UM0673

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UM0673 - UM0673

UM0673 User manual
STEVAL-ISF001V1, board based L6563
power board STEVAL-ISF001V1 designed industrial domestic applications. board must used demonstration purposes order evaluate potential (fixed-off-time control, patented implement high-power with performance comparable standard continuous-mode PFC, using simpler controller chip originally designed (transition-mode) operating conditions. This demonstration board works directly from mains supply single range voltage (185 Vrms Vrms) provides stable regulated output capable maximum voltage necessary supply driver generated auxiliary winding main inductor, external power supply needed start operation board. design
quick install re-usable (the Gerber files available free) ready downsizing required.
Note: Figure
Please read Section this manual before attempting operation. Line, inductor, switch diode current FF-CCM Figure Line, inductor, switch diode current
AM01972v1
AM01980v1
September 2009
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www.st.com
Contents
UM0673
Contents
Board description Safety operating instructions
General
2.1.1 Power board intended
Power board installation
2.2.1 2.2.2 Electronic connection demonstration board setup
Hardware layout Environmental considerations
board connection
STEVAL-ISF001V1 description STEVAL-ISF001V1 circuit description
schematics Experimental measurements Revision history
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List figures
List figures
Figure Figure Figure Figure Figure Figure Figure Figure Figure Line, inductor, switch diode current FF-CCM PFC. Line, inductor, switch diode current STEVAL-ISF001V1 demonstration board Power board STEVAL-ISF001V1 (top view) Schematic STEVAL-ISF001V1 board Common-mode inductor (MAGNETICA 1745.0005) technical sheet. Common-mode inductor (MAGNETICA 1951.0001) technical sheet. Common-mode inductor (MAGNETICA 1929.0001) technical sheet. Boost inductor with auxiliary winding, (MAGNETICA 1922.0001) technical sheet
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Board description
UM0673
Board description
STEVAL-ISF001V1 used several kinds applications:
Inverter motor control conditioning system Welding machine power supply section.
This demonstration board offers customization options well, making excellent choice original platform more complete dedicated system. Special care been taken during layout process provide very level interference. Considering power delivered level current present board, advise major modification layout customization system order avoid noise that could cause board malfunction. board includes:
input stage composed power rectifier bridge input filter stage necessary comply with emission levels control stage composed L6563 power stage composed Power MOSFET power ultra-fast diodes power inductor designed manufactured specifically this application output filter stage composed electrolytic capacitor sized have ripple required specification. STEVAL-ISF001V1 demonstration board
Figure
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Safety operating instructions
Safety operating instructions
General
During assembly operation board poses several inherent hazards including bare wires surfaces. board components improperly used installed incorrectly, there danger serious personal injury damage property. operations involving transportation, installation use, well maintenance carried skilled technical personnel (national accident prevention rules must observed). purposes these basic safety instructions, "skilled technical personnel" suitably qualified people familiar with installation, use, maintenance power electronic systems.
Warning:
Many sources serious hazard present this board. board works directly from mains, galvanically isolated, provides output high-voltage levels that cause serious electrical shock, serious burns death. surfaces that cause burns present board.
This board must used only power laboratory only engineers technicians experienced power electronics technology under protection. STMicroelectronics responsible damages property personal injury.
2.1.1
Power board intended
power board designed demonstration purposes only shall used electrical installation machinery. technical data well information concerning supply conditions shall taken from documentation strictly observed.
Power board installation
installation cooling shall accordance with specifications targeted application (see Section 2.2.2).
Excessive strain board shall avoided. particular, components bent isolating distances altered during course transportation handling. contact shall made with electronic components contacts. boards contain electrostatically-sensitive components that prone damage through improper use. Electrical components must mechanically damaged destroyed avoid potential health risks).
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Safety operating instructions
UM0673
2.2.1
Electronic connection
National accident prevention rules must followed when working main power supply, with power supply, powering board general. electrical installation shall completed accordance with appropriate requirements (e.g., cross-sectional areas conductors, fusing, connections. further information, Section 2.2.2).
2.2.2
demonstration board setup
preferable supply isolated protected against overload short-circuit during evaluation test power board compliance with technical equipment accident prevention rules). proper load, able dissipate case absorb reuse power delivered system, used. case resistive dissipative dummy load, user must attention temperature that load could reach provide necessary equipment avoid surfaces fire hazards during tests (fan, water-cooled load, etc).
Caution:
touch boards components after disconnection from voltage supply, several parts power terminals which contain possibly energized capacitors need allowed discharge.
Hardware layout
Figure Power board STEVAL-ISF001V1 (top view)
mains input connector present right side board. Connect sinusoidal supply voltage with amplitude range Vrms Vrms. power source able supply power required system, according output load user intends connect output port.
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Safety operating instructions output connector present left side (close output electrolytic capacitors). Please note that output voltage regulated system target value (consider tolerance value passive components board), which gives value resistive load between minimum power delivered) maximum power delivered).
Warning:
STEVAL-ISF001V1 insulation shield other type protection.
Caution:
demonstration board must handled very carefully, high-potential (energy) parts open touched. user MUST avoid connecting removing cables during operation board touching part system when connected main power supply. After turning power supply off, load disconnected, DC-link capacitor still hold voltage. preferable test ambient temperature higher than degrees Celsius.
Note: Note:
Environmental considerations
STEVAL-ISF001V1 must only used power laboratory. high voltage involved system presents serious shock hazard. board used measure capture waveforms other interaction between board laboratory equipment, AC-isolated power supply used.
Note:
measurement equipment must isolated from main power supply before powering PFC. oscilloscope with kit, safer isolate supply oscilloscope isolated differential probes. This prevents shock from occurring result touching SINGLE point circuit does prevent shocks when touching MORE points circuit. isolated power supply constructed using isolation transformer variable transformer.
Note:
Isolating application rather than oscilloscope highly recommended case.
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board connection
UM0673
board connection
board manufactured ready use. Using jumper supply driver L6563 connected directly supply generated auxiliary winding present boost inductor isolated low-voltage external supply. This option used debug test inductor equipped with auxiliary winding. jumper position standard auxiliary power supply already present board. external supply used, position connect supply capable least (+15 pin1, ground pin2). Connect board power supply. suitable cable, terms insulation cross-section, able conduct current from supply according load connected output port. Connect output port load.
Note:
Even system able start maintain output voltage regulated target value, also under open-load condition, technical specification terms cannot guaranteed. systems accept minimum power load work properly. Supply board with sinusoidal supply voltage with amplitude range Vrms Vrms. power source able supply power required system, according output load user intends connect output port.
Caution:
supply system with voltage value higher than Vrms, risk serious damage board property present this case. supply system with voltage below minimum allowed, Vrms, systems cannot start operate properly this condition. voltage supply maximum output load present worst operating conditions system sufficient cooling mandatory.
Note:
STEVAL-ISF001V1 description
demonstration board STEVAL-ISF001V1 developed STMicroelectronics provides compact, ready-to-use solution implementation simple system able supply load with power close maximum delivered most typical domestic installations. such range power continuous-mode operation becomes mandatory drain from mains current with value which does exceed maximum allowed from metering system have reasonable size devices involved system's operations. standard continuous-mode driver chip necessitates using more expensive complex driver with required passive components. STMicroelectronics patented solution that allows using simple driver, designed transition-mode operation, fixed-off-time, variable frequency, modulation. This kind modulation gives current boost inductor that comparable with current typical continuous-mode modulation. Modulating fixing TOFF signal applied main switch, possible maintain continuous current inductor around sinusoidal envelope.
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board connection consequence maintaining constant TOFF varying TON, overall period modulated which gives variable frequency control. Using variable frequency control advantages terms noise input filter size. fact, noise energy spread over frequency range with lower energy content each frequency. further technical information correct sizing calculation device board, please consult STMicroelectronics' AN1792 "Design fixed-off-time-controlled pre-regulators with L6562". features STEVALISF001V1 include:
power systems based L6563 Power stage based MDmeshII Power MOSFET Vrms <265 Vrms Vout regulated (±5%) Iout Driver with inductor saturation detection Optimized input filter.
STEVAL-ISF001V1 circuit description
Figure shows entire electronic schematic. Starting from input section, common-mode filter fitted order compliant with regulations concerning industrial domestic applications. (EN55014 EN55022). alternative voltage from mains then rectified input low-frequency bridge that provides rectified sinusoidal waveform (with frequency that doubled with respect input main waveform) next boost stage. capacitor been calculated have residual ripple, around sinusoidal envelope maximum load minimum input voltage, peak value. main boost inductor, designed produced MAGNETICA (Italy), ferrite inductor core designed minimize hysteresis losses. technical sheet with complete order code given Figure inductor secondary-side winding that provides low-voltage auxiliary supply driver L6563. startup current voltage main inductor still zero, voltage generated secondary auxiliary winding. this condition, only during startup, resistors R13, each, with Zener diode (fitted limitation purposes) charge capacitor supply driver that starts operation. soon signal starts switch, voltage present across auxiliary winding, supply voltage across capacitor maintained. boost diodes paralleled conduct peak inductor current period. maximum power minimum input voltage peak current reach Diode resistor used limit inrush current, electrolytic capacitor output, during startup small decrease mains.
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board connection
UM0673
chosen switching devices Power MOSFETs, MDmeshII family, STW55NM60N. These Power MOSFETs placed parallel assure RDS(on), limiting conduction power losses. Good efficiency good thermal behavior system reached. order properly drive Power MOSFETs minimize switching losses, during transient, small push-pull driver interposed between driver gates. reading current conducted Power MOSFETs, equal current main inductor during period, necessary driver right current level inductor according input instantaneous voltage output power delivered load. This current sensed sensing resistor paralleling 0,07 non-inductive sensing resistors. output voltage sensed driver through resistive composed R12, R16, R17, R24. described L6563 datasheet, pre-regulator output voltage monitoring/disable function exists. This senses output voltage preregulator through resistor divider used protection purposes. voltage exceeds shut down, consumption goes almost startup level this condition latched. PWM_LATCH asserted high. Normal operation resumed only cycling Vcc. This function used protection case feedback loop fails. net, ZCD, used desired TOFF time according sizing calculation application (for complete design rules, please refer "Design fixed-offtime-controlled pre-regulators with L6562"). small signal used implement TOFF modulation according input voltage. moment voltage input waveform (near zero-crossing input sinusoidal supply) order minimize distortion input current input voltage, TOFF period needs reduced. Acting this way, ratio between TOFF increased distortion input current reduced.
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schematics
Table
Item
schematics
Bill material
Reference C2,C4 C6,C8 D3,D17 D5,D7,D8,D9 Q1,Q2 Part 0.22 300Vac 300Vac diode bridge 1N5406 STTH12S06 (TO-220) Zener 1N4148 Zener Fuse 220AC three-way connector OUT/400 two-way connector 20vDC supply stripline Jumper stripline STS01DTP06 (SMD) L6563 (SMD) External signal stripline MAGNETICA 1745.0005 STW55NM60N (heatsink PADA 8355)
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schematics Table
Item
UM0673
Bill material (continued)
Reference R3,R4 R7,R13,R26 R9,R10,R11 R12,R16,R17 R19,R21 R20,R22 R24,R29 R30,R31 R33,R34
Part BC557 (ex. SIEMENS S464) 0.07 Lob5 non-inductive MAGNETICA 1922.0001 MAGNETICA 1389.0008 MAGNETICA 1929.0001 31µH Metal oxide varistor 0.68 (SMD)
have mounted from surface
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UM0673 Figure Schematic STEVAL-ISF001V1 board
schematics
AM01975v1
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Experimental measurements
UM0673
Experimental measurements
Table below shows performance board during testing. Table preliminary electrical measurements
Vout Iout Pout Low-power range Efficiency Vout Iout Pout Medium-power range Efficiency Vout Iout Pout High-power range Efficiency Vout Iout Pout Full load Efficiency 2640 96.9% 0.988 2650 96.5% 0.997 2640 0.998 1558 96.7% 0.995 2559 1550 97.2 0.995 2558 1546 97.5 0.985 2562 96.5 0.989 1506 0.985 1506 97.3% 0.975 1507 0.971 1.49 96.5% 0.964 1.49 96.2% 0.95 1.49 0.75 0.75 0.75
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Experimental measurements Common-mode inductor (MAGNETICA 1745.0005) technical sheet
Product Technical Specification Code: 1745.0005
Product: Common Mode Inductor 2x2mH
Customer: STMicroelectronics
Customer Code:
TYPICAL APPLICATION
TECHNICAL DATA
270VAC 60HZ 1500V -10° ÷+45° 29X26 H46mm 100g CIRCA
DIFFERENTIAL MODE
DISTURB SUPPRESSION AC/DC POWER LINE INDUCTANCE (1-4=2-3) 270V MAX. (MEASURE 1KHZ,
SCHEMATIC
RESISTANCE (1-4=2-3)
(MEASURE D.C,
LEAKAGE INDUCTANCE
(MEASURE
S.C, 10KHZ,
OPERATING VOLTAGE
50-60HZ, MAX,
OPERATING CURRENT
(MEASURE
OPERATING FREQUENCY
(CURRENT MAX,
INSULATION (1-4 2-3)
50HZ, TEST DURATION
OPERATING TEMPERATURE RANGE
MAX)
MAXIMUM DIMENSIONS
WEIGHT
SETUP MEASURE
ATTENUATION
COMMON MODE
COMMON MODE
0.1uF
DIFFERENTIAL MODE
0.1uF
MAGNETICA
AM01976v1
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Experimental measurements Figure
UM0673
Common-mode inductor (MAGNETICA 1951.0001) technical sheet
Product Technical Specification Code: 1951.0001
Product: Common Mode Inductor 2x220uH/18A
Customer: Microelectronics
TYPICAL APPLICATION TECHNICAL DATA
Customer Code:
SUPPRESSION AC/DC POWER LINE 270V INDUCTANCE (1-4=2-3) MAX. (MEASURE 1KHZ,
SCHEMATIC
RESISTANCE (1-4=2-3)
200uH 8.9m 1.2% 270VAC 60HZ 1500V -10° ÷+45° 30X34 H32MM APPROX
COMMON MODE DIFFERENTIAL MODE
(MEASURE D.C,
LEAKAGE INDUCTANCE
(MEASURE 1-4; S.C, 10KHZ,
OPERATING VOLTAGE 50-60HZ, MAX, OPERATING CURRENT
(MEASURE
OPERATING FREQUENCY
(CURRENT MAX,
INSULATION (1-4 2-3)
50HZ, DURATION TEST
OPERATING AMBIENT TEMPERATURE
MAX)
MAXIMUM DIMENSIONS WEIGHT
SETUP MEASURE
INSERTION LOSS
COMMON MODE
0.1uF
DIFFERENTIAL MODE
0.1uF
MAGNETICA
AM01977v1
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UM0673 Figure
Experimental measurements Common-mode inductor (MAGNETICA 1929.0001) technical sheet
Product Technical Specification Code: 1929.0001
Product: Common Mode Inductor 2x30uH/8A
Customer: STMicroelectronics
Customer Code:
TYPICAL APPLICATION
TECHNICAL DATA
30uH 7.36m 400DC 60HZ 1500V -10° ÷+45° 40X21 H40MM APPROX
DIFFERENTIAL MODE
DISTURB SUPPRESSION AC/DC POWER LINE INDUCTANCE (1-4=2-3) 400V MAX. (MEASURE 1KHZ,
SCHEMATIC
RESISTANCE (1-4=2-3)
(MEASURE D.C,
LEAKAGE INDUCTANCE
(MEASURE S.C, 10KHZ, OPERATING VOLTAGE 50-60HZ, MAX,
OPERATING CURRENT
(MEASURE
OPERATING FREQUENCY
(CURRENT MAX,
INSULATION (1-4 2-3)
50HZ, TEST DURATION
OPERATING TEMPERATURE RANGE
MAX)
MAXIMUM DIMENSIONS
WEIGHT
SETUP MEASURE
ATTENUATION
COMMON MODE
COMMON MODE
0.1uF
DIFFERENTIAL MODE
0.1uF
MAGNETICA
AM01978v1
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Experimental measurements Figure
UM0673
Boost inductor with auxiliary winding, (MAGNETICA 1922.0001) technical sheet
Product Technical Specification Code 1922.0001
Product: Inductor 1.5mH
Customer: STMicroelectronics
Customer Code:
TYPICAL APPLICATION
TECHNICAL DATA
INDUCTOR BUCK, BOOST BUCK-BOOST DC/DC INDUCTANCE CONVERTER, SUITABLE ALSO HALF-BRIDGE, PUSH(MEASURE 1KHZ, PULL FULL-BRIDGE APPLICATIONS 1,2,3-4,5,6
SCHEMATIC
1.5mH ±15% 18uH ±15%
RESISTANCE
MEASURE,
1,2,3-4,5,6
100m 185m 500V 250KHZ -10° ÷+45° 75X80 H62mm 820g APPROX
1-2-3
OPERATING CURRENT
MEASURE
OPERATING VOLTAGE
70KHZ,
SATURATION CURRENT MEASURE, 35%NOM, RESONANCE FREQUENCY
4-5-6
OPERATING AMBIENT TEMPERATURE
MAX)
MAXIMUM DIMENSIONS WEIGHT
INDUCTANCE CURRENT
INDUCTANCE FREQUENCY
L/L(1kHz)
100%
800% 600% 400% 200%
[kHz]
FUNCTION
BOBBIN START BOBBIN START BOBBIN START BOBBIN
DESCRIPTION
FUNCTION
BOBBIN BOBBIN AUXILIARY BOBBIN START AUXILIARY BOBBIN
(*)PIN WITH SAME SUBSCRIPT MUST CONNECTED TOGETHER
MAGNETICA
AM01979v1
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Revision history
Revision history
Table
Date 24-Sep-2009
Document revision history
Revision Initial release. Changes
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