100W Universal Input PFC Converter

 Semiconductor Components Industries, LLC, 2003 February, 2003 - Rev. 2 1 Publication Order Number: AND8106/D AND8106/D 100 Watt, Universal Input, PFC Converter ON Semiconductor General Description This 100 watt converter demonstrates the wide range of features found on the NCP1650. This chip is capable of controlling PFC converters well into the kilowatt range. In addition to excellent power factor, this chip offers fixed frequency operation in continuous and discontinuous modes of operation. It has a wide variety of protection features, including instantaneous current limiting, average current limiting, and true power limiting. This unit will provide 400 V of well regulated power from an input source with a frequency range from 50 Hz to 60 Hz, and a voltage range of 85 Vrms to 265 Vrms. It is fully self contained and includes a high voltage start-up circuit, and bias supply that operates off of the boost inductor. Features • Fixed Frequency Operation • Shutdown Circuit • Operation Over the Universal Input Range • Multiple Protection Schemes • True Power Limiting • Start-Up and Bias Circuits Included Circuit Description Start-Up Circuit The start-up circuit allows the unit to use power from the input line to begin operation, and then shuts down to allow operation off of the bias winding, which reduces losses in the circuit. The start-up circuit has three modes of operation. One is used for starting the NCP1650 when the chip is functional, one is for bias power during shutdown operation, and the third is the off state. When power is initially applied to the unit, the gate of the pass transistor will be high, and the FET will be fully enhanced. The current into the VCC capacitance at pin 1 will be limited by the three 10 k� resistors in series with the FET. Figure 1. Start-Up Circuit Schematic FQP1N60 10 k 10 k 10 k Vout 1.2 M MMSZ5248BT1 1 �F Vbias Vin 1 NCP1650 This circuit will provide current as long as the FET is enhanced. For this to occur, the gate to source voltage must be greater than the gate threshold voltage. For this device that value is nominally, 4.0 V. The zener breakdown voltage is 18 V, so the FET will turn off at: Vchg max� 18 V� 4.0 V� 14 Volts As the output capacitor is charged up during the turn-on sequence, the bias supply voltage will also increase until the source of the FET exceeds 14 V. At this point, the FET will cease conduction, and all of the VCC power will be supplied via the bias circuit from the power inductor. If the unit is commanded into the shutdown mode, the chip will reduce its bias current to 0.5 mA and the start-up circuit will then maintain a regulated voltage of approximately 14 V on the VCC pin until the device becomes operational. APPLICATION NOTE http://onsemi.com A N D8106/D http://onsem i.com 2 Figure 1. Applications Circuit Schem atic 470 �H 470 �H L2 L3 F1 D2 D1 D3 D4 C20 C21 0.47 �F 0.1 �F 22 �F 0.1 �F R4 178 k R7 3.3 k C7 C22 Vin Loop Comp FB/SD 7 6 - + Error Amp 4 VR8 8.2 k C8 10 �F R6 178 k R9 56.2 k 10 �FC9 8 9 5 PCOMP PMAX AC Input 4 AC RefC5 C4 0.022 �F 1.0 nFR5 3.57 k Voltage/Power ORing Network Power Multiplier - + Power Amp 2.5 V + - Reference Multiplier Current Shaping Network 3 AC Comp C3 R3 15 Gnd Control Logic Oscillator + - Overshoot Comparator Shutdown 0.75 V 1.08 Vref UVLO Reference Regulator Current Sense Amplifier + - 1.0 �FC26 10 k R20 10 k R21 10 k R22 R23 1.2 MFQP1N60Q3 1 C2 0.1 �F Vref Shutdown Q2 MMBT2222ALT1 12 k R26 R25 4.7 k 0 V - ON 5 V - OFF MUR460 D7 100 �F C25 FQP12N60 Q1 R16 4.7 0.07 � R30 1/2 W L11 mH D6 BAS16LT1 100 �F C23 453 k R27 453 k R28 9.09 k R2916 Out 12 IS- MMSZ5248BT1 D5 2 CT1413 10 11 Ramp Comp C11 Iavgfltr 470 pF R13 51 k C14 470 pF R10 8.25 k Iavg SPECIFICATIONS: Line - 85 Vac to 265 Vac Power - 100 Watts Output Voltage - 400 VDC VinU1 1N5406 .012 �F 810 � AND8106/D http://onsemi.com 3 Voltage Regulation Loop The output voltage is sensed and reduced to the reference level by the resistive divider consisting of R27, R28 and R29. The output voltage of this divider is sensed by the non-inverting input of the error amplifier and compared to the internal 4.0 V reference. Assuming that the unit in not in a power limit condition, the voltage error signal will dominate the loop and be fed through the OR’ing network to provide one of the inputs to the reference multiplier. The other reference multiplier input is the divided down rectified AC input signal. The output of this multiplier is a haversine signal that is an accurate replica of the input AC signal. The current shaping network compares the average current from the current sense amplifier to the reference voltage and forces this current to follow the AC reference voltage. The current out of the current sense amplifier is filtered at a frequency that is less than the switching frequency, but greater than the rectified line frequency. This current is fed into the output filter capacitor(s) that filter it to a DC level. Power Regulation Loop The power multiplier generates the product of the input current (from the current sense amplifier) and the AC rectified input voltage, to generate a signal that represents the input power of the unit. This signal is filtered to a frequency of less than the line frequency, so that it’s output is a DC level. If the load is increased to a level that exceeds the maximum power limit of the circuit, the output of the power multiplier will reach 2.5 V and the output of the power error amplifier will go to some level above ground. This signal will then override the signal from the voltage error amplifier (labeled “error amp” on the schematic), and will dominate the OR’ing network. This signal then determines the level of the reference signal out of the reference multiplier, and determines the input current to the power converter. It should be noted that as this is a boost converter, the power limit circuit will only fold back the output voltage until it reaches the level of the peak line voltage. At this point the converter will shut down, but the input voltage will continue to charge the output capacitors through the rectifier. Shutdown Circuit The shutdown circuit will inhibit the operation of the power converter and put the NCP1650 into a low power shutdown mode. To activate this circuit, apply 5.0 V to the red test point, with the black jack being “ground”. Be aware that the black jack is actually hot as it is connected to the output of the input bridge rectifiers. An isolated 5.0 V supply should be used. If this circuit is not being used, the terminals can be left open, as there is enough resistance built in to the circuit to keep the transistor (Q2) in it’s off state. PCB The printed circuit board Gerber files are located on the ON Semiconductor website under the name NCP650- PCB1. L2 L3 In pu t 85 - 26 5 Va c ON Semiconductor NCP1650 Dem o Board C20 400 Vdc 0.25 am ps R5 R6 R4 D2 D1 D4 D3 C21 C25 Q1 L1 + - R27 R28 R29 Q3 Gnd 0 V/5 VShutdown R23 R22 R21 R20 D7C23 + AND8106/D http://onsemi.com 4 Table 1. Ref Des Description Part Number Manufacturer C2 Cap, Ceramic, Chip, 0.1 �F, 50 V C1608X7R1H104KT TDK C3 Cap, Ceramic, Chip, .012 �F, 50 V C1608X7R1H123KT TDK C4 Cap, Ceramic, Chip, 1.0 nF, 50 V C1608X7R1H102K TDK C5 Cap, Ceramic, Chip, 0.022 �F, 50 V C1608X7R1H223K TDK C7 Cap, Ceramic, Chip, 22 �F, 6.3 V C3225X5R0J226MT TDK C8 Cap, Ceramic, Chip, 10 �F, 10 V C3225X5R1A106MT TDK C9 Cap, Ceramic, Chip, 4.7 �F, 10 V C3216X5R1A475KT TDK C11 Cap, Ceramic, Chip, 470 pF, 50 V C1608C0G1H471JT TDK C14 Cap, Ceramic, Chip, 470 pF, 50 V C1608C0G1H471JT TDK C20 0.47 �F, 275 Vac, X Cap ECQ-U2A474ML Panasonic C21 Cap, Polyprop, 0.1 �F, 400 Vdc MKP1841-410-405 Vishay-Sprague C22 Cap, Ceramic, Chip, 0.1 �F, 50 V C1608X7R1H104KT TDK C23 100 �F, Alum Elect, 25 V ECA-1EM101I Panasonic C25 100 �F, Alum Elect, 450 V ECO-S2WP100EX Panasonic C26 Cap, Ceramic, Chip, 1.0 �F, 25 V C3216X7R1E105KT TDK D1-D4 Diode, Rectifier, 600 V, 3.0 A 1N5406 ON Semiconductor D5 Diode, Zener, 18 V, Axial Lead MMSZ5248BT1 ON Semiconductor D6 Diode, Signal, 75 V, 200 mA, SOT-23 BAS19LT1 ON Semiconductor D7 Diode, Ultra-Fast, 600 V, 8.0 A MURHF860CT ON Semiconductor F1 Fuse, 2.0 A, 250 Vac 1025TD2A Bussman L1 Inductor, 1000 �H, 2.4 A Max CTX22-15557 Coiltronics L2 2.5 A Sat, 100 �H Inductor, Diff Mode TSL1315S-101K2R5 TDK L3 2.5 A Sat, 100 �H Inductor, Diff Mode TSL1315S-101K2R5 TDK Q1 FET, 10.5 A, 0.7 �, 600 V, N-chl FQP12N60 Fairchild Q2 Bipolar Transistor, 50 V MMBT2222ALT1 ON Semiconductor Q3 FET, 1.0 A, 600 V, N-chl FQP1N60 Fairchild R3 Resistor, SMT, 810 � CRCW1206810JNTA Vishay R4 Resistor, Axial Lead, 178 k, _ Watt, 1% CMF-55-178K00FKRE Vishay R5 Resistor, Axial Lead, 3.57 k, _ Watt, 1% CMF-55-3K5700FKBF Vishay R6 Resistor, Axial Lead, 178 k, _ Watt, 1% CMF-55-178K00FKRE Vishay R7 Resistor, SMT, 8.6 k CRCW12068K60JNTA Vishay R8 Resistor, SMT, 9.1 k CRCW12069K10JNTA Vishay R9 Resistor, SMT, 56.2 k, 1% CRCW120656K2FKTA Vishay R10 Resistor, SMT, 8.25 k, 1% CRCW12068K2FKTA Vishay R13 Resistor, SMT, 51 k CRCW120651K0JNTA Vishay R16 Resistor, SMT, 10 CRCW1206100JRE4 Vishay R20 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R21 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R22 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R23 Resistor, Axial Lead, 1.2 M, _ Watt CCF-07-125J Vishay R25 Resistor, SMT, 4.7 k CRCW12064K70JNTA Vishay AND8106/D http://onsemi.com 5 Table 1. (continued) Ref Des Description Part Number Manufacturer R26 Resistor, SMT, 12 k CRCW120612K0JNTA Vishay R27 Resistor, Axial Lead, 453 k, _ Watt, 1% CMF-55-453K00FKBF Vishay R28 Resistor, Axial Lead, 453 k, _ Watt, 1% CMF-55-4533F Vishay R29 Resistor, Axial Lead, 9.09 k, _ Watt, 1% CCF-55-9K09FHR362 Vishay R30 1.0 W, 0.07 �, 1% Resistor WSL2512R0700FTB Vishay U1 PFC Controller NCP1650 ON Semiconductor Hardware H1 Printed Circuit Board NCP1650-PWB1 www.onsemi.com H2 Connector 171602 Weidmuller H3 Connector 171602 Weidmuller H4 Test Point, Red 5005 Keystone H5 Test Point, Black 5006 Keystone H6 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H7 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H8 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H9 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H10 Heatsink, TO-220 590302B03600 Aavid Thermalloy H11 Heatsink, TO-220 590302B03600 Aavid Thermalloy Table 2. Vendor Contacts Vendor U.S. Phone/Internet ON Semiconductor 1-800-282-9855 www.onsemi.com/ TDK 1-847-803-6100 www.component.tdk.com/ Vishay www.vishay.com/ Bussman (Cooper Ind.) 1-888-414-2645 www.cooperet.com/ Coiltronics (Cooper Ind.) 1-888-414-2645 www.cooperet.com/ Fairchild www.fairchildsemi.com/ Panasonic www.eddieray.com/panasonic/ Weidmuller www.weidmuller.com/ Keystone 1-800-221-5510 www.keyelco.com/ HH Smith 1-888-847-6484 www.hhsmith.com/ Aavid Thermalloy www.aavid.com/ Performance Data Table 3. Regulation Line/Load No Load 50 Watts 100 Watts 85 Vrms 405.5 405.1 403.9 115 Vrms 405.6 405.2 404.3 220 Vrms 405.4 405.5 404.9 265 Vrms 438.4 405.5 405 AND8106/D http://onsemi.com 6 Table 4. Harmonics and Distortion 115 Vac, 100 Watts 230 Vac, 100 Watts V harmon A harm. % V harmon A harm. % 2nd 0.084 0.03 0.169 0.12 3rd 0.505 2.8 0.722 2.6 5th 0.482 1.3 0.132 4.4 7th 0.168 0.5 0.075 0.17 9th 0.074 0.17 0.133 0.23 11th 0.088 0.13 0.134 0.17 13th 0.212 0.27 0.073 0.15 15th 0.324 0.37 0.265 0.28 17th 0.413 0.35 0.488 0.32 19th 0.632 0.31 1.12 0.44 PF - 0.998 - 0.9928 THD (A) - 3.68 - 6.2 Ifund - 0.919 - 0.451 Table 5. Efficiency 85 Vrms 115 Vrms 230 Vrms 265 Vrms Pin @ No Load 2.87 4.06 5.07 5.11 Pin 108.8 106.9 103.2 103.7 Vo 403.2 404.3 404.9 405 Io 0.246 0.246 0.243 0.244 Efficiency 0.912 0.930 0.953 0.953 AND8106/D http://onsemi.com 7 Notes AND8106/D http://onsemi.com 8 ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. 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PUBLICATION ORDERING INFORMATION JAPAN: ON Semiconductor, Japan Customer Focus Center 2-9-1 Kamimeguro, Meguro-ku, Tokyo, Japan 153-0051 Phone: 81-3-5773-3850 ON Semiconductor Website: http://onsemi.com For additional information, please contact your local Sales Representative. AND8106/D Literature Fulfillment: Literature Distribution Center for ON Semiconductor P.O. Box 5163, Denver, Colorado 80217 USA Phone: 303-675-2175 or 800-344-3860 Toll Free USA/Canada Fax: 303-675-2176 or 800-344-3867 Toll Free USA/Canada Email: ONlit@hibbertco.com N. American Technical Support: 800-282-9855 Toll Free USA/Canada