Fairchild FEBFAN9611 S01U300A User Manual

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User Guide for

FEBFAN9611_S01U300A

Evaluation Board

FAN9611 300W Interleaved Dual-BCM,

Low-Profile, PFC Evaluation Board

Featured Fairchild Product:

FAN9611

Direct questions or comments

about this evaluation board to:

“Worldwide Direct Support”

Fairchild Semiconductor.com

Table of Contents



1. Overview of the Evaluation Board ............................................................................................. 3

2. Key Features ............................................................................................................................... 5

3. Specifications ............................................................................................................................. 6

4. Test Procedure ............................................................................................................................ 7

4.1. Safety Precautions .............................................................................................................7

5. Schematic ................................................................................................................................... 9

6. Boost Inductor Specification .................................................................................................... 10

7. Four-Layer PCB and Assembly Images ................................................................................... 11

8. Bill of Materials (BOM) ........................................................................................................... 14

9. Inrush Current Limiting ............................................................................................................ 16

10.Test Results ............................................................................................................................. 18

10.1.Startup .............................................................................................................................18

10.2.Steady State Operation ....................................................................................................20

10.3.Line Transient .................................................................................................................24

10.4.Load Transient ................................................................................................................25

10.5.Brownout Protection .......................................................................................................27

10.6.Phase Management .........................................................................................................28

10.7.Efficiency ........................................................................................................................30

10.8.Harmonic Distortion and Power Factor ..........................................................................32

10.9.EMI .................................................................................................................................33

11.References ............................................................................................................................... 34

12.Ordering Information .............................................................................................................. 34

13.Revision History ..................................................................................................................... 34

The following user guide supports the FAN9611 300W evaluation board for interleaved boundary-conduction-mode power-factor-corrected supply. It should be used in

conjunction with the FAN9611 datasheet, Fairchild application note AN-6086 —Design

Considerations for Interleaved Boundary-Conduction Mode PFC Using FAN9611 / FAN9612

and FAN9611/12 PFC Excel®-based Design Tool.

1. Overview of the Evaluation Board

The FAN9611 interleaved, dual Boundary-Conduction-Mode (BCM), Power-FactorCorrection (PFC) controllers operate two parallel-connected boost power trains 180º out of phase. Interleaving extends the maximum practical power level of the control technique from about 300W to greater than 800W. Unlike the Continuous Conduction Mode (CCM) technique often used at higher power levels, BCM offers inherent zerocurrent switching of the boost diodes (no reverse-recovery losses), which permits the use of less expensive diodes without sacrificing efficiency. Furthermore, the input and output filters can be smaller due to ripple current cancellation between the power trains and doubling of effective switching frequency.

The advanced line feed-forward with peak detection circuit minimizes the output voltage variation during line transients. To guarantee stable operation with less switching loss at light load, the maximum switching frequency is clamped at 525kHz. Synchronization is maintained under all operating conditions.

Protection functions include output over-voltage, over-current, open-feedback, undervoltage lockout, brownout, and redundant latching over-voltage protection. FAN9611 is available in a lead-free, 16-lead, Small-Outline Integrated-Circuit (SOIC) package.

This FAN9611 evaluation board uses a four-layer Printed Circuit Board (PCB) designed for 300W (400V/0.75A) rated power. The maximum rated power is 350W and the Maximum On-Time (MOT) power limit is set to 360W. The FEBFAN9611_S01U300A is optimized to demonstrate all the FAN9611 efficiency and protection features in a lowprofile height form factor less than 18mm.

Figure 1. FEBFAN9611_S01U300A, Top View, 152mm x 105mm

Figure 2. FEBFAN9611_S01U300A, Side View (Low Profile), Cross Section=18mm

Figure 3. FEBFAN9611_S01U300A, Bottom View, 152mm x 105mm

2. Key Features

 180° Out-of-Phase Synchronization  Automatic Phase Disable at Light Load  1.8A Sink, 1.0A Source, High-Current Gate Drivers  Transconductance (g  Voltage-Mode Control with (V  Closed-Loop Soft-Start with Programmable Soft-Start Time for Reduced Overshoot  Minimum Restart Timer Frequency to Avoid Audible Noise  Maximum Switching Frequency Clamp  Brownout Protection with Soft Recovery  Non-Latching OVP on FB Pin and Second-Level Latching Protection on OVP Pin  Open-Feedback Protection  Over-Current and Power-Limit Protection for Each Phase  Low Startup Current: 80µA Typical  Works with DC input or 50Hz to 400Hz AC Input

) Error Amplifier for Reduced Overshoot

M

)2 Feed-Forward

IN

ZCD1

ZCD2

5VB

MOT

AGND

SS

COMP

FB

1

2

3

4

5

6

3V

7

8

VALLEY DETECTOR

5V

I

MOT

1.25V

REF

CHANNEL 1

CHANNEL 2

V

5V

BIAS

K1 VINI

5V

5µA

16

0.2V

2µA

15

14

13

12

11

10

9

CS1

CS2

VDD

DRV1

DRV2

PGND

VIN

OVP

0.195V

AB

PROTECTION LOGIC

(Open FB, Brownout Protec tion,

OVP, Latched OVP)

UVLO

S

INPUT VOLTAGE SENSE

(Input Voltage Squarer, Input UVLO, Brownout)

V

DD

QQR

A

QQR

B

SYNCHRONIZATION

RESTART TIMERS

FREQUENCY CLAMPS

DD

5V

2

MOT

2

MOT

gm

A

5V

B

Phase

Management

Figure 4. Block Diagram

3. Specifications

This evaluation board has been designed and optimized for the conditions in Table 1.

Table 1. Electrical and Mechanical Requirements

Min. Typ. Max.

V

80V 120V 265V

IN_AC

P

V

OUT_PFC_RIPPLE

P

OUT_PFC(MOT LIMIT)

t

SOFT_START

t

ON_OVERSHOOT



>30%P

OUT



>30%P

OUT

90V

IN_AC(ON)

IN_AC(OFF)

f

50Hz 60Hz 65Hz

VIN_AC

V

395V 400V 405V

OUT_PFC

P

300W 350W

OUT_PFC

f

18kHz 300kHz

SW_P FC

t

20ms

HOLD_UP

250ms 300ms

_PFC_120V

OUT(TYP)

_PFC_230V

OUT(TYP)

PF

0.991

_120V

PF

0.980

_230V

Height 18mm

JC

80V

10V 11V

360W

10V

96% 96.5%

95% 98%

Mechanical and Thermal

60⁰C

The trip points for the built-in protections are set as below in the evaluation board.

 The line UVLO (brownout protection) trip point is set at 80V

(10VAC hysteresis).

AC

 The pulse-by-pulse current limit for each MOSFET is set at 6A.

The current-limit function can be observed by measuring the individual inductor current waveforms while operating at 85V power limit is set at ~120% of the rated output power. The power-limit function can be observed while operating at >115V operating in power limit, the output voltage drops and the COMP voltage is saturated, but the AC line current remains sinusoidal. The phase-management function permits phase shedding / adding ~18% of the nominal output power for high line (230V can be increased by modifying the MOT resistor (R6) as described in Fairchild

Application Note AN-6086 —Design Considerations for Interleaved Boundary-

Conduction Mode PFC Using FAN9611 / FAN9612.

and increasing the load to 360W. The maximum

AC

and increasing the load beyond 360W. When

AC

). This level

AC

4. Test Procedure

Before applying power to the FEBFAN9611_S01U300A evaluation board; the DC bias supply for V should be connected to the board as shown in Figure 5.

Table 2. Specification Excerpt from FAN9611 Datasheet

Symbol Parameter Conditions Min. Typ. Max. Unit

Supply

I

STARTUP

IDD

I

DD_DYM

VON

V

OFF

V

HYS

4.1. Safety Precautions

The FEBFAN9611_S01U300A evaluation module produces lethal voltages and the bulk output capacitors store significant charge. Please be extra careful when probing and handling the module and observe a few precautions:

, AC voltage supply for line input, and DC electronic load for output

DD

Startup Supply Current VDD = VON – 0.2V

Operating Current Output Not Switching

Dynamic Operating Current fSW = 50kHz; C

UVLO Start Threshold VDD Increasing

UVLO Stop Threshold Voltage VDD Decreasing

UVLO Hysteresis V

ON

– V

OFF

80 110 µA

3.7 5.2 mA

= 2nF

LOAD

4 6 mA

9.5 10.0 10.5 V

7.0 7.5 8.0 V

2.5 V

 Start with a clean working surface, clear of any conductive material.  Be careful while turning on the power switch to the AC source.  Never probe or move a probe on the DUT while the AC line voltage is present.  Ensure the output capacitors are discharged before disconnecting the test leads. One

way to do this is to remove the AC power with the DC output load still switched on. The load then discharges the output capacitors and the module is safe to disconnect.

Power-On Procedure

1. Supply V

specification for V

2. Connect the AC voltage (90~265V

FAN9611 has brownout protection, any input voltage less than the designed minimum AC line voltage triggers brownout protection. FEBFAN9611_S01U300A does not start until the AC input voltage is greater than 90V

3. Change load current (0~0.75A) and check the operation

4. Verify the output voltage is regulating between 395V

for the control chip first. It should be higher than 10.5V (refer to the

DD

turn-on threshold voltage in Table 2).

DD

) to start the FAN9611 evaluation board. Since

AC

.

AC

DC<VOUT

<405VDC

AC Source

PF, THD, P

0-265V

AC

IN

DVM

Voltage

DVM

Current

Electronic Load

400V, 0-1A

DVM

Current

DC Bias Supply

0-12V

Figure 5. Recommended Test Set-Up

All efficiency data shown in this document was taken using the test set up shown in Figure 5 with the output voltage being measured directly at the output bulk capacitors (not through the output connector (J2)).

Power-Off Procedure

1. Make sure the electronic load is set to draw at least 100mA of constant DC current.

2. Disconnect (shut down) AC line voltage source.

3. Disconnect (shut down) 12V DC bias power supply.

4. Disconnect (shut down) DC electronic load last to ensure that the output capacitors

are fully discharged before handling the evaluation module.

5. Schematic

Figure 6. FEBFAN9611_S01U300A 300W Evaluation Board Schematic

6. Boost Inductor Specification

750340834 from Wurth Electronics (www.we-online.com)

 Core: EFD30 (A

=69mm2)

e

 Bobbin: EFD30  Inductance : 270H

Figure 7. Boost Inductor (L1, L2) in the Evaluation Board

Figure 8. Wurth 750340834 Mechanical Drawing

Table 3. Inductor Turns Specifications

Pin Turns Wire

N

1  6 69 (3 Layers) 30xAWG#38 Litz

BOOST

Insulation Tape

N

10  9 7 AWG#28

AUX

Insulation Tape

Fairchild FEBFAN9611 S01U300A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual