AND8324/D 300 W, Wide Mains, PFC Stage Driven by the NCP1654 Prepared by: Patrick Wang ON Semiconductor http://onsemi.com Introduction The NCP1654 is a Power Factor Controller to efficiently drive Continuous Conduction Mode (CCM) step−up pre−converters. As shown by the ON Semiconductor application note AND8322, “Four Key Steps to Design a Continuous Conduction Mode PFC Stage Using the NCP1654”, which details the four key steps to design a NCP1654 driven PFC stage, this circuit represents a major leap towards compactness and ease of implementation. Housed in a SO−8 package, the circuit minimizes the external components count without sacrificing performance and flexibility. In particular, the NCP1654 integrates all the key protections to build robust PFC stages like an effective input power runaway clamping circuitry. When needed or wished, the NCP1654 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 NCP1654/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 85 VRMS to 265 VRMS • Regulation output voltage: 390 V • Switching frequency: 65 kHz © Semiconductor Components Industries, LLC, 2009 October, 2009 − Rev. 2 This application was tested using an active 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 NCP1654 VCC is to be supplied by a 15 V external power supply. The external voltage source that is to be applied to the NCP1654 VCC, should exceed 10.5 V typical, to allow the circuits start up. After start up, the VCC operating range is from 9 V to 20 V. The voltage applied to the NCP1654 VCC must NOT exceed 20 V. The NCP1654 is a continuous conduction mode and fixed frequency controller (65 kHz). The coil (650 uH) is selected to limit the peak to peak current ripple in the range of 36 % 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 AND8322, ”Four Key Steps to Design a Continuous Conduction Mode PFC Stage Using the NCP1654”. As detailed in the document, the board yields very nice Power Factor ratios and effectively limits the Total Harmonic Distortion (THD). 1 Publication Order Number: AND8324/D TB1 AC Inlet H L 3 2 1 5A Fuse F1 C1 0.47mF 150mH L3 2 x 6.8mH L2 C2 0.47mF Figure 1. Application Schematic http://onsemi.com 2 C7 C3 0.1mF R11 82.5k R10 0 R13 3.3M R9 3.3M GBU8J 8A 600V 0.47mF DB1 1nF C6 R7 3.6k R8 47k 4 3 2 1 BO CS VM FB VCC DRV 5 5 6 7 8 220nF C5 Vcontrol IC1 0.1 R6 650mH NCP1654 GND 2 L1 2.2mF C12 12k R12 R3 23.2k 10pF C10 R5 10 1N4148 D2 22mF C8 + +15V 0.1mF C9 R4 10k R1 1.8M SPP20N60S5 1.8M R2 Q1 2 1 MSR860G D1 TB3 180mF 450V C4 + 390V 2 1 TB2 AND8324/D AND8324/D Table 1. BILL OF MATERIAL Reference Description Part Number Manufacturer C1 0.47 uF / 275 V type X2 F1772−447−2000 VISHAY C2 0.47 uF / 275 V type X2 F1772−447−2000 VISHAY C3 0.1u, 400V, High Ripple, Polypropylene Cap ECWF4104JL Matsushita C4 180 mF 450 V 2222 159 47181 BC Components C5 0.22 mF / 50V K224K20X7RF53H5 VISHAY C7 0.47 mF / 50V K474K20X7RF53H5 VISHAY C9 0.1 mF / 50V K104K15X7RF53H5 VISHAY C6 1 nF / 50 V K102K15X7RF53H5 VISHAY C10 100 pF / 50 V K101K15X7RF53H5 VISHAY C8 22 mF / 25 V 2222 013 36229 BC Components C12 2.2 mF / 50 V B32529D5225J EPCOS DB1 600 V, 8.0 A Bridge Dode GBU8J VISHAY D1 8.0 A, 600 V MSR860G ON Semiconductor D2 1N4148 1N4148 VISHAY F1 5 A Fuse, Time Delay Fuse (FST 5x20) 0034.3124 SCHURTER IC1 CCM PFC Controller NCP1654 ON Semiconductor L1 650 mH GA3199−AL CoilCraft 2702.0010A Pulse B82725−J2402−N20 EPCOS Wurth Elektronik L2 4 A, 2 x 6.8 mH, CM Choke L3 150 uH, 5A, WE−FI Series, DM Choke 7447055 Q1 20 A 600 V MOSFET SPP20N60C3 Infineon R1 Resistor, Axial Lead, 1.8 M, 1/4 W, 1% CCF501M80FKE36 VISHAY R2 Resistor, Axial Lead, 1.8 M, 1/4 W, 1% CCF501M80FKE36 VISHAY R9 Resistor, Axial Lead, 3.3 M, 1/4 W, 1% CCF503M30FKE36 VISHAY R13 Resistor, Axial Lead, 3.3 M, 1/4 W, 1% CCF503M30FKE36 VISHAY R10 Jumper Jumper R3 Resistor, Axial Lead, 23.2 k, 1/4 W, 1% CCF5023K2FKE36 VISHAY R4 Resistor, Axial Lead, 10 k, 1/4 W CCF5010K0FKE36 VISHAY R5 Resistor, Axial Lead, 10, 1/4 W CCF5010R0FKE36 VISHAY R6 Resistor, Axial Lead, 0.1, 3 W, 1% LVR3 Series LVR03 R1000 F E12 VISHAY R7 Resistor, Axial Lead, 3.6 k, 1/4 W 1% CCF503K60FKE36 VISHAY R8 Resistor, Axial Lead, 47 k, 1/4 W CCF5047K0FKE36 VISHAY VISHAY R11 Resistor, Axial Lead, 82.5 k, 1/4 W, 1% CCF5082K5FKE36 R12 Resistor, Axial Lead, 12 k, 1/4 W, 1% CCF5012K0FKE36 VISHAY TB1 AC Inlet Connector GSF1.1201.31 SCHURTER TB2 DC Output Plug Socket 20.101/2 (Order Code 3044531) IMO TB3 VCC Connector Plug Socket PM5.08/2/90. (Order Code 5015571) WEIDMULLER HS1 Heatsink(2.9°C/W) SK481 100mm Fischer Elektronik Q1 Isolator TO−220 3223−07FR−43 BERGQUIST D1 Isolator TO−220 3223−07FR−43 BERGQUIST DB1 Clip for heatsink (TO−220) THFU 1 Fischer Elektronik Q1 Clip for heatsink (TO−220) THFU 1 Fischer Elektronik D1 Clip for heatsink (TO−220) THFU 1 Fischer Elektronik Board Legs TCBS−801 RICHCO Board Legs TCBS−801 RICHCO Board Legs TCBS−801 RICHCO Board Legs TCBS−801 RICHCO PCB http://onsemi.com 3 AND8324/D Figure 2. The Board For the sake of consistency, this application note reports the performance and results that were obtained using the CoilCraft. However, it has been checked that the other coil yield high performance too. Two coils from two different vendors have been validated on this board: • GA3199−AL from Coil Craft • 2702.0010A from Pulse http://onsemi.com 4 AND8324/D PCB LAYOUT Figure 3. Components Placement (Component Side) Figure 4. PCB Layout (Solder Side) http://onsemi.com 5 AND8324/D GENERAL BEHAVIOR EFFICIENCY AND PF AT 85 VAC AND 110 VAC Table 2. EFFICIENCY, PF AT DIFFERENT LOAD AND LINE CONDITIONS Vin Iin (A) Pin (W) Vo (V) Io (A) Po (W) PF Efficiency THD 85 Vac 60 Hz 3.87 326.5 392.6 0.77 302.3 0.999 92.6% 3.7% 3.50 295.4 392.6 0.70 274.6 0.999 93.0% 3.6% 3.00 253.1 392.7 0.60 236.2 0.999 93.3% 3.6% 2.48 210.1 392.8 0.50 196.8 0.999 93.7% 3.4% 1.98 167.5 392.9 0.40 157.4 0.999 94.0% 3.2% 1.48 125.5 392.8 0.30 118.4 0.999 94.3% 3.6% 1.00 84.5 393.1 0.20 79.6 0.998 94.3% 6.6% 0.49 41.2 393.7 0.10 39.2 0.998 95.2% 8.7% 0.25 21.0 397.1 0.05 19.5 0.991 93.0% 11.9% 2.93 319.5 392.7 0.77 302.9 0.999 94.8% 3.3% 2.65 289.9 392.8 0.70 275.4 0.999 95.0% 3.2% 2.27 248.0 392.8 0.60 236.1 0.999 95.2% 3.2% 1.89 206.4 392.9 0.50 196.8 0.999 95.4% 3.3% 1.51 165.0 392.9 0.40 157.5 0.998 95.5% 4.0% 1.13 123.9 393.0 0.30 118.4 0.998 95.5% 6.3% 0.76 82.5 393.1 0.20 79.0 0.998 95.8% 7.6% 0.38 41.6 394.3 0.10 39.8 0.993 95.6% 8.6% 0.20 20.9 397.4 0.05 19.6 0.973 93.6% 11.1% 110 Vac 60 Hz http://onsemi.com 6 AND8324/D Table 3. EFFICIENCY AND PF AT 230 VAC AND 265 VAC Vin Iin (A) Pin (W) Vo (V) Io (A) Po (W) PF Efficiency THD 230 Vac 50 Hz 1.36 309.4 393 0.77 303.0 0.996 97.9% 6.1% 1.23 281.0 393 0.70 275.1 0.995 97.9% 6.3% 1.05 240.7 393.1 0.60 235.5 0.994 97.9% 7.1% 0.89 201.5 393.2 0.50 197.1 0.992 97.8% 7.1% 0.71 161.3 393.2 0.40 157.7 0.990 97.8% 7.2% 0.54 121.1 393.3 0.30 118.2 0.983 97.6% 7.4% 0.37 81 393.7 0.20 78.8 0.966 97.3% 7.3% 0.20 41.1 394.6 0.10 39.6 0.892 96.5% 13.0% 0.12 20.6 395.4 0.05 19.4 0.752 94.5% 15.8% 1.18 308.2 393 0.77 302.3 0.993 98.1% 6.9% 1.07 281.1 393.1 0.70 275.8 0.992 98.1% 6.8% 0.92 241.2 393.1 0.60 236.5 0.991 98.0% 6.7% 0.77 201.2 393.2 0.50 197.1 0.988 98.0% 7.0% 0.62 161.2 393.2 0.40 157.8 0.982 97.9% 6.9% 0.47 121.1 393.4 0.30 118.4 0.972 97.8% 7.3% 0.33 81.4 393.8 0.20 79.0 0.943 97.1% 11.8% 0.19 41.1 394.5 0.10 39.7 0.840 96.6% 22.6% 0.13 21.5 395 0.05 20.4 0.650 94.7% 23.0% 265 Vac 50 Hz 1.0 99 0.99 97 HALF LOAD 96 95 FULL LOAD 94 85Vac 230Vac 0.97 0.96 265Vac 0.95 0.94 0.93 0.92 93 92 85 110Vac 0.98 POWER FACTOR EFFICIENCY (%) 98 0.91 170 255 0.90 70 340 170 270 OUTPUT POWER INPUT VOLTAGE (Vac) Figure 5. Efficiency vs. Input Voltage Figure 6. Power Factor vs. Output Power http://onsemi.com 7 AND8324/D TYPICAL WAVEFORMS Iin Vac Figure 7. Vac = 85 Vac, Pin = 326.5 W, Vout = 392.6 V, Iout = 0.77 A, PF = 0.999, THD = 3.74% Vac Iin Figure 8. Vac = 230 Vac, Pin = 309 W, Vout = 393 V, Iout = 0.77 A, PF = 0.996, THD = 6.1% http://onsemi.com 8 AND8324/D NO LOAD OPERATION Iin VM Vout Vin Figure 9. Vac = 230 Vac, Pin = 147 mW, Vout = 396 V, Iout = 0 A Soft−Start When in light load, the circuit enters a welcome burst mode that enables the circuit to keep regulating. VM pin oscillates around its internal reference voltage (2.5 V). The power losses @ 230 Vac are nearly 147 mW. This result was obtained by using a W.h. meter (measure duration: 1 sec) The NCP1654 grounds the “Vcontrol” capacitor when it is off, i.e., before each circuit active sequence (“Vcontrol” being the regulation block output). Only charging by the 28−mA internal current source of the error amplifier (the 200 mA of the dynamic response enhancer being disabled during the start−up phase), “Vcontrol” ramps up slowly. As a result, the power delivery rises gradually and the PFC pre−regulator starts up smoothly and noiselessly. Iin Vcontrol Vout DRV Figure 10. Vac = 85 Vac, Vout = 392.6 V, Iout = 0.77 A http://onsemi.com 9 AND8324/D Transient Load Vcontrol is sharply pulled high by the internal 200 mA current source of the dynamic response enhancer. As a result, a higher power is delivered to output. Hence it prevents the output voltage from dropping deeply. When output loading changes from full load to no load, the output voltage raises, and Vfb rises to activate the OVP function. The output voltage is clamped by the OVP function. When output loading changes from no load to full load, the output voltage drops, Vfb drops below 95% of Vref, Iin Vout Vcontrol Figure 11. Vac = 85 Vac, Vout = 392.6 V, Iout = 0 A ~ 0.77 A http://onsemi.com 10 AND8324/D Under Voltage Protection (UVP) FB open test at 265 Vac, Iout = 0.1 A. The PFC circuit operates first, then short the FB Pin to ground. As Vfb is lower than 8% of Vref, UVP activates and shuts down the output. It is to protect the buck capacitor from damaging. Iin Vf b Vout DRV Figure 12. Vac = 265 Vac, Vout = 394.5 V, Iout = 0.1 A Brown Out Test When the input voltage decreases to 68 Vac, VBO is below 0.7 V, brown out function is triggered and driver stops. Vac Iin VBO Vout Figure 13. Vac = 68 Vac, Vout = 393.7 V, Iout = 0.1 A http://onsemi.com 11 AND8324/D Brown Out Recovery Test When the input voltage increases above 78.4 Vac, VBO is above 1.3 V and driver resumes operation. Vac Iin VBO Vout Figure 14. Vac = 78.4 Vac, Vout = 393.7 V, Iout = 0.1 A ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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