NCP1653EVB

ON Semiconductor Is Now To learn more about onsemi™, please visit our website at www.onsemi.com onsemi and       and other names, marks, and brands are registered and/or common law trademarks of Semiconductor Components Industries, LLC dba “onsemi” or its affiliates and/or subsidiaries in the United States and/or other countries. onsemi owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. A listing of onsemi product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent-Marking.pdf. onsemi reserves the right to make changes at any time to any products or information herein, without notice. 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Should Buyer purchase or use onsemi products for any such unintended or unauthorized application, Buyer shall indemnify and hold onsemi and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that onsemi was negligent regarding the design or manufacture of the part. onsemi is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner. Other names and brands may be claimed as the property of others. AND8185/D 300 W, Wide Mains, PFC Stage Driven by the NCP1653 Prepared by: Joel Turchi ON Semiconductor http://onsemi.com APPLICATION NOTE Introduction This application was tested using a resistive load. As in many applications, the PFC controller is fed by an output of the downstream converter, there is generally no need for an auto−supply circuitry. Hence, in our demo−board, the NCP1653 VCC is to be supplied by a 15 V external power supply. The external voltage source that is to be applied to the NCP1653 VCC, should exceed 13.25 V typically, to allow the circuit startup. After startup, the VCC operating range is from 9.5 to 18 V. The voltage applied to the NCP1653 VCC must NOT exceed 18 V. The NCP1653 is a continuous conduction mode and fixed frequency controller (100 kHz). The coil (600 H) is selected to limit the peak−to−peak current ripple in the range of 30% at the sinusoid top, in full load and low line conditions. Again, for details on how the application is designed, please refer to the ON Semiconductor application note AND8184/D. As detailed in the document, the board yields very nice Power Factor ratios and effectively limits the Total Harmonic Distortion (THD). The NCP1653 is a Power Factor Controller to efficiently drive Continuous Conduction Mode (CCM) step−up pre−converters. As shown by the ON Semiconductor application note AND8184/D, that details the four key steps to design a NCP1653 driven PFC stage, this circuit represents a major leap towards compactness and ease of implementation. Housed in a DIP8 or SO−8 package, the circuit minimizes the external components count without sacrificing performance and flexibility. In particular, the NCP1653 integrates all the key protections to build robust PFC stages like an effective input power runaway clamping circuitry. When needed or wished, the NCP1653 also allows operation in Follower Boost mode(1) to drastically lower the pre−converter size and cost, in a straight−forward manner. For more information on this device, please refer to the ON Semiconductor data sheet NCP1653/D. The board illustrates the circuit capability to effectively drive a high power, universal line application. More specifically, it is designed to meet the following specifications: • Maximum output power: 300 W • Input voltage range: from 90 Vrms to 265 Vrms • Regulation output voltage: 385 V • Switching frequency: 100 kHz (1)The “Follower Boost” mode makes the pre−converter output voltage stabilize at a level that varies linearly versus the AC line amplitude. This technique aims at reducing the difference between the output and input voltages to optimize the boost efficiency and minimize the cost of the PFC stage (refer to MC33260 and NCP1653 data sheet at www.onsemi.com).  Semiconductor Components Industries, LLC, 2005 April, 2005 − Rev. 1 1 Publication Order Number: AND8185/D AND8185/D Figure 1. The Board Three coils from three different vendors have been validated on this board: • C1062−B from CoilCraft • MB09008 from microSpire • SRW42EC−E02H001 from TDK. For the sake of consistency, this application note reports the performance and results that were obtained using the CoilCraft coil. However, it has been checked that the two other coils yield high performance too. http://onsemi.com 2 U1 KBU6K L1 600 H + C15 680 nF − 4.7 nF Type = Y1 C13 CM1 4.7 nF Type = Y1 L4 150 H C11 1 F Type X2 R9 680 k 680 k 560 k 390 V U2 NCP1653 R2 470 k C9 100 nF C8 1 nF R8 + 15 V − R4 4.7 Meg C12 R5 C6 1 nF C7 100 nF 1 8 2 7 3 6 4 5 +C4 C3 100 n 22 F R1 R6 2.85 k R3 56 k 0.1 N Earth 90 TO 265 Vac M1 SPP20N60S 4.5 R7 L C2 + 100 F Type = snap−in 450 V C5 1 nF R10 10 k + − AND8185/D 3 http://onsemi.com Figure 2. Application Schematic C1 100 nF Type = X2 N D1 CSD04060 AND8185/D PCB LAYOUT Figure 3. Component Placement Figure 4. PCB Layout (Components’ Side) http://onsemi.com 4 AND8185/D GENERAL BEHAVIOR − TYPICAL WAVEFORMS Iin: ac line current (CH4 – 10 A/div) Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 5. Vac = 90 V, Pin = 326.5 W, Vout = 365 V, Iout = 822 mA, PF = 0.999, THD = 4 % Iin: ac line current (CH4 – 10 A/div) Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 6. Vac = 220 V, Pin = 325 W, Vout = 384 V, Iout = 814 mA, PF = 0.989, THD = 8 % http://onsemi.com 5 AND8185/D THD and Efficiency at Vac = 110 V Pin (W) Vout (V) Iout (A) PF (−) THD (%) eff (%) 331.3 370.0 0.83 0.998 4 93 296.7 373.4 0.74 0.998 4 93 157.3 381.8 0.38 0.995 7 92 109.8 383.5 0.26 0.993 9 91 80.7 384.4 0.19 0.990 10 91 67.4 385.0 0.16 0.988 10 91 10 93 8 92 Efficiency (%) 94 THD (%) 12 6 4 2 91 90 89 0 88 50 100 150 200 250 300 50 350 100 150 200 250 300 350 Pin (W) Pin (W) Figure 7. THD vs. Pin Figure 8. Efficiency vs. Pin The Total Harmonic Distortion keeps below 10% from Pmax (maximum power – 300 W) down to about Pmax/5. The efficiency remains higher than 90% for input powers ranging from 67 to 330 W. In standby (no load conditions), the PFC stage enters a stable burst mode, where the circuit keeps regulating the output voltage and minimizes the power consumption (See Figure 11). http://onsemi.com 6 AND8185/D THD and Efficiency at Vac = 220 V Pin (W) Vout (V) Iout (A) PF (−) THD (%) eff (%) 66.9 386.6 0.16 0.920 15 92 80.2 386.5 0.19 0.933 14 92 110.0 386.7 0.27 0.960 11 95 157.3 386.4 0.38 0.978 9 93 215.7 386.2 0.53 0.985 8 95 311.4 385.4 0.77 0.989 9 95 21 99 18 97 Efficiency (%) THD (%) 15 12 9 95 93 91 6 89 3 0 50 100 150 200 250 300 87 50 350 Pin (W) 100 150 200 250 300 350 Pin (W) Figure 9. THD vs. Pin Figure 10. Efficiency vs. Pin Similarly to the 110 Vac results, low THD values are obtained. The Total Harmonic Distortion keeps below 15% from Pmax (maximum power – 300 W) down to about Pmax/5. Again the efficiency keeps high in a large power range. More specifically, it remains higher than 91% for input powers ranging from 67 to 330 W. In standby (no load conditions), the PFC stage enters a stable burst mode, where the circuit keeps regulating the output voltage and minimizes the power consumption. http://onsemi.com 7 AND8185/D Thermal Measurements Measurements Conditions: • • • • • • The following results were obtained using a thermal camera, after a 1 h operation at 25°C ambient temperature. These data are indicative. They show that the demo−board may require additional heatsink capability if used in high ambient temperature applications. Vac = 90 V Pin = 326 W Vout = 365 V Iout = 0.82 A PF = 0.999 THD = 3 % Coil Coil Power MOSFET Heatsink Bulk Capacitor Output Diode (ferrite) (wires) Input Bridge 100°C 80°C 50°C 75°C 100°C 130°C 85°C No Load Operation Iin: ac line current (CH3 – 10 A/div) 388V Vout (CH3) Vin (CH2) Vpin5 (CH1) Figure 11. Pout = 0 W, Vac = 230 V When in light load, the circuit enters a welcome burst mode that enables the circuit to keep regulating. Vpin5 oscillates around the pin5 internal reference voltage (2.5 V). The power losses @ 220 Vac, are nearly 130 mW. This result was obtained by using a W.h meter (measure duration: 1 h). http://onsemi.com 8 AND8185/D Soft−Start bandwidth required by PFC stages, “Vcontrol” increases slowly. As a result, the power delivery rises gradually and the PFC pre−regulator startup smoothly and noiselessly. The NCP1653 grounds the “Vcontrol” capacitor when it is off, i.e., before each circuit active sequence (“Vcontrol” being the regulation block output). Provided the low regulation DRV (Vpin7) Vpin2 (CH3) (Vcontrol – regulation output) Vout (CH1) Vin (CH2) Figure 12. http://onsemi.com 9 AND8185/D Bill Of Materials Ref Des Description Part Number Manufacturer C1 100 nF / 275 V type X2 PHE840MX6100M RIFA C2 100 F / 450 V 2222 159 37101 BC Components C3 100 nF / 50 V various C4 47 F / 35 V various C5 1 nF / 50 V various C6 1 nF / 50 V various C7 100 nF / 50 V various C8 1 nF / 50 V various C9 100 nF / 50 V various C11 1 F / 275 V type X2 PHE840MD7100M RIFA C12 4.7 nF / 250 V type Y DE1E3KX472MA5B muRata C13 4.7 nF / 275 V type Y DE1E3KX472MA5B muRata C15 680 nF / 275 V type X2 PHE840MD6680M RIFA R1 Resistor, Axial Lead, 4.5
, 1/4 W, 1% various R2 Resistor, Axial Lead, 470 k
, 1/4 W, 1% various R3 Resistor, Axial Lead, 56 k
, 1/4 W, 1% various R4 Resistor, Axial Lead, 4.7 M
, 1/4 W, 1% various R5 Resistor, Axial Lead, 680 k
, 1/4 W, 1% various R6 Resistor, Axial Lead, 2.8 k
, 1/4 W, 1% R7 Resistor, Axial Lead, 0.1
, 3 W, 1% R8 Resistor, Axial Lead, 680 k
, 1/4 W, 1% various R9 Resistor, Axial Lead, 560 k
, 1/4 W, 1% various R10 Resistor, Axial Lead, 10 k
, 1/4 W, 1% various various RLP3 0R1 1% VISHAY L1 Coil 600 H Coil 650 H Coil 600 H C1062−B MB09008 SRW42EC−E03H001 CoilCraft microSpire TDK L4 DM Choke 150 H/5 A, WI−FI series Wurth Elektronik CM1 Filter (4 A, 2*6.8mH). B82725−J2402−N20 EPCOS U1 Diodes Bridge KBU6K General Semiconductor D1 Output Diode CSD04060 CREE M1 MOSFET SPP20N60S5 Infineon Heatsink (2.9°C/W) 437479 AAVID THERMALLOY Controller NCP1653 ON Semiconductor CM1 U2 http://onsemi.com 10 AND8185/D Vendors Contacts Vendor Contact Product Information CoilCraft www.coilcraft.com microSpire TDK www.microspire.com Info@tdk.de www.tdk.co.jp/tetop01/ www.cree.com/Products/pwr_sales2.asp www.cree.com/Products/pwr_index.asp EPCOS CREE www.epcos.fr/ http://onsemi.com 11 AND8185/D ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages. “Typical” parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. SCILLC does not convey any license under its patent rights nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part. SCILLC is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner. PUBLICATION ORDERING INFORMATION LITERATURE FULFILLMENT: Literature Distribution Center for ON Semiconductor P.O. Box 61312, Phoenix, Arizona 85082−1312 USA Phone: 480−829−7710 or 800−344−3860 Toll Free USA/Canada Fax: 480−829−7709 or 800−344−3867 Toll Free USA/Canada Email: orderlit@onsemi.com N. American Technical Support: 800−282−9855 Toll Free USA/Canada ON Semiconductor Website: http://onsemi.com Order Literature: http://www.onsemi.com/litorder Japan: ON Semiconductor, Japan Customer Focus Center 2−9−1 Kamimeguro, Meguro−ku, Tokyo, Japan 153−0051 Phone: 81−3−5773−3850 http://onsemi.com 12 For additional information, please contact your local Sales Representative. AND8185/D