ON Semiconductor NCP1653EVB 300 W, Wide Mains, PFC Stage Driven by the NCP1653 Evaluation User Manual

ON Semiconductor NCP1653EVB 300 W, Wide Mains, PFC Stage Driven by the

NCP1653 Evaluation

Introduction

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* 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:

specifications

• Maximum output power: 300 W
• Input voltage range: from 90 Vrms to 265 Vrms
• Regulation output voltage: 385 V
• Switching frequency: 100 kHz

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 KHZ) 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 “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).

NCP1653EVB

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 evaluation board 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.

NCP1653EVB

NCP1653EVB

NCP1653EVB GENERAL BEHAVIOR − TYPICAL WAVEFORMS

NCP1653EVB

Table 1. THD AND EFFICIENCY AT Vac = 110 V

P in (W)| V out (V)| I out (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

• 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).

NCP1653EVB

Table 2. THD AND EFFICIENCY AT Vac = 220 V

P in (W)| V out (V)| I out (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

• 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.

NCP1653EVB

Thermal Measurements

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.

Measurements Conditions:

• Vac = 90 V
• Pin = 326 W
• Vout = 365 V
• Iout = 0.82 A
• PF = 0.999
• THD = 3%

Power MOSFET

|

Heatsink

|

Bulk Capacitor

|

Output Diode

| Coil

(ferrite)

| Coil

(wires)

|

Input Bridge

---|---|---|---|---|---|---
100°C| 80°C| 50°C| 75°C| 100°C| 130°C| 85°C

No Load Operation

• 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).

Soft-Start

• 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
• 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.

Test Procedure

1. Apply a 500 W/400 W resistive load across the output (between the “+VOUT” and “−VOUT” terminals of the board).
2. Adjust a 350 W or more, isolated ac power source so that it outputs a 110 VRMS, sinusoidal voltage (50 or 60 Hz).
3. Place a power analyzer able to measure:
4. The power delivered by the power source (“Pin”)
5. The power factor (“PF”) and the Total Harmonic Distortion (“THD”) of the current absorbed from the ac power source
6. Plug the application to the ac power source.
7. Supply the controller by applying 15 V to the VCC socket (between the “+12 V” and “GND” terminals of the board) and measure:
   Parameters| Comments| Limits
   ---|---|---
   VOUT| Voltage Measured between “+VOUT” and “−VOUT”| 365 V < VOUT < 385 V
   PF| Power Factor| > 0.990
   THD| Total Harmonic Distortion| < 8%
   Efficiency|  | > 91%
8. Observe the input current (current drawn from the ac power source) using a current probe and the oscilloscope. The current is nearly sinusoidal.
9. Gradually decrease the power source input voltage until the input current top becomes flat. Measure the plateau (see Figure 14). It must be between 4.9 and 5.3 A (over-current limitation). This test must be very short to avoid any excessive heating of the board. Immediately stop the test if the input current exceeds 5.3 A, or if the input voltage is below 75 VRMS).
10. Increase the ac power source voltage to 220 V and measure:
    Parameters| Comments| Limits
    ---|---|---
    VOUT| Voltage Measured between “+VOUT” and “−VOUT”| 375 V < VOUT < 395 V
    PF| Power Factor| > 0.980
    THD| Total Harmonic Distortion| < 12%
    Efficiency|  | > 93%
11. Observe the output voltage (i.e., the voltage between the “+VOUT” and “−VOUT” terminals of the board) with an oscilloscope. Unplug the PFC stage from the power source. Set the triggering level at about 200 V, the trigger position being set at 10% of the screen. Program the scope to observe 50 or 100 ms in single acquisition mode.
12. Abruptly apply the power source. Check that the output voltage keeps below 450 V (Over-Voltage Protection) (see Figure 15).

Table 3. BILL OF MATERIALS FOR THE NCP1653 EVALUATION BOARD

Designator

| ****

Qty.

| ****

Description

| ****

Value

| ****

Tolerance

| ****

Footprint

| ****

Manufacturer

| Manufacturer Part Number| Substitution Allowed| Lead Free
---|---|---|---|---|---|---|---|---|---
U2| 1| Power Factor Controller| −| −| DIP8| ON Semiconductor| NCP1653PG| No| Yes
C1| 1| Class X2 Capacitor| 100 nF, 275 V| 20%| Axial| Evox Rifa| PHE840MX6100M| No| Yes
C2| 1| Electrolytic Capacitor| 100 µF, 450 V| 20%| Radial| Vishay BC Components| 2222 159 37101| No| Yes
C3, C7, C9| 3| Polyester Film Capacitor| 100 nF, 100 V| 10%| Axial| AVX| BQ014E0104K| Yes| Yes
C4| 1| Electrolytic Capacitor| 47 µF, 35 V| 20%| Radial| Panasonic| ECA1VM470| Yes| Yes
C5, C6, C8| 3| Polyester Film Capacitor| 1 nF, 100 V| 10%| Axial| AVX| BQ014E0102K| Yes| Yes
C11, C15| 2| Class X2 Capacitor| 1 µF, 275 V| 20%| Axial| Evox Rifa| PHE840MD7100M| No| Yes
C12, C13| 2| Class Y2 Capacitor| 4.7 nF, 250 V| 20%| Disc| Vishay Roederstein| WYO472MCMCF0KR| Yes| Yes
R1| 1| Axial Resistor| 4.5 Q, 1/4 W| 1%| Axial| Panasonic| ERO−S2PHF4R53| Yes| Yes
R2| 1| Axial Resistor| 470 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF55470KFKE36| Yes| Yes
R3| 1| Axial Resistor| 56 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF5556K0FKE36| Yes| Yes
R4| 1| Axial Resistor| 4.7 MQ, 1/4 W| 1%| Axial| Phoenix Passive Comp.| 2306 242 64705| Yes| Yes
R5, R8| 2| Axial Resistor| 680 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF55680KFKE36| Yes| Yes
R6| 1| Axial Resistor| 2.8 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF552K80FKE36| Yes| Yes
R7| 1| Axial Resistor| 0.1 Q, 1/4 W| 1%| Axial| Vishay Sfernice| RLP3 0R10 1%| No| Yes
R9| 1| Axial Resistor| 560 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF55560KFKE36| Yes| Yes
R10| 1| Axial Resistor| 10 kQ, 1/4 W| 1%| Axial| Vishay Dale| CCF5510K0FKE36| Yes| Yes
R12| 1| Strap (Short Circuit)| −| −| Through| −| −| Yes| Yes
L1| 1| PFC Coil| 600 µH| −| −| Coilcraft| C1062−B| No| Yes
L4| 1| DM Filter| 150 µH, 5 A| 20%| Toroidal| Wurth Elektronik| 7447055| No| Yes
CM1| 1| CM Filter| 2´6.8 mH, 4 A| 30%| −| Epcos| B82725J2402N20| No| Yes
U1| 1| Bridge Rectifier| 6 A, 800 V| −| KBU| Vishay General Semi.| KBU6K| No| Yes
D1| 1| Diode| 600 V, 4 A| −| TO220| Cree| CSD04060A| No| Yes
M1| 1| MOSFET| 600 V, 20 A| −| TO220| Infineon| SPP20N60S5| No| Yes
H1| 1| Heatsink| 2.9°C/W| −| −| Aavid Thermalloy| KM100−1| Yes| Yes
 | 4| Board Supports| −| −| −| Richco| TCBS−8−01| Yes| Yes
F1| 1| Fuse| 250 V, 4 A| −| −| Schurter| FTT 0034.5049| Yes| Yes
 | 2| Thermal Pad (TO220)| −| −| −| Bergquist| 3223−07FR−43| Yes| Yes
 | 1| Heatsink Clip (TO218)| −| −| −| Aavid Thermalloy| 4473| Yes| Yes
 | 2| Heatsink Clip (TO220)| −| −| −| Aavid Thermalloy| 4426| Yes| Yes
CN1| 1| AC Connector| −| −| −| Schurter| GSF1.1201.31| Yes| Yes
J1, GND| 2| Terminal Block| −| −| Pitch: 5mm| Weidmuller| 1715250000| Yes| Yes
 | 3| Screws| −| −| −| −| MPMS 003 0008 PH| −| −
STRAP| 1| Strap (Short Circuit)| −| −| −| 3M| 923345−06−C| Yes| Yes

Table 4. VENDORS CONTACTS

www.tdk.co.jp/tetop01/
EPCOS| −| www.epcos.fr/
CREE| www.cree.com/Products/pwr_sales2.asp| www.cree.com/Products/pwr_index.asp

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