ST STEVAL-ISF003V1 User Manual
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ST STEVAL-ISF003V1 User Manual

ST STEVAL-ISF003V1 User Manual

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UM2076
User manual
Getting started with the STEVAL-ISF003V1
Introduction
The STEVAL-ISF003V1 evaluation board allows the inrush-current which charges a DC bus capacitor to
be limited to comply with standard IEC 61000-3-3. This inrush current limitation is based on a soft-start
procedure of the mixed bridge diodes and SCRs rectifier using 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 / PTC resistor traditionally
used to limit inrush current. Also in this case, no relay is required to bypass this resistor as it is no longer
used.

Figure 1: STEVAL-ISF003V1 board (top view)

July 2016
DocID029457 Rev 1
1/43
www.st.com

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Summary of Contents for ST STEVAL-ISF003V1

  • Page 1: Figure 1: Steval-Isf003V1 Board (Top View)

    Getting started with the STEVAL-ISF003V1 Introduction The STEVAL-ISF003V1 evaluation board allows the inrush-current which charges a DC bus capacitor to be limited to comply with standard IEC 61000-3-3. This inrush current limitation is based on a soft-start procedure of the mixed bridge diodes and SCRs rectifier using progressive phase control at board start- 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.

  • Page 2: Table Of Contents

    STEVAL-ISF003V1 power supplies and typical consumption ..20 Inrush-current limitation ............... 22 IEC 61000-3-3 overview ..............22 STEVAL-ISF003V1 compliance with the IEC 61000-3-3 limit ..22 Mains voltage dips and interruptions .......... 26 AC voltage monitoring and zero-voltage synchronization ..30 Zero voltage and AC line voltage sensor circuits ......
  • Page 3 UM2076 Contents Conclusion ..................41 Revision history ................42 DocID029457 Rev 1 3/43...
  • Page 4 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 4/43...
  • Page 5 Figure 3: Connection of a PFC at the HVDC output ................... 8 Figure 4: Inrush current at STEVAL-ISF003V1 start-up on 230 V line (1 mF output DC capacitor) ..9 Figure 5: Solution using relays to limit the inrush current and standby losses ........... 9 Figure 6: J1 jumper plugged on board (bypass mode) ................

  • Page 6: Demonstration Board Overview

     standby losses in 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...

  • Page 7: Target Applications

     Microcontroller unit (MCU): STM8S003F3  Flyback IC: VIPER26LD Operating range The STEVAL-ISF003V1 board is designed to operate inside following operating ranges:  RMS line voltage range:85 to 264 V  Line voltage frequency range: 45 to 65 Hz ...

  • Page 8: Performance Characteristics

    Demonstration board overview UM2076  Allowed DC output capacitor (or DC bus capacitor): up to 2 mF. This value is the equivalent of all capacitors in parallel at the bridge output, like C3 and C at the PFC in the figure below. If an interleaved PFC is used, all the output capacitors of each PFC must be added.

  • Page 9: Standby Consumption

    16.1 A (I ). The input RMS current easily complies with the IEC 61000-3-3 standard. Figure 4: Inrush current at STEVAL-ISF003V1 start-up on 230 V line (1 mF output DC capacitor) Standby consumption Mixed SCR/Diode rectifier bridges prevent undesirable standby losses through full bridge disconnection by simply turning off the SCRs;...

  • Page 10: Table 2: Comparison Of Standby Losses

    Demonstration board overview UM2076 STEVAL-ISF003V1 board (without modifications) with SCRs in the OFF state (SW2 HVDC switch in OFF position) and the J1 bypass mode jumper is unplugged (PTC not connected). Same as 1, but the following circuits used for demonstration purposes and which consume undesired power in standby are disconnected: ...

  • Page 11: Getting Started

    UM2076 Getting started Getting started Safety instructions The high voltage levels used to operate the STEVAL-IHT008V1 evaluation board may present a serious electrical shock hazard. This evaluation board must be used in a suitable laboratory and only by qualified personnel who are familiar with the installation, use, and maintenance of power electrical systems.

  • Page 12: Figure 7: J1 Jumper Position Left Free (Phase Control Mode)

    Getting started UM2076 To control the inrush current with SCRs, do not plug the J1 jumper. Figure 7: J1 jumper position left free (phase control mode) Connect L, N and PE (if required) on the respective J3, J6 and J7 headers to an un- powered mains plug.

  • Page 13: Dc Bus Capacitor Discharge For Demonstration Purposes

    DC bus capacitor discharge for demonstration purposes With default STEVAL-ISF003V1 output 47 nF capacitor (C3) and associated 470 kΩ resistors (R54, 55, and R56) used in parallel to discharge the C3 capacitor, the DC bus discharging time is a few milliseconds, if no load is connected.

  • Page 14: Possible Board Variations

     POWER_ON (LED14): lights when the AC line is plugged to the AC line. Possible board variations The STEVAL-ISF003V1 board allows some external components to be added to the front- end circuit so designers can evaluate entire systems. 2.5.1 EMI filter and DC bus capacitor alteration The EMI filter and DC capacitors are simple through-hole devices so they are easy to change.

  • Page 15: Motor Inverter Connection

    . 2.5.4 Control with an external microcontroller You can control the STEVAL-ISF003V1 front-end circuit with an external MCU instead of the embedded STM8S003F3 MCU to directly check the compliance of your own firmware with this kind of circuit.
  • Page 16 "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).

  • Page 17: Schematic Diagrams

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

  • Page 18: Figure 12: Steval-Isf003V1 Control Circuit Schematic

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

  • Page 19: Figure 13: Steval-Isf003V1 Flyback Smps Schematic

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

  • Page 20: Steval-Isf003V1 Power Supplies And Typical Consumption

    The two figures below give the typical output voltage according to the current sunk from each output. The measurements were taken with the STEVAL-ISF003V1 connected to 230 V and 120 V lines for the whole temperature operating range (0 to 60 °C). The 15 V_DC, and the 5 V outputs (5V_DC and VCC_INS) are well regulated by the VIPer26LD and LM2931 devices, respectively.

  • Page 21: Figure 14: Typical Output Characteristics Of The 5 V And 15 V Positive Supplies (5V_Dc/15V_Dc)

    UM2076 STEVAL-ISF003V1 power supplies and typical consumption 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) DocID029457 Rev 1 21/43...

  • Page 22: Inrush-Current Limitation

    19.5 13.8 29.3 16.1 STEVAL-ISF003V1 compliance with the IEC 61000-3-3 limit One of the most common solutions to limit inrush current involves adding a resistor (like Figure 5: "Solution using relays to limit the inrush current and standby losses") in series with the DC capacitor (C in the same figure).

  • Page 23: Figure 16: Hv Capacitor Charging Controlled

    In STEVAL-ISF003V1 MCU firmware, the step of SCR turn-on delay reduction is constant from one half-cycle to the next.

  • Page 24: Figure 17: Scr Current Zoom For The Highest Peak Current During Start-Up

    (1 mF output DC capacitor)") shows an example of such progressive DC capacitor charging. The test is performed at start-up when the STEVAL-ISF003V1 board is connected to a 230 V 50 Hz grid, while the output DC capacitor is fully uncharged (i.e., its initial voltage is null), with a 1mF output DC capacitor connected.

  • Page 25: Figure 18: Triac Current For The Highest Peak Current During Start-Up

    DC gate current according to the AC line voltage polarity. The figure above (and Figure 4: "Inrush current at STEVAL-ISF003V1 start-up on 230 V line (1 mF output DC capacitor)") shows a maximum inrush peak current around 22 A. The RMS current is thus far below the 16.1 A limit.

  • Page 26: Mains Voltage Dips And Interruptions

    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 electromagnetic immunity standards, and corresponding test results.
  • Page 27 Notes: 50 Hz line frequency 60 Hz line frequency The STEVAL-ISF003V1 board MCU firmware is programmed to comply with these different tests thus:  If the line voltage remains higher than 70% of the reference voltage (measured at board start-up), no change applies to the SCR (T1 and T2) sequence.

  • Page 28: Figure 19: Board Operation During 1-Cycle Line Interruption

    Mains voltage dips and interruptions UM2076 In the former, the 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.

  • Page 29: Figure 20: Board Operation During 2-Cycle Line Interruption

    UM2076 Mains voltage dips and interruptions In the latter, as the interrupt lasts more than 30 ms, the SCRs are retriggered when the AC voltage is reapplied. To avoid an excessive inrush current due to a long interrupt, the SCRs are controlled in a soft-start procedure like for any system start-up.

  • Page 30: Ac Voltage Monitoring And Zero-Voltage Synchronization

    AC voltage monitoring and zero-voltage UM2076 synchronization AC voltage monitoring and zero-voltage synchronization Zero voltage and AC line voltage sensor circuits The AC line voltage (V ) must be measured to detect the RMS AC line voltage level and to manage the AC line dips (as described in Section 8: "Mains voltage dips and interruptions").

  • Page 31: Zero Ac Line Voltage Detection

    UM2076 AC voltage monitoring and zero-voltage synchronization = 2 MΩ, V For example, with R = 264 V, and V = 4 V, the following AC_RMS_Max AC_IM_Max resistor and K values should be used (a 1% resistor tolerance is recommended): ...

  • Page 32: Scr Switch Insulated Control

    SCR switch insulated control UM2076 SCR switch insulated control The VIPer26LD Flyback provides a DC output voltage to control SCR1 (T1) and SCR2 (T2). The GND terminal (GND_AC) of this output is connected to the HVDC. The high terminal of this output is called VCC_AC. A positive supply is required to source the current to the SCR gates.
  • Page 33 UM2076 SCR switch insulated control ������ − ������_������ − ������_������ ���� �������� ������ �� + �� ��2 ��3 ������ − ������_������ − �� ������_������ ���� ������ ���� ������ �� × ���� �� ��1 Given optocoupler CTR and resistors R and R , the LED resistor (R ) of the optocoupler is defined by Equation 6, where VCC_AC is the power supply to provide the gate current to...

  • Page 34: En55014 Test Results

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

  • Page 35: Steval-Iht008V1 Silk-Screen

    UM2076 STEVAL-IHT008V1 silk-screen STEVAL-IHT008V1 silk-screen Figure 26: STEVAL-IHT008V1 silk-screen DocID029457 Rev 1 35/43...

  • Page 36: Bill Of Materials

    Bill of materials UM2076 Bill of materials Ref. Value Description Part number Manufacturer X7R Ceramic Cap, C1,C2, 100nF, 50V, ±10% C21,C38 SMD 0805 Radial Metal Film capacitor 47nF, 600V, ±20% P15mm Disk ceramic Y2 capacitor C4,C5,C8 2.2nF, 440V, C9,C44 ±20% P7.5mm Disk ceramic X2 capacitor C6, C7...
  • Page 37 UM2076 Bill of materials Ref. Value Description Part number Manufacturer X7R Ceramic Cap, 680pF, 50V, ±10% SMD 0805 X7R Ceramic Cap, 1nF, 50V, ±10% SMD 0805 440V, 600W TVS diode P6KE440A Zener diode 30V, 500mW BZX55C30 DO-35 Automotive Ultrafast D4, D5 12A, 1000V recovery diode STTH1210-Y...
  • Page 38 Bill of materials UM2076 Ref. Value Description Part number Manufacturer Board-To-Board Connector 4 contacts, p2.54mm Board-To-Board Connector 6 contacts, p2.54mm VLMV3100- LED1 bicolor LED VISHAY GS08 WURTH 7448053201 0.9mH/32A common mode choke ELEKTRONIK WURTH 744741102 power inductor ELEKTRONIK MG1, LAM 3 K 100 FISHER 1K/W heatsink...
  • Page 39 UM2076 Bill of materials Ref. Value Description Part number Manufacturer 75R, 0.125W SMD0805, resistor 1.5kΩ, 0.125W SMD0805, resistor R45,R46 47R, 1W Through hole resistor EP1W47RJ connectivity 36kΩ, 0.125W SMD0805, resistor 10kΩ, 0.125W SMD0805, resistor 20kΩ, 0.125W SMD0805, resistor 22kΩ, 0.125W SMD0805, resistor 150R, 0.125W SMD0805, resistor...

  • Page 40: Test Points

    Test points UM2076 Test points Reference Designation Definition Line after EMI filter TP2,TP21,TP33 VCC_AC HVDC Line before EMI filter OUT_ICL A2 output of T_ICL OUT1 A2 output of T1 OUT2 A2 output of T2 OUT3 A2 output of T3 OUT4 A2 output of T4 TP10 OUT5...

  • Page 41: Conclusion

    UM2076 Conclusion 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.

  • Page 42: Table 6: Document Revision History

    Revision history UM2076 Revision history Table 6: Document revision history Date Version Changes 28-Jun-2016 Initial release. 42/43 DocID029457 Rev 1...
  • Page 43 ST products and/or to this document at any time without notice. Purchasers should obtain the latest relevant information on ST products before placing orders. ST products are sold pursuant to ST’s terms and conditions of sale in place at the time of order acknowledgement.

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