FEBFAN9673Q_B1H5000A - ON SEMICONDUCTOR

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

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. TX2 Specification .......................................................................................................... 13

7.2. L1 & L2 Specification .................................................................................................... 14

7.3. L3, L4, & L5 Specification ............................................................................................ 15

7.4. 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. AC Trim Up & Trim Down............................................................................................ 18

9.2. PFC ON / OFF & RDY .................................................................................................. 18

9.3. Ripple & Noise ............................................................................................................... 19

9.4. Efficiency ....................................................................................................................... 19

9.5. Current Harmonic ........................................................................................................... 20

10. Notice Letter ........................................................................................................................... 24

11. Safety Precautions ................................................................................................................... 25

12. Revision History ..................................................................................................................... 26

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 Detect™ 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 Detect™ 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 25°C.

Table 1. Summary of Features and Performance

Description

Symbol

Value

Comments

Output Power

PO

5 kW

Efficiency

Eff, η

>95%

Input Voltage

VAC

180~264 V

Input Frequency

47~63 Hz

Output Voltage

VOUT, VPFC

393 V

VPVO=0 V

Brown In / Out Voltage

VAC

170 V / 155 V

PFC Frequency

fSW

40 kHz

PFC RDY

VRDY

2.4 V / 1.55 V

(96% / 62% of VPFC)

3. Photograph

Figure 1. Top View of Evaluation Board

Output

AC Input

4. Printed Circuit Board

Figure 2. Top Side of Evaluation Board

Figure 3. Bottom Side of Evaluation Board

Figure 4. Top Side of Daughter Card

Figure 5. Bottom Side of Daughter Card

5. Schematic

Figure 6. Evaluation Board Schematic

Figure 7. Daughter Card Schematic

6. Bill of Materials

Main Board (PLM281 REV.2)

Reference

Qty.

Part Number

Value

Description

Manufacturer

BD1, BD2, BD3

3

GBPC5006

PLM0276AV0 x3

3

Transfer Card for

Bridge

C1, C2, C5

3

1 µF / 275 V

C10

1

1 µF / 450 V

C12, C13, C14

3

680 µF / 450 V

C16

1

47 nF / 50 V

C18

1

1 nF / 1 kV

C19

1

0.1 µF

C20

1

4.7 µF / 50 V

C21, C25

2

22 µF/ 50 V

C22, C23

2

330 µF / 25 V

C24

1

10 nF / 50 V

C3, C4

2

2.2 pF / 250 V

C8

1

10 µF / 25 V

C9

1

1 nF / 1 kV

CN1

1

CON18

D1, D2

2

S1J

D11

1

UF1007

D13

1

1N4935

Fairchild

D14

1

EGP30D

D3, D4

2

1N5406

Fairchild

D5, D7, D9, D12

4

1N4148

D6, D8, D10

3

FFH30S60STU

Fairchild

F1

1

Slow Blow Fuse

40 A / 250 V

HS1

1

H-sink

HS2, HS3, HS4

3

H-sink

L1, L2

2

FS4015H-2LB

EMI

FORMOSA SHING GA

ENTERPRISE CO., LTE.

L3, L4, L5

3

Core Type:

QP3925H

100 µH

L6

1

10 µH

M1

1

MOV

Q1

1

2N7002A

Q2, Q5, Q8

3

2222A

Q3, Q6, Q9

3

2907

Q4, Q7, Q10

3

FGH40N60SMDF

Fairchild

R1, R2, R4, R5, R6

5

1 MΩ

R11, R21, R31

3

470 Ω

R12, R22, R32

3

20 Ω

Main Board (PLM281 REV.2)

Reference

Qty.

Part Number

Value

Description

Manufacturer

R13, R23, R33

3

12 Ω

R14, R24, R34, R42

4

10 kΩ

R15, R16, R25, R26,

R35, R36

6

30 mΩ / 2 W

R18, R19, R28, R29,

R38, R39

6

470 Ω

R20

1

1.5 MΩ

R3

1

20 Ω

R41

1

38.3 kΩ

R43

1

20 kΩ

R44

1

560 Ω

R48

1

3.9 kΩ

R49, R50, R52

3

0 Ω

R51

1

100 kΩ

R7

1

5.1 MΩ

R8

1

4.7 MΩ

R9A, R10

2

2.2 MΩ

Relay1

1

Power Relay

40 A

TX1

1

750342371

12 VSB

Transformer

Würth Elektronik

U1

1

FSL126HR

Controller

Fairchild

U2

1

PC-817

U3

1

TL431

Daughter Card (PLM0177A REV.6)

Reference

Qty.

Part Number

Value

Description

Manufacturer

C35, C40, C41, C42,

C51, C54

6

SMD 0805

0.01 μF

C38

1

SMD 0805

0.047 μF

C31, C33, C43, C44,

C61

5

SMD 0805

0.1 μF

C36, C37, C39, C52,

C53

5

SMD 0805

0.47 μF

C45, C47, C49

3

SMD 0805

1.2 nF

C46, C48, C50, C62

4

SMD 0805

100 pF

C32

1

10 μ / 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

CON14

D11

1

1N4148

Daughter Card (PLM0177A REV.6)

Reference

Qty.

Part Number

Value

Description

Manufacturer

U1

1

FAN9673

Controller

Fairchild

U2

1

LM358D

Fairchild

R56, R65, R72, R71

4

SMD 0805

0 Ω

R60

1

SMD 0805

10 kΩ

R73

1

SMD 0805

12.1 kΩ

R55

1

SMD 0603

16.2 kΩ

R62, R63, R64

3

SMD 0805

17.4 kΩ

R69

1

SMD 0805

43 kΩ

R54

1

SMD 0805

200 kΩ

R59

1

SMD 0805

20 kΩ

VR1

1

SMD 0805

20 kΩ

R52

1

SMD 0805

23.7 kΩ

R57

1

SMD 0805

30 kΩ

R58

1

SMD 0805

38.3 kΩ

R61

1

SMD 0805

4.7 kΩ

R68

1

SMD 0805

470 kΩ

R66, R67, R70

3

SMD 0805

47 kΩ

R53

1

SMD 0805

75 kΩ

S1

1

DIP-4

Switch

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

3 → 2

0.29φ×1

36

Solenoid Winding

2

Insulation: Polyester Tape t = 0.025 mm, 3-Layer

3

N2

10 → 8

0.35φ×3

10

Solenoid Winding

4

Insulation: Polyester Tape t = 0.025 mm, 3-Layer

5

N1

2 → 1

0.29φ×1

18

Solenoid Winding

6

Insulation: Polyester Tape t = 0.025 mm, 6-Layer

7

N3

5 → 6

0.15φ×1

13

Solenoid Winding

8

Insulation: Polyester Tape t = 0.025 mm, 3-Layer

9

Copper-Foil 1.2T to PIN6

Table 3. Electrical Characteristics

Pins

Specifications

Inductance

3 - 1

800 μH ±5%

7.2. L1 & L2 Specification

7.3. L3, L4, & L5 Specification

 Core: QP3925H (3C94)

 Bobbin: 7 Pins

Figure 9. Transformer Specifications & Construction

Table 4. Winding Specifications

No.

Winding

Pin (S → F)

Wire

Turns

Winding Method

1

N1

1 → 6, 7

0.2φ×35 *1

25

Solenoid Winding

2

Insulation: Polyester Tape t = 0.025 mm, 2-Layer

3

Copper-Foil 1.2T to PIN4, 5

Table 5. Electrical Characteristics

Specifications

Inductance

1 → 6, 7

100 μH ± 5%

7.4. L11 Specification

 Core: Ferrite core DRWW 6x10(6ψ*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

1 → 2

0.55 mm

18

Solenoid Winding

2

Ferrite core DRWW 6x10 (6ψ*10 mm)

Table 7. Electrical Characteristics

Specifications

Inductance

1 - 2

10 μH ± 5%

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 25°C

Test Equipment

AC Source: EXTECH 6220

AC/DC Electronic Load: Chroma 63020

Power Meter: HIOKI 3390

Oscilloscope: Lecroy Wavesurfer 424

Test Items

1. AC Trim Up & Trim Down

2. PFC ON/OFF & RDY

3. Ripple & Noise

4. Efficiency

5. Current Harmonic

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.

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 V264 V 5000 W Load

Figure 12. 264 V180 V 5000 W Load

9.2. PFC ON / OFF & RDY

Test Result:

CH1: VRDY CH3: VPFC CH4: VBridge+

Figure 13. PFC ON

Figure 14. PFC OFF

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)

Output Watts (W)

Efficiency

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%

9.5. Current Harmonic

Test Results:

FAN9673

Input Voltage

Condition

PF

THD (%)

180 V / 50 Hz

25% Load

0.9912

10.55

50% Load

0.9947

9.17

75% Load

0.9971

6.62

100% Load

0.9974

6.40

220 V / 50 Hz

25% Load

0.9800

14.32

50% Load

0.9868

14.36

75% Load

0.9905

12.55

100% Load

0.9924

11.26

264 V / 50 Hz

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 Input Current Waveform & Harmonic

Figure 17. 25% Load

Figure 18. 50% Load

Figure 19. 75% Load

Figure 20. 100% Load

220 V / 50 Hz Input Current Waveform & Harmonic

Figure 21. 25% Load

Figure 22. 50% Load

Figure 23. 75% Load

Figure 24. 100% Load

264 V / 50 Hz Input Current Waveform & Harmonic

Figure 25. 25% Load

Figure 26. 50% Load

Figure 27. 75% Load

Figure 28. 100% Load

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.

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.

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.