ST AN3119 Application note

AN3119

Application note

250 W transition-mode PFC pre-regulator with the new L6563S

Introduction

This application note describes a demonstration board based on the new transition-mode PFC controller L6563S and presents the results of its bench evaluation. The board implements a 250 W, wide-range mains input PFC pre-conditioner suitable for desktop PCs, industrial SMPS, flat screen displays, and all SMPS having to meet the IEC61000-3-2 or the JEITA-MITI standard.

Figure 1. EVL6563S-250W: L6563S 250W TM PFC demonstration board

November 2010

Doc ID 16849 Rev 2

1/32

www.st.com

Contents

AN3119

 

 

Contents

1

Main characteristics and circuit description . . . . . . . . . . . . . . . . .

. . . . 4

2

Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 6

3

Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 7

4

Test results and significant waveforms . . . . . . . . . . . . . . . . . . . . .

. . . 10

 

4.1

Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 10

 

4.2

MOSFET current, TM signals, and L6563S THD optimizer . . . . . . . .

. . . 13

 

4.3

Voltage feed-forward and brown-out function . . . . . . . . . . . . . . . . . . .

. . . 15

 

4.4

Startup operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 19

 

4.5

PFC_OK pin and feedback failure (open-loop) protection . . . . . . . . .

. . . 20

 

4.6

TBO (tracking boost option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 22

 

4.7

Power management and housekeeping functions . . . . . . . . . . . . . . .

. . . 23

5

Layout hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 25

6

Thermal map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 26

7

EMI filtering and conducted EMI pre-compliance measurements

. . . 28

8

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 30

9

Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 31

2/32

Doc ID 16849 Rev 2

AN3119

List of figures

 

 

List of figures

Figure 1. EVL6563S-250W: L6563S 250W TM PFC demonstration board. . . . . . . . . . . . . . . . . . . . . 1 Figure 2. EVL6563S-250W TM PFC demonstration board: electrical schematic . . . . . . . . . . . . . . . . 6 Figure 3. EVL6563S-250W TM PFC: compliance to EN61000-3-2 standard at 250 W. . . . . . . . . . . 10 Figure 4. EVL6563S-250W TM PFC: compliance to JEITA-MITI standard at 250 W . . . . . . . . . . . . 10 Figure 5. EVL6563S-250W TM PFC: compliance to EN61000-3-2 standard at 70 W. . . . . . . . . . . . 10 Figure 6. EVL6563S-250W TM PFC: compliance to JEITA-MITI standard at 70 W . . . . . . . . . . . . . 10 Figure 7. EVL6563S-250W TM PFC: input current waveform @230 V-50 Hz - 250 W load . . . . . . . 11 Figure 8. EVL6563S-250W TM PFC: input current waveform @100 V-50 Hz - 250 W load . . . . . . . 11 Figure 9. EVL6563S-250W TM PFC: input current waveform @230 V-50 Hz - 70 W load . . . . . . . . 11 Figure 10. EVL6563S-250W TM PFC: input current waveform @100 V-50 Hz - 70 W load . . . . . . . . 11 Figure 11. EVL6563S-250W TM PFC: power factor vs. output power. . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 12. EVL6563S-250W TM PFC: THD vs. output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 13. EVL6563S-250W TM PFC: efficiency vs. output power . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 14. EVL6563S-250W TM PFC: average efficiency acc. to ES-2 . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 15. EVL6563S-250W TM PFC: static Vout regulation vs. output power . . . . . . . . . . . . . . . . . 13 Figure 16. EVL6563S-250W TM PFC: MOSFET current at 100 Vac - 50 Hz - full load . . . . . . . . . . . 14 Figure 17. EVL6563S-250W TM PFC: MOSFET current at 100 Vac - 50 Hz - full load . . . . . . . . . . . 14 Figure 18. EVL6563S-250W TM PFC: L6563S control pins-1 at 115 Vac - 60 Hz - full load . . . . . . . 14 Figure 19. EVL6563S-250W TM PFC: L6563S control pins-2 at 115 Vac - 60 Hz - full load . . . . . . . 14 Figure 20. L6562A input mains surge 90 Vac to 140 Vac - no VFF input . . . . . . . . . . . . . . . . . . . . . . 16 Figure 21. EVL6563S-250W TM PFC: input mains surge 90 Vac to 140 Vac. . . . . . . . . . . . . . . . . . . 16 Figure 22. L6562A: input mains dip 140 Vac to 90 Vac - no VFF input . . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 23. EVL6563S-250W TM PFC: input mains dip 140 Vac to 90 Vac . . . . . . . . . . . . . . . . . . . . . 16 Figure 24. L6563 Input current at 100 Vac -50Hz CFF=0.47 µF, RFF=390 kW . . . . . . . . . . . . . . . . . 17 Figure 25. EVL6563S-250W TM PFC: input current at 100 Vac -50 Hz CFF=1 µF, RFF=1 MW . . . . 17 Figure 26. EVL6563S-250W TM PFC: startup attempt at 80 Vac-60 Hz - full load . . . . . . . . . . . . . . . 18 Figure 27. EVL6563S-250W TM PFC: startup with slow input voltage increasing - full load. . . . . . . . 18 Figure 28. EVL6563S-250W TM PFC: turn-off with slow input voltage decreasing - full load . . . . . . . 18 Figure 29. EVL6563S-250W TM PFC: startup at 90 Vac-60 Hz - full load . . . . . . . . . . . . . . . . . . . . . 19 Figure 30. EVL6563S-250W TM PFC: startup at 265 Vac-50 Hz - full load . . . . . . . . . . . . . . . . . . . . 19 Figure 31. EVL6563S-250W load transient at 115 Vac - 60 Hz - full load to no-load . . . . . . . . . . . . . 21 Figure 32. EVL6563S-250W TM PFC: open-loop at 115 Vac - 60 Hz - full load . . . . . . . . . . . . . . . . . 21 Figure 33. EVL6563S-250W TM PFC: open-loop at 115 Vac - 60 Hz - full load - long acquisition . . . 21 Figure 34. L6563S on/off control by a cascaded converter controller via the PFC_OK or RUN pin . . 23 Figure 35. Interface circuits that let the L6563S switch on or off a PWM controller - not latched . . . . 24 Figure 36. Interface circuits that let the L6563S switch on or off a PWM controller - latched . . . . . . . 24 Figure 37. EVL6563S-250W TM PFC: PCB layout (SMT side view) . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 38. Thermal map at 115 Vac - 60 Hz - full load - PCB top side . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 39. Thermal map at 230 Vac - 50 Hz - full load - PCB top side . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 40. EVL6563S-250W CE AVG measurement at 115 Vac-60 Hz - full load - phase wire . . . . . 28 Figure 41. EVL6563S-250W CE AVG measurement at 115 Vac-60 Hz - full load - neutral wire . . . . 28 Figure 42. EVL6563S-250W CE AVG measurement at 230 Vac-50 Hz - full load - phase wire . . . . . 29 Figure 43. EVL6563S-250W CE AVG measurement at 230 Vac-50 Hz - full load - neutral wire . . . . 29

Doc ID 16849 Rev 2

3/32

Main characteristics and circuit description

AN3119

 

 

1 Main characteristics and circuit description

The main characteristics of the SMPS are:

Line voltage range: 90 to 265 Vac

Line frequency (fL): 47 to 63 Hz

Regulated output voltage: 400 V

Rated output power: 250 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: 93 % (@Vin=90 Vac, Pout=250 W)

Maximum ambient temperature: 50 °C

PCB type and size: single side, 35 µm, CEM-1, 88 x 116 mm

This demonstration board implements a power factor correction (PFC) pre-regulator, 250 W continuous power, delivering a regulated 400 V rail from a wide range mains voltage and providing for the reduction of the mains harmonics, allowing the European EN61000-3-2 or the Japanese JEITA-MITI standard to be met. The regulated output voltage is typically the input for the cascaded isolated DC-DC converter which provides the output rails required by the load.

The power stage of the PFC is a conventional boost converter, connected to the output of the D1 rectifier bridge. It is completed by the L2 coil, the D3 diode and the C5 capacitor. The boost switch is represented by the Q1 and Q2 power MOSFETs, connected in parallel. 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. In fact the RMS current flowing into the output stage is lower than current flowing into the input stage at the same input voltage. The board is equipped with an input EMI filter necessary to filter the switching noise coming from the boost stage.

At startup the L6563S is powered by the capacitor C9 which is charged via the R5 and R11 resistors. The L2 secondary winding and the charge pump circuit (C6, R2, D4 and D5) generate the Vcc voltage powering the L6563S during normal operations. The L2 secondary winding is also connected to the L6563S pin #11 (ZCD) through the R14 resistor. Its purpose is to supply the information that L2 has demagnetized, needed by the internal logic to trigger a new switching cycle.

The R4, R8, R12, and R15 divider provides, to the L6563S multiplier, the information for the instantaneous mains voltage which is used to modulate the peak current of the boost.

The R3, R6, R7 with R9 and R10 resistors are dedicated to sensing the output voltage and giving the feedback information necessary to the L6563S to regulate the output voltage. The C7, R13 and C10 components are the error amplifier compensation network necessary to obtain the required loop stability.

The peak current is sensed by the R23 and R24 resistors in series to the MOSFET and the signal is fed into pin #4 (CS) of the L6563S via the filter by R20 and C14.

C12, R27 and R28 are connected to pin #5 (VFF), they complete an internal peak-holding circuit which obtains 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 1/V2 function necessary to compensate the control loop gain dependence on

4/32

Doc ID 16849 Rev 2

AN3119

Main characteristics and circuit description

 

 

the mains voltage. Additionally, pin #10 (RUN) is connected to pin# 5 (VFF) through the R27 and R28 resistor divider, providing a voltage level for brown-out (AC mains under voltage) protection. A voltage on the RUN pin 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 R21, R25, R26 and R33 dividers provide the information regarding the output voltage level to the L6563S pin #7 (PFC_OK). It is required by the L6563S output voltage monitoring and disable 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, realizing the so-called dynamic OVP, preventing the output voltage becoming excessive in case of transient, due to 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 moving up to turn-on the threshold.

Additionally, if the voltage on pin #7 (PFC_OK) is tied below 0.23 V, the L6563S is shut down. To restart the L6563S operation the voltage on pin #7 (PFC_OK) must increase above 0.27 V. This function can be used as a remote on/off control input.

To allow the interfacing of the board with a D2D converter the J3 connector allows the powering of the L6563S with an external Vcc. It also gives the opportunity to manage failure or abnormal conditions via the PWM_LATCH (#8) and PWM_STOP (#9) pins. The L6563S operation can also be disabled or enabled to properly manage light load or failure conditions by the D2D via the PFC_OK pin (#7), still available at pin #5 of J3 (on/off). For further details please see Section 4.7.

Doc ID 16849 Rev 2

5/32

6/32

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

Electrical

 

 

 

 

 

 

 

 

 

 

 

 

 

 

'

 

 

 

 

 

 

 

 

diagram Electrical

diagram

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

)

 

 

 

 

'

 

 

/

 

 

 

5

 

 

 

 

 

-

 

 

 

)86($

/

 

 

 

 

 

 

 

 

17& 5 6

 

 

 

 

 

 

 

 

' ;% +

 

 

 

 

 

 

 

 

 

 

-

 

 

 

 

 

 

X+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9GF

 

 

 

 

 

 

 

a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9GF

 

 

 

 

 

 

 

 

 

 

 

 

 

'

 

 

 

 

 

-3;

 

1&

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

677+ /

 

 

 

 

 

 

571

 

 

 

&

 

 

 

 

 

 

 

 

 

 

 

 

&

 

 

 

571

 

 

 

 

 

 

 

 

 

&

5;

 

 

 

 

 

 

 

 

 

 

 

1 ;

 

 

 

 

B

 

 

 

 

X) 9

 

 

 

 

 

 

 

 

 

 

 

 

a

X) 9

5

 

 

 

 

 

 

 

 

 

 

 

 

 

9DF

 

 

/+ < 5 &

 

 

 

&

5

'

 

 

 

 

 

 

9RXW

 

 

 

 

 

 

 

 

 

 

 

-3;

 

5

 

 

 

 

 

 

X) ;

 

 

 

 

1

5

//

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

TM 250WEVL6563SFigure2.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

'

 

 

 

 

 

 

 

 

5

=

 

 

 

 

5

 

 

 

 

 

%=; &

 

 

 

 

 

5

 

 

 

 

 

 

 

 

-3;

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

0

 

 

 

 

 

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

5

3&% 5(9

 

5

5

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Doc

 

 

 

.

.

 

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

&

 

8

 

 

&

 

 

 

5

 

 

 

 

 

 

4

 

 

 

2 Rev 16849 ID

 

1

 

/ 6

 

 

 

5

 

5

 

 

 

 

 

 

 

 

 

demonstration PFC

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

67) 10 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

&

 

 

 

 

 

.

 

'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5;

1

 

,19

9&&

 

 

 

 

 

//

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

5;

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

67) 10 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

&203

*'

5

 

 

 

 

5

5

 

 

 

 

 

 

 

 

&

 

 

 

 

 

 

 

 

 

5

 

-3;

 

 

 

 

 

 

 

5

 

 

 

 

-3;

 

 

 

 

 

 

 

 

5

 

 

 

1

08/7

*1'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

'

5

 

 

 

 

 

 

 

 

.

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

//

5

 

 

 

 

 

 

 

 

 

 

 

&6

=&'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+($7 6,1.

 

 

 

 

 

9))

581

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

-3;

 

 

 

 

 

 

5

5

5

 

 

0

 

 

 

 

 

7%2

3:0 6723

 

 

&

 

 

 

 

5

5

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

&

&

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-3;

 

 

 

 

 

 

 

 

 

 

 

X)

S)

 

3)& 2.

3:0 /$7&+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-3;

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

board:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

5

&

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.

 

 

 

-3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

:,5(-803(5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

electrical

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

&

 

 

 

 

9&&

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

X) 9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

*1'

 

 

 

 

 

 

schematic

 

 

 

 

 

 

 

 

 

 

 

 

 

5

.

 

 

3:0B6723

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.

 

 

 

3:0B/$7&+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

21 2))

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

-

 

 

 

 

 

 

 

 

AN3119

 

V-!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-3;

 

 

 

 

&21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5HY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AN3119

Bill of material

 

 

3 Bill of material

Table 1.

EVL6563S-250W TM PFC demonstration board BOM

 

Des.

 

Part type/

Case style

Description

Supplier

 

part value

/package

 

 

 

 

 

 

 

 

 

 

C1

 

470N-X2

6X26.5 mm

X2 - FLM CAP - B32923A3474M

EPCOS

 

 

 

 

 

 

C10

 

680N

0805

25 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C11

 

2N2

0805

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C12

 

1 µF

0805

25 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C13

 

2N2

0805

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C14

 

220 pF

0805

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C15

 

2N2

0805

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C2

 

1 µF-X2

11X26.5 mm

X2 - FLM CAP - B32923C3105+***

EPCOS

 

 

 

 

 

 

C4

 

1.5 µF-520 V

12X26.5 mm

520V - FLM CAP - B32673Z5155

EPCOS

 

 

 

 

 

 

C5

 

100 µF - 450 V

Dia. 18X35 mm

450 V, aluminium ELCAP, TXW series, 105 °C

RUBYCON

 

 

 

 

 

 

C6

 

10 N

1206

100 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C7

 

68 N

0805

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C8

 

470 N

1206

50 V CERCAP - general purpose

AVX

 

 

 

 

 

 

C9

 

68 µF-35 V

Dia. 6.3X11 mm

35 V - Aluminium ELCAP - FM series - 105 °C

Panasonic

 

 

 

 

 

 

D1

 

D10XB60H

DWG

Single-phase bridge rectifier

SHINDENGEN

 

 

 

 

 

 

D2

 

1N5406

DO-201

Rectifier - general purpose

VISHAY

 

 

 

 

 

 

D3

 

STTH5L06

DO-201

Ultrafast high voltage rectifier

STMicroelectronics

 

 

 

 

 

 

D4

 

LL4148

MINIMELF

High speed signal diode

VISHAY

 

 

 

 

 

 

D5

 

BZX55-C18

MINIMELF

Zener diode

VISHAY

 

 

 

 

 

 

D6

 

LL4148

MINIMELF

High speed signal diode

VISHAY

 

 

 

 

 

 

D7

 

LL4148

MINIMELF

High speed signal diode

VISHAY

 

 

 

 

 

 

F1

 

FUSE 4A

DWG

Fuse T4A - time delay

WICHMANN

 

 

 

 

 

 

HS1

 

HEAT-SINK

DWG

Heat sink for D1& Q1, Q2 - H=23 mm

 

 

 

 

 

 

 

J1

 

CON2-IN

 

Input connector - pitch 7.62 MM - 2 pins

MOLEX

 

 

 

 

 

 

J2

 

CON5

DWG

Output connector - pitch 5.08 MM - 5 pins

MOLEX

 

 

 

 

 

 

J3

 

CON5

 

PCB term. block, pitch 2.5 MM - 5 W

MOLEX

 

 

 

 

 

 

JP2

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

JPX1

 

Wire jumper

 

Insulated wire jumper

 

 

 

 

 

 

 

JPX10

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

JPX2

 

Wire jumper

 

Insulated wire jumper

 

 

 

 

 

 

 

JPX3

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

Doc ID 16849 Rev 2

7/32

Bill of material

 

 

 

AN3119

 

 

 

 

 

 

 

Table 1.

EVL6563S-250W TM PFC demonstration board BOM (continued)

 

 

 

 

 

 

 

 

 

 

Des.

 

Part type/

Case style

Description

 

Supplier

 

 

part value

/package

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

JPX4

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

 

 

 

 

JPX5

 

Wire jumper

 

Insulated wire jumper

 

 

 

 

 

 

 

 

 

 

 

JPX6

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

 

 

 

 

JPX7

 

Wire jumper

 

Insulated wire jumper

 

 

 

 

 

 

 

 

 

 

 

JPX8

 

Wire jumper

 

Wire jumper

 

 

 

 

 

 

 

 

 

L1

LH30-792Y3R0-01

DWG

Input Emi filter - 7.9 mH-3A

TDK

 

 

 

 

 

 

 

 

L2

 

180 µH

DWG

PFC inductor PFC3819QM-181K09B01

TDK

 

 

 

 

 

 

 

 

Q1

 

STF12NM50N

TO-220FP

N-channel power MOSFET

STMicroelectronics

 

 

 

 

 

 

 

 

Q2

 

STF12NM50N

TO-220FP

N-channel power MOSFET

STMicroelectronics

 

 

 

 

 

 

 

 

R1

 

NTC 1R0-S237

DWG

NTC resistor P/N B57237S0109M000

EPCOS

 

 

 

 

 

 

 

 

 

R10

 

27 kΩ

0805

SMD STD film res - 1/8 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R11

 

150 kΩ

1206

SMD STD film res - 1/4 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R12

 

2.2 MΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R13

 

100 kΩ

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R14

 

100 kΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R15

 

51 kΩ

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R16

 

6.8 Ω

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R17

 

3.9 Ω

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R18

 

6.8 Ω

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R19

 

3.9 Ω

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R2

 

47 Ω

1206

SMD STD film res - 1/4 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R20

 

220 Ω

1206

SMD STD film res - 1/4 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R21

 

3.3 MΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R23

 

0.22 Ω

PTH

SFR25 axial STD film res - 0.4 W - 5 % -

VISHAY

 

 

250 ppm/°C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R24

 

0.22 Ω

PTH

SFR25 axial STD film res - 0.4 W - 5 % -

VISHAY

 

 

250 ppm/°C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R25

 

3.3 MΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R26

 

2.2 MΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R27

 

56 kΩ

0805

SMD STD film res - 1/8 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R28

 

1 MΩ

0805

SMD STD film res - 1/8 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R29

 

10 Ω

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R3

 

1 MΩ

1206

SMD STD film res - 1/4 W - 1 % -

100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R30

 

1 kΩ

0805

SMD STD film res - 1/8W - 5 % -

250ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

R31

 

1 kΩ

0805

SMD STD film res - 1/8 W - 5 % -

250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

 

8/32

Doc ID 16849 Rev 2

AN3119

 

 

 

Bill of material

 

 

 

 

 

 

 

Table 1.

EVL6563S-250W TM PFC demonstration board BOM (continued)

 

 

 

 

 

 

 

 

 

Des.

 

Part type/

Case style

Description

Supplier

 

 

part value

/package

 

 

 

 

 

 

 

 

 

 

 

 

 

R32

 

100 Ω

0805

SMD STD film res - 1/8 W - 5 % - 250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R33

 

51 kΩ

0805

SMD STD film res - 1/8 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R4

 

2.2 MΩ

1206

SMD STD film res - 1/4 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R5

 

150 kΩ

1206

SMD STD film res - 1/4 W - 5 % - 250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R6

 

1 MΩ

1206

SMD STD film res - 1/4 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R7

 

1 MΩ

1206

SMD STD film res - 1/4 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R8

 

2.2 MΩ

1206

SMD STD film res - 1/4 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

R9

 

62 kΩ

0805

SMD STD film res - 1/8 W - 1 % - 100 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

RX1

 

0 Ω

1206

SMD STD film res - 1/4 W - 5 % - 250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

RX3

 

47 Ω

1206

SMD STD film res - 1/4 W - 5 % - 250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

RX4

 

0 Ω

1206

SMD STD film res - 1/4 W - 5 % - 250 ppm/°C

VISHAY

 

 

 

 

 

 

 

 

U1

 

L6563S

SO14

Enhanced PFC controller

STMicroelectronics

 

 

 

 

 

 

 

 

Z1

 

PCB rev. 1

 

 

 

 

 

 

 

 

 

 

 

Doc ID 16849 Rev 2

9/32

ST AN3119 Application note

Test results and significant waveforms

AN3119

 

 

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. As shown in the following images, the circuit is able to reduce the harmonics well below the limits of both standards from full load down to light load. 70 W of output power has been chosen because it is almost the lowest power limit at which the harmonics must be limited according to the above mentioned standards. Measurements are given in Figure 3, 4, 5, and 6:

Figure 3. EVL6563S-250W TM PFC:

Figure 4. EVL6563S-250W TM PFC:

 

 

 

compliance to EN61000-3-2

 

 

 

 

compliance to JEITA-MITI standard

 

 

 

standard at 250 W

 

 

 

 

at 250 W

 

 

 

 

0HDVXUHG YDOXH (1 &ODVV ' OLPLWV

 

 

 

 

0HDVXUHG YDOXH

-(,'$0,7, OLPLWV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+DUPRQLF &XUUHQW >$@

 

 

 

+DUPRQLF &XUUHQW >$@

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+DUPRQLF 2UGHU >Q@

 

 

 

 

+DUPRQLF 2UGHU >Q@

 

 

 

!-V

 

 

 

 

 

!-V

Vin = 230 Vac - 50 Hz, Pout = 250 W, THD = 3.95 %, PF =0.985

Vin = 100 Vac - 50 Hz, Pout = 250 W, THD = 3.77 %, PF = 0.999

Figure 5. EVL6563S-250W TM PFC:

Figure 6. EVL6563S-250W TM PFC:

 

 

 

compliance to EN61000-3-2

 

 

 

 

compliance to JEITA-MITI standard

 

 

 

standard at 70 W

 

 

 

 

at 70 W

 

 

 

 

0HDVXUHG YDOXH (1 &ODVV ' OLPLWV

 

 

 

 

0HDVXUHG YDOXH

-(,'$0,7, OLPLWV

 

 

 

 

 

 

 

 

 

 

+DUPRQLF &XUUHQW >$@

 

 

 

+DUPRQLF &XUUHQW >$@

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+DUPRQLF 2UGHU >Q@

 

 

 

 

+DUPRQLF 2UGHU >Q@

 

 

 

!-V

 

 

 

 

 

!-V

Vin = 230 Vac - 50 Hz, Pout = 70 W, THD = 10.84 %, PF = 0.869

Vin = 100 Vac - 50 Hz, Pout = 70 W, THD = 5.4 %, PF = 0.995

10/32

Doc ID 16849 Rev 2

Loading...
+ 22 hidden pages