45W USB Type-C™ PD Adapter Board With Controllers STCH03 QR Flyback, SRK1001 Adaptive Synchronous Rectifier and STUSB4761 USB Type-C™ PD
45W USB Type-C™ PD Adapter Board With Controllers STCH03 QR Flyback, SRK1001 Adaptive Synchronous Rectifier and STUSB4761 USB Type-C™ PD
45W USB Type-C™ PD Adapter Board With Controllers STCH03 QR Flyback, SRK1001 Adaptive Synchronous Rectifier and STUSB4761 USB Type-C™ PD
Application note
Introduction
This application note describes the operation and the performance of the EVLSTCH03-45WPD demo board.
The EVLSTCH03-45WPD is designed to deliver a maximum output current of 3 A and a variable output voltage between 5 V
and 20 V. The maximum power that the EVLSTCH03-45WPD demo board can deliver is 45 W.
The EVLSTCH03-45WPD is based on the quasi-resonant flyback controller STCH03, the synchronous rectifier controller
SRK1001, and the USB-PD Type-C controller STUSB4761 .
The EVLSTCH03-45WPD 45W USB Type-C Power Delivery 3.0 adapter is a USB-IF certified solution and reference design, the
respective Test ID reference are:
• Power Brick EVLSTCH03-45WPD TID: 2071
• PD Controller STUSB4761 TID: 2070
Important:
This product is intended for evaluation purpose only. Although it is designed to satisfy safety isolation requirement it shall be
operated in a designated test area by personnel qualified and all testing should be performed with an isolation transformer to
provide the AC input to the demo board.
1 Introduction chapter 1
This application note describes how to design a 45 W Type-C Power Delivery adapter solution that supports the
following PDOs: 5 V / 3 A, 9 V / 3 A, 12 V / 3 A, 15 V / 3 A, 20 V / 2.25 A and accepts a wide inputs main range
(90 VAC to 265 VAC).
The EVLSTCH03-45WPD represents an effective solution where isolation from the AC mains is required, and
where cost effectiveness, high efficiency and low standby power are essential.
The EVLSTCH03-45WPD is an isolated power supply developed for USB Type-C Power Delivery adapter
applications. The primary side of the evaluation board implements a Quasi Resonant flyback converter based on
an STCH03 controller with optocoupler feedback for the voltage regulation. The secondary side implements an
Adaptive Synchronous Rectification based on the SRK1001 controller in order to increase the overall efficiency of
the system. The management of the USB Type-C Power delivery is based on an STUSB4761 controller. Figure 2
below shows the block diagram of the demo board.
OPTO
The features of the three controllers used to realize this adapter allow a compact and lightweight design with high
power density and with very low stand-by consumption, below 30 mW.
This evaluation board is compliant with CoC Tier 2 regulations thanks to the new MDmesh M6 technology primary
Power MOSFET STF7N65M6 and new STripFET F7 technology and synchronous Power MOSFET
STL110N10F7 that offer a very low on-state resistance.
The EVLSTCH03-45WPD is protected against destructive electrostatic discharge from the USB Type-C connector
using a Dual Transil array for ESD protection, ESDA25L.
2 Specifications
Table 1 shows the specifications of the demonstration board. This design could be used to develop a charger/
adapter and the circuit board would need to be modified depending on shape and form factor of the housing.
Performance should be evaluated with the new design and layout/components adjusted to meet the target
specification.
No-load input power PNO-LOAD < 30 mW, at VOUT = 5 V and no cable plug in
AN5442 - Rev 1
Schematic
RED
TURRET
TP13
TP1 VSRC TP10
HV TP9
1
L1 VSRC Vout = 5Vdc, 9Vdc,12Vdc, 15Vdc, 20Vdc
R34 33R Q4 Q5
1
47uH T1
R31 DMP3017SFGQ-7 DMP3017SFGQ-7 Iout MAX = 3 A
V_RECT 1
1
0R010 D6
4 V_OUT
D1 5 C11 1uF
+
AC IN F1
3A - 600V C3 9 D11
J1 3.15A - 300Vac 470pF R1 R2
+ + D2 C9 C10
+ + USB-C-Receptacle_3
SMAZ24
2 2 3 C1 C2 1kV RS1K
KBP306G 47uF 47uF R3
1 10 R22 18R R30 26 25
C18 1nF 560uF 560uF C21 SCH2 SCH1
R18 400V 400V
180K 180K 18R 25V 25V 47K 10uF
6
-
C27 B12 A1
NM 4.7M STL110N10F7 25V GNDB2 GNDA1
C5 TP6 7 B11 A2
RV1 Rx+1 Tx+1 RS1K
100nF GD 3 B10 A3
D9
1N4148WS
47pF 750344353/4 CC2 Sbu1
STD7N65M6 D8 B4 A9
R4 VbusB1 VbusA2
B3 A10
TP5 4R7 Tx-2 Rx-2
TP3 B2 A11
GND Tx+2 Rx+2
ZCD BAV21W B1 A12
R8 VSRC GNDB1 GNDA2
TP4 R32
100K R7 27 28
HV GD U1 SENSE R28 10K SCH3 SCH4
1
7
0 U4
D4 330
J2
HV
GD
2 5 SENSE 1 8
NC SENSE D7 DIS/Sync TON
D10
STCH03 BAT43WS 2 7 R27
GD TOFF
BAV21W
1
1N4148WS
GND ZCD 3 6 R29
FB
VDD
GND VAUX R45
R20 R6
R9 R24 4 5 C17 510R TP11 100R
3
8
C14 47pF VCC DVS
VDD 0R36 0R36 7K5 14K 1% TURRET
1% 1%
SRK1001 1uF
C19
R26
TP2 R10 R21 D12
0R 100k 68K NM
FB 4.7uF ESDA25L
C20
25V
Q3 R44
BSS169 100pF
0R
R25
U3A 4 VSRC
C13 47k
+ C8
C7
4
3
2
1
C6 TP7 TP12
100pF 100nF SLC SDA 2V7
22uF 4.7uF
NM 50V 100V
3 D5
CC2
CC1
SFH617A-2
Fault
C24
VConn
BZV55-C18 100nF
C23 5 16
SCL VDD 50V
R36 U5 C25
470nF 6 15
C15 1K SDA Vreg_2V7 1uF
50V STUSB4761
4.7nF 7 14 10V
X1-Y1 250Vac GND Vreg_1V2
8 13 C26 1uF
Isense VBus-EN
10V
R41
Tsense
Opto
FB
Vsense
4K7
2V7
R42 R39
9
R40
10
11
12
10K 4K7
4K7 RT2
t
R35
NTC 100K
R37 U3B 3K
15K SFH617A-2
RT3
t
The circuit diagram of the EVLSTCH03-45WPD evaluation board is shown in Figure 3.
C22
2
Figure 3. EVLSTCH03-45WPD evaluation board schematic
page 4/44
Schematic
AN5442
AN5442
Bill of materials
4 Bill of materials
5 PCB layout
The PCB layout top side and bottom side of the EVLSTCH03-45WPD evaluation board are shown in Figure 4 and
Figure 5 respectively. The PCB uses a two-layer technology in FR4 material with copper thickness of 70 µm.
Figure 4. EVLSTCH03-45WPD PCB top layer layout Figure 5. EVLSTCH03-45WPD PCB bottom layer layout
6 Board description
The EVLSTCH03-45WPD is an evaluation board based on the quasi-resonant flyback controller STCH03, the
synchronous rectifier controller SRK1001, and the USB Power Delivery controller STUSB4761. Figure 6 and
Figure 7 below show the top and bottom views of the demo board respectively.
Once the breakdown voltage of the Power MOSFET to be used has been defined, typically 650 V or 800 V, the
maximum output voltage must be used to set the right turns ratio of the power transformer. At this point, using the
maximum value of the current that can be delivered by the adapter and the turns ratio of the transformer, it is
possible to define the other parameters as current sense resistor RSENSE, zero current sense resistor RZCD,
undervoltage sense resistor RUVP and overvoltage sense resistor ROVP.
DBRIDGE
AC IN F + + CCLP RCLP1
CIN1 CIN2 DCLP
RV C RCLP2
AC IN
RT
RVDD DVDD
+C
VDD
RZCD
HV VDD
GD
RGD
STCH03
ZCD SENSE
GND FB
RSENSE
ROVP
CFB OPTO
Figure 9. Voltage between drain and source of the Power MOSFET, VDS
VMARGIN
DEMAGNETIZED
TRANSFORMER VSPIKE
RINGING LEAKAGE
INDUCTANCE AND VREFLECTED
PARASITIC CAPACITANCE
The maximum voltage on the Power MOSFET drain is given by the following equation:
Equation 1
(1)
Equation 4
(4)
NPRI KI
IPSR = N 2R
SEC SENSE
The constraint is to use a resistance value for RZCD-2 lower than 120 kΩ.
Equation 8
(8)
RZCD − 2 ≤ 120 kΩ
DBRIDGE
AC IN F + + CCLP RCLP1
CIN1 CIN2 DCLP
RV C RCLP2
AC IN
RT
RVDD DVDD
+C
DZCD RZCD-1 VDD
HV VDD
GD
RZCD-2 RGD
STCH03
ZCD SENSE
GND FB
RSENSE
ROVP
CFB OPTO
In this way, the phase relative to the feedforward compensation is separated from the triggering and output
voltage monitoring, Figure 11 shows the two different phases.
DZCDON DZCDOFF
RZCD-2 RZCD-1+RZCD-2
When the primary Power MOSFET is in the ON state, the DZCD diode is open and the equivalent resistance is
given by RZCD-1 plus RZCD-2, line feedforward function continues to work properly and the current limitation does
not depend on the input line voltage. While when the primary Power MOSFET is in an OFF state the DZCD diode
is a short-circuit and the equivalent resistance is only RZCD-2. In this phase the ZCD pin senses the transformer
demagnetization for quasi-resonant operation and a negative going edge triggers the Power MOSFET turn-on,
furthermore the output voltage is monitored to realize the undervoltage and overvoltage protections.
Equation 9
(9)
NSEC
V
NAUX UVP
RUVP = NSEC
RZCD − 2
VOUT − UVP − VUVP
NAUX
Where VOUT-UVP is the UVP desired threshold value, VUVP is an internal parameter of the device, NAUX is the
number of the auxiliary windings, NSEC is the number of secondary side windings and RZCD-2 is defined by
Equation 8.
The DOVP diode is a short-circuit when the ZCD pin voltage is greater than the internal VOVP threshold and
therefore the RUVP and ROVP resistors are connected in parallel. ROVP resistor is chosen to set the level of OVP
according to Equation 10.
Equation 10
(10)
VOVP
RZCD − 2RUVP
NAUX
VOUT − OVP − VOVP
NSEC
ROVP = VOVP
RUVP − RZCD − 2
NAUX
VOUT − OVP − VOVP
NSEC
DBRIDGE
AC IN F + + CCLP RCLP1
CIN1 CIN2 DCLP
RV C RCLP2
AC IN
RT
RVDD DVDD
+C
VDD
DZCD RZCD-1
HV VDD
RZCD-2 GD
RGD
STCH03
ZCD SENSE
GND FB
DZCD RSENSE
RUVP
ROVP
CFB OPTO
10
PRI
90-265Vac 9 4
60-150kHz 5
SEC
5/9/12/15V - 3A
1 20V - 2.25A
6
3
7
AUX
12V - 50mA
1. PD Power (PDP): The output power of a Source, as specified by the manufacturer and expressed in Fixed Supply PDOs.
2. UVLO / OVLO accuracy: +/- 2% across temperature range
The on-board temperature is monitored: in case of over-temperature conditions, (by default 70°C) the
STUSB4761 advertises lower power profiles.
VBUS current used for regulation is measured thanks to a 10 mΩ (default) shunt resistor between VDD and
ISENSE_DISCH pins. In case the measured VBUS current reaches the regulation threshold (+12.5% above the
SRC current from the PDO selected by the sink), the STUSB4761 enters in CC mode: voltage is decreased down
to the undervoltage (UVLO) condition defined for the selected contract.
To guarantee the regulation accuracy, one must follow the shunt layout recommendations as shown in Figure 14
below. A more detailed description of how to route the STUSB4761 PCB can be found in the AN5430 Application
Note (3).
STUSB4761 NVM configuration can be customized statically to align PD controller behavior according to final
application requirements. Customization applies to various parameters such as number of PDO, voltage, current,
discharge time, protection thresholds, etc…
Parameter customization is possible:
• Either by direct access through I²C interface,
• Or by using specific commands packaged as ST proprietary unstructured VDM when STUSB4761 is
connected in debug accessory mode (OrientedDebug Accessory.SRC state)
A more detailed description of temperature adaptive power, factory settings and customization can be found in the
STUSB4761 datasheet or product page (4).
7 Typical waveforms
In this section the converter operating waveforms are shown, in particular the waveforms of the primary and
secondary are reported in various line and load conditions.
Figure 15. Start-up waveforms at 115 VAC - No load Figure 16. Start-up waveforms at 115 VAC - Full load
Violet = VIN 200 V/div, Blue = VOUT 2.5 V/div, Violet= VIN 200 V/div, Blue = VOUT 2.5 V/div,
Green = IOUT 1.5 A/div Green = IOUT 1.5 A/div
Figure 17. Start-up waveforms at 230 VAC - No load Figure 18. Start-up waveforms at 230 VAC Full load
Violet = VIN 200 V/div, Blue = VOUT 2.5 V/div, Violet = VIN 200 V/div, Blue = VOUT 2.5 V/div,
Green = IOUT 1.5 A/div Green = IOUT 1.5 A/div
Figure 19. Flyback primary side waveforms at VOUT Figure 20. Flyback primary side waveforms at VOUT
= 5 V - IOUT = 3 A (VIN = 90 VAC) = 5 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 70 V/div, Green = VSENSE 300 mV/div ; Blue = VDS 100 V/div, Green = VSENSE 300 mV/div ;
VDS-MAX = 249.2 V VDS-MAX = 492 V
Figure 21. Flyback primary side waveforms at VOUT Figure 22. Flyback primary side waveforms at VOUT
= 9 V - IOUT = 3 A (VIN = 90 VAC) = 9 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 70 V/div, Green = VSENSE 300 mV/div ; Blue = VDS 100 V/div, Green = VSENSE 300 mV/div ;
VDS-MAX = 294 V VDS-MAX = 532 V
Figure 23. Flyback primary side waveforms at VOUT Figure 24. Flyback primary side waveforms at VOUT
= 12 V - IOUT = 3 A (VIN = 90 VAC) = 12 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 70 V/div, Green = VSENSE 300 mV/div ; Blue = VDS 100 V/div, Green = VSENSE 300 mV/div ;
VDS-MAX = 327.6 V VDS-MAX = 564 V
Figure 25. Flyback primary side waveforms at VOUT Figure 26. Flyback primary side waveforms at VOUT
= 15 V - IOUT = 3 A (VIN = 90 VAC) = 15 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 70 V/div, Green = VSENSE 300 mV/div ; Blue = VDS 100 V/div, Green = VSENSE 300 mV/div ;
VDS-MAX = 361.2 V VDS-MAX = 588 V
Figure 27. Flyback primary side waveforms at VOUT Figure 28. Flyback primary side waveforms at VOUT
= 20 V - IOUT = 2.25 A (VIN = 90 VAC) = 20 V - IOUT = 2.25 A (VIN = 265 VAC)
Blue = VDS 70 V/div, Green = VSENSE 300 mV/div ; Blue = VDS 100 V/div, Green = VSENSE 300 mV/div ;
VDS-MAX = 378 V VDS-MAX = 628 V
Figure 29. Flyback secondary side waveforms at Figure 30. Flyback secondary side waveforms at
VOUT = 5 V - IOUT = 3 A (VIN = 90 VAC) VOUT = 5 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 20 V/div, Green = IDS 10 A/div ; Blue = VDS 100 V/div, Green = IDS 10 A/div ;
VDS-MAX = 29.6 V VDS-MAX = 88 V
Figure 31. Flyback secondary side waveforms at Figure 32. Flyback secondary side waveforms at
VOUT = 9 V - IOUT = 3 A (VIN = 90 VAC) VOUT = 9 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 20 V/div, Green = IDS 10 A/div ; Blue = VDS 100 V/div, Green = IDS 10 A/div ;
VDS-MAX = 31.2 V VDS-MAX = 88 V
Figure 33. Flyback secondary side waveforms at Figure 34. Flyback secondary side waveforms at
VOUT = 12 V - IOUT = 3 A (VIN = 90 VAC) VOUT = 12 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 20 V/div, Green = IDS 10 A/div ; Blue = VDS 100 V/div, Green = IDS 10 A/div ;
VDS-MAX = 33.6 V VDS-MAX = 87.2 V
Figure 35. Flyback secondary side waveforms at Figure 36. Flyback secondary side waveforms at
VOUT = 15 V - IOUT = 3 A (VIN = 90 VAC) VOUT = 15 V - IOUT = 3 A (VIN = 265 VAC)
Blue = VDS 20 V/div, Green = IDS 10 A/div ; Blue = VDS 100 V/div, Green = IDS 10 A/div ;
VDS-MAX = 36.8 V VDS-MAX = 88.8 V
Figure 37. Flyback secondary side waveforms at Figure 38. Flyback secondary side waveforms at
VOUT = 20 V - IOUT = 2.25 A (VIN = 90 VAC) VOUT = 20 V - IOUT = 2.25 A (VIN = 265 VAC)
Blue = VDS 20 V/div, Green = IDS 10 A/div ; Blue = VDS 100 V/div, Green = IDS 10 A/div ;
VDS-MAX = 40 V VDS-MAX = 89.6 V
Figure 39. Dynamic load transient zero to full load Figure 40. Dynamic load transient zero to full load
at VOUT = 5 V - IOUT = 3 A (VIN = 115 VAC) at VOUT = 5 V - IOUT = 3 A(VIN = 230 VAC)
Blue = VOUT1 V/div, Green = IOUT 1 A/div Blue = VOUT 1 V/div, Green = IOUT 1 A/div
VOUT-MAX = 5.32 V ; VOUT-MIN = 4.7 V VOUT-MAX = 5.32 V ; VOUT-MIN = 4.7 V
Figure 41. Dynamic load transient zero to full load Figure 42. Dynamic load transient zero to full load
at VOUT = 9 V - IOUT = 3 A (VIN = 115 VAC) at VOUT = 9 V - IOUT = 3 A (VIN = 230 VAC)
Blue = VOUT 1 V/div, Green = IOUT 1 A/div Blue = VOUT 1 V/div, Green = IOUT 1 A/div
VOUT-MAX = 9.48 V ; VOUT-MIN = 8.84 V VOUT-MAX = 9.44 V ; VOUT-MIN = 8.84 V
Figure 43. Dynamic load transient zero to full load Figure 44. Dynamic load transient zero to full load
at VOUT = 12 V - IOUT = 3 A (VIN = 115 VAC) at VOUT = 12 V - IOUT = 3 A (VIN = 230 VAC)
Blue = VOUT 1.4 V/div, Green = IOUT 1 A/div Blue = VOUT 1.4 V/div, Green = IOUT 1 A/div
VOUT-MAX = 12.6 V ; VOUT-MIN = 11.87 V VOUT-MAX = 12.54 V ; VOUT-MIN = 11.87 V
Figure 45. Dynamic load transient zero to full load Figure 46. Dynamic load transient zero to full load
at VOUT = 15 V- IOUT = 3 A (VIN = 115 VAC) at VOUT = 15 V - IOUT = 3 A (VIN = 230 VAC)
Blue = VOUT 1.7 V/div, Green = IOUT 1 A/div Blue = VOUT 1.7 V/div, Green = IOUT 1 A/div
VOUT-MAX = 15.71 V ; VOUT-MIN = 14.89 V VOUT-MAX = 15.71 V ; VOUT-MIN = 14.89 V
Figure 47. Dynamic load transient zero to full load Figure 48. Dynamic load transient zero to full load
at VOUT = 20 V - IOUT = 2.25 A (VIN = 115 VAC) at VOUT = 20 V - IOUT = 2.25 A (VIN = 230 VAC)
Blue = VOUT 2.2 V/div, Green = IOUT 1 A/div Blue = VOUT 2.2 V/div, Green = IOUT 1 A/div
VOUT-MAX = 20.86 V ; VOUT-MIN = 19.89 V VOUT-MAX = 20.86 V ; VOUT-MIN = 20.86 V
Figure 49. Output voltage ripple at VOUT = 5 V - IOUT Figure 50. Output voltage ripple at VOUT = 5 V - IOUT
= 3 A (VIN = 115 VAC) = 3 A (VIN = 230 VAC)
Figure 51. Output voltage ripple at VOUT = 9 V - IOUT Figure 52. Output voltage ripple at VOUT = 9 V - IOUT
= 3 A (VIN = 115 VAC) = 3 A (VIN = 230 VAC)
Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 130 mV Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 128 mV
Figure 53. Output voltage ripple at VOUT = 12 V - Figure 54. Output voltage ripple at VOUT = 12 V -
IOUT = 3 A (VIN = 115 VAC) IOUT = 3 A (VIN = 230 VAC)
Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 150 mV Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 144 mV
Figure 55. Output voltage ripple at VOUT = 15 V - Figure 56. Output voltage ripple at VOUT = 15 V -
IOUT = 3 A (VIN = 115 VAC) IOUT = 3 A (VIN = 230 VAC)
Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 176 mV Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 160 mV
Figure 57. Output voltage ripple at VOUT = 20 V - Figure 58. Output voltage ripple at VOUT = 20 V -
IOUT = 2.25 A (VIN = 115 VAC) IOUT = 2.25 A (VIN = 230 VAC)
Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 176 mV Blue = VOUT 50 mV/div AC ; VOUT-PKPK = 178 mV
The energy efficiency of the adapter meets all DOE and UE CoC requirements, since the 4 points average
efficiency and efficiency at 10% of rated load are always higher than the most stringent EU CoC rev. 5 - Tier 2
(2016).
The adapter efficiency and no-load consumption are measured at nominal input voltages and in the various
operating profiles.
Output profile
% of rated power
5V 9V 12V 15V 20V
25% 87.92 90.18 90.32 90.22 89.48
50% 88.38 90.80 90.97 90.99 90.72
75% 87.97 90.65 90.92 91.03 90.91
100% 87.39 90.35 90.70 90.81 90.61
Avg eff. % 87.92 90.50 90.73 90.76 90.43
EU CoC rev. 5 - Tier 2 limit 81.84 87.30 88.30 88.85 88.85
10% 85.36 86.97 86.99 87.33 85.53
EU CoC rev. 5 - Tier 2 limit 72.48 77.30 78.30 78.85 78.85
Output profile
% of rated power
5V 9V 12V 15V 20V
25% 82.00 87.07 88.06 88.66 87.88
50% 85.84 89.48 90.23 90.14 90.27
75% 86.59 90.15 90.89 91.31 91.14
100% 86.70 90.39 91.16 91.62 91.58
Avg eff. % 85.29 89.27 90.09 90.43 90.22
EU CoC rev. 5 - Tier 2 limit 81.84 87.30 88.30 88.85 88.85
10% 74.90 78.71 80.65 82.01 80.74
EU CoC rev. 5 - Tier 2 limit 72.48 77.30 78.30 78.85 78.85
90.00
88.00
86.00
EFFICIENCY [%]
84.00
82.00
115 VAC / 60 Hz 230 VAC / 50 Hz
80.00
78.00
5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
POUT [W]
90.00
88.00
86.00
EFFICIENCY [%]
84.00
82.00
115 VAC / 60 Hz
78.00
5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
POUT [W]
90.00
88.00
EFFICIENCY [%]
86.00
84.00
82.00
115 VAC / 60 Hz
230 VAC / 50 Hz
80.00
78.00
5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
POUT [W]
92.00
90.00
88.00
EFFICIENCY [%]
86.00
84.00
82.00
115 VAC / 60 Hz
78.00
5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
POUT [W]
92.00
90.00
88.00
EFFICIENCY [%]
86.00
84.00
115 VAC / 60 Hz
82.00
230 VAC / 50 Hz
80.00
78.00
5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
POUT [W]
9 Thermal measurements
A thermal analysis of the board was performed with an infrared thermal imaging camera. The test was conducted
with the output voltage profile selected to 15 V and full load. The board was submitted at minimum voltage and
maximum voltage and after 30 minutes while the input voltage minimum and maximum input voltage 90 VAC and
265 VAC respectively.
Figure 64. Thermal image at 90 VAC (top side) Figure 65. Thermal image at 90 VAC (bottom side)
Figure 66. Thermal image at 265 VAC (top side) Figure 67. Thermal image at 265 VAC (bottom side)
10 Conducted EMI
A pre-compliance test for EN55022 – Class B European regulation for domestic equipment is performed,
measuring the line conducted noise emissions at nominal mains voltages and full load.
The various measurements shown below have been performed using the average EMI detector configuration of
the EMC analyzer receiver.
The Class B limits for domestic equipment are more severe compared to the Class A requirements, dedicated to
information technology equipment. The lower limit in the graphs refers to the Class B average measurement
set-up.
The results show a comfortable margin between the measurements and the required limits.
Figure 68. EMI measurements for 5 V output Figure 69. EMI measurements for 5 V output
profile, Line scan (115 VAC) profile, Line scan (230 VAC)
Figure 70. EMI measurements for 5 V output Figure 71. EMI measurements for 5 V output
profile, Neutral scan (115 VAC) profile, Neutral scan (230 VAC)
Figure 72. EMI measurements for 9 V output Figure 73. EMI measurements for 9 V output
profile, Line scan (115 VAC) profile, Line scan (230 VAC)
Figure 74. EMI measurements for 9 V output Figure 75. EMI measurements for 9 V output
profile, Neutral scan (115 VAC) profile, Neutral scan (230 VAC)
Figure 76. EMI measurements for 12 V output Figure 77. EMI measurements for 12 V output
profile, Line scan (115 VAC) profile, Line scan (230 VAC)
Figure 78. EMI measurements for 12 V output Figure 79. EMI measurements for 12 V output
profile, Neutral scan (115 VAC) profile, Neutral scan (230 VAC)
Figure 80. EMI measurements for 15 V output Figure 81. EMI measurements for 15 V output
profile, Line scan (115 VAC) profile, Line scan (230 VAC)
Figure 82. EMI measurements for 15 V output Figure 83. EMI measurements for 15 V output
profile, Neutral scan (115 VAC) profile, Neutral scan (230 VAC)
Figure 84. EMI measurements for 20 V output Figure 85. EMI measurements for 20 V output
profile, Line scan (115 VAC) profile, Line scan (230 VAC)
Figure 86. EMI measurements for 20 V output Figure 87. EMI measurements for 20 V output
profile, Neutral scan (115 VAC) profile, Neutral scan (230 VAC)
11 Reference
Revision history
Contents
1 Introduction chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6 Board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6.1 Input stage and filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Flyback controller and primary MOSFET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.1 Power MOSFET selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
List of figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
List of tables
Table 1. EVLSTCH03-45WPD evaluation board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 2. EVLSTCH03-45WPD evaluation board bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 3. Transformer electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 4. STUSB4761 configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 5. Efficiency measurements summary at VIN = 115 VAC / 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 6. Efficiency measurements summary at VIN = 230 VAC / 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 7. No-Load consumption measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 8. Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
List of figures
Figure 1. EVLSTCH03-45WPD evaluation board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2. EVLSTCH03-45WPD evaluation board block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3. EVLSTCH03-45WPD evaluation board schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4. EVLSTCH03-45WPD PCB top layer layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 5. EVLSTCH03-45WPD PCB bottom layer layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6. EVLSTCH03-45WPD top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7. EVLSTCH03-45WPD bottom view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8. STCH03 configuration basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9. Voltage between drain and source of the Power MOSFET, VDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10. Splitting of the RZCD resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 11. ZCD operational phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12. Splitting of the OVP and UVP threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 13. Transformer electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 14. STUSB4761 layout recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 15. Start-up waveforms at 115 VAC - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 16. Start-up waveforms at 115 VAC - Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 17. Start-up waveforms at 230 VAC - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 18. Start-up waveforms at 230 VAC Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 19. Flyback primary side waveforms at VOUT = 5 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 20. Flyback primary side waveforms at VOUT = 5 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 21. Flyback primary side waveforms at VOUT = 9 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 22. Flyback primary side waveforms at VOUT = 9 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 23. Flyback primary side waveforms at VOUT = 12 V - IOUT = 3 A (VIN = 90 VAC). . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 24. Flyback primary side waveforms at VOUT = 12 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 25. Flyback primary side waveforms at VOUT = 15 V - IOUT = 3 A (VIN = 90 VAC). . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 26. Flyback primary side waveforms at VOUT = 15 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 27. Flyback primary side waveforms at VOUT = 20 V - IOUT = 2.25 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . 22
Figure 28. Flyback primary side waveforms at VOUT = 20 V - IOUT = 2.25 A (VIN = 265 VAC) . . . . . . . . . . . . . . . . . . . . . 22
Figure 29. Flyback secondary side waveforms at VOUT = 5 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 30. Flyback secondary side waveforms at VOUT = 5 V - IOUT = 3 A (VIN = 265 VAC) . . . . . . . . . . . . . . . . . . . . . . 22
Figure 31. Flyback secondary side waveforms at VOUT = 9 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 32. Flyback secondary side waveforms at VOUT = 9 V - IOUT = 3 A (VIN = 265 VAC) . . . . . . . . . . . . . . . . . . . . . . 23
Figure 33. Flyback secondary side waveforms at VOUT = 12 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . 23
Figure 34. Flyback secondary side waveforms at VOUT = 12 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . 23
Figure 35. Flyback secondary side waveforms at VOUT = 15 V - IOUT = 3 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . . . 24
Figure 36. Flyback secondary side waveforms at VOUT = 15 V - IOUT = 3 A (VIN = 265 VAC). . . . . . . . . . . . . . . . . . . . . . 24
Figure 37. Flyback secondary side waveforms at VOUT = 20 V - IOUT = 2.25 A (VIN = 90 VAC) . . . . . . . . . . . . . . . . . . . . 24
Figure 38. Flyback secondary side waveforms at VOUT = 20 V - IOUT = 2.25 A (VIN = 265 VAC) . . . . . . . . . . . . . . . . . . . 24
Figure 39. Dynamic load transient zero to full load at VOUT = 5 V - IOUT = 3 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . . 25
Figure 40. Dynamic load transient zero to full load at VOUT = 5 V - IOUT = 3 A(VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . . 25
Figure 41. Dynamic load transient zero to full load at VOUT = 9 V - IOUT = 3 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . . 25
Figure 42. Dynamic load transient zero to full load at VOUT = 9 V - IOUT = 3 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . . 25
Figure 43. Dynamic load transient zero to full load at VOUT = 12 V - IOUT = 3 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . 25
Figure 44. Dynamic load transient zero to full load at VOUT = 12 V - IOUT = 3 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . 25
Figure 45. Dynamic load transient zero to full load at VOUT = 15 V- IOUT = 3 A (VIN = 115 VAC). . . . . . . . . . . . . . . . . . . . 26
Figure 46. Dynamic load transient zero to full load at VOUT = 15 V - IOUT = 3 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . 26
Figure 47. Dynamic load transient zero to full load at VOUT = 20 V - IOUT = 2.25 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . 26
Figure 48. Dynamic load transient zero to full load at VOUT = 20 V - IOUT = 2.25 A (VIN = 230 VAC). . . . . . . . . . . . . . . . . 26
Figure 49. Output voltage ripple at VOUT = 5 V - IOUT = 3 A (VIN = 115 VAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 50. Output voltage ripple at VOUT = 5 V - IOUT = 3 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 51. Output voltage ripple at VOUT = 9 V - IOUT = 3 A (VIN = 115 VAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 52. Output voltage ripple at VOUT = 9 V - IOUT = 3 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 53. Output voltage ripple at VOUT = 12 V - IOUT = 3 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 54. Output voltage ripple at VOUT = 12 V - IOUT = 3 A (VIN = 230 VAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 55. Output voltage ripple at VOUT = 15 V - IOUT = 3 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 56. Output voltage ripple at VOUT = 15 V - IOUT = 3 A (VIN = 230 VAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 57. Output voltage ripple at VOUT = 20 V - IOUT = 2.25 A (VIN = 115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 58. Output voltage ripple at VOUT = 20 V - IOUT = 2.25 A (VIN = 230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 59. Efficiency vs. output power at VOUT = 5 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 60. Efficiency vs. output power at VOUT = 9 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 61. Efficiency vs. output power at VOUT = 12 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 62. Efficiency vs. output power at VOUT = 15 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 63. Efficiency vs. output power at VOUT = 20 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 64. Thermal image at 90 VAC (top side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 65. Thermal image at 90 VAC (bottom side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 66. Thermal image at 265 VAC (top side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 67. Thermal image at 265 VAC (bottom side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 68. EMI measurements for 5 V output profile, Line scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 69. EMI measurements for 5 V output profile, Line scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 70. EMI measurements for 5 V output profile, Neutral scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 71. EMI measurements for 5 V output profile, Neutral scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 72. EMI measurements for 9 V output profile, Line scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 73. EMI measurements for 9 V output profile, Line scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 74. EMI measurements for 9 V output profile, Neutral scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 75. EMI measurements for 9 V output profile, Neutral scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 76. EMI measurements for 12 V output profile, Line scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 77. EMI measurements for 12 V output profile, Line scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 78. EMI measurements for 12 V output profile, Neutral scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 79. EMI measurements for 12 V output profile, Neutral scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 80. EMI measurements for 15 V output profile, Line scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 81. EMI measurements for 15 V output profile, Line scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 82. EMI measurements for 15 V output profile, Neutral scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 83. EMI measurements for 15 V output profile, Neutral scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 84. EMI measurements for 20 V output profile, Line scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 85. EMI measurements for 20 V output profile, Line scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 86. EMI measurements for 20 V output profile, Neutral scan (115 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 87. EMI measurements for 20 V output profile, Neutral scan (230 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36