MODEL 7700 SERIES NEW HIGHER POWER VERSION Power Factor Correction Power Module MODELS/RANGE 7700B 7700-2A 1,500 Watts / 3,000 Watts 2,000 Watts / 4,000 Watts FEATURES AND BENEFITS • Module contains all power components necessary to provide power factor correction in a switching power supply. - Rectifier bridge with SCRs for inrush current limiting - Ultrafast platinum output diode - 500V .1Ω Max. FET (7700B) - Low gate charge, 500V, .0675Ω max. FET (7700-2A) • Provides optimum use of available line current • Allows power supply to meet harmonic requirement • Module design reduces cost of heat sink • Saves significant space and assembly time • Low cost • Internal temperature sensing • Replaces up to 10 each TO-220 or TO-247 discrete power semiconductors • Custom module versions available to meet specific requirements such as: - Motor drives - Power servo amplifiers - Solenoid drivers - Solid state relays - 3 phase rectifier bridges APPLICATIONS Designed to optimally facilitate a boost type power factor correction (PFC) system for designs with up to 36A rms input current. Standard applications include switching power supplies from 1,000 watts to 4,000 watts with line voltages up to 300 V rms. Specifications subject to change without notice. 7-19 Model 7700 Series 7 ELECTRICAL CHARACTERISTICS Parameter MOS FET Continuous Drain Current Symbol Conditions1 Model ID TC = 25°C B -2A B -2A B -2A B -2A B -2A B -2A B, -2A B, -2A B -2A B, -2A B, -2A B B B -2A -2A -2A B -2A B -2A B -2A B -2A B -2A TC = 100°C Pulsed Drain Current IDM Single Pulse Avalanche Energy EAS Repetitive Avalanche Energy EAR Avalanche Current IAR Gate to Source Voltage Leakage Current Drain to Source ON Voltage VGS IDSS VDS(ON) Gate Threshold Voltage Gate Leakage Current Total Gate Charge Gate Source Charge Gate Drain (Miller) Charge Total Gate Charge Gate Source Charge Gate Drain (Miller) Charge Continous Source Current (Body Diode) Pulsed Source Current (Body Diode) Body Diode Forward Voltage VGS(TH) IGSS Qg Qgs Qgd Qg Qgs Qgd IS VGS = 0V, VDS = 500V IC = 28A, VGS = 10V VDS = VGS, ID = 1mA VGS ±20V ID = 56A, VDS = 400V VGS = 10V ID = 80A, VDS = 400V VGS = 10V ISM VSD Reverse Recovery Time (Body Diode) Reverse Recovery Charge (Body Diode) Internal Gate Resistor trr RG Junction Temperature Thermal Resistance TJ RTHJC Qrr IS IS IF IF IF IF = 56A, VGS = 0V = 80A, VGS = 0V = 56A, di/dt = 400Aµs = 80A, di/dt = 400Aµs = 56A, di/dt = 400Aµs = 80A, di/dt = 400Aµs 7-20 Min. Typ. 1.5 1.0 2.0 0.4 0.5 B -2A B, -2A 1.25 0.25 B -2A 0.20 .15 Max. Units 56 80 34.8 48 224 320 760 960 19 28 8.7 20 ±30 100 2.8 2.7 4.0 ±400 600 80 320 480 128 196 56 80 224 320 1.4 1.8 810 860 28.8 39.6 A A A A A A mJ mJ mJ mJ A A V µA V V V nA nC nC nC nC nC nC A A A A V V ns ns ns ns 150 Ω Ω °C .025 .20 °C/W °C/W Model 7700 Series ELECTRICAL CHARACTERISTICS Parameter SCRS Average On Current RMS On Current (As AC switch) Peak Repetitive Off Voltage Symbol Conditions1 Model IT(AV) TC = 75°C, 180° half sine wave B -2A B -2A B -2A B -2A B -2A B -2A B, -2A B, -2A B, -2A B, -2A B, -2A B, -2A B -2A B -2A B, -2A IRMS VRRM/ VDRM Peak One Cycle Non-Repetitive ITSM Surge Current Reverse and Direct Leakage IR/ID Current On Voltage VT TJ = TJMax., t = 10ms (50 Hz), sine VR = VRRM, VD = VDRM Gate Trigger Voltage (Includes drop across RG) VGT Gate Trigger Current (Each SCR Individually) VGT Holding Current IH IT = 25A IT = 45A VD= 6V, 22Ω VD= 6V, 22Ω. TJ = -40°C VD= 6V, 22Ω. TJ = 125°C VD= 6V, 22Ω VD= 6V, 22Ω. TJ = -40°C VD= 6V, 22Ω. TJ = 125°C (Each SCR Individually) Internal Gate Resistor RG Connected to each SCR Junction Temperature Thermal Resistance Tj Rthjc Bridge Diodes Average Forward Current IF(AV) Peak Repetitive Reverse Voltage Peak One Cycle Non-Repetitive Surge Current Reverse Leakage Current IFSM Forward Voltage VF Junction Temperature Thermal Resistance TJ RTHJC TC= 105°C, 180°, half sine wave TJ = TJ Max., t = 10ms (50 Hz), sine VR = VRRM IF = 25A IF = 40A B -2A B -2A B -2A B -2A B -2A B, -2A B -2A 7-21 Typ. 0.5 0.5 0.2 0.3 0.1 5 10 2 Max. Units 20 35 30 55 600 800 300 400 25 300 1.6 1.6 3.5 1.5 1.5 60 120 35 100 100 150 A A A A V V A A µA µA V V V V V mA mA mA mA mA Ω Ω °C 2.0 1.0 °C/W °C/W 20 40 600 800 300 400 100 300 1.2 1.2 150 A A V V A A µA µA V V °C 1.8 1.2 °C/W °C/W 10 10 B -2A VRRM IR/ Min. 1.4 0.7 0.5 0.5 1.5 1.0 Model 7700 Series 7 ELECTRICAL CHARACTERISTICS Parameter Output Diode Average Forward Current Symbol Conditions1 Model IF(AV) TC= 120°C TJ = TJMax., t = 10ms (50 Hz), sine VR = VRRM Peak Repetitive Reverse Voltage Peak One Cycle Non-Repetitive Surge Current Reverse Leakage Current IFSM Forward Voltage VF Reverse Recovery Time trr Junction Temperature Thermal Resistance TJ RTHJC TH1 NTC Thermistor Resistance Resistance Ratio Dissipation Constant Thermal Time Constant VRRM IR/ R25 RT/R25 IF = 24A IF = 50A IF = 6A, di/dt = 300Aµs IF = 2A, di/dt = 200Aµs Min. Max. Units B -2A B, -2A 24 60 600 A A V B -2A B -2A B -2A B -2A B, -2A 500 500 60 1 2.8 2.8 35 40 175 A A µA mA V V ns ns °C 0.9 0.75 1.0 0.9 °C/W °C/W 25 27.5 KΩ 10 mW/°C sec 1.0 0.5 B -2A I = 1mA T = 80°C T = 90°C T = 100°C T = 110°C PD t B, -2A B, -2A B, -2A B, -2A B, -2A B, -2A B, -2A Typ. 22.5 .126 .0916 .0679 .0511 1.0 1 - TCase = 25°C unless otherwise specified. 7-22 Model 7700 Series SYSTEM DIAGRAM 4 CT AC Line EMI Filter 3 L1 8 9 CT 1 7 + Co 2 Dotted line denotes BI Model 7700 and associated pins. Load 5 14 Pin 1: AC 1 Pin 2: AC 2 Pin 3: Bridge Output Pin 4: SCR Gates Pin 5: Ground Pin 6: Ground Pin 7: FET Drain Pin 8: Ultrafast Anode Pin 9: Ultrafast Cathode Pin 10: Gate Ground Pin 11: Gate Drive Pin 12: N.C. Pin 13: TH 1 Pin 14: TH 2 Vo 13 12 11 10 6 Gate Driver Thermal Shutdown Circuitry PFC PWM 7 7-23 Model 7700 Series OUTLINE DIMENSIONS (Inch) 3.050 Max. 2.560 Pin .050 x .020 14 Places .505 ±.010 Pin 14 R .235 .950 1.100±.015 ∅ .280 ∅ .150 1.440 Max. .160 Ref. Pin 1 6X .175 6X .275 .330 .075 Ref. .150 .154±.015 .515 Ref. .361 .286 Part Number Lot Number Date Code ORDERING INFORMATION 77 0 0 B Model Range, Watts: B = 1,500 to 3,000 Watts -2A = 2,000 to 4,000 Watts Package Circuit Function: 0 = Power Factor Correction 7-24 Model 7700 Series MODEL 7700 APPLICATION NOTES OUTPUT VOLTAGE OUTPUT CAPACITOR The dc output voltage must be greater than the highest peak line voltage expected: The output capacitor size is often limited by the line dropout requirements of the power supply: VO > VIN MAX x 1.414 CO MIN = 2 x POUT x td VO2 - VO MIN2 Where: POUT is the output power, td is the dropout time, and VO MIN is the minimum allowed output voltage. DISCONTINUOUS CONDUCTION When the line voltage approaches zero volts the PFC PWM will be forced towards its maximum duty cycle. This will cause the current to become discontinuous, which will result in some distortion. The line voltage at which the current will become discontinuous will be: The 120Hz output voltage ripple can be calculated to insure it meets the system requirements: VO P– P 120 = VO x (1 - DCMAX ) VIN discontinuous = DCMAX (2xPV ) x (2 xπ1x f xC + ESR) O O O The maximum rms 120Hz ripple current will be: The line voltage at which the PWM will be duty cycle limited will be: I RMS 120 = VIN duty cycle limited = VO x (1-DCMAX) 1.414x PO VO The 100KHz output voltage ripple will be: INDUCTOR L1 (1.414 x V ) The inductor value controls the amplitude of the 100KHz current ripple. This can greatly effect the amount of distortion and thus the amount of EMI filtering required on the input. Ripple current can be calculated for any point along the input sine wave: VIN (t) x DC(t) I P – P(t) = Lx f A good starting point would be to set Ip-p equal to 20% of the 120 Hz peakcurrent, solving for L: L≥ 1.414 x VIN VO 5 x V x (1PIN x f VIN x (1- VO IN ) x Lxf ( 2 xπ1x f xC + ESR) O The maximum rms 100KHz ripple current will be: 1.414 x VIN VIN x (1- V ) I RMS 100K = 2.828 x L x f O GATE DRIVE REQUIREMENTS Where: DC(t)=1-VIN(t)/VO, L is the inductance of L1, and f is the switching frequency. 2 IN VO P– P 100K = ) FET switching times must be fast enough to insure that the FET turns off when the PWM is at maximum duty cycle. Snubbing circuits across the FET will slow the turn off time and should not be used. A discrete gate driver circuit will allow the fastest possible switching times. The Unitrode UC3710 or Telcom TC4422 drivers offer a single chip approach 7-25 Model 7700 Series 7 MODEL 7700 APPLICATION NOTES with only slightly slower switching times. The gate driver must be located as close to the module as possible. Ground sense pin 10 should be used to insure the fastest possible switching times. HEAT RADIATOR The heat radiator requirements can be determined by the maximum power dissipated (at low line) and the maximum ambient temperature. The back side of the module should be limited to about 100°C by utilizing the internal thermistor. RΘ = 100 - TMAX AMB PO LOWLINE Care should be used when attaching the module to the heat radiator. The screws must be tightened incrementally in a crisscross pattern. A torque limiting screwdriver should be used. The high current levels require currrent sense transformers to maintain a reasonable efficiency. We recommend BI Technologies HM31-20200. PFC PWM VENDORS Popular sources are: Unitrode UC3854 Micro Linear ML4812 Linear Technology LT1248 7-26 Model 7700 Series

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