Application note
35 W wide-range high power factor flyback converter
demonstration board using the L6562A
Introduction
This application note describes a demonstration board based on the transition-mode PFC controller L6562A, and presents the results of its bench demonstration. The board is a 35 W, wide-range mains input, power factor corrected SMPS (switched mode power supply) suitable for all low power applications requiring a high PF (power factor), such as lighting applications and power supplies for LEDs. The low-cost L6562A and the simple flyback topology combine to provide a very competitive PFC controller solution.Figure 1.
EVL6562A-35WFLB demonstration board using the L6562A
November 2008 Rev 11/22
www.st.com
ContentsAN2838
Contents
123
Main characteristics and circuit description . . . . . . . . . . . . . . . . . . . . . 4Electrical diagram and bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Test results and significant waveforms . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1
Harmonic content measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
45678910
Thermal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Conducted emission pre-compliance test . . . . . . . . . . . . . . . . . . . . . . 15Burst test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Schematic with output voltage and current loop . . . . . . . . . . . . . . . . . 17Power transformer specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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AN2838List of figures
List of figures
Figure 1.Figure 2.Figure 3.Figure 4.Figure 5.Figure 6.Figure 7.Figure 8.Figure 9.Figure 10.Figure 11.Figure 12.Figure 13.Figure 14.Figure 15.Figure 16.Figure 17.Figure 18.Figure 19.Figure 20.Figure 21.Figure 22.Figure 23.Figure 24.Figure 25.Figure 26.Figure 27.Figure 28.
EVL6562A-35WFLB demonstration board using the L6562A . . . . . . . . . . . . . . . . . . . . . . . 1EVL6562A-35WFLB demonstration board: electrical schematic . . . . . . . . . . . . . . . . . . . . . 6EVL6562A-35WFLB compliance with EN61000-3-2 Class-C limits @ full load. . . . . . . . . . 9EVL6562A-35WFLB compliance with JEIDA-MITI Class-C limits @ full load . . . . . . . . . . . 9Power factor vs. VIN and load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9EVL6562A-35WFLB input current waveform @100 V-50 Hz - 35 W load . . . . . . . . . . . . . 10EVL6562A-35WFLB input current waveform @230 V-50 Hz - 35 W load . . . . . . . . . . . . . 10Efficiency vs. VIN and load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Static VOUT regulation vs. VIN and IOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10EVL6562A-35WFLB output voltage ripple @ 90 VAC - full load. . . . . . . . . . . . . . . . . . . . . 11EVL6562A-35WFLB output voltage ripple @ 265 VAC - full load. . . . . . . . . . . . . . . . . . . . 11EVL6562A-35WFLB VDS and ID @ 90 VAC - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11EVL6562A-35WFLB VDS and ID @ 90 VAC - full load - detail. . . . . . . . . . . . . . . . . . . . . . . 11EVL6562A-35WFLB VDS and ID @ 265 VAC - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 12EVL6562A-35WFLB VDS and ID @ 265 VAC - full load - detail. . . . . . . . . . . . . . . . . . . . . . 12EVL6562A-35WFLB VDS and ID @ 90 VAC - 40 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12EVL6562A-35WFLB VDS and ID @ 90 VAC - 40 mA - detail. . . . . . . . . . . . . . . . . . . . . . . . 12EVL6562A-35WFLB VDS and ID @ 265 VAC - 40 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13EVL6562A-35WFLB VDS and ID @ 265 VAC - 40 mA - detail. . . . . . . . . . . . . . . . . . . . . . . 13Thermal map at 90 VAC - full load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Thermal map at 265 VAC - full load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14115 VAC and full load - phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15115 VAC and full load - neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15230 VAC and full load - phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15230 VAC and full load - neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Burst pulse and characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Electrical schematic with secondary current feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Main characteristics and circuit descriptionAN2838
1 Main characteristics and circuit description
The main characteristics of the SMPS demonstration board are:
●●●●●●●●●●●●
Line voltage range: 90 to 265 VACMinimum line frequency (fL): 47-63 HzRegulated output voltage: 48 VRated output power: 35 W
Power factor (load = 50 %): 0.9 minimumMinimum efficiency: 85 % at full load
Maximum 2 fL output voltage ripple: 1.5 V pk-pk / 0.39 VRMS (@VIN = 90 VAC, POUT = 35 W)Maximum ambient temperature: 50 °CConducted EMI: In acc. with EN55022 Class-BSurge rejection: surge test 2.5 kVPrimary to secondary insulation: 4 kV
PCB type and size: double-sided, 35 µm, FR-4, 120 x 82 mm
The main feature of this converter is that the input current is almost in phase with the mains voltage, therefore the power factor is close to unity. This is achieved by the L6562A
controller, which shapes the input current as a sinewave in phase with the mains voltage.The power supply utilizes a typical flyback converter topology, using a transformer to provide the required insulation between the primary and secondary side. The converter is
connected after the mains rectifier and the capacitor filter, which in this case is quite small to avoid damage to the shape of the input current. The flyback switch is represented by the power MOSFET Q1, and driven by the L6562A.
At startup, the L6562A is powered by the VCC capacitor (C6), which is charged via resistors R1 and R2. The TR1 auxiliary winding (pins 8-7) generates the VCC voltage, rectified by D4 and R4, that powers the L6562A during normal operation. R3 is also connected to the
auxiliary winding to provide the transformer demagnetization signal to the L6562A ZCD pin, turning on the MOSFET at any switching cycle. The MOSFET used is the STP5NK80ZFP, a standard, low-cost 800 V device housed in a TO-220FP package, and needing only a small heat sink. The transformer is layer type, using a standard ferrite size ETD-29 and is
manufactured by Magnetica. The flyback reflected voltage is ~190 V, providing enough room for the leakage inductance voltage spike still within the reliability margin of the MOSFET. The rectifier D2 and the Transil D3 clamp the peak of the leakage inductance voltage spike at MOSFET turn-off.
The resistors R14 and R15 sense the current flowing into the transformer primary side. Once the signal at the current sense pin has reached the level programmed by the internal multiplier of the L6562A, the MOSFET turns off.
The divider R7, R8, R9 and R6 provides to the L6562A multiplier pin with instantaneous voltage information which is used to modulate the current flowing into the transformer primary side.
The divider R20 and R21 is dedicated to sensing the output voltage, and capacitor C16 and diodes D7 and D8 provide a soft-start at turn-on. Output regulation is done by means of an
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AN2838Main characteristics and circuit description
isolated voltage loop by the optocoupler U2, and using an inexpensive TL431 (U3) to drive the optocoupler. The opto-transistor modulates the input voltage of the L6562A internal amplifier, thus closing the voltage loop.
The output rectifier is a fast recovery type, selected according to its maximum reverse
voltage, forward voltage drop and power dissipation. A small LC filter is added on the output, filtering the high frequency ripple.
The board is equipped with an input EMI filter designed for a 3-wire input mains plug. It is composed of two, common mode Pi-filter stages connected after the input connector and the input fuse. A varistor is also connected at the input of the board, improving immunity against input voltage fast transients.
5/22
Electrical diagram and bill of materialAN2838
2 Electrical diagram and bill of material
Figure 2.
EVL6562A-35WFLB demonstration board: electrical schematic
6/22
AN2838Electrical diagram and bill of material
Table 1.
Reference
C1C2C3C4C5C6C7C8C9C10C11C12C13C14C15C16C17C18C19C20C21C22C23C24D1D2D3D4D5D6D7D8D9F1
Bill of material
Part value2.2 nF2.2 nF0.22 µF0.1 µF220 nF47 µF100 nF2.2 nF2.2 nF1 nF1 nF1000 µF1000 µF100 nF2200 nF1 µF4.7 µF0.1 µF2.2 nF2.2 nF2.2 nF2.2 nF100 nF100 nF800 V, 2 AP6KE300ASTTH1L061N4448STTH3R0233 V1N44481N44481N41482 A, 250 V
Fuse PCB mountingRectifier, ultra-fast 3 A, 200 V
Zener, 5%Type/descriptionCeramic Y2Ceramic Y2R.46 275 VAC
R.41 MKP Y2/X1 300 VAC
MKT X2 275 VAC
35 VCeramicCeramicCeramicCeramic Y2Ceramic Y263 V 105 °C YXF63 V 105 °C YXF
CeramicCeramic100 V63 V 105°C
R.41 MKP Y2/X1 300 VAC
Ceramic Y2Ceramic Y2Ceramic Y2Ceramic Y2CeramicCeramic
2KBP08M diode bridge
Transil
Rectifier, ultra-fast 1 A, 600 V
SupplierMurataMurataArcotronics
n.d.n.d.n.d.n.d.n.d.n.d.MurataMurataRubyconRubyconn.d.n.d.n.d.Rubyconn.d.MurataMurataMurataMuratan.d.n.d.n.d.
STMicroelectronicsSTMicroelectronics
n.d.
STMicroelectronics
n.d.n.d.n.d.n.d.n.d.
7/22
Electrical diagram and bill of material
Table 1.
Reference
L1Q1R1R2R3R4R5R6R7R8R9R10R11R12R13R14R15R16R17R18R19R20R21R23R24R25T1T2TR1U1U2U3V1
AN2838
Bill of material (continued)
Part value4135STP5NK80ZFP
150 kΩ150 kΩ68 kΩ10 R
Type/descriptionFilter inductor 15 µH/3 A Power MOSFET, TO-220FP
w/heatsink
AxialAxialAxialAxial
SupplierMagneticaSTMicroelectronics
n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.n.d.
680 kΩ Axial20 kΩ1 MΩ1 MΩ1 MΩ0 R47 kΩ2.2 kΩ10R1R01R012K3K36.8 kΩ4.7 kΩ1K527 kΩ100 kΩ1 kΩ0R365136514126L6562ACNY17-3TL431275 V
AxialAxialAxialAxialshortedAxialAxialAxial
Axial, precision 5%, ¼ WAxial, precision 5%, ¼ W
AxialAxial, ¼ WAxialAxial
Axial, precision 1% Axial, precision 1%
AxialAxialShorted
Common mode choke 2x18 mHCommon mode choke 2x18 mHSwitch-mode transformer
TM PFC controllerOptocoupler DIP-6Voltage reference, TO-92VDR 40J (10/1000 µs) 7 mm
MagneticaMagneticaMagneticaSTMicroelectronics
n.d.
STMicroelectronics
n.d.
8/22
AN2838Test results and significant waveforms
3
3.1
Test results and significant waveforms
Harmonic content measurement
One of the main purposes of this converter is the correction of input current distortion, decreasing the harmonic contents below the limits of the actual regulation. Therefore, the board has been tested according to the European standard EN61000-3-2 Class-C and Japanese standard JEIDA-MITI Class-C, at full load and both nominal input voltage mains. As shown in figures that follow, the circuit is capable of reducing the harmonics well below the limits of both regulations.Figure 3.
EVL6562A-35WFLB Figure 4.compliance with EN61000-3-2 Class-C limits @ full load
EVL6562A-35WFLB
compliance with JEIDA-MITI Class-C limits @ full load
The power factor (PF) has been measured also and the results are reported in Figure5. As shown, the PF remains very close to unity throughout the input voltage mains range.Figure 5.
Power factor vs. VIN and load
The waveforms of the input current and voltage at the nominal input voltage mains and full load condition are illustrated in Figure6 and Figure7.
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Test results and significant waveformsAN2838
Figure 6.
Figure 7.EVL6562A-35WFLB input
current waveform @100 V-50 Hz - 35 W load
EVL6562A-35WFLB input current waveform @230 V-50 Hz - 35 W load
The converter’s efficiency has been measured and it is significantly high in all load and line conditions (see Figure8). At full load, the efficiency is higher than 85% at any input voltage, making this design suitable for high efficiency power supplies. Also, at lower output load the efficiency is better than 82%. At minimum load (40 mA output current) the efficiency is still good.
Figure9 reports the output voltage measured under different line and load conditions. As shown, the voltage regulation over the entire input voltage range is excellent at any output current level.Figure 8.
Efficiency vs. VIN and load
Figure 9.
Static VOUT regulation vs. VIN and IOUT
10/22
AN2838Test results and significant waveforms
Figure 10.EVL6562A-35WFLB output Figure 11.EVL6562A-35WFLB output
voltage ripple @ 90 VAC - full voltage ripple @ 265 VAC - full loadload
In Figure10 and Figure11 the output voltage ripple at twice the input mains frequency is
measured. As shown it is less than 0.4 V peak-to-peak, which is ideal for LED or lighting applications. High frequency noise, including spikes, is significantly reduced as well.In the following illustrations, the MOSFET drain voltage and current are measured at different line and maximum loads.
Figure 12.EVL6562A-35WFLB VDS and Figure 13.EVL6562A-35WFLB VDS and
ID @ 90 VAC - full loadID @ 90 VAC - full load - detail
CH1: drain current - 0.5 A/divCH2: drain voltage - 200 V/div
CH1: drain current - 0.5 A/divCH2: drain voltage - 200 V/div
11/22
Test results and significant waveformsAN2838
Figure 14.EVL6562A-35WFLB VDS and Figure 15.EVL6562A-35WFLB VDS and
ID @ 265 VAC - full loadID @ 265 VAC - full load - detail
CH1: drain current - 0.5 A/divCH2: drain voltage - 200 V/div
CH1: drain current - 0.5 A/divCH2: drain voltage - 200 V/div
Figure14 shows the measurement at the maximum drain voltage of 265 VAC and max load.
In this worst-case condition, the peak drain voltage is 640 VPK, assuring a good margin with respect to the MOSFET BVDSS and contributing strongly to the reliability and low failure rate of the design.
Figure 16.EVL6562A-35WFLB VDS and Figure 17.EVL6562A-35WFLB VDS and
ID @ 90 VAC - 40 mAID @ 90 VAC - 40 mA - detail
CH1: drain current - 0.1 A/divCH2: drain voltage - 100 V/div
CH1: drain current - 0.1 A/divCH2: drain voltage - 100 V/div
12/22
AN2838Test results and significant waveforms
Figure 18.EVL6562A-35WFLB VDS and Figure 19.EVL6562A-35WFLB VDS and
ID @ 265 VAC - 40 mAID @ 265 VAC - 40 mA - detail
CH1: drain current - 0.2 A/divCH2: drain voltage - 200 V/div
CH1: drain current - 0.2 A/div CH2: drain voltage - 200 V/div
The above figures show the MOSFET waveforms at light load. Even in this load condition
the waveforms are correct. It can be noted that at high mains the converter works in burst mode (see Figure19), keeping efficiency at a good level.
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Thermal measurementsAN2838
4 Thermal measurements
To check the reliability of the design, thermal mapping by means of an IR camera was
carried out. Figure20 and Figure21 show thermal measurements on the component side of the board at nominal input voltages and full load. Some pointers visible on the pictures placed across key components show the relevant temperature. Table1 provides the correlation between the measured points and components, for both thermal maps. The ambient temperature during both measurements was 27 °C. According to these
measurement results, all components on the board function within their temperature limits.Figure 20.Thermal map at 90 VAC - full
load
Figure 21.Thermal map at 265 VAC - full
load
Table 2.
Measured temperature @ 90 VAC and 265 VAC - full load
ComponentMOSFET Q1
Temperature @ 90 VAC
57.8 °C58.9 °C65.9 °C64.3 °C54.5 °C55.7 °C56 °C70 °C
Temperature @ 265 VAC
43.8 °C58.1 °C45.6 °C65.1 °C55 °C36. 2 °C38.2 °C59 °C
Secondary diode D5Diode bridge D1Transformer TR1 (bobbin)Transformer TR1 (core)
Choke T1Choke T2Transil D2
14/22
AN2838Conducted emission pre-compliance test
5 Conducted emission pre-compliance test
The following images are the peak measurements of the conducted noise at full load and nominal mains voltages. The limits shown on the diagrams are those of EN55022 Class-B, which is the most popular standard for domestic equipment. As visible in the diagrams, good margins with respect to the limits are present in all test conditions.
Figure 22.115 VAC and full load - phaseFigure 23.115 VAC and full load - neutral
Figure 24.230 VAC and full load - phaseFigure 25.230 VAC and full load - neutral
15/22
Burst testAN2838
6 Burst test
The board has been tested against burst pulses, with good results. The tests have been
carried out using the following equipment and the procedures:
●●
Surge generator: Schaffner NSG 200 E 7 NSG 224 ATest types:––
SYM = symmetric with respect to earth pole (pulse applied between line and neutral)
ASYM = asymmetric (pulse applied between line and earth and between neutral and earth)
●
Output load 700 mA.
Figure 26.Burst pulse and characteristics
Table 3.
ConfigurationBurst test report table
Pulse frequencyPulse number (burst)Pulse number (burst)Pulse number (burst)Pulse number (burst)10101010
Polarity andPulse typeAmplitude
PausePausePauseSYM2.5 kV+ 90°III1 Hz1010
15”15”15”15”15”15”15”15”
1015”1015”15”
SYM2.5 kV- 270°III1 Hz1010
1015”1015”15”
ASYM2.5 kV+ 90°III1 Hz1010
1015”1015”15”
ASYM2.5 kV- 270°III1 Hz1010
1015”1015”15”
●
Test passed with a total of 200 pulses applied and a medium energy of 80 mJ (when connected to a 50 Ω load).
16/22
PausephaseAN2838Schematic with output voltage and current loop
7 Schematic with output voltage and current loop
All tests described in this document have been done using the schematic in Figure1 and
using a TL431 for the output voltage feedback. If a secondary current loop is also needed, the schematic below can be implemented on the PCB by making the modifications listed in Table4.
The proposed schematic has been designed to drive LEDs with a current rating of 700 mA. For correct board functionality the minimum output voltage when the current loop is working is around 30 V. Therefore, the minimum number of LEDs in series that can be connected to the output must be calculated according to this minimum output voltage value.Figure 27.Electrical schematic with secondary current feedback
17/22
Schematic with output voltage and current loopAN2838
Table 4.
ReferenceC15C16C25C26C27D6R4R16R18R19R20R21R25R26R27R30R100J1U3U4
Modification list for TSM1052 implementation
Part value
ModificationRemoved
100 nF2.2 nF220 nF10 nF12 V22 R 10 kΩ
Changed value
AddedAddedAddedChanged valueChanged valueChanged valueRemovedRemoved
5K6220 kΩ0R27100 kΩ4K74K7470RJUMPER
Changed valueChanged value
AddedAddedAddedAdded
Mounted by reworking of PCB
AddedRemoved
TSM1052 STMicroelectronics
Added
Axial, precision 1%Axial, precision 1%
Axial 2 WAxialAxialAxialAxialWire jumper
Current/voltage controller
Type/Description
Ceramic Ceramic Ceramic CeramicZener, 5%AxialAxial
18/22
AN2838Power transformer specification
8 Power transformer specification
●
Transformer type: open––––
Winding type: layer
Coil former: vertical type, 6 + 6 pinsMains insulation: 4 kVUnit finishing: varnished
Electrical characteristics (all measurements taken with pins 10 and 11 shorted)
●●●●●●●●
Converter topology: flyback, TM modeCore type: ETD29
Min. operating frequency: 36 kHz
Primary inductance: 550 H 10% @ 1 kHz - 0.25 V (a)Leakage inductance: 0.8% @ 50 kHz - 0.25 V (b)Parasitic capacitance: 7 pF max. Max. peak primary current: 1.9 APK Turn ratio:––
Pin 9-12 / 8-7: 10.55 ± 5%Pin 9-12 / 5/4-3/2: 3.8 ± 5%
Figure 28.Power transformer
Manufacturer: MagneticaP/N: 4126
a.Measured between pins (9-12)
b.Measured between pins (9-12) with all secondary windings shorted
19/22
ReferencesAN2838
9 References
●●●
L6562A transition-mode PFC controller datasheet
Application note AN1059: Design equations of high-power-factor flyback converters based on the L6561
Application note AN1060: Flyback converters with the L6561 PFC controller
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AN2838Revision history
10 Revision history
Table 5.
Date12-Nov-2008
Document revision history
Revision
1
Initial release
Changes
21/22
AN2838
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