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ST STEVAL-ISF003V1, User Manual

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ST STEVAL-ISF003V1 User Manual Download Page 41

UM2076 

Conclusion

 

 

 

DocID029457 Rev 1 

41/43 

 

13 

Conclusion 

This demonstration board provides an innovative front-end circuit providing inrush-current 
limitation and power loss reduction. The board is much more than the demonstration of the 
efficiency and the robustness of STMicroelectronics solution, this front-end circuit can be 
used as a starting element to build a whole system and accelerate the time-to-market of 
new application designs. 

Summary of Contents for STEVAL-ISF003V1

Page 1: ...ng progressive phase control at board start up This solution can also drastically reduce standby losses as the DC bus can be totally disconnected from the AC mains when it does not have to operate DC bus deactivation is simply achieved by turning off SCRs without requiring an additional relay to open the circuit in standby The steady state losses are also reduced thanks to the removal of the NTC P...

Page 2: ... EMI filter and DC bus capacitor alteration 14 2 5 2 Power factor circuit connection 14 2 5 3 Motor inverter connection 15 2 5 4 Control with an external microcontroller 15 3 Schematic diagrams 17 4 STEVAL ISF003V1 power supplies and typical consumption 20 5 Inrush current limitation 22 5 1 IEC 61000 3 3 overview 22 5 2 STEVAL ISF003V1 compliance with the IEC 61000 3 3 limit 22 6 Mains voltage dip...

Page 3: ...UM2076 Contents DocID029457 Rev 1 3 43 13 Conclusion 41 14 Revision history 42 ...

Page 4: ...able 2 Comparison of standby losses 10 Table 3 Typical STEVAL ISF003V1 control circuit consumption 20 Table 4 Maximum input RMS current variation for 230 V single phase grid according to IEC 61000 3 3 22 Table 5 Dip and interruption tests and STEVAL ISF003V1 performance 27 Table 6 Document revision history 42 ...

Page 5: ...control schematic 17 Figure 12 STEVAL ISF003V1 control circuit schematic 18 Figure 13 STEVAL ISF003V1 flyback SMPS schematic 19 Figure 14 Typical output characteristics of the 5 V and 15 V positive supplies 5V_DC 15V_DC 21 Figure 15 Typical output characteristics of the 5 V positive supply VCC_AC 21 Figure 16 HV capacitor charging controlled 23 Figure 17 SCR current zoom for the highest peak curre...

Page 6: ...n line with ECO European directive The STEVAL ISF003V1 board is also a development tool for designing broad inrush current reduction systems EV chargers telecom power supply etc For this purpose connectors are available for an external power factor corrector an intelligent power module IPM or for an external microcontroller see Section 4 5 Possible board variations 1 2 STEVAL ISF003V1 functional b...

Page 7: ... for components which must be insulated from the mains voltage e g sensors Not used on the demoboard 90 mA For further information regarding the SMPS outputs please refer to Section 6 STEVAL ISF003V1 power supplies and typical consumption 1 3 Target applications Target applications include all those using a diode bridge to rectify the AC line voltage where NTC or PTC resistor removal and loss redu...

Page 8: ...nce with IEC 61000 3 3 with MAX_INRUSH CURRENT potentiometer set to default position see Section 7 Inrush current limitation Compliance with EN55014 CIPSPR 22 method B see Section 11 EN55014 test results IEC 61000 4 4 2 kV criteria A SCR1 and SCR2 withstands a level of 5 kV without triggering This avoids undesired triggering and uncontrolled inrush current in case of EMI noise IEC 61000 4 5 4 kV I...

Page 9: ...gure 4 Inrush current at STEVAL ISF003V1 start up on 230 V line 1 mF output DC capacitor 1 7 Standby consumption Mixed SCR Diode rectifier bridges prevent undesirable standby losses through full bridge disconnection by simply turning off the SCRs this would otherwise require a front end relay like S2 in the figure below to achieve Figure 5 Solution using relays to limit the inrush current and stan...

Page 10: ...rective 2005 32 EC The losses on this demonstration board are mainly due to resistors R54 R55 and R56 to discharge the HV output capacitor resistors R7 and R9 and the current source to control HVDC LED indicating HVDC voltage resistors R6 and R9 to accelerate the HV output capacitor discharge time connected to the demonstration board output the other R24 R25 and R28 resistor divider circuit to sen...

Page 11: ...qualified personnel who are familiar with the installation use and maintenance of power electrical systems The STEVAL ISF003V1 evaluation board is designed for demonstration purposes only and must not be used for either domestic installation or industrial installation 2 2 Board connection and start up To reduce inrush current by operating the board with the PTC plug jumper J1 as indicated by the s...

Page 12: ... an un powered mains plug Figure 8 AC line connections Switch on the mains voltage from this moment do not make any contact with live parts under line voltage The Power_ON LED lights red to indicate the demoboard is powered The ICL STATUS LED first lights red then orange then green and finally turns off to indicate the board is operational This occurs each time the board is connected to the AC lin...

Page 13: ...the SW1 SPDT toggle switch marked HV CAPACITOR DISCHARGE on the PCB is set to the momentary ON position For a 2 mF C3 capacitor the full discharge time is around 15 seconds In this case the SW1 switch must be kept at the momentary ON position for these 15 seconds at least The D6 LED marked HVDC on the PCB remains lit while the HVDC voltage remains above 50 V as soon as this LED turns off switch SW...

Page 14: ...tion requirements e g the power rating However if these components are modified the SCR control law must be updated to maintain IEC 61000 3 3 compliance This can be done by adjusting the maximum peak current during start up with the MAX INRUSH CURRENT potentiometer When this potentiometer is turned clockwise the SCRs are turned on sooner according to the AC line polarity at each half cycle leading...

Page 15: ...nection An inverter or any other DC DC power converter can be added after the PFC or directly behind the HVDC bus output A 15 V positive output referenced to the DC Bus Ground GND_DC is available on header J11 to supply an IPM module if needed The maximum current sunk from this supply must be well below the limit in 2 5 4 Control with an external microcontroller You can control the STEVAL ISF003V1...

Page 16: ...oller outputs see SCRs gate ctrl section in Section 5 Schematic diagrams It is also possible to control the STEVAL ISF003V1 front end circuit with an external MCU by using the embedded STM8S003F3 In this case the inrush current limitation is managed by the embedded STM8S003F3 MCU The control signal required to start the inrush current limitation is available on J16 header HVDC_EXT the input HVDC_E...

Page 17: ...UM2076 Schematic diagrams DocID029457 Rev 1 17 43 3 Schematic diagrams Figure 11 STEVAL IFS003V1 power and insulated control schematic ...

Page 18: ...Schematic diagrams UM2076 18 43 DocID029457 Rev 1 Figure 12 STEVAL ISF003V1 control circuit schematic ...

Page 19: ...UM2076 Schematic diagrams DocID029457 Rev 1 19 43 Figure 13 STEVAL ISF003V1 flyback SMPS schematic ...

Page 20: ...s to two LM2931 positive voltage regulators The VCC_AC level is not regulated its voltage level will be higher if it is not loaded and if the 15 V supply is loaded with its maximum current The current capabilities of the different outputs are for the whole operating range For 5V_DC 90 mA For VCC_AC non regulated 5 V negative output 200 mA For 15V_DC 500 mA with 5V_DC consumption included For VCC_I...

Page 21: ...wer supplies and typical consumption DocID029457 Rev 1 21 43 Figure 14 Typical output characteristics of the 5 V and 15 V positive supplies 5V_DC 15V_DC Figure 15 Typical output characteristics of the 5 V positive supply VCC_AC ...

Page 22: ...e table below gives the associated maximum input current variation related to these different dmax levels To simplify the analysis we can say that an appliance fulfils the IEC 61000 3 3 limit at start up if its RMS current remains below 16 1 A The relative variation is then lower than 3 3 and so the compliance is ensured even if the start up lasts more than 500 ms This is clearly a restricted case...

Page 23: ...his inductor features a 0 9 mH value in common mode but also a 3 µH inductor in differential mode To completely charge this capacitor to the peak line voltage the SCRs must be triggered on the following cycle with a shorter turn on delay than the first one used to start charging see Figure 16 HV capacitor charging controlled Thus by reducing SCR turn on delay by a few ten or hundred microseconds f...

Page 24: ...1mF capacitor connected to the HVDC output Figure 17 SCR current zoom for the highest peak current during start up With the MCU firmware as the default program First SCR turn on is set to 150 µs before next line zero voltage as the first gate current pulse lasts 50 µs This allows the gate current to be removed 100 µs before next half cycle This value is set by SCRs_OFF_Delay_us in the firmware Thi...

Page 25: ...mpliance with the IEC 61000 3 3 standard is fulfilled The peak current during output capacitor charging is not constant indeed only the step reduction of the SCR turn on delay is constant Hence according to the time this SCR turns on the peak current can vary slightly from one period to another Note that we have limited the inrush peak current to below 22 A but the IEC 61000 3 3 limit applies to t...

Page 26: ... interruptions high input currents may occur when line voltages suddenly return to their nominal values for rectifier circuits charging DC capacitors This high current may damage front end components like bridge diodes AC fuses etc Table 5 Dip and interruption tests and STEVAL ISF003V1 performance gives the different requirements in terms of line voltage dips and interruptions for the different el...

Page 27: ...ge is discharged by its load current When the line voltage is reapplied the SCRs are controlled back in soft start to ensure recharging current limitation Clearly SCR restart only occurs if the HVDC ON SPST switch SW2 is kept at the ON position Note that the 1 5 cycle duration to detect voltage dip that lasts too long is given by the parameter Nb_Peak_VAC_Dips which is set to three by default thre...

Page 28: ...he SCRs are kept ON during the line interrupt When the voltage is reapplied the peak current is only 30 A as the DC voltage only decreased by 60 V during the lack of AC voltage Only the SCR1 control is defined in this waveform Figure 19 Board operation during 1 cycle line interruption ...

Page 29: ...a soft start procedure like for any system start up The DC capacitor therefore starts being recharged when the SCR gate current is applied while the AC voltage is higher than the C voltage In the figure below this point occurs around 45 ms after the line voltage is reapplied The peak current is therefore only 27 A which is only around 1 5 times the nominal current and well below any component dama...

Page 30: ...VL VN The resistor divider bridge in the following figure id used to sense VL and VN Figure 21 AC line voltage measurement principle Given VL and VN images the MCU is able to deduce VAC from Equation 1 where VAC_IM is the image of the AC line voltage and K is the proportional coefficient between VAC and VAC_IM defined by the resistors divider bridge Equation 1 𝑉𝐴𝐶 𝑉𝐿 𝑉𝑁 𝐾 𝑉𝐿_𝐼𝑀 𝑉𝑁_𝐼𝑀 𝐾 𝑉𝐴𝐶_𝐼𝑀 Equa...

Page 31: ...chronized with the AC line voltage The zero AC line voltage crossing detection uses the AC line voltage measurement Indeed the zero AC line voltage occurs when the line voltage VL and the neutral voltage VN are equal In this case a comparator U3 connected to the pin 10 of the MCU compares voltages VL_IM and VN_IM As soon as VL_IM is lower than VN_IM the output comparator switches to the low level ...

Page 32: ...istors RF1 1 kΩ and CF1 10nF A capacitor associated with resistors RF3 and RF4 is used to improve optocoupler U1 immunity Figure 23 SCR switch insulated control The gate resistor Rg to limit the given the SCR gate current IGT can be defined according to Equation 4 where VCC_AC is the power supply to provide the gate current to the SCRs VCE_SATPNP is the transistor collector emitter of the PNP tran...

Page 33: ...SATOpto is the transistor collector emitter of the optocoupler VBE_SATPNP is the PNP transistor base emitter and VOH_Min_MCU is the output MCU voltage to drive the optocoupler Equation 6 𝑅𝐿 𝑉𝑂𝐻_𝑀𝑖𝑛_𝑀𝐶𝑈 𝑉𝐹𝑂𝑃𝑇𝑂 1 𝐶𝑇𝑅 𝑉𝐶𝐶_𝐴𝐶 𝑉𝐶𝐸_𝑆𝐴𝑇𝑂𝑃𝑇𝑂 𝑉𝐵𝐸_𝑆𝐴𝑇𝑃𝑁𝑃 𝑅𝐹2 𝑅𝐹3 With the LTV 817 optocoupler and the 2N2907 PNP transistor the resistors should be RF1 1 kΩ RF2 390 Ω RL 270 kΩ CF2 10 nF CF1 10 nF The actual valu...

Page 34: ...EN55014 test results UM2076 34 43 DocID029457 Rev 1 9 EN55014 test results Figure 24 EMI noise test with 2000W load Figure 25 EMI noise test with no load ...

Page 35: ...UM2076 STEVAL IHT008V1 silk screen DocID029457 Rev 1 35 43 10 STEVAL IHT008V1 silk screen Figure 26 STEVAL IHT008V1 silk screen ...

Page 36: ...MD 0805 7 2 C16 C18 470pF 50V 10 X7R Ceramic Cap SMD 0805 8 4 C14 C19 C26 C27 1µF 25V 10 X7R Ceramic Cap SMD 0805 9 1 C22 1µF 25V 10 X7R Ceramic Cap SMD 0805 10 1 C23 680nF 25V 10 X7R Ceramic Cap SMD 0805 11 1 C28 220µF 16V 10 SMD Electrolytic Cap Ø6 3mm h7 7mm 12 1 C29 1 5mF 16V 10 SMD Electrolytic Cap Ø12 5mm h13 5mm 13 2 C30 C41 330nF 50V 10 X7R Ceramic Cap SMD 0805 14 1 C32 220µF 63V 10 SMD El...

Page 37: ...ctifier diode TO247 STBR6012W Y ST 28 4 D11 D12 D13 D16 1A 1000V Standard diode DO 41 1N4007 29 3 D15 D18 D20 1 A 150V Power schottky rectifier DO 41 STPS1150 ST 30 1 D17 1 5kW 300V TVS diode DO 201 1 5KE300A ST 31 1 D19 1A 600V TURBO 2 Ultrafast High Voltage Rectifier DO 41 STTH1L06 ST 32 1 D21 100V 0 15A signal diode DO 35 1N4148 33 3 D22 D23 D24 30V 100mA double series schottky DO 35 BAR43S ST ...

Page 38: ...ET transistor STN4NF03L ST 51 1 R2 PTC_56R_ 440VAC PTC THERMISTOR B59107J130 A20 EPCOS 52 2 R3 R4 100R_0 125w SMD0805 resistor 53 1 R5 2 5kΩ 5W Through hole resistor CW0052K50 0JE73 VISHAY 54 4 R6 R7 R8 R9 250kΩ 0 125W SMD0805 resistor 55 2 R10 R12 2 7MΩ 0 33W Through hole resistor 56 1 R11 3 3kΩ 0 125W Through hole resistor 57 3 R13 R19 R53 1kΩ 0 125W SMD0805 resistor 58 2 R14 R20 270R 0 125W SMD...

Page 39: ... RK09K1130A P5 ALPS 78 2 SIOV1 SI OV7 250VAC 250VAC_roud_varistor_ 14mm S14K250 79 2 SIOV2 SI OV3 385VAC 385VAC_roud_varistor_ 14mm S14K385 80 1 SW1 DPDT ON ON 8UD8WR2C2 M2RES RS 81 1 SW2 28V 5A SPDT ON ON 5MS1S402A M2QES RS 82 20 TP1 to TP20 test point 20 136 VERO 83 2 T1 T2 1200V 50 A Automotive SCR TN5050H 12WY ST 84 1 T3 12W flyback transformer E16 74010 MYRRA 85 2 U1 U2 50mA Optocoupler DIP4 ...

Page 40: ... of T4 TP10 OUT5 A2 output of T5 TP11 HVDC 2 TP12 N Neutral before EMI filter TP13 N1 Neutral after EMI filter TP14 TP24 TP29 GND_DC TP15 G1 Gate signal of T1 TP16 G2 Gate signal of T2 TP17 G3 Gate signal of T3 TP18 G4 Gate signal of T4 TP19 G5 Gate signal of T5 TP20 G_ICL Gate signal of T_ICL TP22 GND_AC TP23 15V_DC TP25 VCC_INS TP26 Drain_viper TP27 GND_INS TP28 5V_DC TP30 ZVS TP31 VL1_MEAS MCU ...

Page 41: ...uit providing inrush current limitation and power loss reduction The board is much more than the demonstration of the efficiency and the robustness of STMicroelectronics solution this front end circuit can be used as a starting element to build a whole system and accelerate the time to market of new application designs ...

Page 42: ...Revision history UM2076 42 43 DocID029457 Rev 1 14 Revision history Table 6 Document revision history Date Version Changes 28 Jun 2016 1 Initial release ...

Page 43: ...asers are solely responsible for the choice selection and use of ST products and ST assumes no liability for application assistance or the design of Purchasers products No license express or implied to any intellectual property right is granted by ST herein Resale of ST products with provisions different from the information set forth herein shall void any warranty granted by ST for such product S...

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