UM11553
TEA2016AAT 160 W TV application design example
Rev. 1 — 4 February 2021 User manual
Document information
Information Content
Keywords TEA2016AAT, 160 W, multiple outputs, 12 V × 5 A and 100 V × 1 A, PFC,
LLC, resonant controller, burst mode, power supply, programmable setting,
I
2
C
Abstract The TEA2016AAT is controller IC for resonant power supplies which includes
a PFC. It provides high efficiency at all power levels.
To reach a high efficiency at all power levels, the TEA2016AAT provides
a low-power (LP) operation mode and extensive burst mode configuration
options.
Most LLC resonant converter controllers regulate the output power by
adjusting the operating frequency. The TEA2016AAT regulates the output
power by adjusting the voltage across the primary resonant capacitor for
accurate state control and a linear power control.
Parameter settings in an internal multiple times programmable memory (MTP)
define the operation modes and protections. For product development, an IC
version is available to make setting changes on the fly. To optimize controller
properties to application-specific requirements, this feature provides flexibility
and ease of design.
The TEA2016AAT provides extra functions, like external OTP sensing and
power good signal. To provide the correct handling, protections can be
configured.
The efficiency at high power levels is above 90 %. No-load power
consumption is below 150 mW. At 120 mW output power, the input power is
below the 260 mW. So it meets the TV application typical requirements.
This design example includes a dual output (12 V and 100 V) for a TV
application.
NXP Semiconductors
UM11553
TEA2016AAT 160 W TV application design example
Rev Date Description
v.1 20210204 Initial version
Revision history
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TEA2016AAT 160 W TV application design example
1 Introduction
WARNING
Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present when operating this
product, constitute a risk of electric shock, personal injury, death and/
or ignition of fire. This product is intended for evaluation purposes only.
It shall be operated in a designated test area by personnel qualified
according to local requirements and labor laws to work with non-
insulated mains voltages and high-voltage circuits. This product shall
never be operated unattended.
This document describes the 160 W power supply design using the TEA2016AAT. It
contains a functional description and a set of preliminary measurements to show the
main characteristics.
1.1 TEA2016AAT
The TEA2016AAT provides high efficiency at all power levels. A high-performance cost-
effective resonant power supply can be designed. It meets the efficiency regulations of
Energy Star, the Department of Energy (DoE), the Eco-design Directive of the European
Union, the European Code of Conduct, and other guidelines.
In general, resonant converters show an excellent efficiency at high-power levels, while
at lower levels their efficiency reduces because of the relatively high magnetizing current
losses. To reach a high efficiency at all power levels, the TEA2016AAT provides a low-
power (LP) operation mode and extensive burst-mode configuration options.
Most LLC resonant converter controllers regulate the output power by adjusting the
operating frequency. The TEA2016AAT regulates the output power by adjusting the
voltage across the primary resonant capacitor. The result is accurate state control and a
linear power control.
The primary resonant capacitor voltage provides accurate information about the output
power to the controller via a voltage divider. The voltage divider sets the output power
levels. It determines when the system switches from the high-power mode to low-power
mode and when it switches from low-power mode to burst mode.
An extensive number of parameter settings define the operation modes and protections.
Protections can be stored/programmed in an internal memory. This feature provides
flexibility and ease of design. It optimizes controller properties to application-specific
requirements or even optimizes/corrects performance during power supply production.
At start-up, the IC loads the parameter settings. For easy design work during product
development, an IC version is available, which makes it possible to make setting
changes on the fly.
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TEA2016AAT 160 W TV application design example
aaa-030882
1
2
3
4
5
6
7
8
10
9
12
11
14
13
16
15
IC
SNSMAINS SNSFB
SNSBOOST SNSCURLLC
SNSCURPFC SNSCAP
GND SUPIC
GATEPFC HVS
GATELS HB
HVS SUPHS
DRAINPFC GATEHS
Figure 1. TEA2016AAT pinning diagram
2 Safety warning
The 160 W power supply is connected to the mains voltage. Avoid touching the board
while it is connected to the mains voltage and when it is in operation. An isolated housing
is obligatory when used in uncontrolled, non-laboratory environments.
Galvanic isolation from the mains phase using a fixed or variable transformer is always
recommended.
019aab173
019aab174
a. Isolated b. Not isolated
Figure 2. Isolation symbols
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TEA2016AAT 160 W TV application design example
3 Specifications
Symbol Parameter Value Condition
Input
V
mains
AC mains voltage 90 V to 264 V AC
f
mains
mains frequency 47 Hz to 63 Hz -
P
i(noload)
no-load input power < 150 mW at 230 V/50 Hz
P
i(load=120mW)
standby power
consumption
< 260 mW at 230 V/50 Hz
P
i(load=240mW)
standby power
consumption
< 500 mW at 230 V/50 Hz
PF power factor
> 0.9
at 230 V/50 Hz;
maximum load
condition
Output
V
out
output voltage 12 V; 100 V
I
out
output current
5 A; 1 A
nominal current
P
out
maximum nominal
output power
160 W
V
out(ripple)
output voltage ripple
< 300 mV (p-p) at PCB end
V
out(p-p)
peak-to-peak out
voltage level during
dynamic load
< ±5 % 100 Hz; dynamic load
at the PCB end
t
holdup
hold-up time > 10 ms at 115 V/60 Hz; full
load
t
startup
start-up time < 500 ms at 115 V/60 Hz; full
load
t
rise
output voltage rising
time
< 20 ms at 115 V/60 Hz; full
load
η
AVG
average efficiency > 89 % average of 100 %,
75 %, 50 %, 25 %
η
10%
10 % load efficiency > 80 %
EMC and safety
CE conduction EMI > 3 dB full load
T
comp
component
temperature
see Section 5.12 at room temperature
OPP overpower protection 200 W 124 % of maximum
nominal power
P
short
input power during
output short
< 1 W average power
consumption without
any damage
Table 1. Design specification
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TEA2016AAT 160 W TV application design example
4 Board photographs
The 160 W TV design example uses the TEA2016AAT in an SO16 package. Figure 3
shows the top side and bottom side.
a. Top view
b. Bottom view
Figure 3. Design example
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5 Performance
5.1 Test facilities
• Oscilloscope: Agilent DSO9064A; Agilent DSOX3034T; Tektronix DPO7054
• AC power source: Chroma model 61502
• Electronic load: Chroma 63105; 63101
• Digital power meter: WT210
5.2 Start-up behavior
5.2.1 Start-up time
Total start-up time from mains switch-on until the output voltage reaches 12 V is
< 500 ms, regardless of mains voltages.
Conditions Specification Output condition Test result
115 V/60 Hz < 500 ms 12 V/5 A and
100 V/1 A
428 ms
Table 2. Start-up time
CH2: VOUT_12V (5 V/div)
CH3: AC mains voltage (500 V/div); Time: 100 ms/div
Figure 4. Start-up time at 115 V mains voltage, 12 V/5 A and 100 V/1 A
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5.2.2 Start-up voltage output risetime
Output voltage rising time during start-up measures the time between 0 % of nominal
output voltage and 95 % of nominal output voltage. The rising time is under 20 ms.
Conditions Specification Output condition Test result
115 V/60 Hz < 20 ms 12 V/5 A and
100 V/1 A
12 ms
Table 3. Start-up rising time
CH1: VOUT_100V (20 V/div)
CH2: VOUT_12V (5 V/div)
Time: 2 ms/div
Figure 5. Output voltage rising time at 115 V mains voltage, 12 V/5 A and 100 V/1 A
5.3 Efficiency
5.3.1 Average efficiency
Average efficiency is measured after 20 minutes aging time. The specification is based
on CoC-tier2 regulation. The output load currents for 12 V and 100 V are decreased with
the same ratio for different load conditions.
Condition Specificati
on
Average 25 % load 50 % load 75 % load 100 % load
115 V/60 Hz > 89 % 91.68 % 90.75 % 92.35 % 92.19 %
91.43 %
230 V/50 Hz
> 89 % 92.64 % 90.59 % 93.14 % 93.59 % 93.24 %
Table 4. Average efficiency result (measured at the PCB end)
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5.3.2 10 % load efficiency
Average efficiency is measured after 20 minutes aging time. Specification is based on
CoC-tier2 regulation. The 12 V/0.5 A and 100 V/0.1 A conditions are used for 10 % load
efficiency.
Condition Specification Measurement
condition
Efficiency
115 V/60 Hz > 80 % 85.44 %
230 V/50 Hz > 80 %
At the PCB end
85.88 %
Table 5. 10 % load efficiency (measured at the PCB end)
5.3.3 Standby power consumption
For standby power consumption measurement, 100 V output is the no-load condition.
12 V output loads specific output power.
Condition Specification Output power Input power
consumption
115 V/60 Hz < 260 mW 228 mW
230 V/50 Hz < 260 mW
120 mW
231 mW
Table 6. Standby power consumption (measured at the PCB end)
Condition Specification Output power Input power
consumption
115 V/60 Hz < 500 mW 380 mW
230 V/50 Hz < 500 mW
240 mW
382 mW
Table 7. Standby power consumption (measured at the PCB end)
5.3.4 No-load power consumption
Condition Specification Output power Input power
consumption
115 V/60 Hz < 150 mW 87 mW
230 V/50 Hz < 150 mW
no load
92 mW
Table 8. Standby power consumption (measured at the PCB end)
5.3.5 Power factor value
Condition Specification Output power Power factor value
115 V/60 Hz > 0.9 0.988
230 V/50 Hz > 0.9
12 V/5 A; 100 V/1 A
0.931
Table 9. Power factor value
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TEA2016AAT 160 W TV application design example
5.4 Cross regulation
Mains condition Output load at
12 V
Output load at
100 V
12 V output
voltage
100 V output
voltage
5 A 1 A 12.7 V 101 V
5 A 0.1 A 12.48 V 101.7 V
0.1 A 1 A 12.95 V 94.8 V
230 V/50 Hz
0 A 0 A 12.5 V 100 V
Table 10. Cross regulation (measured at the PCB end)
5.5 Half-bridge resonant converter operation
The TEA2016AAT incorporates a cycle-by-cycle VCAP control method. It operates
as high-power mode, low-power mode, and burst mode. The three operation modes
optimize the efficiency.
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TEA2016AAT 160 W TV application design example
a. High-power mode at 115 V mains voltage; 12 V/5 A
and 100 V/1 A
b. Low-power mode at 115 V mains voltage; 12 V/2 A
and 100 V/0.2 A
CH1: GATELS (10 V/div)
CH2: GATEPFC (10.2 V/div)
CH3: LLC resonant current (2.5 A/div)
Time: 20 μs/div and 10 μs/div
c. Burst mode operation at 115 V mains voltage; 12 V/0.5 A and 100 V/0.04 A
CH1: LLC resonant current (500 mA/div)
CH2: GATELS (5 V/div)
CH3: GATEPFC (5 V/div)
Time: 2 ms/div and 10 μs/div
Figure 6. Half-bridge resonant converter operation
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5.6 PFC operation
The TEA2016AAT PFC incorporates a fixed t
on
control method. It also contains the valley
detection function. The maximum frequency of the TEA2016AAT is 125 kHz.
a. PFC operation at 90 V mains voltage; 12 V/5 A and
100 V/1 A
b. PFC operation at 264 V mains voltage; 12 V/5 A and
100 V/1 A
CH1: PFC output voltage (50 V/div)
CH2: GATEPFC (5 V/div)
CH3: DRAINPFC (100 V/div)
Time: 5 ms/div and 5 μs/div
CH1: PFC output (50 V/div)
CH2: PFC gate (5 V/div)
CH3: DRAINPFC (100 V/div)
Time: 5 ms/div and 5 μs/div
Figure 7. PFC operation
5.7 Output voltage ripple and noise
The output voltage ripple is measured at the PCB end. To reduce spurious noise signal,
the end capacitor and ground lead of the voltage probe are removed. A 0.1 μF/50 V
ceramic capacitor and a 10 μF/50 V electrolytic capacitor are placed on the voltage
probe.
LLC operation mode Output power condition Maximum 12 V output
voltage ripple
HP mode 160 W 115 mV
LP mode 34 W 92 mV
BM mode 10 W 268 mV
Table 11. Maximum output voltage ripple and noise
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a. Maximum ripple at 115 V mains voltage; 12 V/5 A and
100 V/1 A
b. Maximum ripple at 115 V mains voltage; 12 V/2 A and
100 V/0.1 A
c. Maximum ripple at 115 V mains voltage; 12 V/0.5 A and 100 V/0.04 A
CH2: VOUT_12V (100 mV/div)
CH3: LLC resonant current (2.5 A/div and 1 A/div)
Time: 40 μs/div and 20 μs/div and 4 ms/div
Figure 8. Output voltage ripple and noise
5.8 Dynamic load response
The peak-to-peak of the output voltage during dynamic load condition is measured
at the PCB end. The output load is changed between maximum nominal load and
no load for dynamic load. The slew rate is set as 2.5 A/μs. To reduce spurious noise
signal, the end capacitor and the ground lead of the voltage probe are removed. The
0.1 μF/50 V ceramic capacitor and the 10 μF/50 V electrolytic capacitor are placed on the
voltage probe. At the same time, the condition of the output loads at 12 V and 100 V are
dynamic.
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TEA2016AAT 160 W TV application design example
Condition Output load
at 12 V
Output load
at 100 V
Load step
frequency
Vpk_pk
at 12 V
Vpk_pk
at 100 V
115 V/60 Hz 0 A to 5 A 0 A to 1 A 100 Hz 823 mV 5.78 V
Table 12. Output undershoot and overshoot at dynamic load
Dynamic at 115 V mains voltage with a frequency of 100 Hz
CH1: VOUT_100V (5 V/div)
CH2: VOUT_12V (500 mV/div)
CH3: IOUT_12V (5 A/div)
Time: 20 ms/div
Figure 9. Output undershoot and overshoot at dynamic load
5.9 Power-off behavior
The output voltage hold-up time is measured from the mains disconnection. The output
voltage drops to 95 % of the nominal voltage. The mains is disconnected at zero
degrees. The hold-up time is longer than 10 ms.
Condition Specification Output load Hold-up time
115 V/60 Hz > 10 ms 100 % 52 ms
Table 13. Hold-up time
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Hold-up time at 115 V mains voltage, 12 V/5 A and 100 V/1 A
CH2: VOUT_12V (5 V/div)
CH3: AC mains voltage (250 V/div)
Time: 20 ms/div
Figure 10. Power-off and hold-up time
5.10 MOSFET voltage stress
The voltage between the drain and the source requires 10 % margin from absolute
maximum ratings for each MOSFET.
Mains condition Output power
Components
Specification Result
264 V/50 Hz 160 W PFC MOSFET < 540 V 406 V
264 V/50 Hz 160 W LLC high side
MOSFET
< 540 V 408 V
264 V/50 Hz 160 W LLC low side
MOSFET
< 540 V 400 V
Table 14. MOSFET voltage stress
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TEA2016AAT 160 W TV application design example
a. PFC MOSFET stress at 264 V mains voltage; 12 V/5 A and 100 V/1 A
CH1: PFC MOSFET VDS (100 V/div)
Time: 20 μs/div
b. LLC MOSFET stress at 264 V mains voltage; 12 V/5 A
and 100 V/1 A
c. LLC MOSFET stress at 264 V mains voltage, 12 V/5 A
and 100 V/1 A
CH1: LLC high side MOSFET VDS (100 V/div)
Time: 20 μs/div
CH1: LLC low side MOSFET VDS (100 V/div)
Time: 20 μs/div
Figure 11. MOSFET voltage stress measurement
5.11 Protections
5.11.1 LLC overpower protection
Overpower protection is tested with increasing output current of 12 V in steps of 160 mA.
The output current of 100 V is fixed at 1 A. The restart time after an overpower protection
event is 1 s.
Condition OPP level OPP restart time
115 V/50 Hz 208.5 W 1 s
Table 15. Overpower protection level and restart time
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TEA2016AAT 160 W TV application design example
Overpower protection at 115 V mains
CH1: IOUT_12V (2 A/div)
CH3: VOUT_12V (5 V/div)
Time: 2 s/div
Figure 12. Overpower protection measurement
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TEA2016AAT 160 W TV application design example
5.11.2 Output short overcurrent protection (OCP)
The TEA2016AAT incorporates OCP protection via the SNSCURLLC pin. This OCP
protects the system from output short conditions within a short time. When SNSCURLLC
exceeds 4 V or drops to below 1 V, GATEHS or GATELS is disabled immediately to limit
the maximum resonant current. After a 5-cycle consecutive current limit, the OCP is
triggered.
Output short overcurrent protection at 115 V mains
CH1: SNSCURLLC (1 V/div)
CH2: GATELS (5 V/div)
Time: 500 μs/div and 20 μs/div
Figure 13. Output short overcurrent protection
5.11.3 Brownin/brownout protection
To avoid excessive power loss and temperature increase at very low mains voltage,
brownin/brownout protection is implemented on the TEA2016AAT. Brownin is measured
by increasing the mains voltage. Brownout is measured by decreasing the mains voltage.
Condition Output
power
Test result
Brownin level; the mains voltage is increased 160 W 72 V (AC)
Brownout level; the mains voltage is decreased 160 W 61 V (AC)
Table 16. Brownin/brownout protection level
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a. Brownin at 12 V/5 A and 100 V/1 A b. Brownout at 12 V/5 A and 100 V/1 A
CH1: AC mains voltage (100 V/div)
CH3: GATEPFC (5 V/div)
Time: 1 s/div
Figure 14. Brownin/brownout protection
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5.12 Component temperature performance
Temperature is measured at a room temperature condition.
a. Top view
b. Bottom view
Figure 15. Temperature performance at 90 V mains voltage; 12 V/5 A and 100 V/1 A
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