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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 components that may shatter or explode if they fail. Appropriate 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 performance characteristics shown in Figure 1 when operated as specified in the Test Conditions.
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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 topside. Since the current sense for the FAN4810 is not differential, care must be taken to prevent a large di/dt from occurring across the PCB trace joining the output cap (assumed to be the reference return for the IC) to the current sense resistor. 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 stargrounding 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 25C 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 F, 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 circuits, 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 limitations the actual output with no fan is limited to 400W at inputs below 115VAC, and up to 40C ambient. Figure 2 displays the maximum power vs. line voltage with no fan. Above 115VAC input the maximum output power is 500W.
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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, 1/8 W, 1%, SMD 1206 453k, 1/8 W, 1%, SMD 1206 100k, 1/8 W, 1%, SMD 1206 15.8k, 1/8 W, 1%, SMD 1206 0.050, 3W, 1% 41.2k, 1/8 W, 1 %, SMD 1206 127k, 1/4 W, 1%, SMD 1210 2.37k, 1/8 W, 1%, SMD 1206 10k, 1/8 W, 5%, SMD 1206 47, 1/4 W, 5%, SMD 1210 511k, 1/8 W, 5%, SMD 1206 33.2k, 1/8 W, 1%, SMD 1206 39k, 2W, 5%, metal film 0, Jumper, 1206 200k, 1/8 W, 5%, SMD 1206 100, 1/8 W, 5%, 1206 10, 1/8 W, 5%, 1206 22, 1/8 W, 5%, 1206 0.47F, 250 VAC, 20% Metallized Polyester 0.47F, 16V, 10% X7R Ceramic 1206 0.1F, 50V, 10%, X7R Ceramic 1206 0.047F 630VDC, 10%, polypropylene 330F, 450V, 20%, Electrolytic 2.2nF, 50V, 10%, X7R Ceramic 1206 47pF, 25V, 10%, Ceramic 0.01F, 50V, 10%, X7R Ceramic 1206 1F, 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
1500F, 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
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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. 420H, 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
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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
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FAN4810EVAL
PRODUCT SPECIFICATION
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, and (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 a significant injury of the user. www.fairchildsemi.com
6/17/04 0.0m 003 Stock#DS30004810 (c) 2004 Fairchild Semiconductor Corporation
2. A critical component in 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.

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