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FAN4810EVAL
Evaluation Kit User’s Guide
Power Factor Controller
General Description
The FAN4810 Evaluation Board is a power-factor-corrected
500W off-line power supply. The supply has a single 400V
output and operates over an input voltage range of 90 VAC to
265 VAC. The Evaluation Board uses an average mode boost
PFC that allows it to be fully complaint with IEC 61000-3-2
limits for harmonic emission.
When operating the FAN4810 Evaluation Board there are
two things to keep in mind. A minimum load of 15 to 20
Watts is required to prevent output from rising to the OVP
point. This will provide continuous operation and prevent the
PFC from periodic shutdown due to OVP. Also, there is no
current inrush limiting included in the Evaluation Board.
Because of this it is suggested that the input voltage is
always ramped up slowly.
How to Operate
Use the following procedure to safely operate the power
supply.
1.
2.
3.
Connect a 100W load across the output terminals
(J3 and J4).
Connect a DC voltmeter across the output terminals.
Connect an isolated variable AC source (such as a
variac) to input terminals J1 and J2. A DC source may
be substituted at the input for easier examination of the
waveforms.
Slowly increase the AC input voltage to at least 90VAC
(Do not exceed 265VAC). If applying a DC input
increase it to 120 Volts.
Confirm that the output voltage increases as the input
voltage is increased.
As the input voltage approaches very close to 90VAC
(120VDC) the Board output should read approximately
404VDC within 5 sec.
Remove the AC input and verify that the output voltage
has dropped to zero.
Connect a 500W load across the output terminals and
reapply the AC input.
4.
Evaluation Kit Contents
The FAN4810 Evaluation Kit contains the following items:
1.
2.
FAN4810 Evaluation Kit Users Guide
Fully Functional FAN4810 Evaluation Board
5.
6.
7.
Circuit Design
Refer to Application Note, AN-6004 for detailed design
information on this board.
8.
Performance Data
CAUTION!
The FAN4810 Evaluation Board contains voltage
potentials capable of causing serious injury, and compo-
nents that may shatter or explode if they fail. Appropri-
ate precautions must be taken to prevent injury should
such situations occur. The use of protective eyeware is
strongly recommended.
To safely observe circuit waveforms, an isolation
transformer should be used between the Evaluation
Board and the AC line.
Do not operate this board with DC/AC voltages
outside the design limits.
Replace circuit components only with those
recommended in the parts list of this User’s Guide.
To measure the Eval Board performance across the range
of permissible input voltages use an isolated Variac or
adjustable AC source. It is suggested that the input voltage is
increased slowly as the evaluation board has no inrush
current limiting.
A typical FAN4810 evaluation board will have the perfor-
mance characteristics shown in Figure 1 when operated as
specified in the Test Conditions.
REV. 1.0.2 6/17/04
FAN4810EVAL
PRODUCT SPECIFICATION
FAN4810 with 500 Watt Load
97
96
95
Efficiency (%)
94
6
93
5.5
92
91
90
89
90
110
130
150
170
190
210
230
V line (RMS)
Efficiency
THD
5
4.5
4
250
THD (%)
7.5
7
6.5
The unit will safely provide 500W at 90 VAC input with
adequate fan cooling. Note that even though the FAN4810
Evaluation board can achieve 500 Watts with additional fan
cooling, the heatsinks utilized are not optimal for use with
a fan.
Layout Considerations
The FAN4810 Evaluation board contains high impedance,
low-level signals and low impedance, high level circuits;
consequently extra care is required in component placement,
grounding and PC trace routing. In order to shield low-level
circuits from the high level signals, control circuits were
placed in surface mount form on the bottom side of the
board. This allowed a return shield to be placed on the top-
side. Since the current sense for the FAN4810 is not differen-
tial, care must be taken to prevent a large di/dt from occur-
ring across the PCB trace joining the output cap (assumed to
be the reference return for the IC) to the current sense resis-
tor. Since the best reference for the IC is at the output cap
return potential (the most stable potential), the difference
between this potential and the current sense resistor return
potential must be kept to a minimum. This is done by star-
grounding all the 400V return connections to the output
capacitor, and/or maintaining very low inductive/resistive
paths from all power devices to the output capacitor return.
Some general layout guidelines:
A. Return the low side of the timing capacitor (C18)
directly to the IC ground pin.
Figure 1. FAN4810 Evaluation Board Test Results
Test Conditions:
500 Watt load on output at 25ºC
Equipment Used:
Voltech Digital Single-Phase Power
Analyzer Model PM100, 500W Electronic load.
Power Ratings
500
480
Output (W)
Pout
460
440
420
400
85
90
95
100
105
110
115
Input (VAC)
B. Bypass the reference and supply voltage pins directly to
the IC ground pin with a 1 µF, low ESR/ESL capacitor.
C. Return all compensation components directly to the IC
ground pin, keeping the lead lengths as short as possible.
D. Make sure that low-level, noise free, returns do not share
return paths with high-level, or noisy, signals (
e.g.
, gate
drive).
E. Isolate and/or shield rapidly changing waveforms, such
as the drain of Q1 from sensitive, high impedance cir-
cuits, such as the timing capacitor, PFC current sense
input, error amplifier input/output,
etc.
Figure 2. Output Power vs. Line Voltage
The FAN4810 Evaluation Board is designed to provide up to
500W output with an input of 90VAC. Due to thermal limita-
tions the actual output with no fan is limited to
≤
400W at
inputs below 115VAC, and up to 40ºC ambient. Figure 2
displays the maximum power vs. line voltage with no fan.
Above 115VAC input the maximum output power is 500W.
2
REV. 1.0.2 6/17/04
PRODUCT SPECIFICATION
FAN4810EVAL
FAN4810 Evaluation Board Parts List
Qty
Resistors
2
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
1
8
453k
Ω
, 1/8 W, 1%, SMD 1206
453k
Ω
, 1/8 W, 1%, SMD 1206
100k
Ω
, 1/8 W, 1%, SMD 1206
15.8k
Ω
, 1/8 W, 1%, SMD 1206
0.050
Ω
, 3W, 1%
41.2k
Ω
, 1/8 W, 1 %, SMD 1206
127k
Ω
, 1/4 W, 1%, SMD 1210
2.37k
Ω
, 1/8 W, 1%, SMD 1206
10k
Ω
, 1/8 W, 5%, SMD 1206
47
Ω
, 1/4 W, 5%, SMD 1210
511k
Ω
, 1/8 W, 5%, SMD 1206
33.2k
Ω
, 1/8 W, 1%, SMD 1206
39k
Ω
, 2W, 5%, metal film
0
Ω
, Jumper, 1206
200k
Ω
, 1/8 W, 5%, SMD 1206
100
Ω
, 1/8 W, 5%, 1206
10
Ω
, 1/8 W, 5%, 1206
22
Ω
, 1/8 W, 5%, 1206
0.47µF, 250 VAC, 20% Metallized Polyester
0.47µF, 16V, 10% X7R Ceramic 1206
0.1µF, 50V, 10%, X7R Ceramic 1206
0.047µF 630VDC, 10%, polypropylene
330µF, 450V, 20%, Electrolytic
2.2nF, 50V, 10%, X7R Ceramic 1206
47pF, 25V, 10%, Ceramic
0.01µF, 50V, 10%, X7R Ceramic 1206
1µF, 50V, 10%, X7R Ceramic 1210
Any
Any
Any
Any
Ohmite, 15FR050
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
Wima MKS4-R
Murata / GRM42-6X7R474K016AB
Murata / GRM42-6X7R104K050AB
WIMA, MKP10
Panasonic TSU-Series
Any
Any
Any
Any
R1A, R1B
R2A, R2B
R3
R4
R5
R6
R7A, R7B, R7C
R8
R9
R10
R11
R12
R14, R13
R15
R16
R17
R18
R19
C1
C2
C3, C8, C19
C4
C5
C6
C7
C9
C10, C11, C12,
C13, C14, C16,
C20, C21
C15
C17
C18
D1
D2
D3, D4
D5
D6, D7
D8
B1
3
Description
Vendor/Parts/Distributor
Designation
Capacitors
1
1
1
Diodes
1
1
2
1
2
1
1
1500µF, 25V, Electrolytic
1000pF, 50V, 20%, X7R Ceramic 1206
470pF, 25V, 5%, C0G Ceramic 1206
600V, 15A Stealth Diode
600V, 3A Rectifier Diode
50V, 1A Fast Recovery Diode
20V 1W Zener Diode
100V, 3A Rectifier Diode
20V, 500mA Schottky Rectifier
600V, 25A Bridge Rectifier
Panasonic / ECA-1EFQ152L
Any
Any
Fairchild ISL9R1560P2
Fairchild 1N5406
Fairchild RGF1A
Fairchild 1N4747A
Fairchild 1N5401
Fairchild MBR0520L
Fairchild GBPC2506
REV. 1.0.2 6/17/04
FAN4810EVAL
PRODUCT SPECIFICATION
FAN4810 Evaluation Board Parts List
(continued)
Qty
Transistors
1
1
2
ICs
1
1
Fuse
1
2
1
1
1
1
4
1
2
2
5
5
5
1
1
8
8 Amp 250 VAC Fast Acting
5x20 Fuse Clips
TO220 Heatsinks
TO220/TO218 Heatsink
TO220 Insulator, Sarcon Tube
TO218 Insulator
Standard Banana Plug
6-32 1/2" Phillips Machine Screw
6-32 Lock Washer
6-32 Hex Nut
4-40 5/16" Phillips Machine Screw
4-40 Lock Washer
4-40 0.875" Hex threaded spacers
Unthreaded round aluminum or nylon
Spacer, 1/4" OD, 0.140” ID, 1/4" Length
Blank Evaluation Board
Thru-Hole Test Pins, 3M Series 2400
Digi-Key / 929834-02-36-ND
TP1, TP2, TP3,
TP4, TP5, TP6,
TP7, TP8
Johnson Components
Digi-Key / J176-ND
Johnson Components
Digi-Key / J169-ND
Little Fuse / Series 217
Little Fuse
Aavid / 534265BO3453
Thermalloy / 6300B
Fujipoly / 30T-11-1000L
Fujipoly / 30T-TO-3PF
Bergquist / K10-104
Johnson Comp. / 108-0740-001
(Ref. D1)
(Ref. Q1)
(Ref. D1)
(Ref. Q1)
J1, J2, J3, J4
(Ref. Q1)
(Ref. Q1)
(Ref. Q1)
F1
Hardware
FAN4810IM Power Factor Cont.
420
µ
H, 10A
Fairchild Semiconductor
Premier Magnetics Inc. / TSD-902
Pulse / P0316
U1
L1
Magnetics
500V, 24A MOSFET
MMBT3904, 200mA, 40V, NPN Transistor
MMBT3906, 200mA, 40V, PNP Transistor
Fairchild FQA24N50
Fairchild
Fairchild
Q1
Q2
Q3, Q4
Description
Vendor/Parts/Distributor
Designation
4
REV. 1.0.2 6/17/04
PRODUCT SPECIFICATION
FAN4810EVAL
D2 1N5406
TP4
12, 11
J1
AC INPUT
F1
R2A
L1
7, 8
TP1
TP2
J3
D1
R7A
400 VDC
C1
R7B
R1A
R2B
R14
R13
J2
R1B
D5
D7
C2
R5B
R4
TP3
TP5
R19
Q1
R7C
C5
C4
D6
R5A
C3
R3
R9
R8
C17
J4
TP6
R10
400 VDC RTN
R15
TP7
C15
Q3
Q2
C10
R18
C21
D3
C12
6
L1
5
R17
C7
R12
R6
1
2
3
4
IEAO
IAC
ISENSE
VRMS
C6
VEAO
FB
VREF
VCC
16
15
14
13
12
11
10
9
R11
C13
C16
D4
R16
TP8
Q4
C19
C18
C14
5 CLKSD PFC OUT
6
CLK OUT
NC
7
GND
RAMP1
8
NC
GND
FAN4810
C20
C11
C9
C8
D8
Figure 3. Schematic
REV. 1.0.2 6/17/04
5
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