STEVAL-ILL042V1: high power factor flyback LED driver
based on the L6562A and TSM101
Introduction
The high-PF flyback configuration, used to drive a new design of the 60 W LED array, is
based on the L6562A and the TSM101 controller (Figure 1).
This configuration uses an isolated feedback with an optocoupler and a secondary side
r e fe r e n c e/ e r ro r a m p l if i e r, t h e T S M 1 0 1, fo r vo l ta g e an d cu r r en t re g u la t i on .
T h e T S M 1 0 1 i n c l u d e s t w o o p a m p s : o n e o p a m p i s u s e d f o r c o n s t a n t v o l t a g e c o n t r o l
and the other for constant current control. A precise internal current generator, available,
can be used to offset the intervention threshold of the constant current regulation.
The L6562A is a PFC controller operating in transition-mode. The highly linear multiplier
includes a special circuit, able to reduce AC input current distortion, that allows wide-rangemains operation with an extremely low THD, even over a large load range.
The TSM101 compares the DC voltage and current level of a switching power supply to an
internal reference. It provides a feedback through an optocoupler to the L6562A controller in
the primary side.
This system, designed by using the L6562A and the TSM101 controller, offers more
advantages in terms of output current and voltage stability.
The input capacitance is so small here that the input voltage is very close to a rectified
sinewave. Besides, the control loop has a narrow bandwidth so as to be little sensitive to the
twice-mains frequency ripple appearing at the output.
Efficiency is high at heavy load, more than 90% is achievable: TM operation ensures slow
turn-on losses in the MOSFET and the high PF reduces dissipation in the bridge rectifier.
The output voltage exhibits a considerable twice-mains frequency ripple, unavoidable if a
high PF is desired. Speeding up the control loop may lead to a compromise between a
reasonably low output ripple and a reasonably high PF. To keep the ripple low, a large output
capacitance (in the thousand F) is anyway required.
There is some margin to select a 950 V device. This minimizes gate drive and
capacitive losses. Assuming that the MOSFET dissipates 5% of the input power, that
losses are due to conduction only, and that R
R
at 25 °C should be about 2 Ω. An STP7N95K3 (R
DS(on)
doubles at working temperature, the
DS(on)
1.35 Ω max.) in TO-220
DS(on)
Zener-protected SuperMESH3 is selected.
7. Catch diode selection:
V
Maximum drain voltage: .
V
maxREV
maxPK
V
n
out
371
493.1
378V
=+=+=130
A suitable device is an STTH3L06, a TURBO 2 ultrafast high voltage rectifier with
I
= 3 A (minimum current rating is 1.166 A), V
F
= 600 V (V
RRM
RRM>VREVmax
).
From the relevant datasheet the power dissipation is estimated as:
Equation 3
2
IRIVP
RMSsthou tfout
=⋅+⋅=
0.89 0.4620.055 0.8620.45W=⋅+⋅
This means , acceptable value.
T
jTambRthPout
75 75 0.45⋅+=⋅+108.75°C==
8. Output capacitor selection:
The minimum capacitance value that meets the specification on the 100/120 Hz ripple
is:
Equation 4
I
C
mi nout
1
=
f
⋅π
L
)K(2H
out
V
)K(2F
V
=
⋅⋅
V
Δ
o
462.0*
124.04714.3
⋅⋅⋅
F1025
μ=
Three 330 µF electrolytic capacitors have an ESR low enough (max. 446 mΩ) to consider
the high frequency ripple negligible as well as sufficient AC capability.
9. Clamp network:
With a proper construction technique, the leakage inductance can be reduced less than
1% of the primary inductance, which it is in the present case. A Transil clamp is
selected.
The clamp voltage is V
= VR+ΔV = 195 + 100 = 295 V. The steady-state power
CL
dissipation is estimated to be about 1 W. A 1.5KE350A Transil is selected. The blocking
diode is an STTH1L06.
10. Multiplier bias and sense resistor selection:
Assuming a peak value of 2.6 (@ V
peak value at minimum line voltage is V
= 265 V) on the multiplier input (MULT, 3) the
AC
185
--------- -
MULTpkmin
2.6
= which,
265
1.81V=⋅
multiplied by the maximum slope of the multiplier, 1, gives 1.81 V peak voltage on
current sense (CS, pin 4).
Since the linearity limit (3 V) is not exceeded, this is acceptable. The driver ratio is
then . Considering 260 µA for the divider, the lower resistor
2.6
--------------------------6.93 10
2265⋅()
3–
⋅=
Doc ID 018991 Rev 111/22
Design and calculation parametersAN3424
is 10 kΩ, and the upper one 1 MΩ. Choose the sense resistor 0.5 Ω, while its
power rating is .
PS0.5 I
2
RMSp
0.5 0.5952177m W=⋅=⋅=
11. Feedback and control loop:
The selected optocoupler is an ISO1-CNY-17.
The TSM101 is a voltage and current controller that regulates the output and current
voltage provided to the LED.
By considering V
V band-gap voltage reference, the V
= 130 V and that the value at pin 7 is compared to the internal 1.24
out
pin7
is:
Equation 5
VV
R
6
130
⋅=
out7pin
RR
+
76
⋅=
k5.1
k156k5.1
+
V24.1
=
with R6 = 1.5 kΩ, R7 = 156 kΩ.
= 0.6 Ω is the sense resistor used for current measurement. The current regulation
R
5
is effective when the voltage drop across it is equal to the voltage on pin 5 of TSM101.
For medium currents (<1 A), a voltage drop across R
R
can be realized with standard low cost 0.4 W resistors in parallel.
5
of 200 mV = VR5 is a good value,
5
Equation 6
V
R
5R
5
Ich
(two 1.2 Ω resistors in parallel)
Ω==57.0
R2 and R3 can be chosen using the following formula:
Equation 7
⎛
⎜
RR
⋅=
32
⎜
⎝
Fixed R3 = 2 kΩ, we can have R2 = 10 kΩ.
⎞
VV
−
5Rref
⎟
V
⎟
5R
⎠
12/22Doc ID 018991 Rev 1
AN3424Design and calculation parameters
The complete electrical schematic of this application is illustrated in Figure 7.
Figure 7.60 W high-PF with L6562 and TSM101: electrical schematic
Vout
2.2uF
18O
3x330uF
36kO
1.5KE350A
STTH1L06
10O
18kO
10O
100nF
47uF
18V
R7=156kO
0.5W
R5
2x1.2O
LL4148
LL4148
R6=1.5kO
5
3
8
TSM101
6
4
R2=10kOR3=2kO
1
7
47kO
68kO
100nF
1uF
0.5O
STP7N95K3
1N4148
1MO
2.2nF
100nF
+
Filter
Bridge
Mains
10O
10kO
3
7
4
150pF
L6562
8
2
300kO
1nF
750kO
65
1
0O
30kO
2.2kO
AM10535v1
Doc ID 018991 Rev 113/22
Design and calculation parametersAN3424
12. Experimental results:
These results have been obtained at input voltage between 185 and 265 V.
Ambient temperature: 23 °C
–V
–I
–P
= 118.7 V
OUT
= 358 mA
OUT
= 42.5 W
OUT
Figure 8.Pin vs. Vin
Figure 9.THD vs. Vin
14/22Doc ID 018991 Rev 1
AN3424Design and calculation parameters
Figure 10. PF vs. Vin
Figure 11. Efficiency vs. Vin
Figure 12. Startup @ 230 V L6562A Vcc (red) MOSFET drain voltage (brown)
These measurements were performed at ambient temperature of 25 °C and at minimum
input voltage (185 V, worst case for PFC section).
Thermal measurement on the power device was performed on the board using infrared
thermocamera FLUKE.
For the PFC section, the temperature was measured on the power MOSFET and on the
diode.
On the power MOSFET with a mounted heatsink, having thermal resistance R
°C/W, the temperature on the top of the package was 40 °C. On the top of the Transil diode
the temperature was 35 °C, for the clamp diode 35 °C, for the IC driver 47 °C, and for the
output diode 55 °C.
= 11.40
th
18/22Doc ID 018991 Rev 1
AN3424EMC tests results
5 EMC tests results
EMC test was conducted according to the EN55015A standard.
The test was performed using the following apparatus:
●EMC ANALYZER Agilent E7401A
●LISN EMCO model 3825/2, 50 Ω, 10 kHz - 100 MHz.
The test was performed using peak detector and the limits of average and quasi peak of EN
55015A standard in the range 150 kHz - 30 MHz at 230 V 50 Hz input voltage.
Figure 17. Peak measure: line wire
In Figure 17 it is possible to observe that the conduced emissions are out of the limits in the
range 5 - 6 MHz.
Figure 18. Peak measure: neutral wire
Doc ID 018991 Rev 119/22
ConclusionsAN3424
6 Conclusions
The high-PF flyback configuration used to drive a new design of the 60 W LED array and
based on the PFC L6562A and on the voltage and current TSM101 controller works
correctly in a single range [185 - 265] V. In the same range the efficiency is very high, more
than 92% (
Thermal measurements show that the power MOSFET reaches T = 40 °C.
Thanks to the TSM101, the system offers an excellent LED current regulation in terms of
current precision and works properly in all input conditions and output load, by offering high
performance with a simple and reliable design.
Figure 11).
20/22Doc ID 018991 Rev 1
AN3424Revision history
7 Revision history
Table 4.Document revision history
DateRevisionChanges
08-Nov-20111Initial release.
Doc ID 018991 Rev 121/22
AN3424
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