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march 2007 rev 1 1/29 AN2485 application note 400 w fot-controlled pfc pre -regulator with the l6563 introduction this application note describes an evaluation board based on the transition-mode pfc controller l6563 and presents the results of the bench evaluation. the board implements a 400 w, wide-range mains input, a pfc pre-conditioner suitable for atx psu, or a flat screen display. the chip is operated with fixed-off-time control in order to use a low-cost device like the l6563 which is usually prohibitive at this power level. fixed-off-time control allows continuous conduction mode operation which is normally achieved with more expensive control chips and more complex control architectures. l6563 400w fot pfc demo board (eval6563-400w) www.st.com
contents AN2485 2/29 contents 1 main characteristics and cir cuit description . . . . . . . . . . . . . . . . . . . . . 4 2 test results and signifi cant waveforms . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 inductor current in fot and l6563 thd optimizer . . . . . . . . . . . . . . . . . 10 2.3 voltage feedforward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.4 start-up and run pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.5 start-up at light load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.6 open loop protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.7 power management/housekeeping functions . . . . . . . . . . . . . . . . . . . . . . 17 3 layout hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4 audible noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5 thermal measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 6 conducted emission pre-compli ance test . . . . . . . . . . . . . . . . . . . . . . 22 7 bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8 pfc coil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8.1 general description and characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8.2 electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8.3 mechanical aspect and pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 9 references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 10 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AN2485 list of figures 3/29 list of figures figure 1. eval6563-400w evaluati on board: electrical schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 figure 2. eval6563-400w compliance to en61000-3-2 at 23 0 vac-full load . . . . . . . . . . . . . . . . . . 7 figure 3. eval6563-400w compliance to je ida-miti at 100 vac-full load . . . . . . . . . . . . . . . . . . . . 7 figure 4. eval6563-400w compliance to en61000-3-2 at 230 va c-70 w load . . . . . . . . . . . . . . . . 7 figure 5. eval6563-400w compliance to je ida-miti at 100 vac-70 w load . . . . . . . . . . . . . . . . . . 7 figure 6. eval6563-400w input current waveform at 100 v - 60 hz - 400 w load . . . . . . . . . . . . . . 8 figure 7. eval6563-400w input current waveform at 230 v - 50 hz - 400 w load . . . . . . . . . . . . . . 8 figure 8. eval6563-400w input current waveform at 100 v - 60 hz - 200 w load . . . . . . . . . . . . . . 8 figure 9. eval6563-400w input current waveform at 230 v - 50 hz - 200 w load . . . . . . . . . . . . . . 8 figure 10. eval6563-400w inpu t current waveform at 100 v - 60 hz - 70 w load . . . . . . . . . . . . . . . 8 figure 11. eval6563-400w inpu t current waveform at 230 v - 50 hz - 70 w load . . . . . . . . . . . . . . . 8 figure 12. power factor vs. vin and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 13. thd vs. vin and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 14. efficiency vs. vin and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 15. static vout regulation vs. vin and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 16. eval6563-400w indu ctor current ripple envelo pe at 115 vac - 60 hz - full load . . . . . . . 10 figure 17. eval6563-400w indu ctor current ripple (detail) at 115 vac - 60 hz - full load . . . . . . . . . 10 figure 18. eval6563-400w indu ctor current ripple envelo pe at 230 vac - 50 hz - full load . . . . . . . 11 figure 19. eval6563-400w indu ctor current ripple (detail) at 230 vac - 50 hz - full load . . . . . . . . . 11 figure 20. eval6563-400w inpu t mains surge from 90 vac to 140 vac - full load - c ff = 470 nf . . 12 figure 21. l6562 fot input mains surge from 90 vac to 140 vac - full load - no v ff input . . . . . . . 12 figure 22. eval6563-400w inpu t mains dip from 140 vac to 90 vac - full load - c ff = 470 nf . . . . 13 figure 23. l6562 fot input mains dip from 90 vac to 140 vac - full load - no v ff input . . . . . . . . . 13 figure 24. eval6563-400w input current shape at 100 vac-60 hz vs. v ff ripple - c ff = 470 nf . . 14 figure 25. eval6563-400w input current shape at 100 vac-60 hz vs. v ff ripple - c ff = 1.5 uf . . . 14 figure 26. eval6563-400w start-up at 90 va c-60 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 27. eval6563-400w start-up at 265 vac-50 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 28. eval6563-400w start-up at 80 va c-60 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 29. eval6563-400w start- up at 265 v -50 hz - 30 ma load . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 30. eval6563-400w start-up at 265 v -50 hz - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 31. eval6563-400w open lo op at 115 vac-60 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 32. l6563 on/off co ntrol by a cascaded converter controlle r via pfc_ok or run pin . . . . . 17 figure 33. interface circuits that let the l6563/a switch on or off a pwm controller . . . . . . . . . . . . . . 18 figure 34. eval6563-400w pcb layo ut (not 1:1 scaled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 figure 35. thermal map at 115 vac-60 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 36. thermal map at 230 vac-50 hz - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 37. 115 vac and full load - phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 38. 115 vac and full load - neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 39. 230 vac and full load - phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 40. 230 vac and full load - neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 41. electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 figure 42. pin side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 figure 43. mechanic aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
main characteristics and circuit description AN2485 4/29 1 main characteristics and circuit description the main characteristics of the smps are: line voltage range: 90 to 265 vac minimum line frequency (f l ): 47 hz regulated output voltage: 400 v rated output power: 400 w maximum 2f l output voltage ripple: 10 v pk-pk hold-up time: 22 ms (v drop after hold-up time: 300 v) maximum switching frequency: 85 khz (@vin=90 vac, pout=400 w) minimum estimated efficiency: 90% (@vin=90 vac, pout=400 w) maximum ambient temperature: 50 c emi: in acc. with en55022 class-b pcb type and size: single side, 70 um, cem-1, 148.5 x 132 mm low profile design: 35 mm component maximum height the evaluation board implements a power factor correction (pfc) pre-regulator delivering 400 w continuous power on a regulated 400 v rail from a wide range mains voltage. the board provides for the reduction of the mains harmonics which allows meeting the standards of the european norm en61000-3-2 or the japanese norm jeida-miti. this rail is the input for the cascaded isolated dc-dc converter that provides the output rails required by the load. the board is equip ped with enough he at sinking to allow full-load operation in still air. with an appropriate airflow, and without any change in the circuit, the evaluation board can easily deliver up to 450 w. the controller is the l6563 (u1), integrating all the functions needed to control the pfc stage and to interface with the downstream converter. the l6563 controller chip is designed for transition-mode (tm) operation, where the boost inductor works next to the boundary between continuous (ccm) and discontinuous conduction mode (dcm). however, with a slightly different usage, the chip can operate so that the boost inductor works in ccm, surpassing the limitations of tm operation in terms of powe r handling capability. the gate- drive capability of the l6563 is also adequate to drive the mo sfets used at higher power levels. this approach, which couples the simplicity and cost-effectiveness of tm operation with the high-current capability of ccm operatio n, is the fixed-off-time (fot) control. the control modulates the on-time of the power switch, while its off-time is kept constant. more precisely, the line-modulated fot (lm-fot), where the off-time of the power switch is not rigorously constant but is mo dulated by the instanta neous mains voltage, will be used. please refer to an1792 (?design of fixed-off-time-controlled pfc pre-regulators with the l6562?) for a detailed description of this technique as indicated in section 9: references (point 2). the power stage of the pfc is a conventional boost converter, connected to the output of the rectifier bridge d2. it includes the coil l4, the diode d3 and the capacitors c6 and c7. the boost switch is represented by the power mosfets q1 and q2. the ntc r2 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 efficiency during low line operation. additionally, the splitting in two of output capacitors (c6 and c7) provides for managing the ac current
AN2485 main characteristics and circuit description 5/29 mainly by the film capacitor c7 which allows fo r a less costly electrolytic to bear only the dc part. at start-up the l6563 is powered by the vcc capacitor (c12) that is charged via the resistors r3 and r4. the l4 secondary winding (pins #8-11) and the charge pump circuit (r5, c10, d5 and d4) generate the vcc voltage powering the l6563 during normal operations. the divider r32, r33 and r34 provides the l6563 multiplier with the information of the instantaneous voltage that is used to modulate the boost current. the instantaneous voltage information is also used to get the average value of the ac line by the v ff (voltage feed- forward) pin. divider r9, r10, r11, r12, and r13 is dedicated to sense output voltage while divider r6, r7, r8, and r24 is dedicated to protect the circuit in case of voltage loop failures. the line-modulated fot is obtained by the timing generator components d6, c15, r15, c16, r16, r31, and q3. the board is equipped with an input emi filter designed for a 2-wire input mains plug. it is composed of two stages, a common mode pi-filter connected at the input (c1, l1, c2, c3) and a differential mode pi-filter after the input bridge (c4, l3, c5). the board also offers the possibility to easily connect a downstream converter and test the interface signals managed by the l6563.
main characteristics and circuit description AN2485 6/29 figure 1. eval6563-400w evaluation board: electrical schematic r102 0r0 +400vout r19 1k0 l2 res c20 330pf l1 cm-1.5mh-5a r26 150k l3 dm-51uh-6a c15 100pf c16 220pf r22 0r39-1w r15 3k3 c11 470nf/50v c12 47uf/50v r16 15k 1 2 j1 q2 stp12nm50fp d6 ll4148 c1 470nf-x2 r20 0r39-1w d5 bzx85-c15 r23 0r39-1w r1 1m5 d1 1n5406 1 2 3 4 5 j2 d3 stth8r06 f1 8a/250v r3 180k c21 10nf r17 6r8 r34 10k r18 6r8 q3 bc857c c19 2nf2 r33 620k d7 ll4148 c4 470nf-630v r32 620k d8 ll4148 r8 2m2 r2 ntc 2r5-s237 r6 2m2 l4 pq40-500uh q1 stp12nm50fp r7 2m2 r28 res r4 180k r31 1k5 r21 0r39-1w r24 36k + - ~ ~ d2 d15xb60 c17 10nf r5 47r 1 2 3 j3 res c5 470nf-630v r12 82k r13 15k inv 1 comp 2 mu lt 3 cs 4 vff 5 tbo 6 pfc-ok 7 pwm-latch 8 pwm-stop 9 run 10 zcd 11 gnd 12 gd 13 vcc 14 u1 l6563 r11 680k r10 680k r35 3r9 r36 3r9 r30 res r9 680k c2 470nf-x2 r14 56k c3 680nf-x2 c6 470nf-630v c8 res c18 470nf c14 1uf c9 res r27 240k c13 100nf d4 ll4148 r29 res c7 330uf-450v c10 18n +400vdc 5-6 1-2 +400vdc 90 - 265vac nc rtn +400vdc 811 rtn +400vdc 1 2 jp101 jumper r101 0r0 1 2 jp102 jumper
AN2485 test results and significant waveforms 7/29 2 test results and significant waveforms 2.1 harmonic 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 european and janapese regulations. the board has been tested according to european norm en61000-3-2 class-d and japanese norm jeida-miti class-d, at full load and 70 w output power, at both the nominal input voltage mains. as shown in figure 2 , 3 , 4 , and 5 , the circuit is able to reduce the harmonics well below the limits of both regulations from full load down to light load. 70 w of output power has been chosen because it is almost the lower power limit at which the harmonics must be limited according to these international norms. for user reference, waveforms of the input current and voltage at the nominal input voltage mains and different load conditions are given in figure 6 , 7 , 8 , 9 , 10 , and 11 . figure 2. eval6563-400w compliance to en61000-3-2 at 230 vac-full load figure 3. eval6563-400w compliance to jeida-miti at 100 vac-full load 0.001 0.01 0.1 1 10 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 harmonic order [n] harmonic current [a] measured value en61000-3-2 class-d limits 0.001 0.01 0.1 1 10 1 3 5 7 9 111315171921232527293133353739 harmonic order [n] harmonic current [a] measured value jeida-miti class-d limits figure 4. eval6563-400w compliance to en61000-3-2 at 230 vac-70 w load figure 5. eval6563-400w compliance to jeida-miti at 100 vac-70 w load 0.001 0.01 0.1 1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 harmonic order [n] harmonic current [a] measured value en61000-3-2 class-d limits 0.001 0.01 0.1 1 1 3 5 7 9 111315171921232527293133353739 harmonic order [n] harmonic current [a] measured value jeida-miti class-d limits
test results and significant waveforms AN2485 8/29 figure 6. eval6563-400w input current waveform at 100 v - 60 hz - 400 w load figure 7. eval6563-400w input current waveform at 230 v - 50 hz - 400 w load figure 8. eval6563-400w input current waveform at 100 v - 60 hz - 200 w load figure 9. eval6563-400w input current waveform at 230 v - 50 hz - 200 w load figure 10. eval6563-400w input current waveform at 100 v - 60 hz - 70 w load figure 11. eval6563-400w input current waveform at 230 v - 50 hz - 70 w load
AN2485 test results and significant waveforms 9/29 the power factor (pf) and the total harmonic distortion (thd) have been measured too and the results are reported in figure 12. and figure 13. as shown, the pf at full load and half load remains close to unity throughout th e input voltage mains ra nge while it decreases at high mains range when the circuit is deliver ing 70 w. thd is low, remaining within 25% at maximum input voltage. efficiency is very good at all load and line cond itions. at full load it is always significantly higher than 90%, making this design suitable for high efficiency power supply. the measured output voltage variation at different line and load conditions is given in figure 15. as shown, the voltage is perfectly stable over the input voltage range due to the voltage feed-forward function embedded in the l6593. only at 265 vac and light load, there is a negligible deviation of 1 v due to the intervention of the burst mode (for the "static ovp") function. figure 12. power factor vs. vin and load figure 13. thd vs. vin and load 0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 90 100 115 130 180 230 265 v in [v rms ] pf 400w 200w 70w 0 5 10 15 20 25 30 90 100 115 130 180 230 265 v in [v rms ] thd [ %] 400w 200w 70w figure 14. efficiency vs. vin and load figur e 15. static vout regulation vs. vin and load 75% 80% 85% 90% 95% 100% 90 100 115 130 180 230 265 v in [v rms ] eff [%] 400w 200w 70w 15w 400 400.5 401 401.5 402 402.5 403 403.5 404 90 100 115 130 180 230 265 v in [v rms ] v out [v dc ] 400w 200w 70w 15w
test results and significant waveforms AN2485 10/29 2.2 inductor current in fo t and l6563 thd optimizer figure 16 , 17 , 18 , and 19 show the waveforms relevant to the inductor current at different voltage mains. as shown in figure 16. and figure 18. , the inductor current waveform over a line half-period is very similar to that of a ccm pfc. it is also possible to note the transition angle from dcm to ccm that occurs closer to the zero crossing of the current sine wave at low mains and move toward the top if the circuit is working at high mains. in figure 17. and figure 19. the magnification of the waveforms at the peak of the sine wave, shows the different ripple current and off-times, whic h is modulated by th e input mains voltage. on both the drain voltage traces reported in figure 16. and figure 18. , close to the zero crossing points of the sine wave, it is possible to note the action of the thd optimizer embedded in the l6563. it is a circuit that mi nimizes the conduction dead-angle occurring to the ac input current near the zero-crossings of the line voltage (crossover distortion). in this way, the thd (total harmonic distortion) of th e current is considerably reduced. a major cause of this distortion is the inability of the system to transfer ener gy effectively when the instantaneous line voltage is very low. this effect is magnified by the high frequency filter capacitor placed after the bridge rectifier, which retains some residual voltage that causes the diodes of the bridge rectifier to be reverse-biased and the input current flow to temporarily stop. to overcome this issue the device forces the pfc pre-regulator to process more energy near the line voltage zero-crossings as compared to that commanded by the control loop. the result is both a minimization of the time interval where energy transfer is lacking and a full discharge of the high-frequency filter capacitor after the bridge. essentially, the circuit artificially increases the on-time of the power switch with a positive offset added to the output of the multiplier in t he proximity of the line voltage zero-crossings. this offset is reduced as the instantaneous line voltage increases, so that it becomes negligible as the line voltage moves toward the top of the sinusoid. the offset is modulated by the voltage on figure 16. eval6563-400w inductor current ripple envelope at 115 vac - 60 hz - full load figure 17. eval6563-400w inductor current ripple (detail) at 115 vac - 60 hz - full load ch1: q1/q2 drain voltage ch2: mult voltage - pin #3 ch4: l4 inductor current ripple envelope ch1: q1/q2 drain voltage ch2: mult voltage - pin #3 ch4: l4 inductor current ripple envelope
AN2485 test results and significant waveforms 11/29 the v ff pin, so as to have little offset at low line, where energy transfer at zero crossings is typically quite good, and a larger offset at high line where the energy transfer gets worse. in order to maximize the benefit from the thd optimizer circuit, the high-frequency filter capacitors after the bridge rectifier should be minimized, compatible with emi filtering needs. a large capacitance in fact introduc es a conduction dead-angle of the ac input current in itself thus reducing the effectiveness of the optimizer circuit. 2.3 voltage feedforward the power stage gain of pfc pre-regulators varies with the square of the rms input voltage as well as the crossover frequency fc of the overall open-loop gain because the gain has a single pole characteristic. this leads to large trade-offs in the design. for example, setting the gain of the error amplifier to get fc = 20 hz at 264 vac means having fc = 4 hz at 88 vac, which results in sluggish control dynamics. additionally, the slow control loop causes large transient current flow during rapid line or load changes that are limited by the dynamics of the multiplier outp ut. this limit is consider ed when selecting the sense resistor to let the full load power pass under minimum line voltage conditions, with some margin. a fixed current limit allows excessive power input at high line, whereas a fixed power limit requires the current limit to vary inve rsely with the line voltage. voltage feedforward can compensate for the gain variation with the line voltage and provides a solution to the above-mentioned issues. it consists of deriving a voltage proportional to the input rms voltage, feeding this voltage into a squarer/divider circuit (1/v 2 corrector) and providing the resulting signal to the multiplier that generates the current reference for the inner curren t control loop. in this way a change of the line voltage will cause an inversely proportional change of the half sine amplitude at the output of the multiplier so that the current reference is adapted to the new operating conditions with (ideally) no need for invoking the slow dynamics of the error amplifier. additionally, the loop gain will be constant throughout the input voltage range, which improves significantly dynamic behavior at low line and simplifies loop design. figure 18. eval6563-400w inductor current ripple envelope at 230 vac - 50 hz - full load figure 19. eval6563-400w inductor current ripple (detail) at 230 vac - 50 hz - full load ch1: q1/q2 drain voltage ch2: mult voltage - pin #3 ch4: l4 inductor current ripple envelope ch1: q1/q2 drain voltage ch2: mult voltage - pin #3 ch4: l4 inductor current ripple envelope
test results and significant waveforms AN2485 12/29 the l6563 achieves voltage feedforward with a technique that makes use of just two external parts and limits the feedforward time constant trade-off issue to only one direction. a capacitor c ff (c18) and a resistor r ff (r26 + r27), both connected to the v ff pin (#5), complete an internal peak-holding circuit that provides a dc voltage equal to the peak of the rectified sine wave applied on pin mult (pin #3). r ff provides a means to discharge c ff when the line voltage decreases. in this way, in case of sudden line voltage rise, c ff is rapidly charged through the low impedance of the internal diode and no appreciable overshoot is visible at the pre-regulator's output. in case of line voltage drop, c ff is discharged with the time constant r ff c ff , which can be in the hundred ms to achieve an acceptably low steady-state ripple and have low current distortion. the dynamics of the voltage feed-forward input is limited downwards at 0.5 v, that is, the output of the multiplier no longer increases if the voltage on the v ff pin is below 0.5 v. this helps to prevent excessive power flow when the line voltage is lower than the minimum specified value. the behavior of the eval6563-400w demo board in case of an input voltage surge from 90 to 140 vac is shown in figure 20. the graph shows that the v ff function provides for the stability of the output voltage which is not affect ed by the input voltage surge. in fact, thanks to the v ff function, the compensation of the input voltage variation is very fast and the output voltage remains perfectly stable at its nominal value. the opposite is confirmed in figure 21. which shows the behavior of a pfc using the l6562 working in fot and delivering a similar output power. in case of a mains surge the controller cannot compensate for it, and the output vo ltage stability is guaran teed by the feedback loop only. unfortunately, as previously stated, its bandwidth is poor therefore the output voltage has a significant deviation from the nominal value. the circuit has the same behavior in case of mains surge at any input voltage, and it is not affected if the input mains surge happens at any point on the input sine wave. figure 20. eval6563-400w input mains surge from 90 vac to 140 vac - full load - c ff = 470 nf figure 21. l6562 fot input mains surge from 90 vac to 140 vac - full load - no v ff input ch1: output voltage ch2: input rectif ied mains voltage ch4: input current ch3: v ff voltage - pin #5 ch1: output voltage ch2: input rectified mains voltage ch4: input current ch3: v ff voltage - pin #5
AN2485 test results and significant waveforms 13/29 figure 22. shows the circuit behavior in case of mains dip. as previously described, the time constant of the v ff pin provides a very fast compensation in case of surge, which is the most critical transition, and a slower compensation in case of mains dip. as shown, in that case the output voltage changes, but in few mains cycles it returns to the nominal value. a controller without the v ff function will instead perform differently. in figure 23. the behavior of a pfc using the l6562 working in fot and delivering a similar output power is shown. in case of a mains dip, the output voltage variation is larger and the output voltage requires more time to return to the original value. deriving a voltage proportional to the rms line voltage implies a form of integration, which has its own time constant. if the time consta nt is too small the voltage generated will be affected by a considerable amount of ripple at twice the mains frequency so causing distortion of the current reference (resulting in high thd and poor pf). if the time constant is too large there will be a considerable delay in setting the right am ount of feedforward, resulting in excessive overshoot or undershoot of the pre-regulator's output voltage in response to large line voltage change s. clearly, a trade-off is required. for reference, figure 24. and figure 25. compare the input current shape and the measurement of the thd and 3 rd harmonic amplitude for different c ff values. figure 25. shows that increasing 3 times the c ff capacitor improves the current shape and both the thd and the third harmonic current are also decreased, but not very significantly. the time constant used for v ff (c ff = 470 nf, r ff = 150 k+240 k) is a good compromise. figure 22. eval6563-400w input mains dip from 140 vac to 90 vac - full load - c ff = 470 nf figure 23. l6562 fot input mains dip from 90 vac to 140 vac - full load - no v ff input ch1: output voltage ch2: input rectif ied mains voltage ch4: input current ch3: v ff voltage - pin #5 ch1: output voltage ch2: input rectified mains voltage ch4: input current ch3: v ff voltage - pin #5
test results and significant waveforms AN2485 14/29 2.4 start-up and run pin figure 26. and figure 27. detail the waveforms during the start-up of the circuit, at mains plug-in. the vcc voltage rises to the turn-on threshold, and the l6563 starts the operation. for a short time the energy is supplied by the vcc capacitor, then the auxiliary winding and the charge pump circuit take over. at the same time, the output voltage rises from peak value of the rectified mains to the nominal value of the pfc output voltage. the good margin phase of the compensation network allows a clean start-up, without any large overshoot that would trigger the dynamic and static over voltage protection. figure 24. eval6563-400w input current shape at 100 vac-60 hz vs. v ff ripple - c ff = 470 nf figure 25. eval6563-400w input current shape at 100 vac-60 hz vs. v ff ripple - c ff = 1.5 uf thd [%]: 3.39% - 3 rd harmonic: 0.126 a ch4: input current ch3: v ff voltage - pin #5 thd [%]: 2.75% - 3 rd harmonic: 0.109 a ch4: input current ch3: v ff voltage - pin #5 figure 26. eval6563-400w start-up at 90 vac- 60 hz - full load figure 27. eval6563-400w start-up at 265 vac-50 hz - full load ch1: output voltage ch2: pin #14 - vcc voltage ch4: pin #13 - gate drive ch3: pin #10 - run ch1: output voltage ch2: pin #14 - vcc voltage ch4: pin #13 - gate drive ch3: pin #10 - run
AN2485 test results and significant waveforms 15/29 a dangerous event for any pfc is the operation during an undervoltage of the mains. this condition may cause overheating of the primary power section due to an excess of rms current. to prevent the pfc from this abnormal operation a brownout protection is needed. it is basically a not-latched shutdown function that must be activated when a condition of mains under voltage is detected. the l6563 has a dedicated inhibit pin (run, #10), embedding a comparator with hysteresis, stopping the l6563 operation if the voltage applied is below its threshold. because the l6563 v ff pin delivers a voltage signal proportional to the input mains, the complete brownout function can be easily implemented using a simple resistor divider connected between the v ff and the run pins. in this demo board, the divider resistors setting the turn-on threshold are r26 and r27 on the schematic in figure 1. in figure 28. a start-up tentative below the threshold shows that the run pin does not allow the ic operation. figure 28. eval6563-400w start-up at 80 vac-60 hz - full load 2.5 start-up at light load figure 29. eval6563-400w start-up at 265 v - 50 hz - 30 ma load figure 30. eval6563-400w start-up at 265 v - 50 hz - no load ch1: q1/q2 drain voltage ch2: output voltage ch4: pin #14 - vcc voltage ch3: pin #13 - gate drive ch1: q1/q2 drain voltage ch2: output voltage ch4: pin #14 - vcc volta g e ch3: pin #13 - gate drive
test results and significant waveforms AN2485 16/29 the board, as is, is able to properly handle an output load as low as 12 w. with lower load levels the system will not start up correctly at hi gh line because burst pulses last so long that the vcc voltage drops below the uvlo of the l6563. in that condition, if the load increases suddenly, the pfc output voltage drops until the ic resumes normal operation. supplying the l6563 from an external source (typically it's the auxiliary voltage powering the controller of the downstream converter or of an auxiliary power supply), the minimum load that can be properly handled goes to virtually zero. 2.6 open loop protection figure 31. eval6563-400w open loop at 115 vac-60 hz - full load the l6563 is equipped with an ovp, which monitors the current flowing through the compensation network and entering in the error amplifier (pin comp, #2). when this current reaches about 18 a, the output voltage of the multiplier is forced to decrease, thus reducing the energy drawn from the mains. if the current exceeds 20 a, the ovp is triggered (dynamic ovp), and the external power transistor is switched off until the current falls approximately below 5 a. however, if the overvoltage persists (in case the load is completely disconnected, for example), the error amplifier eventually saturates low and triggers an internal comparator (static ovp) that keeps the external power switch turned off until the output voltage returns close to the regulated value. the ovp function is able to handle "normal" overvoltage conditions, that is, those resulting from an abrupt load/line change or occurring at start-up. it cannot handle the overvoltage generated, for instance, when the upper resistor of the output divider fails open. the voltage loop can no longer read the information on the output voltage and forces the pfc pre- regulator to work at maximum on-time, causing the output voltage to rise with no control. a pin of the l6563 (pfc_ok, #7) is dedicated to providing an additional monitoring of the output voltage with a separate resistor divider (r6, r7, r8 high, r24 low, see figure 1. ). this divider is selected so that the voltage at the pin reaches 2.5 v if the output voltage exceeds a preset value, usually larger than the maximum vo that can be expected (including worst-case load/line transients). if v o = 400 v, vox = 460 v, select r6+r7+r8 = 6.6 m ? . three resistor in series have been chosen according to their voltage rating, so r24 = 6.6 m ? 2.5/(460-2.5) = 36 k ? . when the ovp function is triggered, the gate drive activity is immediately stopped, the device is shut down, its quiescent consumption is reduced below 250 a , and the condition ch1: q1/q2 drain voltage ch2: output voltage ch4: pin #8 - pwm_latch ch3: pin #7 - pfc_ok
AN2485 test results and significant waveforms 17/29 is latched as long as the supply voltage of the ic is above the uvlo threshold. at the same time the pin pwm_latch (pin #8) is asserted high. pwm_latch is an open source output able to deliver 3.7 v min. with 0.5 ma load, intended for tripping a latched shutdown function of the pwm controller ic in the cascaded dc-dc converter, so that the entire unit is latched off. to restart the system, it is necessary to recycle the input power, so that the vcc voltages of both the l6563 and the pwm controller go below their respective uvlo thresholds. the pfc_ok pin doubles its function as a not-latched ic disable. a voltage below 0.2 v shuts down the ic, reducing its consumption below 1 ma. in this case both pwm_stop and pwm_latch keep their high impedance status. to restart the ic simply let the voltage at the pin go above 0.26 v. note that this function offers a complete protection against not only feedback loop failures or erroneous settings, but also against a failure of the protection itself. either resistor of the pfc_ok divider failing short or open (or the pfc_ ok (#7) pin is floating) results in shutting down the l6563 and stopping the pre-regulator. the event of an open loop is shown in figure 31. the protection intervention stops the operation of the l6563 and the activation of the pwm_latch pin. 2.7 power management/housekeeping functions a special feature of the l6563 is that it fac ilitates the implementati on of the "housekeeping" circuitry needed to coordinate the operation of the pfc stage to that of the cascaded dcdc converter. the housekeeping circuitry functions ensure that transient conditions like power- up or power down sequencing or failures of power stage are properly handled. the l6563 provides some pins for these functions. one communication line between the l6563 and the pwm controller of the cascaded dc- dc converter is the pwm_latch pin (#8), which is normally open when the pfc works properly. it goes high if the l6563 loses control of the output voltage (because of a failure of the control loop) or if the boost inductor saturates. its aim is to latch off the pwm controller from the cascaded dc-dc converter as well. a second communication line can be established via the disable function included in the run pin. typically, this line is used to allow the pwm controller of the cascaded dc-dc converter to shut down the l6563 in case of light load, in order to minimize the no-load input consumption of the power supply. figure 32. l6563 on/off control by a cascaded converter controller via pfc_ok or run pin l666 8 pfc_ s top 14 16 vcc 10 k ? bc557 2.2 k ? l656 3 l656 3 a vcc 14 8 .2 v l656 3 l656 3 a (run) pfc_ok bc547 l666 8 14 pfc_ s top 7 (10) 2.2 k ? 8 vref 100 k ? l65 99 pfc_ s top 14 l656 3 l656 3 a ( run ) pfc_ok 7 ( 10 )
layout hints AN2485 18/29 the third communication line is the pwm_stop pin (pin #9), which works in conjunction with the run pin (pin #10). the purpose of the pwm_stop pin is to inhibit the pwm activity of both the pfc stage and the cascaded dc-dc converter. the pwm_stop pin is an open collector, normally open, that goes low if the device is disabled by a voltage lower than 0.52 v on the run pin (#10). it is important to point out that this function works correctly in systems wh ere the pfc stage is the master and the cascaded dc-dc converter is the slave or, in other words, where the pfc stage starts first, powers both controllers and enables/disables the operation of the dc-dc stage. this function is quite flexible and can be used in different ways. in systems comprising an auxiliary converter and a main converter (e.g. desktop pc's silver bo x or hi-end flat-tv or monitor), where the auxiliary conv erter also powers the controllers of the main converter, the pin run (#10) can be used to start and stop the main converter. in the simplest case, to enable/disable the pwm controller the pwm_stop (#9) pin can be connected to either the output of the error amplifier or, if the chip is provided with it, to its soft-start pin. the eval6563-400w offers the possibility to test the hous ekeeping functions by connecting them to the cascaded converter via the series resistors r28, r29, r30. regarding the pwm_stop (#9) pin that is an open collector type, if it needs a pull-up resistor, connect it close to the cascaded pwm for better noise immunity. figure 33. interface circuits that let the l6563/a switch on or off a pwm controller 3 layout hints the layout of any converter is a very important phase in the design process which may not always have the necessary attention required by the engineers. even if it the layout phase appears time-consuming, a good layout does save time during the functional debugging and the qualification phases. additionally, a power supply circuit with a correct layout needs smaller emi filters or less filter stages and subsequently provides consistent cost savings. the l6563 does not need any special attention to the layout, but the general layout rule for any power converter must be applied carefully. basic rules using the eval6563-400w schematic as a reference are listed below. th ey can be used for other pfc circuits having any power level, working either in fot or tm control. 1. keep power and signal rtn separated. connect the return pins of components carrying high current such as c4, c5, sense resistors, c6 and c7 as close as possible. l666 8 pfc_ s top 14 16 vcc 10 k ? bc557 2.2 k ? l656 3 l656 3 a vcc 14 8 .2 v l656 3 l656 3 a (run) pfc_ok bc547 l666 8 14 pfc_ s top 7 (10) 2.2 k ? 8 vref 100 k ? l65 99 pfc_ s top 14 l656 3 l656 3 a ( run ) pfc_ok 7 ( 10 )
AN2485 layout hints 19/29 this point is the rtn star point. a downstream converter must be connected to this return point. 2. minimize the length of the traces relevant to l3, boost inductor l4, boost rectifier d4 and output capacitor c6 and c7. 3. keep signal components as close as possible to l6563 pins. keep the tracks relevant to the pin #1 (inv) net as short as possible. components and traces relevant to the error amplifier must be placed far from traces and connections carrying signals with high dv/dt like mosfet drains (q1 and q2). 4. connect heat sinks to power gnd. 5. add an external shield to the boost inductor and connect it to power gnd. 6. connect the rtn of signal components including the feedback, pfc_ok and mult dividers close to the l6563 pin #12 (gnd). 7. connect a ceramic capacitor (100470 nf) to pin #14 (vcc) and to pin #12 (gnd), close to the l6563 connect this point to the rtn star point (see point 1. ). figure 34. eval6563-400w pcb layout (not 1:1 scaled)
audible noise AN2485 20/29 4 audible noise differential mode currents in a circuit with high frequency and low frequency components (like in a pfc) may produce audible noise due to inter-modulation between operating frequency and mains line frequency. the phenomenon is produced because of mechanical vibration of reactive components like capacitors and inductors. current flowing in the winding can cause vibration of wires or ferrite which produces buzzing noise, therefore, to avoid this boost and filter inductors have to be wound with correct wire tension, and the component has to be varnished or dipped. frequently, x-capacitors and filter capacitors after bridge generate acoustic noise because of ac current that causes the electrodes to vibrate and produce buzzing (noise). thus, minimize ac current inserting a differential mode, pi-filter between the bridge and the boost inductor helps to reducing the ac oustic noise and addi tionally the emi filter will benefit too. such actions decrease significantly the ripple current that otherwise has to be filtered by the emi filter. the capacitors selected are polypropylene, preferably dipped type, because boxed ones are generally more at risk to generate acoustic noise. the acoustic noise can also be due to an incorrect circuit behavior for an abnormal current modulation. it can be due to the dynamic ovp intervention that stops the ic switching cycles which consequently creates a discontinui ty of the input line current shape that can produce vibrations as described above, occurring typically at light load. in this case, only a board re-layout can help, taking into consideration the points outlined in section 3: layout hints . in addition, grounding the boost inductor may help, because in this case we decrease the emissions from the most efficient "antenna" of our circuit. in fact, in case of improper layout some picofarads of layout parasitic capacitance together with the very high dv/dt of the mosfet drain voltage may inject noise somewhere in the circuit. 5 thermal measures in order to check the design re liability, a thermal mapping by means of an ir camera was done. figure 35. and figure 36. show thermal measures on board component side at nominal input voltages and full load. captions visible on the pictures placed across key components show the relevant temperature. table 1. provides the correlation between measured points and components for both thermal maps. the ambient temperature during both measurements was 27c. according to these measurement results all components of the board are working within their temperature limits.
AN2485 thermal measures 21/29 figure 35. thermal map at 115 vac-60 hz - full load figure 36. thermal map at 230 vac-50 hz - full load table 1. measured temperature table at 115 vac and 230 vac - full load point component temperature @115 vac temperature @230 vac a d2 64.7c 51.3c b q2 76.5c 62.0c c q1 74.1c 61.9c d d3 72.8c 65.6c e c7 41.0c 41.5c f l1 58.5c 43.5c g l3 59.2c 50.6c h l4 ? core 57.0c 56.5c i l4 - winding 65.1c 60.9c c 80. 6 73. 9 67. 2 60. 5 53. 8 47.1 40. 4 33. 7 26. 9 c 79. 9 73. 2 66. 6 60. 0 53. 3 46. 7 40. 0 33. 4 26. 8
conducted emission pre-compliance test AN2485 22/29 6 conducted emission pre-compliance test figure 37 , 38 , 39 , and 40 show the peak measurement of the conducted noise at full load and nominal mains voltages. the limits shown on the diagrams are en55022 class-b, which is the most common norm for domestic equipment using a two-wire mains connection. as shown on the graphs, under all test conditions there is a good margin of the measures with respect to the limits. figure 37. 115 vac and full load - phase figure 38. 115 vac and full load - neutral figure 39. 230 vac and full load - phase figure 40. 230 vac and full load - neutral
AN2485 bill of material 23/29 7 bill of material table 2. bill of material ref. des. part type- part value case/ package description supplier c1 470 nf-x2 dwg x2 film capaci tor r46-i 3470--m1- arcotronics c10 18 n 1206 100v smd cercap - gen. purpose avx c11 470 nf/50 v 1206 50v smd cercap - gen. purpose avx c12 47 uf/50 v dia6.3x11 aluminium elcap - yxf series - 105c rubycon c13 100 nf 0805 50v smd cercap - gen. purpose avx c14 1 f 1206 50v smd cercap - gen. purpose avx c15 100 pf 0805 50v smd cercap - gen. purpose avx c16 220pf 0805 50v smd cercap - gen. purpose avx c17 10 nf 0805 50v smd cercap - gen. purpose avx c18 470 nf 1206 50v smd cercap - gen. purpose avx c19 2 nf2 0805 50v smd cercap - gen. purpose avx c2 470 nf-x2 dwg x2 film capaci tor r46-i 3470--m1- arcotronics c20 330 pf 0805 50v smd cercap - gen. purpose avx c21 10 nf 1206 50v smd cercap - gen. purpose avx c3 680nf-x2 dwg x2 film capaci tor r46-i 3680--m1- arcotronics c4 470 nf-630 v dwg film capacitor mkp - b32653a6474j epcos c5 470 nf-630 v dwg film capacitor mkp - b32653a6474j epcos c6 470 nf-630 v dwg film capacitor mkp- b32653a6474j epcos c7 330 f-450 v dia35x35 aluminium elcap - lls series - 85c nichicon d1 1n5406 do-201 std recovery rectifier vishay d2 d15xb60 dwg rectifier bridge shindengen d3 stth8r06 to-220fp ultrafast high voltage rectifier stmicroelectronics d4 ll4148 minimelf fast switching diode vishay d5 bzx85-c15 minimelf zener diode vishay d6 ll4148 minimelf fast switching diode vishay d7 ll4148 minimelf fast switching diode vishay d8 ll4148 minimelf fast switching diode vishay f1 8 a/250 v 5x20mm 8a mains input fuse wickmann j1 3-pins conn. (central rem.) p 3.96 kk series molex j2 5-pins conn. (central rem.) p 3.96 kk series molex
bill of material AN2485 24/29 jp101 jumper wire jumper jp102 jumper wire jumper l1 1.5 mh-5a dwg cm choke - lfr2205b delta electronics l3 dm-51 h-6 a dwg filter inductor - lsr2306-1 delta electronics l4 pq40-500 h dwg pfc inductor - 86h-5410b delta electronics q1 stp12nm50fp to-220fp n-channel power mosfet stmicroelectronics q2 stp12nm50fp to-220fp n-channel power mosfet stmicroelectronics q3 bc857c sot-23 small signal bjt - pnp vishay r1 1 m5 axial hv resistor bc components r10 680 k 1206 smd std film res - 1% - 250ppm/c bc components r11 680 k 1206 smd std film res - 1% - 250ppm/c bc components r12 82 k 0805 smd std film res - 1% - 250ppm/c bc components r13 15 k 0805 smd std film res - 1% - 250ppm/c bc components r14 56 k 0805 smd std film res - 5% - 250ppm/c bc components r15 3k3 0805 smd std film res - 1% - 100ppm/c bc components r16 15 k 0805 smd std film res - 1% - 100ppm/c bc components r17 6r8 0805 smd std film res - 5% - 250ppm/c bc components r18 6r8 0805 smd std film res - 5% - 250ppm/c bc components r19 1k0 1206 smd std film res - 5% - 250ppm/c bc components r2 ntc 2r5-s237 dwg ntc resistor 2r5 s237 epcos r20 0r39-1 w axial axial res - 5% - 250ppm/c bc components r21 0r39-1 w axial axial res - 5% - 250ppm/c bc components r22 0r39-1 w axial axial res - 5% - 250ppm/c bc components r23 0r39-1 w axial axial res - 5% - 250ppm/c bc components r24 36 k 0805 smd std film res - 5% - 250ppm/c bc components r26 150 k 1206 smd std film res - 1% - 250ppm/c bc components r27 240 k 0805 smd std film res - 1% - 100ppm/c bc components r3 180 k 1206 smd std film res - 5% - 250ppm/c bc components r31 1k5 0805 smd std film res - 1% - 100ppm/c bc components r32 620 k 1206 smd std film res - 5% - 250ppm/c bc components r33 620 k 1206 smd std film res - 5% - 250ppm/c bc components r34 10 k 1206 smd std film res - 5% - 250ppm/c bc components r35 3r9 0805 smd std film res - 5% - 250ppm/c bc components r36 3r9 0805 smd std film res - 5% - 250ppm/c bc components table 2. bill of material (continued) ref. des. part type- part value case/ package description supplier
AN2485 bill of material 25/29 r4 180 k 1206 smd std film res - 5% - 250ppm/c bc components r5 47r 1206 smd std film res - 5% - 250ppm/c bc components r6 2m2 1206 smd std film res - 5% - 250ppm/c bc components r7 2m2 1206 smd std film res - 5% - 250ppm/c bc components r8 2m2 1206 smd std film res - 5% - 250ppm/c bc components r9 680 k 1206 smd std film res - 1% - 250ppm/c bc components r101 0r0 1206 smd std film res - 5% - 250ppm/c bc components r102 0r0 1206 smd std film res - 5% - 250ppm/c bc components u1 l6563 so-14 advanced tm pfc controller stmicroelectronics table 2. bill of material (continued) ref. des. part type- part value case/ package description supplier
pfc coil specification AN2485 26/29 8 pfc coil specification 8.1 general description and characteristics application type: consumer, home appliance inductor type: open coil former: horizontal type, 6+6 pins max. temp. rise: 45 c max. operating ambient temp.: 60 c 8.2 electrical characteristics converter topology: boost pfc preregulator, fot control core type: pq40-30 material grade pc44 or equivalent max operating freq: 100 khz primary inductance: 500 h 10% @1 khz-0.25 v (see note: 1 ) primary rms current: 4.75 a note: 1 measured between pins #1-2 and #5-6 figure 41. electrical diagram table 3. winding charactericstics start pins end pins number of turns wire type wire diameter notes 11 8 5 (spaced) single ? 0.28 mm bottom 5 - 6 1 - 2 65 multistrand ? g2 litz ? 0.2 mm x 30 top
AN2485 pfc coil specification 27/29 8.3 mechanical aspect and pin numbering maximum height from pcb: 31 mm ferrite: two symmetrical half cores, pq40-30 material grade: pc44 or equivalent central leg air gap: to be defined, in order to get the required inductance value coil former type: vertical, 6+6 pins pin distance: 5 mm row distance: 45.5 mm cut pins: #9-12 external copper shield: not insulated (for emi reasons), connected to pin #11 (gnd) figure 42. pin side view figure 43. mechanic aspect manufacturer: delta electronics p/n: 86h-5410b
references AN2485 28/29 9 references 1. "l6563 advanced transition-mode pfc controller" datasheet 2. "design of fixed-off-time-controlled pfc pre-regulators with the l6562", an1792 3. "eval6562-375w evaluation board l6562-based 375w fot-controlled pfc pre- regulator" an1895 4. "l6561, enhanced transition-mode power factor corrector", an966 10 revision history table 4. revision history date revision changes 22-mar-2007 1 first issue
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