Title
Reference Design Report for a Low-Power,
Low-Cost 180 W PFC Front End Using
HiperPFS™ PFS708EG
Specification
90 VAC – 264 VAC Input; 380 VDC Output
Application
PFC Front End
Author
Applications Engineering Department
Document
Number
RDR-248
Date
March 25, 2011
Revision
1.0
Summary and Features
Low component count, low-cost, low-power PFC
EN61000-3-2 Class-D compliance
High PFC efficiency enables 80+ PC Main design
Frequency sliding maintains high efficiency across load range
Feed forward line sense gain – maintains relatively constant loop gain over entire
operating voltage range
Excellent transient load response
Power Integration eSIP low-profile controller package
Integrated +15 VDC auxiliary power supply on board
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered
by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A
complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under
certain patent rights as set forth at .
.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
25-Mar-11
Table of Contents
1
2
3
4
5
Introduction.................................................................................................................5
Design Goals ..............................................................................................................5
Power Supply Specification ........................................................................................7
Schematic...................................................................................................................8
Circuit Description ......................................................................................................9
5.1
Input EMI Filter and Rectifier ...............................................................................9
5.2
PFS708EG Boost Converter ...............................................................................9
5.3
Input Feed Forward Sense Circuit.....................................................................10
5.4
Output Feedback...............................................................................................10
5.5
Bias Supply .......................................................................................................10
5.5.1
Input EMI Filtering ......................................................................................10
5.5.2
TNY274GN Primary ...................................................................................10
5.5.3
Output Rectification ....................................................................................11
5.5.4
Output Feedback........................................................................................11
5.5.5
Overvoltage Shutdown ...............................................................................11
5.5.6
Design Aspects for EMI..............................................................................11
5.5.7
Undervoltage Lockout ................................................................................11
5.6
Bias Supply Series Regulator............................................................................12
6 PCB Layout ..............................................................................................................13
7 Bill of Materials .........................................................................................................14
8 Transformer Design Spreadsheet (T2) .....................................................................17
9 Inductor Design Spreadsheet (L5)............................................................................20
10
Auxiliary Supply Transformer Specification...........................................................23
10.1 Electrical Diagram .............................................................................................23
10.2 Electrical Specifications.....................................................................................23
10.3 Materials............................................................................................................23
10.4 Transformer Build Diagram ...............................................................................24
10.5 Transformer Construction..................................................................................24
10.6 Transformer Illustrations....................................................................................25
11
Switching Inductor Specification ...........................................................................28
11.1 Electrical Diagram .............................................................................................28
11.2 Electrical Specifications.....................................................................................28
11.3 Materials............................................................................................................28
11.4 Inductor Winding Instruction ..............................................................................29
12
EMI Differential Inductor Specification ..................................................................32
12.1 Electrical Diagram .............................................................................................32
12.2 Electrical Specifications.....................................................................................32
12.3 Materials............................................................................................................32
12.4 Inductor Winding Instruction ..............................................................................33
12.5 Inductance Value and Mounting ........................................................................34
13
Heat Sink Specification .........................................................................................35
13.1 eSIP U1 Heat Sink ............................................................................................35
13.2 eSIP U1 Heat Sink Assembly ............................................................................36
13.3 eSIP U1 Heat Sink Assembly and Mounting Hardware.....................................37
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Page 2 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
13.4 Bridge BR1 Heat Sink........................................................................................38
13.5 Bridge BR1 Heat Sink Assembly .......................................................................39
13.6 Bridge BR1 Heat Sink Assembly and Mounting Hardware Assembly................40
14
Performance Data .................................................................................................41
14.1 Auxiliary Supply Efficiency (with PFC disabled).................................................41
14.2 Auxiliary Supply Load Regulation (with PFC disabled) ......................................42
14.3 Auxiliary Supply Line Regulation (with PFC disabled) .......................................43
14.4 No-Load Input Power.........................................................................................44
14.5 PFC Efficiency (with RT1 in-circuit) ...................................................................45
14.6 Input Power Factor ............................................................................................46
14.7 Regulation .........................................................................................................47
14.7.1 Load ...........................................................................................................47
14.7.2 Line.............................................................................................................48
14.7.3 Overload .....................................................................................................49
14.8 THDi ..................................................................................................................50
14.9 Input Current Harmonic Distortion (IEC 61000-3-2 Class-D) .............................51
14.9.1 50% Load at Output....................................................................................51
14.9.2 100% Load at Output..................................................................................52
15
Thermal Performance............................................................................................53
16
Waveforms ............................................................................................................55
16.1 Auxiliary +15 V Supply.......................................................................................55
16.1.1 Load Transient Response ..........................................................................55
16.2 Input Current at 115 VAC and 60 Hz .................................................................56
16.3 Input Current at 230 VAC and 50 Hz .................................................................56
16.4 Start-up at 90 VAC and 60 Hz ...........................................................................57
16.5 Start-up at 115 VAC and 60 Hz .........................................................................57
16.6 Start-up at 230 VAC and 50 Hz .........................................................................58
16.7 Start-up at 264 VAC and 50 Hz .........................................................................58
16.8 Load Transient Response (90 VAC, 60 Hz).......................................................59
16.9 Load Transient Response (115 VAC, 60 Hz).....................................................60
16.10
Load Transient Response (230 VAC, 50 Hz) .................................................60
16.11
Load Transient Response (264 VAC, 50 Hz) .................................................61
16.12
1000 ms Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ...................61
16.12.1
50% Load at Output ................................................................................61
16.12.2
Full Load at Output .................................................................................62
16.13
One Cycle Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ................62
16.13.1
Full Load at Output .................................................................................62
16.14
Line Sag (115 VAC ~ 85 VAC ~ 115 VAC, 60 Hz) .........................................63
16.15
Line Surge (132 VAC ~ 147 VAC ~ 132 VAC, 60 Hz) ....................................63
16.16
Line Sag (230 VAC ~ 170 VAC ~ 230 VAC, 50 Hz) .......................................64
16.17
Line Surge (264 VAC ~ 293 VAC ~ 264 VAC, 50 Hz) ....................................64
16.18
Brown-In and Brown-Out at 6 V / Minute Rate ...............................................65
16.19
Drain Voltage and Current .............................................................................66
16.19.1
Drain Voltage and Current at 115 VAC Input and Full Load....................66
16.19.2
Drain Voltage and Current at 230 VAC Input and Full Load....................67
16.20
Output Ripple Measurements ........................................................................68
Page 3 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
25-Mar-11
16.20.1
Ripple Measurement Technique .............................................................68
16.20.2
Measurement Results.............................................................................69
17
Gain-Phase Measurement Procedure and Results...............................................71
18
Line Surge Test.....................................................................................................73
19
EMI Scans.............................................................................................................74
19.1 EMI Test Set-up ................................................................................................74
19.2 EMI Scans .........................................................................................................75
20
Appendix A - Test Set-up for Efficiency Measurement..........................................77
21
Appendix B - Inductor Current Measurement Set-up ............................................78
22
Revision History ....................................................................................................80
Important Note:
All testing should be performed using an isolation transformer to provide the AC input to
the prototype board.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 4 of 81
25-Mar-11
1
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Introduction
This document is an engineering report describing a PFC power supply utilizing a
HiperPFS PFS708EG integrated PFC controller. This power supply is intended as a
general purpose evaluation platform that operates from universal input line power and
provides a regulated 380 V DC output voltage and a continuous output power of 180 W.
This power supply can deliver rated power at 115 VAC source voltage or higher at
ambient temperature of 25 ºC. For operation at higher temperatures or lower input
voltages, use of forced air cooling is recommended.
The document contains the power supply specification, schematic, bill of materials,
inductor documentation, printed circuit layout, and performance data.
2 Design Goals
To meet the goal of low solution cost the following considerations where made:
Low cost Sendust core for boost inductor
Single strand wire used for boost inductor (vs. more expensive Litz)
Surface mount boost diode to eliminate heat sink
Standard ultrafast diode
Figure 1 – Populated Circuit Board Photograph (Top).
Page 5 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
25-Mar-11
Figure 2 – Populated Circuit Board Photograph (Bottom).
Power Integrations, Inc.
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Page 6 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
3 Power Supply Specification
The table below represents the minimum acceptable performance of the design. Actual
performance is listed in the results section.
Description
Input
Voltage
Frequency
Output
Output Voltage
Output Ripple Voltage p-p
Output Current
Total Output Power
Continuous Output Power
Efficiency
Full Load
Minimum efficiency at 20, 50
and 100 % of POUT
Symbol
Min
Typ
Max
Units
Comment
VIN
fLINE
90
47
264
64
VAC
Hz
3 Wire
50/60
VOUT
VRIPPLE
IOUT
370
380
390
30
0.474
V
V
A
180
W
POUT
20 MHz bandwidth
94
%
Measured at POUT 25 C
80+
94
%
Measured at 115 VAC Input
kV
kV
1.2/50 s surge, IEC 1000-4-5,
Series Impedance:
Differential Mode: 2
Common Mode: 12
o
Environmental
Line Surge
Differential Mode (L1-L2)
Common mode (L1/L2-PE)
1
2
Ambient Temperature
TAMB
0
Auxiliary Supply Output
Auxiliary Supply output current
Auxiliary Supply Input
Auxiliary Supply
VAUX
IAUX
14.5
VAUX
15
Page 7 of 81
50
15.0
o
C
Forced convection required at TAMB
> 25 ºC and/or VIN < 115 V, sea
level
16.5
0.2
V
A
DC Supply Output Voltage
24
V
DC Supply
DC Supply Output Current
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
4
25-Mar-11
Schematic
Figure 3 – PFC Circuit Schematic.
Figure 4 – VAUX Circuit Schematic (Standby).
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Page 8 of 81
25-Mar-11
5
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Circuit Description
This PFC is designed around the Power Integrations PFS708EG integrated PFC
controller. This design is rated for a continuous output power of 180 W and provides a
regulated output voltage of 380 VDC nominal, maintaining a high input power factor and
overall efficiency over line and load, while minimizing overall solution in cost.
5.1 Input EMI Filter and Rectifier
Fuse F1 provides over-current protection to the circuit and isolates it from the AC supply
in the event of a fault. Diode Bridge BR1 rectifies the AC input. Capacitors C3, C4, C5
and C6 in conjunction with inductors L1 and L2, constitute the EMI filter for attenuating
both common mode and differential mode conducted noise. Film capacitor C7 provides
input decoupling charge storage to reduce input ripple current at the switching frequency
and its harmonics.
Resistors R1, R3 and CAPZero IC U2 are provided to discharge the EMI filter capacitors
after line voltage has been removed from the circuit, while dissipating zero power during
operation. CAPZero eliminates the losses from R1 and R3 by acting as a switch that only
closes when the AC input is removed.
Metal Oxide Varistor (MOV) RV1 protects the circuit during line surge events by
effectively clamping the input voltage seen by the power supply.
5.2 PFS708EG Boost Converter
The boost converter stage consists of inductor L5, ultrafast rectifier D2 and the
PFS708EG IC U1. This converter stage operates as a boost converter, thereby
maintaining a sinusoidal input current to the power supply while regulating the output DC
voltage.
During start-up, diode D1 provides an inrush current path to the output capacitor C15
which bypasses the switching inductor L5 and switch U1. This prevents a resonant
interaction between the switching inductor and output capacitor which results in a higher
drain voltage on U1 and potential saturation of the boost inductor.
NTC Thermistor RT1 limits inrush current of the supply when line power is first applied.
For improved efficiency operation, RT1 may be bypassed by a mechanical relay after
power-on, or may be replaced with a fixed resistor and a FET which bypasses the
resistor after the inrush transient.
Capacitor C14 provides a short, high-frequency return path to RTN for improved EMI
results and to reduce U1 MOSFET peak drain voltage overshoot after turn-off. Resistor
R28 provides damping for this return path to minimize ringing. Capacitor C18 and C20
decouple and bypass the U1 VCC pin.
Page 9 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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5.3 Input Feed Forward Sense Circuit
The input voltage of the power supply is sensed by the IC U1 using resistors R4, R5 and
R19. The capacitor C12 bypasses the V pin on IC U1.
5.4 Output Feedback
An output voltage resistive divider network consisting of resistors R9, R10, R11 and R14
provide a scaled voltage proportional to the output voltage as feedback to the controller
IC U1. The circuit consisting of diode D4, transistors Q1, Q2, resistors R12 and R13 and
capacitor C16 form a non-linear feedback circuit which improves the transient response
of the PFC circuit.
Resistor R15 and capacitor C13 provide the control loop dominant pole. Capacitor C17,
C11 and R7 attenuate high-frequency noise.
The resistor R8 in series with capacitor C13 provides a low frequency compensation zero
while diode D3 protects against errant operation caused by an accidentally shorted C13.
If capacitor C13 is accidentally shorted, diode D3 ensures that the voltage at the FB pin
of IC U1 is below the FB_OFF threshold preventing operation of the IC.
5.5 Bias Supply
Integrated into the PFC design is a +15 V, 3.0 W auxiliary flyback power supply utilizing
the TNY274GN. Secondary side constant voltage (CV) is accomplished through
optocoupler feedback with a Zener reference.
5.5.1 Input EMI Filtering
The PFC output is further filtered and decoupled by the bulk storage capacitor C28.
5.5.2 TNY274GN Primary
The IC U3 integrates a power MOSFET, oscillator, control, start-up, and protection
functions of the auxiliary supply.
The high-voltage input is applied to the primary winding of transformer T2. The other end
of the transformer primary is connected to the Drain terminal of IC U3. Diodes D10 and
VR2 form the primary clamp network which limits the peak drain voltage resulting from
leakage inductance of transformer T2 primary winding. The selection of a slow diode for
D10 improves conducted EMI but should be a glass passivated type, with a recovery time
of 4 s.
IC U3 employs ON/OFF control to regulate the output in response to the feedback signal
present on the EN/UV pin. During normal operation, switching of the power MOSFET is
disabled when a current greater than 90 A is sourced from the EN/UV pin. Currents
below this threshold enable a switching cycle, which is terminated when the peak primary
current reaches the internal current limit. An internal state machine sets the current limit
to one of 4 levels appropriate for the operating conditions, ensuring that the switching
frequency remains above the audible range until the transformer flux density drops to a
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Page 10 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
level below that which can create audible noise. This practically eliminates audible noise
when standard dip varnishing of the transformer is employed.
Capacitor C25 is a 0.1 F BP/M pin bypass capacitor.
5.5.3 Output Rectification
Output rectification is provided by diode D11. A low-ESR capacitor C26 achieves
minimum output voltage ripple.
5.5.4 Output Feedback
Output voltage is regulated by the Zener diode VR4. When the output exceeds the Zener
threshold, current will flow in the optocoupler LED which will result in the photo-transistor
of the optocoupler U4 to conduct, thereby inhibiting the next switching cycle by sinking
sufficient current from the enable pin of IC U3. When the voltage reduces, the phototransistor current reduces, allowing a switching cycle to occur when current from the
ENABLE pin falls below the enable threshold. Output regulation is maintained via this
cycle-by-cycle on-off control.
5.5.5 Overvoltage Shutdown
Overvoltage detection is accomplished by sensing the voltage at the output of the bias
winding. The overvoltage threshold is the sum of VR5 and the BYPASS pin voltage (28 V
+ 5.8 V). When an overvoltage condition occurs such that the bias winding output voltage
exceeds the overvoltage threshold, current begins to flow into the BYPASS pin of U3.
When this current exceeds 5 mA, the internal shutdown circuit in the TinySwitch-III IC is
activated. The IC is reset by removing input power allowing the BYPASS pin voltage to
drop below 2 V.
5.5.6 Design Aspects for EMI
The switching frequency jitter feature of TNY274GN provides excellent conducted and
radiated EMI performance for the auxiliary supply circuitry.
5.5.7 Undervoltage Lockout
Resistors R26 and R27 constitute an undervoltage UV detect resistor. The line UV detect
feature of the TinySwitch-III senses the current flowing in EN/UV pin to determine the line
voltage at which to start switching. In addition, this UV detect feature, prevents the power
supply from attempting to restart once output regulation is lost, unless the input voltage is
above the start-up threshold. The R26 and R27 combined value of 3.3 M shown in
Figure 3 will set the auxiliary supply start-up threshold to approximately 90 VDC (65
VAC).
The output of the auxiliary supply is available on an output power connector for use in
powering supervisory or other auxiliary house keeping circuits.
Page 11 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
25-Mar-11
5.6 Bias Supply Series Regulator
The PFS708EG IC requires a regulated VCC supply of 12 V for operation, with an
absolute maximum voltage rating of 13.4 V. VCC levels in excess of this maximum could
result in failure of U1. Resistor R17, Zener diode VR1, and transistor Q3 form a shunt
regulator that prevents the supply voltage to IC U1 from exceeding 12 V. Capacitors C8
and C20 filter the input and series regulated supply voltage to ensure reliable operation of
IC U1.
Resistors R6, R16 provide filtering of an alternate external voltage source and provide
reverse polarity protection in conjunction with diode D5.
Diodes D13 and D14 provide diode ORing, allowing U1 to be powered either from the onboard +15 V auxiliary flyback supply or from an external voltage source.
The on-board +15 V auxiliary supply is made available on J4 to power external
housekeeping circuitry.
Power Integrations, Inc.
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Page 12 of 81
25-Mar-11
6
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
PCB Layout
Figure 5 – Printed Circuit Layout.
Page 13 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
7
25-Mar-11
Bill of Materials
Item
1
2
Qty
1
1
Ref Des
BR1
C29
3
2
C4 C5
4
5
1
1
C6
C7
6
1
C8
7
8
9
10
11
12
13
14
15
16
1
2
1
2
1
1
1
1
1
1
C11
C12 C20
C13
C14 C28
C15
C16
C17
C18
C22
C25
17
1
C26
18
1
C27
19
20
21
22
1
1
1
2
D1
D2
D3
D4 D14
23
1
D5
24
1
D10
25
26
27
1
1
1
28
1
29
1
D11
D12
D13
ESIPCLIP M4
METAL1
F1
30
1
HS1
31
1
HS2
32
1
33
34
35
1
1
2
HSPREADER
_ESIPPFISW1
J1
J2
J3 J4
36
1
JP1
37
1
JP2
38
1
JP3
39
1
JP4
40
1
JP5
41
2
JP6 JP7
Description
600 V, 3 A, Bridge Rectifier
330 nF, 275 VAC, Film, X2
150 pF, 250 VAC, Thru Hole, Ceramic YCapacitor
220 nF, 275 VAC, Film, X2
470 nF, 400 V, Polypropylene Film
47 F, 50 V, Electrolytic, Gen. Purpose,
(6.3 x 11)
10 nF, 50 V, Ceramic, X7R, 0805
100 nF, 50 V, Ceramic, X7R, 0805
4.7 F, 25 V, Ceramic, X7R, 1206
10 nF, 1 kV, Disc Ceramic, X7R
150 F, 450 V, Electrolytic, (25 x 30)
100 nF, 200 V, Ceramic, X7R, 1812
470 pF, 100 V, Ceramic, X7R, 0805
1 F, 25 V, Ceramic, X7R, 1206
1 F, 50 V, Ceramic, X7R, 0805
100 nF, 50 V, Ceramic, X7R, 1206
220 F, 25 V, Electrolytic, Very Low ESR,
72 m, (8 x 11.5)
100 F, 25 V, Electrolytic, Gen. Purpose,
(6.3 x 11)
1000 V, 3 A, Recitifier, DO-201AD
600 V, 3 A, SMC, DO-214AB
130 V, 5%, 250 mW, SOD-123
75 V, 0.15 A, Fast Switching, 4 ns, MELF
50 V, 1 A, Rectifier, Glass Passivated, DO213AA (MELF)
600 V, 1 A, Fast Recovery Diode, 200 ns,
DO-41
100 V, 1 A, Ultrafast Recovery, 35 ns, DO-41
150 V, 1 A, Ultrafast Recovery, 50 ns, DO-41
75 V, 300 mA, Fast Switching, DO-35
Heat sink Hardware, Edge Clip, 20.76 mm L x
8 mm W x 0.015 mm Thk
3.15 A, 250V, Slow, TR5
U-shaped, e-SIP Heat sink w/ mounting
brackets;
L-shaped, diode bridge Heat sink w/ mounting
brackets;
Mfg Part Number
3KBP06M-E4/51
R46KI333000N1M
PHE840MB6220MB12R17
ECW-F4474JL
Mfg
Vishay
Kemet
Vishay /
Roederstein
Kemet
Panasonic
EKMG500ELL470MF11D
Nippon Chemi-Con
ECJ-2VB1H103K
CC0805KRX7R9BB104
ECJ-3YB1E475M
SV01AC103KAR
EET-HC2W151CA
18122C104KAT2A
08051C471KAT2A
C3216X7R1E105K
08055D105KAT2A
GRM319R71H104KA01D
Panasonic
Yageo
Panasonic
AVX
Panasonic
AVX
AVX
TDK
AVX
Murata
EKZE250ELL221MHB5D
Nippon Chemi-Con
EKMG250ELL101MF11D
Nippon Chemi-Con
1N5408-T
STTH3R06S
BAV116W-7-F
LL4148-13
Diodes, Inc.
ST Micro
Diodes, Inc.
Diodes, Inc.
DL4001-13-F
Diodes, Inc.
WKO151MCPCF0KR
1N4937RLG
On Semi
MUR110RLG
MUR115G
1N4148TR
On Semi
On Semi
Vishay
NP975864
Aavid Thermalloy
37213150411
Wickman
PI P/N: 76-00006-05
Power Integrations
PI P/N: 76-00007-04
Power Integrations
Heat Spreader, Custom, Al, 3003, 0.030" Thk
61-00040-00
Custom
5 Position (1x5) header, 0.156 pitch, Vertical
CONN HEADER 3 po (1x3).156 Vertical TIN
2 Position (1x2) header, 0.1 pitch, Vertical
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #22 AWG, 0.2 in
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #22 AWG, 0.8 in
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #22 AWG, 0.3 in
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #18 AWG, 1.0 in
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #22 AWG, 0.6 in
Wire Jumper, [high-temp. e.g. Teflon]
Insulated, #22 AWG, 0.4 in
26-64-4050
26-64-4030
22-23-2021
Molex
Molex
Molex
2855/1 WH005
AlphaWire
2855/1 WH005
AlphaWire
2855/1 WH005
AlphaWire
2857/1 WH005
AlphaWire
2855/1 WH005
AlphaWire
2855/1 WH005
AlphaWire
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Page 14 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Item
42
Qty
1
Ref Des
L1
43
1
L2
44
1
L5
45
1
L8
46
1
47
4
NUT1
POSTCRKT_BRD_632_HEX1
POSTCRKT_BRD_632_HEX2
POSTCRKT_BRD_632_HEX3
POSTCRKT_BRD_632_HEX4
48
1
POWERCLIP1
49
2
Q1 Q3
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
1
1
1
2
1
2
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Q2
R1
R3
R4 R19
R5
R6 R16
R7
R8 R17
R9
R10
R11
R12 R13
R14
R15
R20
R21
R23
R24
R25
R26
R27
R28
RT1
RTV1
RV1
SCREW1
76
1
T2
77
78
79
80
81
1
3
1
1
1
TO-220 PAD1
TP1 TP5 TP7
TP2
TP4
TP6
Page 15 of 81
Description
Common Mode Choke Toroidal
Custom, 330 H constructed on Micrometals
T94-26 toroidal core
Custom, 180 W PFC Inductor, 1.80 mH,
constructed on Lodestone Pacific base PN
VTM120-4
Mfg Part Number
T22148-902S
Mfg
Fontaine Tech
SNX-R1575
Santronics
SNX-R1563
Santronics
Ferrite Bead, 250 , 4A, 2220 SMD
HI2220P251R-10
Laird-Signal
Integrity Products
561-0375A
Eagle Hardware
CLP212TG
Aavid Thermalloy
MMBT4401-TP
Micro Commercial
MMBT4403-7-F
CFR-25JB-750K
ERJ-8GEYJ754V
ERJ-8ENF1504V
MFR-25FBF-1M00
ERJ-8ENF1000V
ERJ-8GEYJ202V
ERJ-8GEYJ302V
RNF14FTD1M50
ERJ-8ENF1604V
ERJ-8ENF7323V
ERJ-8ENF2211V
ERJ-8ENF5762V
ERJ-6GEYJ164V
ERJ-8ENF3012V
MFR-25FBF-681R
ERJ-6GEYJ102V
ERJ-6GEYJ470V
CFR-12JB-20R
ERJ-8GEYJ185V
ERJ-8GEYJ155V
ERJ-12ZYJ1R0U
CL-110
120-SA
V320LA10P
PMSSS 440 0038 PH
PM-9820
[PI P/N: 25-00861-00]
SNX-R1562
K10-104
5011
5010
5012
5014
Diodes, Inc.
Yageo
Panasonic
Panasonic
Yageo
Panasonic
Panasonic
Panasonic
Stackpole
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Yageo
Panasonic
Panasonic
Yageo
Panasonic
Panasonic
Panasonic
GE Sensing
Wakefield
Littlefuse
Building Fasteners
Ho Jinn Plastic
Nut, Hex 4-40, SS
Post, Circuit Board, Female, Hex, 6-32, snap,
0.375L, Nylon
Heat sink Hardware, Edge Clip 34N (7.6 lbs)
14.6 mm L x 10 mm W x 0.6 mm H
NPN, Small Signal BJT, GP SS, 40 V, 0.6 A,
SOT-23
PNP, Small Signal BJT, 40 V, 0.6 A, SOT-23
750 k, 5%, 1/4 W, Carbon Film
750 k, 5%, 1/4 W, Thick Film, 1206
1.50 M, 1%, 1/4 W, Thick Film, 1206
1 M, 1%, 1/4 W, Metal Film
100 , 1%, 1/4 W, Thick Film, 1206
2 k, 5%, 1/4 W, Thick Film, 1206
3 k, 5%, 1/4 W, Thick Film, 1206
1.5M, 1%, 1/4 W, Metal Film
1.60 M, 1%, 1/4 W, Thick Film, 1206
732 k, 1%, 1/4 W, Thick Film, 1206
2.21 k, 1%, 1/4 W, Thick Film, 1206
57.6 k, 1%, 1/4 W, Thick Film, 1206
160 k, 5%, 1/8 W, Thick Film, 0805
30.1 k, 1%, 1/4 W, Thick Film, 1206
681 , 1%, 1/4 W, Metal Film
1 k, 5%, 1/8 W, Thick Film, 0805
47 , 5%, 1/8 W, Thick Film, 0805
20 , 5%, 1/8 W, Carbon Film
1.8 M, 5%, 1/4 W, Thick Film, 1206
1.5 M, 5%, 1/4 W, Thick Film, 1206
1 , 5%, 3/4 W, Thick Film, 2010
NTC Thermistor, 10 , 3.2 A
Thermally conductive Silicone Grease
320 V, 23 J, 10 mm, RADIAL
SCREW MACHINE PHIL 4-40 X 3/8 SS
Bobbin, EE16, Horizontal, 10 pins
Transformer
HEATPAD TO-247 .006" K10
Test Point, BLK,THRU-HOLE MOUNT
Test Point, RED,THRU-HOLE MOUNT
Test Point, WHT,THRU-HOLE MOUNT
Test Point, YEL,THRU-HOLE MOUNT
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Santronics
Bergquist
Keystone
Keystone
Keystone
Keystone
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Item
82
83
84
85
86
87
88
89
90
Qty
1
1
1
1
1
1
1
1
1
Ref Des
TP8
U1
U2
U3
U4
VR1
VR2
VR4
VR5
91
1
WASHER6
92
1
WASHER7
93
94
1
1
Label
Adhesive1
Description
Test Point, ORG,THRU-HOLE MOUNT
HiperPFS, eSIP7/6-TH
CAPZero, SO-8C
TinySwitch-III, SMD-8C
Optocoupler, 35 V, CTR 80-160%, 4-DIP
12 V, 5%, 225 mW, SOT23
200 V, 5 W, 5%, TVS, DO204AC (DO-15)
13 V, 2%, 300 mW, SOD-323
28 V, 5%, 500 mW, DO-213AA (MELF)
Washer, Shoulder, #4, 0.095 Shoulder x
0.117 Dia, Polyphenylene Sulfide PPS
Washer Teflon #6, ID 0.156, OD 0.312, Thk
0.031
“High Voltage” warning label, (eSIP Heat sink)
Hot-melt Adhesive
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
25-Mar-11
Mfg Part Number
5013
PFS708EG
CAP002DG
TNY274GN
LTV-817A
BZX84C12LT1G
P6KE200ARLG
BZX384-B13,115
ZMM5255B-7
Mfg
Keystone
Power Integrations
Power Integrations
Power Integrations
Liteon
On Semi
On Semi
NXP Semi
Diodes, Inc.
7721-10PPSG
Aavid Thermalloy
FWF-6
Distributor
LPP0580
3748-VO-TC
Image-Tek
3M
Page 16 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
8 Transformer Design Spreadsheet (T2)
ACDC_TinySwitchIII_120209;
Rev.1.26;
INPUT
INFO
Copyright Power
Integrations 2008
ENTER APPLICATION VARIABLES
VACMIN
65
VACMAX
290
fL
50
VO
15.00
IO
n
0.75
Z
0.50
tC
0.75
CIN
120.00
ENTER TinySwitch-III VARIABLES
TinySwitch-III
Auto
Chosen Device
TNY274G
STD
ILIMITMIN
ILIMITTYP
ILIMITMAX
fSmin
I^2fmin
UNIT
Volts
Volts
Hertz
Volts
0.20
Power
Chose Configuration
OUTPUT
Amps
3
Watts
120
mSeconds
uFarads
TNY274G
ACDC_TinySwitch-III_120209_Rev1-26.xls;
TinySwitch-III Continuous/Discontinuous
Flyback Transformer Design Spreadsheet
Minimum AC Input Voltage
Maximum AC Input Voltage
AC Mains Frequency
Output Voltage (at continuous power)
Power Supply Output Current (corresponding
to peak power)
Continuous Output Power
Efficiency Estimate at output terminals. Under
0.7 if no better data available
Z Factor. Ratio of secondary side losses to
the total losses in the power supply. Use 0.5
if no better data available
Bridge Rectifier Conduction Time Estimate
Input Capacitance
Recommended TinySwitch-III
Standard
Current Limit
0.233
0.250
0.267
124000
Amps
Amps
Amps
Hertz
7.43
A^2kHz
VOR
115.00
115
Volts
VDS
11.30
11.3
Volts
VD
KP
0.85
0.85
2.03
Volts
KP_TRANSIENT
1.72
ENTER BIAS WINDING VARIABLES
VB
22
VDB
0.95
NB
VZOV
28
22.00
0.95
13.88
28.00
Volts
Volts
90.00
Volts
Volts
Enter "RED" for reduced current limit (sealed
adapters), "STD" for standard current limit or
"INC" for increased current limit (peak or
higher power applications)
Minimum Current Limit
Typical Current Limit
Maximum Current Limit
Minimum Device Switching Frequency
I^2f (product of current limit squared and
frequency is trimmed for tighter tolerance)
Reflected Output Voltage (VOR < 135 V
Recommended)
TinySwitch-III on-state Drain to Source
Voltage
Output Winding Diode Forward Voltage Drop
Ripple to Peak Current Ratio (KP < 6)
Transient Ripple to Peak Current Ratio.
Ensure KP_TRANSIENT > 0.25
Bias Winding Voltage
Bias Winding Diode Forward Voltage Drop
Bias Winding Number of Turns
Over Voltage Protection zener diode voltage.
UVLO VARIABLES
V_UV_TARGET
90
V_UV_ACTUAL
92.20
Volts
RUV_IDEAL
3.51
Mohms
RUV_ACTUAL
3.60
Mohms
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type
EE16
EE16
Core
EE16
Bobbin
EE16_BOBBIN
AE
0.192
LE
3.5
AL
1140
Page 17 of 81
P/N:
P/N:
cm^2
cm
nH/T^2
Target DC under-voltage threshold, above
which the power supply with start
Typical DC start-up voltage based on
standard value of RUV_ACTUAL
Calculated value for UV Lockout resistor
Closest standard value of resistor to
RUV_IDEAL
Enter Transformer Core
PC40EE16-Z
EE16_BOBBIN
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
BW
M
2.50
L
3.00
NS
10
DC INPUT VOLTAGE PARAMETERS
VMIN
87.00
VMAX
410.00
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX
8.6
mm
2.5
mm
3
10
87
410
LP
Minimum DC Input Voltage
Maximum DC Input Voltage
Amps
Amps
Amps
Amps
Duty Ratio at full load, minimum primary
inductance and minimum input voltage
Average Primary Current
Minimum Peak Primary Current
Primary Ripple Current
Primary RMS Current
1037
uHenries
10
73
197
%
nH/T^2
BM
1988
Gauss
BAC
994
Gauss
ur
LG
BWE
1654
0.10
10.8
mm
mm
OD
0.150
mm
INS
0.03
mm
DIA
0.110
mm
37
AWG
LP_TOLERANCE
NP
ALG
10.00
AWG
Bobbin Physical Winding Width
Safety Margin Width (Half the Primary to
Secondary Creepage Distance)
Number of Primary Layers
Number of Secondary Turns
Volts
Volts
0.39
IAVG
0.05
IP
0.2300
IR
0.2300
IRMS
0.10
TRANSFORMER PRIMARY DESIGN PARAMETERS
25-Mar-11
CM
20
Cmils
CMA
208
Cmils/Amp
TRANSFORMER SECONDARY DESIGN PARAMETERS
Lumped parameters
ISP
1.69
ISRMS
0.61
IRIPPLE
0.58
Amps
Amps
Amps
CMS
122
Cmils
AWGS
29
AWG
VDRAIN
672
Volts
PIVS
72
Volts
Typical Primary Inductance. +/- 10% to
ensure a minimum primary inductance of 942
uH
Primary inductance tolerance
Primary Winding Number of Turns
Gapped Core Effective Inductance
Maximum Operating Flux Density, BM 0.1 mm)
Effective Bobbin Width
Maximum Primary Wire Diameter including
insulation
Estimated Total Insulation Thickness (= 2 *
film thickness)
Bare conductor diameter
Primary Wire Gauge (Rounded to next
smaller standard AWG value)
Bare conductor effective area in circular mils
Primary Winding Current Capacity (200 <
CMA < 500)
Peak Secondary Current
Secondary RMS Current
Output Capacitor RMS Ripple Current
Secondary Bare Conductor minimum circular
mils
Secondary Wire Gauge (Rounded up to next
larger standard AWG value)
VOLTAGE STRESS PARAMETERS
Maximum Drain Voltage Estimate (Assumes
20% zener clamp tolerance and an additional
10% temperature tolerance)
Output Rectifier Maximum Peak Inverse
Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output
VO1
IO1
PO1
VD1
NS1
ISRMS1
IRIPPLE1
PIVS1
15
Volts
0.200
3.00
0.850
10.00
0.611
0.58
72
Amps
Watts
Volts
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Amps
Amps
Volts
Main Output Voltage (if unused, defaults to
single output design)
Output DC Current
Output Power
Output Diode Forward Voltage Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple Current
Output Rectifier Maximum Peak Inverse
Page 18 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Voltage
Recommended
Diodes
MUR110,
UF4002,
SB1100
Recommended Diodes for this output
CMS1
122
Cmils
AWGS1
29
AWG
DIAS1
0.29
mm
ODS1
0.36
mm
2nd output
VO2
IO2
PO2
VD2
NS2
ISRMS2
IRIPPLE2
PIVS2
0.00
0.7
0.44
0.000
0.00
2
Volts
Amps
Watts
Volts
Amps
Amps
Volts
Recommended
Diode
CMS2
Cmils
AWGS2
N/A
AWG
DIAS2
N/A
mm
ODS2
N/A
mm
PIVS3
0.00
0.7
0.44
0.000
0.00
2
Volts
Amps
Watts
Volts
Amps
Amps
Volts
Recommended
Diode
CMS3
Cmils
AWGS3
N/A
AWG
DIAS3
N/A
mm
ODS3
N/A
mm
3
Watts
Negative Output
Page 19 of 81
Output Winding Bare Conductor minimum
circular mils
Wire Gauge (Rounded up to next larger
standard AWG value)
Minimum Bare Conductor Diameter
Maximum Outside Diameter for Triple
Insulated Wire
Output Voltage
Output DC Current
Output Power
Output Diode Forward Voltage Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple Current
Output Rectifier Maximum Peak Inverse
Voltage
Recommended Diodes for this output
0
Total power
Output Voltage
Output DC Current
Output Power
Output Diode Forward Voltage Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple Current
Output Rectifier Maximum Peak Inverse
Voltage
Recommended Diodes for this output
0
3rd output
VO3
IO3
PO3
VD3
NS3
ISRMS3
IRIPPLE3
Output Winding Bare Conductor minimum
circular mils
Wire Gauge (Rounded up to next larger
standard AWG value)
Minimum Bare Conductor Diameter
Maximum Outside Diameter for Triple
Insulated Wire
N/A
Output Winding Bare Conductor minimum
circular mils
Wire Gauge (Rounded up to next larger
standard AWG value)
Minimum Bare Conductor Diameter
Maximum Outside Diameter for Triple
Insulated Wire
Total Output Power
If negative output exists enter Output
number; eg: If VO2 is negative output, enter 2
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
25-Mar-11
9 Inductor Design Spreadsheet (L5)
ACDC_PFS_101210;
INPUT
Rev.1.0; Copyright
Power Integrations 2010
Enter Applications Variables
Input Voltage Range
Universal
VACMIN
VACMAX
VBROWNIN
VBROWNOUT
VO
385
PO
180
fL
TA Max
n
INFO
OUTPUT
Universal
90
265
77.76
70.40
50
40
UNITS
V
V
V
V
W
Hz
deg C
0.93
KP
0.390
0.39
16
365.75
20
16
V
V
ms
VHOLDUP_MIN
310
V
I_INRUSH
40
A
VO_MIN
VO_RIPPLE_MAX
tHOLDUP
Yes
Yes
Auto
PFS708
5.50
6.10
6.70
0.73
4.00
1.00
100.00
10.00
83.11
67.65
3.77
2.04
3.04
1.45
4.49
100
A
A
A
ohms
Mohms
uF
nF
nF
kHz
kHz
A
A
W
W
W
deg C
Rth-JS
3.00
degC/W
HEATSINK Theta-CA
Basic Inductor Calculation
10.36
degC/W
LPFC
626.17
uH
LPFC (0 Bias)
1797.35
uH
2.42
A
Forced Air Cooling
PFS Parameters
PFS Part Number
IOCP min
IOCP typ
IOCP max
RDSON
RV
C_VCC
C_V
C_FB
FS_PK
FS_AVG
IP
PFS_IRMS
PCOND_LOSS_PFS
PSW_LOSS_PFS
PFS_TOTAL
TJ Max
LPFC_RMS
Inductor Construction Parameters
Core Type
Sendust
90u
Core Material
Core Geometry
Core
AE
Sendust
90u
TOROID
TOROID
Auto
77589(OD=35.2)
45.4
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
mm^2
ACDC_HiperPFS_101210_Rev1-0.xls;
Continuous Mode Boost Converter Design
Spreadsheet
Select Universal or High_Line option
Minimum AC input voltage
Maximum AC input voltage
Expected Minimum Brown-in Voltage
Specify brownout voltage.
Nominal Output voltage
Nominal Output power
Line frequency
Maximum ambient temperature
Enter the efficiency estimate for the boost
converter at VACMIN
Ripple to peak inductor current ratio at the
peak of VACMIN
Minimum Output voltage
Maximum Output voltage ripple
Holdup time
Minimum Voltage Output can drop to during
holdup
Maximum allowable inrush current
Enter "Yes" for Forced air cooling. Otherwise
enter "No"
Selected PFS device
Minimum Current limit
Typical current limit
Maximum current limit
Typical RDSon at 100 'C
Line sense resistor
Supply decoupling capacitor
V pin decoupling capacitor
Feedback pin decoupling capacitor
Estimated peak frequency of operation
Estimated average frequency of operation
MOSFET peak current
PFS MOSFET RMS current
Estimated PFS conduction losses
Estimated PFS switching losses
Total Estimated PFS losses
Maximum steady-state junction temperature
Maximum thermal resistance (Junction to
heatsink)
Maximum thermal resistance of heatsink
Value of PFC inductor at peak of VACMIN and
Full Load
Value of PFC inductor at No load. This is the
value measured with LCR meter
Inductor RMS current (calculated at VACMIN
and Full Load)
Enter "Sendust", "Pow Iron" or "Ferrite"
Select from 60u, 75u, 90u or 125 u for Sendust
cores. Fixed at PC44 or equivalent for Ferrite
cores. Fixed at 52 material for Pow Iron cores.
Select from Toroid or EE for Sendust cores
and from EE, or PQ for Ferrite cores
Core part number
Core cross sectional area
Page 20 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
LE
AL
VE
HT
MLT
BW
NL
LG
ILRMS
AC Resistance Ratio
3.08
J
7.47
A/mm^2
BM_TARGET
N/A
Gauss
BM
2962
Gauss
BP
1840
Gauss
LPFC_CORE_LOSS
LPFC_COPPER_LOSS
LPFC_TOTAL LOSS
Critical Parameters
IRMS
IO_AVG
Output Diode
Part Number
1.27
2.43
3.70
W
W
W
Core mean path length
Core AL value
Core volume
Core height/Height of window
Mean length per turn
Bobbin width
Inductor turns
Gap length (Ferrite cores only)
Inductor RMS current
Select between "Litz" or "Regular" for double
coated magnet wire
!!! Info. Selected wire gauge is too too thick
and may caused increased proximity losses.
Selecta thinner wire gauge
Inductor wire number of parallel strands
Outer diameter of single strand of wire
Ratio of AC resistance to the DC resistance
(using Dowell curves)
Estimated current density of wires. It is
recommended that 6 < J < 8
Target flux density at VACMIN (Ferrite cores
only)
Maximum operating flux density
Peak Flux density (Estimated at
VBROWNOUT)
Estimated Inductor core Loss
Estimated Inductor copper losses
Total estimated Inductor Losses
2.15
0.47
A
A
AC input RMS current
Output average current
Wire type
89.5
57
4060
9.78
38.4
N/A
177
N/A
2.42
mm
nH/t^2
mm^3
mm
cm
mm
22
AWG
1
0.643
mm
mm
A
Regular
AWG
22
Filar
OD
1
Auto
Type
Info
STTH3R06
ULTRAFAST
Manufacturer
VRRM
IF
TRR
VF
PCOND_DIODE
PSW_DIODE
P_DIODE
TJ Max
ST
600
3
70
1.1
0.51
3.00
3.52
125
V
A
ns
V
W
W
W
deg C
Rth-JS
20.00
degC/W
HEATSINK Theta-CA
Output Capacitor
CO
3.67
degC/W
150.00
uF
VO_RIPPLE_EXPECTED
10.7
V
T_HOLDUP_EXPECTED
19.7
ms
ESR_LF
ESR_HF
IC_RMS_LF
IC_RMS_HF
1.11
0.442
0.33
0.95
ohms
ohms
A
A
CO_LF_LOSS
0.12
W
CO_HF_LOSS
0.40
W
Total CO LOSS
Input Bridge and Fuse
I^2t Rating
0.52
W
10.53
A^2s
Page 21 of 81
Auto
PFC Diode Part Number
Diode Type - Special - Diodes specially
catered for PFC applications, SiC - Silicon
Carbide type, UF - Ultrafast recovery type
Diode Manufacturer
Diode rated reverse voltage
Diode rated forward current
Diode Reverse recovery time
Diode rated forward voltage drop
Estimated Diode conduction losses
Estimated Diode switching losses
Total estimated Diode losses
Maximum Operating temperature
Maximum thermal resistance (Junction to
heatsink)
Maximum thermal resistance of heatsink
Minimum value of Output capacitance
Expected ripple voltage on Output with
selected Output capacitor
Expected holdup time with selected Output
capacitor
Low Frequency Capacitor RMS current
High Frequency Capacitor RMS current
Estimated Low Frequency ESR loss in Output
capacitor
Estimated High frequency ESR loss in Output
capacitor
Total estimated losses in Output Capacitor
Minimum I^2t rating for fuse
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Fuse Current rating
VF
IAVG
PIV_INPUT BRIDGE
PCOND_LOSS_BRIDGE
3.27
0.90
2.03
375
3.49
A
V
A
V
W
0
uF
8.42
1N5407
ohms
R2
1.54
Mohms
R3
1.54
Mohms
R4
698.00
kohms
C2
100.00
nF
R5
2.20
kohms
R6
2.20
kohms
R7
57.60
kohms
C3
470.00
pF
R8
R9
R10
C4
D3
160.00
2.49
10.00
10.00
1N4148
kohms
kohms
kohms
uF
D4
1N4001
Q1
2N4401
Q2
2N4403
CIN
RT
D_Precharge
Feedback Components
Loss Budget (Estimated at VACMIN)
PFS Losses
Boost diode Losses
Input Bridge losses
Inductor losses
Output Capacitor Loss
Total losses
4.49
3.52
3.49
3.70
0.52
15.71
Efficiency
0.92
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W
W
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Minimum Current rating of fuse
Input bridge Diode forward Diode drop
Input average current at 70 VAC.
Peak inverse voltage of input bridge
Estimated Bridge Diode conduction loss
Input capacitor. Use metallized polypropylene
or film foil type with high ripple current rating
Input Thermistor value
Recommended precharge Diode
Feedback network, first high voltage divider
resistor
Feedback network, second high voltage divider
resistor
Feedback network, third high voltage divider
resistor
Feedback network, loop speedup capacitor
Feedback component, NPN transistor bias
resistor
Feedback component, PNP transistor bias
resistor
Feedback network, lower divider resistor
Feedback component- noise suppression
capacitor
Feedback network - pole setting resistor
Feedback network - zero setting resistor
Feedback pin filter resistor
Feedback network - compensation capacitor
Feedback network reverse blocking Diode
Feedback network - capacitor failure detection
Diode
Feedback network - speedup circuit NPN
transistor
Feedback network - speedup circuit PNP
transistor
Total estimated losses in PFS
Total estimated losses in Output Diode
Total estimated losses in input bridge module
Total estimated losses in PFC choke
Total estimated losses in Output capacitor
Overall loss estimate
Estimated efficiency at VACMIN. Verify
efficiency at other line voltages
Page 22 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
10 Auxiliary Supply Transformer Specification
10.1 Electrical Diagram
3.0 W PFC VAUX - Flyback-EE16
Figure 6 – Transformer Electrical Diagram.
10.2 Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Leakage Inductance
1 second, 60 Hz, from pins 1, 2, 4, 5 to pins 8, 10
Pins 4-5, all other windings open, measured at 100 kHz,
1.0 Vpk-pk
Pins 4-5, all other windings open
Pins 4-5, with secondary pins shorted, measured at 100 kHz,
1.0 Vpk-pk
3000 VAC
1037 H ±10%
1.1 MHz Min
41.5 H Max
10.3 Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Description
Core: EE16, NC-2H (Nicera) or Equivalent, gapped for ALG of 197 nH/T²
Bobbin: EE16, Horizontal, 10 pins, (5/5), Ho Jinn Plastic Elect. Co, Ltd. part #: PM-9820
Tape: Polyester web 2.50 mm wide
Barrier Tape: Polyester film (1 mil base thickness), 8.60 mm wide
Teflon Tubing # 22
Varnish
Magnet wire: #37 AWG, Solderable Double Coated
Magnet wire: #29 AWG, Solderable Double Coated
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10.4 Transformer Build Diagram
Figure 7 – Transformer Build Diagram.
10.5 Transformer Construction
Winding
preparation
Left Margin Tape
Right Margin Tape
WD1
Primary
Insulation
WD2
Bias Winding
Insulation
WD3
Secondary
Insulation
Gap
Core Assembly
Varnish
Position the bobbin on the mandrel such that the pin side is on the left side of
bobbin mandrel. Winding direction is clock-wise direction
Wind 2.5mm margin tape [Item 3] on left hand side of the bobbin
Wind 2.5mm margin tape [Item 3] on right hand side of the bobbin
Start on pin(s) 4 using item [5] at the start leads and wind 73 turns (x 1 filar) of item
[7] in 3 layer(s) from left to right. At the end of 1st layer, continue to wind the next
layer from right to left. At the end of 2nd layer, continue to wind the next layer from
left to right. On the final layer, spread the winding evenly across entire bobbin.
Finish this winding on pin(s) 5 using item [5] at the finish leads.
Add 1 layer of tape, item [4], for insulation.
Start on pin(s) 2 using item [5] at the start leads and wind 14 turns (x 1 filar) of item
[7]. Wind in same rotational direction as primary winding. Spread the winding
evenly across entire bobbin. Finish this winding on pin(s) 1 using item [5] at the
finish leads.
Add 3 layers of tape, item [4], for insulation.
Start on pin(s) 10 using item [5] at the start leads and wind 10 turns (x 1 filar) of
item [8]. Spread the winding evenly across entire bobbin. Wind in same rotational
direction as primary winding. Finish this winding on pin(s) 8 using item [5] at the
finish leads.
Add 2 layers of tape, item [4], for insulation.
Grind the cores to get 1037 µH,
Assemble and secure core halves with tape. Item [1].
Dip varnish uniformly in item [6]. Do not vacuum impregnate.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
10.6 Transformer Illustrations
Bobbin
Preparation
One bobbin EE16
horizontal (5/5) and
two core NC-2H or
equivalent.
Winding
Preparation
Position the bobbin on
the mandrel as
shown. Use 2.5 mm
margin tape (item [3])
on the left-hand side.
Use 2.5 mm margin
tape (item [3]) on the
right-hand side.
WD1 Primary
Starting at pin 4 using
item [5] at the start
leads, wind 73 turns
of item [7] in four
layers, with tight
tension; wind first
layer from left to right
and at the end of the
first layer, wind
second layer from
right to left, then left to
right for third layer
and right to left for
fourth layer,
terminating at pin 5
using item [5] at the
finish leads.
Insulation and
Margin Tape
Apply one layer of
tape (item [4]) for
insulation. Use 2.5
mm margin tape for
both sides left and
right.
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WD2 Bias
Winding
Starting at pin 2 using
item [5] at start leads,
wind 14 single-filar
turns of item [7] in one
layer. Bring the wire
back to the left-hand
side and terminate at
pin 1, using item [5] at
the finish leads.
Insulation.
Tape and
Margin.
Apply three layers of
tape (item [4]). Use
2.5 mm margin for
both sides left and
right.
WD3 Secondary
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Starting at pin 10
using item [5] at the
start leads, wind 10
turns (x1 filar) of item
[8] in one layer
spreading the winding
evenly across entire
bobbin. Wind in the
same rotational
direction as primary
winding. Terminate at
pin 8 using item [5] at
the finish leads.
Page 26 of 81
25-Mar-11
Insulation
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Apply two layers of
tape (item [4]).
Finish Wrap
Apply three layers of
tape for finish wrap.
Final Assembly
Assemble, grind the
cores to get 1037 H,
and secure the cores
with tape. Varnish
item [6].
Page 27 of 81
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11 Switching Inductor Specification
11.1 Electrical Diagram
Figure 8 – Inductor Electrical Diagram.
11.2 Electrical Specifications
Primary Inductance
Pins 1-4 measured at kHz, 0.4 V RMS
1.8 mH 8%
11.3 Materials
Item
[1]
[2]
[3]
[4]
[5]
Description
Core: Selmag, Inc.: Sendust core: CS270090;
Alternate: Magnetics Inc, Mfg: 77934-A7
Magnet wire: #22 AWG insulated magnet wire.
Base: Toroid mounting base, Lodestone Pacific, P/N VTM160-4, or similar. See below.
PI P/N: 76-00004-00.
High Temperature Epoxy, Mfg: MG Chemicals, P/N: 832HT-375ML, Digikey: 473-1085-ND,
or similar, PI P/N: 66-00087-00.
Divider: Tie-wrap, Panduit, P/N: PLT.7M-M or similar.
Figure 9 – Top View of Toroid Mounting Base Item [3].
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
11.4 Inductor Winding Instruction
Insert 2 dividers item [5] in the core item [1] to divide into 2 sections equally. See photo. Superglue
dividers in place if necessary to prevent slipping.
Take approximately 17 feet of wire item [2], Align center of wire with 1 divider. This location on the
inductor is your ‘top’ reference point.
Center of wire
Start winding on the left section with approximately 24 turns of wire item [2], for the 1st layer, wind
wire laminar fashion and ensure that turns do not overlap.
Next, wind another 24 turns on the right hand side of the core.
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Continue winding on the right hand side for the 2nd layer approximately 22 turns, spread wire
evenly and try to ensure that turns do not overlap.
Continue winding on the right section on the 3rd layer the remaining [approximately 17] turns,
distributing wire evenly and try to ensure that turns do not overlap.
Wind the same as above for the 2nd and 3rd layers on the left section. Inductor leads will finish at
the ‘bottom’ of the inductor after all turns are wound.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Invert toroid with ‘top’ side down for mounting.
Place wound toroid into the mount with ‘top’ side down.
Solder the leads to pins 1 and 4 of mounting base item [3].
Secure the ‘top’ side of the inductor to the base by using High Temperature Epoxy item [4].
Front view
Page 31 of 81
Back view
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12 EMI Differential Inductor Specification
12.1 Electrical Diagram
Figure 10 – Inductor Electrical Diagram.
12.2 Electrical Specifications
Primary Inductance
Pins 1-2 measured at kHz, 0.4 V RMS
330 H +8%
12.3 Materials
Item
[1]
[2]
[3]
Description
Core: Micrometals T94-26
Magnet wire: #23 AWG insulated magnet wire, approximately 8 ft.
Hot-melt mounting glue
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
12.4 Inductor Winding Instruction
Obtain approximately 8 feet of item [2] and begin winding around toroidal core, item [1] as
illustrated below:
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12.5 Inductance Value and Mounting
Verify inductor value is within electrical specifications.
Log measured inductance and self-resonant frequency for report.
Trim leads 1 and 2, tin leads and mount inductor on PC board by inserting leads through
board, soldering leads, then stabilizing inductor mechanically by application of item [3]
between inductor and PC board.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
13 Heat Sink Specification
(Note: Heat sinks are designed for operation with open-frame convection cooling for
115 VAC operation at 100% rated load. Heat sink dimensions may be reduced for
designs employing augmented [e.g.:forced-air] cooling.)
13.1 eSIP U1 Heat Sink
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13.2 eSIP U1 Heat Sink Assembly
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13.3 eSIP U1 Heat Sink Assembly and Mounting Hardware
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13.4 Bridge BR1 Heat Sink
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
13.5 Bridge BR1 Heat Sink Assembly
Page 39 of 81
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13.6 Bridge BR1 Heat Sink Assembly and Mounting Hardware Assembly
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14 Performance Data
All measurements performed at room temperature, 60 Hz input frequency for voltages
below 150 VAC and input frequency of 50 Hz for 150 VAC and higher.
All performance data is with Thermistor RT1 in-circuit to represent a low-cost configuration.
14.1 Auxiliary Supply Efficiency (with PFC disabled)
80
Efficiency (%)
75
70
65
60
90 VAC
115 VAC
55
230 VAC
265 VAC
50
0.00
0.03
0.05
0.08
0.10
0.13
0.15
0.18
0.20
0.23
Output Load Current (A)
Figure 11 – Auxiliary Supply Efficiency, PFC Disabled.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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14.2 Auxiliary Supply Load Regulation (with PFC disabled)
15.35
90 VAC
115 VAC
15.30
230 VAC
Output Voltage (V)
265 VAC
15.25
15.20
15.15
15.10
15.05
0.00
0.03
0.05
0.08
0.10
0.13
0.15
0.18
0.20
0.23
0.25
Output Load Current (A)
Figure 12 – Auxiliary Supply Load Regulation.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14.3 Auxiliary Supply Line Regulation (with PFC disabled)
15.30
20%
40%
60%
80%
100%
Output Voltage (V)
15.25
15.20
15.15
15.10
15.05
15.00
60
80
100
120
140
160
180
200
220
240
260
Input Line Voltage (VAC)
Figure 13 – Auxiliary Supply Line Regulation.
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280
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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14.4 No-Load Input Power
250
245
Input Power (mW)
240
235
230
225
220
215
210
205
200
80
100
120
140
160
180
200
220
240
260
280
Input Voltage (VAC)
Figure 14 – No-Load Input Power.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14.5 PFC Efficiency (with RT1 in-circuit)
100
99
Efficiency (%)
98
97
96
95
94
90 VAC
115 VAC
230 VAC
264 VAC
93
92
91
0
20
40
60
80
100
120
140
160
180
Output Power (W) [180 W Rated]
Figure 15 – Efficiency vs. Output Power.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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14.6 Input Power Factor
1.00
Input Power Factor (PF)
0.95
0.90
0.85
0.80
0.75
0.70
0.65
90 VAC
115 VAC
230 VAC
264 VAC
0.60
0.55
0
20
40
60
80
100
120
140
160
180
200
Output Power (W)
Figure 16 – Input Power Factor vs. Output Power.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14.7 Regulation
14.7.1 Load
400
395
Output Voltage (V)
390
385
380
375
370
90 VAC
115 VAC
230 VAC
264 VAC
365
360
0
20
40
60
80
100
120
140
160
180
Output Power (W) [180 W Rated]
Figure 17 – Load Regulation.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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14.7.2 Line
383
382
Output Voltage (VDC)
381
380
379
378
377
376
10% Load
25% Load
50% Load
75% Load
100% Load
375
374
373
80
100
120
140
160
180
200
220
240
260
280
Input Voltage (VAC)
Figure 18 – Line Regulation.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14.7.3 Overload
385
Output Voltage (VDC)
380
375
370
365
360
355
350
90 VAC
115 VAC
230 VAC
264 VAC
345
340
160
170
180
190
200
210
220
230
240
250
260
Output Power (W) [180 W Rated]
Figure 19 – Overload Regulation.
Page 49 of 81
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270
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
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14.8 THDi
70
60
THDi (%)
50
40
90 VAC
115 VAC
230 VAC
264 VAC
30
20
10
0
0
20
40
60
80
100
120
140
160
180
200
Output Power (W)
Figure 20 – Input Current THD vs. Load.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
14.9 Input Current Harmonic Distortion (IEC 61000-3-2 Class-D)
Measured at 230 VAC Input 50Hz
14.9.1 50% Load at Output
0.70
Input Harmonic Current
Class D Harmonic Limit
0.60
Amplitude (A)
0.50
0.40
0.30
0.20
0.10
0.00
3
5
7
9
11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic #
Figure 21 – Amplitude of Input Current Harmonics for 50% Load at 230 VAC Input.
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14.9.2 100% Load at Output
0.70
Input Harmonic Current
Class D Harmonic Limit
0.60
Amplitude (A)
0.50
0.40
0.30
0.20
0.10
0.00
3
5
7
9
11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic #
Figure 22 – Amplitude of Input Current Harmonics for 100% Load at 230 VAC Input.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
15 Thermal Performance
The unit was allowed to reach thermal equilibrium prior to thermal measurement with a
FLIR camera. Table 1 shows full load temperature of key components measured at
equilibrium, room temperature and without any forced air cooling. Tests were performed
with auxiliary supply loaded to 200 mA.
Temperature (C)
180 W Load
Item
115 VAC 230 VAC
Ambient
23.4
23.1
PFS708EG (U1)
97.2
57.8
Inductor (L5)
68.8
51.6
Output Rectifier (D2)
87.8
63
Output Capacitor (C15)
55.5
44.0
Switching Capacitor (C7)
70.6
49.0
Bridge (BR1)
88.7
57.3
Input X2 Capacitor (C3)
35.7
30.5
Input X2 Capacitor (C6)
59.0
42.1
Input CM Choke(L1)
49.0
34.2
Input DM Choke (L2)
55.0
36.0
Thermistor (RT1)
160
112
Heat-Sink (HS1) [eSIP]
75.7
50.8
Heat Sink (HS2) [BR1]
72.8
50.0
Table 1 – Steady State Thermal Performance.
Page 53 of 81
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Figure 23 – Infra-Red Image of the Top and Bottom of the Board at Thermal Equilibrium,115 VAC, Full
Load, No Forced-Air Flow, 25ºC Ambient.
Figure 24 – Infra-Red Image of the Top and Bottom Sides of the Board at Thermal Equilibrium, 230 VAC,
Full Load, No Forced-Air Flow, 25ºC Ambient.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16 Waveforms
16.1 Auxiliary +15 V Supply
16.1.1 Load Transient Response
Figure 25 – Transient Response, 115 VAC,
50%-100%-50% Load Step.
Upper: VOUT, 50 mV / div., AC Coupled
Lower: ILOAD 100 mA / div., 2 ms / div.
Page 55 of 81
Figure 26 – Transient Response, 230VAC / 50 Hz.,
50-100-50% Load Step.
Upper: VOUT, 50 mV / div., AC Coupled
Lower: ILOAD 100 mA, 2 ms / div.
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16.2 Input Current at 115 VAC and 60 Hz
Figure 27 – 115 VAC, 50% Load.
Upper: VIN, 200 V / div.
Lower: IIN, 1 A, 10 ms / div.
Figure 28 – 115 VAC, 100% Load.
Upper: VIN, 200 V / div.
Lower: IIN, 2 A, 10 ms / div.
16.3 Input Current at 230 VAC and 50 Hz
Figure 29 – 230 VAC, 50% Load.
Upper: VIN, 200 V / div.
Lower: IIN, 500 mA, 10 ms / div.
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Figure 30 – 230 VAC, 100% Load.
Upper: VIN, 200 V / div.
Lower: IIN, 1 A, 10 ms / div.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16.4 Start-up at 90 VAC and 60 Hz
Load in CC mode during turn-on of PFC
Figure 31 – 90 VAC, No-Load.
Upper: VIN, 500 V / div.
Second: IIN, 5 A / div.,
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
Figure 32 – 90 VAC, Full Load.
Upper: VIN, 500 V / div.
Second: IIN, 5 A / div.,
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
16.5 Start-up at 115 VAC and 60 Hz
Load in CC mode during turn-on of PFC
Figure 33 – 115 VAC, No-Load.
Upper: VIN, 500 V / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
Page 57 of 81
Figure 34 – 115 VAC, Full Load.
Upper: VIN, 500 V / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
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16.6 Start-up at 230 VAC and 50 Hz
Load in CC mode during turn-on of PFC
Figure 35 – 230 VAC, No-load.
Upper: VIN, 1 kV / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
Figure 36 – 230 VAC, Full Load.
Upper: VIN, 1 kV / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
16.7 Start-up at 264 VAC and 50 Hz
Load in CC mode during turn-on of PFC
Figure 37 – 264 VAC, No-load.
Upper: VIN, 1 kV / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
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Figure 38 – 264 VAC, Full Load.
Upper: VIN, 1 kV / div.
Second: IIN, 5 A / div.
Third: VOUT, 200 V / div.
Lower: VCC, 10 V, 50 ms / div.
Page 58 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16.8 Load Transient Response (90 VAC, 60 Hz)
In the figures shown below, signal averaging was used to better enable viewing the load
transient response. The oscilloscope was triggered using the load current step as a
trigger source. Since the output switching and line frequency occur essentially at random
with respect to the load transient, contributions to the output ripple from these sources
will average out, leaving the contribution only from the load step response.
Figure 39 – Transient Response, 90 VAC,
10-100-10% Load Step.
Upper: VIN, 500 V / div.
Second: IIN, 5 A /div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
Page 59 of 81
Figure 40 – Transient Response, 90 VAC,
50-100-50% Load Step
Upper: VIN, 500 V / div.
Second: IIN, 5 A / div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
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16.9 Load Transient Response (115 VAC, 60 Hz)
Figure 41 – Transient Response, 115 VAC,
10-100-10% Load Step.
Upper: VIN, 500 V / div.
Second: IIN, 2 A /div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
Figure 42 – Transient Response, 115VAC,
50-100-50% Load Step
Upper: VIN, 500 V / div.
Second: IIN, 2 A /div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
16.10 Load Transient Response (230 VAC, 50 Hz)
Figure 43 – Transient Response, 230 VAC,
10-100-10% Load Step.
Upper: VIN, 1 kV / div.
Second: IIN, 2 A / div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
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Figure 44 – Transient Response, 230VAC,
50-100-50% Load Step
Upper: VIN, 1 kV / div.
Second: IIN, 2 A / div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div
Page 60 of 81
25-Mar-11
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16.11 Load Transient Response (264 VAC, 50 Hz)
Figure 45 – Transient Response, 264 VAC,
10-100-10% Load Step.
Upper: VIN, 1 kV / div.
Second: IIN, 2 A / div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
Figure 46 – Transient Response, 264 VAC,
50-100-50% Load Step.
Upper: VIN, 1 kV / div.
Second: IIN, 2 A / div.
Third: VOUT (AC Coupled), 50 V / div.
Lower: ILOAD 500 mA, 100 ms / div.
16.12 1000 ms Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz)
16.12.1
50% Load at Output
Figure 47 – Line Dropout 115 VAC, 1000 ms.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 200 V, 200 ms / div.
Page 61 of 81
Figure 48 – Line Dropout 230 VAC, 1000 ms.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 200 V, 200 ms / div.
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16.12.2
25-Mar-11
Full Load at Output
Figure 49 – Line Dropout 115 VAC, 1000 ms.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 200 V, 200 ms / div.
Figure 50 – Line Dropout 230 VAC, 1000 ms.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 200 V, 200 ms / div.
16.13 One Cycle Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz)
16.13.1
Full Load at Output
Figure 51 – Line Dropout 115 VAC, 60 Hz.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 100 V / div., 50 ms / div.
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Figure 52 – Line Dropout 230 VAC, 50 Hz.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 100 V / div., 50 ms /div.
Page 62 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16.14 Line Sag (115 VAC ~ 85 VAC ~ 115 VAC, 60 Hz)
Figure 53 – Line Sag 115 VAC, 50% Load.
Upper: VIN, 200 V / div.
Middle: IIN, 2 A / div.
Lower: VOUT (AC Coupled), 10 V / div.,
50 ms / div.
Figure 54 – Line Sag 115 VAC, 100% Load.
Upper: VIN, 200 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT (AC Coupled), 10 V / div.,
50 ms / div.
16.15 Line Surge (132 VAC ~ 147 VAC ~ 132 VAC, 60 Hz)
Figure 55 – Line Surge 132 VAC, 50% Load.
Upper: VIN, 200 V / div.
Middle: IIN, 2 A / div.
Lower: VOUT (AC Coupled), 10 V / div.
Page 63 of 81
Figure 56 – Line Surge 132 VAC, 100% Load.
Upper: VIN, 200 V / div.
Middle: IIN, 2 A / div.
Lower: VOUT (AC Coupled), 10 V / div.
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16.16 Line Sag (230 VAC ~ 170 VAC ~ 230 VAC, 50 Hz)
Figure 57 – Line Sag 230 VAC, 50% Load.
Upper: VIN, 500 V / div.
Middle: IIN, 1 A / div.
Lower: VOUT (AC Coupled), 10 V / div.
Figure 58 – Line Sag 230 VAC, 100% Load.
Upper: VIN, 500 V / div.
Middle: IIN, 2 A / div.
Lower: VOUT (AC Coupled), 20 V / div
16.17 Line Surge (264 VAC ~ 293 VAC ~ 264 VAC, 50 Hz)
Figure 59 – Line Surge 264 VAC, 50% Load.
Upper: VIN, 500 V / div.
Middle: IIN, 2 A / div.
Lower: VOUT (AC Coupled), 50 V / div. ,
50 ms / div.
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Figure 60 – Line Surge 264 VAC, 100% Load.
Upper: VIN, 500 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT (AC Coupled), 50 V / div. ,
50 ms / div.
Page 64 of 81
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
16.18 Brown-In and Brown-Out at 6 V / Minute Rate
Test conducted by first reducing, followed by increasing input AC voltage source at a rate
of 6 V / min. The PFC converter DC output was loaded to 100% of rated load (electronic
load), which was programmed to release the load when the DC output of the PFC
dropped below 300 V [at brown-out]. The auxiliary +15 V supply is connected to the
output of the PFC and discharges the output capacitor of the PFC after the dynamic load
is released at brown-out.
Measured PFC Brown-Out Threshold
Measured PFC Brown-In Threshold
Measured auxiliary Supply Brown-In Threshold
70.8 VAC
80.6 VAC
61.7 VAC
Note: Operation at low input voltages results in higher power dissipation in many
components on the board. Forced air cooling is necessary during this test.
Figure 61 – Brown-Out Followed by Brown-In at 100% Load.
Top: VIN, 200 V / div.
Middle: IIN, 5 A / div.
Lower: VOUT, 200 V / div., 200 s / div.
Page 65 of 81
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16.19 Drain Voltage and Current
The drain current was measured at jumper JP4 location by replacing JP4 with a very
short wire loop in order to insert the current probe. The drain voltage was measured at
the DRAIN and SOURCE pins of IC U1. Keep the wire loop as short as possible to
minimize drain node inductance since the added inductance at the drain node can result
in a high VDS voltage that could damage U1. Drain current can be indirectly measured by
measuring the switching inductor current during the MOSFET on-time. Refer to Appendix
C for output inductor current measurement set-up and calculations.
16.19.1
Drain Voltage and Current at 115 VAC Input and Full Load
Figure 62 – Input Voltage 115 VAC, 100% Load.
Upper: IDRAIN, 2 A / div.
Lower: VDRAIN, 200 V / div., 1 ms / div.
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Figure 63 – Input Voltage 115 VAC, 100% Load.
Upper: IDRAIN, 2 A / div.
Lower: VDRAIN, 200 V / div., 1 ms / div.
Zoom Upper: IDRAIN, 2 A / div.
Zoom Lower: VDRAIN, 200 V / div., 5 s / div
Page 66 of 81
25-Mar-11
16.19.2
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Drain Voltage and Current at 230 VAC Input and Full Load
Figure 64 – Input Voltage 230 VAC, 100% Load.
Upper: IDRAIN, 2A / div.
Lower: VDRAIN, 200V / div., 1 ms / div.
Page 67 of 81
Figure 65 – Input Voltage 230 VAC, 100% Load.
Upper: IDRAIN, 2 A / div.
Lower: VDRAIN, 200 V / div., 1 ms / div.
Zoom Upper: IDRAIN, 2 A / div.,
Zoom Lower: VDRAIN, 200 V / div., 5 s /
div.
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16.20 Output Ripple Measurements
16.20.1
Ripple Measurement Technique
For DC output ripple measurements, a modified oscilloscope test probe must be utilized
in order to reduce spurious signals due to pickup. Details of the probe modification are
provided in the figures below.
The 4987BA probe adapter is affixed with one capacitor 0.02 F/1 kV ceramic disc type
tied in parallel across the probe tip.
Probe Ground
Probe Tip
Figure 66 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 67 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter
(Modified with wires for ripple measurement, and one parallel decoupling capacitor added.)
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16.20.2
RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
Measurement Results
Figure 68 – Ripple, 90 VAC, 50% Load.
5 ms, 5 V / div.
Figure 69 – Ripple, 90 VAC, 100% Load.
5 ms, 5 V / div.
Figure 70 – Ripple, 115 VAC, 50% Load.
5 ms, 5 V / div.
Figure 71 – Ripple, 115 VAC, 100% Load.
5 ms, 5 V / div.
Page 69 of 81
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Figure 72 – Ripple, 230 VAC, 50% Load.
5 ms, 5 V / div.
Figure 73 – Ripple, 230 VAC, 100% Load.
5 ms, 5 V / div.
Figure 74 – Ripple, 264 VAC, 50% Load.
5 ms, 5 V / div.
Figure 75 – Ripple, 264 VAC, 100% Load.
5 ms, 5 V / div.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
17 Gain-Phase Measurement Procedure and Results
● The PFC stage is supplied form an adjustable DC source for this test. Connect the
circuit as shown in Figure 76. Open the top end of the feedback divider network
and insert a 100 2 W resistor in series as shown. The signal injected in the loop
for gain phase measurement will be injected across this resistor.
● Nodes A and B (two ends of the injection resistor) are connected to Channel 1 and
Channel 2 of the frequency response analyzer using high voltage x100 attenuator
probes. GND leads of both probes are connected to output return as shown.
● The signal to be injected is isolated using the Bode-Box injection transformer
model 200–000 from Venable Industries.
Test Procedure:
● Adjust the input voltage to 150 VDC and confirm that the PFC output voltage is
within regulation limits.
● Inject a signal from the frequency response analyzer.
● The injected signal can be seen in the output voltage ripple of the PFC.
● Plot the gain phase pot by sweeping the injected signal frequency from 3 Hz to
90 Hz.
Figure 76 – System Test Set-up for Loop Gain-Phase Measurement.
Page 71 of 81
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Figure 77 – Bode Plot with VIN = 120 VDC at 100% Load (Red) and 50% Load (Green).
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
18 Line Surge Test
Surge Level
(V)
C.M.
+500
-500
+500
-500
+500
-500
D.M.
+500
-500
C.M.
+1000
-1000
+1000
-1000
+1000
-1000
D.M.
+1000
-1000
C.M.
+1500
-1500
+1500
-1500
+1500
-1500
C.M.
+2000
-2000
+2000
-2000
+2000
-2000
Input Voltage
(VAC)
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
230
Injection
Location
(12Ω source)
L1 to PE
L1 to PE
L2 to PE
L2 to PE
L1, L2 to PE
L1, L2 to PE
(2Ω source)
L1 to L2
L1 to L2
(12Ω source)
L1 to PE
L1 to PE
L2 to PE
L2 to PE
L1, L2 to PE
L1, L2 to PE
(2Ω source)
L1 to L2
L1 to L2
(12Ω source)
L1 to PE
L1 to PE
L2 to PE
L2 to PE
L1, L2 to PE
L1, L2 to PE
(12Ω source)
L1 to PE
L1 to PE
L2 to PE
L2 to PE
L1, L2 to PE
L1, L2 to PE
Injection Phase
(°)
90
Test Results
(Pass / Fail, # Strikes)
10 Strikes each Level
Pass
Pass
Pass
Pass
Pass
Pass
902
270
Pass
Pass
90
270
270
90
901
90
Pass
Pass
Pass
Pass
Pass
Pass
902
270
Pass
Pass
90
270
270
90
901
Pass
Pass
Pass
Pass
Pass
Pass
90
270
270
90
901
90
90
270
270
90
901
90
Pass
Pass
Pass
Pass
Pass
Pass
1 Note: 0° and 270° phase angle [relative to L1] was not tested; however, negative voltage polarity was performed at 90° phase angle
for worst case total negative pulse on alternate phase [neutral].
2 Note: 0° and 270° phase angle [relative to L1] was not tested on both polarities; however, negative voltage polarity was performed at
270° phase angle for worst case total negative pulse on alternate phase [neutral].
Page 73 of 81
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19 EMI Scans
19.1 EMI Test Set-up
Using a plexi-glass board with the underside copper coated, electrically connect the
copper side of the board to test point TP8 with a wire clip. The RD-248 assembly should
be placed on top of the plexi-glass board. Connect output connector J2 to a high-voltage
DC load. All interconnections should be made as short as possible. See Figure 78 for setup.
Copper Clad FR-4 Board
Figure 78 – EMI Test Set-up.
To load
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
19.2 EMI Scans
Figure 79 – 115 VAC, 100% Load.
Figure 80 – 115 VAC, 100% Load EMI Measurement Results.
Page 75 of 81
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Figure 81 – 230 VAC, 100% Load.
Figure 82 – 230 VAC, 100% Load EMI Measurement Results.
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
20 Appendix A - Test Set-up for Efficiency Measurement
The following setup is recommended for system efficiency, PF and THDi measurements.
A 3” 12 VDC muffin fan is placed adjacent to the RD-248 board and powered by a 12 V
supply for forced air cooling. Use of high resolution meters is recommended for output
current and output voltage measurements. See Figure 83 for a typical equipment set-up.
Figure 83 – Front View of the Test Set-up for Efficiency, PF and THDi Measurements.
Page 77 of 81
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21 Appendix B - Inductor Current Measurement Set-up
The switching inductor current can be measured at the input side of L5. Simply remove
the base of L5 from the PCB, bend the input side leg 90°, reinsert into the PCB, then
reconnect the leg to the pad through a short [~1.5”] loop of wire to accommodate a
current probe.
Solder a scope probe adapter jack directly at the D [DRAIN] and S [SOURCE] pins of IC
U1 on the bottom side of the board to measure Drain-Source voltage. See Figure 84 and
85 for details.
Figure 84 – Current Probe and Scope Probe Jack Insertion Locations.
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Figure 85 – Inductor Current and Drain Source Voltage Measurements Set-up.
Page 79 of 81
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22 Revision History
Date
25-Mar-10
Author
DCP
Revision
1.0
Description & changes
Initial Release
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Reviewed
Apps & Mktg
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RDR-248 180 W Low-Power Low-Cost PFC Using PFS708EG
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability.
Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER
INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING,
WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR
PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products)
may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications
assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power
Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS,
Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc.
Other trademarks are property of their respective companies. ©Copyright 2011 Power Integrations, Inc.
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