Fairchild FAN9611 User manual

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© 2009 Fairchild Semiconductor Corporation AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
User Guide for
AN-8026: FAN9611 / FAN9612 400W
1-Layer Evaluation Board (FEB-301)
Featured Fairchild Product:
FAN9611 / FAN9612
Direct questions or comments
about this Evaluation Board to:
“Worldwide Direct Support”
Fairchild Semiconductor.com

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© 2009 Fairchild Semiconductor Corporation 2 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Table of Contents
1. Overview of the Evaluation Board ............................................................................................. 3
2. General Specification.................................................................................................................. 3
3. Test Procedures........................................................................................................................... 4
4. Schematic.................................................................................................................................... 6
5. Specification Approval ............................................................................................................... 7
6. Boost Inductor Specification ...................................................................................................... 9
6.1. Electrical Specification............................................................................................... 10
7. Bill of Materials........................................................................................................................ 12
8. Test Results............................................................................................................................... 16
8.1. Startup......................................................................................................................... 16
8.2. Normal Operation....................................................................................................... 17
8.3. Line and Load Transient............................................................................................. 18
8.4. Brown in/out Protection.............................................................................................. 19
8.5. Phase Management..................................................................................................... 20
8.6. Efficiency.................................................................................................................... 21
8.7. Harmonic Distortion and Power Factor...................................................................... 22
9. References................................................................................................................................. 24

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© 2009 Fairchild Semiconductor Corporation 3 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
The following user guide supports the FAN9611 / FAN9612 400W evaluation board for
interleaved boundary-conduction mode power factor corrected supply. The user guide
should be used in conjunction with the FAN9611/FAN9611 / FAN9612 datasheet as well
as the Fairchild application note AN-6086 — Design Considerations for Interleaved
Boundary-Conduction Mode PFC Using FAN9611 / FAN9612.The user guide and the
evaluation board can also be used to evaluate FAN9611 controller which has the lower
turn-on threshold. Please visit Fairchild’s website at www.fairchildsemi.com for
information.
1. Overview of the Evaluation Board
The FAN9611 / FAN9612 interleaved dual Boundary-Conduction-Mode (BCM) Power-
Factor-Correction (PFC) controller operates two parallel-connected boost power trains
180º out of phase. Interleaving extends the maximum practical power level of the control
technique from about 300W to greater than 800W. Unlike the continuous conduction
mode (CCM) technique often used at higher power levels, BCM offers inherent zero-
current switching of the boost diodes (no reverse-recovery losses), which permits the use
of less expensive diodes without sacrificing efficiency. Furthermore, the input and output
filters can be smaller due to ripple current cancellation between the power trains and
effectively doubling the switching frequency.
The advanced line feedforward with peak detection circuit minimizes the output voltage
variation during line transients. To guarantee stable operation with less switching loss at
light load, the maximum switching frequency is clamped at 600kHz. Synchronization is
maintained under all operating conditions.
Built-in protection functions include output over-voltage, over-current, open-feedback,
under-voltage lockout, brownout, and redundant latching over-voltage. The FAN9611 /
FAN9612 is available in a lead-free 16-lead SOIC package.
Fairchild offers and evaluation board to aide in design and test of applications using the
FAN9611 / FAN9612. The FAN9611 / FAN9612 evaluation board is a single-layer board
designed for 400W (400V/1A) rated power. Thanks to the phase management, the
efficiency is maintained above 95% at low-line and high-line, even down to 10% of the
rated output power. The efficiencies for full-load condition are 96.3% and 98.0% at line
voltages of 115VAC and 230VAC, respectively.
2. General Specification
Specification Min. Max. Units
Input
VIN AC Voltage 90 264 VAC
VIN AC Frequency 47 63 Hz
VDD Supply 13 16 VDC
Output
Output Voltage 400 V
Output Current 1 A
Total Output Power
Maximum Load Output Power 400 W

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© 2009 Fairchild Semiconductor Corporation 4 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
3. Test Procedures
Before testing the board; DC voltage supply for VDD, AC voltage supply for line input,
and DC electric load for output should be connected to the board properly.
1. Supply VDD for the control chip first. It should be higher than 13V (refer to the
specification for VDD turn-on threshold voltage).
2. When VDD is supplied, a "click" sound from the relay is heard. This is normal. Since
the inrush current limit relay is turned on by 5V reference (pin #3), the relay turns on
when FAN9611 / FAN9612 comes out of UVLO by supplying VDD higher than 13V.
3. Connect the AC voltage (90~264VAC) to start the FAN9611 / FAN9612. Since
FAN9611 / FAN9612 has brownout protection and line OVP, any input voltages out
of operation range trigger protections.
4. Change load current (0~1A) and check the operation. The board is designed to go
into phase shedding for output power below around 55W. It goes back to two-
channel interleaving operation for output power above around 110W.
Table 1. Test Equipment
Test Model FEB301-001
Test Date Sept.7, 2009
Test Temperature Ambient
Test Equipment
AC Source: Chroma 61603 AC POWER SOURCE
Electronic Load: Chroma 63108
Power Meter: WT210
Oscilloscope: Lecroy wavesurfer 24Xs
DC Source: ABM 9306D
Test Items
Startup
Normal Operation
Normal Operation
Line and Load Transient
Brown in/out Protection
Phase Management
Efficiency
Harmonic Distortion and Power Factor

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© 2009 Fairchild Semiconductor Corporation 5 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Figure 1. Photograph of Tested Board

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© 2009 Fairchild Semiconductor Corporation 6 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
4. Schematic
Figure 2. FAN9611 / FAN9612 400W Evaluation Board Schematic

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© 2009 Fairchild Semiconductor Corporation 7 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
5. Specification Approval
Customer Fairchild Semiconductor P/N: TRN-0197
Date 08/04/2006 Version A Page 1/1
Dimension Unit: mm
A B
Black Glue E
tube
CD
Middle partition board thickness of 2mm
(Safety Regulation)
Electrical Specification: 1kHz
,
1V
Inductance:L1=L2：9.0mH minimum
DC Resistance: L1=L2：0.05Ωmaximum
Turn and Wire: L1=L2：φ0.9 x 30.5TSx2
Materials List:
Component Material Manufacturer UL File #
1. CORE T22x14x08 TOMITA
2. WIRE THFN-216 Ta Ya Electric Wire Co., Ltd. E197768
UEWN/U PACIFIC Wire &Cable Co., Ltd. E201757
UEWE Tai-l Electric Wire &Cable Co., Ltd. E85640
UWY Jang Shing Wire Co., Ltd. E174837
3. Solder 96.5% Sn,3% Ag,0.5% Cu, Xin Yuan Co., Ltd.
Unit m/m Drawn Check Title
TEL [phone] Ci wun Chen Guo long Huang IDENT#. TRN-0197
FAX [phone]
SEN HUEI INDUSTRIAL CO.,LTD. D W G# I0060
No.26-1, Lane 128, Sec. 2,
Singnan Rd., Jhonghe City,
Taipei County 235, Taiwan
(R.O.C.)
A 30 max
B 5 max
C 11 ref
D 13 ref
E 15±1

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© 2009 Fairchild Semiconductor Corporation 8 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Customer Fairchild Semiconductor P/N: TRN-0256
Date 09/02/2009 Version A Page 1/4
Notes:
1. Pin 1,6,7,8,10,11,12 removed.
2. Add insulation tape *3 turns to fix core and bobbin.
3. The red symbol indicates first pin.
Unit m/m Drawn Check Title
TEL [phone] Ci wun Chen Guo long Huang IDENT# TRN-0256
FAX [phone]
SEN HUEI INDUSTRIAL CO.,LTD. D W G# I3205
No.26-1, Lane 128, Sec. 2,
Singnan Rd., Jhonghe City,
Taipei County 235, Taiwan
(R.O.C.)

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© 2009 Fairchild Semiconductor Corporation 9 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Customer Fairchild Semiconductor P/N: TRN-0256
Date 09/02/2009 Version A Page 3/4
6. Boost Inductor Specification
Figure 3. Boost Inductor in the FAN9611 / FAN9612 Evaluation Board
Note:
1. Pins 2, 4, 5 add tube.
Unit m/m Drawn Check Title
TEL [phone] Ci wun Chen Guo long Huang IDENT# TRN-0256
FAX [phone]
SEN HUEI INDUSTRIAL CO.,LTD. D W G# I3205
No.26-1, Lane 128, Sec. 2,
Singnan Rd., Jhonghe City,
Taipei County 235, Taiwan
(R.O.C.)

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© 2009 Fairchild Semiconductor Corporation 10 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
6.1. Electrical Specification
Inductance Test:at 1kHz, 1V
P(5-3): 200µH ±5%
DC Resistance test at TA = 25°C
P(5-3): 62.44mΩmaximum
P(2-4): 196.7mΩmaximum
Hi-Pot Test:
AC 1000V / 60Hz / 0.5mA hi-pot for one minute between pri to sec
AC 500V / 60Hz/ 0.5mA hi-pot for one minute between pri to core
Insulation Test:
The insulation resistance is between pri to sec and windings to core measured by DC
500V
Must be over 100MΩ
Terminal Strength:
Kg on terminals for 30 seconds, test the breakdown
UNIT m/m DRAWN CHECK TITLE
TEL [phone] Ci wun Chen Guo long Huang IDENT# TRN-0256
FAX [phone]
SEN HUEI INDUSTRIAL CO.,LTD. D W G# I3205
No.26-1, Lane 128, Sec. 2,
Singnan Rd., Jhonghe City,
Taipei County 235, Taiwan
(R.O.C.)

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© 2009 Fairchild Semiconductor Corporation 11 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Customer Fairchild Semiconductor P/N: TRN-0256
Date 09/02/2009 Version A Page 3/4
Materials List:
Component Material Manufacturer File#
1.Bobbin Phenolic
94v-0,T373J,150°C PQ3230
Chang Chun Plastics Co., Ltd. E59481(S)
2.Core MB4 Ferrite Core PQ3230
3.Wire
UEWE
130°C Tai-I Electric Wire & Cable Co., Ltd. E85640﹙S﹚
UEW-2
130°C Jung Shing Wire Co., Ltd. E174837
UEW-B
130°C Chuen Yih wire co., Ltd. E154709﹙S﹙
4.Varnish
BC-346A
180°C John C Dolph Co., Ltd. E51047﹙M﹚
468-2FC
130°C Ripley Resin Engineering Co., Inc. E81777﹙N﹚
5.Tape
0.025tmm
Polyester 3M
#1350 130°C Minnesota mining ＆MFG Co., Ltd. E17385﹙N﹚
#31CT 130°C Nitto Denko Corp. E34833﹙M﹚
6.Tube Teflon tube TFS
600V,200°C Great Holding Industrial Co., Ltd. E156256﹙S﹚
7.Terminals Tin coated-
Copper wire Will Fore Special Wire Corp.
Unit m/m Drawn Check Title
TEL [phone] Ci wun Chen Guo long Huang IDENT# TRN-0256
FAX [phone]
SEN HUEI INDUSTRIAL CO.,LTD. D W G# I3205
No.26-1, Lane 128, Sec. 2,
Singnan Rd., Jhonghe City,
Taipei County 235, Taiwan
(R.O.C.)

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© 2009 Fairchild Semiconductor Corporation 12 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
7. Bill of Materials
Component Qty. Part # Reference
JUMPER WIRE 0.8ψ(mm) 18 JP1~ JP4 JP6~JP19
Resistor 0805 0Ω+/-5% 1JP20
Resistor 0805 39Ω+/-5% 2R28 R29
Resistor 0805 1KΩ+/-5% 3R24 R25 R27
Resistor 0805 14K7Ω+/-1% 1R22
Resistor 0805 10KΩ+/-1% 2R18 R26
Resistor 0805 20K5Ω+/-1% 1R23
Resistor 0805 47KΩ+/-5% 1R39
Resistor 0805 49K9Ω+/-1% 1R11
Resistor 0805 100KΩ+/-5% 1R38
Resistor 0805 120KΩ+/-1% 1R10
Resistor 0805 150KΩ+/-1% 1R9
Resistor 1206 0Ω+/-5% 1JP5
Resistor 1206 4Ω7+/-5% 2R30 R31
Resistor 1206 10KΩ+/-5% 2R4 R8
Resistor 1206 47KΩ+/-5% 2R1 R2
Resistor 1206 430KΩ+/-5% 3R19 R20 R21
Resistor 1206 680KΩ+/-5%
6 R12~R17
NTC13ψ2ΩSCK132 1NTC1
Resistor 1812 0Ω022 +/-5% 2R5 R6
0805 MLCC X7R +/-10% 102P 50V 2C13 C14
0805 MLCC X7R +/-10% 103P 50V 3C12 C15 C18
0805 MLCC X7R +/-10% 473P 50V 1C19
0805 MLCC X7R +/-10% 104P 50V 1C6
0805 MLCC X7R +/-10% 154P 25V 1C9
0805 MLCC X7R +/-10% 222P 50V 1C8
0805 MLCC X7R +/-10% 224P 50V 2C10 C17
0805 MLCC X7R +/-10% 225P 25V 1C2
0805 MLCC X7R +/-10% 683P 50V 1C7

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© 2009 Fairchild Semiconductor Corporation 13 AN-8026 / FEB301_FAN9611 / FAN9612 • Rev. 0.0.4
Bill of Materials (Continued)
Component Qty. Part # Manufacturer Reference
Ceramic Capacitor 103P 500V +80/-20% 1 C5
Electrolytic Capacitor 47µ 50V 105°C 1 LHK JACKCON C11
Electrolytic Capacitor 220µF 450V 105°C 2 LKP JACKCON C3 C4
MPP Capacitor 0.15µF 400V ±5% 1 MPP154J2G15 ALL-RISE C1
X1 Capacitor 0.47µ 300V +/-10% 3 SX1-S474-
1K300S1 SHINY XC1 XC2 XC3
Common Mode Choke 2 TRN0197 SEN HUEI L1 L2
Custom Inductor PQ3230 L=200µH 2 TRN0256 SEN HUEI L3 L4
Rectifier 3A/600V DO-201AD 1 1N5406 Fairchild Semiconductor D3
Ultra Fast Recovery Rectifier 1A/600V 1 ES1J Fairchild Semiconductor D1
Ultra Fast Diode 1A/1000V DO-41 1 UF 4007 Fairchild Semiconductor D9
SMD Diode LL4148 4 D7 D8 D10 D13
Bridge 10A/600V 1 KBJ1006 CP BD1
SMD Schottky Rectifiers 0.5A/30V SOD-123 1 MBR0530 Fairchild Semiconductor D6
Rectifier 8A/600V TO-220F 2 FFPF08S60S Fairchild Semiconductor D4 D5
MOSFET N-CH 300mA/60V 1 2N7002 Fairchild Semiconductor Q3
SMD NPN Amplifier 1 MMBT3904 Fairchild Semiconductor Q8
SMD PNP Amplifier 2 MMBT3906 Fairchild Semiconductor Q4 Q5
MOS 18A/500V TO-220F 2 FDPF18N50 Fairchild Semiconductor Q1 Q2
FUSE CERAMIC 250V10A SLOW 1 37SG SLEEK F1
RELAY 942H-1A-12DS-T 1 BRIGHT TOWARD RY1
WAFER(8639HS) 3-1P 3.96mm180° 3 CN1 CN2 CN3
HS 50(L)*50(H)*20(W)mm 1 MCH0597 SHUN TEH HS1
HS 100(L)*50(H)*20(W)mm 1 MCH0598 SHUN TEH HS2
IC FAN9611 / FAN9612 SMD 1 SOIC-16 Fairchild Semiconductor U1
PCB FCS0390 REV 4 1 Fairchild Semiconductor

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Figure 4. PCB Layout Top Overlay
Figure 5. PCB Layout Bottom Layer

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Figure 6. PCB Layout Bottom Overlay

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8. Test Results
8.1. Startup
Test Condition: 115VAC / 60Hz, 230VAC / 50Hz, no load and full load.
Figure 7. 115V
AC
/ 60Hz No Load
Figure 8. 115V
AC
/ 60Hz Full Load
Note:
2. Only 29V overshoot is observed (7.44% of nominal output voltage) for no-load startup and only 18V (4.62% of
normal output voltage) overshoot is observed for full-load startup.
Figure 9. 230V
AC
/50Hz No Load
Figure 10.230V
AC
/50Hz Full Load
Note:
3. Only 17V overshoot is observed (4.36% of nominal output voltage) for no-load startup and only 18V (4.62% of
normal output voltage) overshoot is observed for full-load startup.

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8.2. Normal Operation
Test Condition: Inductor current of 115VAC / 60Hz, 230VAC / 50Hz full load.
Figure 11.115V
AC
/ 60Hz Full Load
Figure 12.115V
AC
/ 60Hz Full Load
Note:
4. Figure 11 and Figure 12 show the two inductor currents and the sum of two inductor currents at 115VAC line
voltage and full-load conditions. The sum of the inductor currents has relatively small ripple due to the ripple
cancellation of interleaving operation.
Figure 13.230V
AC
/ 50Hz Full Load
Figure 14.230V
AC
/ 50Hz Full Load
Note:
5. Figure 13 and Figure 14 show the two inductor currents and the sum of two inductor currents at 230VAC line
voltage and full-load conditions. The sum of the inductor currents has relatively small ripple due to the ripple
cancellation of interleaving operation.

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8.3. Line and Load Transient
Test Condition: 115VAC to 230VAC full load transient and 230VAC load transient.
Figure 15.230V
AC
to 115V
AC
Line Transient
Figure 16.115V
AC
to 230V
AC
Line Transient
Note:
6. Figure 15 and Figure 16 show the line transient operation and minimal effect on the output voltage due to the line
feed forward function. When the line voltage changes from 230VAC to 115VAC, 14.5V (3.72% of nominal output
voltage) voltage undershoot is observed. When the line voltage changes from 115VAC to 230VAC, almost no
voltage undershoot is observed.
Figure 17.230V
AC
100% to 0% Line Transient
Figure 18.230V
AC
0% to 100% Line Transient
Note:
7. Figure 17 and Figure 18 show the load-transient operation. When the output load changes from 100% to 0%,
23.6V (6.1% of nominal output voltage) voltage overshoot is observed. When the output load changes from 0%
to 100%, 23.9V (6.13% of nominal output voltage) voltage undershoot is observed.

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8.4. Brown in/out Protection
Test Condition: startup and shutdown when slowly increasing and decreasing the line voltage.
Figure 19.Brownin
Figure 20.Brownout
Note:
8. Figure 19 and Figure 20 show the startup and shutdown operation at slowly increasing and decreasing line
voltage, respectively. The power supply starts when the line voltage reaches around 80VAC and shuts down
when line voltage drops below 70VAC.