100 Watt Universal Input PFC Converter

AND8106/D
100 Watt, Universal Input,
PFC Converter
ON Semiconductor
http://onsemi.com
APPLICATION NOTE
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.
Vout
10 k
FQP1N60
Vbias
1 F
MMSZ5248BT1
Vin
Figure 1. Start-Up Circuit Schematic
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:
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.
February, 2003 - Rev. 2
1
NCP1650
Fixed Frequency Operation
Shutdown Circuit
Operation Over the Universal Input Range
Multiple Protection Schemes
True Power Limiting
Start-Up and Bias Circuits Included
 Semiconductor Components Industries, LLC, 2003
10 k
1.2 M
Features
•
•
•
•
•
•
10 k
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.
1
Publication Order Number:
AND8106/D
1N5406
L2
D1
F1
470 H
D2
0.47 F
Vin
R4
178 k
C7
0.1 F
D3
L3
D4
R7
Loop
Comp
R8
6
PCOMP
C26
4V
+
−
Error
Amp
R22
FQP1N60
Vin
Reference
Regulator
Power
+ Amp
−
2
Reference
Multiplier
BAS16LT1
D6
1.08 Vref
−
+
Current
Shaping
Network
L1
MUR460
Q1
FQP12N60
R16
4.7
Out
Current +
Sense
Amplifier -
Oscillator
12
IS-
Gnd
15
Ramp
Comp
14
R13
51 k
CT
10 Iavg 11 Iavgfltr
C14
470 pF
C11
R10
8.25 k 470 pF
R27
453 k
R28
453 k
C25
100 F
16
3
C3
13
C23
100 F
D7
Control
Logic
R3
0 V - ON
5 V - OFF
0.1 F
UVLO
1 mH
AC Comp
810 R25
4.7 k
Overshoot
Comparator
4
.012 F
R26
Vref
0.75 V
Power
Multiplier
1.0 nF
Shutdown
C2
−
+
5
AC Ref
0.022 F
MMBT2222ALT1
12 k
1
Shutdown
9
C9 10 F
R23
1.2 M
D5
MMSZ5248BT1
Voltage/Power
ORing Network
AC Input
C4
R21
Q2
2.5 V
R5
3.57 k
R20
1.0 F
U1
PMAX
10 F
C5
10 k
Q3
8
8.2 k
R9
56.2 k
10 k
0.07 1/2 W
R30
R29
9.09 k
AND8106/D
2
http://onsemi.com
Figure 1. Applications Circuit Schematic
0.1 F FB/SD
C8
10 k
7
C22
22 F
R6
178 k
C21
C20
470 H
3.3 k
SPECIFICATIONS:
Line - 85 Vac to 265 Vac
Power - 100 Watts
Output Voltage - 400 VDC
AND8106/D
Voltage Regulation Loop
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.
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.
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.
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.
PCB
The printed circuit board Gerber files are located on the
ON Semiconductor website under the name NCP650- PCB1.
D3
D4
Q1
D1
D2
Input
400 Vdc
0.25 amps
NCP1650 Demo Board
C20
C21
R4
Q3
+
ON
Semiconductor
R20
R21
R22
C23
+
R6
D7
L1
R27
R28
R23
L3
R5
L2
R29
Gnd
Shutdown 0 V/5 V
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3
85 - 265 Vac
C25
AND8106/D
Table 1.
Ref Des
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
1N5406
ON Semiconductor
MMSZ5248BT1
ON Semiconductor
D1-D4
Description
Diode, Rectifier, 600 V, 3.0 A
D5
Diode, Zener, 18 V, Axial Lead
D6
Diode, Signal, 75 V, 200 mA, SOT-23
D7
Diode, Ultra-Fast, 600 V, 8.0 A
F1
Fuse, 2.0 A, 250 Vac
L1
Inductor, 1000 H, 2.4 A Max
L2
BAS19LT1
ON Semiconductor
MURHF860CT
ON Semiconductor
1025TD2A
Bussman
CTX22-15557
Coiltronics
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
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4
AND8106/D
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
NCP1650-PWB1
www.onsemi.com
Hardware
H1
Printed Circuit Board
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
Performance Data
Table 2. Vendor Contacts
Vendor
ON Semiconductor
Table 3. Regulation
U.S. Phone/Internet
1-800-282-9855
www.onsemi.com/
Line/Load
No Load
50 Watts
100 Watts
85 Vrms
405.5
405.1
403.9
115 Vrms
405.6
405.2
404.3
TDK
1-847-803-6100
www.component.tdk.com/
220 Vrms
405.4
405.5
404.9
Vishay
www.vishay.com/
265 Vrms
438.4
405.5
405
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/
http://onsemi.com
5
AND8106/D
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
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
Table 5. Efficiency
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6
AND8106/D
Notes
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7
AND8106/D
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. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any
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8
AND8106/D
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