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VOUT
VOUT
AC
AC
IN
Turn-On
Turn-On
S
R
Turn-Off
Turn-Off
Q
OCP
RSENSE
SENSE
Feedback
Feedback
OVP
Disable
Ramp
Error Amp
Inductor
Current
MOSFET
Conduction
Diode
Conduction
Peak Inductor
Current
Average
Input
Current
Gating
Signal
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AN6027
APPLICATION NOTE
Block Diagram
2.5V
Ref
VCC 8
UVLO
Vref
VCC
Internal
Bias
12V
8.5V
Drive
Output
Disable
150s
Timer
ZCD 5
S
6.5V
1.4V 1.5V
Zero Current
Detector
CS
OVP
Disable
40k
8pF
0.8V
Ramp
Signal
MOT 2
7 OUT
13V
2.675V
2.5V
0.45V 0.35V
Current Protection
Comparator
Vref
1V Offset
Error
Amplifier
Sawtooth
Generator
Gm
1V~5V
Range
6
GND
COMP
INV
Figure 3. Block Diagram of the FAN7530 Showing Error Amplifier Block, Zero Current Detector Block, Sawtooth
Generator Block, Over-Current Protection Block, and Switch Drive Block
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AN6027
APPLICATION NOTE
Turn-on
Signal
Timer
S
Q
R
VIN
ZCD
5
6.5V
1.4V 1.5V
Zero Current
Detector
OVP
Disable
0.45V
2.5V
Gm
IPEAK
0.35V
tzero
Inductor
Current
V OUT
V ref (2.5V)
Error
Amp
0A
ton
tdis
INV
toff
COMP
INEG
Disable
Signal
V AUX
0V
-nV IN
Delay Time
V clamp
ZCD
Voltage
V th
R ZCD Delay
0V
V OUT
V DS
Minimum
Voltage Turn-on
0V
AN6027
APPLICATION NOTE
Ideally, the switch must be turned on when the inductor current reaches zero; but because of the structure of the ZCD
block and Rzcd delay, it is turned on after some delay time.
During this delay time, the stored charge of the COSS (MOSFET output capacitor) is discharged through the path indicated in Figure 7. This charge is transferred into a small filter
capacitor, Cin1, which is connected to the bridge diode.
Therefore, there is no current flow from the input side,
meaning the input current Iin is zero during this period. For
better total harmonic distortion (THD), it is important to
make tzero / TS as small as possible. As shown in Figure 6,
tzero is proportional to L C oss but ton and tdis are proportional to L. Therefore tzero / TS is approximately inversely
proportional to L . Therefore THD increases as the inductance decreases. Reducing the inductance can decrease the
inductor size and cost but the switching loss increases
because of the increased switching frequency. In real case,
boost diodes junction capacitance and boost inductors parasitic capacitance should be added to COSS when calculating
tzero. That means it is important to minimize the parasitic
capacitance of the boost inductor and diode junction capacitance for better THD.
iin
AC
IN
Off Signal
1V Offset
MOT
Sawtooth
Generator
3
2.9V
Error Amp
Output
CS 4
OCP
S ig n a l
40k
8pF
0 .8 V
V OUT
O v e r-C u rre n t
P ro te c tio n
C o m p a ra to r
iL
C IN1
CO
C OSS
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AN6027
APPLICATION NOTE
4 fsw (min)
ton = L
IL( peak ) (t )
Vin( peak ) sin(t )
= L
= L
toff = L
= L
(6)
1.5V NP
Naux >
(1)
(7)
Vin( peak )
Inductor
Current
2 I in
(2)
Input
Current
2 Vo Io
Vin( peak )
I in
t on / 2
(3)
t on
t off
TS = ton + toff
1
sin(t )
= 2 L Iin( peak )
+
(4)
Vin( peak ) Vo Vin( peak ) sin(t )
2
Vin( peak ) Vo Vin( peak ) sin(t )
4 L Vo Io (max)
Vin ( peak )
=
1 +
2
Vo Vin ( peak )
Vin ( peak )
Vin ( peak )
Vo Io (max) 1 +
V
o Vin ( peak )
2 Iin( peak )
IL( peak ) (t )
Iin( peak ) =
TS (max)
Vin ( peak )2
L=
Cin
(5)
ton
2
0
Vin(max)
t dt
(8)
L Io2(max) Vo2
Vin(max) Vin3( peak _ min)
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AN6027
APPLICATION NOTE
(9)
ID
LOAD
CO
VIN
i a = Ia cos(t )
IO
PFC
(10)
VO
Ia
Ia
=
tan cos1(IDF )
Vin( peak )
= tan1
Cin(max)
2 Vo Io
(11)
ID =
tan cos1(IDF )
(1 cos(2t ))
= Io (1 cos(2t ) )
(12)
(13)
Lin
iA
ia
iC
Cin
VA
IO
+
PFC
Circuit
Va
VO =
IO
CO
VO
Input Filter
Figure 13. Diode Current and Output Voltage Waveform
Im
iA
Co(min)
iC
ia
2 fac Vo(max)
(14)
Re
The maximum MOSFET RMS current is obtained by Equation 15 and the conduction loss of the MOSFET is calculated
by Equation 16. When MOSFET turns on, the MOSFET current rises from zero, so the turn-on loss is negligible. The
MOSFET turn-off loss and the MOSFET discharge loss are
obtained by Equations 17 and 18, respectively. The switching frequency of the critical conduction mode boost PFC
converter varies according to the line and load conditions.
VA
Figure 11. Input Voltage and Current Displacement Due to
Input Filter Capacitance
Io(max)
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AN6027
APPLICATION NOTE
Vin(LL )
1 4 2 Vin( LL )
6
9 Vo
2
Pon = IQrms
RDSon
R o1
1 4 2 Vin( LL )
6
9 Vo
2 2 Vo Io(max)
Pturn off =
PFC OUT
1
Cp
(15)
4
Coss.Vo Vo2 fsw
3
+ Pturn off + Pdisch arg e
Pdisch arg e =
PMOSFET = Pon
(17)
(18)
(19)
IDavg = Io(max)
(20)
PDiode = Vf IDavg
(21)
Ccomp = gm
Ro 2
0.01 2 120Hz (Ro1 + Ro 2 )
(23)
The output voltage sensing resistors, Ro1 and Ro2, are determined by the output voltage at the high line by Equation 22.
The output voltage sensing resistors cause power loss, therefore Ro1 should be higher than 1M. Too high resistance can
cause some delay of the OVP circuit due to internal capacitance (Cp), which may slightly increase the OVP level.
R o2
(16)
1
Vo IL( peak _ max) tf fsw
6
2
2 Vo Io(max)
tf fsw
3 Vin( LL )
INV
(22)
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AN6027
APPLICATION NOTE
crossing point of the AC line, as shown in Figure 18. To minimize the zero crossing distortion, COSS must be minimized
and a larger inductor should be used. There is a limitation in
minimizing COSS and using a large inductor because a small
MOSFET increases MOSFET conduction loss and a larger
inductor is more expensive.
VOUT
Error
Amp
Ro1
INV
1
Gm
Ro2
Vref
3
INEG =
(25)
COMP
IPEAK
Rcomp
tzero
Inductor
Current
Cfilter
Ccomp
Coss
(Vo Vin )
L
0A
ton
tdis
INEG
toff
n(VOUT-VIN)
VAUX
Integrator
C comp
0V
-nVIN
Proportional gain
R comp
Delay Time
Freq
Vclamp
ZCD
Voltage
C filter
High frequency
Noise filter
Vth
RZCD Delay
0V
OUT
N V
To improve the zero crossing distortion, the MOSFET turnon time should be increased near the AC line zero crossing
point. If a resistor is connected between the MOT and the
auxiliary winding, as shown in Figure 19, the function can be
implemented easily. Because the auxiliary winding voltage is
negatively proportional to the input voltage during the MOSFET turn-on time, the current I2 is proportional to the input
voltage (as shown in Figure 19). Therefore, the slope of the
internal ramp changes according to input voltage as the current flowing out of the MOT pin changes, as shown in Figure
20. I2 current is maximum at the highest line voltage and the
zero crossing improvement is best when I2 is 100% ~ 200%
of I1. R2 value should be chosen by experiment.
(24)
Because the ZCD pin has some capacitance, the ZCD resistor and the capacitor cause some delay for ZCD detection, as
shown in Figure 17. Because of this delay, the MOSFET is
not turned on when the inductor current reaches zero and the
MOSFET junction capacitor and the inductor resonate. The
inductor current changes its direction and flows negatively.
The peak value of this negative current is determined by
Equation 25. As shown in Equation 25, the negative current
increases as the input voltage is close to zero and COSS
increases. This negative current decreases average inductor
current and causes zero crossing distortion near the zero
2006 Fairchild Semiconductor Corporation
Rev. 1.0.3 1/11/07
www.fairchildsemi.com
AN6027
APPLICATION NOTE
To start up the FAN7530, the start-up current must be supplied through a start-up resistor. The resistor value is calculated by Equations 26 and 27. The start-up capacitor must
supply IC operating current before the auxiliary winding
supplies IC operating current, maintaining VCC voltage
higher than the UVLO voltage. The start-up capacitor is
determined by Equation 28.
Output
Voltage
1st
Input
Current
3rd
RST
5th
PRST =
CST
(26)
IST max
Vin2( rms _ max)
1W
(27)
Idcc
2 fac HY(ST )min
(28)
RST
AC
IN
VAUX
I2
VO
NAUX
RZCD
R2 ZCD
Rsense <
CO
VCC
FAN7529
INV
PRsense
MOT
CS
I1
COMP
R1
0.8V
IL( peak _ max)
Vo Io(max)
= 2
GND
= 0.8V
4 Vo Io(max)
(29)
Rsense < 1W
2 Vo Io(max)
(30)
(31)
Ramp Slope
Change
Slope
Decrease
VAC
Slope Increase
VEAO
On-time Increase
Ramp
Variable On-time
On-time Decrease
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AN6027
APPLICATION NOTE
4. Design Example
A 100W converter is used here to illustrate the design procedure using a design spreadsheet. Enter the system parameters
in the file to get the designed parameters. The system parameters are as follows:
100W
90Vrms~264Vrms
392V
60Hz
90%
37kHz
0.98
24V
8V
ZCD pin and the ground to increase the delay time for the
MOSFET minimum voltage turn-on.
MOT =
RMOT >
(33)
Switching
Nosie
MOT
1012
600
(32)
106
2 L Po
Internal
Ramp Signal
IC OUT Signal
10
AN6027
APPLICATION NOTE
T1
PFC OUTPUT
VAUX
D2
C5
R4
R3
R5
V1
C6
CS
COMP
R1 R8
F1
ZCD
R11
INV
C1
C9
FAN7530
R2
C2
R6
C11
OUT
Vcc
D1
GND
ZD1
C3 C4
LF1
Q1
MOT
NTC
R10
D3
C10
R9
BD
C7
R7
C8
AC INPUT
Figure 22. Application Circuit Schematic
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11
AN6027
APPLICATION NOTE
NOTE
PART#
Fuse
F1
V1
RT1
VALUE
NOTE
Capacitor
250V/3A
C1
150nF/275VAC
Box Capacitor
TNR
C2
470nF/275VAC
Box Capacitor
C3,C4
2.2nF/3kV
Ceramic Capacitor
NTC
C6
22F/25V
Electrolytic Capacitor
10D-9
C7
47nF/50V
Ceramic Capacitor
Resistor
C8
220nF
MLCC
471
470V
R1
42k
1/4W
C9
100F/450V
Electrolytic Capacitor
R2
370k
1/4W
C10
12nF/100V
Film Capacitor
R3
330k
1/2W
C11
47pF/50V
Ceramic Capacitor
R4
150
1/2W
R5
20k
1/4W
BD
KBL06
Fairchild
R6
100
1/4W
D1
1N4148
Fairchild
R7
0.2
1/2W
D2
BYV26C
600V/1A
R8
10k
1/4W
D3
SB140
Fairchild
R9
10k
1/4W
ZD1
1N4746
Fairchild
R10
2M
1/4W
R11
12.6k
1/4W
IC1
LF1
Diode
Inductor
T1
400H(44T:6T)
EI3026
IC
FAN7530
Line Filter
MOSFET
38mH
Wire 0.45mm
Q1
FQPF13N50C
500V/13A
100W
50W
90VAC
110VAC
220VAC
264VAC
PF
0.999
0.998
0.991
0.985
THD
3.97%
4.43%
5.25%
5.47%
Efficiency
90.3%
92.7%
94.7%
95.2%
PF
0.998
0.997
0.974
0.956
THD
4.81%
5.28%
6.74%
7.67%
Efficiency
90.1%
90.8%
91.7%
92.5%
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12
AN6027
APPLICATION NOTE
Table 4. 200W Demo Board Part List (600H, Wide Input Range Application)
PART#
VALUE
NOTE
PART#
VALUE
Fuse
F1
V1
RT1
NOTE
Capacitor
250V/5A
C1
470nF/275VAC
Box Capacitor
TNR
C2
470nF/275VAC
Box Capacitor
C3,C4
2.2nF/3kV
Ceramic Capacitor
NTC
C6
47F/25V
Electrolytic Capacitor
10D-9
C7
47nF/50V
Ceramic Capacitor
Resistor
C8
220nF
MLCC
471
470V
R1
37k
1/4W
C9
220F/450V
Electrolytic Capacitor
R2
250k
1/4W
C10
12nF/100V
Film Capacitor
R3
330k
1/2W
C11
47pF/50V
Ceramic Capacitor
R4
150
1/2W
R5
20k
1/4W
BD
KBU8K
Fairchild
R6
100
1/4W
D1
1N4148
Fairchild
R7
0.1
1W
D2
SUF30J
600V/3A
R8
10k
1/4W
D3
SB140
Fairchild
R9
10k
1/4W
ZD1
1N4746
Fairchild
R10
2M
1/4W
R11
12.6k
1/4W
IC1
LF1
Diode
Inductor
T1
200H(30T:3T)
PQ3230
IC
FAN7530
Line Filter
MOSFET
22mH
Wire 0.7mm
Q1
FDPF20N50
Fairchild
200W
150W
100W
85VAC
115VAC
230VAC
265VAC
PF
0.999
0.998
0.993
0.990
THD
3.8%
4.3%
6.5%
6.5%
Efficiency
91.8%
94.8%
96.9%
97.3%
PF
0.999
0.998
0.990
0.985
THD
4.7%
5.2%
7.0%
6.9%
Efficiency
93.3%
95.5%
96.9%
97.0%
PF
0.997
0.996
0.981
0.971
THD
6.5%
7.4%
9.0%
8.5%
Efficiency
94.3%
95.3%
96.2%
96.0%
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13
AN6027
APPLICATION NOTE
PART#
Fuse
F1
V1
RT1
VALUE
NOTE
Capacitor
250V/5A
C1
680nF/275VAC
Box Capacitor
TNR
C2
680nF/275VAC
Box Capacitor
C3,C4
2.2nF/3kV
Ceramic Capacitor
NTC
C6
47F/25V
Electrolytic Capacitor
6D-22
C7
33nF/50V
Ceramic Capacitor
Resistor
C8
220nF
MLCC
471
470V
R1
60k
1/4W
C9
33F/450V
Electrolytic Capacitor
R2
330k
1/4W
C10
12nF/100V
Film Capacitor
R3
330k
1/2W
C11
9pF/50V
Ceramic Capacitor
R4
100
1/2W
R5
20k
1/4W
BD
KBU8J
Fairchild
R6
100
1/4W
D1
1N4148
Fairchild
R7
0.06
1W
D2
SUF30J
600V/3A
R8
10k
1/4W
D3
SB140
Fairchild
R9
10k
1/4W
ZD1
1N4746
Fairchild
R10
2M
1/4W
R11
12.6k
1/4W
IC1
LF1
Diode
Inductor
T1
200H(36T:3T)
PQ3535
IC
FAN7530
Line Filter
MOSFET
40mH
Wire 1mm
Q1
FQA28N50
Fairchild
300W
225W
150W
75W
85VAC
115VAC
230VAC
265VAC
PF
0.999
0.998
0.993
0.988
THD
4.5%
4.7%
6.4%
6.5%
Efficiency
91.4%
94.5%
97.4%
97.7%
PF
0.999
0.998
0.989
0.982
THD
3.9%
4.7%
6.1%
6.2%
Efficiency
92.8%
95.1%
97.4%
97.7%
PF
0.998
0.997
0.978
0.963
THD
4.8%
5.8%
7.4%
7.4%
Efficiency
94.0%
95.7%
97.0%
97.3%
PF
0.994
0.989
0.929
0.885
THD
9.3%
10.8%
11.2%
12.0%
Efficiency
94.8%
95.9%
95.3%
95.2%
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14
AN6027
APPLICATION NOTE
Nomenclature
: converter efficiency
cycle
IL(peak): inductor current peak value during one AC line
cycle
IL(peak_max): maximum inductor current peak value
IO (max): maximum output current
IO: output current
IQrms: MOSFET RMS current
ISTmax: maximum start-up supply current
L: boost inductance
Naux: auxiliary winding turn number
NP: boost inductor turn number
Pin: input power
PO(max): maximum output power
PO: output power
Rsense: current sense resistance
2006 Fairchild Semiconductor Corporation
Rev. 1.0.3 1/11/07
www.fairchildsemi.com
15
AN6027
APPLICATION NOTE
DISCLAIMER
FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS
HEREIN TO IMPROVE RELIABILITY, FUNCTION, OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE
APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS
PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.
LIFE SUPPORT POLICY
FAIRCHILDS PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS
WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR CORPORATION. As used
herein:
1. Life support devices or systems are devices or systems which,
(a) are intended for surgical implant into the body, or
(b) support or sustain life, or
(c) whose failure to perform when properly used in accordance
with instructions for use provided in the labeling, can be reason
ably expected to result in significant injury to the user.
2006 Fairchild Semiconductor Corporation
Rev. 1.0.3 1/11/07
www.fairchildsemi.com
16