300 W, Wide Mains, PFC Stage Driven by the NCP1653

AND8185/D
300 W, Wide Mains, PFC
Stage Driven by the
NCP1653
Prepared by: Joel Turchi
ON Semiconductor
http://onsemi.com
APPLICATION NOTE
Introduction
This application was tested using a resistive 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
NCP1653 VCC is to be supplied by a 15 V external power
supply.
The external voltage source that is to be applied to the
NCP1653 VCC, should exceed 13.25 V typically, to allow
the circuit startup. After startup, the VCC operating range is
from 9.5 to 18 V.
The voltage applied to the NCP1653 VCC must NOT
exceed 18 V.
The NCP1653 is a continuous conduction mode and fixed
frequency controller (100 kHz). The coil (600 H) is
selected to limit the peak−to−peak current ripple in the range
of 30% 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 AND8184/D.
As detailed in the document, the board yields very nice
Power Factor ratios and effectively limits the Total
Harmonic Distortion (THD).
The NCP1653 is a Power Factor Controller to efficiently
drive Continuous Conduction Mode (CCM) step−up
pre−converters. As shown by the ON Semiconductor
application note AND8184/D, that details the four key steps
to design a NCP1653 driven PFC stage, this circuit
represents a major leap towards compactness and ease of
implementation.
Housed in a DIP8 or SO−8 package, the circuit minimizes
the external components count without sacrificing
performance and flexibility. In particular, the NCP1653
integrates all the key protections to build robust PFC stages
like an effective input power runaway clamping circuitry.
When needed or wished, the NCP1653 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 NCP1653/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 90 Vrms to 265 Vrms
• Regulation output voltage: 385 V
• Switching frequency: 100 kHz
(1)The
“Follower Boost” mode makes the pre−converter output
voltage stabilize at a level that varies linearly versus the AC
line amplitude. This technique aims at reducing the difference
between the output and input voltages to optimize the boost
efficiency and minimize the cost of the PFC stage (refer to
MC33260 and NCP1653 data sheet at www.onsemi.com).
 Semiconductor Components Industries, LLC, 2005
April, 2005 − Rev. 1
1
Publication Order Number:
AND8185/D
AND8185/D
Figure 1. The Board
Three coils from three different vendors have been
validated on this board:
• C1062−B from CoilCraft
• MB09008 from microSpire
• SRW42EC−E02H001 from TDK.
For the sake of consistency, this application note reports
the performance and results that were obtained using the
CoilCraft coil. However, it has been checked that the two
other coils yield high performance too.
http://onsemi.com
2
U1
KBU6K
L1
600 H
+
C15
680 nF
−
4.7 nF
Type = Y1
C13
CM1
4.7 nF
Type = Y1
L4
150
H
C11
1 F
Type X2
R9
680 k
680 k
560 k
390 V
U2
NCP1653
R2
470 k
C9
100 nF
C8
1 nF
R8
+ 15 V −
R4
4.7
Meg
C12
R5
C6
1 nF
C7
100 nF
1
8
2
7
3
6
4
5
+C4
C3
100 n 22 F
R1
R6
2.85 k
R3
56 k
0.1
N
Earth
90 TO 265 Vac
M1
SPP20N60S
4.5
R7
L
C2
+
100 F
Type = snap−in
450 V
C5
1 nF
R10
10 k
+
−
AND8185/D
3
http://onsemi.com
Figure 2. Application Schematic
C1
100 nF
Type = X2
N
D1
CSD04060
AND8185/D
PCB LAYOUT
Figure 3. Component Placement
Figure 4. PCB Layout (Components’ Side)
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4
AND8185/D
GENERAL BEHAVIOR − TYPICAL WAVEFORMS
Iin: ac line current (CH4 – 10 A/div)
Vout (CH3)
Vin (CH2)
Vpin5 (CH1)
Figure 5.
Vac = 90 V, Pin = 326.5 W, Vout = 365 V, Iout = 822 mA, PF = 0.999, THD = 4 %
Iin: ac line current (CH4 – 10 A/div)
Vout (CH3)
Vin (CH2)
Vpin5 (CH1)
Figure 6.
Vac = 220 V, Pin = 325 W, Vout = 384 V, Iout = 814 mA, PF = 0.989, THD = 8 %
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5
AND8185/D
THD and Efficiency at Vac = 110 V
Pin
(W)
Vout
(V)
Iout
(A)
PF
(−)
THD
(%)
eff
(%)
331.3
370.0
0.83
0.998
4
93
296.7
373.4
0.74
0.998
4
93
157.3
381.8
0.38
0.995
7
92
109.8
383.5
0.26
0.993
9
91
80.7
384.4
0.19
0.990
10
91
67.4
385.0
0.16
0.988
10
91
10
93
8
92
Efficiency (%)
94
THD (%)
12
6
4
2
91
90
89
0
88
50
100
150
200
250
300
50
350
100
150
200
250
300
350
Pin (W)
Pin (W)
Figure 7. THD vs. Pin
Figure 8. Efficiency vs. Pin
The Total Harmonic Distortion keeps below 10% from
Pmax (maximum power – 300 W) down to about Pmax/5.
The efficiency remains higher than 90% for input powers
ranging from 67 to 330 W.
In standby (no load conditions), the PFC stage enters a
stable burst mode, where the circuit keeps regulating the
output voltage and minimizes the power consumption (See
Figure 11).
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6
AND8185/D
THD and Efficiency at Vac = 220 V
Pin
(W)
Vout
(V)
Iout
(A)
PF
(−)
THD
(%)
eff
(%)
66.9
386.6
0.16
0.920
15
92
80.2
386.5
0.19
0.933
14
92
110.0
386.7
0.27
0.960
11
95
157.3
386.4
0.38
0.978
9
93
215.7
386.2
0.53
0.985
8
95
311.4
385.4
0.77
0.989
9
95
21
99
18
97
Efficiency (%)
THD (%)
15
12
9
95
93
91
6
89
3
0
50
100
150
200
250
300
87
50
350
Pin (W)
100
150
200
250
300
350
Pin (W)
Figure 9. THD vs. Pin
Figure 10. Efficiency vs. Pin
Similarly to the 110 Vac results, low THD values are
obtained. The Total Harmonic Distortion keeps below 15%
from Pmax (maximum power – 300 W) down to about
Pmax/5.
Again the efficiency keeps high in a large power range.
More specifically, it remains higher than 91% for input
powers ranging from 67 to 330 W.
In standby (no load conditions), the PFC stage enters a
stable burst mode, where the circuit keeps regulating the
output voltage and minimizes the power consumption.
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7
AND8185/D
Thermal Measurements
Measurements Conditions:
•
•
•
•
•
•
The following results were obtained using a thermal
camera, after a 1 h operation at 25°C ambient temperature.
These data are indicative. They show that the demo−board
may require additional heatsink capability if used in high
ambient temperature applications.
Vac = 90 V
Pin = 326 W
Vout = 365 V
Iout = 0.82 A
PF = 0.999
THD = 3 %
Coil
Coil
Power MOSFET
Heatsink
Bulk Capacitor
Output Diode
(ferrite)
(wires)
Input Bridge
100°C
80°C
50°C
75°C
100°C
130°C
85°C
No Load Operation
Iin: ac line current (CH3 – 10 A/div)
388V
Vout (CH3)
Vin (CH2)
Vpin5 (CH1)
Figure 11.
Pout = 0 W, Vac = 230 V
When in light load, the circuit enters a welcome burst
mode that enables the circuit to keep regulating. Vpin5
oscillates around the pin5 internal reference voltage (2.5 V).
The power losses @ 220 Vac, are nearly 130 mW. This
result was obtained by using a W.h meter (measure duration:
1 h).
http://onsemi.com
8
AND8185/D
Soft−Start
bandwidth required by PFC stages, “Vcontrol” increases
slowly. As a result, the power delivery rises gradually and
the PFC pre−regulator startup smoothly and noiselessly.
The NCP1653 grounds the “Vcontrol” capacitor when it is
off, i.e., before each circuit active sequence (“Vcontrol” being
the regulation block output). Provided the low regulation
DRV (Vpin7)
Vpin2 (CH3)
(Vcontrol – regulation output)
Vout (CH1)
Vin (CH2)
Figure 12.
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9
AND8185/D
Bill Of Materials
Ref Des
Description
Part Number
Manufacturer
C1
100 nF / 275 V type X2
PHE840MX6100M
RIFA
C2
100 F / 450 V
2222 159 37101
BC Components
C3
100 nF / 50 V
various
C4
47 F / 35 V
various
C5
1 nF / 50 V
various
C6
1 nF / 50 V
various
C7
100 nF / 50 V
various
C8
1 nF / 50 V
various
C9
100 nF / 50 V
various
C11
1 F / 275 V type X2
PHE840MD7100M
RIFA
C12
4.7 nF / 250 V type Y
DE1E3KX472MA5B
muRata
C13
4.7 nF / 275 V type Y
DE1E3KX472MA5B
muRata
C15
680 nF / 275 V type X2
PHE840MD6680M
RIFA
R1
Resistor, Axial Lead, 4.5 , 1/4 W, 1%
various
R2
Resistor, Axial Lead, 470 k, 1/4 W, 1%
various
R3
Resistor, Axial Lead, 56 k, 1/4 W, 1%
various
R4
Resistor, Axial Lead, 4.7 M, 1/4 W, 1%
various
R5
Resistor, Axial Lead, 680 k, 1/4 W, 1%
various
R6
Resistor, Axial Lead, 2.8 k, 1/4 W, 1%
R7
Resistor, Axial Lead, 0.1 , 3 W, 1%
R8
Resistor, Axial Lead, 680 k, 1/4 W, 1%
various
R9
Resistor, Axial Lead, 560 k, 1/4 W, 1%
various
R10
Resistor, Axial Lead, 10 k, 1/4 W, 1%
various
various
RLP3 0R1 1%
VISHAY
L1
Coil 600 H
Coil 650 H
Coil 600 H
C1062−B
MB09008
SRW42EC−E03H001
CoilCraft
microSpire
TDK
L4
DM Choke
150 H/5 A, WI−FI series
Wurth Elektronik
CM1 Filter (4 A, 2*6.8mH).
B82725−J2402−N20
EPCOS
U1
Diodes Bridge
KBU6K
General Semiconductor
D1
Output Diode
CSD04060
CREE
M1
MOSFET
SPP20N60S5
Infineon
Heatsink (2.9°C/W)
437479
AAVID THERMALLOY
Controller
NCP1653
ON Semiconductor
CM1
U2
http://onsemi.com
10
AND8185/D
Vendors Contacts
Vendor
Contact
Product Information
CoilCraft
www.coilcraft.com
microSpire
TDK
www.microspire.com
[email protected]
www.tdk.co.jp/tetop01/
www.cree.com/Products/pwr_sales2.asp
www.cree.com/Products/pwr_index.asp
EPCOS
CREE
www.epcos.fr/
http://onsemi.com
11
AND8185/D
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