Application Report
90W Single stage PFC-flyback using L6562A for LED driver
Introduction:
In these years, power LEDs for lighting is quite hot application. For the reasons: their
life of LED is significantly longer at 100,000 to 15,000 full-power hours (11+ years) to
half brightness, the cost of power LEDs is rapidly coming down, and it’s easy to find
different sources from the market recently.
We are always using the words to talk about LED lighting: high efficiency (light out per
watt in), long life… but if we look back to the power supply solution for LED lighting, it’s
hard to find the benefit of the long life. The E-caps using in the switching mode power
supply solution are limiting the total solution’s lifetime. And for several tens watt
application, it’s hard to find suitable solution to meet the regulator requirement: Power
Factor or Harmonic Current requirement, but with low costing also.
In this file, introduces the solution without E-cap, using traditional TM PFC controllor
L6562A to control the flyback topology, combining the functions of PFC(Power Factor
correction) and flyback topology (AC-DC converter), to meet the requirements: Long
lifetime to match the LED Lighting’s feature, PF or Harmonic Current for regulator, and
also low costing for commerce. In this application, there are big advantages as talked
above, but also a little drawback maybe somebody don’t like: double line frequency ripple
voltage on output, and also cause the same frequency ripple current on LEDs. It’s possible
to decrease the value of ripple voltage by adding e-caps at output side as adaptors, but it’s
impossible to get the same small ripple voltage as adaptors do.
Main characteristics and brief circuit description
The main characteristics of the design are listed below:
� Wide range input voltage (90Vac/60Hz ~ 264Vac/50Hz);
� Vout is set at 35V max, and able to low to 24Vdc with CV loading;
� Iout is set at 5A maximum current limitation;
� EN61000-3-2 is implemented;
� Capable of FCC Class B conducted EMI;
� Isolated output, “safe” voltage;
Brief circuit description:
In this application, I’m using L6562A at Primary side for PFC - PWM control, and
TSM1014 at secondary side for CC/CV control.
At primary side:
L6562A as a TM PFC control, I add FOT (fixed off-time) technical here, to change the
TM mode to CCM mode control. The five components: D3, C10, C11, R15, R16
implement this change function. Using this FOT technical, we can limited the peak current
at primary side for several tens power application and the peak voltage stress with primary
MOSFET at starting up stage. A voltage regulator combines with C6, C7, R6, ZD1 and Q2,
to supply L6562A a safety VCC voltage. To meet the requirement of different output
voltage to cover the tolerance of LED forward voltage drop, the voltage supplies from aux.
winding is always a little higher than the max. value of IC VCC pin at normal output
conditions, so this regulator is added here. Resistor R7 is added to give a preliminary
voltage on Pin1 to start up the IC. The value of Resistor R7, R9, R12 should be calculated
to insure the voltage on Pin2 can be high to 6V and low to 0V, when the voltage on R11 is
changing.
The practical value of R14, C9 on Multi pin of IC L6562A and the current sensing
resistor R19A,B,C,D, are using to maximize the PF value, minimize the THD and
harmonic current.
At secondary side:
Transformer secondary winding is split to two equal parts, the VCC of TSM1014 is
regulated from the half point of the secondary winding, to drop to VCC value to the
permitted range of this CC/CV controller. The capacitance of filter C-cap on Vref pin
should not carefully select to avoid any oscillation of the reference voltage, the
recommended value in this board is 10nF.
All the caps value are tried to minimized and replace by ceramic type, thanks to Murata
for their advantage cap’s technical.
And also for the transformer, thanks to TDK for low core loss materials.
Figure 1: Schematic
Table 1: Bill of Materials-1
Des. Part Type/Part Value Description Supplier
CASE STYLE
/PACKAGE
C1 100nF X2 - SAFETY CAP. 6X18mm P=15mm
C2 100nF X2 - SAFETY CAP. 6X18mm P=15mm
C3 1.0uF 450V - MATEL FILM CAPACITOR 6X16mm P=15mm
C4 1.0uF 450V - MATEL FILM CAPACITOR 6X16mm P=15mm
C5 4.7nF 630V CERCAP - GRM31BR72J472KW01L MURATA 1206
C6 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C7 47uF 16V CERCAP - GRM32ER61C476KE15L MURATA 1210
C8 1uF 16V CERCAP - GRM39X5R105K16D52K MURATA 0603
C9 1nF 16V CERCAP - GERNERAL PURPOSE MURATA 0603
C10 N68 16V CERCAP - NPO MURATA 0603
C11 N39 16V CERCAP - NPO MURATA 0603
C12 N33 25V CERCAP - GERNERAL PURPOSE MURATA 0603
C13 2.2nF 630V CERCAP - GRM31BR72J222KW01L MURATA 1206
C14 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C15 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C16 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C17 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C18 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C19 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C20 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C21 100nF 16V CERCAP - GERNERAL PURPOSE MURATA 0603
C22 2.2uF 50V CERCAP - GRM31CR71H225KA12L MURATA 1206
C23 0.47uF 50V CERCAP - GERNERAL PURPOSE MURATA 0805
C24 0.47uF 50V CERCAP - GERNERAL PURPOSE MURATA 0805
C25 10nF 50V CERCAP - GERNERAL PURPOSE MURATA 0603
C26 10nF 50V CERCAP - GERNERAL PURPOSE MURATA 0603
C27 4.7uF 50V CERCAP - GRM31CR71H475KA12L MURATA 1206
C28
C29
C30
CN1 AC INLET 2PINAC GERNERAL PROPOSE WITH SAFETY PTH
CN2 INLET 2PINAC GERNERAL PROPOSE WITH SAFETY PTH
CY1 2N2 Y1 - SAEFETY CAP. DE1E3KX222M MURATA PTH
DB1 D4KB60 4A/600V GERNERAL PURPOSE BRIDGE RECTIFIER
D1 STTH1L06A 1A/600V ULTRAFAST HIGH VOLTAGE RECTIFIER ST SMA
D2 STTH1L06A 1A/600V ULTRAFAST HIGH VOLTAGE RECTIFIER ST SMA
D3 LL4148 FAST SWITCHING DIODE MINIMELF SOD-80
D4 LL4148 FAST SWITCHING DIODE MINIMELF SOD-80
D5 STTH2003CFP 20A/300V HIGHT FREQUENCY SECONDARY RECTIFIERST TO-220FPAB
D6 STTH1L06A 1A/600V ULTRAFAST HIGH VOLTAGE RECTIFIER ST SMA
F1 FUSE - 3.15A FUSE T3.15A/250V - TIME DELAY PTH
L1 CHOKE-L 15uH T6.3, OD15.5, ID8.5 1.0MM WIRE PTH
L2 Jump Jump wire: D=1.0mm PTH
LF1 COM-CHOKE 2mH T7.2, OD14, ID7 0.6MM WIRE T14-7-7
LF2 COM-CHOKE 14mH T8.6, OD16, ID9 0.6MM WIRE T16-9-9
Table 2: Bill of Materials-2
Des. Part Type/Part Value Description Supplier
CASE STYLE
/PACKAGE
J1-2 Jump Jump wire: D=0.8mm PTH
J3 Jump Jump wire: D=0.6mm PTH
J4 0Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
OPTO1 PC817A OPTOCOUPLER SHARP DIP-4 - 10.16MM
Q1 STF11NM65N 12A/650V 0.33Ω N-CHANNEL SECOND GENERATION MDMESH POWER MOSFETST TO-220FP
Q2 MMBT3904 NPN SMALL SIGNAL BJT MMBT3904LT1 SOT23
R1 1MΩ SMD STANDARD FILM RES - 1/4W - 1% - 100ppm/°C 1206
R2 330KΩ SMD STANDARD FILM RES - 1/4W - 1% - 100ppm/°C 1206
R3 330KΩ SMD STANDARD FILM RES - 1/4W - 1% - 100ppm/°C 1206
R4 330KΩ AXIAL STAND. M-FILM RES. - 0.166W - 1% PTH
R4A 47KΩ SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R4B 47KΩ SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R4C 47KΩ SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R4D 47KΩ SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R5 4.7Ω SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0805
R6 2.2KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0805
R7 680KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R8 10KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R9 100KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R10 1MΩ SMD STANDARD FILM RES - 1/4W - 1% - 100ppm/°C 1206
R11 1.0KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R12 39KΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R13
R14 10KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R15 7.5KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R16 3.9KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R17 4.7Ω SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0805
R18 20ΚΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R19 1ΚΩ AXIAL STAND. M-FILM RES. - 0.166W - 5% PTH
R19A 0.18Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R19B 0.18Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R19C 0.18Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R19D 0.18Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R20 24Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R21 24Ω SMD STANDARD FILM RES - 1/4W - 5% - 250ppm/°C 1206
R24 10Ω SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0805
R25 1.5KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0805
R26
R27 1ΚΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R28 4.7ΚΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R29 1ΚΩ SMD STANDARD FILM RES - 0.1W - 5% - 250ppm/°C 0603
R30 100KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R31 2.2KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R32 27KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
R33 1KΩ SMD STANDARD FILM RES - 0.1W - 1% - 100ppm/°C 0603
RS1 5mΩ Resistor wire D=1.0mm PTH
Table 3: Bill of Materials-3
Des. Part Type/Part Value Description Supplier
CASE STYLE
/PACKAGE
T1 TRANSFORMER PQ3220-PC47/PC95 TDK DWG
U1 L6562A TRANSITION-MODE PFC CONTROLLER ST SO-8
U2 TSM1014 LOW CONSUMPTION VOLTAGE AND CURRENT CONTROLLERST SO-8
ZD1 15V/0.5W ZENER DIODE MINIMELF SOD-80
ZD2 22V/0.5W ZENER DIODE MINIMELF SOD-80
ZD3
Electrical Testing Results:
Efficiency
The unit’s efficiency is tested at different input voltage and different output loading on
CV mode. Because the output voltage and current are combined with a large AC
component, the output power is no longer able to simply calculate by the average or RMS
value of Voltage and Current time each other. Below results are basing on the electrical
loading constant voltage mode (CV), to simplify the testing structure, if compare to the
actual characteristics using LEDs, the waveforms and performances are very similar.
Table 4:
Testing conditions: CV loading 33V
Vin Iin (mA) Pin (W) PF Vo (V)_rms Po (W) Eff. (%)
90Vac/60Hz 1028.1 91.56 0.99 33.24 74.36 81.21
100Vac/60Hz 949.4 93.84 0.99 33.26 78.09 83.22
115Vac/60Hz 856.0 96.50 0.98 33.27 81.68 84.64
120Vac/60Hz 813.9 96.00 0.98 33.27 81.92 85.33
220Vac/50Hz 503.6 103.32 0.92 33.30 90.94 88.02
230Vac/50Hz 485.8 103.15 0.92 33.30 91.00 88.22
240Vac/50Hz 467.7 102.51 0.91 33.30 90.24 88.03
264Vac/50Hz 439.4 102.91 0.88 33.30 90.25 87.70
Testing conditions: CV loading 30V
Vin Iin (mA) Pin (W) PF Vo (V)_rms Po (W) Eff. (%)
90Vac/60Hz 1086.6 96.92 0.99 30.28 78.69 81.19
100Vac/60Hz 1124.8 111.38 0.99 30.33 92.05 82.64
115Vac/60Hz 965.1 109.40 0.98 30.33 92.73 84.76
120Vac/60Hz 923.3 109.11 0.99 30.33 92.79 85.04
220Vac/50Hz 488.6 100.16 0.92 30.32 87.73 87.59
230Vac/50Hz 471.5 99.91 0.92 30.32 87.48 87.56
240Vac/50Hz 456.0 99.63 0.91 30.32 87.30 87.62
264Vac/50Hz 426.5 99.34 0.88 30.32 86.92 87.50
Table 5:
Testing conditions: CV loading 27V
Vin Iin (mA) Pin (W) PF Vo (V)_rms Po (W) Eff. (%)
90Vac/60Hz 1064.6 94.83 0.99 27.31 77.49 81.71
100Vac/60Hz 947.6 93.63 0.99 27.31 78.30 83.63
115Vac/60Hz 826.2 93.49 0.98 27.31 79.58 85.12
120Vac/60Hz 793.3 93.51 0.98 27.32 79.84 85.38
220Vac/50Hz 445.0 89.59 0.92 27.31 78.22 87.31
230Vac/50Hz 430.0 89.40 0.90 27.31 77.94 87.18
240Vac/50Hz 417.3 89.39 0.89 27.31 78.04 87.30
264Vac/50Hz 392.8 89.31 0.86 27.31 77.91 87.24
No load input power
Vin Pin (mW) Vo (V)
90Vac/60Hz 708 34.94
100Vac/60Hz 872 34.94
115Vac/60Hz 917 34.94
230Vac/50Hz 771 34.96
240Vac/50Hz 781 34.96
264Vac/50Hz 846 34.96
Harmonic Current
This unit is also designed to follow the requirement per. EN6100-3-2 class C (lighting).
Table 6:
Pin: 95.7 W Iin: 0.844 A
Pin: 100.24 W Iin: 0.4743 A
PF: 0.987
PF: 0.908
Maximum permissible harmonic current expressed as a percentage of the input current at the fundamental frequencyMaximum permissible harmonic current expressed as a percentage of the input current at the fundamental frequencyMaximum permissible harmonic current expressed as a percentage of the input current at the fundamental frequencyMaximum permissible harmonic current expressed as a percentage of the input current at the fundamental frequencyPass/FailPass/FailPass/FailPass/Fail
115Vac/60Hz115Vac/60Hz115Vac/60Hz115Vac/60Hz 230Vac/50Hz230Vac/50Hz230Vac/50Hz230Vac/50Hz 115Vac/60Hz115Vac/60Hz115Vac/60Hz115Vac/60Hz 230Vac/50H230Vac/50H230Vac/50H230Vac/50Hzzzz
2222 2222 0.030.030.030.03 0.070.070.070.07
29.6129.6129.6129.61 27.2427.2427.2427.24 8.738.738.738.73 17.3217.3217.3217.32 (=30*PF)
10101010 10101010 0.790.790.790.79 5.395.395.395.39
7777 7777 0.200.200.200.20 3.373.373.373.37
5555 5555 0.420.420.420.42 2.822.822.822.82
3333 3333
3333 3333 0.630.630.630.63 2.352.352.352.35
3333 3333 0.600.600.600.60 2.222.222.222.22
3333 3333 0.480.480.480.48 2.072.072.072.07
3333 3333 0.340.340.340.34 1.821.821.821.82
3333 3333 0.330.330.330.33 1.581.581.581.58
3333 3333 0.260.260.260.26 1.531.531.531.53
3333 3333 0.310.310.310.31 1.411.411.411.41
3333 3333 0.450.450.450.45 1.271.271.271.27
3333 3333 0.510.510.510.51 1.141.141.141.14
3333 3333 0.340.340.340.34 0.960.960.960.96
3333 3333 0.220.220.220.22 0.860.860.860.86
3333 3333 0.040.040.040.04 0.820.820.820.82
3333 3333 0.160.160.160.16 0.860.860.860.86
3333 3333 0.300.300.300.30 0.800.800.800.80
3333 3333 0.350.350.350.35 0.720.720.720.72
PassPassPassPass
Set CV loading = 30VSet CV loading = 30VSet CV loading = 30VSet CV loading = 30V
Limits for class C equipment (light >25W)Limits for class C equipment (light >25W)Limits for class C equipment (light >25W)Limits for class C equipment (light >25W)
Testing ResultTesting ResultTesting ResultTesting Result
%%%% %%%%
2222
3333
5555
7777
9999
11111111<<<< n n n n <<<< 39 39 39 39
11111111
13131313
25252525
27272727
29292929
15151515
17171717
19191919
21212121
39393939
ResultResultResultResult
Harmonic orderHarmonic orderHarmonic orderHarmonic order
Vin=115Vac/60Hz
Vin=230Vac/50Hz
31313131
33333333
35353535
37373737
23232323
Waveforms and Protection
Normal operating waveforms:
In below section, will try to add some waveform to show the unit’s performance when it
works in steady states.
Vin=115Vac/60Hz, Loading CV=33V Vin=230Vac/50Hz Loading CV=33V
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Above record the waveforms at primary side at nominal conditions. Figure 4,5 record the
extension waveform of figure 2,3 when input voltage at the top of the sine waveform. And
figure 6,7 record the extension waveform of figure 2,3 when input voltage at the bottom of
the sine waveform.
From these waveforms we can find: the unit works in the mode of “fix-off-time”, means
the turn off time of the MOSFET does not change when the input is waving. And the
switching frequency doesn’t change so much when the input voltage change from low to
high.
The waveform in figure 2 and 3, look like some click, but it causes by the display of the
oscilloscope and the actual waveform is smooth.
Vin=115Vac/60Hz, Loading CV=33V Vin=230Vac/50Hz Loading CV=33V
Figure 8
Figure 9
Figure 10
Figure 11
From above, shows the waveforms of output current and output voltage.
Because small value of ceramic capacitors (total is 8*4.7uF for 90W output) is used at the
secondary output section, we can find large low frequency and high frequency ripple
voltage and ripple current. It’s possible to decrease these ripple by increasing the
capacitance of caps if you like. The high frequency can be very small (like peak to peak
smaller than 1% of nominal (average value) output voltage), but for the line frequency
ripple, same as the words at the beginning of this document, it’s almost impossible to do a
large improvement.
Starting-up waveforms:
In below, will show the waveforms at the unit’s starting-up stage.
Vin=90Vac/60Hz, Loading CV=33V Vin=264Vac/50Hz Loading CV=33V
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 12,13 are long time starting-up stage waveforms, Ch1 is Vds voltage waveform
of primary switching power MOSFET, Ch2 is output voltage. Figure 14,15 are the Vds
voltage waveform of the same FET which trigger at the instantaneous starting switch
second. Figure 16, 17 are the waveforms at normal operating condition.
From these waveforms, we can find the switching power MOSFET has enough margin
of voltage stress at starting-up stage. Actually the voltage stress at starting-up stage is
smaller than the value at normal operating condition.
Protection:
The unit has implemented output short circuit protection. And output over voltage
protect by primary sensing from aux winding.
For short circuit protection, the transformer is been specially handled. The primary aux.
winding for Vcc supply is been put between secondary windings. This structure is used to
minimize the effect of the leakage inductance of the aux. winding.
Vin=90Vac/60Hz, Loading CV=33V before short Vin=264Vac/50Hz Loading CV=33V before short
Figure 18
Figure 19
References:
[1]. AN1895 APPLICATION NOTE EVAL6562-375W, 375W FOT-CONTROLLED
PFC, STMicroelectronics
[2]. AN1792 APPLICATION NOTE DESIGN OF FIXED-OFF-TIME-CONTROLLED
PFC PRE-REGULATORS WITH THE L6562, BY CLAUDIO ADRAGNA
[3]. AN1059 APPLICATION NOTES DESIGN EQUATIONS OF HIGH-POWER-
FACTOR FLYBACK CONVERTERS BASED ON THE L6561, BY CLAUDIO
ADRAGNA
Appendix 1:
Transformer Specification
1. SCHEMATIC 2. WINDING
3. WINDING TABLE
Wire Tape
Layer Pin Diameter Type
Turns Margin Tape
Tape
Layer
Winding
Method Remark
N1 1—2 ∮0.65*1 2UEW 22Ts / 9mm*1Ts
One layer one
wire, insulate
between layers
Total 2 layers,
11T for each
layer
N2 7—9 ∮0.7*1 TRW(B) 8Ts / 9mm*1Ts One layer one
wire
N3 6—4 ∮0.15*1 2UEW 13Ts / 9mm*1Ts One layer one
wire
Equally
rounding
N4 10—8 ∮0.7*1 TRW(B) 8Ts / 9mm*1Ts One layer one
wire
N5 2—3 ∮0.65*1 2UEW 22Ts / 9mm*1Ts One layer one
wire
Total 2 layers,
11T for each
layer
WINDING PIN TURNS INDUCTANECE TOLERANCE DCR
mΩMAX
Q
MIN
LP 1�3 44Ts 400 u H ±10% 100 50
NOTE
1. TEST CONDITION : 50KHz 0.1V
2. Pull out PIN 5, Cut short PINCut short PINCut short PINCut short PIN2222 to let it’s height does not exceed the BOBBIN to let it’s height does not exceed the BOBBIN to let it’s height does not exceed the BOBBIN to let it’s height does not exceed the BOBBIN。。。。
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