FEB107-001 User's Guide
Contents
1. Figure 1 Photograph of evaluation board Description Condition Min Typ Max Units Input Voltage Vin 85 265 VAC Output Voltage 1 Vour 12 0 V Output Current 1 lout 20 A Power 120 Vac 290 Efficiency 120 Vac 81 Power Factor 120 Vac 98 2005 Fairchild Semiconductor Page 3of 14 Rev 2 0 March 2005 pecu RI FAIRCHILD pum n mcam SEMICONDUCTOR 1 3 FEB107 001 Schematic WWW fairchildsemi com tL crt r rrr LINE Fi 250VAC 1000uH 1 9 4 1 o E i Jia 5A 250V R24 oro 0 47uF 1 QN 250VAC BRI TY I NEUTRAL 4 2204F 0 01 41 2 450V C20 ANE 250VAC 4 CR18 51V Bors C25 Looe y 500V C18 4 7nF R36 220 Ti gt 12V O 291 789 42 1 R26 1 R14 Gr 20k 101112 ena zowF 2 159 5 62M n4 L125uH Jur 12V RET 1k Rie R7 42 2 10 C26 5 62M aw 0 01 500V R5 36 4 PWM Ir GND Vcc 7 Isense llimit R32 3 4 Veao 100 R25 M Book C5 R61 2k 0 01 Bors 615 R9 ca 0 015u2. FAIRCHILD aa SEMICONDUCTOR m www fairchildsemi com FEB107 001 User s Guide 240W PFC PWM Combo Evaluation Board Featured Fairchild Product FAN4803 www fairchildsemi com FEBsupport 2004 Fairchild Semiconductor Page 1 of 14 Rev 2 0 3 2 05 IEEE mil FAIRCHILD SEMICONDUCTOR www fairchildsemi com Contents 1 General Board Description 3 1 1 The contents of FEB107 001 Evaluation Kit a a nm nennen nnne 3 1 2 Power Supply Specification Table 3 1 37 FEBTOZ O0 T Scheimialic s 4 2 Test Pr ced re 5 LE ER M 5 Sal Performance eiecti Einstein eder tardive e ues 5 3 2 Power ROIN GS soenan r E PHE DEN ERE Entente iia US 5 4 FEBT0O7 OOT Evaluation Kit Parts List i eor eee eee eter aene eren E e ede ed 7 Vendors tot yo La KAA 10 Transtormer SEAN u ET 10 6 Printed Circuit 11 621 PGEsSilkscr en II 11 2 Ko Wo UU EO STA ASAS inus 12 7 IA REI m
3. 0 25W Thru Hole 1 R17 Mouser 295J250 3 3k any 14 Resistor 10 K 5 0 25W Thru Hole 4 R19 R21 Mouser 295J250 10k any R22 R23 15 Resistor 510 Ohm 5 0 25W Thru Hole 1 R20 Mouser 295J250 510 any 16 Resistor 470 5 0 5W Thru Hole 1 R24 Mouser 295J500 470k any 17 Resistor 390 K 5 0 25W Thru Hole 1 R25 Mouser 29SJ250 390k any 18 Resistor 20 K 5 3W Metal Oxide Film 2 R26 R27 Panasonic ERG 35J203 Thru Hole 19 Resistor 20 K 5 0 25W Thru Hole 2 R28 R29 Mouser 295J25 20k any 20 Resistor 200 Ohm 5 0 25W Thru Hole 1 R30 Mouser 295J250 200 any 21 Resistor 100 Ohm 5 0 25W Thru Hole 1 R32 Mouser 295J250 100 any 22 Resistor 220 Ohm 5 1W Metal Oxide 1 R36 Panasonic ERG 15J221 Film Thru Hole Yageo RSF100JB 220R 23 Resistor 330 Ohm 5 0 25W Thru Hole 1 R37 Mouser 295J250 330 any 24 Resistor 22 Ohm 5 0 25W Thru Hole 1 R38 Mouser 30BJ250 22 any 25 Resistor 15 K 5 0 25W Thru Hole 1 RAO Mouser 30BJ250 15k any 26 Resistor O Ohm Jumper 11 JP1 JP11 DigiKey 0 00 Yageo ZO 1 4W B Rev 2 0 March 2005 pecu E MR FAIRCHILD SEMICONDUCTOR www fairchildsemi com FEB107 001 Evaluation Kit Parts List continued 2005 Fairchild Semiconductor Page 8 of 14 Item Description Qty Ref Vendor Part Number 27 Thermistor 10 Ohm 5A RMS 1 DigiKey KCOO6L ND Thru Hole Disc Therm
4. have been added as a low impedance path for shunting output common mode currents back to the source through C20 and C19 Although it is not absolutely necessary for a functioning FEB107 001 Evaluation Board it does help to reduce high frequency output noise and improve output voltage regulation The following list some general layout guidelines A Bypass the VCC pin directly to the IC ground pin with a ceramic capacitor located as close as possible to the IC B Return all compensation components directly to the IC ground pin keeping the lead lengths as short as possible C Make sure that low level noise free returns do not share return paths with high level or noisy signals e g gate drive D Isolate and or shield rapidly changing high voltage waveforms from sensitive high impedance circuits such as the timing capacitor PFC current sense input error amplifier input output erc E Star connect all power return paths to the boost output capacitor C1 7 Featured Products 7 1 FAN4803 Description The FAN4803 is a space saving controller for power factor corrected switched mode power supplies that offers very low start up and operating currents Power Factor Correction PFC offers the use of smaller lower cost bulk capacitors reduces power line loading and stress on the switching FETs and results in a power supply fully compliant to IEC1000 3 2 specifications The FAN4803 includes circuits for the implementat
5. DEM 12 FAN48OS Description ce ERE RERREE EXE et te HRS A uium 12 7 1 1 4803 12 8 Resources helerences nhe MAKAA NIA 13 8 1 Application e x 13 2005 Fairchild Semiconductor Page 2 of 14 Rev 2 0 March 2005 Se FAIRCHILD Saree SEMICONDUCTOR 1 General Board Description The FEB107 001 Evaluation Board is a power factor corrected 12V 20A off line power supply It is designed to meet IEC1000 3 2 over the universal input voltage range of 85 to 265VAC The Evaluation Board demon strates that the FAN4803 can be designed with a low cost single sided PCB at a power level size and cost that is compatible with most desk top computer power supply requirements The FAN4803 is the replacement for the M14803 but either IC will work with this board 1 1 Contents of FEB107 001 Evaluation Kit FEB107 001 Evaluation Board FEB107 001 Evaluation Kit Users Guide CD ROM containing the following FEB107 001 Evaluation Kit Users Guide FAN4803 Data Sheet Additional Fairchild data sheets for parts listed on the Bill of Materials Application Note AN 42043 ML 803 240W Off Line Power Supply with PFC Application Note AN 42047 Power Factor Correction PFC Basics 1 2 Power Supply Specification Table www fairchildsemi com
6. 03 Evol Boord Rev Q L XY Figure 4 Fan Position Page 6 of 14 Rev 2 0 March 2005 _ EE y FAIRCHILD ui SEMICONDUCTOR 4 FEB107 001 Evaluation Kit Parts List www fairchildsemi com 2005 Fairchild Semiconductor Page 7 of 14 Item Description Qty Ref Vendor Part Number Resistors Resistor 36 Ohm 5 0 25W Thru Hole 4 R2 R5 R8 Mouser 30BJ250 36 any 2 Resistor 0 15 Ohm 5 Wirewound 1 R3 Huntington Electric ALSR 3J 15 Thru Hole Ohmite 23JR15 3 Resistor 1 K 596 0 25W Thru Hole 2 RA R18 Mouser 29SJ250 1k any 4 Resistor 1 2 Ohm 596 0 25W Thru Hole 1 R Any 5 Resistor 10 Ohm 5 0 25W Thru Hole 2 RZ R31 Mouser 30BJ250 10 any 6 Resistor 1 5 K 596 0 25W Thru Hole 1 R9 Mouser 29SJ250 1 5k any 7 Resistor 0 75 Ohm 5 3W Metal Oxide 1 RIO Panasonic ERX 3SJR75 Film Thru Hole 8 Resistor 150 Ohm 5 0 25W Thru Hole 1 R11 Mouser 295J250 150 any Resistor 5 62 M 1 0 25W Thru Hole 2 R12 R13 Dale 55 5 62 or equivalent 10 Resistor 150 Ohm 596 2W Metal Oxide 1 R14 Yageo RSF200JB 150R Film Thru Hole Panasonic 25 151 11 Resistor 9 09 K 1 0 25W Metal Film 1 R15 Mouser 29MF250 9 09k any Thru Hole 12 Resistor 2 37 K 1 0 25W Metal Film R16 Mouser 29MF250 2 37k any Thru Hole 13 Resistor 3 3 K 5
7. 20 AAVID 2 Ref Q4 AAVID 593002B03400 593002B03400 74 Hardware Heatsink Assembly kit Thermalloy 2 Ref Q3 4 Thermalloy 48805 48805 75 Hardware 4 40 x 25 screws 76 Hardware Ground Plate Paradigm Metals 0 Not supplied Paradigm Metals PLATE ref P O 28678 PLATE ref P O 28678 77 Hardware Round Aluminum 4 40 threaded 4 Digikey J170 ND 0 375 spacers 78 Hardware 6 32 X 0 25 Screw 8 79 FAN4803EVAL P C Board Rev 1 Fairchild Rev B 80 Hardware 4 40 x 375 Philips screws 8 Ref Q3 Q4 4 1 Vendors for parts The components listed in the parts list are available from the following list Future Active Incorporated 800 723 5817 Digi Key Corporation 800 344 4539 Mouser Electronics 800 346 6873 Premier Magnetics 949 452 0511 http www premiermag com Xfmrs Inc 317 834 1066 http www xfmrs com index html Pulse Engineering 619 674 8100 http www pulseeng com default cfm 5 Transformer Specification FEB107 001 Forward Transformer Spec 1 SCHEMATIC DIAGRAM TOP VIEW 7 f Secondary 1 Outside 10 Primary Primary 2 ut Secondary Bias 9 3 odi Secondary Bobbin i 9 Bias pas Primary A 6 0 f Secondary Inside O 12 2005 Fairchild Semiconductor Page 10 of 14 Rev 2 0 March 2005 E AA FAIRCHILD ui SEMICONDUCTOR 2 WINDING SPECIFICATION www fairchildsemi com PIN WIRE TURNS Primary A 2 1 28AWG 84 Secondary
8. 7 8 9 gt 10 11 12 3x10 7 Bias 536 28AWG 4 Primary B 2 1 28AWG 84 3 CORE amp BOBBIN CORE EE4035 BOBBIN EE4035 6 Printed Circuit Board The PCB is a single layer board constructed of FR4 6 1 PCB Silkscreen Figure 3 FEB107 001 PCB top silkscreen 2005 Fairchild Semiconductor Page 11 of 14 Rev 2 0 March 2005 Lae FAIRCHILD SEMICONDUCTOR www fairchildsemi com 6 2 Layout considerations The FEB107 001 Evaluation board contains high impedance low level signals and low impedance high level circuits Consequently it requires extra care in component placement grounding and PC trace routing In order to shield low level circuits from the high level signals the control circuits are placed in surface mount form on the bottom side of the board Since the current sense for the FAN4803 is not differential care must be taken to prevent large di dt across the PCB trace joining the output capacitor and the current sense resistor As the best place to reference the IC is at the output capacitor return potential the most stable potential the difference between this potential and the current sense resistor return potential must be kept to a minimum This is accomplished by starring all 400V return connections to the output capacitor and or starring very low inductive resistive paths from all power devices to the output capacitor return Output common mode capaci tors C23 and C26 along with a ground plane
9. 73 59 Inductor 1 7mH MicroMetals Powered Iron 1 12 Premier Magnetics TSD 1274 60 Ferrite Bead 1 L3 Panasonic EXC ELSA39 61 Transformer 100pH 1 TI XFMRS Inc 4317 00 62 Transformer Gate Drive 450 1 1 1 1 T2 Pulse Engineering P0584 Hardware 63 Fuse 5 A 250 VAC 5 x 20 mm 1 Fl Littlefuse DigiKey Series 216 F921 ND 64 Hardware Fuse Clips PC Mount for 5 x 20 1 F1 ref Littelfuse etc 111501 or equiv mm fuse 65 Hardware 2 Screw terminal Strip 375 Pitch 1 J2 Tyco 3 1437652 5 Molex Beau 71502 Augat RDI LC6 P107 02 RDI 6PCV 02 Augat RDI LC6 P107 02 66 Hardware 0 156 Square 3 Pin Header 1 Molex 26 60 4030 67 Hardware Housing for 0 156 Square 3 Pin 1 Molex 09 50 3031 Header 68 Hardware Terminal for 0 156 Square 3 Pin 0 J1 ref Molex 08 50 0106 Header not supplied 69 Heat Sink 720 High Rise TO 220 AAVID 4 Ref CRT CR2 AAVID 590102B00150 590102B00150 Q2 Q5 70 Hardware 8 32 Lock Washer 8 Ref CR2 Q2 Q5 Rev 2 0 March 2005 pecu E MR FAIRCHILD pum ee SEMICONDUCTOR FEB107 001 Evaluation Kit Parts List continued www fairchildsemi com Item Description Qty Ref Vendor Part Number 71 Heat Sink Tube Berquist 5 400 3 Ref CR1 G2 Berquist SPT400 11 25 11 25 Q5 72 Heat Sink Tube Berquist SPT400 13 5 25 Ref CR2 Berquist 5 400 13 5 25 73 Heat Sink Twisted Fin TO 2
10. F R31 1 5 0 15uF 10 4 4 5 us C23 R29 R28 1 1 R15 20k 20k 0 014F CRI Rio 9 09k 10k Tak R20 4 510 4 Detail Below Figure 2 107 001 Schematic PFC OUT PWM OUT GND Vcc ISENSE ILIMIT VEAO VDC 2005 Fairchild Semiconductor TOP VIEW Figure 3 FAN4803 Pin Configuration Page 4of 14 Rev 2 0 March 2005 pecu E MR FAIRCHILD SEMICONDUCTOR www fairchildsemi com 2 Test Procedure Caution The FEB107 001 Evaluation Board contains voltage potentials capable of causing serious injur y and components which if failing may shatter or explode Please use extreme caution when operating this board The use of protective wear is strongly recommended To safely observe in circuit waveforms an isolation transformer should be inserted between the AC line and the Board Do not operate this Board with AC voltages outside the design limits When replacing components on this Evaluation Board use only those shown in the following parts list Use the following procedure to safely operate the power supply 1 Connect a load active or resistive to the output terminals Set the load to zero amps 2 Connect a DC voltmeter across the output terminals 3 Connect an isolated variable AC source such as a Variac to the AC input connector Line and Neutral with the voltage initially set to zero 4 Adjust the AC input voltage within the range of 85 to 265VAC 5 The output voltag
11. PFC Basics 2005 Fairchild Semiconductor Page 13 of 14 Rev 2 0 March 2005 228 FAIRCHILD SEMICONDUCTOR www fairchildsemi com WARNING AND DISCLAIMER Replace components on the Evaluation Board only with those parts shown on the parts list in the User s Guide Contact an authorized Fairchild representative with any questions The Evaluation board is for demonstration purposes only and neither the Board nor this User s Guide constitute a sales contract or create any kind of warranty whether express of implied as to the applications or products involved Fairchild warranties that its products will meet Fairchild s published specifications but does not guarantee that its products will work in any specific application Fairchild reserves the right to makes changes without notice to any products described herein to improve reliability function or design Either the applicable sales contract signed by Fairchild and Buyer or if no contract exists Fairchild s Stand Terms and Conditions on the back of Fairchild invoices govern the terms of sale of the products described herein LIFE SUPPORT POLICY FAIRCHILD S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF FAIRCHILD SEMICONDUCTOR CORPORATION As used herein 1 Life support devices or systems are devices or 2 A critical component is any component of a life systems which a are in
12. RT Vox 2005 Fairchild Semiconductor Page 14 of 14 Rev 2 0 March 2005
13. e should read 12VDC 1 6 Increase the load to 19 5A The output as measured at the output terminals should regulate within 0 1 of the nominal reading The ripple voltage should read less than 30mV RMS 7 The input power factor should be greater than 0 95 Efficiency should be greater than 80 8 Reduce the AC input to zero and verify that the output voltage drops to zero 3 Test Results 3 1 Performance Data To measure the Evaluation Board performance across the range of permissible input voltages use an isolated Variac or adjustable AC source A typical FEB107 001 Evaluation Board will have the performance characteris tics shown in Table 1 when operated under the test conditions listed Table 1 Performance data 3 2 Power Ratings Input 85VAC 120VAC 230VAC 265VAC Units Efficiency 63 81 68 82 76 0 99 0 98 0 96 0 97 Power 50 290 50 290 W The FEB107 001 Evaluation Board is designed to deliver up to 240 Watts at 85VAC when used with a properly rated and positioned cooling fan The power rating without a fan is limited to 150 Watts A 12V fan can be placed as suggested in Figure 1 and operated from the evaluation board 12V output 2005 Fairchild Semiconductor Page 5 of 14 Rev 2 0 March 2005 Se FAIRCHILD Sey SEMICONDUCTOR 2005 Fairchild Semiconductor www fairchildsemi com FAN 4 75 sq x 1 25 thick 197 2 a FAN48
14. ion of a leading edge average current boost type PFC and a trailing edge PWM The FAN4803 1 s PFC and PWM operate at the same frequency 67kHz The PFC frequency of the FAN4803 2 is automatically set at half that of the 134kHz PWM This higher frequency allows the user to design with smaller PWM components while maintaining the optimum operating frequency for the PFC An overvoltage comparator shuts down the PFC section in the event of a sudden decrease in load The PFC section also includes peak current limiting for enhanced system reliability 7 1 1 FAN4803 Features Internally synchronized PFC and PWM in one 8 pin IC Patented one pin voltage error amplifier with advanced input current shaping technique Peak or average current continuous boost leading edge PFC Input Current Shaping Technology High efficiency trailing edge current mode PWM Low supply currents start up 150pA typ operating 2mA typ Synchronized leading and trailing edge modulation 2005 Fairchild Semiconductor Page 12 of 14 Rev 2 0 March 2005 iii FAIRCHILD SEMICONDUCTOR www fairchildsemi com Reduces ripple current in the storage capacitor between the PFC and PWM sections Overvoltage UVLO and brownout protection PFC VccOVP with PFC Soft Start 8 Resources References 8 1 Application Notes Application Note AN 42043 ML4803 240W Off Line Power Supply with Application Note AN 42047 Power Factor Correction
15. oDisc F503EL THERMOMETRICS INC CL 50 Capacitors 28 Capacitor 220yF 20 450VDC Ci Panasonic ECO S2WB221CA Electrolytic Radial 29 Capacitor 2200pF 20 16VDC C2 Panasonic ECA 1 CFQ222 Electrolytic Radial 30 Capacitor 1yF 20 50VDC Z5U Radial 5 C3 C6 C9 Panasonic ECU S1H105MEB C21 C22 31 Capacitor 0 47pF 20 250VDC Film 1 CA Panasonic ECQ E2A474MW Radial 32 Capacitor 0 01 pF 20 5 250 3 C5 C23 C29 Panasonic ECU S1H103MEB Radial 33 Capacitor 0 1pF 20 50VDC 250 Radial 3 C7 C12 C17 Panasonic ECU S1H104MEB 34 Capacitor 0 15 10 100VDC XZR C8 Panasonic ECU S1H154KBB Radial 35 Capacitor 0 01pF 10 5OVDC XZR C10 Panasonic ECU S1H103KBA Radial 36 Capacitor 1000 20 25VDC 1 Cll Panasonic ECA 1EM102 Electrolytic Radial 37 Capacitor InF 10 100VDC X7R Radial 1 C13 Panasonic ECU S1H102KBB 38 Capacitor 4 7nF 10 25VDC Film Radial 1 C14 Panasonic ECS F1EE475K 39 Capacitor 15nF 10 100VDC X7R Radial 1 C15 Panasonic ECU S1H153KBB 40 Capacitor 0 01 pF 10 500VDC Ceramic C16 C25 Panasonic ECK D2H103KB5 Radia C26 41 Capacitor 4 7nF 1076 100VDC X7R 1 C18 Panasonic ECU S1H472KBB Radia 42 Capacitor 4 7nF 10 250VDC Film 2 C19 C20 Panasonic ECQ U2A472MV Radia 43 Capacitor 0 01nF 10 25VDC Ceramic 1 C27 Panasonic ECK F1E103ZV Radia 44 Capacitor 25VDC 250 1206 C28 Any Surface Mount Semiconductors 45 Bipolar Transi
16. stor PNP TO 92 FSID Ql Fairchild 2N3906 2N3906 46 MOSFET 0 85Ohm 500V TO 220 4 Q2 Q4 Fairchild Fairchild HGTP3N60A4D Q5 IRF840B 47 Diode Bridge Rectifier 600V 4A KBL FSID 1 BR Fairchild KBLO KBLO 48 Diode HyperFast 600V 4A 20ns 1 CRI Fairchild 1519 460 2 TO 220AC FSID 15198460 2 Rev 2 0 March 2005 pecu E MR FAIRCHILD SEMICONDUCTOR www fairchildsemi com FEB107 001 Evaluation Kit Parts List continued 2005 Fairchild Semiconductor Page 9 of 14 Item Description Qty Ref Vendor Part Number 49 Diode Schottky 60V 30A TO 247 FSID 1 CR2 Fairchild MBR3060PT MBR3060PT 50 Diode Ultra Fast 600V 1A 75ns 2 CR3 CRA Fairchild UFA005 DO 41 FSID UF4005 51 Diode Zener 16V 0 5W DO 35 FSID 2 CR5 CR9 Fairchild 1N5246B 1N5246B 52 Diode Schottky 30V 1A DO 41 FSID 4 CR7 CR10 Fairchild 1N5818 1N5818 CR11 CR12 53 Diode Signal 75V W DO 35 FSID 3 CR8 CR15 Fairchild 1N4148 1N4148 CR16 54 Diode Transorb 51V W DO 15 FSID 1 CR18 Fairchild P6KE51CA P6KE51CA 55 IC PFC PWM Combo DIP FSID Ul Fairchild FAN4803CP 1 FAN4803CP 1 56 IC Shunt Regulator 92 FSID TL431CLP 1 U2 Fairchild TL431CLP 57 IC Optolsolator DIP 6 FSID MOC8102 U3 Fairchild MOC8102 Fairchild MOC8112 Magnetics 58 Inductor 91pH MicroMetals Powered 1 LI Premier Magnetics TSD 12
17. tended for surgical implant into support device or system whose failure to perform can the body or b support or sustain life or c whose be reasonably expected to cause the failure of the life failure to perform when properly used in accordance support device or system or to affect its safety or with instructions for use provided in the labeling can be effectiveness reasonably expected to result in significant injury to the user TRADEMARKS The following are registered and unregistered trademarks Fairchild Semiconductor owns or is authorized to use and is not intended to be an exhaustive list of all such trademarks ACEx FAST IntelliMAX POP SPM ActiveArray FASTr ISOPLANAR Power247 Stealth Bottomless FPS LittleFET PowerEdge SuperFET CoolFET FRFET MICROCOUPLER PowerSaver SuperSOT 3 CROSSVOLT GlobalOptoisolator MicroFET PowerTrench SuperSOT 6 DOME GTO MicroPak QFET SuperSOT 8 EcoSPARK HiSeC MICROWIRE Qs SyncFET E CMOS MSX QT Optoelectronics TinyLogic EnSigna i Lo MSXPro Quiet Series TINYOPTO FACT ImpliedDisconnect OCX RapidConfigure TruTranslation FACT Quiet Series OCXPro RapidConnect UHC Across the board Around the world OPTOLOGIC uSerDes UltraFET The Power Franchise OPTOPLANAR SILENT SWITCHER UniFET Programmable Active Droop PACMAN SMART STA
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