AN_TDA4863(G)(-2)_PFC_Calculation

A p p l i c a t i on N o t e , V 1 . 2, O c t . 20 0 3
TDA 4 863
AN-PFC-TDA 4863-3
Calculation-Tool for PFC-Preconverter
using TDA 4863
Author: Wolfgang Frank
http://www.infineon.com/pfc
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Calculation-Tool for PFC-Preconverter
using TDA 4863
Revision History:
29.10.2003
Previous Version:
1.1
Page
Subjects (major changes since last revision)
2
update
V1.2
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Technologies Offices in Germany or the Infineon Technologies Companies and
Representatives worldwide: see our webpage at http://www.infineon.com.
Edition 29.10.2003
Published by Infineon Technologies AG,
St.-Martin-Strasse 53,
81669 München, Germany
© Infineon Technologies AG 2002.
All Rights Reserved.
Attention please!
The information herein is given to describe certain components and shall not be considered as warranted
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We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement, regarding
circuits, descriptions and charts stated herein.
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Information
For further information on technology, delivery terms and conditions and prices please contact your nearest
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question please contact your nearest Infineon Technologies Office.
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be endangered.
Calculation-Tool for PFC-Preconverter
using TDA 4863
Table of Contents
Page
1
Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2
Related PFC Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3
3.1
3.2
3.3
3.4
Calculation Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiplier Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Summary of Used Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Application Note
3
5
5
5
6
6
V1.2, 29.10.2003
Calculation-Tool for PFC-Preconverter
using TDA 4863
Short Description
1
Short Description
This application note describes the handling of the calculation tool “PFCCal-DCM_1.xls”
which is available on our website http://www.infineon.com/pfc. It is an excel-sheet and
allows a flexible use for PFC preconverters used in many switch mode power supplies.
The calculation is based on the condition, that the switching frequency is always above
a generic minimum frequency. Please note, that the calculation tool is only suitable for
DCM-designs using TDA 4863. There is no warranty for the results when using other IC.
The first sheet is a README-sheet and give a rough overview of the calculation flow.
The second sheet is the calculation itself followed by two sheets providing the databases
for the ferrite cores and resistive components.
For further information, please refer to the Infineon application notes concerning
TDA 4863 and PFC ([1], [2], [3]).
2
Related PFC Circuit
Figure 1 shows the schematic of the PFC preconverter which the tool is related to. All
components are identically enumerated as in PFCCalc.xls.
L1
D5
VOUT
DC
R8
D6
R12
D1...D4
L2
VOLTAGE
AMPLIFIER
OUTPUT
C1
2,5V Reference
Undervoltage
Lockout 12,5V - 10V
Internal Supply
2
Restart Timer
2,2V
C6
VIN AC
R2
C2
VOLTAGE
SENSE
1
0,2 V
0,2V C4
0
&
0
&
0
0
40µA
0
0
8
S
Q
R
Q
5k
3
R7
M1
0V...4V
Multiplier
Q1
7
DRIVE
OUTPUT
0
6
200ns
LEB
C1
10k
M3
QM = M1*(M2-VFB)*K
0,3 V-1< K < 0,7V-1
VFB = 2,5V
C4
VCC
R10
0
0,6V
M2
2,5V...4,3V
MULTIPLIER
&
0
0
R6
C8
5V
16V
0
R4
5
1,5V
1,0V
TDA
4863
C5
VOP
1,2V
C2
C3
R9
ZERO
CURRENT
DETECTOR
GROUND
C10
4
CURRENT
SENSE
1,0V
R11
R5
GND
Figure 1
Schematic of PFC Circuit
Application Note
4
V1.2, 29.10.2003
Calculation-Tool for PFC-Preconverter
using TDA 4863
Calculation Sections
3
Calculation Sections
The color of the excel cells indicate their function. Yellow cells represent input cells. They
ask for basic data being filled in by the user. Nevertheless, they may also contain values
by default. Green cells indicate that the value shown is the result of a component
according to Figure 1. White cells are protected against any inputs.
Pull-down menus give the user a choice of possible values for the related component.
The choice of the menu entry is not mandatory. It is still possible to use individual values
which are directly typed into the cells.
3.1
Input Section
The input values of this section are:
•
•
•
•
•
RMS-value of lowest AC input voltage Vinmin
RMS-value of lowest AC input voltage Vinmax
Rated output power of preconverter Pout
Estimated efficiency eta
Minimum switching frequency fp
These values define the maximum inductor current IinpmaxHF which results in the shunt
resistor R11 according to Figure 1.
3.2
Output Section
This section calculates the voltage divider consisting of R4 and R5 according to
Figure 1. It is used for sensing the output voltage and for the adjustment of the
overvoltage protection (OVP) level.
In line 24 the necessary resistor value for R5 is calculated based on the projected output
voltage and overvoltage level. The next step is to look after the nearest value in the pulldown menu right below in line 27. This will lead to a default value for R4 calculated in
line 28. Due to the high voltage stress of resistor R4, it is split into two resistors in series.
It is therefore necessary to choose half the value of line 28 in the pull-down menu of
line 29. The resulting series resistor and the resulting output voltage as well as the OVP
level are displayed in line 30 to 32. Both the value in line 27 and in line 29 can also be
manipulated manually by directly filling in the values into the corresponding cell.
The tolerance of R4 and R5 are directly influencing the precision of the output voltage
and the OVP level. The menus of line 27 and line 29 contain therefore values of the E96
series with a tolerance of 1%.
This section calculates also the minimum bus capacitor C8 which provides the specified
output characteristics if the mains interrupt for a given holdup time.
Application Note
5
V1.2, 29.10.2003
Calculation-Tool for PFC-Preconverter
using TDA 4863
Calculation Sections
3.3
Multiplier Section
The multiplier section provides the information of the input voltage waveform which has
to be traced. This means, that the input voltage is divided with the resistors R6 and R7
according to Figure 1 and fed into the multiplier pin. Again, R6 is split into two resistors
in series, because it is also stressed by higher voltage. Therefore, the value chosen in
the menu of line 40 is doubled in line 41 and is highly recommended to be high-ohmic in
order to avoid unnecessary losses. Then choose the nearest value of resistor R7 in the
menu in line 43. The values of R6 and R7 must be changed if the test results in “NO” in
line 44.
The tolerance of these components needs not to be very low, because it has almost no
influence on the THD or the power factor. The entries of the menus are taken from the
E12 series with 5% tolerance.
3.4
Inductor Section
The input values of this section are:
• the maximum flux density swing during one pulse period
• the saturation flux density
• the core type
The lines 55, 57 and 58 show default values, when using a core type of the pull-down
menu. They are taken from the EPCOS data book [4]. However, it is also possible to fill
in individual values there.
The lines 52 to 58 result in the airgap of the core which is given in line 59. If a core of the
menu of line 54 is used, then the menu of line 60 will show all available airgaps of this
type. Again, one can neglect those values and fill in an individual one.
Then the next integer number has to be inserted in line 63 and the effective inductance
of the PFC inductor is shown in line 64. The test in line 65 and 66 proves, if the core
probably saturates. It is recommended to change to a larger airgap or to a larger core if
the saturation current is smaller than the highest peak inductor current IinpmaxHF.
The design of the detector winding which is necessary to capture the zero crossing of
the inductor current is dependent on the IC supply circuit used. Please refer to [1] for
further information.
Application Note
6
V1.2, 29.10.2003
Calculation-Tool for PFC-Preconverter
using TDA 4863
Summary of Used Nomenclature
4
Summary of Used Nomenclature
Physics:
General identifiers:
Special identifiers:
A .........cross area
b, B .....magnetic inductance
C .........capacitance
d, D .....duty cycle
f...........frequency
i, I ........current
L..........inductance
N .........number of turns
p, P .....power
t, T.......time, time-intervals
v, V......voltage
W ........energy
η..........efficiency
AL ........... inductance factor
V(BR)CES .. collector-emitter breakdown
voltage of IGBT
VF........... forward voltage of diodes
Vrrm .......... maximum reverse voltage of diodes
big letters: contant values and time intervals
small letters: time variant values
K1, K2 ..ferrite core constants
Components:
C .........capacitor
D .........diode
IC ........integrated circuit
L..........inductor
R .........resistor
TR .......transformer
Indices:
AC.......alternating current value
DC.......direct current value
BE .......basis-emitter value
CS.......current sense value
OPTO..optocoupler value
P .........primary side value
Pk........peak value
R .......... reflected from secondary to primary side
S .........secondary side value
Sh .......shunt value
UVLO ..undervoltage lockout value
Z..........zener value
Application Note
7
fmin......... value at minimum pulse frequency
i ..............running variable
in ............input value
max ........maximum value
min .........minimum value
off ...........turn-off value
on ...........turn-on value
out ..........output value
p .............pulsed
rip ...........ripple value
1, 2, 3 .....on-going designator
V1.2, 29.10.2003
Calculation-Tool for PFC-Preconverter
using TDA 4863
References
5
References
[1]
Infineon Technologies AG: TDA 4863 - Power factor and boost converter
controller for high power factor and low THD; Preliminary data sheet; Infineon
Technologies AG; Munich; Germany; 07/01.
[2]
M. Herfurth, W Frank: TDA 4863 - Technical description; Application Note
AN-PFC-TDA4863-1; Infineon Technologies; Munich; Germany; 02/02.
[3]
W Frank: TDA 4863 - Getting started with TDA 4863; Application Note
AN-PFC-TDA4863-2; Infineon Technologies; Munich; Germany; 02/02.
[4]
EPCOS: Data book library 2002; data book CDROM; EPCOS; Germany; 2001.
Application Note
8
V1.2, 29.10.2003
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