NCP1653EVB 300 W, Wide Mains, PFC Stage Driven by the NCP1653 Evaluation BoardUser's Manual http://onsemi.com EVAL BOARD USER’S MANUAL Introduction The NCP1653 is a Power Factor Controller to efficiently drive Continuous Conduction Mode (CCM) step-up pre-converters. As shown by the ON Semiconductor application note AND8184/D, that details the four key steps to design a NCP1653 driven PFC stage, this circuit represents a major leap towards compactness and ease of implementation. Housed in a DIP8 or SO−8 package, the circuit minimizes the external components count without sacrificing performance and flexibility. In particular, the NCP1653 integrates all the key protections to build robust PFC stages like an effective input power runaway clamping circuitry. When needed or wished, the NCP1653 also allows operation in Follower Boost mode* 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 NCP1653/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 90 Vrms to 265 Vrms Regulation output voltage: 385 V Switching frequency: 100 kHz This application was tested using a resistive 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 NCP1653 VCC is to be supplied by a 15 V external power supply. The external voltage source that is to be applied to the NCP1653 VCC, should exceed 13.25 V typically, to allow the circuit startup. After startup, the VCC operating range is from 9.5 to 18 V. The voltage applied to the NCP1653 VCC must NOT exceed 18 V. The NCP1653 is a continuous conduction mode and fixed frequency controller (100 kHz). The coil (600 mH) is selected to limit the peak-to-peak current ripple in the range of 30% 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 AND8184/D. As detailed in the document, the board yields very nice Power Factor ratios and effectively limits the Total Harmonic Distortion (THD). *The “Follower Boost” mode makes the pre-converter output voltage stabilize at a level that varies linearly versus the AC line amplitude. This technique aims at reducing the difference between the output and input voltages to optimize the boost efficiency and minimize the cost of the PFC stage (refer to MC33260 and NCP1653 data sheet at www.onsemi.com). Semiconductor Components Industries, LLC, 2012 September, 2012 − Rev. 1 1 Publication Order Number: EVBUM2139/D NCP1653EVB Figure 1. The Board For the sake of consistency, this evaluation board reports the performance and results that were obtained using the CoilCraft coil. However, it has been checked that the two other coils yield high performance too. Three coils from three different vendors have been validated on this board: C1062−B from CoilCraft MB09008 from microSpire SRW42EC−E02H001 from TDK http://onsemi.com 2 L Figure 2. Schematic for the NCP1653 Evaluation Board http://onsemi.com 3 N C13 Earth C11 1 mF Type X2 4.7 nF Type = Y1 90 TO 265 Vac L4 150 mH CM1 C12 N 4.7 nF Type = Y1 C15 680 nF U1 KBU6K − + C9 100 nF C1 100 nF Type = X2 C8 1 nF R2 470 k R4 4.7 Meg C6 1 nF C7 100 nF 7 6 5 2 3 4 R6 2.85 k 8 1 U2 NCP1653 680 k 680 k 560 k R9 0.1 R7 R3 56 k C5 1 nF +C4 C3 100 n 22 mF + 15 V − R8 R5 L1 600 mH 4.5 R1 R10 10 k M1 SPP20N60S D1 CSD04060 C2 + 100 mF Type = snap−in 450 V − + 390 V NCP1653EVB NCP1653EVB PCB LAYOUT Figure 3. Component Placement Figure 4. PCB Layout (Components’ Side) http://onsemi.com 4 NCP1653EVB GENERAL BEHAVIOR − TYPICAL WAVEFORMS Iin: ac line current (CH4 – 10 A/div) Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 5. Vac = 90 V, Pin = 326.5 W, Vout = 365 V, Iout = 822 mA, PF = 0.999, THD = 4 % Iin: ac line current (CH4 – 10 A/div) Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 6. Vac = 220 V, Pin = 325 W, Vout = 384 V, Iout = 814 mA, PF = 0.989, THD = 8 % http://onsemi.com 5 NCP1653EVB Table 1. THD AND EFFICIENCY AT Vac = 110 V Pin (W) Vout (V) Iout (A) PF (−) THD (%) eff (%) 331.3 370.0 0.83 0.998 4 93 296.7 373.4 0.74 0.998 4 93 157.3 381.8 0.38 0.995 7 92 109.8 383.5 0.26 0.993 9 91 80.7 384.4 0.19 0.990 10 91 67.4 385.0 0.16 0.988 10 91 10 93 8 92 Efficiency (%) 94 THD (%) 12 6 4 2 91 90 89 0 50 100 150 200 250 300 88 350 50 100 150 200 250 300 350 Pin (W) Pin (W) Figure 7. THD vs. Pin Figure 8. Efficiency vs. Pin The Total Harmonic Distortion keeps below 10% from Pmax (maximum power – 300 W) down to about Pmax/5. The efficiency remains higher than 90% for input powers ranging from 67 to 330 W. In standby (no load conditions), the PFC stage enters a stable burst mode, where the circuit keeps regulating the output voltage and minimizes the power consumption (See Figure 11). http://onsemi.com 6 NCP1653EVB Table 2. THD AND EFFICIENCY AT Vac = 220 V Pin (W) Vout (V) Iout (A) PF (−) THD (%) eff (%) 66.9 386.6 0.16 0.920 15 92 80.2 386.5 0.19 0.933 14 92 110.0 386.7 0.27 0.960 11 95 157.3 386.4 0.38 0.978 9 93 215.7 386.2 0.53 0.985 8 95 311.4 385.4 0.77 0.989 9 95 21 99 18 97 Efficiency (%) THD (%) 15 12 9 6 93 91 89 3 0 95 50 100 150 200 250 300 87 50 350 Pin (W) 100 150 200 250 300 350 Pin (W) Figure 9. THD vs. Pin Figure 10. Efficiency vs. Pin Similarly to the 110 Vac results, low THD values are obtained. The Total Harmonic Distortion keeps below 15% from Pmax (maximum power – 300 W) down to about Pmax/5. Again the efficiency keeps high in a large power range. More specifically, it remains higher than 91% for input powers ranging from 67 to 330 W. In standby (no load conditions), the PFC stage enters a stable burst mode, where the circuit keeps regulating the output voltage and minimizes the power consumption. http://onsemi.com 7 NCP1653EVB Thermal Measurements Measurements Conditions: The following results were obtained using a thermal camera, after a 1 h operation at 25C ambient temperature. These data are indicative. They show that the demo-board may require additional heatsink capability if used in high ambient temperature applications. Vac = 90 V Pin = 326 W Vout = 365 V Iout = 0.82 A PF = 0.999 THD = 3% Coil Coil Power MOSFET Heatsink Bulk Capacitor Output Diode (ferrite) (wires) Input Bridge 100C 80C 50C 75C 100C 130C 85C No Load Operation Iin: ac line current (CH3 – 10 A/div) 388V Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 11. Pout = 0 W, Vac = 230 V When in light load, the circuit enters a welcome burst mode that enables the circuit to keep regulating. Vpin5 oscillates around the pin5 internal reference voltage (2.5 V). The power losses @ 220 Vac, are nearly 130 mW. This result was obtained by using a W.h meter (measure duration: 1 h). http://onsemi.com 8 NCP1653EVB Soft-Start The NCP1653 grounds the “Vcontrol” capacitor when it is off, i.e., before each circuit active sequence (“Vcontrol” being the regulation block output). Provided the low regulation bandwidth required by PFC stages, “Vcontrol” increases slowly. As a result, the power delivery rises gradually and the PFC pre-regulator startup smoothly and noiselessly. DRV (Vpin7) Vpin2 (CH3) (Vcontrol – regulation output) Vout (CH1) Vin (CH2) Figure 12. http://onsemi.com 9 NCP1653EVB Test Procedure 1. Apply a 500 W/400 W resistive load across the output (between the “+VOUT” and “−VOUT” terminals of the board). 2. Adjust a 350 W or more, isolated ac power source so that it outputs a 110 VRMS, sinusoidal voltage (50 or 60 Hz). 3. Place a power analyzer able to measure: The power delivered by the power source (“Pin”) The power factor (“PF”) and the Total Harmonic Distortion (“THD”) of the current absorbed from the ac power source 4. Plug the application to the ac power source. 5. Supply the controller by applying 15 V to the VCC socket (between the “+12 V” and “GND” terminals of the board) and measure: Parameters Comments Limits VOUT Voltage Measured between “+VOUT” and “−VOUT” 365 V < VOUT < 385 V PF Power Factor > 0.990 THD Total Harmonic Distortion < 8% Efficiency 7. Gradually decrease the power source input voltage until the input current top becomes flat. Measure the plateau (see Figure 14). It must be between 4.9 and 5.3 A (over-current limitation). This test must be very short to avoid any excessive heating of the board. Immediately stop the test if the input current exceeds 5.3 A, or if the input voltage is below 75 VRMS). 8. Increase the ac power source voltage to 220 V and measure: Parameters Comments Limits VOUT Voltage Measured between “+VOUT” and “−VOUT” 375 V < VOUT < 395 V PF Power Factor > 0.980 THD Total Harmonic Distortion < 12% Efficiency > 93% 9. Observe the output voltage (i.e., the voltage between the “+VOUT” and “−VOUT” terminals of the board) with an oscilloscope. Unplug the PFC stage from the power source. Set the triggering level at about 200 V, the trigger position being set at 10% of the screen. Program the scope to observe 50 or 100 ms in single acquisition mode. 10. Abruptly apply the power source. Check that the output voltage keeps below 450 V (Over-Voltage Protection) (see Figure 15). > 91% 6. Observe the input current (current drawn from the ac power source) using a current probe and the oscilloscope. The current is nearly sinusoidal. Oscilloscope Isolated Current Probe High Voltage, Voltage Probe (500 V) NCP1653 Demo-Board Input Socket Isolated AC Power Source (350 W, 50 or 60 Hz Sinusoidal Voltage) +VOUT VCC V 500 W/400 W Resistive Load A Power Analyzer (e.g., PM1200) WARNING: GND −VOUT Ground Terminal of the Probe +15 V dc The board contains high voltage, hot, live parts. Be very cautious when manipulating or testing it. It is the responsibility of those who utilize the board, to take all the precautions to avoid that themselves or other people are injured by electric hazards or are victim of any other pains caused by the board. Figure 13. Test Procedure Schematic http://onsemi.com 10 NCP1653EVB Figure 14. Over-Current Limitation (Measured @ VAC = 75 V) Figure 15. Over-Voltage Protection (Start-Up Sequence @ 220 VAC) http://onsemi.com 11 NCP1653EVB Table 3. BILL OF MATERIALS FOR THE NCP1653 EVALUATION BOARD Designator Qty. Description Value Tolerance Footprint Manufacturer Manufacturer Part Number Substitution Allowed Lead Free U2 1 Power Factor Controller − − DIP8 ON Semiconductor NCP1653PG No Yes C1 1 Class X2 Capacitor 100 nF, 275 V 20% Axial Evox Rifa PHE840MX6100M No Yes C2 1 Electrolytic Capacitor 100 mF, 450 V 20% Radial Vishay BC Components 2222 159 37101 No Yes C3, C7, C9 3 Polyester Film Capacitor 100 nF, 100 V 10% Axial AVX BQ014E0104K Yes Yes C4 1 Electrolytic Capacitor 47 mF, 35 V 20% Radial Panasonic ECA1VM470 Yes Yes C5, C6, C8 3 Polyester Film Capacitor 1 nF, 100 V 10% Axial AVX BQ014E0102K Yes Yes C11, C15 2 Class X2 Capacitor 1 mF, 275 V 20% Axial Evox Rifa PHE840MD7100M No Yes C12, C13 2 Class Y2 Capacitor 4.7 nF, 250 V 20% Disc Vishay Roederstein WYO472MCMCF0KR Yes Yes R1 1 Axial Resistor 4.5 W, 1/4 W 1% Axial Panasonic ERO−S2PHF4R53 Yes Yes R2 1 Axial Resistor 470 kW, 1/4 W 1% Axial Vishay Dale CCF55470KFKE36 Yes Yes R3 1 Axial Resistor 56 kW, 1/4 W 1% Axial Vishay Dale CCF5556K0FKE36 Yes Yes R4 1 Axial Resistor 4.7 MW, 1/4 W 1% Axial Phoenix Passive Comp. 2306 242 64705 Yes Yes R5, R8 2 Axial Resistor 680 kW, 1/4 W 1% Axial Vishay Dale CCF55680KFKE36 Yes Yes R6 1 Axial Resistor 2.8 kW, 1/4 W 1% Axial Vishay Dale CCF552K80FKE36 Yes Yes R7 1 Axial Resistor 0.1 W, 1/4 W 1% Axial Vishay Sfernice RLP3 0R10 1% No Yes R9 1 Axial Resistor 560 kW, 1/4 W 1% Axial Vishay Dale CCF55560KFKE36 Yes Yes R10 1 Axial Resistor 10 kW, 1/4 W 1% Axial Vishay Dale CCF5510K0FKE36 Yes Yes R12 1 Strap (Short Circuit) − − Through − − Yes Yes L1 1 PFC Coil 600 mH − − Coilcraft C1062−B No Yes L4 1 DM Filter 150 mH, 5 A 20% Toroidal Wurth Elektronik 7447055 No Yes CM1 1 CM Filter 26.8 mH, 4 A 30% − Epcos B82725J2402N20 No Yes U1 1 Bridge Rectifier 6 A, 800 V − KBU Vishay General Semi. KBU6K No Yes D1 1 Diode 600 V, 4 A − TO220 Cree CSD04060A No Yes M1 1 MOSFET 600 V, 20 A − TO220 Infineon SPP20N60S5 No Yes H1 1 Heatsink 2.9C/W − − Aavid Thermalloy KM100−1 Yes Yes 4 Board Supports − − − Richco TCBS−8−01 Yes Yes 1 Fuse 250 V, 4 A − − Schurter FTT 0034.5049 Yes Yes 2 Thermal Pad (TO220) − − − Bergquist 3223−07FR−43 Yes Yes 1 Heatsink Clip (TO218) − − − Aavid Thermalloy 4473 Yes Yes 2 Heatsink Clip (TO220) − − − Aavid Thermalloy 4426 Yes Yes CN1 1 AC Connector − − − Schurter GSF1.1201.31 Yes Yes J1, GND 2 Terminal Block − − Pitch: 5mm Weidmuller 1715250000 Yes Yes 3 Screws − − − − MPMS 003 0008 PH − − 1 Strap (Short Circuit) − − − 3M 923345−06−C Yes Yes F1 STRAP http://onsemi.com 12 NCP1653EVB Table 4. VENDORS CONTACTS Vendor Contact Product Information CoilCraft − www.coilcraft.com microSpire − www.microspire.com TDK [email protected] www.tdk.co.jp/tetop01/ EPCOS − www.epcos.fr/ CREE www.cree.com/Products/pwr_sales2.asp www.cree.com/Products/pwr_index.asp ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. A listing of SCILLC’s product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent−Marking.pdf. SCILLC reserves the right to make changes without further notice to any products herein. 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