User Guide for FEBFAN9673Q_B1H5000A Evaluation Board 5 kW Three-Channel CCM PFC with 12 VSB Module Evaluation Board Featured Fairchild Product: FAN9673Q Direct questions or comments about this evaluation board to: "Worldwide Direct Support" Fairchild Semiconductor.com (c) 2013 Fairchild Semiconductor Corporation 1 FEBFAN9673Q_B1H5000A * Rev. 1.3 Table of Contents 1. Introduction ............................................................................................................................... 3 1.1. Features ............................................................................................................................ 3 2. Evaluation Board Specifications ............................................................................................... 3 3. Photograph ................................................................................................................................ 4 4. Printed Circuit Board ................................................................................................................ 5 5. Schematic .................................................................................................................................. 8 6. Bill of Materials ...................................................................................................................... 10 7. Transformer and Winding Specifications ............................................................................... 13 7.1. 7.2. 7.3. 7.4. TX2 Specification .......................................................................................................... 13 L1 & L2 Specification .................................................................................................... 14 L3, L4, & L5 Specification ............................................................................................ 15 L11 Specification ........................................................................................................... 16 8. Test Conditions & Test Equipment......................................................................................... 17 8.1. Features .......................................................................................................................... 17 8.2. Test Procedure ................................................................................................................ 17 9. Performance of Evaluation Board ........................................................................................... 18 9.1. 9.2. 9.3. 9.4. 9.5. AC Trim Up & Trim Down............................................................................................ 18 PFC ON / OFF & RDY .................................................................................................. 18 Ripple & Noise ............................................................................................................... 19 Efficiency ....................................................................................................................... 19 Current Harmonic ........................................................................................................... 20 10. Notice Letter ........................................................................................................................... 24 11. Safety Precautions ................................................................................................................... 25 12. Revision History ..................................................................................................................... 26 (c) 2013 Fairchild Semiconductor Corporation 2 FEBFAN9673Q_B1H5000A * Rev. 1.3 This user guide supports the 5000 W evaluation board for a three-channel CCM PFC using the FAN9673. It should be used in conjunction with the FAN9673 datasheet as well as Fairchild's application notes and technical support team. Please visit Fairchild's website at www.fairchildsemi.com/. 1. Introduction The FAN9673 is a 32-pin, Continuous Conduction Mode (CCM) Power Factor Correction (PFC) controller IC intended for PFC pre-regulators. The FAN9673 includes average current and boost-type power factor correction, which results in a power supply that fully complies with the IEC1000-3-2 specification. A TriFault DetectTM function helps reduce external components and provides full protection for feedback loops, such as over voltage. An over-voltage comparator shuts down the PFC stage in the event of a sudden load decrease. The RDY signal can be used for power-on sequence control. The Channel Management (CM) function can enable / disable the each channel independently. The FAN9673 also includes PFC soft-start, peak current limiting, and input voltage brown-in/out protection. 1.1. Features Continuous Conduction Mode Control Maximum Three-Channel PFC Control Average Current Mode Control PFC Slave Channels External Signal / Channel Management Function Control Programmable Operation Frequency Range: 18 kHz~40 kHz or 55 kHz~75 kHz Programmable PFC Output Voltage Two Types of Current Limit TriFault DetectTM Protects Against Feedback Loop Failure SAG Protection Programmable Soft Start Under-Voltage Lockout (UVLO) Differential Current Sensing Available in 32-Pin LQFP Package 2. Evaluation Board Specifications All data for this table was measured at an ambient temperature of 25C. Table 1. Summary of Features and Performance Description Symbol Value Output Power PO 5 kW Efficiency Eff, >95% Input Voltage VAC 180~264 V Input Frequency 47~63 Hz Output Voltage VOUT, VPFC 393 V Brown In / Out Voltage VAC 170 V / 155 V PFC Frequency fSW 40 kHz VRDY 2.4 V / 1.55 V (96% / 62% of VPFC) PFC RDY (c) 2013 Fairchild Semiconductor Corporation Comments 3 VPVO=0 V FEBFAN9673Q_B1H5000A * Rev. 1.3 3. Photograph Output AC Input Figure 1. Top View of Evaluation Board (c) 2013 Fairchild Semiconductor Corporation 4 FEBFAN9673Q_B1H5000A * Rev. 1.3 4. Printed Circuit Board Figure 2. Top Side of Evaluation Board (c) 2013 Fairchild Semiconductor Corporation 5 FEBFAN9673Q_B1H5000A * Rev. 1.3 Figure 3. Bottom Side of Evaluation Board (c) 2013 Fairchild Semiconductor Corporation 6 FEBFAN9673Q_B1H5000A * Rev. 1.3 Figure 4. Top Side of Daughter Card Figure 5. Bottom Side of Daughter Card (c) 2013 Fairchild Semiconductor Corporation 7 FEBFAN9673Q_B1H5000A * Rev. 1.3 5. Schematic Figure 6. (c) 2013 Fairchild Semiconductor Corporation Evaluation Board Schematic 8 FEBFAN9673Q_B1H5000A * Rev. 1.3 Figure 7. (c) 2013 Fairchild Semiconductor Corporation Daughter Card Schematic 9 FEBFAN9673Q_B1H5000A * Rev. 1.3 6. Bill of Materials Main Board (PLM281 REV.2) Reference Qty. Part Number Value BD1, BD2, BD3 3 GBPC5006 PLM0276AV0 x3 3 C1, C2, C5 3 1 F / 275 V C10 1 1 F / 450 V C12, C13, C14 3 680 F / 450 V C16 1 47 nF / 50 V C18 1 1 nF / 1 kV C19 1 0.1 F Manufacturer Transfer Card for Bridge C20 1 4.7 F / 50 V C21, C25 2 22 F/ 50 V C22, C23 2 330 F / 25 V C24 1 10 nF / 50 V C3, C4 2 2.2 pF / 250 V C8 1 10 F / 25 V C9 1 1 nF / 1 kV CON18 CN1 1 D1, D2 2 S1J D11 1 UF1007 D13 1 1N4935 D14 1 EGP30D D3, D4 2 1N5406 D5, D7, D9, D12 4 1N4148 D6, D8, D10 3 FFH30S60STU F1 1 Slow Blow Fuse HS1 1 H-sink HS2, HS3, HS4 3 H-sink L1, L2 2 FS4015H-2LB L3, L4, L5 3 Core Type: QP3925H L6 1 10 H M1 1 MOV Q1 1 2N7002A Q2, Q5, Q8 3 2222A Q3, Q6, Q9 3 2907 FGH40N60SMDF Fairchild Fairchild Fairchild 40 A / 250 V EMI FORMOSA SHING GA ENTERPRISE CO., LTE. 100 H Q4, Q7, Q10 3 R1, R2, R4, R5, R6 5 1 M R11, R21, R31 3 470 R12, R22, R32 3 20 (c) 2013 Fairchild Semiconductor Corporation Description Fairchild 10 FEBFAN9673Q_B1H5000A * Rev. 1.3 Main Board (PLM281 REV.2) Reference Qty. R13, R23, R33 3 12 R14, R24, R34, R42 4 10 k 6 30 m / 2 W 6 470 1 1.5 M R15, R16, R25, R26, R35, R36 R18, R19, R28, R29, R38, R39 R20 Part Number Value R3 1 20 R41 1 38.3 k R43 1 20 k R44 1 560 Description Manufacturer R48 1 3.9 k R49, R50, R52 3 0 R51 1 100 k R7 1 5.1 M R8 1 4.7 M R9A, R10 2 2.2 M Relay1 1 Power Relay TX1 1 750342371 12 VSB Transformer Wurth Elektronik U1 1 FSL126HR Controller Fairchild U2 1 PC-817 U3 1 TL431 40 A Daughter Card (PLM0177A REV.6) Reference Qty. Part Number Value C35, C40, C41, C42, C51, C54 6 SMD 0805 0.01 F C38 1 SMD 0805 0.047 F C31, C33, C43, C44, C61 5 SMD 0805 0.1 F C36, C37, C39, C52, C53 5 SMD 0805 0.47 F C45, C47, C49 3 SMD 0805 1.2 nF C46, C48, C50, C62 4 SMD 0805 100 pF C32 1 Manufacturer 10 / 50 V C13, C14, C15 3 SMD 0805 2.2 nF C55, C56, C57, C58, C59, C60 6 SMD 0805 2.2 nF C34, C63, C64 1 SMD 0805 470 pF CN1 1 D11 1 (c) 2013 Fairchild Semiconductor Corporation Description CON14 1N4148 11 FEBFAN9673Q_B1H5000A * Rev. 1.3 Daughter Card (PLM0177A REV.6) Reference Qty. Part Number U1 1 FAN9673 Value U2 1 LM358D R56, R65, R72, R71 4 SMD 0805 0 R60 1 SMD 0805 10 k R73 1 SMD 0805 12.1 k R55 1 SMD 0603 16.2 k R62, R63, R64 3 SMD 0805 17.4 k R69 1 SMD 0805 43 k R54 1 SMD 0805 200 k R59 1 SMD 0805 20 k VR1 1 SMD 0805 20 k R52 1 SMD 0805 23.7 k R57 1 SMD 0805 30 k R58 1 SMD 0805 38.3 k R61 1 SMD 0805 4.7 k Manufacturer Controller Fairchild Fairchild R68 1 SMD 0805 470 k R66, R67, R70 3 SMD 0805 47 k R53 1 SMD 0805 75 k S1 1 DIP-4 (c) 2013 Fairchild Semiconductor Corporation Description Switch 12 FEBFAN9673Q_B1H5000A * Rev. 1.3 7. Transformer and Winding Specifications 7.1. TX2 Specification Core: EE-16 (3C94) Bobbin: 10 Pins Figure 8. Transformer Specifications & Construction Table 2. Winding Specifications No. Winding Pin (S F) Wire Turns Winding Method 1 N1 32 0.29x1 36 Solenoid Winding 10 Solenoid Winding 18 Solenoid Winding 13 Solenoid Winding 2 Insulation: Polyester Tape t = 0.025 mm, 3-Layer 3 4 N2 0.35x3 Insulation: Polyester Tape t = 0.025 mm, 3-Layer 5 6 10 8 N1 21 0.29x1 Insulation: Polyester Tape t = 0.025 mm, 6-Layer 7 N3 56 0.15x1 8 Insulation: Polyester Tape t = 0.025 mm, 3-Layer 9 Copper-Foil 1.2T to PIN6 Table 3. Electrical Characteristics Inductance (c) 2013 Fairchild Semiconductor Corporation 13 Pins Specifications 3-1 800 H 5% FEBFAN9673Q_B1H5000A * Rev. 1.3 7.2. L1 & L2 Specification (c) 2013 Fairchild Semiconductor Corporation 14 FEBFAN9673Q_B1H5000A * Rev. 1.3 7.3. L3, L4, & L5 Specification Core: QP3925H (3C94) Bobbin: 7 Pins Figure 9. Transformer Specifications & Construction Table 4. No. Winding Specifications Winding Pin (S F) Wire Turns Winding Method N1 1 6, 7 0.2x35 *1 25 Solenoid Winding 1 2 Insulation: Polyester Tape t = 0.025 mm, 2-Layer 3 Copper-Foil 1.2T to PIN4, 5 Table 5. Electrical Characteristics Inductance (c) 2013 Fairchild Semiconductor Corporation 15 Pin Specifications 1 6, 7 100 H 5% FEBFAN9673Q_B1H5000A * Rev. 1.3 7.4. L11 Specification Core: Ferrite core DRWW 6x10(6*10 mm) Bobbin: 2 Pins Figure 10. Transformer Specifications & Construction Table 6. Winding Specifications No. Winding Pin (S F) Wire Turns Winding Method 1 N1 12 0.55 mm 18 Solenoid Winding 2 Table 7. Ferrite core DRWW 6x10 (6*10 mm) Electrical Characteristics Inductance (c) 2013 Fairchild Semiconductor Corporation 16 Pin Specifications 1-2 10 H 5% FEBFAN9673Q_B1H5000A * Rev. 1.3 8. Test Conditions & Test Equipment 8.1. Features Table 8. Test Conditions & Test Equipment Test Mode FEBFAN9673Q_B1H5000A Test Date Nov.4, 2013 Test Temperature Ambient 25C AC Source: EXTECH 6220 AC/DC Electronic Load: Chroma 63020 Power Meter: HIOKI 3390 Oscilloscope: Lecroy Wavesurfer 424 Test Equipment 1. AC Trim Up & Trim Down 2. PFC ON/OFF & RDY 3. Ripple & Noise 4. Efficiency 5. Current Harmonic Test Items 8.2. Test Procedure Before powering up the board, verify that the AC voltage source is connected to line input terminals on the evaluation board and the AC-DC electronic load is connected to the PFC output. 1. Set the electronic load to no-load or light-load condition and apply the AC voltage across the input of the evaluation board. 2. When the AC voltage (180~264 VAC) is supplied to the board, the FAN9673 begins normal operation and the on-board flyback converter provides the 12 VSB output. The Flyback transformer's auxiliary winding supplies the VDD voltage for the FAN9673 to power up the PFC stage. 3. PFC startup is controlled by the VEA level. Prior to the soft-start voltage reaching 6 V, the VEA level is limited by soft start. 4. After the bulk capacitor or PFC output voltage reaches the steady-state value, 392 V, the load condition of the electronic load can be changed to test system performance. Hint: 1. It is recommended that an external fan be added to help dissipate the heat on the NTC, IGBT, diode, and bridge on the evaluation board. (c) 2013 Fairchild Semiconductor Corporation 17 FEBFAN9673Q_B1H5000A * Rev. 1.3 9. Performance of Evaluation Board 9.1. AC Trim Up & Trim Down Test Condition: Switch the input voltage from 180 V to 264 V or from 264 V to 180 V, the output voltages should be normal and the output of PFC bus should be less than 450 V. Test Result: CH1: VVEA CH3: VPFC CH4: VBridge+ Figure 11. 180 V264 V 5000 W Load Figure 12. 264 V180 V 5000 W Load 9.2. PFC ON / OFF & RDY Test Result: CH1: VRDY CH3: VPFC CH4: VBridge+ Figure 13. (c) 2013 Fairchild Semiconductor Corporation PFC ON 18 Figure 14. PFC OFF FEBFAN9673Q_B1H5000A * Rev. 1.3 9.3. Ripple & Noise Test Result: CH3: VPFC Figure 15. 180 V / 50 Hz Figure 16. 264 V / 50 Hz 9.4. Efficiency Test Condition: Measure efficiency at min., mid., and max. loading. Test Result: FAN9673 Input Watts (W) A. VIN=180 V at 25% Load 1295 1250 96.5% B. VIN=180 V at 50% Load 2590 2500 96.5% C. VIN=180 V at 75% Load 3885 3750 96.5% D. VIN=180 V at 100% Load 5195 5000 96.2% E. VIN=220 V at 25% Load 1288 1250 97.0% F. VIN=220 V at 50% Load 2573 2500 97.1% G. VIN=220 V at 75% Load 3856 3750 97.2% H. VIN=220 V at 100% Load 5149 5000 97.1% I. VIN=264 V at 25% Load 1280 1250 97.6% J. VIN=264 V at 50% Load 2553 2500 97.9% K. VIN=264 V at 75% Load 3836 3750 97.7% L. VIN=264 V at 100% Load 5122 5000 97.6% (c) 2013 Fairchild Semiconductor Corporation 19 Output Watts (W) Efficiency FEBFAN9673Q_B1H5000A * Rev. 1.3 9.5. Current Harmonic Test Results: FAN9673 Input Voltage Condition PF THD (%) 25% Load 0.9912 10.55 50% Load 0.9947 9.17 75% Load 0.9971 6.62 100% Load 0.9974 6.40 25% Load 0.9800 14.32 50% Load 0.9868 14.36 75% Load 0.9905 12.55 100% Load 0.9924 11.26 25% Load 0.9365 25.85 50% Load 0.9369 33.22 75% Load 0.9526 29.59 100% Load 0.9600 27.29 180 V / 50 Hz 220 V / 50 Hz 264 V / 50 Hz (c) 2013 Fairchild Semiconductor Corporation 20 FEBFAN9673Q_B1H5000A * Rev. 1.3 180 V / 50 Hz Input Current Waveform & Harmonic Figure 17. 25% Load Figure 18. 50% Load Figure 19. 75% Load Figure 20. 100% Load (c) 2013 Fairchild Semiconductor Corporation 21 FEBFAN9673Q_B1H5000A * Rev. 1.3 220 V / 50 Hz Input Current Waveform & Harmonic Figure 21. 25% Load Figure 22. 50% Load Figure 23. 75% Load Figure 24. 100% Load (c) 2013 Fairchild Semiconductor Corporation 22 FEBFAN9673Q_B1H5000A * Rev. 1.3 264 V / 50 Hz Input Current Waveform & Harmonic (c) 2013 Fairchild Semiconductor Corporation 23 Figure 25. 25% Load Figure 26. 50% Load Figure 27. 75% Load Figure 28. 100% Load FEBFAN9673Q_B1H5000A * Rev. 1.3 10. Notice Letter To properly operate the high-power interleaved CCM PFC evaluation board, cooling fans must be enabled to remove the heat from switching IGBTs and diodes. The fans are usually set up as shown in the following picture. Figure 29. Recommended Fan Setup Note: 2. Fans are not provided with the evaluation board. Supply fans for testing. (c) 2013 Fairchild Semiconductor Corporation 24 FEBFAN9673Q_B1H5000A * Rev. 1.3 11. Safety Precautions Before applying power to the FEBFAN9673Q_B1H5000A evaluation board, it is imperative that all involved personnel read and understand the safety precautions and understand the power on/off procedures. The FEBFAN9673Q_B1H5000A evaluation board operates at lethal voltages and has bulk capacitors that store significant charge. Accidental contact can lead to lab equipment damage, personnel injury, and may be fatal. Be exceptionally careful when probing and handling this board. Always observe normal laboratory precautions, including: A. All connected computers and measurement equipment MUST be isolated from the AC mains before operating voltages are applied to the board. Alternatively, AC/DC power to the board may be isolated. B. When using an oscilloscope with this board, it must be isolated from the AC line. Alternatively, high-voltage (700 V+) isolated probes may be utilized. C. Start with a clean working surface, clear of any conductive material. D. Be careful while turning on the power switch to the AC source. E. Never probe or move a probe on the board while the AC line voltage is present. F. Ensure the bulk capacitors are discharged before disconnecting the high power load. Note: 3. Even when a computer is isolated from AC mains through external supply, a connection to earth-potential may exist through LAN, VGA, or other connections to peripherals. (c) 2013 Fairchild Semiconductor Corporation 25 FEBFAN9673Q_B1H5000A * Rev. 1.3 12. Revision History Rev. Date Description 1.0.0 Jan 2014 Initial release 1.0.1 April 2014 Update to BOM 1.0.2 July 2014 Update to BOM 1.3 March 2014 Updated Part number to FEBFAN9673Q_B1H5000A WARNING AND DISCLAIMER Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Users' Guide. Contact an authorized Fairchild representative with any questions. This board is intended to be used by certified professionals, in a lab environment, following proper safety procedures. Use at your own risk. The Evaluation board (or kit) 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 or implied, as to the applications or products involved. Fairchild warrantees that its products meet Fairchild's published specifications, but does not guarantee that its products work in any specific application. Fairchild reserves the right to make 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 standard Terms and Conditions on the back of Fairchild invoices, govern the terms of sale of the products described herein. 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 FAIRCHILD'S 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 reasonably expected to result in significant injury to the user. 2. A critical component is any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness. ANTI-COUNTERFEITING POLICY Fairchild Semiconductor Corporation's Anti-Counterfeiting Policy. Fairchild's Anti-Counterfeiting Policy is also stated on our external website, www.fairchildsemi.com, under Sales Support. Counterfeiting of semiconductor parts is a growing problem in the industry. All manufacturers of semiconductor products are experiencing counterfeiting of their parts. Customers who inadvertently purchase counterfeit parts experience many problems such as loss of brand reputation, substandard performance, failed applications, and increased cost of production and manufacturing delays. Fairchild is taking strong measures to protect ourselves and our customers from the proliferation of counterfeit parts. Fairchild strongly encourages customers to purchase Fairchild parts either directly from Fairchild or from Authorized Fairchild Distributors who are listed by country on our web page cited above. Products customers buy either from Fairchild directly or from Authorized Fairchild Distributors are genuine parts, have full traceability, meet Fairchild's quality standards for handling and storage and provide access to Fairchild's full range of up-to-date technical and product information. Fairchild and our Authorized Distributors will stand behind all warranties and will appropriately address any warranty issues that may arise. Fairchild will not provide any warranty coverage or other assistance for parts bought from Unauthorized Sources. Fairchild is committed to combat this global problem and encourage our customers to do their part in stopping this practice by buying direct or from authorized distributors. EXPORT COMPLIANCE STATEMENT These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations for the ultimate destination listed on the commercial invoice. Diversion contrary to U.S. law is prohibited. U.S. origin products and products made with U.S. origin technology are subject to U.S Re-export laws. In the event of re-export, the user will be responsible to ensure the appropriate U.S. export regulations are followed. (c) 2013 Fairchild Semiconductor Corporation 26 FEBFAN9673Q_B1H5000A * Rev. 1.3