ST AN3065 APPLICATION NOTE
AN3065
Application note
100 W transition-mode PFC pre-regulator with the L6563S
Introduction
This application note describes a demonstration board based on the transition-mode PFC controller L6563S and presents the results of its bench demonstration. The board implements a 100 W, wide-range mains input, PFC pre-conditioner suitable for ballast, adapters, flatscreen displays, and all SMPS having to meet the IEC61000-3-2 or the JEITAMITI regulation.
The L6563S is a current-mode PFC controller operating in transition mode (TM) and implementing an internal high-voltage startup circuitry.
Figure 1. EVL6563S-100W: L6563S 100W TM PFC demonstration board
September 2010 |
Doc ID 16279 Rev 2 |
1/33 |
www.st.com
Contents |
AN3065 |
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Contents
1 |
Main characteristics and circuit description . . . . . . . . . . . . . . . . . |
. . . . 4 |
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2 |
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . 6 |
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3 |
Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . 7 |
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4 |
Test results and significant waveforms . . . . . . . . . . . . . . . . . . . . . |
. . . 10 |
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4.1 |
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 10 |
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4.2 |
Inductor current in TM and L6563S THD optimizer . . . . . . . . . . . . . . |
. . . 12 |
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4.3 |
Voltage feed-forward and brownout function . . . . . . . . . . . . . . . . . . . |
. . . 15 |
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4.4 |
Startup operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 20 |
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4.5 |
PFC_OK pin and feedback failure (open loop) protection . . . . . . . . . |
. . . 20 |
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4.6 |
TBO (tracking boost option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 22 |
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4.7 |
Power management and housekeeping functions . . . . . . . . . . . . . . . |
. . . 23 |
5 |
Layout hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 25 |
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6 |
EMI filtering and conducted EMI pre-compliance measurements |
. . . 27 |
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7 |
PFC coil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 29 |
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7.1 |
General description and characteristics . . . . . . . . . . . . . . . . . . . . . . . |
. . . 29 |
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7.2 |
Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 29 |
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7.3 |
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 29 |
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7.4 |
Winding characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 30 |
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7.5 |
Mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 30 |
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7.6 |
Unit identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 30 |
8 |
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 31 |
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9 |
Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 32 |
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2/33 |
Doc ID 16279 Rev 2 |
AN3065 |
List of figures |
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List of figures
Figure 1. EVL6563S-100W: L6563S 100W TM PFC demonstration board. . . . . . . . . . . . . . . . . . . . . 1 Figure 2. EVL6563S-100W TM PFC demonstration board: electrical schematic . . . . . . . . . . . . . . . . 6 Figure 3. EVL6563S-100W TM PFC: compliance to EN61000-3-2 standard . . . . . . . . . . . . . . . . . . 10 Figure 4. EVL6563S-100W TM PFC: compliance to JEITA-MITI standard . . . . . . . . . . . . . . . . . . . . 10 Figure 5. EVL6563S-100W TM PFC: input current waveform at 230 V, 50 Hz, 100 W load . . . . . . . 11 Figure 6. EVL6563S-100W TM PFC: input current waveform at 100 V, 50 Hz, 100 W load . . . . . . . 11 Figure 7. EVL6563S-100W TM PFC: power factor vs. output power. . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 8. EVL6563S-100W TM PFC: THD vs. output power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 9. EVL6563S-100W TM PFC: efficiency vs. output power . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 10. EVL6563S-100W TM PFC: average efficiency acc. to ES-2 . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 11. EVL6563S-100W TM PFC: static Vout regulation vs. output power. . . . . . . . . . . . . . . . . . 12 Figure 12. EVL6563H 100W TM PFC: Vds and inductor current at 100 Vac, 50 Hz, full load. . . . . . . 13 Figure 13. EVL6563H 100W TM PFC: Vds and inductor current at 100 Vac, 50 Hz, full load (detail). 13 Figure 14. EVL6563H 100W TM PFC: Vds and inductor current at 230 Vac, 50 Hz, full load. . . . . . . 14 Figure 15. EVL6563H 100W TM PFC: Vds and inductor current at 230 Vac, 50 Hz, full load (detail). 14 Figure 16. EVL6563S-100W TM PFC: Vds and inductor current at 100 Vac, 50 Hz, full load. . . . . . . 15 Figure 17. EVL6563S-100W TM PFC: Vds and inductor current at 230 Vac, 50 Hz, full load. . . . . . . 15 Figure 18. L6562A input mains surge 90 Vac to 140 Vac, no VFF input . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 19. EVL6563S-100W TM PFC: input mains surge 90 Vac to 140 Vac. . . . . . . . . . . . . . . . . . . 16 Figure 20. L6562A input mains dip 140 Vac to 90 Vac, no VFF input . . . . . . . . . . . . . . . . . . . . . . . . . 17 Figure 21. EVL6563S-100W TM PFC: input mains dip 140 Vac to 90 Vac . . . . . . . . . . . . . . . . . . . . . 17 Figure 22. L6563: input current at 100 Vac, 50 Hz, CFF=0.47 µF, RFF=390 kΩ. . . . . . . . . . . . . . . . . 18 Figure 23. EVL6563S-100W TM PFC: input current at 100 Vac, 50 Hz, CFF=1 µF, RFF=1 MΩ . . . . 18 Figure 24. EVL6563S-100W TM PFC startup attempt at 80Vac, 60 Hz, full load . . . . . . . . . . . . . . . . 19 Figure 25. EVL6563S-100W TM PFC: startup with slow input voltage increasing, full load . . . . . . . . 19 Figure 26. EVL6533S-100W TM PFC: turn-off with slow input voltage decreasing, full load . . . . . . . 19 Figure 27. EVL6563S-100W TM PFC startup at 90 Vac, 60 Hz, full load . . . . . . . . . . . . . . . . . . . . . . 20 Figure 28. EVL6563S-100W TM PFC startup at 265 Vac, 50 Hz, full load . . . . . . . . . . . . . . . . . . . . . 20 Figure 29. EVL6563S-100W TM PFC load transient at 115 Vac, 60 Hz, full load to no load . . . . . . . 22 Figure 30. EVL6563S-100W TM PFC open loop at 115 Vac, 60 Hz, full load. . . . . . . . . . . . . . . . . . . 22 Figure 31. L6563S on/off control by a cascaded converter controller via the PFC_OK or RUN pin . . 23 Figure 32. Interface circuits that let the L6563S switch on or off a PWM controller, not latched . . . . . 24 Figure 33. Interface circuits that let the L6563S switch on or off a PWM controller, latched . . . . . . . . 24 Figure 34. EVL6563S-100W TM PFC PCB layout (SMT side view) . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 35. EVL6563S-100W TM PFC CE peak measurement at 100 Vac, 50 Hz, full load, phase . . 27 Figure 36. EVL6563S-100W TM PFC CE peak measurement at 100 Vac, 50 Hz, full load, neutral. . 27 Figure 37. EVL6563S-100W TM PFC CE peak measurement at 230 Vac, 50 Hz, full load, phase . . 28 Figure 38. EVL6563S-100W TM PFC CE peak measurement at 230 Vac, 50 Hz, full load, neutral. . 28 Figure 39. Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 40. Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Doc ID 16279 Rev 2 |
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Main characteristics and circuit description |
AN3065 |
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1 Main characteristics and circuit description
The main characteristics of the SMPS are listed below:
●Line voltage range: 90 to 265 Vac
●Minimum line frequency (fL): 47 Hz
●Regulated output voltage: 400 V
●Rated output power: 100 W
●Maximum 2fL output voltage ripple: 20 V pk-pk
●Hold-up time: 10 ms (VDROP after hold-up time: 300 V)
●Minimum switching frequency: 40 kHz
●Minimum estimated efficiency: 92% (at Vin = 90 Vac, Pout = 100 W)
●Maximum ambient temperature: 50 °C
●PCB type and size: single side, 35 µm, CEM-1, 90 x 83 mm
This demonstration board implements a power factor correction (PFC) pre-regulator,100 W continuous power, on a regulated 400 V rail from a wide-range mains voltage and provides for the reduction of the mains harmonics, allowing to meet the European EN61000-3-2 or the Japanese JEITA-MITI standard. The regulated output voltage is typically the input for the cascaded isolated DC-DC converter that provides the output rails required by the load.
The board is designed to allow full-load operation in still air.
The power stage of the PFC is a conventional boost converter, connected to the output of the rectifier bridge D1. It is completed by the coil L2, the diode D3 and the capacitor C6. The boost switch is represented by the power MOSFET Q1. The NTC R1 limits the inrush current at switch-on. It has been connected on the DC rail, in series to the output electrolytic capacitor, in order to improve the efficiency during low line operation because the RMS current flowing into the output stage is lower than current flowing into the input one at the same input voltage, thus increasing efficiency. The board is equipped with an input EMI filter necessary to filter the commutation noise coming from the boost stage.
At startup the L6563S is powered by the capacitor C11 that is charged via the resistors R7 and R16. Then the L2 secondary winding and the charge pump circuit (C7, R4, D4 and D5) generate the Vcc voltage powering the L6563S during normal operation. The L2 secondary winding is also connected to the L6563S pin #11 (ZCD) through the resistor R5. Its purpose is supply the information that L2 has demagnetized, needed by the internal logic for triggering a new switching cycle.
The divider R9, R12, R17 and R19 provides the L6563S multiplier with the information of the instantaneous mains voltage that is used to modulate the peak current of the boost.
The resistors R2, R8, R10 with R13 and R14 are dedicated to sense the output voltage and feed back to the L6563S the information necessary to regulate the output voltage. The components C9, R18 and C8 constitute the error amplifier compensation network necessary to keep the required loop stability.
The peak current is sensed by resistors R25 and R26 in series to the MOSFET and signal is fed into pin #4 (CS) of the L6563S via the filter composed of R24 and C15.
C13, R27 and R32 connected to pin #5 (VFF) complete an internal peak-holding circuit that derives the information on the RMS mains voltage. The voltage signal at this pin, a DC level equal to the peak voltage on pin #3 (MULT), is fed to a second input to the multiplier for the
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AN3065 |
Main characteristics and circuit description |
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1/V2 function necessary to compensate the control loop gain dependence on the mains voltage. Additionally, pin #10 (RUN) is connected to pin# 5 (VFF) through a resistor divider R27 and R32, providing a voltage threshold for brownout protection (AC mains undervoltage). A voltage below 0.8 V shuts down (not latched) the IC and brings its consumption to a considerably lower level. The L6563S restarts as the voltage at the pin rises above 0.88 V.
The divider R3, R6, R11 and R15 provides the L6563S pin #7 (PFC_OK) with the information regarding the output voltage level. It is required by the L6563S output voltage monitoring and disables functions used for PFC protection purposes.
If the voltage on pin #7 exceeds 2.5 V, the IC stops switching and restarts as the voltage on the pin falls below 2.4 V implementing the so-called dynamic OVP, which prevents an excessive output voltage in case of transients, because of the slow response of the error amplifier. However, if contemporaneously the voltage of the INV pin falls below 1.66 V (typ.), a feedback failure is assumed. In this case the device is latched off. Normal operation can be resumed only by cycling Vcc, bringing its value lower than 6 V before rising up to the turn-on threshold.
Additionally If the voltage on pin #7 (PFC_OK) is tied below 0.23 V, the L6563S is shut down. To restart operation of the L6563S the voltage on pin #7 (PFC_OK) has to increase above 0.27 V. This function can be used as a remote on/off control input.
To allow interfacing of the board with a D2D converter, the connector J3 allows powering the L6563S with an external Vcc and also manages failure or abnormal conditions via the pins PWM_LATCH and PWM_STOP. The L6563S can be also disabled or enabled to manage
properly light load or failure by the D2D via the PFC_OK pin (#7), available at pin #5 of J3 (ON/OFF). For further details please see Section 4.7.
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7/33
2 Rev 16279 ID Doc
3 |
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Bill of material |
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Table 1. |
EVL6563S-100W TM PFC demonstration board bill of material |
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Des. |
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Part type/part value |
Case/package |
Description |
Supplier |
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C1 |
|
470N |
DWG |
X2 - FLM CAP - R46-I 3470--M1- |
ARCOTRONICS |
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C4 |
|
470N |
DWG |
X2 - FLM CAP - R46-I 3470--M1- |
ARCOTRONICS |
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C2 |
|
2N2 |
DWG |
Y1 - SAFETY CAP. DE1E3KX222M |
muRata |
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C3 |
|
2N2 |
DWG |
Y1 - SAFETY CAP. DE1E3KX222M |
muRata |
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C5 |
|
470N - 400 V |
DWG |
400V - FLM CAP - B32653A4474 |
EPCOS |
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C6 |
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47 µF - 450 V |
Dia. 18 x 31.5 mm |
450 V - ALUMINIUM ELCAP - ED SERIES - 105°C |
NIPPON-CHEMICON |
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C7 |
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4N7 |
1206 |
100 V CERCAP - general purpose |
AVX |
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C8 |
|
680N |
1206 |
25 V CERCAP - general purpose |
AVX |
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C9 |
|
68N |
0805 |
50 V CERCAP - general purpose |
AVX |
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C10 |
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100N |
1206 |
50 V CERCAP - general purpose |
AVX |
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C11 |
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47 µF-50 V |
Dia. 5 x 10 mm |
50 V - aluminium ELCAP - YXF series - 105°C |
Rubycon |
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C12 |
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2N2 |
1206 |
50 V CERCAP - general purpose |
AVX |
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C16 |
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2N2 |
1206 |
50 V CERCAP - general purpose |
AVX |
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C13 |
|
1 µF |
0805 |
25 V CERCAP - general purpose |
AVX |
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C14 |
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2N2 |
0805 |
50 V CERCAP - general purpose |
AVX |
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C15 |
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220 pF |
0805 |
50 V CERCAP - general purpose |
AVX |
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D1 |
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GBU4J |
STYLE GBU |
Single phase bridge rectifier |
VISHAY |
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D2 |
|
1N4005 |
DO - 41 |
Rectifier - general purpose |
VISHAY |
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D3 |
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STTH2L06 |
DO - 41 |
Ultrafast high-voltage rectifier |
STMicroelectronics |
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D4 |
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LL4148 |
MINIMELF |
High-speed signal diode |
VISHAY |
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D5 |
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BZX79-C18 |
DO - 35 |
Zener diode |
VISHAY |
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D6 |
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N.M. |
MINIMELF |
Not mounted |
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material of Bill
AN3065
|
Table 1. |
EVL6563S-100W TM PFC demonstration board bill of material (continued) |
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Des. |
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Part type/part value |
Case/package |
Description |
Supplier |
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F1 |
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FUSE 4 A |
DWG |
Fuse T4A - time delay |
Wichmann |
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HS1 |
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HEAT-SINK |
DWG |
Heatsink for D1& Q1 |
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JP1 |
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WIRE JUMPER |
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Bare copper wire jumper |
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JP2 |
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N.M. |
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NOT MOUNTED |
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J1 |
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MKDS 1,5/ 3-5,08 |
DWG |
PCB term. block, screw conn., pitch 5 mm - 3 W |
PHOENIX CONTACT |
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J2 |
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MKDS 1,5/ 2-5,08 |
DWG |
PCB term. block, screw conn., pitch 5 mm - 2 W |
PHOENIX CONTACT |
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J3 |
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CON5 |
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PCB term. block, pitch 2.5 mm - 5 W |
MOLEX |
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L1 |
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HF2826-203Y1R5-T01 |
DWG |
Input EMI filter - 20 mH-1.5 A |
TDK |
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L2 |
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SRW2620PQ-X22V102 |
DWG |
PFC inductor - 0.52 mH (X08141-01-B) |
TDK |
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Doc |
Q1 |
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STF7NM50N |
TO-220FP |
N-Channel power MOSFET |
STMicroelectronics |
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R1 |
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NTC 2R5-S237 |
DWG |
NTC RESISTOR P/N B57237S0259M000 |
EPCOS |
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ID |
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16279 |
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R2 |
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1M0 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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Rev |
R8 |
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1M0 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R10 |
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1M0 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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2 |
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R3 |
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3M3 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R6 |
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3M3 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R4 |
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100 Ω |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R5 |
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68 kΩ |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R7 |
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180 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R16 |
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180 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R9 |
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2M2 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R11 |
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2M2 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R12 |
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2M2 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R17 |
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2M2 |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
8/33 |
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R13 |
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62 kΩ |
0805 |
SMD standard film RES - 1/8 W - 1% - 100 ppm/°C |
VISHAY |
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AN3065
material of Bill
9/33
2 Rev 16279 ID Doc
Table 1. |
EVL6563S-100W TM PFC demonstration board bill of material (continued) |
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|||
Des. |
|
Part type/part value |
Case/package |
Description |
Supplier |
|
|
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|
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|
R14 |
|
27 kΩ |
0805 |
SMD standard film RES - 1/8 W - 1% - 100 ppm/°C |
VISHAY |
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R15 |
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51 kΩ |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R18 |
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82 kΩ |
0805 |
SMD standard film RES - 1/8 W - 5% - 250 ppm/°C |
VISHAY |
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R19 |
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51 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R20 |
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N.M. |
0805 |
Not mounted |
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R21 |
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27 Ω |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R22 |
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100 kΩ |
0805 |
SMD standard film res - 1/8 W - 5% - 250 ppm/°C |
VISHAY |
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R23 |
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N.M. |
0805 |
|
VISHAY |
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R24 |
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220 Ω |
PTH |
SFR25 axial stand. film RES - 0.4W - 5% - 250 ppm/°C |
VISHAY |
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R25 |
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0.47 Ω |
PTH |
SFR25 axial stand. film RES - 0.4W - 5% - 250 ppm/°C |
VISHAY |
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R26 |
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0.68 Ω |
PTH |
SFR25 axial stand. film RES - 0.4 W - 5% - 250 ppm/°C |
VISHAY |
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R27 |
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56 kΩ |
1206 |
SMD standard film RES - 1/4 W - 1% - 100 ppm/°C |
VISHAY |
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R28 |
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1 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R29 |
|
1 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R30 |
|
1 kΩ |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R31 |
|
10 Ω |
1206 |
SMD standard film RES - 1/4 W - 5% - 250 ppm/°C |
VISHAY |
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R32 |
|
1M0 |
0805 |
SMD standard film RES - 1/8 W - 1% - 250 ppm/°C |
VISHAY |
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U1 |
|
L6563S |
SO-14 |
Enhanced transition-mode PFC controller |
STMicroelectronics |
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material of Bill
AN3065
Test results and significant waveforms |
AN3065 |
|
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4 Test results and significant waveforms
4.1Harmonic content measurement
One of the main purposes of a PFC pre-conditioner is the correction of input current distortion, decreasing the harmonic contents below the limits of the relevant regulations. Therefore, this demonstration board has been tested according to the European standard EN61000-3-2 Class-D and Japanese standard JEITA-MITI Class-D, at full load at both the nominal input voltage mains.
The circuit is able to reduce the harmonics well below the limits of both regulations from full load down (measurements are shown in Figure 3 and 4) to light load. Please note that all
measures and waveforms have been done using a Pi-filter for filtering the noise coming from the circuit, using a 20 mH common-mode choke and two 470NF-X2 filter capacitors.
Figure 3. EVL6563S-100W TM PFC: |
Figure 4. EVL6563S-100W TM PFC: |
compliance to EN61000-3-2 |
compliance to JEITA-MITI standard |
standard |
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0HDVXUHG YDOXH 
(1 &ODVV ' OLPLWV
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+DUPRQLF &XUUHQW >$@ |
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+DUPRQLF 2UGHU >Q@
!-V
Vin = 230 Vac - 50 Hz
Pout = 100 W
THD = 2.31 %
PF = 0.982
0HDVXUHG YDOXH 
-(,7$0,7, &ODVV ' OLPLWV
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+DUPRQLF &XUUHQW >$@ |
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+DUPRQLF 2UGHU >Q@
!-V
Vin = 100 Vac - 50 Hz
Pout = 100 W
THD = 2.30 %
PF = 0.999
10/33 |
Doc ID 16279 Rev 2 |
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