ST Power Factor Controllers. Luca Salati

Transcription

1 ST Power Factor Controllers Luca Salati

2 PFC controller: what a PFC is? 2 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 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)

3 Passive PFC vs. active PFC 3 Simple but bulky and heavy circuitry Electronic circuit Smaller and lighter Typical PF in the range V, I V, I Typical PF in the range More economic solution below 400W (source: EPSMA 1 ) Increased available power from the wall socket Become not suitable when power increases (e.g. above 1kW) Constant bus voltage

4 Active PFC: digital vs. analog controllers 4 Digital Analog Flexibility Algorithm upgrade and customization is painless Add/remove features at any time Application safety Safety not relying on SW Higher frequency No need for powerful CPU ST has both, you can choose..

5 Product portfolio

6 Power Factor Control portfolio and roadmap 6 F E A T U R E S L6562A TM PFC L4981A/B AVG CURRENT MODE PFC L6563S 14 pin ADVANCED TM PFC L6563H 16pin L6563S+HV Start Up L6564/T 10pins TM PFC L4984 CCM 10Pins PFC L6564H 14pins TM PFC CCM TM Full production Presentation Title

7 Continuous conduction mode PFC s L4984D

8 L4984D PFC controller: introduction 8 WHERE: Power Factor Control stage of SMPS connected to AC input Mains WHY: according to EN international norm, a PFC STAGE is required, that fixes limits of Total Harmonic Distortion (THD) INPUT SMPS CURRENT: SINUSOIDAL IN PHASE WITH MAINS VOLTAGE

9 L4984D introduction 9 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

10 L4984D introduction 10 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 Small PCB No output capacitor explosion No MOSFET damaging No MOSFET over-heating Application flexibility

11 L4984D performances W reference design (EVL W) Efficiency > 94% on 85VAC 264VAC input range THD<10% at full load on 85VAC 264VAC input range

12 L4984D companion MOSFET / rectifiers 12 L 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

13 L4984D - summary 13 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

14 Transition mode PFC s

15 Product evolution for TM 15 L6562A / AT L6564 / T INV COMP MULT CS Vcc GD GND ZCD Low Cost Adv. Features L6564H INV COMP MULT CS VFF Vcc GD GND ZCD PFC_OK INV 1 14 Vcc COMP 2 13 GD MULT CS GND ZCD Advanced features + High Voltage Start up Interface to PWM ctrl L6563S VFF PFC_OK N.C N.C. N.C. HVS L6563H Interface to PWM ctrl + High Voltage Start up

16 Product evolution for PFC - FOCUS 16 L6562A / AT L6564 / T INV COMP MULT CS Vcc GD GND ZCD Low Cost Adv. Features L6564H INV COMP MULT CS VFF Vcc GD GND ZCD PFC_OK INV 1 14 Vcc COMP 2 13 GD MULT CS GND ZCD Advanced features + High Voltage Start up VFF 5 10 N.C. PFC_OK 6 9 N.C. N.C. 7 8 HVS 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

17 L6564 family Power Factor Controller

18 L6564H can be used in: L6564 / H introduction 18 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 regulation by limiting the Total Harmonic Distortion (THD) L6564H LEDs SMPS INPUT CURRENT: SINUSOIDAL IN PHASE WITH MAINS VOLTAGE

19 from L6562A to L pins more but more than just 2 pins 19 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 SSOP10 (SO8 body) 1mm pitch 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

20 L6564H as standard PFC pre-regulator 20 Set of protections for complete application reliability 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 boost AC MAINS L6564H

21 L6564H as single-stage controller for LEDs 21 Set of protections for complete application reliability 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 flyback LEDs AC MAINS L6564H

22 L6564H companion MOSFET 22 PFC Transition Mode 25W 50W 50W 100W STx3N62K3 STx5N62K3 STx7N60M2 STx10N60M2 ST Power MOSFETs >100W STx13N60M2 STx18N65M5 STx7N80K5 STx15N80K5 Single stage high PF flyback 15W 75W STx21N90K5 STx6N95K5 STx20N95K5 DIFFERENT TECHNOLOGIES for BEST PERFORANCES 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 Temperatures [ C] Efficiency [%] Vac SuperMESH 5 vs MDmesh test benchmark STF15N80K5 STF11NM80 Load level [%] EVL6566B_65W_QR board Thermal 230 Vac STF15N80K5 STF11NM Load level [%] 23 SuperMESH 5 STF15N80K5 shows better efficiency and thermal profile vs STF11NM80 from previous generation MDmesh series

24 L6562 and L6564H tools & support 24 Standard PFC (stand alone) EVL6564H-100W reference design for standard PFC Auxiliary reference designs for SMPS (vending machine, industrial SMPS ) EVL WFLB: 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)

25 25 New common features & benefit details Presentation Title

26 Inductor saturation detection 26 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 Vcs 1.7V Vcs Vcs 1.7V 1.7V Multiplier Output DIL Multiplier Output DIL Multiplier Output DIL Tdelay Inductor not saturating t Inductor slightly saturating Tdelay t Tdelay t Inductor saturating hard Presentation Title

27 High-voltage start-up (L6564H only) 27 HV input Integrated HV circuitry to start-up the IC and the SMPS REMOVED 700V rated no need of external components HV mosfet Zener Resistors and capacitors Standard solution (external components) HV input HVS It improves: 15MW 8 efficiency Start-up restarts after faults L6564H Vcc_OK HV_EN IHV CONTROL 14 Vcc Icharge 12 GND Presentation Title

28 (PFC_OK) Feedback disconnection and remote ON/OFF 28 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) COMP Vout 2.5V E/A To Multiplier INV PFC_OK 2.5/2.4V 9.5V 1.66V DISABLE (not latched) OVP OVP 0.23/0.27V FEEDBACK DISCONNECTION (LATCHED DISABLE ) DISABLE (not latched) Presentation Title

29 Voltage feedforward (L6564H only) 29 AC rectified Totally compensates line changes keeping constant the power throughput MULT 1/V 2 L6564 MULTIPLIER MAINS DROP DETECTOR Constant loop gain and bandwidth improves THD and PF at high line No max current/power limit trade-off VFF C FF R FF ideal diode allows fast response to sudden line surges Mains SURGES and DROPS rejection Output voltage over/undershoot rejection RC sets max input current 3 rd harmonic distortion and is part of the Mains detector Mains detector and discharge resistor allow fast response to sudden line drops not depending on the external RC Presentation Title

30 Brownout protection 30 PREVENTS PFC OPERATION IN CASE OF LOW MAINS VOLTAGE AVOID SPURIOUS OPERATION IN CASE OF MAINS SAG Vin Vin L6564 VFF 0.88V 0.8V MULT 1/V 2 MULTIPLIER /0.88V to IC disable Vcc VFF PWM Vout 400V Presentation Title