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L6562A做隔离90W 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 hou...

L6562A做隔离90W
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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