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
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A
N
D8106/D
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i.com
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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
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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
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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
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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
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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
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Notes
AND8106/D
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changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any
particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all
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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