Power Supply topologies for Metering Applications€¦ · Power supply requirements - Output •...

Power Supply topologies for

Metering Applications

EMEA Marketing & Application team

Agenda

• Power supply requirements

• AC/DC topologies for single- and three-phase meters

• ST component selection and usage

• Application reference designs

• AC/DC converters & controllers

• DC/DC converters

• Low-dropout voltage regulators (LDOs)

• Power MOSFETs for Metering

Metering SMPS Requirements

Power supply requirements - Input

• Single phase

• From 60 to 180 VAC

• To 265 to 300 VAC

• In short periods of time (6 hours – one week)

• To 440 to 500 VAC

• Preferred single rectifier – for non-isolated SMPS

• Poly phase

• From 60 to 180 VAC

• To 440 to 500 VAC

• Input connection

• Bridge connection – SMPS works even if only 2 wires are connected

• Single rectifier – SMPS stops working if the Neutral is disconnected

• Common requirements – high level of surge protection (4 to 6 kV)

Power supply requirements - Output

• Simple e-meter

• No communication – only measurement and data processing

• Output power: ~ 1 to 5 W

• Output voltage: 3.3/5 V – typical supply for MCU, metering, and display

• Smart e-meter – includes communication – PLC, GSM

• Output power

• Average: 2 to 6 W

• Peak power: up to 5 to 15 W

• Output voltages: 3.3/5 V and 10 to 15 V

• Concentrator

• Output power: 10 to 25 W

• Output voltages: 3.3/5 V and 10 to 15 V

Power supply requirements - Others

• Operating frequency

• The communication frequency of Smart meters is typically between 60

and 100 kHz

• Therefore, the preferred operating frequency is > 100 kHz

• Magnetic field immunity

• The SMPS must be able to survive magnetic fields up to 0.5 T!!!

• Distance of field source to SMPS – several centimeters

• Typically the SMPS must survive, but operation can be halted

• In certain cases, limited operation may also be required in this condition

e-meter

E-meter supply topology

PLM

MCU

Metrology

Human

interface

Metrology in poly

phase

SMPS

3.3/5 V

10 to 15 V

3.3/5V ISO

//

An SMPS consists of:

• AC/DC converter

• 10 to 15 V – communication – typically

directly generated by AC/DC

• 3.3/5V – MCU and other circuits

• Directly generated by SMPS

• + simple, - lower precision

• DC-DC from 10 to 15 V

• + more components, - precision

of both outputs is good

• LDO – either from unregulated output

of AC/DC or from 10 to 15 V

• 3.3V/5V ISO – mandatory for 3-phase e-

meter using shunts – either isolated DC-

DC or other output from AC/DC from

transformer

AC/DC - Topologies

AC/DC Topologies applicable for Metering SMPS

BUCK converter – eMetersFLYBACK converter

SMART meters and Concentrators

Buck Converter Limitations and Advantages

• Output

• 5 to 15 V, up to 300 mA (Viper26)

• Tolerance ±1 V

• Input

• Considering 100 V surge pulse up to 700 VDC

• It means 500 VAC

• Minimum voltage from 40 VDC (Viper06) to 100 VDC (Viper26)

• Operating frequency

• 30 or 60 kHz for Viper06

• 60 kHz for Viper16 or Viper26

• 115 kHz recommended only in case of 15 V output and no operation in CCM

• Applicable components

• Viperx6, Viperx1

Flyback Converter Limitations and Advantages

• Output

• Any voltage (typically 3.3V and 15V)

• Simple to realize more outputs

• High precision for one output (±3%)

• Power

• Altair04-900: 4 to 12 W (peak)

• Viperx1/6: 12 to 20 W

• L6566BH: Up to 30 W (in fact, not limited)

• Input maximum

• Viper: Up to 440 VAC for a limited time

• Altair04-900: Up to 460 VAC (permanent connection)

• L6566BH + 950V/1.2kV MOSFET: Up to 500 VAC

• Operating frequency

• Typically above 100 kHz (115 kHz, 100 to 130 kHz)

ST components selection and usage

RV1

L1

D5

STTH108

D4

STTH108

C5

C1

C6

L2

R6

R1

R4 R3

C3R7

GND

5 - 12V

3.3V

D1

~ACC4 PWM

Controller

R5

C8

Drain

GND

VDD FB

COMP LIM

U1

D3

C2

R2

IN OUT

GND

LR

U2

D2

C7

Simple e-Meter – Buck converter

Ultrafast high-voltage rectifier

STTH108

VIPerPlus family

Off-line converters (controller + HV MOSFET)

VIper06X, Viper06L, Viper01X, Viper11X, Viper16L, Viper26L LDK220, LDL212, ST715

Regulators

Monolithic solution

RV1

L1

C5

C1

R6

R1

R7

~ACC4

D8D2

Drain

GND

VDD

FB

COMP LIM

U1

C8

D5 STTH108

R10

C9

D6

R9

R12

D3

D7

T1

GND

R11

D4

3.3V - 5V

10V - 15V

C3

C2

PWM

Controller

Ultrafast high-voltage rectifier

STTH108

VIPerPlus family

Off-line converters (controller + HV

MOSFET)

Viper01H, Viper11H, Viper06H,

Viper16H, and Viper26H

1- phase meter, Concentrator – Flyback no isol.

Signal Schottky diodes

(30V to 80V families)

BAT*, BAR*

*6263, TMBYV*

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage surge suppressor

(400W – 600W – 100V – 200V)

SMAJ, SMAJ6J, SMBJ, P6KE

Monolithic solution – limitation 800V MOSFET

R22~AC

R23

R7

10k

R6

R8

C3

100n

D8

Q1

STx2N95K5

T1

D9

R9

C12

C13

C422uF/35V

D3 STTH108

C9C14

ZCD11

GN

D3

OS

C13

GD4

CO

MP

9

CS

7

SS

14

MO

DE

/SC

12

VR

EF

10

DIS

8

VFF15

AC

_O

K16

Vcc

5

HV

S1

FM

OD

6U1

L6566BH

D4

C10

C8

D2

C5

C622uF/400V

RV1

D6R1

C15

D7

C1122uF/400V

R18

R4

L1

+

-

U2

D5

R20

GND

10V - 15V

3.3V - 5V

R21

1- phase meter, Concentrator – Flyback no isol

Ultrafast high-voltage rectifier

STTH108

Off-line controller

L6566BH

Signal Schottky diodes

(30V to 80V families)

BAT*, BAR*

*6263, TMBYV*

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage surge suppressor

(400W – 600W – 100V – 200V)

SMAJ, SMAJ6J, SMBJ, P6KE

Standard OA

TS391

Discrete solution – MOSFET up to 1.5 kV available, drawback higher complexity

K5 Power MOSFET

STx2N95K5, STx5N95K5 (950V)

STx2N105K5, STx5N105K5,

STx7N105K5 (1050V)

STx1N120K5, STx8N120K5 (1200V)

~ACC3

D2D1

Drain

GND

VDD

ZCD/FB

COMP IREF S

U1 Altair04-900

C7

D6 STTH108

R5

C8

D7R4

D3

D4

T1

PWM

Controller

GND

R6

D5

3.3V - 5V

10V - 15V

C4

C2

R7C6

D8D9R8

D10D11R9

RV2

RV3

RV1

L1

C5

C1

R2

R1

R3

3-phase meter – Flyback, single rectifier

Ultrafast high-voltage

rectifier

STTH108

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage surge

suppressor

(400W – 600W – 100V –

200V)

SMAJ, SMAJ6J, SMBJ, P6KE

Monolithic solution – simple, drawback peak power limited up to 8 – 9W

Altair04-900

Off-line converters (controller + 900V

MOSFET)

R22~AC

R23

R7

10k

R6

R8

C3

100n

D8

Q1

STx2N95K5

T1

D9

R9

C12

C13

C422uF/35V

D3 STTH108

C9C14

ZCD11

GN

D3

OS

C13

GD4

CO

MP

9

CS

7

SS

14

MO

DE

/SC

12

VR

EF

10

DIS

8

VFF15

AC

_O

K16

Vcc

5

HV

S1

FM

OD

6

U1

L6566BH

D4

C10

C8

D2

D10R2

D11

D12R3

D13

RV2

RV3

C5

C622uF/400V

RV1

D6R1

D7

C15

C1122uF/400V

R18

R4

L1

+

-

U2

D5

R20

GND

3.3V - 5V

10V - 15V

R21

3-phase meter – Flyback, single rectifier

Ultrafast high-voltage

rectifier

STTH108

Off-line controller

L6566BH

Signal Schottky diodes

(30V to 80V families)

BAT*, BAR*

*6263, TMBYV*

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage surge suppressor

(400W – 600W – 100V – 200V)

SMAJ, SMAJ6J, SMBJ, P6KE

Standard OA

TS391

Discrete solution – MOSFET up to 1.5 kV available, no power limitation, drawback higher complexity

K5 Power MOSFET

STx2N95K5, STx5N95K5 (950V)

STx2N105K5, STx5N105K5,

STx7N105K5 (1050V)

STx1N120K5, STx8N120K5 (1200V)

C3

Drain

GND

VDD

ZCD/FB

COMP IREF S

U1 Altair04-900

C7

D6 STTH108

R5

C8

D7R4

D3D4

T1

PWM

Controller

GND

R6

D5

3.3V - 5V

10V - 15V

C4

C2RV1

RV2

RV3

- +

D2

- +

D9

R1

R8

R9

R7C6

C9

L1

C5

C1

R2

R3

3-phase meter – Flyback, bridge rectifier

Ultrafast high-voltage

rectifier

STTH108

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage surge

suppressor

(400W – 600W; 100V – 200V)

SMAJ, SMAJ6J, SMBJ, P6KE

Monolithic solution – simple, drawback peak power limited up to 8 – 9W

Altair04-900

Off-line converters (controller + 900V

MOSFET)

R7

L1

D1

T1

D4C2

C1

GND

10V - 15V

3.3V - 5V

RV1

RV2

RV3

- +

D5

- +

D7

R1 15R

R3 15R

R5 15R

C8

C6

R11

R6

C3

R4

Q1

STx2N95K5

R16

1nF/Y1C5

R8

C4

C9

U3TL431

R12U2

R14

D3STTH108

C11

ZCD11

GN

D3

OS

C13

GD4

CO

MP

9

CS

7

SS

14

MO

DE

/SC

12

VR

EF

10

DIS

8

VFF15

AC

_O

K16

Vcc

5

HV

S1

FM

OD

6

U1

L6566BH

D6R2

R15 C12

R9

C10

R13

R17

D2

C7

R10

D8

3-phase meter – Flyback, bridge rectifier

Ultrafast high-

voltage

rectifier

STTH108

Off-line controller

L6566BH

Signal Schottky

diodes

(30V to 80V families)

BAT*, BAR*

*6263, TMBYV*

Ultrafast high-voltage rectifier

(200V-300V 1A, 2A families)

STTH*02

Schottky diodes

(60V to 150V families)

STPS*60, STPS*80,

STPS*100, STPS*150

Transient voltage

surge suppressor

(400W – 600W – 100V

– 200V)

SMAJ, SMAJ6J, SMBJ,

P6KE

ADJ Voltage

Reference

family

Discrete solution – MOSFET up to 1.5 kV available, no power limitation, drawback higher complexity

K5 Power MOSFET

STx2N95K5, STx5N95K5 (950V)

STx2N105K5, STx5N105K5,

STx7N105K5 (1050V)

STx1N120K5, STx8N120K5 (1200V)

Reference designs

Demo board - STEVAL-ISA010V1Super Wide Input Range Viper16 Buck Converter

■ Buck topology

■ Common Neutral

■ Input voltage range: 85 to 500 VAC

■ Output voltages: 12V and 5V

■ Output current (max.): 150 mA (total for both outputs)

■ Conductive EMI EN55022 Class B

■ Stand-by less than 100 mW at 230 VAC

Documentation: AN2872

R9 1k

C7 1n8

R2 750k

R5 750k

R6 750k

R8 750k

C1

150n/X2

D3

1N4007

L1 2.2mH

D5STTH108

D6

15V

D2

STTH108

C310u/450V

C910uF/35V

C5220uF/25V

L2 1mH

R1 22R

R4

9k1

R3

24k

12

J1

85 - 500VACC2150n/X2

C610uF/35V

1

2

3

J2

Output

C8

100n

D1 1N4148

3 1

2

VOUTVIN

GND

U2 L78L05

D4

1N4007

Drain7

Drain8

S1

VDD2

FB4

CO

MP

5

LIM

3

U1 Viper16

C410u/450V

R7 N.A.

21

Demo board - STEVAL-ISA105V1Power supply for energy meter and power line

modem based on Altair04-900

■ Flyback

■ Input voltage range: 90 to 480 VAC

■ Output power: 7W peak

■ Output voltages: 5, 3.3, and 12V

Documentation: AN4154

22

AC-DC converters and controllers

VIPerPlus FamilyAdvanced controller with embedded 800V Power MOSFET

Robustness and Reliability

800V Power MOSFET, thermal shutdown, soft start, OLP protection, auto-restart

Energy saving

Power consumption less than 30mW at no load

High integration

Direct feedback, jittering, HV start-up

Flexibility

power scalability up to 12W, no auxiliary winding, clamp-less design, no CM EMC filter

Output

rectification and

filtering

Input

rectification and

filtering

Feedback

..directly

from AC Mains

voltage...

.. to +/- DC bus

(3V3, 5V, 12V)

to supply:

~

Microcontroller

PWM driver

Relay

PWM

Controller

24

ST Offline Converters Overview 25

32W350mA

19W (900V)Ext RSENSE

7W700mA

4.5W1 / 1.15A

24W400mA

14WExt RSENSE

20W480/600 mA

VIPer06 VIPer16

VIPer25

VIPer26

VIPer28

VIPer27

Altair 04 Altair 05

VIPer17

800V

5W 8W 12W 15WFly-back Converter85-265VAc

VIPerPlus*7

VIPerPlus*8

VIPerPlus*5

VIPerPlus*6

Altair0*

VIPerPlus0P

VIPerPlus*1

Buck Converter 150mA 200mA 350mA

VIPer38

VIPer37

VIPer35

VIPer11VIPer01

VIPer0P

In development

26

CC/CV regulation with no opto-coupler

Avalanche rugged internal power MOSFET Internal HV start-up circuit

Quasi-resonant ZVS operation

Valley skipping at medium-light load

Burst mode operation at no-load for under 60 mW consumption

Automatic self-supply

Input voltage feed-forward for mains-independent CC regulation

Overcurrent protection against transformer saturation and secondary

diode short circuit

Low quiescent current (< 1 mA)

7W5W

ALTAIR04 ALTAIR05

Maximum output power for VIN = 85 to 265 VAC

ALTAIR04 ALTAIR05

Breakdown voltage 900 V 800 V

Resistance Drain Source

(Tj = 25°C)16 Ω 11 Ω

Minimum Drain start-up

voltage50 V 50 V

Supply voltage range 11.5 to 23 V 11.5 to 23 V

Main features

eDesignSuite supported

ALTAIR family: Off-line all-primary sensing switching regulator

Off-line converters

Altair04-900

L6566 family: Multi-mode controllers

27

Fixed frequency or quasi resonant operations Advanced light load management

On-board high-voltage start-up generator Low quiescent current (< 3 mA)

Adaptive UVLO

Line feed-forward for constant power capability vs mains voltage

Pulse-by-pulse OCP, shutdown on overload (latched or auto-restart)

Transformer saturation detection

Latched or auto-restart OVP

Brownout protection

-600/+800 mA totem pole gate driver with active pull-down during

ULVO

SO16N package

L6566A

Controllers with selectable

quasi-resonant (QR) or fixed-frequency (FF) operation

Common features

Suited

for SMPS

with PFC front end

L6566B L6566BH

Suited

for single

stage SMPS

Suited

for single

stage SMPS running off

rectified 3-phase input

line

840V high-voltage

start-up

700V high-voltage start-up700V high-voltage start-up

Programmable

frequency modulation

for EMI reduction

Programmable

frequency modulation

for EMI reduction

Switched supply

rail for PFC

controller

eDesignSuite supported

Primary controllers

Industrial: Off-line SMPS ICs

DC-DC converters

DC-DC – post regulation 29

ST1S4x ST1S5x

L6984

High-efficiency (Sync. Rect.)

Low BOM

Cost-effective

Low Stand-by Consumption (ST1S5x)

AC-DC

SMPS

DC-DC

Buck

DC-DC

Buck

11 – 15V5V

3.3V

AC-DC

SMPS

DC-DC

Buck

11 – 15V

5V

3.3V

DC-DC

Buck1.2V

ST1S31/32, ST1S12

(ST1S4x and ST1S5x)

High-efficiency (Sync. Rect.)

Low BOM

Cost-effective

Low Stand-by Consumption (ST1S5x)

Linear Regulators:

Low quiescent current LDOs30

• Ultra low quiescent current (Iq)

(down to 1.4 µA)

• Very low dropout

• Wide range of miniaturized packages

• Output current from 50 to 150 mA

• Extended input voltage range (up to 24V on

ST715)

• Maximize battery life

• Reduce standby power consumption

• Minimized PCB area occupation

• Easy design and implementation

Main benefits

LDOs

Linear Regulators:

Cost-effective LDOs32

LDK120

• 200 mA, low dropout, Noise reduction pin

• Available in SOT23-5L, SC70, and DFN6 1.2x1.3 mm

LDK130

• 300 mA, low dropout, Noise reduction pin

• Available in SOT23-5L, SC70, and DFN6 1.2x1.3 mm

LDK220

• 200 mA, low dropout

• Available in SOT23-5L, SC70, and DFN6 1.2x1.3 mm

LDKxx:

Low current (up to 300mA)

LDL112

• 1.2A, very low dropout, Reverse current protection

• Available in SO8, and DFN6 2x2 mm and 3x3 mm

LDL212

• 1.2A, very low dropout

• Available in SO8, and DFN6 2x2 mm and 3x3 mm

LDLxx:

Medium current (1.2 A)

Power MOSFETs for metering applications

34

K5 Power MOSFET Series

PowerFLAT 5*6 HV

D2PAK

Widest Super-Junction MOSFET Product Portfolio • 800V, 900V, 950V, 1050V, 1200V, up to 1500V

BEST silicon performance in the Market• Outstanding RDS(on) to optimize efficiency

Designed for High Efficiency• Ultra-low gate charge (Qg) for faster switching

• Low Ciss and Coss for reduced energy losses

Higher power density, Best-in-class RDS(on) MDmesh™ K5 series

TO-247 TO-220FP wide Creepage

MDmesh™ K5 series selection SMPS < 75 W

BVDSS[V] RDS(on)[Ω] Max ID [A] Sales Type Packages

800

3.25 2.4 STx3LN80K5 DPAK / IPAK/ TO-220 / FP

2.6 3 STx4LN80K5 DPAK / IPAK/ TO-220 / FP

1.75 3.8 STx5N80K5 DPAK / TO-220 / TO-220FP/D2PAK/I2PAK/I2PAKFP

1.15 5.6 STx7LN80K5 TO-220 / TO-220FP/DPAK, I2PAKFP /IPAK / PowerFLAT 5x6 VHV

0.90 7.2 STx9N80K5 TO-247 /TO-220 / TO-220FP/I2PAKFP/DPAK/ PowerFLAT 5x6 VHV

0.610 8.5 STx10LN80K5 TO-220/ TO-220FP/DPAK / I2PAKFP&PowerFLAT 5x6 HV

0.445 12 STx14N80K5 TO-220FP / D2PAK/I2PAKFP

900

2,1 3 STx4N90K5 DPAK / TO-220 / TO-220FP

1,10 6 STx6N90K5 DPAK / IPAK/ TO-220 / I2PAK/ TO- 220FP/TO-247

0,81 7 STx7N90K5 DPAK / TO-220 /FP/TO-247

0,68 8 STx8N90K5 D2PAK / TO-220 / TO-220FP/TO-247

950

5 2 STx2N95K5 TO-220 / FP / DPAK / IPAK

2.5 3.5 STx5N95K5 TO-220 / FP / DPAK

1.25 9 STx6N95K5 TO-220 / FP / DPAK / IPAK / TO-247/ H2PAK

0.8 8 STx10N95K5 TO-220 / TO-220FP/ TO-247/D2PAK

1050

8 1.5 STx2N105K5 DPAK;IPAK;TO-220;TO-3PF

3.5 3 STx5N105K5 TO-220 / FP

2 4 STx7N105K5 TO-247/ TO-220 / FP

1.3 6 STx10N105K5 TO-220 / TO-220FP/ TO-247

120010 1.5 STx1N120K5 TO-220

2.4 6 STx8N120K5 TO-220 /H2PAK / TO-247

35

eDesignSuite

eDesignSuite is a software platform that helps developers

select the right product for power conversion and speeds up

the design-in

AC-DC & DC-DC converters are supported by eDesignSuite

• Go to my.st.com/analogsimulator

• Register the first time and log in

• Insert your design specifications

• Get the suitable products

• Choose one, simulate and purchase

• Circuit BOM

• Electrical waveforms

• Additional information (stability, efficiency, etc.)

eDesignSuite 37

eDesignSuite 38

Defined specsComponents that can be fine-tuned

Operating

point

Waveforms Efficiency Bode

plotsLosses

split

Standard functions