300 W, Wide Mains, PFC Stage Driven by the NCP1654

AND8324/D
300 W, Wide Mains, PFC
Stage Driven by the
NCP1654
Prepared by: Patrick Wang
ON Semiconductor
http://onsemi.com
Introduction
The NCP1654 is a Power Factor Controller to efficiently
drive Continuous Conduction Mode (CCM) step−up
pre−converters. As shown by the ON Semiconductor
application note AND8322, “Four Key Steps to Design a
Continuous Conduction Mode PFC Stage Using the
NCP1654”, which details the four key steps to design a
NCP1654 driven PFC stage, this circuit represents a major
leap towards compactness and ease of implementation.
Housed in a SO−8 package, the circuit minimizes the
external components count without sacrificing performance
and flexibility. In particular, the NCP1654 integrates all the
key protections to build robust PFC stages like an effective
input power runaway clamping circuitry.
When needed or wished, the NCP1654 also allows
operation in Follower Boost mode(1) to drastically lower the
pre−converter size and cost, in a straight−forward manner.
For more information on this device, please refer to the
ON Semiconductor data sheet NCP1654/D.
The board illustrates the circuit capability to effectively
drive a high power, universal line application. More
specifically, it is designed to meet the following
specifications:
• Maximum output power: 300 W
• Input voltage range: from 85 VRMS to 265 VRMS
• Regulation output voltage: 390 V
• Switching frequency: 65 kHz
© Semiconductor Components Industries, LLC, 2009
October, 2009 − Rev. 2
This application was tested using an active load. As in
many applications, the PFC controller is fed by an output of
the downstream converter, there is generally no need for an
auto−supply circuitry. Hence, in our demo board, the
NCP1654 VCC is to be supplied by a 15 V external power
supply.
The external voltage source that is to be applied to the
NCP1654 VCC, should exceed 10.5 V typical, to allow the
circuits start up. After start up, the VCC operating range is
from 9 V to 20 V.
The voltage applied to the NCP1654 VCC must NOT
exceed 20 V.
The NCP1654 is a continuous conduction mode and fixed
frequency controller (65 kHz). The coil (650 uH) is selected
to limit the peak to peak current ripple in the range of 36 %
at the sinusoid top, in full load and low line conditions.
Again, for details on how the application is designed, please
refer to the ON Semiconductor application note AND8322,
”Four Key Steps to Design a Continuous Conduction Mode
PFC Stage Using the NCP1654”.
As detailed in the document, the board yields very nice
Power Factor ratios and effectively limits the Total
Harmonic Distortion (THD).
1
Publication Order Number:
AND8324/D
TB1
AC Inlet
H
L
3
2
1
5A Fuse
F1
C1
0.47mF
150mH
L3
2 x 6.8mH
L2
C2
0.47mF
Figure 1. Application Schematic
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2
C7
C3
0.1mF
R11
82.5k
R10
0
R13
3.3M
R9
3.3M
GBU8J 8A 600V
0.47mF
DB1
1nF
C6
R7
3.6k
R8
47k
4
3
2
1
BO
CS
VM
FB
VCC
DRV
5
5
6
7
8
220nF
C5
Vcontrol
IC1
0.1
R6
650mH
NCP1654
GND
2
L1
2.2mF
C12
12k
R12
R3
23.2k
10pF
C10
R5
10
1N4148
D2
22mF
C8
+
+15V
0.1mF
C9
R4
10k
R1
1.8M
SPP20N60S5
1.8M
R2
Q1
2
1
MSR860G
D1
TB3
180mF 450V
C4
+
390V
2
1
TB2
AND8324/D
AND8324/D
Table 1. BILL OF MATERIAL
Reference
Description
Part Number
Manufacturer
C1
0.47 uF / 275 V type X2
F1772−447−2000
VISHAY
C2
0.47 uF / 275 V type X2
F1772−447−2000
VISHAY
C3
0.1u, 400V, High Ripple, Polypropylene Cap
ECWF4104JL
Matsushita
C4
180 mF 450 V
2222 159 47181
BC Components
C5
0.22 mF / 50V
K224K20X7RF53H5
VISHAY
C7
0.47 mF / 50V
K474K20X7RF53H5
VISHAY
C9
0.1 mF / 50V
K104K15X7RF53H5
VISHAY
C6
1 nF / 50 V
K102K15X7RF53H5
VISHAY
C10
100 pF / 50 V
K101K15X7RF53H5
VISHAY
C8
22 mF / 25 V
2222 013 36229
BC Components
C12
2.2 mF / 50 V
B32529D5225J
EPCOS
DB1
600 V, 8.0 A Bridge Dode
GBU8J
VISHAY
D1
8.0 A, 600 V
MSR860G
ON Semiconductor
D2
1N4148
1N4148
VISHAY
F1
5 A Fuse, Time Delay Fuse (FST 5x20)
0034.3124
SCHURTER
IC1
CCM PFC Controller
NCP1654
ON Semiconductor
L1
650 mH
GA3199−AL
CoilCraft
2702.0010A
Pulse
B82725−J2402−N20
EPCOS
Wurth Elektronik
L2
4 A, 2 x 6.8 mH, CM Choke
L3
150 uH, 5A, WE−FI Series, DM Choke
7447055
Q1
20 A 600 V MOSFET
SPP20N60C3
Infineon
R1
Resistor, Axial Lead, 1.8 M, 1/4 W, 1%
CCF501M80FKE36
VISHAY
R2
Resistor, Axial Lead, 1.8 M, 1/4 W, 1%
CCF501M80FKE36
VISHAY
R9
Resistor, Axial Lead, 3.3 M, 1/4 W, 1%
CCF503M30FKE36
VISHAY
R13
Resistor, Axial Lead, 3.3 M, 1/4 W, 1%
CCF503M30FKE36
VISHAY
R10
Jumper
Jumper
R3
Resistor, Axial Lead, 23.2 k, 1/4 W, 1%
CCF5023K2FKE36
VISHAY
R4
Resistor, Axial Lead, 10 k, 1/4 W
CCF5010K0FKE36
VISHAY
R5
Resistor, Axial Lead, 10, 1/4 W
CCF5010R0FKE36
VISHAY
R6
Resistor, Axial Lead, 0.1, 3 W, 1% LVR3 Series
LVR03 R1000 F E12
VISHAY
R7
Resistor, Axial Lead, 3.6 k, 1/4 W 1%
CCF503K60FKE36
VISHAY
R8
Resistor, Axial Lead, 47 k, 1/4 W
CCF5047K0FKE36
VISHAY
VISHAY
R11
Resistor, Axial Lead, 82.5 k, 1/4 W, 1%
CCF5082K5FKE36
R12
Resistor, Axial Lead, 12 k, 1/4 W, 1%
CCF5012K0FKE36
VISHAY
TB1
AC Inlet Connector
GSF1.1201.31
SCHURTER
TB2
DC Output Plug Socket
20.101/2
(Order Code 3044531)
IMO
TB3
VCC Connector Plug Socket
PM5.08/2/90.
(Order Code 5015571)
WEIDMULLER
HS1
Heatsink(2.9°C/W)
SK481 100mm
Fischer Elektronik
Q1
Isolator TO−220
3223−07FR−43
BERGQUIST
D1
Isolator TO−220
3223−07FR−43
BERGQUIST
DB1
Clip for heatsink (TO−220)
THFU 1
Fischer Elektronik
Q1
Clip for heatsink (TO−220)
THFU 1
Fischer Elektronik
D1
Clip for heatsink (TO−220)
THFU 1
Fischer Elektronik
Board Legs
TCBS−801
RICHCO
Board Legs
TCBS−801
RICHCO
Board Legs
TCBS−801
RICHCO
Board Legs
TCBS−801
RICHCO
PCB
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3
AND8324/D
Figure 2. The Board
For the sake of consistency, this application note reports
the performance and results that were obtained using the
CoilCraft. However, it has been checked that the other coil
yield high performance too.
Two coils from two different vendors have been validated
on this board:
• GA3199−AL from Coil Craft
• 2702.0010A from Pulse
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4
AND8324/D
PCB LAYOUT
Figure 3. Components Placement (Component Side)
Figure 4. PCB Layout (Solder Side)
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AND8324/D
GENERAL BEHAVIOR
EFFICIENCY AND PF AT 85 VAC AND 110 VAC
Table 2. EFFICIENCY, PF AT DIFFERENT LOAD AND LINE CONDITIONS
Vin
Iin (A)
Pin (W)
Vo (V)
Io (A)
Po (W)
PF
Efficiency
THD
85 Vac
60 Hz
3.87
326.5
392.6
0.77
302.3
0.999
92.6%
3.7%
3.50
295.4
392.6
0.70
274.6
0.999
93.0%
3.6%
3.00
253.1
392.7
0.60
236.2
0.999
93.3%
3.6%
2.48
210.1
392.8
0.50
196.8
0.999
93.7%
3.4%
1.98
167.5
392.9
0.40
157.4
0.999
94.0%
3.2%
1.48
125.5
392.8
0.30
118.4
0.999
94.3%
3.6%
1.00
84.5
393.1
0.20
79.6
0.998
94.3%
6.6%
0.49
41.2
393.7
0.10
39.2
0.998
95.2%
8.7%
0.25
21.0
397.1
0.05
19.5
0.991
93.0%
11.9%
2.93
319.5
392.7
0.77
302.9
0.999
94.8%
3.3%
2.65
289.9
392.8
0.70
275.4
0.999
95.0%
3.2%
2.27
248.0
392.8
0.60
236.1
0.999
95.2%
3.2%
1.89
206.4
392.9
0.50
196.8
0.999
95.4%
3.3%
1.51
165.0
392.9
0.40
157.5
0.998
95.5%
4.0%
1.13
123.9
393.0
0.30
118.4
0.998
95.5%
6.3%
0.76
82.5
393.1
0.20
79.0
0.998
95.8%
7.6%
0.38
41.6
394.3
0.10
39.8
0.993
95.6%
8.6%
0.20
20.9
397.4
0.05
19.6
0.973
93.6%
11.1%
110 Vac
60 Hz
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6
AND8324/D
Table 3. EFFICIENCY AND PF AT 230 VAC AND 265 VAC
Vin
Iin (A)
Pin (W)
Vo (V)
Io (A)
Po (W)
PF
Efficiency
THD
230 Vac
50 Hz
1.36
309.4
393
0.77
303.0
0.996
97.9%
6.1%
1.23
281.0
393
0.70
275.1
0.995
97.9%
6.3%
1.05
240.7
393.1
0.60
235.5
0.994
97.9%
7.1%
0.89
201.5
393.2
0.50
197.1
0.992
97.8%
7.1%
0.71
161.3
393.2
0.40
157.7
0.990
97.8%
7.2%
0.54
121.1
393.3
0.30
118.2
0.983
97.6%
7.4%
0.37
81
393.7
0.20
78.8
0.966
97.3%
7.3%
0.20
41.1
394.6
0.10
39.6
0.892
96.5%
13.0%
0.12
20.6
395.4
0.05
19.4
0.752
94.5%
15.8%
1.18
308.2
393
0.77
302.3
0.993
98.1%
6.9%
1.07
281.1
393.1
0.70
275.8
0.992
98.1%
6.8%
0.92
241.2
393.1
0.60
236.5
0.991
98.0%
6.7%
0.77
201.2
393.2
0.50
197.1
0.988
98.0%
7.0%
0.62
161.2
393.2
0.40
157.8
0.982
97.9%
6.9%
0.47
121.1
393.4
0.30
118.4
0.972
97.8%
7.3%
0.33
81.4
393.8
0.20
79.0
0.943
97.1%
11.8%
0.19
41.1
394.5
0.10
39.7
0.840
96.6%
22.6%
0.13
21.5
395
0.05
20.4
0.650
94.7%
23.0%
265 Vac
50 Hz
1.0
99
0.99
97
HALF LOAD
96
95
FULL LOAD
94
85Vac
230Vac
0.97
0.96
265Vac
0.95
0.94
0.93
0.92
93
92
85
110Vac
0.98
POWER FACTOR
EFFICIENCY (%)
98
0.91
170
255
0.90
70
340
170
270
OUTPUT POWER
INPUT VOLTAGE (Vac)
Figure 5. Efficiency vs. Input Voltage
Figure 6. Power Factor vs. Output Power
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AND8324/D
TYPICAL WAVEFORMS
Iin
Vac
Figure 7. Vac = 85 Vac, Pin = 326.5 W, Vout = 392.6 V, Iout = 0.77 A, PF = 0.999, THD = 3.74%
Vac
Iin
Figure 8. Vac = 230 Vac, Pin = 309 W, Vout = 393 V, Iout = 0.77 A, PF = 0.996, THD = 6.1%
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8
AND8324/D
NO LOAD OPERATION
Iin
VM
Vout
Vin
Figure 9. Vac = 230 Vac, Pin = 147 mW, Vout = 396 V, Iout = 0 A
Soft−Start
When in light load, the circuit enters a welcome burst
mode that enables the circuit to keep regulating. VM pin
oscillates around its internal reference voltage (2.5 V).
The power losses @ 230 Vac are nearly 147 mW. This
result was obtained by using a W.h. meter (measure
duration: 1 sec)
The NCP1654 grounds the “Vcontrol” capacitor when it is
off, i.e., before each circuit active sequence (“Vcontrol” being
the regulation block output). Only charging by the 28−mA
internal current source of the error amplifier (the 200 mA of
the dynamic response enhancer being disabled during the
start−up phase), “Vcontrol” ramps up slowly. As a result, the
power delivery rises gradually and the PFC pre−regulator
starts up smoothly and noiselessly.
Iin
Vcontrol
Vout
DRV
Figure 10. Vac = 85 Vac, Vout = 392.6 V, Iout = 0.77 A
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9
AND8324/D
Transient Load
Vcontrol is sharply pulled high by the internal 200 mA current
source of the dynamic response enhancer. As a result, a
higher power is delivered to output. Hence it prevents the
output voltage from dropping deeply.
When output loading changes from full load to no load,
the output voltage raises, and Vfb rises to activate the OVP
function. The output voltage is clamped by the OVP
function.
When output loading changes from no load to full load,
the output voltage drops, Vfb drops below 95% of Vref,
Iin
Vout
Vcontrol
Figure 11. Vac = 85 Vac, Vout = 392.6 V, Iout = 0 A ~ 0.77 A
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AND8324/D
Under Voltage Protection (UVP)
FB open test at 265 Vac, Iout = 0.1 A. The PFC circuit operates first, then short the FB Pin to ground. As Vfb is lower than
8% of Vref, UVP activates and shuts down the output. It is to protect the buck capacitor from damaging.
Iin
Vf b
Vout
DRV
Figure 12. Vac = 265 Vac, Vout = 394.5 V, Iout = 0.1 A
Brown Out Test
When the input voltage decreases to 68 Vac, VBO is below 0.7 V, brown out function is triggered and driver stops.
Vac
Iin
VBO
Vout
Figure 13. Vac = 68 Vac, Vout = 393.7 V, Iout = 0.1 A
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11
AND8324/D
Brown Out Recovery Test
When the input voltage increases above 78.4 Vac, VBO is above 1.3 V and driver resumes operation.
Vac
Iin
VBO
Vout
Figure 14. Vac = 78.4 Vac, Vout = 393.7 V, Iout = 0.1 A
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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 particular purpose, nor does SCILLC assume any liability
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AND8324/D
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