ON Semiconductor Fairchild PFC SPM Design Manual

ON Semiconductor Fairchild PFC SPM Design Manual

With analog pfc ic

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  • Page 1 ON Semiconductor does not convey any license under its patent rights nor the rights of others. ON Semiconductor products are not designed, intended, or authorized for use as a critical component in life support systems or any FDA...
  • Page 2 ® PFC SPM Design Guide Application Note AN-9041 PFC SPM® Design Guide with Analog PFC IC Written by: Application Engineering Part Motion Control System Team HV PCIA FAIRCHILD SEMICONDUCTOR © 2005 Rev. 1.0.1-2012 Fairchild Semiconductor – System Engineering Group...
  • Page 3: Table Of Contents

    ® PFC SPM Design Guide Contents System Configurations ................3 Protection Circuits .................. 3 Over Current Protection (OCP) ......................3 Over Voltage Protection ......................... 4 Under Voltage Protection ........................4 Design Example (PFC SPM® DEMO BOARD) ........5 Operating conditions of PFC SPM® demo board: .................. 5 Output capacitance and Inductance design ....................
  • Page 4: System Configurations

    ® PFC SPM Design Guide 1. System Configurations R el ay Thermistor N /F LVIC Shunt Resistor SENSE Control IC Fig.1 Typical block diagram of PFC SPM® system An inrush-current prevention circuit is required due to the large DC link capacitance as shown in Fig. 1. The relay of the circuit should be closed after DC link capacitor is charged far enough.
  • Page 5: Over Voltage Protection

    ® PFC SPM Design Guide Over Voltage Protection OV (Over Voltage) protection can be also implemented by dual protection. The DC-link voltage changes slowly because of its large capacitance. So OVP does not need fast response. Therefore it is optional to activate the OVP of PFC controller. [OVP Level 1 - PFC controller] OVP level 1 suppresses voltage overshoot in transient situation.
  • Page 6: Design Example (Pfc Spm® Demo Board)

    ® PFC SPM Design Guide 3. Design Example (PFC SPM® DEMO BOARD) A general PFC example is implemented for 5[kW] air-conditioning applications whose input voltage is 187~276[V]. Operating conditions of PFC SPM® demo board: Table 1. The operating conditions. Item Symbol Value Unit...
  • Page 7: Inductance & Input Current Ripple

    ® PFC SPM Design Guide Inductance & Input Current Ripple I where: : Peak to peak current of PFC inductor Lp-p : Input AC voltage : DC link Voltage OUTDC f : Switching frequency L : Inductance of PFC inductor ...
  • Page 8: Current Loop Amplifier

    ® PFC SPM Design Guide The following is the block diagram of PFC controller ucc3818. The average current mode control is composed of two types of loops- voltage loop and current loop. The voltage loop controls the output DC-Link voltage. It regulates the output voltage. There is a 120[Hz] ripple voltage in the output DC-Link, which is caused by the 60[Hz] ac input current.
  • Page 9: Control Loop Implementation

    ® PFC SPM Design Guide s : j(= j2f) Control Loop Implementation Current Loop [Step 1] Crossover frequency Theoretical crossover frequency is given by following equation.   (Eq.3) [Step 2] Fz and Fp decision     [Step 3] Rz, Cp, Cz decision is same to R .
  • Page 10 ® PFC SPM Design Guide O U T =3.3kHz =6.7kHz =20kHz Fig.4 Current loop circuit Fig.5 Desired current error amplifier response  (Eq.6)   (Eq.7)  (Eq.8)  © 2005 Rev. 1.0.1-2012 Fairchild Semiconductor – System Engineering Group...
  • Page 11: Voltage Loop

    ® PFC SPM Design Guide Voltage Loop 5000         OUTDC EAOUT A resistor(R ) is added between E/A input and sensing resistor. By virtue of large R can be replaced by small SMD type capacitor. ...
  • Page 12 ® PFC SPM Design Guide        peak sense   GMMAX (Assuming the input current is 50A = 100V  R = 470[Ω] = 0.002[Ω]( small resistance can cause distortions at low level current) sense &...
  • Page 13: Over Current Protection

    ® PFC SPM Design Guide  (when, input voltage V = 90[V [ 4 . = 33[kΩ], C = 100[uF] Over Current Protection O C P O U T VREF(7.5V) VAC- PKLIMIT PFCM UCC3818 Fig.8 Over current protection circuit The actual protection level can be slightly different from the calculated value. It depends on PCB layout pattern.
  • Page 14: Over Voltage Protection

    ® PFC SPM Design Guide Over Voltage Protection O V P 1 O VP 2 Fig.9 Over voltage protection circuit About demo board, the designed values are: = 15 [kΩ], R = 1.8 [kΩ], R = 870 (270+270+330) [kΩ] And the expected OC levels are: 1) OVP level 1 ...
  • Page 15: Dc-Link Voltage Control

    ® PFC SPM Design Guide DC-link Voltage Control Outer OP-AMP Fig.10 DC link voltage control circuit The relation between V and parameters is:                   ...
  • Page 16: Experimental Results

    ® PFC SPM Design Guide 4. Experimental Results Fig. 12 shows the overall schematics of implemented PFC converter. Table 2 shows the components that are used for the implemented hardware. Fig. 13 shows the input ac current and DC-link voltage waveforms.
  • Page 17 ® PFC SPM Design Guide Table 2. BOM of PFC SPM® demo board. © 2005 Rev. 1.0.1-2012 Fairchild Semiconductor – System Engineering Group...
  • Page 18 ® PFC SPM Design Guide (50V/div) (10A/div) Fig. 13. Full load test results (I = 16A Table 3. Power factor and input power measurement. Power [kW] Power Factor [%] Fig.13 and I are RMS values DISCLAIMER FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION, OR DESIGN.
  • Page 19 FDA Class 3 medical devices or medical devices with a same or similar classification in a foreign jurisdiction or any devices intended for implantation in the human body. Should Buyer purchase or use ON Semiconductor products for any such unintended or unauthorized...

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