Fairchild FAN4810EVAL Power factor controller Datasheet

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FAN4810EVAL
Evaluation Kit User’s Guide
Power Factor Controller
General Description
How to Operate
The FAN4810 Evaluation Board is a power-factor-corrected
500W off-line power supply. The supply has a single 400V
output and operates over an input voltage range of 90 VAC to
265 VAC. The Evaluation Board uses an average mode boost
PFC that allows it to be fully complaint with IEC 61000-3-2
limits for harmonic emission.
Use the following procedure to safely operate the power
supply.
1.
Connect a 100W load across the output terminals
(J3 and J4).
2.
Connect a DC voltmeter across the output terminals.
When operating the FAN4810 Evaluation Board there are
two things to keep in mind. A minimum load of 15 to 20
Watts is required to prevent output from rising to the OVP
point. This will provide continuous operation and prevent the
PFC from periodic shutdown due to OVP. Also, there is no
current inrush limiting included in the Evaluation Board.
Because of this it is suggested that the input voltage is
always ramped up slowly.
3.
Connect an isolated variable AC source (such as a
variac) to input terminals J1 and J2. A DC source may
be substituted at the input for easier examination of the
waveforms.
4.
Slowly increase the AC input voltage to at least 90VAC
(Do not exceed 265VAC). If applying a DC input
increase it to 120 Volts.
Evaluation Kit Contents
5.
Confirm that the output voltage increases as the input
voltage is increased.
6.
As the input voltage approaches very close to 90VAC
(120VDC) the Board output should read approximately
404VDC within 5 sec.
7.
Remove the AC input and verify that the output voltage
has dropped to zero.
8.
Connect a 500W load across the output terminals and
reapply the AC input.
The FAN4810 Evaluation Kit contains the following items:
1.
FAN4810 Evaluation Kit Users Guide
2.
Fully Functional FAN4810 Evaluation Board
Circuit Design
Refer to Application Note, AN-6004 for detailed design
information on this board.
Performance Data
CAUTION!
The FAN4810 Evaluation Board contains voltage
potentials capable of causing serious injury, and components that may shatter or explode if they fail. Appropriate precautions must be taken to prevent injury should
such situations occur. The use of protective eyeware is
strongly recommended.
To safely observe circuit waveforms, an isolation
transformer should be used between the Evaluation
Board and the AC line.
To measure the Eval Board performance across the range
of permissible input voltages use an isolated Variac or
adjustable AC source. It is suggested that the input voltage is
increased slowly as the evaluation board has no inrush
current limiting.
A typical FAN4810 evaluation board will have the performance characteristics shown in Figure 1 when operated as
specified in the Test Conditions.
Do not operate this board with DC/AC voltages
outside the design limits.
Replace circuit components only with those
recommended in the parts list of this User’s Guide.
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FAN4810EVAL
PRODUCT SPECIFICATION
The unit will safely provide 500W at 90 VAC input with
adequate fan cooling. Note that even though the FAN4810
Evaluation board can achieve 500 Watts with additional fan
cooling, the heatsinks utilized are not optimal for use with
a fan.
FAN4810 with 500 Watt Load
97
7.5
96
7
6.5
94
6
93
5.5
THD (%)
Efficiency (%)
95
92
5
91
Efficiency
THD
90
89
90
110
130
150
170
190
210
230
4.5
4
250
V line (RMS)
Figure 1. FAN4810 Evaluation Board Test Results
Test Conditions: 500 Watt load on output at 25ºC
Equipment Used: Voltech Digital Single-Phase Power
Analyzer Model PM100, 500W Electronic load.
Power Ratings
The FAN4810 Evaluation board contains high impedance,
low-level signals and low impedance, high level circuits;
consequently extra care is required in component placement,
grounding and PC trace routing. In order to shield low-level
circuits from the high level signals, control circuits were
placed in surface mount form on the bottom side of the
board. This allowed a return shield to be placed on the topside. Since the current sense for the FAN4810 is not differential, care must be taken to prevent a large di/dt from occurring across the PCB trace joining the output cap (assumed to
be the reference return for the IC) to the current sense resistor. Since the best reference for the IC is at the output cap
return potential (the most stable potential), the difference
between this potential and the current sense resistor return
potential must be kept to a minimum. This is done by stargrounding all the 400V return connections to the output
capacitor, and/or maintaining very low inductive/resistive
paths from all power devices to the output capacitor return.
Some general layout guidelines:
500
A. Return the low side of the timing capacitor (C18)
directly to the IC ground pin.
480
Output (W)
Layout Considerations
Pout
B. Bypass the reference and supply voltage pins directly to
the IC ground pin with a 1 µF, low ESR/ESL capacitor.
460
C. Return all compensation components directly to the IC
ground pin, keeping the lead lengths as short as possible.
440
420
400
85
90
95
100
105
110
115
Input (VAC)
Figure 2. Output Power vs. Line Voltage
D. Make sure that low-level, noise free, returns do not share
return paths with high-level, or noisy, signals (e.g., gate
drive).
E. Isolate and/or shield rapidly changing waveforms, such
as the drain of Q1 from sensitive, high impedance circuits, such as the timing capacitor, PFC current sense
input, error amplifier input/output, etc.
The FAN4810 Evaluation Board is designed to provide up to
500W output with an input of 90VAC. Due to thermal limitations the actual output with no fan is limited to ≤400W at
inputs below 115VAC, and up to 40ºC ambient. Figure 2
displays the maximum power vs. line voltage with no fan.
Above 115VAC input the maximum output power is 500W.
2
REV. 1.0.2 6/17/04
PRODUCT SPECIFICATION
FAN4810EVAL
FAN4810 Evaluation Board Parts List
Qty
Description
Vendor/Parts/Distributor
Designation
Resistors
2
453kΩ, 1/8 W, 1%, SMD 1206
Any
R1A, R1B
2
453kΩ, 1/8 W, 1%, SMD 1206
Any
R2A, R2B
1
100kΩ, 1/8 W, 1%, SMD 1206
Any
R3
1
15.8kΩ, 1/8 W, 1%, SMD 1206
Any
R4
1
0.050Ω, 3W, 1%
Ohmite, 15FR050
R5
1
41.2kΩ, 1/8 W, 1 %, SMD 1206
Any
R6
1
127kΩ, 1/4 W, 1%, SMD 1210
Any
R7A, R7B, R7C
1
2.37kΩ, 1/8 W, 1%, SMD 1206
Any
R8
1
10kΩ, 1/8 W, 5%, SMD 1206
Any
R9
1
47Ω, 1/4 W, 5%, SMD 1210
Any
R10
1
511kΩ, 1/8 W, 5%, SMD 1206
Any
R11
1
33.2kΩ, 1/8 W, 1%, SMD 1206
Any
R12
2
39kΩ, 2W, 5%, metal film
Any
R14, R13
1
0Ω, Jumper, 1206
Any
R15
1
200kΩ, 1/8 W, 5%, SMD 1206
Any
R16
1
100Ω, 1/8 W, 5%, 1206
Any
R17
1
10Ω, 1/8 W, 5%, 1206
Any
R18
1
22Ω, 1/8 W, 5%, 1206
Any
R19
Capacitors
1
0.47µF, 250 VAC, 20% Metallized Polyester
Wima MKS4-R
C1
1
0.47µF, 16V, 10% X7R Ceramic 1206
Murata / GRM42-6X7R474K016AB
C2
3
0.1µF, 50V, 10%, X7R Ceramic 1206
Murata / GRM42-6X7R104K050AB
C3, C8, C19
1
0.047µF 630VDC, 10%, polypropylene
WIMA, MKP10
C4
1
330µF, 450V, 20%, Electrolytic
Panasonic TSU-Series
C5
1
2.2nF, 50V, 10%, X7R Ceramic 1206
Any
C6
1
47pF, 25V, 10%, Ceramic
Any
C7
1
0.01µF, 50V, 10%, X7R Ceramic 1206
Any
C9
8
1µF, 50V, 10%, X7R Ceramic 1210
Any
C10, C11, C12,
C13, C14, C16,
C20, C21
1
1500µF, 25V, Electrolytic
Panasonic / ECA-1EFQ152L
C15
1
1000pF, 50V, 20%, X7R Ceramic 1206
Any
C17
1
470pF, 25V, 5%, C0G Ceramic 1206
Any
C18
1
600V, 15A Stealth Diode
Fairchild ISL9R1560P2
D1
1
600V, 3A Rectifier Diode
Fairchild 1N5406
D2
2
50V, 1A Fast Recovery Diode
Fairchild RGF1A
D3, D4
1
20V 1W Zener Diode
Fairchild 1N4747A
D5
2
100V, 3A Rectifier Diode
Fairchild 1N5401
D6, D7
1
20V, 500mA Schottky Rectifier
Fairchild MBR0520L
D8
1
600V, 25A Bridge Rectifier
Fairchild GBPC2506
B1
Diodes
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FAN4810EVAL
PRODUCT SPECIFICATION
FAN4810 Evaluation Board Parts List (continued)
Qty
Description
Vendor/Parts/Distributor
Designation
Transistors
1
500V, 24A MOSFET
Fairchild FQA24N50
Q1
1
MMBT3904, 200mA, 40V, NPN Transistor
Fairchild
Q2
2
MMBT3906, 200mA, 40V, PNP Transistor
Fairchild
Q3, Q4
FAN4810IM Power Factor Cont.
Fairchild Semiconductor
U1
420µH, 10A
Premier Magnetics Inc. / TSD-902
Pulse / P0316
L1
8 Amp 250 VAC Fast Acting
Little Fuse / Series 217
F1
ICs
1
Magnetics
1
Fuse
1
Hardware
4
2
5x20 Fuse Clips
Little Fuse
1
TO220 Heatsinks
Aavid / 534265BO3453
(Ref. D1)
1
TO220/TO218 Heatsink
Thermalloy / 6300B
(Ref. Q1)
1
TO220 Insulator, Sarcon Tube
Fujipoly / 30T-11-1000L
(Ref. D1)
1
TO218 Insulator
Fujipoly / 30T-TO-3PF
Bergquist / K10-104
(Ref. Q1)
4
Standard Banana Plug
Johnson Comp. / 108-0740-001
J1, J2, J3, J4
1
6-32 1/2" Phillips Machine Screw
(Ref. Q1)
2
6-32 Lock Washer
(Ref. Q1)
2
6-32 Hex Nut
(Ref. Q1)
5
4-40 5/16" Phillips Machine Screw
5
4-40 Lock Washer
5
4-40 0.875" Hex threaded spacers
Johnson Components
Digi-Key / J176-ND
1
Unthreaded round aluminum or nylon
Spacer, 1/4" OD, 0.140” ID, 1/4" Length
Johnson Components
Digi-Key / J169-ND
1
Blank Evaluation Board
8
Thru-Hole Test Pins, 3M Series 2400
Digi-Key / 929834-02-36-ND
TP1, TP2, TP3,
TP4, TP5, TP6,
TP7, TP8
REV. 1.0.2 6/17/04
PRODUCT SPECIFICATION
FAN4810EVAL
D2 1N5406
12, 11
J1
AC INPUT
TP2
TP1
L1
TP4
7, 8
J3
F1
D1
R7A
400 VDC
R2A
C1
R7B
R1A
R14
R2B
R13
R7C
TP5
J2
R19
C5
Q1
D6
R5A
R3
C3
R9
D5
D7
C4
R1B
R8
C17
C2
R5B
TP3
R4
J4
TP6
400 VDC RTN
R10
R15
R18
TP7
Q2
C10
D3
6
C12
C21
C15
L1
5
Q3
R17
C16
C7
R12
R6
1
2
3
4
IEAO
C6
D4
VEAO
16
FB
15
IAC
ISENSE
VREF
VRMS
VCC
12
TP8
11
10
9
C20
R11
FAN4810
C18
Q4
R16
13
5 CLKSD PFC OUT
6
CLK OUT
NC
7
GND
RAMP1
8
NC
GND
C19
14
C13
C11
C9
C14
C8
D8
Figure 3. Schematic
REV. 1.0.2 6/17/04
5
FAN4810EVAL
PRODUCT SPECIFICATION
DISCLAIMER
FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO
ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. FAIRCHILD DOES NOT ASSUME
ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN;
NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.
LIFE SUPPORT POLICY
FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES
OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR
CORPORATION. As used herein:
1. Life support devices or systems are devices or systems
which, (a) are intended for surgical implant into the body,
or (b) support or sustain life, and (c) whose failure to
perform when properly used in accordance with
instructions for use provided in the labeling, can be
reasonably expected to result in a significant injury of the
user.
2. A critical component in any component of a life support
device or system whose failure to perform can be
reasonably expected to cause the failure of the life support
device or system, or to affect its safety or effectiveness.
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