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EVA4201
User Manual
22 pgs776.77 Kb0

Serma EVA4201, EVA4301 User Manual

Documentation
EVA4201/4301 – User Guide
Evaluation Board for
80W
Featured Products: PE4201/PE4301
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 2 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
Table of Contents
1.
Revision History ....................................................................................................................... 2
2.
Safety Instructions .................................................................................................................... 3
3.
Introduction .............................................................................................................................. 3
3.1
Features ................................................................................................................................... 3
3.2
IC`s General Description .......................................................................................................... 3
4
How to design an application ................................................................................................... 4
4.1
Given board specification ......................................................................................................... 4
4.2
Calculating the Current ............................................................................................................ 4
4.3
Inductor .................................................................................................................................... 6
4.4
Current Sense Resistor ............................................................................................................ 7
4.5
Error Amplifier Compensations .............................................................................................. 10
4.6
Self Biasing ............................................................................................................................. 11
4.7
EMI and Driver SlewRate ....................................................................................................... 12
4.8
Start-Up Bypass Rectifier ....................................................................................................... 12
5
Description ............................................................................................................................. 13
5.1
Evaluation Board Specifications ............................................................................................. 14
5.2
Wire bridges ........................................................................................................................... 14
5.3
Schematic .............................................................................................................................. 15
5.4
Component Placement........................................................................................................... 16
5.5
Board Picture and Layout ...................................................................................................... 17
5.6
Bill of Material ......................................................................................................................... 18
6
Operating ............................................................................................................................... 19
6.1
Caution ................................................................................................................................... 19
6.2
Load ....................................................................................................................................... 19
6.3
AC-Input ................................................................................................................................. 19
6.4
Power-up Sequence ............................................................................................................... 19
7.
List of Abbreviations ............................................................................................................... 20
8.
Notes ...................................................................................................................................... 21
9.
Contact Addresses ................................................................................................................. 22
1. Revision History
Version Date Changes Page
Initial Version V1.0 12/2008 V1.1 04/2013 Formula (2) 4
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 3 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
2. Safety Instructions
Please take caution - the board operates at 405V DC and is directly plugged into the power network. Operating this Board requires an isolated transformer!
The EVA4201/4301 was designed to help understand and evaluate the features of two Power Factor Correction IC`s. Used external devices are standard components chosen for safe operation and do not represent a completely fine-tuned OEM application. The BOM (bill of material) for a final application may look slightly different.
The board can also be used with PEs high precision PFC ICs, the PE4202 and the PE4302.
3. Introduction
3.1 Features
The board is designed to support applications of our two PFC-IC’s PE4201 and PE4301
PE4201 PE4301
- Low Total Harmonic Distortion (THD) - Wide Range Input
- Low StartUp Current (<5µA) - Low Total Harmonic Distortion (THD)
- Low Operating Current (<450µA) - Low Operating Current (<550µA)
- Disable Function (<170µA) - Disable Function (<100µA)
- Under-Voltage Lockout with >8V Hysteresis - Under-Voltage Lockout with >8V Hysteresis
- Over voltage and Over current protection with - Over voltage protection, Peak current separate Reference protection and Open loop protection with
- Reduced operating Frequency at low Output separate Reference Power - low Peak current protection threshold
- High Efficiency at high and low Output Power - Operating Frequency between 40 kHz and
- Internal Clamping Resistor at G 250 kHz dependent upon load
- fast Driver turn ‘off’ - High Efficiency at high and low Output Power
- very fast Driver ‘off’ at over current sense - Internal Clamping Resistor at Driver
- Driver load up to 5nF - Soft start
- fast Driver Switch ‘off’
Application with PE4201/PE4301
• Active power factor correction
• Switch mode power supplies
3.2 IC`s General Description
The PE4201 and PE4301 are wide input range controller ICs for active power factor correction converters. Both ICs provide many protection functions, such over voltage protection, open loop protection, supply under voltage lockout, output under voltage protection and peak current limit protection. These protection functions are working with separate reference. The PE4201 operates in the CRM with voltage mode PWM control and in DCM under light load condition. The maximum switching frequency is clamped with an internal delay circuit. Compensations for voltage loop are external. The PE4301 IC operates in the CCM with average current control. The switching frequency depends upon load. At high output load the frequency is low and with low load the frequency is high. The Compensation for voltage loop and soft start is external. For more information refer to the datasheets.
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 4 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
4 How to design an application
4.1 Given board specification
PE4201/PE4301
The board setup in the original state has the following specification parameters. The following chapters show, what has to be changed to design an active PFC supply towards different parameters. Please take caution when calculating. Wrong device parameter calculation can damage the Evaluation board or other devices.
AC Line Input voltage 85 VAC ... 265 VAC AC Line Frequency 47 ... 63Hz Switching Frequency 40 ... 250 kHz Output voltage 340 -405V DC (adjustable) Output Load max 80W Over Voltage Threshold 416V DC
4.2 Calculating the Current
PE4201
The input power:
86,96W=
92%
80W
=
η
out
P
=
in
P (1)
The input current:
A0,52=
110V
0,66*86,96W
=
AC
V
in
P
=
ACin_LL
I
D∗
(2)
A=
265V
86,96W
=
AC
V
in
P
=
ACin_HL
I
0,33
(3)
D… Duty Cycle at 110V
The peak current:
A=0,52A22=
ACin_LL
I22=
pk_LL
I
1,48
∗∗∗∗
(4)
A0,93=A33,022=
ACin_HL
I22=
pk_HL
I ∗∗∗∗
(5)
This peak current affects the component selection on the current sense resistor, Power-MOSFET, diode and inductor.
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 5 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
0,11A0,40A20,220,2
ACin_LLLL
==I=∆I ∗∗∗∗
0,093A0,33A20,220,2
ACin_HLHL
==I=∆I ∗∗∗∗
,61A0
2
0,22
A40,02
2
2
LL
ACin_LLpk_LL
=+=
∆I
+I=I ∗∗
,51A0
2
0,22
A33,02
2
2
LL
ACin_HLpk_HL
=+=
∆I
+I=I ∗∗
PE4301
The input power:
86,96W
92%
80W
out
in
==
η
P
=P
(6)
The input current:
0,40A
110V
86,96W
AC
in
ACin_LL
==
V
P
=I
(7)
0,33A
265V
86,96W
AC
in
ACin_HL
==
V
P
=I
(8)
The ripple current ∆I is set to 20%
(9)
(10)
The peak current:
(11)
(12)
This peak current affects the component selection on the current sense resistor, MOSFET, diode and inductor.
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 6 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
out
inout
V
VV=D−
0,615V
405
110V2405V
LL
==D
∗−
0,074V
405
265V2405V
HL
==D
∗−
4.3 Inductor
PE4201
For CRM operation, the maximum 'on' time and the maximum 'off' time control the lowest frequency. The minimum CRM inductance L
(CRM)
at low and high line input voltage can be calculated as follows:
f
1
pk
I
in
V
out
V
in
V
out
V
=
(CRM)
L ∗∗
−
(13)
µH=
40kHz
1
1,48A
V2
405V
V2405V
=
(CRM)
L
1623
110110
∗
∗
∗
∗−
(14)
µH=
40kHz
1
0,93A
265V2
405V
265V2405V
=
(CRM)
L
754
∗
∗
∗
∗−
(15)
For high line voltage and high output power the inductor has to have a nominal inductance of 400µH. The switching frequency at low line voltage can be calculated according to equation (16):
(CRM)
L
1
pk
I
in
V
out
V
in
V
out
V
=f ∗∗
−
(16)
39,9kHz=
1623µH
1
1,48A
110V2
405V
110V2405V
=f ∗
∗
∗
∗−
(17)
PE4301
For CCM operation, the maximum 'on' time and the maximum 'off' time control are the lowest frequencies. The minimum CCM inductance L
(CCM)
at low and high line input voltage can be calculated
as follows:
Duty Cycle
(18)
(19)
(20)
CCM Inductor
ISO 9001 / ISO 14001 01/06/2016 © Productivity Engineering GmbH
Page 7 of 22
EVA4204/4301
User Guide
Evaluation Board for 80W PFC Supply
∆If
DV
=L
∗
∗∗
in
CCM
2
(21)
µH21425
A11,040kHz
0,615110V2
CCM_LL
==L
∗
∗∗
(22)
µH7536
0,093A40kHz
0,074265V2
CCM_HL
==L
∗
∗∗
(23)
For high line voltage and high output power the inductor set to 8000µH. The switching frequency at low line voltage obtains as:
∆IL
DV
=f
∗
∗∗
CCM
in
2
(24)
kHz6,109
A11,08000µH
0,62110V2
==f
∗
∗∗
(25)
4.4 Current Sense Resistor
PE4201
The current sense resistor provides the threshold voltage for the over-current protection function. The maximum inductor peak current is set to 1,48 A.
0,15
Ω
=
1,48A
0,22V
=
OCP
I
SHPCP
V
=
s
R
(26)
R
sense
=0,15 Ω
PE4301
1,55
Ω
=
0,61A
0,95V
=
OCP
I
CSPCP
V
=
s
R
(27)
R
sense
=1,55 Ω
For higher/lower output power the resistor RS has to be reduced/increased and the inductor has to be re-calculated.
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