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The L6561, controller specifically designed for Power Factor Correction (PFC) circuits, may be successfully used in flyback converters as well. The excellent performance of the device, along with its characteristics in terms of low current consumption, makes L6561-based flyback converters really attractive in medium-low power applications. There are basically three different configurations that an L6561-based flyback converter can assume, each of them with its own characteristics, benefits and peculiarities. This paper describes these configurations and highlights advantages/drawbacks with the aim of identifying the most suitable applications they can fit.
INTRODUCTION Common practice bounds their use in conventional boost PFC stages, yet Transition Mode (TM) Power Factor Corrector ICs can be used in applications different from those they are primarily intended for. This is particularly true for the L6561, PFC controller for medium-low power applications, because of its peculiar characteristics. Reference [2] presents a special example showing how to extend the use of this device to Mag Amp applications. Figure 1 - L6561 Internal Block Diagram
COMP 2 INV 1 2.5V + MULT 3 4 40K CS
MULTIPLIER
VOLTAGE REGULATOR
OVER-VOLTAGE DETECTION
5pF
VCC
VCC INTERNAL SUPPLY 7V R1 + R2 VREF2 2.1V 1.6V + ZERO CURRENT DETECTOR STARTER UVLO R Q S DRIVER 7
20V
GD
The outperforming L6561 offers a number of unique advantages that make the device an interesting alternative to the traditionally used PWM controllers where quite a good performance is required at low cost:
June 2001
1/11
Vout
DISABLE
DISABLE
ZCD
VCC
ZCD
VCC
L6561
GD OPTO + TL431
L6561
GD OPTO + TL431
a) TM Flyback
b) Synchronised Flyback
Vout Vac CIN
DISABLE
L6561
COMP INV GD OPTO + TL431 (BW <100 Hz)
c) High-PF Flyback
Each of them has its own peculiarities but they all share some key points: low parts count, which helps reduce total cost and space; high efficiency at very light load: an L6561-based flyback can be easily compliant with Blue Angel standards; standby function: the internal start-up timer may be used to make the system work at a (fixed) low frequency under light load conditions, so as to minimise losses; disable function: pin ZCD, if grounded, turns off the L6561 and reduces its consumption at a couple of mA; this can be used either for power management or protection.
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L4955V5.1
2 100 F
22 1N4148 47 F N3 47 k
4.7 nF
33 k
2 1
L6561
6 4
5 7
22 STD1NB60
7.5 k 2
TRANSFORMER SPECS: CORE: E20x10x6, 3C85 material or equivalent 0.5 mm air gap for a primary inductance of 1.7 mH N1: 2 series windings 66 T each, AWG32 ( 0.24 mm) N2: 11 T, AWG24 ( 0.57 mm) N3: 21 T, AWG32
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5 Vdc / 3A
L4955V5.1
2 220 F
22 1N4148 47 F N3 47 k
4.7 nF
33 k
2 1
L6561
6 4
5 7
22 STP3NB60FP
7.5 k 1
TRANSFORMER SPECS: CORE: E20x10x6, 3C85 material or equivalent 0.5 mm air gap for a primary inductance of 0.8 mH N1: 2 series windings 48 T each, AWG30 ( 0.30 mm) N2: 8 T, 2xAWG22 ( 0.71 mm) N3: 15 T, AWG32 ( 0.24 mm)
Fig. 5 shows another example of low-power TM flyback application, an AC-DC adapter for battery charger of cellular phones. The system looks very simple and very few parts are required. The feedback uses a popular arrangement making use of a TL431 as secondary reference/error amplifier and of an optocoupler for transferring the control signal to the primary side. This provides very good regulation of the output voltage and galvanic isolation from the primary side at the same time. The self-supply winding both powers the L6561and provides transformers demagnetisation signal to the ZCD pin. The start-up circuit arrangement and its component values ensures that the wake-up time of the converter does not exceed 3 s at 90 VAC supply (it will be less than 1 s at 270 VAC). In fig. 6 an example of multi-output SMPS for inkjet printer is presented. The converter accepts input voltages from 85 to 270 Vac and is rated for 40W output power. The 28V output is used for motors, the 12V output for the printhead and the 5V bus supplies the logic circuitry.
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2A fuse
4x1N4007 85 to 270 Vac 10 F 400V BZW04-154
110 k
N1 STTA106
47 k
N2
GND
1N4148 33F N3
1 k
8
10
STD1NB60
4N35 0.022F
4.7 k
L6561
4 2 3
100k
TL431
1.8 k
6 2 1/2 W
4N35
3.3 nF
10 k
1 k
TRANSFORMER SPECS: CORE: E19x8x5, 3C85 material or equivalent 0.6 mm air gap for a primary inductance of 1.8mH N1:170 T, AWG34 ( 0.20 mm) N2: 15 T, 3xAWG34 N3: 19 T, AWG34
The isolated feedback is realised with the configuration TL431 + optocoupler. Output cross-regulation is improved by multiple sensing technique. The system works in TM but can be forced to work at fixed frequency (that of L6561s internal timer) for minimum consumption at light load by the STANDBY signal (see fig. 6). This signal can be generated by either the P or a current sense circuit that enables low (fixed) frequency operation when the load current falls below a defined threshold. To achieve this functionality, the ZCD pin is connected to ground through a 4.3 k resistor. Figure 6. 40W, Wide-range Mains SMPS for Inkjet Printer.
4700pF 4KV 4700pF 4KV
2A fuse
4.7M KBU4G 85 to 270 Vac 100 F 400V
110 k 56 k 2W
22 nF 250V N1
N2
2 x 470F 35V
12V / 1.5A N3
STTA106
43 k
GND B YW100-50
4.3 k
47 k
STANDBY
8
10
ST P4NA60FP
220
7
47 k
L6561
4 2 3
100 k
DISABL E 1 6
4N35
100 nF 0.39 1/2 W
3.9 k 270 k
5.1 k
TL431
3.3 nF
4N35
10 k 1 k
2.7 k
TRANS FORMER SPECS : CORE: ETD29x16x10, 3C85 material or equivalent 1 mm air gap for a primary inductance of 530 H N1: 69 T, AWG25 ( 0.51 mm) N2: 11 T, AWG25 N3: 9 T, AWG20 ( 0.89 mm) N4: 4 T, AWG25 N5: 11 T, AWG32 ( 0.24 mm)
5/11
4700pF 4KV
4700pF 4KV
5A fuse
KBU4G 85 to 270 Vac 220F 400V
110 k
4.7M
56 k 3W
47 nF 250V N1
STTA106
10
1N4148
6.3V 5W
47F
N7
N4
8 5
10
BYW100-100 STP7NB60FP N5
1 k
+15V 5W
47 k
L6561
4 2 3 1 6 1N4148
82 k 9.1 k 100 k 0.47 0.47
DI SABLE
N6
15 V
3.3 nF 10 k 1 k
4N35
2.2 nF
2.7 k
47F 25V
4N35
470 k
100 k
330 k
TRANSFORMER SPECS: ETD44 core, 3C85 grade or equivalent 1 mm air gap for a primary inductance of 380 H N1 : 38 T, 2 series windings, 19T each, 4xAWG29 ( 0.29 mm) N2 : 48 T, AWG25 ( 0.45 mm) N3 : 32 T, AWG25 N4 : 3 T, AWG25 N5, N6 : 6 T, AWG25 N7 : 6 T, AWG32 ( 0.24 mm)
330 pF TL431
1 nF
4.7 k
6/11
7/11
9.1 k 39 k 20 k 220 nF
L6561
7 1 6
1N4148
2.2 nF
The optional 2.2F capacitor connected in parallel to the upper resistor of the feedback divider acts as a soft-start circuit. The diode between the capacitor and TL431s control pin decouple the capacitor during steady-state operation so that it does not interfere with the loop gain. The other diode provides a discharge path when the converter is turned off, so that the system is always soft-started at power-up. Figure 9. 30W, offline, High-PF battery charger with secondary post-regulation
2A fuse DF06M 85 to 270 Vac STPS 8H100D
1 6 7
20 k
L4955
4 3 5
22 F
2200 F
22 k
220 1W
2.7 k
4.7 nF
L6561
7 6 4 10 STP5NA60
5.1 k
0.5
TRANSFORMER SPEC: Core E25/13/7, 3C85 grade or equivalent 0.7 mm air gap for a primary inductance of 720 H N1 : 2 series winding, 39 T each, AWG28 ( 0.37 mm) N2 : 12T, 3xAWG26 ( 0.40mm) N3 : 14T, AWG31 ( 0.23 mm )
Fig. 9 presents a 30W off-line, universal mains battery charger suitable for lead-acid batteries. Compared to the previous circuit, the primary side does not change so much. The basic difference concerns the feedback that here is based on sensing the voltage developed by the auxiliary winding. This technique ensures a high PF in such flyback configuration because of the poor coupling between secondary and auxiliary winding at low frequency. It is then quite easy to get a gain low enough at twice
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DF06M
85 to 270 Vac
15 Vdc / 2A
12 k
470 nF
3 M
470 k 47 k 1N4148 47 F 1
STTA106
4N35
L78L12
2
3 220 nF 39 k 2 9.1 k
2.2 k
L6561
7 1 6 4 10 STP5NA60
2.2 k 100 nF
2 8 1 11 k 5
3
1N4148
20 k 4N35 1 nF
TSM 101
20 k 2.4 k
4 1.1 k
1N4148
TRANSFORMER SPEC: Core E25/13/7 , 3C85 grade or equivalent 0.7 mm air gap for a primary inducta nce of 720 H N1: 2 series windin g, 39 T each, AWG28( 0.37 mm) N2: 12T , 3xAWG26 ( 0.40mm) N3: 25T , AWG31( 0.23 mm)
4.7 nF
The same battery charger can be realised without a post-regulator. Such a system is shown in fig. 10. It uses again an isolated feedback with an optocoupler and a secondary side reference/error amplifier, the TSM101, for voltage and current regulation. This device basically incorporates a TL431 and two op-amps with or-ed outputs. One op-amp will be used for constant voltage control and the other one for constant current control. A precise internal current generator, available at pin 3, can be used to offset the intervention threshold of the constant current regulation. For more details, please refer to Ref. [5]. The voltage generated by the self-supply winding tracks the output voltage, which can be quite low (<9V) when the battery is nearly exhausted. To let the system work even under this condition the self-supply will deliver a voltage above L6561s UVLO when the output voltage falls to its minimum. As a result, however, when the charger is in voltage regulation (battery disconnected or end-of-charge) the self-supply voltage will exceed the maximum rating of the L6561. This requires the use of a linear regulator (L78L12 in the present case) to limit the excursion of the voltage. The diode in series to the output of the L78L12 prevents current diversion through the regulator at start-up. The switch connected between TSM101s pin 2 and ground enables/disables the above mentioned internal current reference. If the switch is open, pin 2 is pulled up through the 10 k resistor, the internal current generator is disabled and the constant current characteristic is set at 2A. If the switch is closed, pin 2 is grounded and the internal current reference will be enabled. Pin 3 will be offset by about 160 mV and the constant current threshold will be set at 0.3A.
9/11
10/11
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