NCP1653EVB Manual Datasheet by ON Semiconductor

 Semiconductor Components Industries, LLC, 2012

September, 2012 − Rev. 1

1Publication Order Number:

EVBUM2139/D

NCP1653EVB

300 W, Wide Mains,

PFC Stage Driven by

the NCP1653 Evaluation

BoardUser's Manual

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:

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 mH) 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).

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EVAL BOARD USER’S MANUAL

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Figure 1. The Board

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.

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NCP1653EVB

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−

KBU6K

EarthNL

90 TO 265 Vac

100 nF

Type = X2

100 nF

1 nF

470 k

4.7

Meg

1 nF

100 nF

2.85 k

NCP1653

1 nF

0.1

R10

10 k

−

15 V

680 k

560 k

SPP20N60S

600 mH

CSD04060

100 mF

Type = snap−in

450 V

−

390 V

Figure 2. Schematic for the NCP1653 Evaluation Board

4.5

56 k

100 n

+C4

22 mF

C11

1 mF

Type X2

C13

4.7 nF

Type = Y1

C12

4.7 nF

Type = Y1

C15

680 nF

150

CM1

.u m n. m “In“ an .000... I

NCP1653EVB

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PCB LAYOUT

Figure 3. Component Placement

Figure 4. PCB Layout (Components’ Side)

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GENERAL BEHAVIOR − TYPICAL WAVEFORMS

Vac = 90 V, Pin = 326.5 W, Vout = 365 V, Iout = 822 mA, PF = 0.999, THD = 4 %

Iin: ac line current (CH4 – 10 A/div)

Vout (CH3)

Vin (CH2)

Vpin5 (CH1)

Figure 5.

Vac = 220 V, Pin = 325 W, Vout = 384 V, Iout = 814 mA, PF = 0.989, THD = 8 %

Iin: ac line current (CH4 – 10 A/div)

Vout (CH3)

Vin (CH2)

Vpin5 (CH1)

Figure 6.

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Table 1. THD AND EFFICIENCY AT Vac = 110 V

(W)

Vout

(V)

Iout

(A)

(−)

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

50 100 150 200 250 300 350

THD (%)

Figure 7. THD vs. Pin

Pin (W)

The Total Harmonic Distortion keeps below 10% from

Pmax (maximum power – 300 W) down to about Pmax/5.

50 100 150 200 250 300 350

Efficiency (%)

Figure 8. Efficiency vs. Pin

Pin (W)

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).

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Table 2. THD AND EFFICIENCY AT Vac = 220 V

(W)

Vout

(V)

Iout

(A)

(−)

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

50 100 150 200 250 300 350

THD (%)

Figure 9. THD vs. Pin

Pin (W)

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.

50 100 150 200 250 300 350

Efficiency (%)

Figure 10. Efficiency vs. Pin

Pin (W)

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.

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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

Pout = 0 W, Vac = 230 V

Iin: ac line current (CH3 – 10 A/div)

Vout (CH3)

Vin (CH2)

Vpin5 (CH1)

388V

Figure 11.

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).

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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.

DRV (Vpin7)

Vpin2 (CH3)

(Vcontrol – regulation output)

Vout (CH1)

Vin (CH2)

Figure 12.

[F w

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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:

The power delivered by the power source

(“Pin”)

The power factor (“PF”) and the Total Harmonic

Distortion (“THD”) of the current absorbed

from the ac power source

4. Plug the application to the ac power source.

5. 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%

6. Observe the input current (current drawn from the

ac power source) using a current probe and the

oscilloscope. The current is nearly sinusoidal.

7. 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).

8. 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%

9. 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.

10. Abruptly apply the power source. Check that the

output voltage keeps below 450 V (Over-Voltage

Protection) (see Figure 15).

Figure 13. Test Procedure Schematic

Oscilloscope

Power Analyzer

(e.g., PM1200)

NCP1653 Demo-Board

Input

Socket

+VOUT

−VOUT

VCC GND

+15 V dc

500 W/400 W

Resistive Load

Ground Terminal

of the Probe

High Voltage, Voltage Probe (500 V)

Isolated AC Power

Source

(350 W, 50 or 60 Hz

Sinusoidal Voltage)

Isolated Current Probe

WARNING: The board contains high voltage, hot, live parts. Be very cautious when manipulating or testing it. It is the

responsibility of those who utilize the board, to take all the precautions to avoid that themselves or other people

are injured by electric hazards or are victim of any other pains caused by the board.

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NCP1653EVB

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Figure 14. Over-Current Limitation (Measured @ VAC =75V)

Figure 15. Over-Voltage Protection (Start-Up Sequence @ 220 VAC)

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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 mF, 450 V 20% Radial Vishay BC

Components

2222 159 37101 No Yes

C3, C7, C9 3Polyester Film

Capacitor

100 nF, 100 V 10% Axial AVX BQ014E0104K Yes Ye s

C4 1 Electrolytic

Capacitor

47 mF, 35 V 20% Radial Panasonic ECA1VM470 Yes Yes

C5, C6, C8 3Polyester Film

Capacitor

1 nF, 100 V 10% Axial AVX BQ014E0102K Yes Yes

C11, C15 2Class X2 Capacitor 1 mF, 275 V 20% Axial Evox Rifa PHE840MD7100M No Yes

C12, C13 2Class Y2 Capacitor 4.7 nF, 250 V 20% Disc Vishay Roederstein WYO472MCMCF0KR Yes Yes

R1 1 Axial Resistor 4.5 W, 1/4 W 1% Axial Panasonic ERO−S2PHF4R53 Yes Yes

R2 1 Axial Resistor 470 kW, 1/4 W 1% Axial Vishay Dale CCF55470KFKE36 Yes Yes

R3 1 Axial Resistor 56 kW, 1/4 W 1% Axial Vishay Dale CCF5556K0FKE36 Yes Yes

R4 1 Axial Resistor 4.7 MW, 1/4 W 1% Axial Phoenix Passive

Comp.

2306 242 64705 Yes Ye s

R5, R8 2Axial Resistor 680 kW, 1/4 W 1% Axial Vishay Dale CCF55680KFKE36 Yes Yes

R6 1 Axial Resistor 2.8 kW, 1/4 W 1% Axial Vishay Dale CCF552K80FKE36 Yes Yes

R7 1 Axial Resistor 0.1 W, 1/4 W 1% Axial Vishay Sfernice RLP3 0R10 1% No Yes

R9 1 Axial Resistor 560 kW, 1/4 W 1% Axial Vishay Dale CCF55560KFKE36 Yes Yes

R10 1 Axial Resistor 10 kW, 1/4 W 1% Axial Vishay Dale CCF5510K0FKE36 Yes Yes

R12 1 Strap

(Short Circuit)

− − Through − − Yes Yes

L1 1 PFC Coil 600 mH− − Coilcraft C1062−B No Yes

L4 1 DM Filter 150 mH, 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 KM100−1Yes Yes

4Board Supports − − − Richco TCBS−8−01 Yes Yes

F1 1 Fuse 250 V, 4 A − − Schurter FTT 0034.5049 Ye s Yes

2Thermal Pad

(TO220)

− − − Bergquist 3223−07FR−43 Yes Yes

1Heatsink Clip

(TO218)

− − − Aavid Thermalloy 4473 Yes Yes

2Heatsink Clip

(TO220)

− − − Aavid Thermalloy 4426 Yes Yes

CN1 1 AC Connector − − − Schurter GSF1.1201.31 Yes Yes

J1, GND 2Terminal Block − − Pitch: 5mm Weidmuller 1715250000 Yes Yes

3 Screws − − − − MPMS 003 0008 PH − −

STRAP 1 Strap

(Short Circuit)

− − − 3M 923345−06−CYes Yes

www,cmlcraﬂ.com www mlCrOSgwe com wwwjdk co. guetogou www,egcos.fr www,cree.com/Pmducts/pwv saleszaso www.cree,com/onduc\s/pwr mdex.aSD and J and

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Table 4. VENDORS CONTACTS

Vendor Contact Product Information

CoilCraft −www.coilcraft.com

microSpire −www.microspire.com

TDK Info@tdk.de www.tdk.co.jp/tetop01/

EPCOS −www.epcos.fr/

CREE www.cree.com/Products/pwr_sales2.asp www.cree.com/Products/pwr_index.asp

ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC owns the rights to a number of patents, trademarks,

copyrights, trade secrets, and other intellectual property. A listing of SCILLC’s product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent−Marking.pdf. SCILLC

reserves the right to make changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any

particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without

limitation special, consequential or incidental damages. “Typical” parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications

and actual performance may vary over time. All operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. SCILLC

does not convey any license under its patent rights nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for

surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where

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any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture

of the part. SCILLC is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner.

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