RDK-236

Title Reference Design Report for a High Performance 347 W PFC Stage Using HiperPFS™ PFS714EG Specification 90 VAC – 264 VAC Input; 380 VDC Output Application PFC Front End Stage Author Applications Engineering Department Document Number RDR-236 Date November 18, 2010 Revision 1.1 Summary and Features  Low component count, high performance 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, thermal resistance package 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-236 347 W PFC Using PFS714EG 18-Nov-10 Table of Contents 1 2 3 4 Introduction.................................................................................................................4 Power Supply Specification ........................................................................................5 Schematic...................................................................................................................6 Circuit Description ......................................................................................................7 4.1 Input EMI Filter and Rectifier ...............................................................................7 4.2 PFS714EG Boost Converter ...............................................................................7 4.3 Bias Supply Regulator .........................................................................................7 4.4 Input Feed Forward Sense Circuit.......................................................................7 4.5 Output Feedback.................................................................................................8 5 PCB Layout ................................................................................................................9 6 Bill of Materials .........................................................................................................10 7 Inductor Specification ...............................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................12 7.4 Inductor Winding Instruction ..............................................................................13 8 Performance Data ....................................................................................................16 8.1 Efficiency (RT1 and RT2 Shorted).....................................................................16 8.2 Input Power Factor ............................................................................................17 8.3 Regulation .........................................................................................................18 8.3.1 Load ...........................................................................................................18 8.3.2 Line ............................................................................................................19 8.4 Input Current Harmonic Distortion (IEC 61000–3–2 Class–D) ..........................20 8.4.1 50% Load at Output ...................................................................................20 8.4.2 100% Load at Output .................................................................................21 9 Thermal Performance...............................................................................................22 10 Waveforms............................................................................................................24 10.1 Input Current at 115 VAC and 60 Hz .................................................................24 10.2 Input Current at 230 VAC and 50 Hz .................................................................24 10.3 Start-up at 90 VAC and 60 Hz ...........................................................................25 10.4 Start-up at 115 VAC and 60 Hz .........................................................................25 10.5 Start-up at 230 VAC and 50 Hz .........................................................................26 10.6 Start-up at 264 VAC and 50 Hz .........................................................................26 10.7 Load Transient Response (90 VAC, 60 Hz) ......................................................27 10.8 Load Transient Response (115 VAC, 60 Hz) ....................................................28 10.9 Load Transient Response (230 VAC, 50 Hz) ....................................................28 10.10 Load Transient Response (264 VAC, 50 Hz).................................................29 10.11 1000 ms Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ...................29 10.11.1 50% Load at Output................................................................................29 10.11.2 Full Load at Output .................................................................................30 10.12 One Cycle Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ................30 10.12.1 Full Load at Output .................................................................................30 10.13 Line Sag (115 VAC – 85 VAC – 115 VAC, 60 Hz) .........................................31 10.14 Line Surge (132 VAC – 147 VAC – 132 VAC, 60 Hz)....................................31 10.15 Line Sag (230 VAC – 170 VAC – 230 VAC, 50 Hz) .......................................32 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 56 18-Nov-10 RDR-236 347 W PFC Using PFS714EG 10.16 Line Surge (264 VAC – 293 VAC – 264 VAC, 50 Hz) ....................................32 10.17 Brown–In and Brown–Out at 6 V / Minute Rate .............................................33 10.18 Drain Voltage and Current .............................................................................34 10.18.1 Dain Voltage and Current at 115 VAC Input and Full Load.....................34 10.18.2 Drain Voltage and Current at 230 VAC Input and Full Load....................35 10.19 Output Ripple Measurements ........................................................................36 10.19.1 Ripple Measurement Technique .............................................................36 10.19.2 Measurement Results .............................................................................37 11 Gain–Phase Measurement Procedure and Results ..............................................39 12 Line Surge Test .....................................................................................................41 13 EMI Scans.............................................................................................................42 13.1 EMI Test Set-up.................................................................................................42 13.2 EMI Scans .........................................................................................................43 14 Appendix A – Efficiency with Other Diode and Core Materials..............................45 15 Appendix B – Test Set-up for Efficiency Measurement .........................................50 16 Appendix C – Inductor Current Measurement Set-up............................................52 17 Revision History ..........................................................................................................55 Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Page 3 of 56 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-236 347 W PFC Using PFS714EG 18-Nov-10 1 Introduction This document is an engineering report describing a PFC power supply utilizing a HiperPFS PFS714EG integrated PFC controller. This power supply is intended as a general purpose evaluation platform that operates from universal input and provides a regulated 380 V DC output voltage and a continuous output power of 347 W. This power supply can deliver the rated power at 110 VAC or higher at a room 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. Figure 1 – Populated Circuit Board Photograph. . Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 56 18-Nov-10 RDR-236 347 W PFC Using PFS714EG 2 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 0.913 V V A 347 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 50 Auxiliary Supply Input Auxiliary Supply VAUX 15 24 Page 5 of 56 C Forced convection required at TAMB >25 ºC and/or VIN