High Efficiency - ON Semiconductor

DN05057/D
High Efficiency,
<30mW No‐load PFC
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DESIGN NOTE
Table 1. DEVICE DETAILS
Device
Application
Input Voltage
Output Power
Topology
I/O Isolation
NCP1615C
Adapter
85 to 265 Vac
Up to 120 W
PFC
Non-isolated
Characteristic
Output Specification
Output Voltage
400 Vdc Nominal
Nominal Current
300 mA
No Load Standby
< 30 mW
Min Current
Zero
Description
Key Features
• High Voltage Startup Circuit
• Critical Conduction Mode (CrM)
• Novel CCCF Based Control Scheme Maximizes
The NCP1615C is a high voltage PFC controller designed
to drive PFC boost stages based on an innovative Current
Controlled Frequency Foldback (CCFF) method. In this
mode, the circuit classically operates in critical conduction
mode (CrM) when the inductor current exceeds
a programmable value. When the current is below this preset
level, the NCP1615C linearly decays the frequency down to
a minimum of about 26 kHz when the input current is zero.
CCFF maximizes the efficiency at both nominal and light
load. In particular, the standby losses are reduced to
a minimum. An innovative circuitry allows near-unity
power factor even when the switching frequency is reduced.
The integrated high voltage startup circuit eliminates the
need for external startup components and consumes
negligible power during normal operation. Housed in
a SOIC−16 package, the NCP1615C also incorporates the
features necessary for robust and compact PFC stages, with
few external components.
Efficiency Across Line and Load
• Skip Mode Near the Line Zero Crossing
• Fast Line/Load Transient Compensation
•
•
•
•
•
•
•
(Dynamic Response Enhancer)
Valley Turn On
Input Voltage Range Detection
PFCOK Signal
Input to Force Controller into Standby Mode
Input Filter Capacitor (X2) Discharge Circuitry Enables
Very Low Standby Power Applications
Line Removal Detection to Reset the Downstream
Converter
Power Savings Mode Enables < 30 mW No-Load Power
Safety Features
• Restart Pin Allows Adjustment of Bulk Voltage
•
•
•
•
•
•
•
•
© Semiconductor Components Industries, LLC, 2015
January, 2015 − Rev. 1
1
Hysteresis in Standby Mode
Adjustable Bulk Undervoltage Detection (BUV)
Soft Overvoltage Protection
Integrated Brownout Detection
Overcurrent Protection
Open Pin Protection for FB and BUV Pins
Internal Thermal Shutdown
Latch Input
Low Power Mode Operation if the Bypass Diode is
Shorted
Publication Order Number:
DN05057/D
DN05057/D
• Open Ground Pin Fault Monitoring
• Line Overvoltage Detection
•
Instructions
• Always Use an Isolated AC Supply when Testing
• When Operating with Ext. Vcc Bias (J3), it is Important
•
to Connect the AC Line Voltage First, then Connect
External Vcc. Failure to Do This will Activate the Line
Removal Detection Feature, and the Board will Not
Start until Vcc is Discharged to ~4.5 V
To Enter Power Savings Mode (PSM), Remove the
Jumper Labeled “PSM” (J4)
To Enter Standby Mode, Apply 5 V to the Test Point
Labeled “STDBY”
TRANSFORMER DESIGN
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DN05057/D
CIRCUIT SCHEMATIC
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DN05057/D
EFFICIENCY PLOTS
Standby Power vs. Input Voltage
25.00
Standby Power (mW)
20.00
15.00
10.00
5.00
VAC
Pin (mW)
85
4.55
115
5.42
230
16.2
265
19.2
0.00
0
50
100
150
200
250
300
Input Voltage (Vac)
Figure 1. Standby Power
Efficiency vs. Output Power
98.0
97.0
Efficiency (%)
96.0
95.0
94.0
93.0
92.0
91.0
0
20
40
60
80
100
120
Output Power (W)
85 Vac
115 Vac
230 Vac
140
VAC
Pin (W)
Io (mA)
Vout (V)
Po (W)
Eff (%)
85
31.0
71.2
397.8
28.3
91.4
85
62.4
146.5
397.9
58.3
93.5
85
94.0
221.3
398.0
88.1
93.7
93.5
85
126.2
296.5
398.1
118.0
115
30.9
71.7
398.2
28.6
92.3
115
61.6
146.1
398.3
58.2
94.4
115
92.6
220.9
398.3
88.0
95.0
115
124.0
296.5
398.3
118.1
95.2
230
30.2
71.4
398.2
28.4
94.2
230
62.0
146.4
398.2
58.3
94.1
230
92.3
221.9
398.3
88.4
95.8
230
122.4
296.5
398.3
118.1
96.5
265
30.1
71.8
398.3
28.6
95.0
265
61.3
147.1
398.2
58.6
95.6
265
92.1
221.9
398.3
88.4
96.0
265
122.3
297.2
398.3
118.4
96.8
265 Vac
Average efficiency = 94.57%
Figure 2. Efficiency
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DN05057/D
POWER SAVINGS MODE
VCC is regulated at VCC(PS_on), typically
11 V, by turning on the HV start-up circuit
at the valley of every half-cycle.
The start-up circuit turns on at the valley
of every half-cycle provided that VCC is
below VCC(PS_on).
The start-up circuit is disabled once VCC
exceeds VCC(PS_on). There is no hysteresis in the comparator ensuring that VCC
will be below the VCC(PS_on) regulation
level during the next half-cycle.
Measured data with 2-wire connection:
− 5.42 mW at 115 Vac
− 16.2 mW at 230 Vac
VCC in Regulation
Ch. 1 (Yellow): VCC
(AC Coupled)
Ch. 2 (Blue): HV
Figure 3. Power Savings Mode
POWER FACTOR
Power Factor vs. Output Power
1.000
0.980
Power Factor
0.960
0.940
0.920
0.900
0.880
0.860
0.840
0
20
40
60
80
100
120
Output Power (W)
85 Vac
115 Vac
230 Vac
265 Vac
Figure 4. Power Factor
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5
140
VAC
Pin (W)
Po (W)
85
31.0
28.3
0.973
PF
85
62.4
58.3
0.988
85
94.0
88.1
0.992
85
126.2
118.0
0.992
115
30.9
28.6
0.961
115
61.6
58.2
0.979
115
92.6
88.0
0.987
115
124.0
118.1
0.990
230
30.2
28.4
0.916
230
62.0
58.3
0.957
230
92.3
88.4
0.970
230
122.4
118.1
0.977
265
30.1
28.6
0.864
265
61.3
58.6
0.950
265
92.1
88.4
0.961
265
122.3
118.4
0.970
DN05057/D
DEMO BOARD
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DN05057/D
BILL OF MATERIALS
Table 2. BILL OF MATERIALS
Component
Type
Value
−
DM Choke
L2
−
L3
−
1
C1
1
Qty
Ref
1
L1
1
1
Rating
Pkg/Dimensions
P/N
Supplier
150 mH
7447021_WURTH
7447021
WURTH
CM Choke
8.5 mH
IND_744823210
744823210
WURTH
PFC
Transformer
300 mH
EFD−30
750313750
WURTH
−
X2
100 nF
305 Vac
5 x 10.5 x 18 mm
B32922C3104M
C2
−
X2
220 nF
305 Vac
7 x 12.5 x 18 mm
B32922C3224M
1
C10
SMT
Ceramic
10 mF
6.3 V
C0603W
C1608X5R0J106K080AB
TDK
1
C16
SMT
Ceramic
100 pF
50 V
C0603W
C1608X7R1H101K
TDK
1
C15
SMT
Ceramic
100 nF
50 V
C0603W
C1608X7R1H104K080AA
TDK
3
C8, C9,
C11
SMT
Ceramic
220 nF
50 V
C0603W
C1608X7R1H224K080AB
TDK
1
C7
SMT
Ceramic
2.2 mF
16 V
C0805W
C2012X7R1C225K125AB
TDK
1
C13
SMT
Ceramic
10 nF
50 V
C0805W
C2012X7R1H103K
TDK
1
C14
SMT
Ceramic
1 nF
50 V
C0603W
CGA3E2X7R1H102K080AA
TDK
2
C3, C4
−
Y2
1 nF
250 Vac
5 mm
DE2E3KY102MA2BM01
Murata
1
C5
−
MKP
470 nF
400 V
15 mm
ECW−F4474JL
Panasonic
1
C6
−
Electrolytic
100 mF
450 V
18 x 40 mm
EKXG451ELL101MM40S
UCC
1
C12
−
Electrolytic
220 mF
35 V
8 x 15 mm
EKY−350ELL221MH15D
UCC
1
F1
−
Fuse
3A
250 V/3 A
2AG
0224003.HXP
LITTELFUSE
1
RV1
−
MOV
2.5 kA
470 V
10 mm
S10K300
EPCOS
2
R1, R2
SMT
Resistor
Open
R1206W
2
R6, R20
SMT
Resistor
Open
R0603W
2
R17,
R19
SMT
Resistor
0
R0603W
CRCW06030000Z0EA
Vishay/Dale
1
R9
SMT
Resistor
10 kW
R0603W
CRCW060310K0FKEA
Vishay/Dale
1
R14
SMT
Resistor
120 kW
R0603W
CRCW0603120KFKEA
Vishay/Dale
4
R24,
R25,
R26,
R27
SMT
Resistor
1 kW
R0603W
CRCW06031K00FKEA
Vishay/Dale
1
R13
SMT
Resistor
270 kW
R0603W
CRCW0603270KFKEA
Vishay/Dale
2
R12,
R18
SMT
Resistor
27 kW
R0603W
CRCW060327K0FKEA
Vishay/Dale
2
R5, R7
SMT
Resistor
4.7 kW
R0603W
CRCW06034K70FKEA
Vishay/Dale
1
R15
SMT
Resistor
4.99 MW
R0603W
CRCW06034M99FKEA
Vishay/Dale
1
R11
SMT
Resistor
22 W
R0805W
CRCW080522R0JNEA
Vishay/Dale
1
R16
SMT
Resistor
27 W
R0805W
CRCW080527R0JNEA
Vishay/Dale
1
R10
SMT
Resistor
2.2 W
R0805W
CRCW08052R20JNEA
Vishay/Dale
2
R3, R4
SMT
Resistor
1 kW
R1206W
CRCW12061K00JNEA
Vishay/Dale
2
R22,
R23
SMT
Resistor
1.8 MW
R1206W
CRCW12061M80JNEA
Vishay/Dale
1
R21
SMT
Resistor
681 kW
R1206W
CRCW1206681KFKEA
Vishay/Dale
1
R8
−
Resistor
100 mW
3W
LOB3R100FLFLT
TT Electronics
1
RT1
−
NTC
10 W
5 mm
B57153S0100M000
EPCOS
1
RT2
−
NTC
220 kW
2.5 mm
NTCLE100E3224JB0
Vishay/Dale
1
Q3
SMT
NPN
MMBT3904L
40 V/200 mA
SOT−23
MMBT3904LT1G
ON Semiconductor
1
Q2
SMT
PNP
MMBT589
30 V/1 A
SOT−23
MMBT589LT1G
ON Semiconductor
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DN05057/D
Table 2. BILL OF MATERIALS (continued)
Qty
Component
Type
Ref
Value
Rating
Pkg/Dimensions
P/N
Supplier
1
D4
−
Fast Acting
1N5406
600 V/3 A
DO201AD
1N5406G
ON Semiconductor
1
BD1
−
Bridge
GBU406
600 V/4 A
18.5 x 22 mm
GBU406
Diodes
4
D3, D6,
D7, D8
SMT
General
Purpose
MMSD4148
100 V/200 mA
SOD−123
MMSD4148T1G
ON Semiconductor
1
ZD3
SMT
Zener
22 V
500 mW
SOD−123
MMSZ22T1G
ON Semiconductor
1
ZD1
SMT
Zener
27 V
500 mW
SOD−123
MMSZ27T1G
ON Semiconductor
1
ZD2
SMT
Zener
33 V
500 mW
SOD−123
MMSZ33T1G
ON Semiconductor
2
D1, D2
−
Rectifier
MRA4007
1000 V/1 A
SMA
MRA4007T3G
ON Semiconductor
1
D5
−
Fast Acting
MUR550
520 V/5 A
1
U1
−
PFC Controller
NCP1615C
1
Q1
−
HV MOSFET
IPA50R250CP
4
TP1,
TP2,
TP3,
TP4
−
Test Point
TESTPOINT
2
J3, J4
−
SIP−2P
1
J2
−
1
J1
4
1
DO201AD
MUR550APFRLG
ON Semiconductor
SO16NB_LESS_PIN_15
NCP1615CDR2G
ON Semiconductor
TO−220FP
IPA50R250CP
Infineon
0.1″ Pitch
104351−1
TE Connectivity
2T Screw Block
10 mm Pitch
ED200/2DS
On Shore
Technology
−
3T Screw Block
5 mm Pitch
OSTTA030161
On Shore
Technology
J5, J6,
J7, J8
−
Standoff
MTGNP685H370V6P
4820
Keystone
Electronics
HS1
−
Heatsink
Cut to fit
500 V/13 A
REFERENCES
[1] NCP1615 Datasheet (NCP1615/D)
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DN05057/D