ST Power Factor Controllers€¦ · Active PFC: digital vs. analog controllers 4 •Algorithm upgrade and customization is painless •Add/remove features at any time Flexibility

ST Power Factor Controllers

Luca Salati

PFC controller: what a PFC is? 2

18/11/2013

• Power factor (PF) it's a measure of the

efficiency of a power distribution system

• A system with low PF – for a given amount of

power - presents higher circulating currents

resulting in higher losses

• Low PF reduce transmission efficiency

• IEC 61000-3-2 sets the limit for many electrical

equipment including household appliances

• Mandatory in EU (for CE marking) and JP

• Minimum PF requirement specified by many

national regulations (e.g. Energy star 2.0 in US)

Passive PFC vs. active PFC 3

18/11/2013

3

Simple but bulky

and heavy circuitry

V, I

Typical PF in the

range 0.7-0.8

More economic

solution below 400W (source: EPSMA1)

Electronic circuit

Smaller and lighter

V, I Typical PF in the

range 0.9-0.99

Become not suitable

when power increases

(e.g. above 1kW)

Increased available

power from the wall

socket

Constant bus voltage

Active PFC: digital vs. analog controllers 4 4

• Algorithm upgrade and

customization is painless

• Add/remove features at any

time

Flexibility

• Safety not relying on SW

Application safety

• No need for powerful CPU

Higher frequency

ST has both, you can choose..

Digital Analog

Product portfolio

18/11/2013

Power Factor Control portfolio and roadmap

18/11/2013

6

Presentation Title

F

E

A

T

U

R

E

S

L6564/T 10pins

TM PFC

L6563S 14 pin

ADVANCED

TM PFC

L4981A/B AVG CURRENT

MODE PFC

L6562A TM PFC

L6563H 16pin

L6563S+HV

Start Up

L4984 CCM 10Pins

PFC

Full production

L6564H 14pins

TM PFC

CCM

TM

Continuous conduction mode

PFC’s – L4984D

18/11/2013

L4984D – PFC controller: introduction 8

18/11/2013

• WHERE: Power Factor Control stage of SMPS connected to AC input Mains

• WHY: according to EN 61000-3-2 international norm, a PFC STAGE

• is required, that fixes limits of Total Harmonic Distortion (THD)

INPUT SMPS CURRENT:

• SINUSOIDAL

• IN PHASE WITH MAINS

VOLTAGE

L4984D introduction 9

18/11/2013

• PF controller for CCM operation (fixed-off-time) with low THD

• Set of protections for complete application reliability

• Adjustable OVP on output voltage (No Latched)

• Inductor saturation (No Latched)

• Open loop protection

• Input Mains under-voltage detection

• Remote ON/OFF control input pin

• Small package

L4984D introduction 10

18/11/2013

• PF controller for CCM operation (fixed-off-time) with low THD


• Adjustable OVP on output voltage (No Latched)

• Inductor saturation (No Latched)

• Open loop protection

• Input Mains under-voltage detection

• Remote ON/OFF control input pin

• Small package

No output capacitor explosion

No MOSFET damaging

No MOSFET over-heating

Application flexibility

Small PCB

L4984D performances 11

18/11/2013

• 350W reference design (EVL4984-350W)

• Efficiency > 94% on 85VAC – 264VAC input range

• THD<10% at full load on 85VAC – 264VAC input range

L4984D companion MOSFET / rectifiers 12

18/11/2013

L4984 – 10 pin CCM power factor controller

RECTIFIER (600V reverse voltage)

SiC (Silicon Carbide) STPSCxx06

Turbo 2 STTHxxR06

Tandem STTH806DTI

MOSFET (>500V breakdown)

High power (>1kW) MDmesh V

e.g. STW69N65M5 for ~2KW

Medium power (~200W to 1KW) MDmesh II Plus Low Qg

e.g. STP24N60M2 for ~400W

L4984D - summary 13

18/11/2013

• L4984D is the right solution for middle-high power SMPS and is the

best trade-off between full set features, performance and price, form

factor.

• L4984D is able to address a wide range of applications:

• Industrial, e.g. lighting & home appliances

• HEV/EV battery chargers

• Solar Inverters

• Servers SMPS for Data centers

• high end game consoles, desktop, and workstation

• Suitable also for modified buck for LED applications from

e.g 120VDC bus

Transition mode PFC’s

18/11/2013

Product evolution for TM 15

18/11/2013 Presentation Title

Low Cost

L6563H

Interface to PWM ctrl

+ High Voltage Start up

L6563S

Interface to PWM ctrl

L6564H

HVS

CS

COMP

MULT

VFF

GD

GND

ZCD

PFC_OK

INV Vcc

N.C.

2

3

4

1

5

6

7 8

10

11

12

13

14

N.C.

N.C.

9

Advanced features


L6562A / AT

INV

COMP

MULT

CS

Vcc

GD

GND

ZCD

1

2

3

4 5

6

7

8

Adv. Features

INV

COMP

MULT

CS

VFF

Vcc

GD

GND

ZCD

PFC_OK

1

2

3

4

5 6

7

8

9

10

L6564 / T

Product evolution for PFC - FOCUS 16


Low Cost

L6564H

HVS

CS

COMP

MULT

VFF

GD

GND

ZCD

PFC_OK

INV Vcc

N.C.

2

3

4

1

5

6

7 8

10

11

12

13

14

N.C.

N.C.

9

Advanced features


L6562A / AT

INV

COMP

MULT

CS

Vcc

GD

GND

ZCD

1

2

3

4 5

6

7

8

Adv. Features

INV

COMP

MULT

CS

VFF

Vcc

GD

GND

ZCD

PFC_OK

1

2

3

4

5 6

7

8

9

10

L6564 / T

• L6564H introduces new features:

• vs L6564:

• High voltage start-up (700V) for higher efficiency

• vs L6562A :

• High voltage start-up (700V) for higher efficiency

• Features for increased application reliability

L6564 family

Power Factor Controller

L6564 / H introduction 18

18/11/2013

• L6564H can be used in:

• Power Factor Control stages of SMPS connected to AC input Mains up to 150W

• LED lighting SMPS, single stage SMPS up to 60-70W

• to make the application compliant to EN 61000-3-2 regulation by limiting the Total Harmonic

Distortion (THD)

SMPS INPUT CURRENT:

• SINUSOIDAL

• IN PHASE WITH MAINS

VOLTAGE

L6564H

LEDs

…from L6562A to L6564

2 pins more but more than just 2 pins

• Inductor Saturation Detection

• Choke optimization without risk of mosfet damaging

• Feedback Disconnection Protection and new OVP

• Reliability increased

• Easier PCP lay-out

• Remote ON/OFF

• Voltage Feed Forward

• Line Transient rejection

• Brown-out protection

• Input undervoltage detection

• L6564T with Electrical Parameters guaranteed from -40C to +125C.

Ideal for OUTDOOR applications

19

18/11/2013

SSOP10 (SO8 body) 1mm pitch

L6564H as standard PFC pre-regulator 20

18/11/2013


• adjustable protection against output over-voltage (not latched)

• inductor saturation protection (not latched)

• open loop protection

• input Mains under-voltage detection

• input voltage feed-forward

• input pin for remote ON/OFF control

• 700V High-Voltage Start-Up on-chip

L6564H AC MAINS

boost

L6564H as single-stage controller for LEDs 21

18/11/2013


• open LED string detection (not latched)

• transformer saturation protection (not latched)

• input Mains under-voltage detection

• input voltage feed-forward

• input pin for remote ON/OFF control

• 700V High-Voltage Start-Up on-chip

L6564H

AC MAINS

LEDs

flyback

DIFFERENT

TECHNOLOGIES

for

BEST

PERFORANCES

ST Power MOSFETs

PFC

Transition Mode

25W – 50W STx3N62K3 STx5N62K3

50W – 100W STx7N60M2 STx10N60M2

>100W STx13N60M2 STx18N65M5

Single stage

high PF flyback 15W – 75W

STx7N80K5 STx15N80K5

STx21N90K5

STx6N95K5 STx20N95K5

L6564H companion MOSFET 22

SuperMESH3, MDmesh II Plus Low Qg, MDmesh V

• Low Rdson(on), best in class in dV/dt, Available in PowerFLAT packages

SuperMESH5 ™

• Outstanding static and dynamics performances at 800V-950V

23

EVL6566B_65W_QR board

SuperMESH 5 STF15N80K5 shows better efficiency and thermal profile vs STF11NM80 from

previous generation MDmesh series

SuperMESH 5 vs MDmesh test benchmark

80.0

82.0

84.0

86.0

88.0

90.0

92.0

94.0

0 10 20 30 40 50 60 70 80 90 100

Effi

cie

ncy

[%

]

Load level [%]

Efficiency @ 230 Vac

STF15N80K5

STF11NM80

25

30

35

40

45

50

55

60

65

70

0 10 20 30 40 50 60 70 80 90 100

Tem

pe

ratu

res

[°C

]

Load level [%]

Thermal profile @ 230 Vac

STF15N80K5

STF11NM80

L6562 and L6564H tools & support 24

18/11/2013

• Standard PFC (stand alone)

• EVL6564H-100W reference design for standard PFC

• Auxiliary reference designs for SMPS (vending machine, industrial

SMPS…)

• EVL6564 – 50WFLB: 50W wide range high power factor flyback converter

demonstration board based on the L6564

• Auxiliary reference designs for LEDs

• STEVAL–ILL043V1: 75W Two independent LED strings power supply based on L6562A in HPF Flyback

• STEVAL–ILL042V1: 60W LED power supply based on L6562A and TSM101 (AN3424)

• EVL6564H-25W-BB: 25W, 80VOUT for LED based on L6564H

• Design support

• AN4077: 100W transition-mode PFC pre-regulator with the new L6564H

• AN4028: 50W wide-range high power factor flyback converter using the L6564

• Excel spreadsheet DESIGNING WITH THE L6564H (AVAILABLE ON REQUEST)

New common features & benefit

details


25

Inductor saturation detection

• Inductor cost is optimized such that often it works close to saturation. During

some critical condition it could anyhow enter saturation (=current limitation lost

and mosfet explosion)

• Disable IC if saturation is detected (NOT LATCH)

• After disable Starting Time is doubled

• Safe operation even with Vout<Vin

• 150 ns (typ.) internal masking time LEB no external filter required

26


Tdelay

DIL Multiplier

Output

Vcs

t

1.7V

Tdelay t Tdelay t

Inductor not

saturating

Inductor slightly

saturating

Inductor saturating

hard

Multiplier

Output Multiplier

Output

1.7V 1.7V

DIL DIL

Vcs Vcs

High-voltage start-up (L6564H only)

• Integrated HV circuitry to start-up

the IC and the SMPS

• 700V rated

• no need of external components

• HV mosfet

• Zener

• Resistors and capacitors

• It improves:

• efficiency

• Start-up

• restarts after faults

27


15MW

GND

14

12

8

Icharge

Vcc_OK

IHV

CONTROL

HV_EN

HVS

Vcc

HV input

HV input

REMOVED

L6564H

Standard

solution

(external

components)

(PFC_OK) Feedback disconnection and remote

ON/OFF

• OVP protection if the voltage pin exceeds 2.5V / PFC stopped

• feedback disconnection: if OVP protection AND the voltage at the INV pin is

lower than 1.66V PFC is stopped (LATCHED /

• Remote ON/OFF control pin if voltage < 0.23V (1.5mA standby)

28


PFC_OK

INV

Vout

9.5V

0.23/0.27V

DISABLE

(not

latched)

2.5/2.4V

(LATCHED

DISABLE ) OVP

DISABLE

(not

latched)

OVP

FEEDBACK

DISCONNECTION

2.5V

E/A To Multiplier

COMP

1.66V

Voltage feedforward (L6564H only)

• Totally compensates line changes

keeping constant the power

throughput

• Constant loop gain and bandwidth

• improves THD and PF at high line

• No max current/power limit trade-off

• Mains SURGES and DROPS

rejection

• Output voltage over/undershoot

rejection

29


RC sets max input

current 3rd harmonic

distortion

and is part of the

Mains detector

VFF

L6564

MULT MULTIPLIER

1/V 2

AC rectified

“ideal” diode allows

fast response to

sudden line surges

DETECTOR

MAINS DROP

Mains detector and

discharge resistor

allow fast response

to sudden line drops

not depending on the

external RC

CFF

RFF

Brownout protection

• PREVENTS PFC OPERATION IN CASE OF LOW MAINS VOLTAGE

• AVOID SPURIOUS OPERATION IN CASE

OF MAINS SAG

30


VFF

L6564

MULT

MULTIPLIER

1/V 2

Vin

-

+

0.8/0.88V

to IC

disable

Vin

VFF

Vcc

PWM

Vout 400V

0.8V

0.88V

Documents

ST Power Factor Controllers€¦ · Active PFC: digital vs. analog controllers 4 •Algorithm upgrade and customization is painless •Add/remove features at any time Flexibility