Powerint公司的100W PFC" title="PFC">PFC電源參考設計是采用HiperPFS系列的 PFS704EG 器件,該系列器件集成了CCM PFC控制器,柵極驅動器和高壓功率MOSFET,和EN61000-3-2 Class C與D兼容,10%和20%負載時的效率高,從10%到滿負荷的效率大于95%,可提供高達1kW的峰值輸出功率,頻率可根據火線電壓和頻率調整,主要用在PC,大功率適配器,打印機,大功率LED照明,工業和家用電器,視頻游戲機控制臺等.本文介紹了HiperPFS 系列產品亮點和主要特性, 功能框圖, 374W,180W和900W PFC電源電路圖,以及采用PFS740EG的高性能小型100W PFC電源參考設計技術指標,電路圖,材料清單和PCB布局圖.

The HiperPFS device family members incorporate a continuous condition mode (CCM) boost PFC controller, gate driver, and high voltage power MOSFET in a single, low-profile eSIP™ power package that is able to provide near unity input power factor. The HiperPFS devices eliminate the PFC converter’s need for external current sense resistors, the power loss associated with those components, and leverages an innovative control technique that adjusts the switching frequency over output load, input line voltage, and even input line cycle. This control technique is designed to maximize efficiency over the entire load range of the converter, particularly at light loads. Additionally, this control technique significantly minimizes the EMI filtering requirements due to its wide-bandwidth spread spectrum effect. HiperPFS includes Power Integrations’ standard set of comprehensive protection features, such as integrated soft-start, UV, OV, brown-in/out, and hysteretic thermal shutdown. HiperPFS also provides cycle-by-cycle current limit for the power MOSFET, power limiting of the output for over-load protection, and pin-to-pin short-circuit protection.

HiperPFS’s innovative variable-frequency continuous conduction mode of operation (VF-CCM) minimizes switching losses by maintaining a low average switching frequency, while also varying the switching frequency in order to suppress EMI, the traditional challenge with continuous-conduction-mode solutions. Systems using HiperPFS typically reduce the total X and Y capacitance requirements of the converter, the inductance of both the boost choke and EMI noise suppression chokes, reducing overall system size and cost. Additionally, compared with designs that use discrete MOSFETs and controllers, HiperPFS devices dramatically reduce component count and board footprint while simplifying system design and enhancing reliability. The innovative variable-frequency, continuous conduction mode controller enables the HiperPFS to realize all of the benefits of continuous-conduction mode operation while leveraging low-cost, small, simple EMI filters.

Many regions mandate high power factor for many electronic products with high power requirements. These rules are combined with numerous application-specific standards that require high power supply efficiency across the entire load range, from full load to as low as 10% load. High efficiency at light load is a challenge for traditional PFC approaches in which fixed MOSFET switching frequencies cause fixed switching losses on each cycle, even at light loads. HiperPFS simplifies compliance with new and emerging energy-efficiency standards over a broad market space in applications such as PCs, LCD TVs, notebooks, appliances, pumps, motors, fans, printers, and LED lighting.

HiperPFS advanced power packaging technology and high efficiency simplifies the complexity of mounting the package and thermal management, while providing very high power capabilities in a single compact package; these devices are suitable for PFC applications from 75 W to 1 kW

HiperPFS 系列產品亮點:

Protected Power Factor Correction Solution

• Incorporates high-voltage power MOSFET, controller, and gate driver

• EN61000-3-2 Class D compliance

• Integrated protection features reduce external component count

• Accurate built-in brown-in/out protection

• Accurate built-in undervoltage (UV) protection

• Accurate built-in overvoltage (OV) protection

• Hysteretic thermal shutdown (OTP)

• Internal power limiting function for overload protection

• Cycle-by-cycle power switch current limit

• No external current sense required

• Provides “lossless” internal sensing via sense-FET

• Reduces component count and system losses

• Minimizes high current gate drive loop area

• Minimizes output overshoot and stresses during start-up

• Integrated power limit and frequency soft start

• Improve dynamic response

• Input line feed-forward gain adjustment for constant loop gain across entire input voltage range

• Eliminates up to 40 discrete components for higher reliability and lower cost

Intelligent Solution for High Efficiency and Low EMI

• Continuous conduction mode PFC uses novel constant volt/ amp-second control engine

• High efficiency across load using a UF boost diode

• Low cost EMI filter

• Universal input device (PFS704 – PFS716) utilize frequency sliding technique for light load efficiency improvements

• >95% efficiency from 10% load to full load at low line input voltage

• >96% efficiency from 10% load to full load at high line input voltage

• High line input device (PFS723–PFS729) maintain higher average switching frequency to minimize boost inductance and core size

• >94% efficiency from 10% load to full load

• Variable switching frequency to simplify EMI filter design

• Varies over line input voltage to maximize efficiency and minimize EMI filter requirements

• Varies with input line cycle voltage by >60 kHz to maximize spread spectrum effect

Advanced Package for High Power Applications

• Up to 1 kW peak output power capability in a highly compact package

• Simple clip mounting to heat sink

• Can be directly connected to heat sink with insulation pad

• Provides thermal impedance equivalent to a TO-220

• Staggered pin arrangement for simple routing of board traces and high voltage creepage requirements

• Single package solution for PFC converter reduces assembly costs and layout size

HiperPFS系列主要特性:

• Single chip solution for boost power factor correction (PFC)

• EN61000-3-2 Class C and D compliant

• High light load efficiency at 10% and 20% load

• >95% efficiency from 10% load to full load

• <130 mW no-load consumption at 230 VAC with output in regulation

• <50 mW no-load consumption at 230 VAC in remote off state

• Frequency adjusted over line voltage, and line cycle

• Spread-spectrum across >60 kHz window to simplify EMI filtering requirements

• Lower boost inductance

• Provides up to 1 kW peak output power

• >1 kW peak power delivery in power limit voltage regulation mode

• High integration allows smaller form factor, higher power density designs

• Incorporates control, gate driver, and high-voltage power MOSFET

• Internal current sense reduces component count and system losses

• Protection features include: UV, OV, OTP, brown-in/out, cycle-by-cycle current limit, and power limiting for overload protection

• Halogen free and RoHS compliant

HiperPFS系列應用:

• PC

• High power adaptors

• Printer

• High power LED lighting

• LCD TV

• Industrial and appliance

• Video game consoles

• Generic PFC converters

圖1. HiperPFS系列功能框圖

圖2.采用PFS714EG的347W PFC電源電路圖

圖3.采用PFS708EG的180W PFC電源電路圖

圖4.采用PFS729EG的900W PFC電源電路圖

采用PFS740EG的高性能小型100W PFC電源參考設計

This document is an engineering report describing a PFC power supply utilizing a HiperPFS PFS704EG integrated PFC controller. This power supply is intended as a general purpose evaluation platform that operates from universal input and provides a regulated 380 VDC output voltage and a continuous output power of 100 W.

This power supply can deliver the rated power at 110 VAC or higher at a room temperature of 25 ºC. For operation at higher temperatures or lower input voltages, use of forced air cooling is recommended.

The document contains the power supply specification, schematic, bill of materials, inductor documentation, printed circuit layout, and performance data.

100W PFC電源參考設計主要特性:

Low component count, high performance PFC

EN61000-3-2 Class D compliance

High PFC efficiency enables 80 Plus PC Main design
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Frequency sliding maintains high efficiency across load range

Feed forward line sense gain - maintains relatively constant loop gain over entire operating voltage range

Excellent transient load response

Power Integration eSIPTM low-profile, low thermal resistance package

Low profile, <15 mm above PCB

圖5.100W PFC電源參考設計外形圖

100W PFC電源指標:


圖6.100W PFC電源參考設計電路圖
100W PFC電源參考設計材料清單(BOM):



圖7.100W PFC電源參考設計PCB布局圖(122.2 mm) x 2.24” (56.9 mm)
詳情請見:
http://www.powerint.com/sites/default/files/product-docs/hiperpfs_family_datasheet.pdf
和
http://www.powerint.com/sites/default/files/PDFFiles/der272.pdf