ST STEVAL-ISF001V2 Bedienungsanleitung

December 2012 Doc ID 15337 Rev 2 1/19

UM0673

User manual

STEVAL-ISF001V2, 3 kW FOT PFC board

based on the L6563S

Introduction

The power board STEVAL-ISF001V2 is a 3 kW PFC designed for industrial and domestic

applications. The board must be used for demonstration purposes in order to evaluate the

potential of the FOT (fixed-off-time control, patented by ST) to implement a high-power PFC

with performance comparable to a standard continuous-mode PFC, but using a simpler

controller chip originally designed for TM (transition-mode) PFC operating conditions. This

demonstration board works directly from the AC mains supply in the single range voltage

(185 Vrms - 265 Vrms) and provides a 400 V stable and regulated DC bus output capable of

a maximum of 7.5 A.

The low voltage necessary to supply the driver is generated by an auxiliary winding on the

main inductor, so an external power supply is not needed to start the operation of the board.

The design is:

■

quick to set up and install

■

re-usable (the Gerber files are available for free)

■

ready for downsizing if required.

Note: Please read Section 2 of this manual before attempting any operation.

Figure 1. Line, inductor, switch and diode

current in FF-CCM PFC Figure 2. Line, inductor, switch and diode

current in TM PFC

AM01972v1

AM01980v1

www.st.com

Contents UM0673

2/19 Doc ID 15337 Rev 2

Contents

1 Board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Power board 3 kW FOT PFC intended use . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Power board 3 kW FOT PFC installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2.1 Electronic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2.2 3 kW FOT PFC demonstration board setup . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Hardware layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 PFC board connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 STEVAL-ISF001V2 description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 STEVAL-ISF001V2 circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 BOM and schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Experimental measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

UM0673 Board description

Doc ID 15337 Rev 2 3/19

1 Board description

The STEVAL-ISF001V2 can be used for several kinds of applications:

●

Inverter for motor control

●

Air conditioning system

●

Welding machine DC power supply section.

This demonstration board offers customization options as well, making it an excellent choice

as an original platform for a more complete and dedicated system. Special care has been

taken during the layout process to provide a very low level of interference. Considering the

power delivered and the level of current present on the board, we advise no major

modification of the layout for customization of the system in order to avoid noise that could

cause the board to malfunction.

The board includes:

●

An input stage composed of a 25 A power rectifier bridge

●

An input filter stage necessary to comply with the EMC emission levels

●

A control stage composed of the L6563S

●

A power stage composed of a power MOSFET and power ultra-fast diodes

●

A power inductor designed and manufactured specifically for this application

●

An output filter stage composed of an electrolytic capacitor sized to have the ripple

required by the specification.

Figure 3. STEVAL-ISF001V2 demonstration board

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Safety and operating instructions UM0673

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2 Safety and operating instructions

2.1 General

During assembly and operation the 3 kW FOT PFC board poses several inherent hazards

including bare wires and hot surfaces. If the board or its components are improperly used or

installed incorrectly, there is danger of serious personal injury and damage to property.

All operations involving transportation, installation and use, as well as maintenance is to be

carried out by skilled technical personnel (national accident prevention rules must be

observed). For the purposes of these basic safety instructions, "skilled technical personnel"

are suitably qualified people who are familiar with the installation, use, and maintenance of

power electronic systems.

Warning: Many sources of serious hazard are present on this board.

The board works directly from the mains, is not galvanically

isolated, and provides on the output high-voltage DC levels

that can be the cause of serious electrical shock, serious

burns or death. Hot surfaces that can cause burns are

present on the board.

This board must be used only in a power laboratory only by engineers and technicians who

are experienced in power electronics technology and under protection.

STMicroelectronics is not responsible for damages to property nor personal injury.

2.1.1 Power board 3 kW FOT PFC intended use

The power board 3 kW FOT PFC is designed for demonstration purposes only and shall not

be used for electrical installation or machinery. The technical data as well as information

concerning the supply conditions shall be taken from the documentation and strictly

observed.

2.2 Power board 3 kW FOT PFC installation

The installation and cooling of the 3 kW FOT PFC shall be in accordance with the

specifications and the targeted application (see Section 2.2.2).

●

Excessive strain on the board shall be avoided. In particular, no components are to be

bent or isolating distances altered during the course of transportation or handling.

●

No contact shall be made with electronic components and contacts.

●

The boards contain electrostatically-sensitive components that are prone to damage

through improper use. Electrical components must not be mechanically damaged or

destroyed (to avoid potential health risks).

UM0673 Safety and operating instructions

Doc ID 15337 Rev 2 5/19

2.2.1 Electronic connection

National accident prevention rules must be followed when working on the main power

supply, with the power supply, or powering the board in general.

The electrical installation shall be completed in accordance with the appropriate

requirements (e.g., cross-sectional areas of conductors, fusing, PE connections. For further

information, see Section 2.2.2).

2.2.2 3 kW FOT PFC demonstration board setup

It is preferable to use an AC supply isolated and protected against overload and short-circuit

during the evaluation test of the power board 3 kW FOT PFC (in compliance with technical

equipment and accident prevention rules).

A proper load, able to dissipate or in any case absorb and reuse the power delivered by the

system, has to be used. In the case of a resistive and dissipative dummy load, the user must

pay attention to the temperature that the load could reach and provide the necessary

equipment to avoid hot surfaces and fire hazards during the tests (fan, water-cooled load,

etc).

Caution: Do not touch the boards and its components after disconnection from the voltage supply, as

several parts and power terminals which contain possibly energized capacitors need to be

allowed to discharge.

2.3 Hardware layout

Figure 4. Power board 3 kW FOT PFC STEVAL-ISF001V2 (top view)

The mains input connector is present on the right side of the board. Connect a sinusoidal

supply voltage with amplitude in the range of 185 Vrms to 265 Vrms. The power source has

to be able to supply the power required by the system, according to the output load the user

intends to connect on the output port.

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Safety and operating instructions UM0673

6/19 Doc ID 15337 Rev 2

The output connector is present on the left side (close to the output electrolytic capacitors).

Please note that the output voltage is regulated by the system for the target value of 400 V

(consider a tolerance of 5%, due to the net value of the passive components on the board),

which gives a value for a resistive load between 530 Ω( minimum power delivered) to 53 Ω

( maximum power delivered).

Warning: The STEVAL-ISF001V2 has no insulation shield or any other

type of protection.

Caution: The demonstration board must be handled very carefully, as high-potential (energy) parts

are open and can be touched. The user MUST avoid connecting or removing cables during

operation of the board or touching any part of the system when it is connected to the main

power supply.

Note: After turning the power supply off, if the load is disconnected, the DC-link capacitor may still

hold voltage.

Note: It is preferable to test the kit in ambient temperature not higher than 45 degrees Celsius.

2.4 Environmental considerations

The STEVAL-ISF001V2 must only be used in a power laboratory. The high voltage involved

in the system presents a serious shock hazard. If the board is to be used to measure or

capture waveforms or any other interaction between the board and laboratory equipment,

an AC-isolated power supply has to be used.

Note: Any measurement equipment must be isolated from the main power supply before powering

up the PFC. To use an oscilloscope with the kit, it is safer to isolate the AC supply AND the

oscilloscope or use isolated differential probes. This prevents a shock from occurring as a

result of touching any SINGLE point in the circuit but does NOT prevent shocks when

touching TWO or MORE points in the circuit.

An isolated AC power supply can be constructed using an isolation transformer and a

variable transformer.

Note: Isolating the application rather than the oscilloscope is highly recommended in any case.

UM0673 PFC board connection

Doc ID 15337 Rev 2 7/19

3 PFC board connection

The PFC board is manufactured ready to use. Using jumper J3, the supply of the driver

L6563S can be connected directly to the supply generated by the auxiliary winding present

on the boost inductor or to an isolated low-voltage external supply. This option can be used

to debug or to test an inductor not equipped with an auxiliary winding. Set jumper J3 to

position 2-3 to use the standard auxiliary power supply already present on the board. If an

external supply is used, set J3 to position 1-2 and connect a 15 V DC supply capable of at

least 100 mA to J4 (+15 on J4 pin1, ground on J4 pin2). Connect the board to the AC power

supply.

Use a suitable cable, in terms of insulation and cross-section, to be able to conduct the

current from the supply according to the load connected to the output port.

Connect the output port to the load.

Note: Even if the system is able to start up and maintain the output voltage regulated to the target

value, also under open-load condition, the technical specification in terms of PF and THD

cannot be guaranteed.

The systems accept a minimum power load to work properly.

Supply the PFC board with a sinusoidal supply voltage with amplitude in the range of 185

Vrms to 265 Vrms. The power source has to be able to supply the power required by the

system, according to the output load the user intends to connect to the output port.

Caution: Do not supply the system with a voltage value higher than 265 Vrms, as risk of serious

damage to the board and to property is present in this case. Do not supply the system with a

voltage below the minimum allowed, 185 Vrms, as the systems cannot start or operate

properly in this condition.

Note: Low voltage supply and maximum output load present the worst operating conditions for the

system and sufficient cooling is mandatory.

3.1 STEVAL-ISF001V2 description

The demonstration board STEVAL-ISF001V2 developed by STMicroelectronics provides a

compact, and ready-to-use solution for the implementation of a simple PFC system able to

supply load with power close to the maximum delivered in most typical domestic

installations. For such a range of power the use of a continuous-mode PFC operation

becomes mandatory to drain from the mains a current with an rms value which does not

exceed the maximum allowed from the metering system and to have a reasonable size of

the devices involved in the system’s operations.

The use of a standard continuous-mode driver chip necessitates using a more expensive

and complex driver with all the required passive components.

STMicroelectronics has patented a solution that allows using a simple driver, designed for a

transition-mode operation, in a fixed-off-time, variable frequency, PWM modulation. This

kind of modulation gives a current on the boost inductor of the PFC that is comparable with

the current of a typical continuous-mode modulation.

Modulating T

and fixing T

OFF

of the PWM signal applied to the main switch, it is possible

to maintain continuous current on the inductor around a sinusoidal envelope. As a

PFC board connection UM0673

8/19 Doc ID 15337 Rev 2

consequence of maintaining constant T

OFF

and varying T

, the overall PWM period is

modulated which gives a variable frequency control.

Using a variable frequency control has advantages in terms of noise input filter size. In fact,

the noise energy is spread over a frequency range with lower energy content for each

frequency.

For further technical information and correct sizing and calculation of the device on the

board, please consult STMicroelectronics’ AN1792 "Design of fixed-off-time-controlled PFC

pre-regulators with the L6562".

The features of the STEVALISF001V1 include:

●

PFC FOT power systems based on the L6563S

●

Power stage based on MDmesh™ V Power MOSFET

●

185 Vrms < Vin rms <265 Vrms

●

Vout 400 V regulated (±5%)

●

Iout max 7.5 A

●

Driver with inductor saturation detection

●

Optimized EMC input filter.

3.2 STEVAL-ISF001V2 circuit description

Figure 5 shows the entire electronic schematic.

Starting from the input section, a common-mode EMC filter is fitted in order to be compliant

with the EMC regulations concerning industrial and domestic applications. (EN55014 and

EN55022).

The alternative voltage from the mains is then rectified by the input low-frequency bridge

that provides a rectified sinusoidal waveform (with a frequency that is doubled with respect

to the input main waveform) to the next boost stage. The capacitor C7 has been calculated

to have a residual ripple, around the sinusoidal envelope at maximum load and minimum

input voltage, of 6% of the Vin peak value.

The main boost inductor, designed and produced by MAGNETICA (Italy), is a ferrite

inductor core designed to minimize the hysteresis losses.

The technical sheet with a complete order code is given in Figure 6.

The inductor has a secondary-side winding that provides the low-voltage auxiliary supply to

the driver L6563S.

At the startup the current and voltage on the main inductor is still zero, so any voltage can

be generated by the secondary auxiliary winding. In this condition, and only during the

startup, the two resistors R7 and R13, 150 kΩeach, with the Zener diode D4 (fitted for

limitation purposes) charge the capacitor C12 and supply the driver that starts the PWM

operation. As soon the PWM signal starts to switch, a voltage is present across the auxiliary

winding, so the low supply voltage across the capacitor C12 is maintained.

The two boost diodes paralleled conduct the peak inductor current at the end of the T

period. At the maximum power and minimum input voltage the peak current can reach 29 A.

Diode D2 and NTC resistor NV1 are used to limit the inrush current, due to the electrolytic

capacitor on the output, during the startup or small decrease of the mains.

UM0673 PFC board connection

Doc ID 15337 Rev 2 9/19

The chosen switching devices are two power MOSFETs, MDmesh™ V family,

STW88N65M5. These two power MOSFETs placed in parallel assure a low R

DS(on)

, limiting

the conduction power losses.

Good efficiency and good thermal behavior of the system can be reached.

To properly drive the power MOSFET and to minimize switching losses, during the on and

off transient, a small push-pull driver was interposed between the driver and the two gates.

A reading of the current conducted by the two power MOSFETs, equal to the current on the

main inductor during the T

period, is necessary for the driver to set the right current level

on the inductor according to the input instantaneous voltage and the output power delivered

to the load. This current is sensed by a sensing resistor paralleling two 0,07 Ωnon-inductive

sensing resistors. The output DC bus voltage is sensed by the driver through the resistive

net composed of R12, R16, R17, and R24.

As described in the L6563S datasheet, a PFC pre-regulator output voltage

monitoring/disable function exists. This pin senses the output voltage of the PFC pre-

regulator through a resistor divider and is used for protection purposes. If the voltage at the

pin exceeds 2.5 V, the IC is shut down, its consumption goes almost to the startup level and

this condition is latched. The PWM_LATCH pin is asserted high. Normal operation can be

resumed only by cycling Vcc. This function is used for protection in case the feedback loop

fails.

The RC net, on pin ZCD, is used to fix the desired T

OFF

time according to the sizing

calculation of the application (for complete design rules, please refer to "Design of fixed-off-

time-controlled PFC pre-regulators with the L6562").

The small signal bit Q3 is used to implement a T

OFF

modulation according to the input

voltage. At the moment of low voltage on the input waveform (near the zero-crossing of the

input sinusoidal supply) and in order to minimize the distortion on the input current due to

the low input voltage, the T

OFF

period needs to be reduced. Acting in this way, the ratio

between T

and T

OFF

is increased and the distortion on the input current can be reduced.

BOM and schematics UM0673

10/19 Doc ID 15337 Rev 2

4 BOM and schematics

Table 1. Bill of material

Item Qty Reference Part

1 1 C1 0.22 μF 300Vac X2

22 C2,C4 10nFY2

31 C3 2.2μF 300Vac X2

4 1 C7 220 nF 630 V

5 2 C6,C8 330 μF 450 V

6 1 C9 18 nF

71 C10 1μF

8 1 C11 100 nF

9 1 C13 470 nF 50 V

10 1 C12 47 μF 50 V

11 1 C16 680 pF

12 1 C17 1.5 nF

13 1 C18 10 nF

14 1 C19 1 nF

15 1 C20 2.2 nF

16 1 C21 1.5 nF

17 1 D1 25 A 220 AC diode bridge

18 1 D2 1N5406

19 2 D3,D17 STTH12S06FP

20 1 D4 30 V Zener

21 4 D5,D7,D8,D9 1N4148

22 1 D6 20 V Zener

23 1 F1 Fuse 16 A

24 1 P1 220AC 16 A three-way connector

25 1 P2 OUT/400 V 8 A two-way connector

26 1 P3 20vDC Aux supply stripline

27 1 J1 Jumper stripline

28 1 U2 STS01DTP06 (SMD)

29 1 U1 L6563S (SMD)

30 1 P4 External signal stripline

31 1 L1 MAGNETICA 1745.0005 2 mH 18 A

32 1 Q1,Q2

(1)

STW88N65M5 (heatsink PADA 8355)

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