AND8106/D 100 Watt, Universal Input, PFC Converter ON Semiconductor http://onsemi.com APPLICATION NOTE General Description This 100 watt converter demonstrates the wide range of features found on the NCP1650. This chip is capable of controlling PFC converters well into the kilowatt range. In addition to excellent power factor, this chip offers fixed frequency operation in continuous and discontinuous modes of operation. It has a wide variety of protection features, including instantaneous current limiting, average current limiting, and true power limiting. This unit will provide 400 V of well regulated power from an input source with a frequency range from 50 Hz to 60 Hz, and a voltage range of 85 Vrms to 265 Vrms. It is fully self contained and includes a high voltage start-up circuit, and bias supply that operates off of the boost inductor. Vout 10 k FQP1N60 Vbias 1 F MMSZ5248BT1 Vin Figure 1. Start-Up Circuit Schematic This circuit will provide current as long as the FET is enhanced. For this to occur, the gate to source voltage must be greater than the gate threshold voltage. For this device that value is nominally, 4.0 V. The zener breakdown voltage is 18 V, so the FET will turn off at: Circuit Description Start-Up Circuit The start-up circuit allows the unit to use power from the input line to begin operation, and then shuts down to allow operation off of the bias winding, which reduces losses in the circuit. The start-up circuit has three modes of operation. One is used for starting the NCP1650 when the chip is functional, one is for bias power during shutdown operation, and the third is the off state. When power is initially applied to the unit, the gate of the pass transistor will be high, and the FET will be fully enhanced. The current into the VCC capacitance at pin 1 will be limited by the three 10 k resistors in series with the FET. February, 2003 - Rev. 2 1 NCP1650 Fixed Frequency Operation Shutdown Circuit Operation Over the Universal Input Range Multiple Protection Schemes True Power Limiting Start-Up and Bias Circuits Included Semiconductor Components Industries, LLC, 2003 10 k 1.2 M Features • • • • • • 10 k Vchg max 18 V 4.0 V 14 Volts As the output capacitor is charged up during the turn-on sequence, the bias supply voltage will also increase until the source of the FET exceeds 14 V. At this point, the FET will cease conduction, and all of the VCC power will be supplied via the bias circuit from the power inductor. If the unit is commanded into the shutdown mode, the chip will reduce its bias current to 0.5 mA and the start-up circuit will then maintain a regulated voltage of approximately 14 V on the VCC pin until the device becomes operational. 1 Publication Order Number: AND8106/D 1N5406 L2 D1 F1 470 H D2 0.47 F Vin R4 178 k C7 0.1 F D3 L3 D4 R7 Loop Comp R8 6 PCOMP C26 4V + − Error Amp R22 FQP1N60 Vin Reference Regulator Power + Amp − 2 Reference Multiplier BAS16LT1 D6 1.08 Vref − + Current Shaping Network L1 MUR460 Q1 FQP12N60 R16 4.7 Out Current + Sense Amplifier - Oscillator 12 IS- Gnd 15 Ramp Comp 14 R13 51 k CT 10 Iavg 11 Iavgfltr C14 470 pF C11 R10 8.25 k 470 pF R27 453 k R28 453 k C25 100 F 16 3 C3 13 C23 100 F D7 Control Logic R3 0 V - ON 5 V - OFF 0.1 F UVLO 1 mH AC Comp 810 R25 4.7 k Overshoot Comparator 4 .012 F R26 Vref 0.75 V Power Multiplier 1.0 nF Shutdown C2 − + 5 AC Ref 0.022 F MMBT2222ALT1 12 k 1 Shutdown 9 C9 10 F R23 1.2 M D5 MMSZ5248BT1 Voltage/Power ORing Network AC Input C4 R21 Q2 2.5 V R5 3.57 k R20 1.0 F U1 PMAX 10 F C5 10 k Q3 8 8.2 k R9 56.2 k 10 k 0.07 1/2 W R30 R29 9.09 k AND8106/D 2 http://onsemi.com Figure 1. Applications Circuit Schematic 0.1 F FB/SD C8 10 k 7 C22 22 F R6 178 k C21 C20 470 H 3.3 k SPECIFICATIONS: Line - 85 Vac to 265 Vac Power - 100 Watts Output Voltage - 400 VDC AND8106/D Voltage Regulation Loop If the load is increased to a level that exceeds the maximum power limit of the circuit, the output of the power multiplier will reach 2.5 V and the output of the power error amplifier will go to some level above ground. This signal will then override the signal from the voltage error amplifier (labeled “error amp” on the schematic), and will dominate the OR’ing network. This signal then determines the level of the reference signal out of the reference multiplier, and determines the input current to the power converter. It should be noted that as this is a boost converter, the power limit circuit will only fold back the output voltage until it reaches the level of the peak line voltage. At this point the converter will shut down, but the input voltage will continue to charge the output capacitors through the rectifier. The output voltage is sensed and reduced to the reference level by the resistive divider consisting of R27, R28 and R29. The output voltage of this divider is sensed by the non-inverting input of the error amplifier and compared to the internal 4.0 V reference. Assuming that the unit in not in a power limit condition, the voltage error signal will dominate the loop and be fed through the OR’ing network to provide one of the inputs to the reference multiplier. The other reference multiplier input is the divided down rectified AC input signal. The output of this multiplier is a haversine signal that is an accurate replica of the input AC signal. The current shaping network compares the average current from the current sense amplifier to the reference voltage and forces this current to follow the AC reference voltage. The current out of the current sense amplifier is filtered at a frequency that is less than the switching frequency, but greater than the rectified line frequency. This current is fed into the output filter capacitor(s) that filter it to a DC level. Shutdown Circuit The shutdown circuit will inhibit the operation of the power converter and put the NCP1650 into a low power shutdown mode. To activate this circuit, apply 5.0 V to the red test point, with the black jack being “ground”. Be aware that the black jack is actually hot as it is connected to the output of the input bridge rectifiers. An isolated 5.0 V supply should be used. If this circuit is not being used, the terminals can be left open, as there is enough resistance built in to the circuit to keep the transistor (Q2) in it’s off state. Power Regulation Loop The power multiplier generates the product of the input current (from the current sense amplifier) and the AC rectified input voltage, to generate a signal that represents the input power of the unit. This signal is filtered to a frequency of less than the line frequency, so that it’s output is a DC level. PCB The printed circuit board Gerber files are located on the ON Semiconductor website under the name NCP650- PCB1. D3 D4 Q1 D1 D2 Input 400 Vdc 0.25 amps NCP1650 Demo Board C20 C21 R4 Q3 + ON Semiconductor R20 R21 R22 C23 + R6 D7 L1 R27 R28 R23 L3 R5 L2 R29 Gnd Shutdown 0 V/5 V http://onsemi.com 3 85 - 265 Vac C25 AND8106/D Table 1. Ref Des Part Number Manufacturer C2 Cap, Ceramic, Chip, 0.1 F, 50 V C1608X7R1H104KT TDK C3 Cap, Ceramic, Chip, .012 F, 50 V C1608X7R1H123KT TDK C4 Cap, Ceramic, Chip, 1.0 nF, 50 V C1608X7R1H102K TDK C5 Cap, Ceramic, Chip, 0.022 F, 50 V C1608X7R1H223K TDK C7 Cap, Ceramic, Chip, 22 F, 6.3 V C3225X5R0J226MT TDK C8 Cap, Ceramic, Chip, 10 F, 10 V C3225X5R1A106MT TDK C9 Cap, Ceramic, Chip, 4.7 F, 10 V C3216X5R1A475KT TDK C11 Cap, Ceramic, Chip, 470 pF, 50 V C1608C0G1H471JT TDK C14 Cap, Ceramic, Chip, 470 pF, 50 V C1608C0G1H471JT TDK C20 0.47 F, 275 Vac, X Cap ECQ-U2A474ML Panasonic C21 Cap, Polyprop, 0.1 F, 400 Vdc MKP1841-410-405 Vishay-Sprague C22 Cap, Ceramic, Chip, 0.1 F, 50 V C1608X7R1H104KT TDK C23 100 F, Alum Elect, 25 V ECA-1EM101I Panasonic C25 100 F, Alum Elect, 450 V ECO-S2WP100EX Panasonic C26 Cap, Ceramic, Chip, 1.0 F, 25 V C3216X7R1E105KT TDK 1N5406 ON Semiconductor MMSZ5248BT1 ON Semiconductor D1-D4 Description Diode, Rectifier, 600 V, 3.0 A D5 Diode, Zener, 18 V, Axial Lead D6 Diode, Signal, 75 V, 200 mA, SOT-23 D7 Diode, Ultra-Fast, 600 V, 8.0 A F1 Fuse, 2.0 A, 250 Vac L1 Inductor, 1000 H, 2.4 A Max L2 BAS19LT1 ON Semiconductor MURHF860CT ON Semiconductor 1025TD2A Bussman CTX22-15557 Coiltronics 2.5 A Sat, 100 H Inductor, Diff Mode TSL1315S-101K2R5 TDK L3 2.5 A Sat, 100 H Inductor, Diff Mode TSL1315S-101K2R5 TDK Q1 FET, 10.5 A, 0.7 , 600 V, N-chl FQP12N60 Fairchild Q2 Bipolar Transistor, 50 V MMBT2222ALT1 ON Semiconductor Q3 FET, 1.0 A, 600 V, N-chl FQP1N60 Fairchild R3 Resistor, SMT, 810 CRCW1206810JNTA Vishay R4 Resistor, Axial Lead, 178 k, _ Watt, 1% CMF-55-178K00FKRE Vishay R5 Resistor, Axial Lead, 3.57 k, _ Watt, 1% CMF-55-3K5700FKBF Vishay R6 Resistor, Axial Lead, 178 k, _ Watt, 1% CMF-55-178K00FKRE Vishay R7 Resistor, SMT, 8.6 k CRCW12068K60JNTA Vishay R8 Resistor, SMT, 9.1 k CRCW12069K10JNTA Vishay R9 Resistor, SMT, 56.2 k, 1% CRCW120656K2FKTA Vishay R10 Resistor, SMT, 8.25 k, 1% CRCW12068K2FKTA Vishay R13 Resistor, SMT, 51 k CRCW120651K0JNTA Vishay R16 Resistor, SMT, 10 CRCW1206100JRE4 Vishay R20 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R21 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R22 Resistor, Axial Lead, 10 k, _ Watt CCF-07-103J Vishay R23 Resistor, Axial Lead, 1.2 M, _ Watt CCF-07-125J Vishay R25 Resistor, SMT, 4.7 k CRCW12064K70JNTA Vishay http://onsemi.com 4 AND8106/D Table 1. (continued) Ref Des Description Part Number Manufacturer R26 Resistor, SMT, 12 k CRCW120612K0JNTA Vishay R27 Resistor, Axial Lead, 453 k, _ Watt, 1% CMF-55-453K00FKBF Vishay R28 Resistor, Axial Lead, 453 k, _ Watt, 1% CMF-55-4533F Vishay R29 Resistor, Axial Lead, 9.09 k, _ Watt, 1% CCF-55-9K09FHR362 Vishay R30 1.0 W, 0.07 , 1% Resistor WSL2512R0700FTB Vishay U1 PFC Controller NCP1650 ON Semiconductor NCP1650-PWB1 www.onsemi.com Hardware H1 Printed Circuit Board H2 Connector 171602 Weidmuller H3 Connector 171602 Weidmuller H4 Test Point, Red 5005 Keystone H5 Test Point, Black 5006 Keystone H6 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H7 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H8 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H9 Standoff, 4-40, Alum, Hex, .500 Inches 8403 HH Smith H10 Heatsink, TO-220 590302B03600 Aavid Thermalloy H11 Heatsink, TO-220 590302B03600 Aavid Thermalloy Performance Data Table 2. Vendor Contacts Vendor ON Semiconductor Table 3. Regulation U.S. Phone/Internet 1-800-282-9855 www.onsemi.com/ Line/Load No Load 50 Watts 100 Watts 85 Vrms 405.5 405.1 403.9 115 Vrms 405.6 405.2 404.3 TDK 1-847-803-6100 www.component.tdk.com/ 220 Vrms 405.4 405.5 404.9 Vishay www.vishay.com/ 265 Vrms 438.4 405.5 405 Bussman (Cooper Ind.) 1-888-414-2645 www.cooperet.com/ Coiltronics (Cooper Ind.) 1-888-414-2645 www.cooperet.com/ Fairchild www.fairchildsemi.com/ Panasonic www.eddieray.com/panasonic/ Weidmuller www.weidmuller.com/ Keystone 1-800-221-5510 www.keyelco.com/ HH Smith 1-888-847-6484 www.hhsmith.com/ Aavid Thermalloy www.aavid.com/ http://onsemi.com 5 AND8106/D Table 4. Harmonics and Distortion 115 Vac, 100 Watts 230 Vac, 100 Watts V harmon A harm. % V harmon A harm. % 2nd 0.084 0.03 0.169 0.12 3rd 0.505 2.8 0.722 2.6 5th 0.482 1.3 0.132 4.4 7th 0.168 0.5 0.075 0.17 9th 0.074 0.17 0.133 0.23 11th 0.088 0.13 0.134 0.17 13th 0.212 0.27 0.073 0.15 15th 0.324 0.37 0.265 0.28 17th 0.413 0.35 0.488 0.32 19th 0.632 0.31 1.12 0.44 PF - 0.998 - 0.9928 THD (A) - 3.68 - 6.2 Ifund - 0.919 - 0.451 85 Vrms 115 Vrms 230 Vrms 265 Vrms Pin @ No Load 2.87 4.06 5.07 5.11 Pin 108.8 106.9 103.2 103.7 Vo 403.2 404.3 404.9 405 Io 0.246 0.246 0.243 0.244 Efficiency 0.912 0.930 0.953 0.953 Table 5. Efficiency http://onsemi.com 6 AND8106/D Notes http://onsemi.com 7 AND8106/D ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. 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