Low-Voltage Power Factor Correction Development Kit User’s Guide
2018 Microchip Technology Inc. DS50002832A Note the following details of the code protection feature on Microchip devices: • Microchip products meet the specification contained in their particular Microchip Data Sheet.
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DS50002832A-page 2 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Table of Contents
Preface ...... 5 Chapter 1. Overview...... 9 1.1 Introduction ...... 9 1.2 Low-Voltage Power Factor Correction Development Kit ...... 10 1.2.1 LVPFC Development Board ...... 10 1.2.2 Digital Power Plug-In Module (DP PIM) Board ...... 12 1.3 System Setup ...... 13 1.4 Test Points ...... 14 1.5 Electrical Characteristics ...... 15 1.6 Mating Socket Pinout ...... 15 1.7 Measurement Results ...... 16 Appendix A. Board Layout and Schematics...... 23 A.1 LVPFC Development Board Schematics ...... 24 A.2 LVPFC Development Board PCB Layout ...... 26 A.3 Auxiliary Power Supply Module Schematics ...... 28 A.4 Auxiliary Power Supply Module PCB Layout ...... 29 Appendix B. Bill of Materials (BOM)...... 31 B.1 Bill of Materials – LVPFC Development Board ...... 31 B.2 Bill of Materials – Auxiliary Power Supply Module ...... 34 Appendix C. Example Algorithm ...... 37 C.1 Interleaved PFC Boost Converter in Transition Mode ...... 37 C.2 Interleaved PFC Boost Converter in Continuous Conduction Mode ...... 39 Appendix D. Optional Supporting Equipment...... 41 D.1 Introduction ...... 41 D.2 Isolation Transformer ...... 41 D.3 Active Load 50W ...... 42 Worldwide Sales and Service ...... 44
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DS50002832A-page 4 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Preface
NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and documentation are constantly evolving to meet customer needs, so some actual dialogs and/or tool descriptions may differ from those in this document. Please refer to our website (www.microchip.com) to obtain the latest documentation available. Documents are identified with a “DS” number. This number is located on the bottom of each page, in front of the page number. The numbering convention for the DS number is “DSXXXXXXXXA”, where “XXXXXXXX” is the document number and “A” is the revision level of the document. For the most up-to-date information on development tools, see the MPLAB® IDE online help. Select the Help menu, and then Topics to open a list of available online help files.
INTRODUCTION This chapter contains general information that will be useful to know before using the Low-Voltage Power Factor Correction (LVPFC) Development Kit. Items discussed in this chapter include: • Document Layout • Conventions Used in this Guide • Recommended Reading • The Microchip Website • Product Change Notification Service • Customer Support • Document Revision History DOCUMENT LAYOUT This document describes how to use the LVPFC Development Kit to ensure safe voltage levels at moderate power. The document is organized as follows: • Chapter 1. “Overview” — This chapter introduces the LVPFC Development Kit and provides a brief overview of its various features. • Appendix A. “Board Layout and Schematics” — This appendix presents the schematics and board layouts for the LVPFC Development Kit and the Auxiliary Power Supply module. • Appendix B. “Bill of Materials (BOM)” — This appendix presents the Bill of Materials for the LVPFC Development Kit and the Auxiliary Power Supply module. • Appendix C. “Example Algorithm” — This appendix provides algorithm examples for the LVPFC Development Board. • Appendix D. “Optional Supporting Equipment” — This appendix presents the recommended supporting equipment to be used with the LVPFC Development Board.
2018 Microchip Technology Inc. DS50002832A-page 5 Low-Voltage Power Factor Correction Development Kit User’s Guide
CONVENTIONS USED IN THIS GUIDE This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS Description Represents Examples Arial font: Italic characters Referenced books MPLAB® IDE User’s Guide Emphasized text ...is the only compiler... Initial caps A window the Output window A dialog the Settings dialog A menu selection select Enable Programmer Quotes A field name in a window or “Save project before build” dialog Underlined, italic text with A menu path File>Save right angle bracket Bold characters A dialog button Click OK A tab Click the Power tab N‘Rnnnn A number in verilog format, 4‘b0010, 2‘hF1 where N is the total number of digits, R is the radix and n is a digit. Text in angle brackets < > A key on the keyboard Press
DS50002832A-page 6 2018 Microchip Technology Inc. Preface
RECOMMENDED READING This user’s guide describes how to use LVPFC Development Kit. Other useful document(s) are listed below. The following Microchip document(s) are recommended as supplemental reference resources. • “Digital Power Development Board User’s Guide” (DS50002814) This document is available for download from the Microchip website (www.microchip.com).
THE MICROCHIP WEBSITE Microchip provides online support via our website at www.microchip.com. This website is used as a means to make files and information easily available to customers. Accessible by using your favorite Internet browser, the website contains the following information: • Product Support – Data sheets and errata, application notes and sample programs, design resources, user’s guides and hardware support documents, latest software releases and archived software • General Technical Support – Frequently Asked Questions (FAQs), technical support requests, online discussion groups, Microchip consultant program member listing • Business of Microchip – Product selector and ordering guides, latest Microchip press releases, listing of seminars and events; and listings of Microchip sales offices, distributors and factory representatives
PRODUCT CHANGE NOTIFICATION SERVICE Microchip’s customer notification service helps keep customers current on Microchip products. Subscribers will receive e-mail notification whenever there are changes, updates, revisions or errata related to a specified product family or development tool of interest. To register, access the Microchip website at www.microchip.com, click on Product Change Notification and follow the registration instructions.
CUSTOMER SUPPORT Users of Microchip products can receive assistance through several channels: • Distributor or Representative • Local Sales Office • Corporate Application Engineer (CAE) • Embedded Solutions Engineer (ESE) Customers should contact their distributor, representative or Embedded Solutions Engineer (ESE) for support. Local sales offices are also available to help customers. A listing of sales offices and locations is included in the back of this document. Technical support is available through the website at: http://www.microchip.com/support.
DOCUMENT REVISION HISTORY Revision A (December 2018) This is the initial version of this document.
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DS50002832A-page 8 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Chapter 1. Overview
1.1 INTRODUCTION When developing high-voltage applications, especially offline Power Factor Correction (PFC) applications, engineers face safety concerns with high-voltage and high-energy electronic devices. The purpose of the Low-Voltage Power Factor Correction (LVPFC) Development Kit is to offer safe voltage levels at moderate power, while designing algorithms for a boost Power Factor Correction topology. These algorithms can be applied on real systems under development with minimal effort. The LVPFC Development Kit utilizes Microchip’s latest Digital Power Plug-In Module (DP PIM) with the dsPIC33EP128GS806 device, supporting fully digital and advanced power control algorithm schemes. However, the pinout is standardized and the kit supports all currently available DP PIMs, thus allowing users to evaluate different devices under the same conditions. For more information on the available DP PIMs, visit: https://www.microchip.com. Figure 1-1 shows the high-level block diagram.
FIGURE 1-1: HIGH-LEVEL BLOCK DIAGRAM
LVPFC ϭϮϬ VC/ ϭϮ VC/ Development ϰϬ VDC V C ϮϯϬ Ϯϰ VC Board ϱϬ sÃø
/ƐŽůĂƟŽŶ ϱϬtĐƟǀĞ>ŽĂĚ
dƌĂŶƐĨŽƌŵĞƌϭϬ͗ϭ ŽŶƐƚĂŶƚWŽǁĞƌ ŽŶƐƚĂŶƚƵƌƌĞŶƚ Note: Please note that the Isolation Transformer has 10:1 turns ratio. Therefore, every voltage at the primary side will be scaled down by a factor of 10. For documentation simplicity, further on we will talk about 24 VAC input voltage.
The topics covered in this chapter include: • Low-Voltage Power Factor Correction Development Kit • System Setup • Test Points • Electrical Characteristics • Mating Socket Pinout • Measurement Results
2018 Microchip Technology Inc. DS50002832A-page 9 Low-Voltage Power Factor Correction Development Kit User’s Guide
1.2 LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT The LVPFC Development Kit consists of: 1. LVPFC Development Board. 2. Digital Power Plug-In Module (DP PIM) Board. Optional supporting equipment: 3. Isolation Transformer. 4. Active Load 50W.
1.2.1 LVPFC Development Board The LVPFC Development Board is based on conventional Interleaved Boost Power Factor Correction (PFC) topology. The converter supports a 24 VAC input, but the PCB is designed following high-voltage design rules. With some modifications, the board can support a universal offline voltage range of 80 VAC to 260 VAC, and up to 200W output power at 400 VDC output voltage. Figure 1-2 shows the high-level overview.
FIGURE 1-2: LVPFC DEVELOPMENT BOARD
Input Voltage EMI VͺÝÄÝ Bridge VÖ¥ͺÝÄÝ Output Voltage 12 VAC to 24 VAC Phase 1 36 V to 42 V 3 ARMS_MAX Filter RecƟĮer 50 WÃø Current Sense (CS) Bulk UWVR 5W Flyback Gate Drive Capacitors 12V Secondary and ZCD 12V Primary 4 kV Isolated Phase 2
Current Sense Gate Drive and ZCD DC-DC 5V Regulator
sͺÝÄÝ sÖ¥ͺÝÄÝ PWM1 and 2 Legend: CS1 and 2 ZCD1 and 2 PFC Development Board UART (I 2C) 5W Flyback Board DP PIM Board GPIO DC-DC Regulator dsPIC33EPXX Programming Digital Power PIM Board
The main blocks of the LVPFC Development Board are: • EMI/EMC Filter at the Input (capable of high voltage)
• Bridge Rectifier (3 AMAX, capable of high voltage) • Phase 1 (MOSFET, Current Transformer, diode rectifier) • Phase 2 (MOSFET, Current Transformer, diode rectifier) • Ultra-Wide Voltage Range (UWVR) 5W Flyback (capable of low and high voltage); provides a 12V primary, non-galvanic isolated and 12V secondary, 4 kV galvanic isolated voltage • Switch Mode Step-Down Regulator, 5V/400 mA, Pin-to-Pin Compatible with the LAN780X Family of Linear Regulators
DS50002832A-page 10 2018 Microchip Technology Inc. Overview
The LVPFC Development Board supports: • Single-Phase or Dual Phase Operation Mode • Discontinuous, Transition, Continuous Current Mode of Operation • Input AC Voltage, Output DC Voltage: Resistive Voltage Divider Sense • Current Sense in Each Power Switch Leg: Current Transformers • Zero-Cross Detection (ZCD): Auxiliary Winding Placed at Storage Chokes • Inrush Current Limiter: Negative Temperature Coefficient (NTC) Resistor and Relay • Output Overvoltage Protection (OVP): Analog Comparator with Hysteresis and Disabling Gate Drivers; power Reset (unplug the power) is needed to reset the comparator • Mating Socket for DP PIM Board The LVPFC Development Board has the following features, as shown in Figure 1-3:
FIGURE 1-3: LVPFC DEVELOPMENT BOARD
1. Socket for Digital Power Plug-In Module (DP PIM) boards. Socket type is Samtec, Inc. (Part #: MECF-30-01-L-DV-WT). 2. Auxiliary Power Supply module. 3. Input power connector. 4. Output power connector. 5. Input EMI filter. 6. PFC storage chokes. 7. Current Transformers. 8. Output bulk capacitors. 9. Input rectifier, power MOSFETs with their heat sink. 10. Inrush current limiter (NTC resistor and relay). 11. DC-DC 5V regulator. Board dimensions are: 160 mm (length) x 100 mm (height).
2018 Microchip Technology Inc. DS50002832A-page 11 Low-Voltage Power Factor Correction Development Kit User’s Guide
1.2.2 Digital Power Plug-In Module (DP PIM) Board The dsPIC33EP128GS806 Digital Power Plug-In Module (DP PIM) is a demonstration board that showcases the Microchip dsPIC33EP128GS806 16-Bit Digital Signal Controller (DSC) features. The DP PIM provides access to the dsPIC33EP128GS806 analog inputs, the Digital-to-Analog Converter (DAC) outputs, the Pulse-Width Modulation (PWM) outputs and the General Purpose Input and Output (GPIO) ports. The Microchip series of DP PIMs for digital power share the same pinout at the mating socket. However, these DP PIMs show slightly different performing characteristics. Figure 1-4 shows the features of the dsPIC33EP128GS806 DP PIM Board.
FIGURE 1-4: dsPIC33EP128GS806 DP PIM BOARD
PCB Top View PCB Bottom View 11 4 4
10 10 8 1
2 5 6
3 7
9 9 A D DA
1. Microchip dsPIC33EP128GS806 16-bit Digital Signal Controller (64-pin TQFP package). 2. ICSP™ programming header (6-pin, 2.54 mm header). 3. On-board LDO (3.6 VDC to 6.3 VDC) with Power Good (PG) function. 4. Solder pad for ground connection. 5. Micro-USB connector. (Please note that there is no galvanic isolation provided at this point.) 6. MCP2221A USB to UART/I2C serial converter. 7. Power indicator LED (green). 8. User LED (red). 9. Board edge connection interface for analog inputs/outputs, PWM outputs and GPIO ports. 10. Analog input with op amp buffer via test point loop connector; can be used for Bode plot measurements. 11. Test point loops for DAC outputs. Board dimensions are: 51 mm (length) x 38.5 mm (width). For more information on the DP PIM Board, refer to the “dsPIC33EP128GS806 Digital Power Plug-In Module (PIM) User’s Guide” (DS50002761).
1.2.2.1 SOCKET FOR DP PIM BOARDS Insert the DP PIM Board under test into the socket located at the end of the board. This socket has a slot that defines the DP PIM Board direction. Be careful not to break the slot when inserting the DP PIM Board into the socket. The DP PIM Board has a micro-USB connector that can be used for communication with the dsPIC® device. The UART protocol and Graphical User Interface (GUI) are used to establish communication. For more information, please visit: www.microchip.com.
DS50002832A-page 12 2018 Microchip Technology Inc. Overview
1.3 SYSTEM SETUP Figure 1-5 shows the standard test setup. For more information on the isolation transformer and the active load, refer to Appendix D. “Optional Supporting Equipment”.
FIGURE 1-5: STANDARD SYSTEM SETUP
12V Auxiliary V = 12V Power Supply I = 200 mA GUI Firmware Debugging + Purpose Only
!
GND +V J9 LVPFC Development Board
AC ! Power Meter DP PIM Board
I V J1 J2 J3
LN GND sÖ¥ UVLO = 36V 24 V Po = 45W 120 V/ + 230 V 0 V 120 V ... 12 V Wall Adapter 230 V IsolaƟon Transformer 10:1 50W AĐƟve Load Constant Power Constant Current
Isolation Transformer: Be careful to position the input voltage selector into the proper place (120V or 230V) before plugging into mains. The Protective Earthing (PE) connection between the transformer and the LVPFC Development Board is not mandatory. Use the switch at the front panel to provide or cut off the power to the LVPFC Development Board. The isolation transformer can be coupled with an adjustable AC source to support a wider AC input voltage range. Output impedance of the transformer should be very close to the Line Insertion Stabilization Network (LISN), which is used for EMI measurements. It allows a certain grade of impedance matching and interference to bring the LVPFC Development Board closer to real-world applications. If using a different type of transformer, please take care that the leakage inductance is in the range of 50 µH (±20%). Also, if using an active AC source only, the usage of differential voltage probes is mandatory. Active Load: Please read the user manual of the device before operating. Incorrect setup can damage the LVPFC Development Board. The purpose of the PFC stage is to source loads, such as a DC/DC downstream converter, which is acting as a constant power system. Therefore, all measurements must be done under this condition. The active load, prepared for this development kit, can act as a downstream converter with the following features: constant power, constant current, Undervoltage Lockout (UVLO), load step of 100 Hz and 50% duty cycle (pulse). If different equipment is used, please note that some functions on the supplementary equipment may not be available and special care must be taken during start-up, light or no load conditions. DP PIM Board USB Connection: Use the micro-USB cable to connect the DP PIM Board with the host PC and run the dSMPS GUI to communicate with the dsPIC device; it is allowed only if the board is galvanically isolated (isolation transformer is used). For more information, refer to the user’s guide of the specific DP PIM Board that is used.
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12V Auxiliary Power Supply: Connecting this voltage source to the board provides a permanent 12V. It is useful for debugging purposes, where powering a main power train is not needed. Test Points: Use an oscilloscope to access the test points at the edge of the board. For reference potential, use GND_P or GND_A; this is allowed only if the board is galvanically isolated (isolation transformer is used). AC Power Meter: Use the AC power meter for algorithm optimizations at the AC line (power factor, THD, efficiency, etc.); it is not mandatory for basic algorithm development.
1.4 TEST POINTS Test loop points are placed mostly on the LVPFC Development Board. They can be used to access analog and PWM signals coming from or to the DP PIM Board. Table 1-1 lists the test points on the LVPFC Development Board.
TABLE 1-1: TEST POINTS Test Point Name Function/Description TP1, TP2 GND_P (power reference GND) TP3 Switching Node, Phase 1 TP4 Power GND Reference Potential AGND Analog GND Reference Potential TP6 Switching Node, Phase 2 CH2 Output PFC Voltage, Spectrum Analyzer Injection Point CH1 Spectrum Analyzer Injection Point VAC Rectified Input AC Voltage ZCD1 Zero-Cross Detection, Phase 1 ZCD2 Zero-Cross Detection, Phase 2 PFC-PWM1 dsPIC® DSC PWM Output, Phase 1 PFC-PWM2 dsPIC DSC PWM Output, Phase 2 CS1 Current Transformer – Current Sense, Phase 1 CS1 Current Transformer – Current Sense, Phase 2 Relay dsPIC DSC Output Control – Relay On/Off VAC_SENSE Input AC Voltage Sense Line VPFC_SENSE PFC Voltage Sense Line 5V System VDD Rail
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1.5 ELECTRICAL CHARACTERISTICS Table 1-2 shows the electrical characteristics of the LVPFC Development Board.
TABLE 1-2: ELECTRICAL CHARACTERISTICS Parameter Low-Voltage Solution High-Voltage Solution
Input Voltage Range (VAC) 8 to 26 80 to 260
Output Power (WMAX)50200
Output Load Current (AMAX) 1.28 0.51
Input Current (AMAX)3 Efficiency (%) ~90 ~96 Operating Temperature Range 0°C to +40°C
1.6 MATING SOCKET PINOUT The pinout is shown in Table 1-3.
TABLE 1-3: MATING SOCKET PINOUT Name Mating Socket Pin Function/Description GND_A 1, 2 Analog Ground CS2 6 Current Sense, Phase 2 ZCD2 8 Zero-Cross Detection, Phase 2 Temp 9 Temperature Sense VPFC_SENSE 10 Output PFC Voltage Sense CS1 12 Current Sense, Phase 1 VAC_SENSE 14 Input AC Voltage Sense ZCD1 18 Zero-Cross Detection, Phase 1 PFC-PWM2 42 PWM Output, Phase 2 PFC-PWM1 45 PWM Output, Phase 1 Relay 46 Inrush Control – Relay On/Off +5V 57, 59 VDD Rail GND_D 58, 60 Digital Ground
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1.7 MEASUREMENT RESULTS
If not otherwise stated, all measurements were done at 24 VAC input voltage and 50W output load, using the setup shown in Figure 1-5. The algorithm used was supporting the interleaved Transition Mode (TM) regulation technique. The regulated output voltage was 40 VDC. Distortion in the input AC signal is coming from the mains voltage. The input current distortion close to zero cross is due to the fact that the voltage below 1.2V cannot cross the bridge rectifier at the input. This 1.2V is approximately 4% of the input voltage. In case of full voltage scale at the mains, this error would be one decade below, that is, 0.4%. Figure 1-6 through Figure 1-12 show the oscilloscope measurements.
FIGURE 1-6: SWITCHING NODES
Legend: C1 (yellow): Gate Voltage C2 (red): Drain Voltage C4 (green): Input Current
Time Base: 10 µs/div
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FIGURE 1-7: 100 Hz OUTPUT RIPPLE VOLTAGE
Legend: C1 (yellow): VOUT (AC coupled) C4 (green): Input Current
Time Base: 5 ms/div
2018 Microchip Technology Inc. DS50002832A-page 17 Low-Voltage Power Factor Correction Development Kit User’s Guide
FIGURE 1-8: VPFC_SENSE, VAC_IN TEST POINTS
Legend: C1 (yellow): VPFC_SENSE C2 (red): VAC_IN C4 (green): Input Current
Time Base: 5 ms/div
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FIGURE 1-9: ZERO-CROSS DETECTION (ZCD), PWM TEST POINTS
Condition: Input current close to minimum.
Legend: C1 (yellow): ZCD Test Point C2 (red): PWM Test Point C4 (green): Input Current
Time Base: 5 µs/div
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FIGURE 1-10: ZERO-CROSS DETECTION (ZCD), PWM TEST POINTS
Condition: Input current at the peak.
Legend: C1 (yellow): ZCD Test Point C2 (red): PWM Test Point C4 (green): Input Current
Time Base: 10 µs/div
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FIGURE 1-11: CURRENT TRANSFORMER (CT), PWM TEST POINTS Condition: Input current close/around zero cross.
Legend: C1 (yellow): CT Test Point C2 (red): PWM Test Point C4 (green): Input Current
Time Base: 10 µs/div
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FIGURE 1-12: CURRENT TRANSFORMER (CT), PWM TEST POINTS Condition: Input current at the peak.
Legend: C1 (yellow): CT Test Point C2 (red): PWM Test Point C4 (green): Input Current
Time Base: 10 µs/div
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Appendix A. Board Layout and Schematics
This appendix contains the schematics and board layouts for the LVPFC Development Board. The topics covered in this appendix include: • LVPFC Development Board Schematics • LVPFC Development Board PCB Layout • Auxiliary Power Supply Module Schematics • Auxiliary Power Supply Module PCB Layout
2018 Microchip Technology Inc. DS50002832A-page 23 Low-Voltage Power Factor Correction Development Kit User’s Guide PFC V GND MAX J3 TERMINAL 1x2 J2 TERMINAL 1x2 Vpfc_sense 1 2 1 2 = 1.3A C23 6800 pF 50V 0603 PFC MAX = 50W = 36V ...42 V _ GND_P C18 33 μF 450V P5D12.5H27 PFC MAX GND_A OUT P U I R4 2.20k 0603 1% DNP CAP1931 GND_P Altium.com = 2,12V @ 31V = 2.73V @ 40V = 0,06832 x V Designed with GND_A C19 47 μF 63V SENSE SENSE SENSE V V V GND_P R16 10k 1206 1% y L4 4.7 μH R15 10k 1206 1% C20 0.1 μF 500V 1210 R23 120R 0603 1% 3V @ 5A peak current CS2 DNP GND_P measurment onl p GND_A C1 330 μF 450V P10D35H35 R14 10k 1206 1% 50V R22 120R 0603 1% 1500 μF C5 PFC e loo g V GND_P GND_P GND_A C22 680 pF 100V 0805 R9 CH2 and CH1 for BODE volta 15R 1206 1% D11 1N4148 CH2 CH1 1500 μF 50V C4 PFC GND_P R21 10k 1206 1% V GND_P R8 51R 0603 1% GND_A = 5A = 2A 1 4 = 300 mW TP2 MAX MAX _ _ GND_P MAX _ Ptot = 1W T2 CS4100V-01L D D3 ES3B 2 3 RMS PEAK P I I TP1 Q4 IPP126N10N3G 2 3 GND_P TP6 1 MATICS (PAGE 1 OF 2) OF MATICS (PAGE 1 R25 10R 1206 ZCD1 R13 120R 0603 1% CS1 R24 10R 1206 GND_A R12 120R 0603 1% GND_P 7 6 4 5 GND_A D13 1N4148 D14 3.3V D8 1N4148 OUT OUT GND GND 3V @ 5A peak current = 5A = 1.3A R11 10k 1206 1% GND_A +12V_P = 450 mW MAX MAX _ DD DD C21 680 pF 100V 0805 MCP14A0452 _ R2 U2 15R 1206 1% GND_A MAX = 0.63A IN EN V V _ D1 1N4148 D 2 3 1 8 AV RMS PEAK 1 4 I I I P GND_P 10R R32 GND_A T1 CS4100V-01L C13 1 μF 16V D2 ES3B 2 3 = 5A = 2A Q2 = 300 mW GND_P IPP126N10N3G MAX MAX R1 1k 0603 1% _ _ MAX 2 3 _
GND_P
D RMS PEAK
P I I 7 12 12 7 Ptot = 1W TP3 1
R26 3.3k 0603 1% P2 P4
12 1 2 GND_P R18 10R 1206 R17 10R 1206
P1 P3 L1 50 μH L3 50 μH
6 3 3 6 R10 1k 0603 1% GND_P GND_A 7 6 4 5 D12 RS3J C9 0.47 μF 310V GND_A PFC-PWM2 +12V_P OUT OUT GND GND D9 1N4148 Vac GND_A U1 MCP14A0452 DD DD C8 0.47 μF 310V GND_P N DEVELOPMENT BOARD SCHE IN EN V V R31 10R 2 3 1 8 D15 1N4148 D16 3.3V C12 1 μF 16V - + 1 4 VAC GND_P GND_A R19 3.3k 0603 1% 3 2 ~ D5 ~ 600V/3A KBP306GTB ZCD2 GND_P MOV1 275V Drive_Enable Disc 10 mm D10 1N4148 Q3 2N7002-7-F PFC-PWM1 3 2 +5V GND_P show the board schematics. 1 -t R20 10k 0603 1% 3 1 2 TH1 10R GND_P RL1 4 R39 100R 0603 1% D7 US1J G6C-1114P-US-DC5 Figure A-2 D6 US1J Relay and C10 4700 pF 300V P7.5D8H11 PE R7 10k 1206 1% 0.33 μF C11 4700 pF 300V P7.5D8H11 AC 275V C3 PE R6 10k 1206 1% 4 3 Figure A-1 R5 10k 1206 1% 1 2 2 mH R30 2.20k 0603 1% PFC GND_A L2 1 2 C24 6800pF 50V 0603 = 2,12V @ 31V = 1.16V @ 17V = 0,06832 x V GND_A C7 0.68 μF 310V Radial SENSE SENSE SENSE V V V AC Vac_sense F2 F1 F2395-ND 5A 250 V AC Fuse has to be added Fuse Holder 5x20 mm <42V <50W PE PFC OUT ...26 V 1 2 3 AC MAX J1 = 0W
90% Ploss<6W IN 12 V V 3 A TERMINAL 1x3 FIGURE A-1: POWER FACTOR CORRECTIO LOW-VOLTAGE A.1 DEVELOPMENTBOARD SCHEMATICS LVPFC
DS50002832A-page 24 2018 Microchip Technology Inc. Board Layout and Schematics SENSE IN _ _ PFC AC PFC-PWM1 PFC-PWM2 ZCD1 V CS1 V CS2 ZCD2 CS1 CS2 ZCD1 ZCD2 Vac_sense Vpfc_sense PFC-PWM1 PFC-PWM2 Altium.com Designed with Temp C6 1 μF 16V GND_P Temp +5V PFC-PWM1 R27 100R 0603 1% 1 3 5 7 9 11 13 15 17 19 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 2 OUT J4 EDGE 60P Female MECF-30-01-L-DV-WT V 2 4 6 8 DD 10 12 14 16 18 20 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 V GND U3 MCP9700 1 3 C ° MATICS (PAGE 2 OF 2) OF MATICS (PAGE 2 GND_P CS2 CS1 GND_P GND_A ZCD2 ZCD1 Relay C16 1 μF 16V Vac_sense Vpfc_sense PFC-PWM2 GND_P C ° R33 10R +5V = 500 mV + Temp * 10 mV/ TEMP Temp = 10 mV/ Temp U AGND GND_A J8 TERMINAL 1x2 2 1 GND +12V_S
N DEVELOPMENT BOARD SCHE
GND_A
6
6
R29 0R 1206 5 5 Out
+5V GND_P Isolation Barrier 4kV Barrier Isolation +12V_S = 55V R28 10R 0603 = 24V 0603 C2 1 μF 16V
ENABLE DISABLE TP4
4 GND_P Overvoltage Protection V V The comparator will disable gate drivers as soon the PFC Voltage hits 55V 4 kV Isolation Barrier
4 GND_P Drive_Enable
Out 3 3 GND_P R35 10k 0603 1% HV9123 Drive Enable +12V_P
5V 47 μF 35V C15
2
2 +5V
1 1
In GND_P 1 GND_P MOD2 MCHP-10749 UWVR_5W_Flyback T U4 MIC6270 3 OUT PFC V- V+ 5 2 V OUT GND_P V + IN+ IN- 2 GND 3 4 GND_P IN V MOD1 1 MCHP-10751 7805 Replacement 50V 0603 C17 R34 6.2k 0603 1% 100 pF 47 μF 35V C25 GND_P +12V_P R38 10k 0603 1% R37 10k 0603 1% 3.73V GND_P +12V_P hysteresis = 2V PFC PFC D4 STPS1150A R36 7.5k 0603 1% Vpfc_sense = 2,12V @ 31V = 2.73V @ 40V = 0,06832 x V GND_P 1 2 SENSE SENSE SENSE 3.75V @ 55 V V V V +5V J9 +V Gnd TERMINAL 1x2 For development purpose only External Supply 10V..12V-500 mA FIGURE A-2: POWER FACTOR CORRECTIO LOW-VOLTAGE
2018 Microchip Technology Inc. DS50002832A-page 25 Low-Voltage Power Factor Correction Development Kit User’s Guide
A.2 LVPFC DEVELOPMENT BOARD PCB LAYOUT The LVPFC Development Board is a two-layer FR4, 1.55 mm, Plated-Through-Hole (PTH) PCB construction with a copper thickness of 70 µm. Figure A-3 and Figure A-4 show the top and bottom assembly of the LVPFC Development Board.
FIGURE A-3: LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT BOARD TOP ASSEMBLY
2 1 2 1
1 2 3 4 5 6
1
2 1
3
2 1 2
0
0 1 2 3
60 59
1 58 57 4 1 1
1 56 55 4 3 2 1 1 2 3 1 2 3 2
1 2 54 53
1 2 52 51 1 1
50 49 1
48 47
1 46 45
44 43 1 2
42 41 2 3 2 3 2 1 1 40 39
1 2 38 37 2
36 35
34 33
2 2 32 31
4 3 30 29
2 28 27 1
26 25
24 23
1 2 1 1 1 20 19
1 18 17 4 1 4 1 1 16 15
14 13 1 2
12 11
10 9 1 1 12 1 12
8 7 1
2 11 2 11 6 5
4 3 3 10 3 10
1 2 1 1
1 1 1 2 2 1 0
0
2 1 1
2 1 13 14 13 14
1
1
1 1
1 2 3
4 9 4 9
1
5 8 5 8 2 2 1 1 1 2 1 2 1
6 7 6 7
DS50002832A-page 26 2018 Microchip Technology Inc. Board Layout and Schematics
FIGURE A-4: LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT BOARD BOTTOM ASSEMBLY
1 2 2 1 1 2
1 2
1 2
2 1
3
6 5 4 3 2 1
1
2 1 1 2
1 1
2 2 1 1
4 3 2 1 2 4 3 2 1 2
1 2 2 1
1 1 1 2 2
3 2 2 1 1 2 3 5 6 7 8 5 6 7 8
2 2 2 1
0 1 1 1 1
0 3 2 1 1 1 2 2 2 2
1 1 4 1 2
1 1 3 2 1 3 2 1 1 2 3 4 2
2 1 1
2 1
1 1 2 2 1 2 1 1 2 1 1 2 2 1 1 2
1
2
2 1 2 1
2 1 2 3 2 3 2 1 2 1 1
1 2 2 1 5 4 2 1 2 2 2
1 1 1 2 3
2 2 2 1
3 4 1 2
2 1 2 1
2 1 2 1 1 2
1 2 2 1 1 2 2 1 2 1 1 1 1
1
1 1 4 1 2 1 4 1 2 2 1 1
2 1
2 1 2
2 1
1 12 1 12 1 1 2
1
11 2 11 2
10 3 10 3
1
1 1 2 0 1 2
0
2 1 1 1 2
1 2 14 13 14 13
1
1
3 2 1
1 2 1 2 1 2
9 4 9 4 1 2 1
8 5 8 5 1 2 1 2 1 1 1 2 2
7 6 7 6
1 2 2 1 2 1 2 1 2 1 2 1
3 1 2 1 2 3
2018 Microchip Technology Inc. DS50002832A-page 27 Low-Voltage Power Factor Correction Development Kit User’s Guide J2 HDR-2.54 Male 1x2 2 1 GND mA max C9 1 μF 16V GND Altium.com Designed with = 11V...13V, 250 OUT V C7 16V 100 μF GND 12V_S LD1 RED 0805 LD2 RED RAD_1.8 mm R4 5.6k 0603 1% GND L2 1 μH ). 12V_IN C6 16V 220 μF TP11 = 2.5A = 0.8A = 400 mA TP3 GND GND MAX MAX _ MAX _ urpose only V_ R26 for Loop measurements p RMS A PEAK I D1: I I TP13 TP7 Figure 1-3 R2 470R 0805 D9 MM3Z12VST1G R26 10R 0603 1% R9 150R 0603 1% R23 10k R24 0R 0603 D1 DFLS1150-7 GND GND 12V_S C1 0805 200V 47 pF GND 5 8 1 2 * C10 2200 pF 300V Y2 063092-b TR1 * * 4 1 3 2 U3 TP2 4 3 Isolation Barrier 4 kV PGND FOD817A3SD PGND Isolation Barrier 4 kV DD V D2 C8 4.7 μF 25V 0805 DFLS1150-7 C12 16V 100 μF PGND MAX = 100 mW IN PGND = 380 mA V = 300 mA PGND TP10 MAX R20 3.3R 1206 1% _ MAX MAX _ _ PGND 12V_P
TP6 Q3 IPA60R950C6XKSA1 DCOND 1 = 12V @ 3 W
RMS PEAK
P I I R19 3.3R 1206 1% 2 OUT J4 HDR-2.54 Male 1x2 2 3 V PGND 12V_P 1 C5 1000 pF 250V 0805 D4 US1K R5 10R 1206 1% Q2 FMMT2222A Q4 MMBT2907A DD V C4 1000 pF 250V 0805 PGND TP1 R16 1k 0603 1% 100R R8 R6 100R D10 BAT54HT1G C17 1000 pF 50V 0603 R3 27k P15L11.5D4.5 5% TP4 D5 C13 1 μF 16V PGND BAT54HT1G R13 6.2k 0603 1% R15 18k 0603 1% DD PGND V
U1 HV9123
5
Vss V DD
6 7
PGND
C23 100 pF 50V 0603
SENSE Us = 1V @ 400 mA
4
OSC OUT OSC OUTPUT
8 1% DISCHRG 20k
0603 TP8 C2 1.5 μF 450V P7.5L17.5W9.3H17.5 10 = 8V...11V
1%
BIAS 562k 0603 DD R18 R12 PGND 16 V 1%
R7
220k 0603 135 kHz
PGND
V REF
SW 11
F OSC IN OSC
9 RESET
1206
13 C21 0.1 μF 16V
shows the Auxiliary Power Supply module schematics (refer to to (refer schematics module Supply Power Auxiliary the shows
V SHDWN IN
R1 22R 1 IN 12 V L1 100 μH Radial FB COMP 15 14 C3 3.3 μF 450V P3.5D8H13 = 85% = 100 ns = 130 kHz MIN MAX SW DC F PW C28 0.022 μF 50V 0603 Figure A-5 2 1 C22 1000 pF 50V 0603 R33 4.3k 0603 1% = 450V J3 = 25V R29 15k 0603 1% MIN MAX R27 4.3k 0603 1% _ _ IN IN HDR-2.54 Male 1x2 V V PGND = 4V REF R25 8.66k 0603 1% U TP12 TP14 GND R32 10R 0603 1% TP9 12V_P urpose only R32 for Loop measurements p FIGURE A-5: AUXILIARY POWER SUPPLY MODULE SCHEMATIC A.3 AUXILIARY POWER SUPPLY MODULE SCHEMATICS
DS50002832A-page 28 2018 Microchip Technology Inc. Board Layout and Schematics
A.4 AUXILIARY POWER SUPPLY MODULE PCB LAYOUT The Auxiliary Power Supply module is a two-layer FR4, 1.55 mm, Plated-Through-Hole PCB construction. Figure A-6 and Figure A-7 show the top and bottom assembly of the Auxiliary Power Supply module.
FIGURE A-6: AUXILIARY POWER SUPPLY MODULE TOP ASSEMBLY
1
2 1 1 2
1 2
1 2
8
1 2 2 1 1
1 2 2 1
1 1
3
3 1
4 2 1 5
1
1
1 2
1 1
1 2
1 2 1 2 1 2 1
1 1 1
2018 Microchip Technology Inc. DS50002832A-page 29 Low-Voltage Power Factor Correction Development Kit User’s Guide
FIGURE A-7: AUXILIARY POWER SUPPLY MODULE BOTTOM ASSEMBLY
1
2 1 2 1 1 2 2 1 1 2
2 1
2 1
8 1 2
1 2 1 2 1
1 2
1 2 1 1 2 1
2 2 1 2 1 2 2 1 1 2 1 1 2 2 1 2 2 1 1 2 3 2 1 2 1 1 16 2 1 1 1 2 1 3 1 15 2 1 1 2 1 1 2 1 2 14 2 1 4 3 1 2 5 4 13 2 1 2 2 5 12 2 1 2 1 1 6 11 1 2 1 2 1 1 2 1 2 1 7 10 2 1 2 1 1 2 1 1 1 8 9 1 2 3 2 1 1 2 2 1 4 1 1 2 1 1 2 1 2 2
1 1 2 1 1 2 1 1 2 2 3
1 2
DS50002832A-page 30 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Appendix B. Bill of Materials (BOM)
This appendix contains the Bill of Materials (BOMs) for the LVPFC Development Board and for the Auxiliary Power Supply module. • Bill of Materials – LVPFC Development Board • Bill of Materials – Auxiliary Power Supply Module
B.1 BILL OF MATERIALS – LVPFC DEVELOPMENT BOARD Table B-1 shows the Bill of Materials for the LVPFC Development Board.
TABLE B-1: BILL OF MATERIALS (BOM) – LVPFC DEVELOPMENT BOARD Manufacturer Part Qty Designator Description Manufacturer Number 4 AGND, TP1, TP2, TP4 Connector Test Point, Loop, Keystone Electronics Corp. 5011 Black, Through-Hole (TH) 5 C2, C6, C12, C13, C16 Capacitor, Ceramic, 0.1 µF, Taiyo Yuden Co., Ltd. EMK107B7105KA-T 16V, 10%, X7R, SMD, 0603 1 C3 Capacitor, Film, 0.33 µF, 10%, Wurth Elecktronic 890324025034CS 275 VAC, Radial 2 C4, C5 Capacitor, 1500 µF, 20%, 50V Wurth Elecktronic 860010680026 1 C7 Capacitor, Film, 0.68 µF, 10%, Wurth Elecktronic 890334025045 310 VAC, Radial 2 C8, C9 Capacitor, Film, 0.47 µF, 10%, Wurth Elecktronic 890334024005CS 310 VAC, Radial 2 C10, C11 Capacitor, Ceramic, 4700 pF, Murata Electronics® DE2E3KY472MN3AU02F 300V, 20%, Radial, P7.5D8H11 1 C14 Capacitor, Ceramic, 0.022 µF, Johanson Dielectrics 501R18W223KV4E 500V, 10%, X7R, SMD, 1206 2 C15, C25 Capacitor, Aluminum, 47 µF, Wurth Elecktronic 860010572005 35V, 20%, Radial, P2D5H12.5 1 C17 Capacitor, Ceramic, 100 pF, Vishay Intertechnology, Inc. VJ0603Y101KXACW1BC 50V, 10%, X7R, SMD, 0603 1 C19 Capacitor, Aluminum, 47 µF, Wurth Elecktronic 860080774008 20%, 63V, Through-Hole 1 C20 Capacitor, Ceramic, 0.1 µF, KEMET C1210C104KCRACTU 500V, 10%, X7R, SMD, 1210 2 C21, C22 Capacitor, Ceramic, 680 pF, Yageo Corporation CC0805KRX7R0BB681 100V, X7R, 0805 2 C23, C24 Capacitor, Ceramic, 6800 pF, KEMET C0603C682K5RACTU 50V, 10%, X7R, SMD, 0603 3 CH1, CH2, VAC Connector Test Point, Loop, Keystone Electronics Corp. 5010 Red, TH
2018 Microchip Technology Inc. DS50002832A-page 31 Low-Voltage Power Factor Correction Development Kit User’s Guide
TABLE B-1: BILL OF MATERIALS (BOM) – LVPFC DEVELOPMENT BOARD (CONTINUED) Manufacturer Part Qty Designator Description Manufacturer Number 8 CS1, CS2, PFC-PWM1, Misc., Test Point PC Mini, Keystone Electronics Corp. 5004 PFC-PWM2, Vac_in, 0.040", D, Yellow Vpfc_sense, ZCD1, ZCD2 7 D1, D8, D9, D10, D11, Diode, Rectifier, 1N4148, Micro Commercial 1N4148W-TP D13, D15 1.25V, 150 mA, 100V, Components SOD-123 2 D2, D3 Diode, Rectifier, ES3B, Vishay Intertechnology, Inc. ES3B-E3/57T 900 mV, 3A, 100V, DO-214AB_SMC 1 D4 Diode, Schottky, STPS1150A, STMicroelectronics STPS1150A 790 mV, 1A, 150V, DO-214AC_SMA 1 D5 Diode, Rectifier Bridge, 600V, SMC Diode Solutions Co. KBP306GTB 3A, TH, SIP-4 LTD 2 D6, D7 Diode, Rectifier, US1J 1.7V, Micro Commercial US1J-TP 1A, 600V, DO-214AC_SMA Components 1 D12 Diode, Rectifier, RS3J, 1.3V, Vishay Intertechnology, Inc. RS3J-E3/57T 3A, 600V, DO-214AB_SMC 2 D14, D16 Diode, Zener, BZX84-C3V3, NXP Semiconductors BZX84-C3V3,215 3.3V, 250 mW, SOT-23-3 2 F1 Fuse Holder, 5 mm, TH Littelfuse® 01110501Z 1 F2 Fuse, Glass, 5A, 250 VAC, Littelfuse 0217005.HXP 5x20 mm 1 J1 Connector, Terminal, 5 mm, On-Shore Technology, Inc. OSTVI030152 1x3, Female, 12-28AWG, 16A, TH, R/A 2 J2, J3 Connector, Terminal, 5.08 mm, On-Shore Technology, Inc. OSTVI022152 1x2 Female, 12-28AWG, 16A, TH, R/A 1 J4 Connector, Edge, MECF, Samtec, Inc. MECF-30-01-L-DV-WT 1.27 mm, 60P, Female, SMD, Vertical 2 J8, J9 Connector, Terminal, 2.54 mm, PHOENIX CONTACT 1725656 1x2, Female, 20-30AWG, 6A, TH, R/A 2 L1, L3 Inductor, Customized Part, Wurth Elecktronic 750316197 11.5A, T/H, PFC 1 L2 Common-mode Choke, 2 mH, Wurth Elecktronic 7448031002 10A, 2 LN, TH 1 L4 Inductor, Fixed, 4.7 µH, 6.5A, Wurth Elecktronic 744750230047 12.5 mOhm, TH 1 MOV1 Varistor, MO, 420V, 45J, Disc, TDK Corporation S10K420 10 mm 2 Q2, Q4 N-FET, IPP126N10N3G, 100V, Infineon Technologies AG IPP126N10N3GXKSA1 58A, 0.0123R, 94W, TO-220-3 1 Q3 N-FET, 2N7002-7-F, 60V, Diodes Incorporated® 2N7002-7-F 170 mA, 370 mW, SOT-23-3 2 R1, R10 Resistor, TKF, 1k, 1%, 1/10W, Panasonic® - ECG ERJ-3EKF1001V SMD, 0603
DS50002832A-page 32 2018 Microchip Technology Inc. Bill of Materials (BOM)
TABLE B-1: BILL OF MATERIALS (BOM) – LVPFC DEVELOPMENT BOARD (CONTINUED) Manufacturer Part Qty Designator Description Manufacturer Number 2 R2, R9 Resistor, TKF, 15R, 1%, 1/4W, Panasonic® - ECG ERJ-8ENF15R0V SMD, 1206 2 R4, R30 Resistor, TF, 2.20k, 1%, 1/8W, Vishay Intertechnology, Inc. MCT06030C2201FP500 SMD, 0603 8 R5, R6, R7, R11, R14, Resistor, TKF, 10k, 1%, 1/4W, Vishay Intertechnology, Inc. CRCW120610K0FKEA R15, R16, R21 SMD, 1206 1 R8 Resistor, TKF, 51R, 1%, Yageo Corporation RC0603FR-0751RL 1/10W, SMD, 0603 4 R12, R13, R22, R23 Resistor, TKF, 120R, 1%, Stackpole Electronics, Inc. RMCF0603FT120R 1/10W, SMD, 0603 4 R17, R18, R24, R25 Resistor, TKF, 10R, 1%, 1/4W, Panasonic - ECG ERJ-8ENF10R0V SMD, 1206 2 R19, R26 Resistor, TKF, 3.3k, 1%, Panasonic - ECG ERJ-3EKF3301V 1/10W, SMD, 0603 4 R20, R35, R37, R38 Resistor, TKF, 10k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1002V SMD, 0603 2 R27, R39 Resistor, TKF, 100R, 1%, Panasonic - ECG ERJ-3EKF1000V 1/10W, SMD, 0603 4 R28, R31, R32, R33 Resistor, TKF, 10R, 1%, Stackpole Electronics, Inc. RMCF0603FT10R0 1/10W, SMD, 0603 1 R29 Resistor, TKF, 0R, SMD, 1206 Panasonic - ECG ERJ-8GEY0R00V 1 R34 Resistor, TKF, 6.2k, 1%, Panasonic - ECG ERJ-3EKF6201V 1/10W, SMD, 0603 1 R36 Resistor, TKF, 7.5k, 1%, Panasonic - ECG ERJ-3EKF7501V 1/10W, SMD, 0603 1 RL1 Relay Power, SPST-NO, 5V, Omron Electronics LLC – G6C-1114P-US-DC5 10A, 250 VAC, TH EMC Division 2 SCR1, SCR2 Machine Screw Pan, Phillips, B&F™ Fasteners Supply MPMS 003 0008 PH M3 2 T1, T2 Transformer, Current, 1:100, Coilcraft CS4100V-01L 1 MHz, 24A, TH 1 TH1 Resistor, Thermistor, NTC, TDK Corporation B57235S100M54 10R, 3A, Radial 2 WASHER1, WASHER2 Washer Flat, M3, Nylon Essentra Components MFW030A 1 MOD1 Microchip Module, Microchip Technology Inc. 04-10751 MCHP-10751 7805, Replacement 1 MOD2 Microchip Module, Microchip Technology Inc. 04-10749 MCHP-10749, UWVR, 5W, Flyback 2 U1, U2 Microchip Analog FET Driver, Microchip Technology Inc. MCP14A0452-E/SN MCP14A0452-E/SN, SOIC-8 1 U3 Microchip Analog Temperature Microchip Technology Inc. MCP9700T-E/TT Sensor, -40C to +150°C, MCP9700T-E/TT, SOT-23-3 1 U4 IC Comparator, Precision, Microchip Technology Inc. MIC6270YM5-TR 2-36V, SOT23-5
2018 Microchip Technology Inc. DS50002832A-page 33 Low-Voltage Power Factor Correction Development Kit User’s Guide
B.2 BILL OF MATERIALS – AUXILIARY POWER SUPPLY MODULE Table B-2 shows the Bill of Materials for the Auxiliary Power Supply module.
TABLE B-2: BILL OF MATERIALS (BOM) – AUXILIARY POWER SUPPLY MODULE Manufacturer Part Qty Designator Description Manufacturer Number 1 C1 Capacitor, Ceramic, 47 pF, 200V, KEMET C0805C470J2GACTU 5%, C0G, NP0, SMD, 0805 1 C2 Capacitor, Film 1.5 µF, 450V, 5%, Panasonic® - ECG ECW-FD2W155JB RAD, P7.5L17.5W9.3H17.5 1 C3 Capacitor, Aluminum, 3.3 µF, 450V, Rubycon Corporation 450PK3R3MEFC8X11.5 20%, RAD_P3.5D8H13 2 C4, C5 Capacitor, Ceramic, 1000 pF, 250V, Murata Electronics® GRM21AR72E102KW01D 10%, X7R, SMD, 0805 1 C6 Capacitor, Aluminum, 220 µF, 16V, Wurth Elecktronic 870025374003 20%, 0.015R, RAD_P3.5D8H8 2 C7, C12 Capacitor, 100 µF, 20%, 16V Wurth Elecktronic 860010372006 1 C8 Capacitor, Ceramic, 4.7 µF, 25V, TDK Corporation C2012X5R1E475M125AB 20%, X5R, SMD, 0805 2 C9, C13 Capacitor, Ceramic, 1 µF, 16V, Taiyo Yuden Co., Ltd. EMK107B7105KA-T 10%, X7R, SMD, 0603 1 C10 Capacitor, Ceramic, 2200 pF, 300V, Murata Electronics DE2E3KY222MN3AU02F 20%, RAD_P7.5D8H11 2 C17, C22 Capacitor, Ceramic, 1000 pF, 50V, AVX Corporation 06035A102JAT2A 5%, C0G, SMD, 0603 1 C21 Capacitor, Ceramic, 0.1 µF, 16V, AVX Corporation 0603YC104KAT2A 10%, X7R, SMD, 0603 1 C23 Capacitor, Ceramic, 100 pF, 50V, Cal-Chip Electronics Inc. GMC10CG101J50NTLF 5%, NP0, SMD, 0603 1 C28 Capacitor, Ceramic, 0.022 µF, 50V, AVX Corporation 06035C223JAT2A 5%, X7R, SMD, 0603 2 D1, D2 1.0A High-Voltage Schottky Barrier Diodes Incorporated® DFLS1150 Rectifier 1 D4 Diode, Rectifier, US1K, 1.7V, 1A, Diodes Incorporated US1K-13 800V, DO-214AC_SMA 2 D5, D10 Diode, Schottky, BAT54HT1G, 30V, ON Semiconductor® BAT54HT1G 200 mA, 40V, SOD-323 1 D9 Diode, Zener, 12V, 200 mW, ON Semiconductor MM3Z12VST1G SOD-323 3 J2, J3, J4 Connector Header, 2.54 Male, 1x2, Molex® 0901210762 Gold, 6.75 mm, TH, R/A 1 L1 Inductor, Fixed, 100 µH, 900 mA, Wurth Elecktronic 744772101 190 mOhm 1 L2 Inductor, Fixed, 1 µH, 2.7A, Wurth Elecktronic 74438335010 47 mOhm, SMD 1 LD1 Diode, LED, Red, 2V, 20 mA, OSRAM Opto LS R976-NR-1 104 mcd, Diffuse, SMD, 0805 Semiconductors GmbH. 1 LD2 Diode, LED, Red, 1.85V, 30 mA, Kingbright Electronic Co., WP4060SRD 200 mcd, Diffuse, RAD, 1.8 mm Ltd. 1 Q2 Transistor, BJT, NPN, Diodes Incorporated MMBT2222A-7-F FMMT2222A, 40V, 600 mA, 330 mW, SOT-23-3
DS50002832A-page 34 2018 Microchip Technology Inc. Bill of Materials (BOM)
TABLE B-2: BILL OF MATERIALS (BOM) – AUXILIARY POWER SUPPLY MODULE (CONTINUED) Manufacturer Part Qty Designator Description Manufacturer Number 1 Q3 Transistor, FET N-CH, Infineon Technologies AG IPA60R950C6XKSA1 IPA60R950C6XKSA1, 600V, 4.4A, 0.95R, 26W, TO-220-3 1 Q4 Transistor, BJT, PNP, MMBT2907A, ON Semiconductor® MMBT2907A 60V, 800 mA, 350 mW, SOT-23-3 1 R1 Resistor, 22R, 1/4W, 1%, 1206, SMD Panasonic® - ECG ERJ-8ENF22R0V 1 R2 Resistor, TKF, 470R, 1%, 1/16W, Panasonic - ECG ERJ-6ENF4700V SMD, 0805 1 R3 Resistor, MO, 27k, 5%, 1W, AX, Yageo Corporation RSF100JB-73-27K P15L11.5D4.5 1 R4 Resistor, TKF, 5.6k, 1%, 1/10W, Yageo Corporation RC0603FR-075K6L SMD, 0603 1 R5 Resistor, TKF, 10R, 1%, 1/4W, Panasonic - ECG ERJ-8ENF10R0V SMD, 1206 2 R6, R8 Resistor, TKF, 100R, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1000V SMD, 0603 1 R7 Resistor, TKF, 220k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF2203V SMD, 0603 1 R9 Resistor, TKF, 150R, 1%, 1/10W, Stackpole Electronics, Inc. RMCF0603FT150R SMD, 0603 1 R12 Resistor, TKF, 562k, 1%, 1/10W, Stackpole Electronics, Inc. RMCF0603FT562K SMD, 0603 1 R13 Resistor, TKF, 6.2k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF6201V SMD, 0603 1 R15 Resistor, TKF, 18k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1802V SMD, 0603 1 R16 Resistor, TKF, 1k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1001V SMD, 0603 1 R18 Resistor, TKF, 20k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF2002V SMD, 0603 2 R19, R20 Resistor, TKF, 3.3R, 1%, 1/2W, Susumu Co., LTD. RL1632R-3R30-F SMD, 1206 1 R23 Resistor, TKF, 10k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1002V SMD, 0603 1 R24 Resistor, TKF, 0R, 1/10W, SMD, Panasonic - ECG ERJ-3GSY0R00V 0603 1 R25 Resistor, TKF, 8.66k, 1%, 1/10W, Yageo Corporation RC0603FR-078K66L SMD, 0603 2 R26, R32 Resistor, TKF, 10R, 1%, 1/10W, Panasonic - ECG ERJ-3EKF10R0V SMD, 0603 2 R27, R33 Resistor, TKF, 4.3k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF4301V SMD, 0603 1 R29 Resistor, TKF, 15k, 1%, 1/10W, Panasonic - ECG ERJ-3EKF1502V SMD, 0603 1 TR1 Transformer, SMPS, Flyback 6:1:1, Kaschke Components 063092-a 20V-375V, 5.5W, TH GmbH 1 U3 Optoisolator, FOD817A3SD, SMD-4 ON Semiconductor FOD817A3SD 1 U1 Microchip Analog, PWM Controller, Microchip Technology Inc. HV9123NG-G 3 MHz, HV9123NG-G, SOIC-16
2018 Microchip Technology Inc. DS50002832A-page 35 Low-Voltage Power Factor Correction Development Kit User’s Guide
NOTES:
DS50002832A-page 36 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Appendix C. Example Algorithm
This appendix provides algorithm examples for the LVPFC Development Board. Examples presented are: • Interleaved PFC Boost Converter in Transition Mode • Interleaved PFC Boost Converter in Continuous Conduction Mode
C.1 INTERLEAVED PFC BOOST CONVERTER IN TRANSITION MODE Figure C-1 shows a standard representation of a high-level block diagram of the implementation of an algorithm example of the interleaved PFC boost converter control system working in Transition mode. The exact implementation is subject to change with alternative control schemes and algorithms, and will be documented in subsequent code examples.
Note: In order to maintain interleaved operation, the Slave phase must have the same switching frequency as the Master phase.
Black building blocks represents hardware blocks, while blue building blocks represent software blocks. Software blocks have the following functions: •INT1: -Calculates VIN average and VOUT average every half of AC cycle (for instance, 10 ms for 50 Hz, 8.33 ms for 60 Hz) - Voltage compensator on VOUT average • ADCAN0 Interrupt: -Verifies VIN zero crossing - Accumulates VIN and VOUT - Stores current in IPH1 • IC1 Interrupt: - Measures PWM1 period of time - Calculates delay at which to trigger the PWM2 TON pulse and to set OC1 •OC1: - Programmed to generate the trigger for the PWM2 TON pulse • ADCAN2 Interrupt: - Stores current in IPH2 - Filters temperature
2018 Microchip Technology Inc. DS50002832A-page 37 Low-Voltage Power Factor Correction Development Kit User’s Guide
FIGURE C-1: INTERLEAVED PFC BOOST CONVERTER IN TRANSITION MODE
RA4_PWM1L VOUT PWM GENERATOR_1 PWM1 Power Stage Phase I
Current Limit CMP1_out for Overcurrent CMP3_out Protection Used to Trigger Next PWM1 Cycle PWM TON CMP1A RA0_CMP1A CMP3_out CS1 DAC (3V) CMP3A DAC RA0_CMP1A INT1 (0.3V) ZCD1 Boost REF FB ADC_TRIG Every VOUT Other Cycle AN3-RB0 ADCBUF3 ADC CORE_3
VAC_SENSE When VIN Zero Crossing, it Generates INT1 Interrupt
AN1-RA1 ADC CORE_1 ADCBUF1
ADCAN0 Interrupt ADC_TRIG ADCBUF0 ADC CORE_0 CS1
IC1BUF IC1 Interrupt CMP3_out IC1
OC1_out – FLT1 Current Reset OC1
RB13_PWM2L Power Stage PWM GENERATOR_2 PWM2 Phase II
ADCAN2 Interrupt Current Limit for Overcurrent Protection
CMP2A ADCBUF2 DAC ADC CORE_2 (3V) CS2
ADCBUF11 ADC Shared Core Temperature AN11
Timer1 Interrupt Every 10 msec Scheduler Called Every 1 msec (Timer2) UART_RX Faultcheck() UART_TXP Protocol 0001 Faulthandler() UART_TX Protocol 0000 Converter State_Machine
Legend: ADC: Analog-to-Digital Converter CMP: Comparator IC: Input Capture to measure the PWM period of frequency PWM: Pulse-Width Modulator ZCD: Zero-Cross Detection
DS50002832A-page 38 2018 Microchip Technology Inc. Example Algorithm
C.2 INTERLEAVED PFC BOOST CONVERTER IN CONTINUOUS CONDUCTION MODE Figure C-2 shows a standard representation of a high-level block diagram of the implementation of an algorithm example of the interleaved PFC boost converter control system working in Continuous Conduction mode. The exact implementation is subject to change with alternative control schemes and algorithms, and will be documented in subsequent code examples. Black building blocks represent hardware blocks, while blue building blocks represent software blocks. Software blocks have the following functions: • ADCAN0 Interrupt: - Calculates the current reference: 2 c2P2Z_compensator_out_V * ADCBUF1/VINAVG 2 Note: ADCBUF1 is proportional to the rectified input AC voltage. VINAVG is proportional to the square of the rectified average value of the input VAC voltage. The “c2P2Z_compensator_out” is the output of the voltage loop. - Samples IPH1 and executes PH1 current loop - Accumulates VIN and VOUT - Verifies zero crossing on VIN - Triggers INT1 if zero crossing is ‘True’ • ADCAN2 Interrupt: - Samples IPH2 and executes PH2 current controller • INT1: Interrupts every 10 msec (VIN zero crossing) -Calculates VIN average and squares it (VINAVG2) -Calculates VOUT average - Runs voltage compensator on VOUT average that calculates the DC current reference for the current loops
2018 Microchip Technology Inc. DS50002832A-page 39 Low-Voltage Power Factor Correction Development Kit User’s Guide
FIGURE C-2: INTERLEAVED PFC BOOST CONVERTER IN CONTINUOUS CONDUCTION MODE
VOUT PWM PWM I/O RA4_PWM1L Power Control Stage GENERATOR_1 Phase I
Current Limit for Overcurrent Protection
Duty Cycle CMP1A DAC RA0_CMP1A CS1 MAX_CURRENT Triggered by PWM1 at TON/2
ADCBUF0 AN3-RB0 ADC CORE_0 Boost VOUT
ADCBUF3 AN3-RB0 c2P2Z_compensator_out_V ADC CORE_3 ADCAN0 Interrupt VAC_SENSE ADCBUF1 AN1-RA1 ADC CORE_1
ADC Cores 0, 1 and 3 Triggered by PWM1 at TON/2
PWM PWM2 I/O RB14_PWM2L Power Control Stage GENERATOR_2 Phase II
Current Limit for Overcurrent Protection
Duty Cycle CMP2A DAC RA2_CMP2A CS2 MAX_CURRENT
ADCBUF2 ADCAN2 Interrupt ADC CORE_2
ADC Core 2 Triggered by PWM2 at TON/2
INT1
Scheduler Called Every 1 msec (Timer2) Timer1 Interrupt Every 10 msec UART_RX UART_TX Protocol 0001 Faultcheck() UART_TX Protocol 0000 Faulthandler() Converter State_Machine
Legend: ADC: Analog-to-Digital Converter DAC: Digital-to-Analog Converter CMP: Comparator IC: Input Capture to measure the PWM period of frequency PWM: Pulse-Width Modulator
DS50002832A-page 40 2018 Microchip Technology Inc. LOW-VOLTAGE POWER FACTOR CORRECTION DEVELOPMENT KIT USER’S GUIDE
Appendix D. Optional Supporting Equipment
D.1 INTRODUCTION This appendix provides information on the following equipment, which is recommended for use to improve the functionality of the LVPFC Development Kit: • Isolation Transformer • Active Load 50W
D.2 ISOLATION TRANSFORMER The Isolation Transformer 10:1 has the following features, as shown in Figure D-1 and Figure D-2.
FIGURE D-1: ISOLATION TRANSFORMER – FRONT PANEL 1 2
1. Illuminated mains power switch. 2. Four 4 mm banana plugs (0 VAC, 12 VAC, 24 Vac, PE connections).
FIGURE D-2: ISOLATION TRANSFORMER – BACK PANEL 1 2 3
1. Slide switch for input voltage selection (120 VAC/230 VAC). 2. Fuse socket. 3. IEC plug for mains connection. Note: The product number is ASC-70 and the manufacturer is ASCALAB d.o.o. (www.ascalab.com).
2018 Microchip Technology Inc. DS50002832A-page 41 Low-Voltage Power Factor Correction Development Kit User’s Guide
D.3 ACTIVE LOAD 50W The Active Load has the following features, as shown in Figure D-3.
FIGURE D-3: ACTIVE LOAD 50W(1,2) Front Back
10 1
1
4 3 2
7 6 5
9 8 2
Front Side Back Side 1. Display 1. 4 mm Banana Plugs 2. On/Off Push Button (red for positive and blue for 3. Pulse Push Button return line) 4. Preset Push Button 2. Plug for External 12 VDC Supply 5. I/P Push Button 6. Coarse Potentiometer 7. Fine Potentiometer 8. UVLO Potentiometer 9. Pulse Potentiometer 10. Preset LED (green) Pulse LED (yellow) On/Off LED (red) Note 1: The ASC-50W device’s standard delivery includes an external AC/DC wall plug adapter. All various AC input plugs are included. Manufacturer: XP Power. Type: VER12US120-JA. 2: The product number is ASC-50W and the manufacturer is ASCALAB d.o.o. (www.ascalab.com).
DS50002832A-page 42 2018 Microchip Technology Inc. Optional Supporting Equipment
NOTES:
2018 Microchip Technology Inc. DS50002832A-page 43 Worldwide Sales and Service
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DS50002832A-page 44 2018 Microchip Technology Inc. 08/15/18