www.fairchildsemi.com 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. REV. 1.0.2 6/17/04 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 REV. 1.0.2 6/17/04 3 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. www.fairchildsemi.com 6/17/04 0.0m 003 Stock#DS30004810 © 2004 Fairchild Semiconductor Corporation