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APPLICATIONNOTE
300W SECONDARY CONTROLLED TWO-SWITCHFORWARD CONVERTER WITH L4990A
by: N.Tricomi C. Adragna
INTRODUCTION
A typical off-line isolated switch-mode power sup-ply has the controller located on the primaryside of the transformer, whereas the output volt-ages to be controlledand thehousekeepingfunc-tions are located on the secondary side. Usuallythe voltage feedback signal is transferred to theprimary controller by using an optocoupler or atransformer.We want to propose here an asymmetrical halfbridge forward converter with the controller lo-cated on the secondary side. This solution offerssome advantages:- direct useof theon-boardvoltagereference- no need of the opto feedback, with its tem-peratureand ageinggain dependence- available on-board housekeeping functionseliminates the need of an additionaldedicateddevice- negligible extra cost on the gate drive trans-formerto satisfysafety requirementsThe controlleroperatingon the secondaryside re-quires a specific concept for the start-up se-quence, realised here with a very simple, lowconsumptionandcost effectivesolution.
POWERSUPPLYDESCRIPTIONTopology
Considering the 300W of output power deliveredto the load, the most appropriate topology is theasymmetricalhalf bridge converter.This topology requires two power MOs transis-tors with a voltage breakdown equal or littlehigher than the max. rectified mains voltage(thanks to the two clamping diodes), with aproperRdson to reach thetarget efficiency.Fig. 1 shows the complete schematic diagram ofthe 300WPower Supply.
Start-upcircuit
As already mentioned in the introduction section,the controller is located on the secondaryside ofthe power transformer, and for this reason, astart-up circuit has to be provided for a correctsystemactivation.The start-up circuit is based on a diac sendinga train of controlledpulses to the low side drivesection; the floating drive section is energised bythe second secondary gate drive transformerwinding .As soon as the L4990 wakes-up, it generates apwmsignal enablingthe start-upcircuit.
Gatedriver
The two power mosfets, T1 and T2, are driven bya small transformer designed to satisfy the iso-lation safety requirements and fast switchingtimes.For optimum magnetic coupling (required by thehigh switching frequencyoperation) andminimumnumber of turns, a high permeability core hasbeen selected.The core is E20/10/5-3C85, 10 turns/winding, noair-gap.
AN890/1297
Symbol Description Parameter
V
I
Input voltage 220Vac (176 Vac to 265 Vac) // 50HzV
O
Output voltage 24V % (ripplevoltage <1%)I
O
Output Current 13A max. continuous, 0.5A minI
l
Limiting Current constant type tillgroundP
o
Output continuos power 312Wf
s
Switching Frequency 200kHz
η
Target Efficiency(full load) = 90% (from mainsto output)
POWERSUPPLYSPECIFICATION
1/10
 
   1   0   R   1   5   1   0   1   3
   R   8
   4   3   0
     Ω
   1   2   1   1
   R   1   1
   1 .   2   K   2   3   4
   C   1   1
   4 .   7
    µ
   F   R   5   4 .   7   K
   C   1   2
   1  n   F
     D     9     6     I     N     4     5     5     A
   L   4   9   9   0   A
   V
   R   E   F
   R   C   T   7   S   S   C   1   6   3   9   0  p   FI   S   E   N   O   U   T   S   G   N   D   P   G   N   D   1   0   T
   C   5
   1
    µ
   F
   P   1
   1   0   K
   C   1   4
   4   7   0  n   F
   T  s   f   2
   1   0   T   1   5   D   C   C   D   C   L
   C   1   0
   2 .   2  n   F   R   1   3 .   6
   D   9
   1   8   V
   C   2   9
   3   3  n   F
   C   7
   1   0   0
    µ
   F   L   6   9   T   9   8   V   C   V   C   C   5   6   F   B
     C     O     M     P
   C   9   1  n   F   R   7   8   0   K
   R   1   2
   6 .   2   K   1   4   D   I   S
   R   1   0
   2   7   0
   C   1   8
   1   0   0  n   F
   R   9
   3 .   3   K
   C   2
   1   0   0   0
    µ
   F
   C   3
   1   0   0   0
    µ
   F
   C   4
   1   0   0   0
    µ
   F   L   1   2   4   T   7   7   9   3   0
   2   4   V   1   3   A
   V  o   R   3   0   1   8   0   D   1   8
    T    5     B     C    2    3    7
   R   2   4
   3   0   K   T   1   C   1   7   1   0   0  n   F   D   1   9   1   0   T   R   2   3   1   8   0   D   1   6
    T    4     B     C    2    3    7
   R   1   9
   3   0   K   C   1   5   1   0   0  n   F   D   1   7
   1    0    T
   T   2
   C   2   6  -   2   7
   2   2   0
    µ
   F
   4   0   0   V
   E   M   I
   2   2   0   V   A   C
   B   R   I   D   G   E
   K   B   U   B   J   D   1   2
   C   2   5
   1   0   0  n   F
   T   3
   B   C   3   3   7   C   2   8
   R   2   0
   7 .   5   K   D   I   A   C   1   T   D   1   D   5
     D   1    5     D   1    4
   D   1   3
   B   Y   T   1   1   6   0   0
   R   1   4
   2   2   K
   C   3
   1   0   0  p   F   3   2   T   T  s   f   1   D   3   D   2   5   0   T
   C   6
   1  n   F
   R   2
   1   0
   R   1   6
   3   6   0   K   5   0   T   1   T
Figure1:
SchematicDiagramof 300Wpower supply
APPLICATIONNOTE
2/10
 
A highpermeabilitycore minimises themagnetis-ing current to maintain a correct operation faraway of the core saturation point, at maximumduty cycleand highcore temperature.The proposed gate drive circuit allows the use ofthe 1:1:1 turns ratio drive transformer; moreover,a controlleddrain current rise time (by R15) and afast fall timeare achieved.A very short min. Ton pulse give the possibility tostabilise the output voltage at max. mains andmin. load.
PowerMOS selection
The two-switch topology allows to use the powerelements with a voltage breakdown equal to themax. rectifiedmainsvoltage.The mosfet used here is the STW15NB50;thisdevice, with 500V of BVdss give us also somesafety margin.The basic parameters of the STW15NB50 arelisted below:Rdson (25
°
C) = 0.36
Ω
max., at Id = 7.5A (0.72
Ω
max. at 100
°
C)Coss = 430pF max., Qg = 80nC max., packagein TO-247At min. supply voltage and max. load current, theconduction lossesfor each transistorare:Pcon = I
2
rmsp
⋅
Rdson(100
°
C) = 2.23
2
⋅
0.72 =3.6W where the effective Irmsp
2
is calculated inthepower transformersection.Estimating in about 3.5W switching and parasiticlosses, the total power losses of each transistorare about7W.Considering 100
°
C of maximum operating junc-tion temperature (at 40
°
C of ambient tempera-ture) and a thermal resistance junction-heatsinkof 0.76
°
C/W, a heatsink of 3.5
°
C/W is requiredto dissipate both the transistors.
Currentsense
Considering the output current rating of 13A con-tinuous, it’s our opinion that a current transformerfor currentsensing is the bestapproach formaxi-mising the efficiency,reliabilityand internalambi-ent temperature in case the power supply has tobe housedin a plasticbox.Due to the constantcurrent limiting requirements,as shown in Fig2, a couple of current transform-ers have been used; one transformer is sensingthe current flowing into D1 (in conduction whenT1 and T2 are ON) and the second one is sens-ing the current flowing into D5, recirculation di-ode.Oring the two transformers by D2 and D3, andclosing the loop with a proper impedance value,R1, we realise a voltage signal reproducing ex-actly the inductorcurrent shape.The current sensingloop is closed by R1 selectedaccordingthetransformersturns.Twosmall toroidferrite cores(41005-TC,Magnet-ics, F material, 3000
µ
) have been used, with 50turns.R1is definedby:R1
=
50
⋅
1VIpkwhere:1V is the nominal threshold voltage of the cur-rentsense.Ipk is the inductor peak current( considering a20% of current ripple, Ipk = Io +
∆
I/2 = 13 + 1.3 =14.3A)The calculatedvalue is R1=3.5
Ω
Fig. 2 shows the constant current characteristicusingtwo current transformers.The differencefrom the two currentvalues, at out-put short-circuit and at current limiting interven-tion, is proportional to the half of chocke ripplecurrent.A choke with higher value or higher switchingfrequency,canreduce this difference.If constant current feature is not requested to beconstanttill the outputis reachingzero V, onesin-gle currenttransformercan be used.The new limiting current characteristic and theschematic diagramare shown in Fig3a and3b:In order to reduce the peak current before hiccupintervention, an offset can be superimposed tothe current sensing circuit to anticipatethe hiccuplimiting current intervention, by using the addi-tionalnetworkshown below( figs. 4a and 4b):
8 10 12 14 Io0510152025Vo
D96IN456 
Figure2:
Outputlimiting currentcharacteristicusingtwo currenttransformers
APPLICATIONNOTE
3/10
of 00

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