AN1606

APPLICATION NOTE
A "BRIDGELESS P.F.C. CONFIGURATION"
BASED ON L4981 P.F.C. CONTROLLER.
by Ugo Moriconi

This technical document describes an innovative topology dedicated to a medium to high power PFC
stage. The originality of this topology is the absence of the bridge that usually is placed between the
EMC filter and the PFC stage. The advantages of this topology can be found in terms of increased efficiency and improved thermal management.

L4981 PFC Controller

This application features the L4981 PFC controller. It is a high performance device operating in average current
mode with many on-chip functions. The driver output stage can deliver 1.5A, which is very important for this type
of application.

A detailed device description can be found in AN628. A functional block diagram is shown in Figure 1.
Figure 1. Functional Diagram

November 2002

1/18

AN1606 APPLICATION NOTE

Description of "Bridgeless PFC Configuration" Topology

The conventional boost topology is the most efficient for PFC applications. It uses a dedicated diode bridge to
rectify the AC input voltage to DC, which is then followed by the boost section. See Figure 2.
This approach is good for a low to medium power range. As the power level increases, the diode bridge begins
to become an important part of the application and it is necessary for the designer to deal with the problem of
how to dissipate the heat in limited surface area. The dissipated power is important from an efficiency point of
view.
Figure 2.
Inductor

D
L
A

Load

M
Mains

V_Rs

Rs

controller

The bridgeless configuration topology presented in this paper avoids the need for the rectifier input bridge yet
maintains the classic boost topology.
This is easily done by making use of the intrinsic body diode connected between drain and source of PowerMOS
switches.
A simplified schematic of the bridgeless PFC configuration is shown in Figure 3.
Figure 3.

D1

D2

Inductor

Mains

L
O
A
D

M2

M1

Controller

2/18

Load

AN1606 APPLICATION NOTE

The circuit shown from a functional point of view is similar to the common boost converter. In the traditional topology current flows through two of the bridge diodes in series. In the bridgeless PFC configuration, current
flows through only one diode with the PowerMOS providing the return path.
To analyze the circuit operation, it is necessary to separate it into two sections. The first section operates as the
boost stage and the second section operates as the return path for the AC input signal.
Referring to Figure 4, the left side (Figure 4a) shows current flow during the positive half cycle and the right side
(Figure 4b) shows current flow during the negative half cycle
Figure 4.
Positive half cycle

Fig4a

D1

Negative half cycle

D2

L
O
A
D

E
R

M1

C
H
O
P

v 0 v in

P
E

M1

M2

return

controller

D2

v in

D1

Fig4b

M2

L
O
A
D

v0

return

controller

Positive "HALF Cycle."

When the AC input voltage goes positive, the gate of M1 is driven high and current flows from the input through
the inductor, storing energy. When M1 turns off, energy in the inductor is released as current flows through D1,
through the load and returns through the body diode of M2 back to the input mains. See Figure 4A
During the-off time, the current throw the inductor L (that during this time discharges its energy), flows in to the
boost diode D1 and close the circuit through the load.

Negative "HALF Cycle".

During the negative half cycle circuit operation is mirrored as shown in Figure 4B. M2 turns on, current flows
through the inductor, storing energy. When M2 turns off, energy is released as current flows through D2, through
the load and back to the mains through the body diode of M1.
Note that the two PowerMOSFETs are driven synchronously. It doesn't matter whether the sections are performing as an active boost or as a path for the current to return. In either case there is benefit of lower power
dissipation when current flows through the PowerMOSFETs during the return phase.

Current Sensing.
The PFC function requires controlling the current drawn from the mains and shaping it like the input voltage
waveform. To accomplish this it is necessary to sense the current and feed its signal to the control circuit.
In average current conventional boost topology, we sense the rectified current rather than the AC input current.
This can be achieved by a simple sensing resistor in the return of the current to the bridge, as shown in Figure5a.

3/18

AN1606 APPLICATION NOTE

The L4981A/B current loop is designed to handle this negative signal. This type of resistor current sense can
easily be achieve in medium power applications. For high power PFC circuits it is necessary to use a magnetic
current transformer for improved efficiency as shown in Figure 5b.
In the bridgeless PFC configuration since an input rectifier bridge is not used, the current is continuously changing its direction and the complexity of current sensing with a simple resistor can increase. Also in high power
applications, resistor sensing may dissipate too much power. In these cases, current sensing with a current
transformer is the preferred approach.
A current sense transformer core is typically high permeability ferrite (toroidal or a small core set). The primary
of the transformer is a single turn of wire through the core. The secondary typically consists of 50 to 100 turns.
Figure 5. .

Fig.5a

Standard Sensing

Inductor

IL

Rs

vs
Iret.

Fig.5b
Magnetic sensing for high power
IL

Typical sense transformers

Inductor

1:n

Rs

vs

Lm_p

Rs

Iret.

This type of sense transformer cannot operate at low frequency and for this reason it must be connected where
the current is switched at high frequency. The magnetic core must be allowed reset.
This is normally accomplished by using a diode. In order to reproduce the inductor's current in boost topology,
two of magnetic sense sections are needed and the simplified schematic is shown in figure 5b.
When the sense transformer solution is applied in the bridgeless topology, the simple sense as in fig5b, is no
longer valid.

4/18

AN1606 APPLICATION NOTE

The circuitry is more complex than in the boost case because here we have two pair of PowerMOS (M1, M2)
and diodes (D1, D2) alternating.
It is necessary to sense the chopping current of the (PowerMOS + diode) section and to sum the signals to be
applied to Rs.
The sensing of the diode's current can be simply done by placing a magnetic sensor at the common cathode
(L2 in fig.6.). Only one of the two diodes operates each half input cycle.
Figure 6.
L2

iin

D1

D2
L1
L
O
A
D

Rs

Q1
M1

controller

M2

vs

Structure of sense transformers

L2

L1

For the PowerMOSFET portion of the circuit, the complexity increases because during the half cycle when one
of the PowerMOSFETs is chopping, the other one has to handle the current flowing back to the mains.
Using the configuration of sensors as shown in Figure 6 it is possible to solve the problem without undue complexity. The unnecessary high frequency portion of the current signal is cancelled because of the method M1 is
connected to L1A as shown in Figure 6b. The problem due to the change of polarity during each half cycle is
solved by using a center tapped secondary and two rectifiers.
Since the coupling of the two windings must not permit the demagnetization of L1, an auxiliary transistor Q1 is
used that opens the circuit during the off-time. For the L4981 controller, the off-time is guaranteed not to be less
than 5% of the period. Q1 can be a small signal transistor because its switched current is low due to the fact
that the transformer secondary will have a large number of turns.
To realize the current sensing transformer, a high permeability toroidal core (ur=>5000) has been used. The
secondary has 50 turns as a compromise to reduce secondary current yet not require a large number of turns.

5/18

AN1606 APPLICATION NOTE

Fig 6b

L2
L1a

L1b

D1

iin

D2
Dc

Inductor

Da

Rs

L
O
A
D

Db

Q1

controller
M1

L1a

L1b

L1
vs

L1=L1a+L1b

M2

L1a

vs

L1b

L1=L1a+L1b

L2

TOT

L1

L2

TOT

vs

vRs

vsa

vsb

vRs

M2_D2 Chopping Phase

M1_D1 Chopping Phase

Other control circuits

Input voltage sensing: in the standard boost topology the rectified input voltage waveform is sensed using a resistor that, by one internal circuit, delivers the mirrored signal to one of the multiplier's inputs (Iac-pin4).
For the bridgeless configuration see the circuit shown in fig.7.

6/18

AN1606 APPLICATION NOTE

Figure 7.

B
R1

Coupled
Inductor

R1

v L(t)

vL(t)

iac(t)

iac(t)

R1

R1

C1

R2

R2

C1
CURRENT
MIRROR

Input voltage sensing (A), and equivalent circuit (B).

It is based on the following consideration: the frequency of the signal of interest (tens of Hz), is much lower than
the switching frequency (tens of kHz). The boost inductor, for the low frequency, behaves like a short circuit.
Since the Powermos's drains are, in turns, close to ground (via the body diode), the resulting equivalent circuit
is shown in fig7b.
The relation between the voltage (from the inductor) and the current that flows in to Iac pin is:

a)

1
1
Y ( s ) = ----------- -------------Req 1 + st
R1
2

Where: Req = R1 + 2 R2 and t = -------- //R2 C1

1
2t

The net introduces one pole at: fp = -----------------

The pole must be located at a frequency high enough not to distort the input waveform and at the same time,
low enough to filter the switching frequency.
In this application the equivalent resistance has been choosen
Req.=324-k that fits well with the current amplifier design.
The resulting R1 is 300k and R2 is 12k
The pole has been placed a decade before the switching frequency:

Fp = 5kHz
b)

that gives:

1
C1 = -------------------------------------------------- = 2.87nF
R1
2 fp -------- //R2
2

In practice, in our test, a standard value of 2.7 nF as ben used.

7/18

AN1606 APPLICATION NOTE

Voltage feed-forward.
Voltage feed-forward, a useful function in wide range applications, requires a DC voltage proportional to the rms.
value of the input mains. For the L4981, this value must be between 1.5V to 5.5V so that it can mirror over a
wide range.
Since the rectified mains frequency is 100 -120Hz, we need a large rejection for this frequency and because the
feed-forward reaction time is proportional to the bandwidth, we introduce a second order filter that allows good
compromise between attenuation of the fundamental frequency and response time.
The circuit (Fig.8) is similar to the fig.7 described earlier.
Figure 8.
Coupled
Inductor

B
Ra

Ra

Ra

Rb

+
Ra

Rb

Ca

Cb

Rc

vLP(t)

Ca
Cb

Rc

vLP(t)

Voltage feed-forward Circuit (A) and equivalent circuit (B).

Defining HLP(s) the transfer functions between the voltage from the inductor and the voltage at the output of the
filter vLP (Fig.8B), we have the following relation:

c)

1
HLP = KL P ------------------------------------------------( 1 + st1 ) ( 1 + st2 )

Rc
KL P = ------------------------------------------------( Ra + 2Rb + 2Rc )

The time constants cannot be expressed in simple way and so that the position of poles can be numerically calculated.
The constant KLP is defined taking in to account the wide-range that is, V_mains is between 88V and 264V:

d)

2 2
V LP = VRMS ----------- KLP

Choosing to calculate this value at the midpoint of the allowed values:

e)

8/18

2 2 88 + 264
1.5 + 5.5
----------- ----------------------- K LP = ----------------------2
2

AN1606 APPLICATION NOTE

To fit this, it has been choosen
R a = 998k ( 2 499 )

R b = 150k

R c = 30k

For the capacitors, we set 80 dB of attenuation on the fundamental frequency using the commercial values: Ca = 390nF
Cb = 470nF

The design places two poles at 3Hz and 14Hz and 80 dB of attenuation at 100Hz.

Practical examples.
The preceeding points of this note have described the topology peculiarity. Remainder of the topics, for PFC
design, are similar to standard P.F.C. boost applications based on L4981A/B (see the related references and
application notes).
Starting from now, we can refer to real design examples.
In fact, in order to verify the efficacy of the described configuration, it have been checked a pair of application's
size. For evaluation porpoise, it has been realized a printed circuit.
Let us beginnes with and 800W P.F.C application.

800W Target:
1 - Wide range input voltage variation 110Vrms to 220Vrms.
2 - Output power 800W.
2 - Output voltage 400Vdc.
A switching frequency of 50 kHz has been chosen as a good compromise between the coil-size and the powerMOS switching losses.

Boost Inductor design.

To design the boost inductor, the parameters under consideration are the percentage current ripple (as low as
possible) and the cost of the bobbin. This portion of the design is the same as for the standard topology.
In this application, in place of a single inductor connected to one of the phases, it has been chosen to split the
inductor into two sections (two windings on the same core) as shown in the connection diagram at fig.9.

9/18

AN1606 APPLICATION NOTE

Figure 9. Connection Diagram for the Coupled Inductor

iL

Inductor

Mains

vs(t)

is(t)

Zin

Leq.

is(t)

Zin
vs(t)

Mains

Equivalent circuit.

Realizing the inductor in this manner improves common mode rejection and avoids the effect of the difference
between drain capacitance of the PowerMOSFETs. In order to simplify the model, assume a near unity coupling
factor and the equivalent circuit is shown in Figure 9b.
The inductance is proportional to the square of the number of turns. For the two windings it will be:

f)

N
N = ---- and
2
N N
N total = ---- + ---2 2

The required number of turns for a given inductance on the same core is the same as it is for one winding or
two windings. The only difference is that the two windings are separated into two sections. For simplicity we can
design the coupled inductor using the same criteria as for a standard inductor - core size, number of turns, and
size of copper wire.
For the core, the preferred design is a gapped ferrite core set.
The size of the core can be chosen considering the maximum current Ipk. that, for the 800W target's parameters
can exceed 14A (placing Ipk. = 15A).

g)

Where:

V core V core, "" min = K L I peck

(mm )

4 lcore
K = 1.4 10 -------------lgap

For the 800W application, the nominal current ripple has been chosen around 25%. This fixes the boost inductance value L=450H.

10/18

AN1606 APPLICATION NOTE

The coil requirements can be met using a gapped core set type E66/33/27, characterized with the following key
parameters:

Ae = 550mm^3;

lcore = 146mm;

m_core = >1600;

Vcore = 80.4*10^3mm^3

The air gap needed to avoid saturation and optimize the coil size is equal to lap = 3mm.

Using the parameters in the formula g).

Vcore>67.5mm^3

This result confirms the core is well above the minimum size.

The used formula for the number of turnes, needed to design the total required inductance L, is:

h)

N =

1gap
l, core
L
------ ----------------------------- + --------------------------------------------2
0 r, core A
A+
--- 1gap

The resulting N=38, in our solution, has been realized with 19 turns +19 turns.

In order to minimize the high frequency losses, the winding has been made using the "multiple wire" approach.
It is possible to estimate the losses for a low frequency current.
Imposing a maximum power value to be dissipated in the copper (Pcu = 5W)

i)

P wire = RDC I RMS , max < 5W

P wire
R DC < ------------------------ = 60m
2
I RMS , max

Using the formula for multiple wires: -

l)

ltu rn N
R DC = Cu ----------------------- < 60m
2
--- d M
4

Were:
In practice 20 wires were used, each having a diameter d=0.4 mm.

Output Capacitor filter.

For the bulk capacitor selection, we consider a reasonable 100Hz voltage ripple.

11/18

AN1606 APPLICATION NOTE

m)

Po
C o = --------------------------------------------------2 2 f fo Vo

were f is the input frequency.

Imposing <10Vac the peak of voltage variation over 400Vo, the Co value will results >318F; the commercial
value is 330F

Power Devices.
The selection of the power devices is dependent upon the topology and the size of the application.
Operating in continuous current mode, fast reverse recovery diodes are needed.
The TURBOSWITCH "STM family", in the 600V voltage range, offers a very good solution for the two boost
diodes, the STTH8R06FP has been chosen.
The insulated TO-220 package makes it easy to assemble the parts on a heat sinke.
Concerning the Powermos requirements, a 500V blocking voltage (Bvdss) is needed, for this application.
The chip selection is more complex. To find the best solution, it must be considered all the parameters that affect
the power dissipation and to compare the results in terms of a cost to benefit ratio. The devices used in the 800W
application (2+2), are the type STY34NB50F.
The four Powermos are efficiently driven without any additional buffer, thanks to the smart characteristics of the
integrated driver.
Figure 10. 800W SCHEMATHIC DIAGRAM.

R1

Vcc

D1+D2+D3+D4
Dz1

NTC

L3

C2
D6

D5

D13

L 2c

L 2a

F1
Input

C3

C1

L 2b
Q1
R2

R27

R28

R29

R32

R33

R30

R31

D7

Q2

Q3

D8

R14

D12

R8

R24

R25

R26

D10

R5 Q5

R4

R9

R7

R10

C16

R23

C5

20

Vcc
C15

C14

8 2
R17

4
11
6

L4981A/B

7
C13

18
17

R22

C6
C7
R18

12

10

C8

3
1

DETAIL for L2

19

15 16
Vcc

9
C12

13

14
R19

R21

L 2a
C10

L 2c
C11
L 2b

C4

R12

R15

R13

R16

Q4

D9
R3

D11

R6

12/18

R11

L1

R20

AN1606 APPLICATION NOTE

B.O.M. for 800W Bridgeless Evaluation Circuit.
Name

Value

Name

Value

Name

Value

Name

Value

Name

Value

R1

68

R2,3,4,5

10

R6

1.8

R7

100

R8

R9

2.7 k

R10

1.5 k

R11,12,14,15

1 M

R13

22 k

R16

25.5 k

R17

3.9k

R18

27 k

R19

220 k

R20

2.7 k

R21

5.6 k

R22,24,27

30 k

R25,26,28,29

499 k

R34

12 k

RSN

12

C1,3

1 F

C2

220 F

C4

330 F

C5

10 nF

C6

1 F

C7

1.8 nF

C8

1 F

C10

120 nF

C11

1 nF

C12

5.6 nF

C13

470 nF

C14

2.7 nF

C15

100 nF

C16

390 nF

NTC

2.5

B57364

F1

20A

R23,30,31,32,33 150 k

L2,#(1/ 50+50)# sense transformer;

L 3#(1/50)# sense transformer

#Ferrites Hy_perm.' Diam.=20mm

D1,2,3,4 ; D7,8,9,10,11,12,13 = 1N4148 ;

Dz1 = 1N4746;

Q5 = BS170

L1=450 H; => E66*33*27-18+18 turns 3mm/gapped# 20 wires //m=0.4 mm each.

D5,6 = STTH8R06FP;

Q1,2,3,4=STY34NB50F

Note: For the evaluation circuit and external coupled inductor EMC where utilized.
The filter has been achieved as follows: Coupled inductor (30 + 30) turns; wire diameter = 0.8mm on a toroidal (40x17x9 mm): Magnetizing inductance (each half inductor) Lm=8mH and a leakage inductance, Ld=50H.

Scaling down the application.

As a second step, based on the same circuit, a 600W P.F.C. has been built.
The target specification designed for server application is.

600W Target:
1- Wide range input mains 110Vrms to 220Vrms.
2- Output power = 600W.
2- Output voltage = 400Vdc.
The switching frequency has been set at 75kHz to use a reduced size and high performance PowerMOS.

13/18

AN1606 APPLICATION NOTE

Boost Inductor design.
The boost inductor has been design as been previously described .
For the 600W application, the nominal current ripple has been set around 22%, gives requires the inductance
value L=440H.
The inductor requirements can be met using the core set type E55/28/21, characterized with the following key
parameters:

A = 357mm^2;

lcore = 123mm;

m_core =>1600;

Vcore = 43.7mm^3

The needed air gap is: lap=2.5mm.

Using the relation g), Vcore>38.8mm^3

The result confirms that the core is good enough.

Using the relation h), the resulting N=42.

For the 600W, the coil has been realized with 21 turns +21 turns.
For minimize the high frequency losses, the "multiple wire" solution has been used.
Imposing the copper losses (Pcu = 3.8W), it has been used 14 wires having a diameter d = 0.4 mm each.

Output Capacitor.
For the selection of CO, the relation as been described in (m). The commercial value = 330F/450V used for
the 800W application is still good for the 600W application.

Power Devices.
For the two boost diodes, as for the 800W application, the STTH8R06FP has been used.
Concerning the Powermos, the devices used in the 600W version application are two STW26NM50F.

14/18

AN1606 APPLICATION NOTE

Figure 11. 600W SCHEMATHIC DIAGRAM.
R1

Vcc

D1+D2+D3+D4
Dz1

NTC

L3

C2
D6

D5

D13

L2c

L2a

F1

R11

R14

R12

R15

R13

R16

L1

Input

C3

C1

L2b

D11

C4

D12

R8

Q2

Q5

D9
R27

R28

R32

R29

R33

D8

R36

R3

R4

R35
R30
R24

R25

R26

C16

R23

R10

R31

C5

20

16

Vcc
C15

R9

R7

R6

C14

8 2
R17

4
11
6

L4981A/B

7
C13

R22

18
17

C6
C7
R18

12

10

C8

3
1

DETAIL for L2

19

15

9
C12

Vcc

13

14
R19

R21

C9

L2a
L2c

R20

C11

C10

L2b

B.O.M. for 600W version Bridgeless Evaluation Circuit.

Name

Value

Name

Value

Name

Value

Name

Value

Name

Value

R1

68

R3,4

10

R6

6.8

R7

100

R8

6.8

R9

2.7 k

R10

1.5 k

R11,12,14,15

1 M

R13

22 k

R16

25.5 k

R17

3.9k

R18

33 k

R19

220 k

R20

2.7 k

R21

5.6 k

R22,24,27

30 k

R25,26,28,29

499 k

R34

12 k

C1,3

1 F

C2

220 F

C4

330 F

C5

10 nF

C6

1 F

C7

1.8 nF

C8

1 F

C10

120 nF

C11

1 nF

C12

5.6 nF

C13

470 nF

C14

2.7 nF

C15

100 nF

C16

390 nF

NTC

2.5

57364

F1

15 A

R23,30,31,32,33 150 k

L2,#(1/ 50+50)# sense transformer ;

L 3#(1/50)# sense transformer

#Ferrites Hy_perm.' Diam.=20mm

D1,2,3,4 D8,9,11,12,13 =1N4148;

Dz1=1N4746;

Q5 = BS170.
15/18

AN1606 APPLICATION NOTE

L1=440 H; => E55*28*21-21+21 turns 2.5mm/gapped# 14 wires // m=0.4 mm each.
D5,6 = STTH8R06FP;

Q2,3 = STW26NM50F

Note: For the evaluation circuit and external coupled inductor EMC where utilized.
The filter has been achieved as follows: Coupled inductor (30 + 30) turns; wire diameter = 0.8mm on a toroidal (40x16x8.5 mm): Magnetizing inductance (each half inductor) Lm=8mH and a leakage inductance, Ld=50uH.

Conclusion:
The innovative bridgeless PFC configuration as described in this application note has been successfully tested.
Details have been presented how to implement the technology, which should prove interesting to designers.
Figure 12 shows the test results of efficiency and power dissipation for the application's 800W prototype.
Figure 12.

EFFICIENCY

[%]
98
B.Less
Standard PFC

97
96
95
94

P0=800 W

93
92
88

110

132

154

176

198

220

242

264

Vin
DISSIPATED POWER

[w]
80
70
60
50
40
30
20
10
0

B.Less
Standard PFC

P0=800 W
88

110

132

154

176

198

220

242

264

Vin

16/18

AN1606 APPLICATION NOTE

Evaluation results for the 800W version.
@Vin=110Vac: Nominal power
Vout

Pout

Pin

PF

TDH

Efficiency

395VDC

800W

860W

0.999

94%

824W

0.997

97%

@Vin=220Vac: Nominal power

395VDC

800W

Evaluation results for the 600W version.

@Vin=110Vac: Nominal power
Vout

Pout

Pin

PF

TDH

Efficiency

395VDC

652W

700W

0.998

6.7

93%

624W

0.994

96.5%

@Vin=220Vac: Nominal power

395VDC

652W

References: a) Parsad N. Enjeti, R. Martinez "A high performance single phase AC to DC rectifier with input power factor
correction" IEEE APEC'93

b) Alexandre Ferrari de Souza and Ivo Barbi "A new ZVS Semi resonant High Power Factor Rectifier with Reduced Conduction Losses"
IEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL.46, NO.1 FEBRUARY 1999.
c) STM Application Notes AN628; AN824.
STMicroelectronics @ www.st.com, http://ccd.sgp.st.com/stonline/books/index.htm

17/18

AN1606 APPLICATION NOTE

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