User manual STEVAL-ISA03V: 40 W SMPS with HV MOSFET and L6565 for three-phase industrial applications Introduction This document introduces a solution for industrial power supplies fed by a three-phase mains. It employs a high voltage (500 V breakdown voltage) power MOSFET to optimize the operation of a quasi-resonant flyback converter based on the primary controller L6565. The demonstration board has been designed and developed specifically for low power applications. The board features two outputs, 4 V and 5 V, and is capable of delivering more than 40 W of output power. The 5 V output is obtained by means of an integrated DC- DC converter based on the L5970AD.5 A switch step-down switching regulator, connected to the 4 V output. The demonstration board is available through order code STEVAL- ISA03V. Figure. STEVAL-ISA03V demonstration board - top side AM0306v Figure. STEVAL-ISA03V demonstration board - bottom side AM0307v September 009 Doc ID 4974 Rev /9 www.st.com
Contents UM0584 Contents Demonstration board description.............................. 3. Bill of materials.............................................. 5 Revision history............................................ 8 /9 Doc ID 4974 Rev
Demonstration board description Demonstration board description The STEVAL-ISA03V demonstration board is based on a quasi resonant flyback converter and employs the STW4N50 power MOSFET as the primary switch. The STW4N50 is a 5 Ω 500 V power MOSFET designed with STMicroelectronics proprietary high voltage "Mesh Overlay" technology, which gives the switch very low R DS(on) per area, low gate charge and high switching performance. The STW4N50 device is available in the TO-0, TO-47 and TO-0FH packages. The main specifications of the demonstration board are provided in table below. Table. STEVAL-ISA03V main specifications Parameter Input voltage range Input frequency range Output Output Output power Safety EMI Value 85 to 460 Vac 50/60 Hz 4 V @.7 A 5 V @ A 40 W EN60950 EN5504 The input section features two connectors: CON for 400 Vac input voltage and CON for 30 Vac input voltage. The output voltages are available on CON3, with a shared ground between the two outputs. The converter is controlled by the L6565, a primary controller for quasi resonant ZVS (zero voltage switching) flyback converters. The IC controls the power capability variations with the mains voltage by means of line voltage feed-forward. In addition to the very low startup and quiescent currents, the device manages light load conditions with optimized consumption thanks to a special function which automatically lowers the operating frequency while maintaining operation as close to ZVS as possible. The IC also includes a disable function, an on-chip filter on current sense, an error amplifier with a precise reference voltage for primary regulation and effective two-level overcurrent protection. The transformer reflected voltage is set to 400 V, providing sufficient margin for the leakage inductance voltage spike, and a small RCD clamper circuit is used to limit excess voltage on the drain of the MOSFET. During normal operation, the IC is powered by the auxiliary winding of the transformer via diode D7. A spike killer circuit for auxiliary voltage fluctuations is provided but not connected (Q, C3, R3). The primary current is measured using external sensing resistors (R0, R) for current mode operation. Output voltage regulation is performed via a secondary feedback on the 4 V output. The feedback network consists of a programmable voltage reference, TL43, driving an optocoupler which ensures the required insulation between the primary and secondary sections. The optotransistor drives the feedback pin (COMP) which controls the operation of the IC. Doc ID 4974 Rev 3/9
Demonstration board description UM0584 LC filters have been added on both outputs to reduce high frequency ripple, with moderate output capacitor values. The flyback transformer is a layer-type based on an ETD9 core and N67 ferrite, manufactured by Tronic, with insulation meeting EN60950 safety standards. Figure 3. Circuit schematic F A L.mH L.mH L3.mH D N4007 D3 N4007 480-650VDC D N4007 C3 n-x D4 N4007 L4 33 mh NTC 5 O C4 n-x C uf C uf R M R M R3 M R4 M C6 n C7.n R4 5k R5 5k C9.n R5.8M R6.8M R7.8M U INV COMP VFF CS L6565 R6 0k VCC GD GND ZCD D8 LL448 C8 00n R8 330k R9 330k R7 56k C0 47u D7 LL448 C4.n - Y R0 50K/W R 50K/W C 470p C5 3.3n/kV D6 D5 STTH08 STTH08 R 6R Q nc C3 6.8n - nc R3.k - nc HS R8. R9 k M STW4N50 R0 R U PC87 T D9 STPS5H00 C5 0u/35V 4 TRANSFORMER Lp=3.5mH Np/Ns=.7 Np=85T-AWG34 Ns=5T-AWG3 Naux=0T-AWG3 Core material N67(CF38) COre shape ETD9 g=.3mm C7 C nc 0uF/0V R R R6 k R7 3k3 L5 0uH U5 TL43 R9 5k6 C6 R 5.6k u/35v L6 5uH D0 R3 STPSL5U k C8 R4 n 3k9 R5 4k7 R8 0k - % C nc C n 400Vac CON C3 n.c. R30.k - % U4 L5970A OUT VCC SYNC GND INH VREF COMP FB 30Vac CON C9 0p J6 CON3 4V/.7A 5V/A C0 0uF/35V + + 3 4 8 7 6 5 7 3 8 + 3 4 8 7 6 5 3 AM0308v 4/9 Doc ID 4974 Rev
Demonstration board description The 5 V output is obtained from the 4 V output by means of an integrated power IC, the L5970AD. The L5970AD is a step-down monolithic power switching regulator with a switch current limit of.5 A, capable of delivering more than A of DC current to the load depending on application conditions. The output voltage can be adjusted down to.35 V by a voltage divider. The device uses an internal P-channel DMOS transistor, with a typical R DS(on) of 00 mω as a switching element to avoid the need for a bootstrap capacitor and to guarantee high efficiency. An internal oscillator sets the switching frequency at 500 khz to minimize the size of external components. The power IC features several protection functions, such as pulse-by-pulse current limiting, with the internal frequency modulation aimed at effective constant current short-circuit protection, feedback disconnection and thermal shutdown. Finally, the device can be synchronized using a dedicated pin, and also inhibited for reduced standby power consumption and time sequence operations. The schematic of the board is shown in Figure 3. The complete power supply is built on a double-sided 35 µm PCB in FR-4, sized 30 x 66 mm. The bill of materials is given in table below.. Bill of materials Table. STEVAL-ISA03V bill of materials Reference Value Description C µf - 450 V Elect. capacitor 85 C C µf - 450 V Elect. capacitor 85 C C3 nf - 660 Vac Polip. capacitor X C4 nf - 660 Vac Polip. capacitor X C5 4.7 nf - kv Polip. capacitor FKP - WIMA C6 nf Elect. capacitor C7. nf Ceramic capacitor C8 00 nf Ceramic capacitor C9. nf Ceramic capacitor C0 47 µf Ceramic capacitor C 470 pf Ceramic capacitor C n.m. Ceramic capacitor C3 6.8 nf (n.m.) Ceramic capacitor C4. nf Polip. capacitor X Y C5 0 µf 35 V Elect. capacitor C6 µf 35 V Elect. capacitor C7 0 µf 0 V Elect. capacitor C8 nf Ceramic capacitor C9 0 pf Ceramic capacitor Doc ID 4974 Rev 5/9
Demonstration board description UM0584 Table. STEVAL-ISA03V bill of materials (continued) Reference Value Description C0 0 µf- 35 V Elect capacitor C n.m. C nf Ceramic capacitor C3 n.m. D, D, D3, D4 N4007 Rectifier 000 V A D5 STTH08 STMicroelectronics turboswitch diode A - 800 V D6 STTH08 STMicroelectronics turboswitch diode A - 800 V D7 LL448 SOD-80 general purpose rectifier 75 V 00 ma D8 LL448 SOD-80 general purpose rectifier 75 V 00 ma D9 STPS5H00 Schottky rectifier 5 A - 00 V D0 STPSL5U Schottky rectifier A - 5 V L, L, L3. mh Inductor - TDK SL70-KR60 L4 33 mh Common mode choke - TDK 333Y0R0 L5 0 µh Inductor - TDK SLF7045T - 00MR3 L6 5 µh Inductor - TDK SLF7045T - 50MR NTC 5 Ω NTC inrush current suppressor - EPCOS 0544 F A Fuse R mω Resistor R mω Resistor R3 mω Resistor R4 mω Resistor R5.8 mω Resistor R6.8 mω Resistor R7.8 mω Resistor R8 330 kω Resistor R9 330 kω Resistor R0 50 kω Resistor, W R 50 kω Resistor, W R Ω Resistor, SMD-06 R3. kω (n.m) Resistor R4 5 kω Resistor, SMD-0805 R5 5 kω Resistor, SMD-0805 R6 0 kω Resistor R7 56 kω Resistor R8. Ω Resistor 6/9 Doc ID 4974 Rev
Demonstration board description Table. STEVAL-ISA03V bill of materials (continued) Reference Value Description R9 kω Resistor R0. Ω Resistor R. Ω Resistor R 4.7 kω Resistor, 0.5 W TRH R3 kω Resistor R4 3.9 kω Resistor R5 4.7 kω Resistor R6. kω Resistor R7 3.3 kω Resistor R8 0 kω Resistor, 0.5 W % R9 5.6 kω Resistor R30. kω Resistor, 0.5 W % T 06036 Switch mode transformer - Tronic U L6565 STMicroelectronics quasi resonant controller U PC87 Optocoupler - Sharp U4 L5970AD STMicroelectronics -.5 A switch step-down switching regulator U5 TL43 STMicroelectronics programmable shunt voltage reference % M STW4N50 STMicroelectronics MOSFET 500 V - 5 Ω - 4 A Q BC547 (n.m.) Small signal PNP transistor Doc ID 4974 Rev 7/9
Revision history UM0584 Revision history Table 3. Document revision history Date Revision Changes 4-Sep-009 Initial release. 8/9 Doc ID 4974 Rev
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