Design Example Report
Title
Specification
Application
Author
Document
Number
Date
Revision
275 W PFC Front End Using HiperPFS
TM
-4
PFS7727H
90 VAC – 264 VAC Input; 385 VDC Output
PFC Front-End
Applications Engineering Department
DER-720
November 5, 2020
1.1
Summary and Features
•
Highly integrated, low component count, low-cost PFC
•
Ultra-low reverse recovery loss diode (Qspeed
TM
)
•
Power Integrations eSIP-16 low-profile controller package
•
“Cool-Pad” package reduces IC mounting hardware
•
Eliminates insulating pad/heat-spreader
•
EN61000-3-2 Class-D compliant
•
High PFC efficiency enables up to 80+ Platinum PC Main design
•
Enhanced light load power factor (PF)
•
PF >0.9 at 20% load and 230 VAC, 50 Hz input
•
PF >0.95 at 50% load
•
Frequency sliding maintains high efficiency across load range
•
>95% from 10 to 100% load (115 VAC and 230 VAC input)
•
Feed forward line sense gain – maintains relatively constant loop gain over entire operating voltage range
•
Excellent transient load response
•
Frequency adjusted over input line voltage and load
•
Spread-spectrum across >60 kHz window simplifies EMI filtering requirements
•
Integrated Qspeed switching diode reduces component count and simplifies assembly
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products) may
be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned
to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations
grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
DER-720 275 W PFC Front-End
05-Nov-20
Table of Contents
Introduction .........................................................................................................4
Power Supply Specification ...................................................................................6
Schematic ............................................................................................................7
Circuit Description ................................................................................................8
4.1
Input EMI Filter and Rectifier..........................................................................8
4.2
PFS7727H Boost Converter.............................................................................8
4.3
Input Feed Forward Sense Circuit ...................................................................9
4.4
Output Feedback ...........................................................................................9
4.5
Bias Supply Series Regulator ..........................................................................9
5 PCB Layout ........................................................................................................ 10
6 Bill of Materials .................................................................................................. 12
7 Inductor Design Spreadsheet .............................................................................. 14
8 Switching Inductor Specification .......................................................................... 19
8.1
Electrical Diagram ........................................................................................ 19
8.2
Electrical Specifications ................................................................................ 19
8.3
Materials ..................................................................................................... 19
8.4
Inductor Build Diagram ................................................................................ 20
8.5
Inductor Construction .................................................................................. 20
8.6
Winding Illustrations .................................................................................... 21
9 eSIP U1 Heat Sink .............................................................................................. 24
9.1
eSIP U1 Heat Sink Machining Drawing .......................................................... 24
9.2
eSIP U1 Heat Sink Fabrication Drawing ......................................................... 25
9.3
eSIP U1 Assembly to Heat Sink Drawing ....................................................... 26
10
Performance Data ........................................................................................... 27
10.1 No-Load/Light Load Input Power .................................................................. 27
10.2 PFC Efficiency .............................................................................................. 29
10.3 Power Factor ............................................................................................... 30
10.4 Regulation ................................................................................................... 31
10.4.1 Load Regulation .................................................................................... 31
10.4.2 Line Regulation ..................................................................................... 32
10.5 Overload ..................................................................................................... 33
10.6 THD ............................................................................................................ 34
10.7 Input Current Harmonic Distortion (IEC 61000-3-2 Class-D) ........................... 35
10.7.1 50% Load at Output ............................................................................. 35
10.7.2 100% Load at Output ............................................................................ 36
11
Thermal Performance ...................................................................................... 37
11.1 115 VAC Thermal Measurements .................................................................. 38
11.2 230 VAC Thermal Measurements .................................................................. 39
12
Input Waveforms ............................................................................................ 40
12.1 Input Current at 115 VAC and 60 Hz ............................................................. 40
12.2 Input Current at 230 VAC and 50 Hz ............................................................. 40
12.3 Start-up Waveforms ..................................................................................... 41
12.3.1 90 VAC and 60 Hz ................................................................................. 41
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
1
2
3
4
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05-Nov-20
DER-720 275 W PFC Front-End
12.3.2 115 VAC and 60 Hz ............................................................................... 41
12.3.3 230 VAC and 50 Hz ............................................................................... 42
12.3.4 264 VAC and 50 Hz ............................................................................... 42
12.4 Load Transient Response ............................................................................. 43
12.4.1 90 VAC, 60 Hz ...................................................................................... 43
12.4.2 115 VAC, 60 Hz..................................................................................... 43
12.4.3 230 VAC, 50 Hz..................................................................................... 44
12.4.4 264 VAC, 50 Hz..................................................................................... 44
12.5 Line Dropout ............................................................................................... 45
12.5.1 1000 ms Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ............... 45
12.5.2 One Cycle Line Dropout (115 VAC / 60 Hz and 230 VAC / 50 Hz) ............. 46
12.6 Input Line Step............................................................................................ 46
12.6.1 Line Sag (115 VAC ~ 85 VAC ~ 115 VAC, 60 Hz) .................................... 46
12.6.2 Line Swell (132 VAC ~ 147 VAC ~ 132 VAC, 60 Hz) ................................ 47
12.6.3 Line Sag (230 VAC ~ 170 VAC ~ 230 VAC, 50 Hz) .................................. 47
12.6.4 Line Swell (264 VAC ~ 293 VAC ~ 264 VAC, 50 Hz) ................................ 48
12.7 Power Good (PG) ......................................................................................... 49
12.7.1 115 VAC and 60 Hz ............................................................................... 49
12.7.2 230 VAC and 50 Hz ............................................................................... 49
12.8 Brown-In and Brown-Out at 6 V / Minute Rate .............................................. 50
12.8.1 Thresholds............................................................................................ 50
12.8.2 Waveforms ........................................................................................... 50
12.8.3 Drain Voltage and Inductor Current........................................................ 52
12.9 Output Ripple Measurements........................................................................ 53
12.9.1 Ripple Measurement Technique ............................................................. 53
12.9.2 Measurement Results ............................................................................ 54
12.10
Gain-Phase Measurement Procedure and Results........................................ 56
12.10.1
Measured Bode Plots ......................................................................... 57
13
Line Surge Test............................................................................................... 59
13.1 Differential Mode Surge ............................................................................... 61
13.2 Common Mode Surge................................................................................... 61
14
EMI Scans ...................................................................................................... 62
14.1 EMI Test Set-up .......................................................................................... 62
14.2 EMI Scans ................................................................................................... 64
15
Appendix A ..................................................................................................... 66
15.1 Test Set-up for Efficiency Measurement ........................................................ 66
16
Revision History .............................................................................................. 68
Important Note:
All testing should be performed using an isolation transformer to provide the AC input to
the prototype board.
Page
3 of 69
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
DER-720 275 W PFC Front-End
05-Nov-20
1
Introduction
This report describes a PFC power supply utilizing a HiperPFS-4 PFS7727H PFC controller
with integrated power MOSFET and switching diode. This power supply is intended as a
general purpose platform that operates from universal input line voltage and provides a
regulated 385 V DC output voltage and continuous output power of 275 W.
The DER-720 power supply is designed to operate with forced air cooling greater than
200 LFM for all input and load conditions up to the rated maximum ambient temperature
of 50
o
C.
This document contains the power supply specification, schematic, bill of materials,
inductor documentation, printed circuit layout, and performance data.
Figure 1 –
Populated Circuit Board Photograph (Top View).
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page
4 of 69
05-Nov-20
DER-720 275 W PFC Front-End
Figure 2 –
Populated Circuit Board Photograph (Back View).
Page
5 of 69
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
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