulation
Auxiliary
Primary
first half
margin
margin
Fig. 9
Example of winding topology with triple insulated wire for secondary winding:
BW*
Primary
second half
Triple Insulated
Wire
Secondary
Auxiliary
Primary
first half
Fig. 10
BW* : value from bobbin datasheet
20 of 24
AN-SMPS-1683X-1
V1.2
Layout Recommendation:
Fig. 11
In order to avoid crosstalk between Power- and Signal-Path on the board we have to use care
regarding the track layout when designing the PCB.
The Power-Path (see Fig. 11) has to be as short as possible and separated from the VCC-Path and
the Feedback-Path. All GND-Paths have to be connected together at pin 8 (star ground) (1 and 14 at
G-type) of TDA16831...34.
21 of 24
AN-SMPS-1683X-1
V1.2
References
[1] Keith Billings, Switch Mode Power Supply Handbook
[2] Ralph E. Tarter, Solid-State Power Conversion Handbook
[3] R. D. Middlebrook and Slobodan Cuk, Advances in Switched-Mode Power
Conversion
[4] Herfurth Michael, Ansteuerschaltungen fr getaktete Stromversorgungen mit
Erstellung eines linearisierten Signalfluplans zur Dimensionierung der Regelung
[5] Herfurth Michael, Topologie, bertragungsverhalten und Dimensionierung hufig
eingesetzter Regelverstrker
[6] TDA16831 4
Off-line SMPS Controller with 600V CoolMOS on Board
Datasheet, Infineon Technologies
Revision History
Application Note AN-SMPS-1683X-1
Actual Release: V1.2 Date:13.03.2000
Page of
actual
Rel.
Page of
Subjects changed since last release
prev. Rel.
24
21
Formatting
22 of 24
AN-SMPS-1683X-1
V1.2
For questions on technology, delivery and prices please contact the Infineon
Technologies Offices in Germany or the Infineon Technologies Companies and
Representatives worldwide: see the address list on the last page or our webpage at
http://www.infineon.com
Edition 2000-03--03
Published by Infineon Technologies AG,
St.-Martin-Strasse 53,
D-81541 Mnchen
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V1.2
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Shenzhen Office
Room 1502,Block A
Tian An International Building
Renim South Road
Shenzhen 518 005
T (+86)7 55 -2 28 91 04
Fax (+86)7 55-2 28 02 17
ZA
Siemens Ltd.
Components Division
P.O.B.3438
Halfway House 1685
T (+27)11-6 52 -27 02
Fax (+27)11-6 52 20 42
AN-SMPS-1683X-1
V1.2