Fairchild FEB107-001 User manual

www.fairchildsemi.com
©2004 Fairchild Semiconductor Page 1 of 14 Rev 2.0 3/2/05
FEB107-001 User’s Guide
240W PFC/PWM Combo Evaluation Board
Featured Fairchild Product: FAN4803
www.fairchildsemi.com/FEBsupport

© 2005 Fairchild Semiconductor Page 2 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
Contents
1. General Board Description .......................................................................................................................3
1.1 The contents of the FEB107-001 Evaluation Kit ....................................................................................3
1.2 Power Supply Specification Table ......................................................................................................3
1.3 FEB107-001 Schematic ....................................................................................................................4
2. Test Procedure.........................................................................................................................................5
3. Test Results .............................................................................................................................................5
3.1 Performance Data............................................................................................................................5
3.2 Power Ratings .................................................................................................................................5
4. FEB107-001 Evaluation Kit Parts List..........................................................................................................7
4.1 Vendors for Parts ...........................................................................................................................10
5. Transformer Specification .......................................................................................................................10
6. Printed Circuit Board .............................................................................................................................11
6.1 PCB Silkscreen ..............................................................................................................................11
6.2 Layout Considerations ....................................................................................................................12
7. Featured Products..................................................................................................................................12
7.1 FAN4803 Description ....................................................................................................................12
7.1.1 FAN4803 Features............................................................................................................12
8. Resources/References............................................................................................................................13
8.1 Application Notes..........................................................................................................................13

© 2005 Fairchild Semiconductor Page 3 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
1. General Board Description
The FEB107-001 Evaluation Board is a power factor corrected 12V 20A off-line power supply. It is designed to
meet IEC1000-3-2 over the universal input voltage range of 85 to 265VAC. The Evaluation Board demon-
strates that the FAN4803 can be designed with a low cost single sided PCB at a power level, size, and cost that is
compatible with most desk top computer power supply requirements. The FAN4803 is the replacement for the
ML4803, but either IC will work with this board.
1.1 Contents of FEB107-001 Evaluation Kit
• FEB107-001 Evaluation Board
• FEB107-001 Evaluation Kit User’s Guide
• CD ROM containing the following
– FEB107-001 Evaluation Kit Users Guide
–FAN4803 Data Sheet
–Additional Fairchild data sheets for parts listed on the Bill of Materials
– Application Note AN-42043 - ML4803 240W Off-Line Power Supply with PFC
– Application Note AN-42047 - Power Factor Correction (PFC) Basics
1.2 Power Supply Specification Table
Figure 1. Photograph of evaluation board
Description Condition Min Typ Max Units
Input Voltage (V
IN
)85265 VAC
Output Voltage 1 (V
OUT
) 12.0 V
Output Current 1 (I
OUT
)20A
Power 120 V
AC
290 W
Efficiency 120 V
AC
81 %
Power Factor 120 V
AC
.98

© 2005 Fairchild Semiconductor Page 4 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
1.3 FEB107-001 Schematic
Figure 2. FEB107-001 Schematic
Figure 3. FAN4803 Pin Configuration
BR1
4.7nF
C19
F1
5A 250V
U3
TH1
10
J1-1
LINE
J1-2
NEUTRAL
J2-1
12V
J2-2
12V RET
250VAC
R24
470k
0.5W
R2
36
R22
10k
0.47µF
C4
250VAC
4.7nF
C20
250VAC
5A
4.7µF
C14
CR1
Q2
R1
36
Q5
CR5
Q1
C2
2200µF
T2
R30 200
0.01µF
C29
CR7
T1
R7
10
0.1µF
C7
CR3
R23
10k
1µF
C3
R8 36
4.7nFC18
R38 22
Q4
R36 220
CR2
CR2
L125uH
1nFC13
0.01µF
C25
R20
510
R173.3k
R14
150
27,8,9
110,11,12 2W
0.01µF
C26
500V
500V
R9
1.5k
R37
330
4
5
2
1
0.1µF
C12 R18 1k
0.1µF
C17
R15
9.09k
R61.2k
U2
R16
2.37k
3
2
1
R4
1k
R3
0.15 3W
Veao
4
Isense
3
Vdc 5
Ilimit 6
GND
2
PWM 8
Vcc 7
PFC
1
U1
ML4803
R25
390k
R21
10k
0.15µF
C8
CR4
3W
0.015µF
C15
R13
5.62M
R12
5.62M
0.01µF
C5
CR12
1µF
C6
0.01µF
C27
1µF
C28
R5 36
CR10
CR11
R11 150
0.01µF
C10
CR9
Q3
R10
0.75
1
10
3
4
R27
20k
3W
R26
20k
3W
C11
1000µF
0.01µF
C16
.
C1
220µF
450V
CR18 51V
L3
R32
100
R31
10
L2
1000µH
L2
1000µH
CR8
CR15 1µF
C9
1µF
C21
CR16
1µF
C22
0.01µF
C23
R29
20k
R19
10k
R28
20k
R40
15k
FAN4803
(Detail Below)
PFC OUT
GND
ISENSE
VEAO
PWM OUT
TOP VIEW
1
2
3
4
8
7
6
5
VCC
ILIMIT
VDC

© 2005 Fairchild Semiconductor Page 5 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
2. Test Procedure
Use the following procedure to safely operate the power supply.
1. Connect a load (active or resistive) to the output terminals. Set the load to zero amps.
2. Connect a DC voltmeter across the output terminals.
3. Connect an isolated variable AC source (such as a Variac) to the AC input connector (Line and
Neutral), with the voltage initially set to zero.
4. Adjust the AC input voltage within the range of 85 to 265VAC.
5. The output voltage should read 12VDC ±1%.
6. Increase the load to 19.5A. The output, as measured at the output terminals, should regulate
within ±0.1% of the nominal reading. The ripple voltage should read less than 30mV RMS.
7. The input power factor should be greater than 0.95. Efficiency should be greater than 80%.
8. Reduce the AC input to zero and verify that the output voltage drops to zero.
3. Test Results
3.1 Performance Data
To measure the Evaluation Board performance across the range of permissible input voltages use an isolated
Variac or adjustable AC source. A typical FEB107-001 Evaluation Board will have the performance characteris-
tics shown in Table 1 when operated under the test conditions listed.
Table 1: Performance data
3.2 Power Ratings
The FEB107-001 Evaluation Board is designed to deliver up to 240 Watts at 85VAC when used with a properly
rated and positioned cooling fan. The power rating without a fan is limited to 150 Watts. A 12V fan can be
placed as suggested in Figure 1 and operated from the evaluation board 12V output.
Caution
The FEB107-001 Evaluation Board contains voltage potentials capable of causing serious injur y, and
components which, if failing, may shatter or explode. Please use extreme caution when operating this
board. The use of protective wear is strongly recommended. To safely observe in-circuit waveforms
an isolation transformer should be inserted between the AC line and the Board. Do not operate this
Board with AC voltages outside the design limits. When replacing components on this Evaluation
Board use only those shown in the following parts list.
Input: 85VAC 120VAC 230VAC 265VAC Units
Efficiency 63 81 68 82 %
P. F. 0.99 0.98 0.96 0.97 n.a.
Power 50 290 50 290 W

© 2005 Fairchild Semiconductor Page 6 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
Figure 4: Fan Position
FAN
4.75" sq. x 1.25" thick
Air
Flow

© 2005 Fairchild Semiconductor Page 7 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
4. FEB107-001 Evaluation Kit Parts List
Item Description Qty Ref. Vendor Part Number
Resistors
1 Resistor 36 Ohm, 5%, 0.25W, Thru Hole 4 R1, R2, R5, R8 Mouser 30BJ250-36 / any
2 Resistor 0.15 Ohm, 5%, 3W, Wirewound,
Thru Hole
1 R3 Huntington Electric
Ohmite
ALSR-3J-.15
23JR15
3 Resistor 1 K, 5%, 0.25W, Thru Hole 2 R4, R18 Mouser 29SJ250-1k / any
4 Resistor 1.2 Ohm, 5%, 0.25W, Thru Hole 1 R6 Any
5 Resistor 10 Ohm, 5%, 0.25W, Thru Hole 2 R7, R31 Mouser 30BJ250-10 / any
6 Resistor 1.5 K, 5%, 0.25W, Thru Hole 1 R9 Mouser 29SJ250-1.5k / any
7 Resistor 0.75 Ohm, 5%, 3W, Metal Oxide
Film, Thru Hole
1 R10 Panasonic ERX-3SJR75
8 Resistor 150 Ohm, 5%, 0.25W, Thru Hole 1 R11 Mouser 29SJ250-150 / any
9 Resistor 5.62 M, 1%, 0.25W, Thru Hole 2 R12, R13 Dale CMF-55-5.62M
Ω / or
equivalent
10 Resistor 150 Ohm, 5%, 2W, Metal Oxide
Film, Thru Hole
1 R14 Yageo
Panasonic
RSF200JB-150R
ERG-2SJ151
11 Resistor 9.09 K, 1%, 0.25W, Metal Film,
Thru Hole
1 R15 Mouser 29MF250-9.09k / any
12 Resistor 2.37 K, 1%, 0.25W, Metal Film,
Thru Hole
1 R16 Mouser 29MF250-2.37k / any
13 Resistor 3.3 K, 5%, 0.25W, Thru Hole 1 R17 Mouser 29SJ250-3.3k / any
14 Resistor 10 K, 5%, 0.25W, Thru Hole 4 R19, R21,
R22, R23
Mouser 29SJ250-10k / any
15 Resistor 510 Ohm, 5%, 0.25W, Thru Hole 1 R20 Mouser 29SJ250-510 / any
16 Resistor 470 K, 5%, 0.5W, Thru Hole 1 R24 Mouser 29SJ500-470k / any
17 Resistor 390 K, 5%, 0.25W, Thru Hole 1 R25 Mouser 29SJ250-390k / any
18 Resistor 20 K, 5%, 3W, Metal Oxide Film,
Thru Hole
2 R26, R27 Panasonic ERG-3SJ203
19 Resistor 20 K, 5%, 0.25W, Thru Hole 2 R28, R29 Mouser 29SJ25-20k / any
20 Resistor 200 Ohm, 5%, 0.25W, Thru Hole 1 R30 Mouser 29SJ250-200 / any
21 Resistor 100 Ohm, 5%, 0.25W, Thru Hole 1 R32 Mouser 29SJ250-100 / any
22 Resistor 220 Ohm, 5%, 1W, Metal Oxide
Film, Thru Hole
1 R36 Panasonic
Yageo
ERG-1SJ221
RSF100JB-220R
23 Resistor 330 Ohm, 5%, 0.25W, Thru Hole 1 R37 Mouser 29SJ250-330 / any
24 Resistor 22 Ohm, 5%, 0.25W, Thru Hole 1 R38 Mouser 30BJ250-22 / any
25 Resistor 15 K, 5%, 0.25W, Thru Hole 1 R40 Mouser 30BJ250-15k / any
26 Resistor 0 Ohm Jumper 11 JP1 - JP11 DigiKey
Yageo
0.0QBK-ND
ZO-1/4W-B

© 2005 Fairchild Semiconductor Page 8 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
FEB107-001 Evaluation Kit Parts List (continued)
27 Thermistor 10 Ohm, 5A RMS,
Thru Hole - Disc
1 TH1 DigiKey
ThermoDisc
THERMOMETRICS, INC.
KC006L-ND
F503EL
CL-50
Capacitors
28 Capacitor 220µF, 20%, 450VDC,
Electrolytic, Radial
1 C1 Panasonic ECO-S2WB221CA
29 Capacitor 2200µF, 20%, 16VDC,
Electrolytic, Radial
1 C2 Panasonic ECA-1CFQ222
30 Capacitor 1µF, 20%, 50VDC, Z5U, Radial 5 C3, C6, C9,
C21, C22
Panasonic ECU-S1H105MEB
31 Capacitor 0.47µF, 20%, 250VDC, Film,
Radial
1 C4 Panasonic ECQ-E2A474MW
32 Capacitor 0.01µF, 20%, 50VDC, Z5U,
Radial
3 C5, C23, C29 Panasonic ECU-S1H103MEB
33 Capacitor 0.1µF, 20%, 50VDC, Z5U, Radial 3 C7, C12, C17 Panasonic ECU-S1H104MEB
34 Capacitor 0.15µF, 10%, 100VDC, X7R,
Radial
1 C8 Panasonic ECU-S1H154KBB
35 Capacitor 0.01µF, 10%, 50VDC, X7R,
Radial
1 C10 Panasonic ECU-S1H103KBA
36 Capacitor 1000µF, 20%, 25VDC,
Electrolytic, Radial
1 C11 Panasonic ECA-1EM102
37 Capacitor 1nF, 10%, 100VDC, X7R, Radial 1 C13 Panasonic ECU-S1H102KBB
38 Capacitor 4.7nF, 10%, 25VDC, Film, Radial 1 C14 Panasonic ECS-F1EE475K
39 Capacitor 15nF, 10%, 100VDC, X7R, Radial 1 C15 Panasonic ECU-S1H153KBB
40 Capacitor 0.01µF, 10%, 500VDC, Ceramic,
Radial
3 C16, C25,
C26
Panasonic ECK-D2H103KB5
41 Capacitor 4.7nF, 10%, 100VDC, X7R,
Radial
1 C18 Panasonic ECU-S1H472KBB
42 Capacitor 4.7nF, 10%, 250VDC, Film,
Radial
2 C19, C20 Panasonic ECQ-U2A472MV
43 Capacitor 0.01nF, 10%, 25VDC, Ceramic,
Radial
1 C27 Panasonic ECK-F1E103ZV
44 Capacitor 1µF , 25VDC, Z5U, 1206 -
Surface Mount
1 C28 Any
Semiconductors
45 Bipolar Transistor PNP, TO-92, FSID:
2N3906
1 Q1 Fairchild 2N3906
46 MOSFET 0.85Ohm, 500V, TO-220 4 Q2, Q3, Q4,
Q5
Fairchild Fairchild HGTP3N60A4D
IRF840B
47 Diode Bridge Rectifier, 600V, 4A , KBL, FSID:
KBL06
1 BR1 Fairchild KBL06
48 Diode HyperFast, 600V, 4A, 20ns,
TO-220AC, FSID: ISL9R460P2
1 CR1 Fairchild ISL9R460P2
Item Description Qty Ref. Vendor Part Number

© 2005 Fairchild Semiconductor Page 9 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
FEB107-001 Evaluation Kit Parts List (continued)
49 Diode Schottky, 60V, 30A , TO-247, FSID:
MBR3060PT
1 CR2 Fairchild MBR3060PT
50 Diode Ultra-Fast, 600V, 1A, 75ns,
DO-41, FSID: UF4005
2 CR3. CR4 Fairchild UF4005
51 Diode Zener, 16V, 0.5W , DO-35, FSID:
1N5246B
2 CR5, CR9 Fairchild 1N5246B
52 Diode Schottky, 30V, 1A , DO-41, FSID:
1N5818
4 CR7, CR10,
CR11, CR12
Fairchild 1N5818
53 Diode Signal, 75V, W , DO-35, FSID:
1N4148
3 CR8, CR15,
CR16
Fairchild 1N4148
54 Diode Transorb, 51V, W , DO-15, FSID:
P6KE51CA
1 CR18 Fairchild P6KE51CA
55 IC PFC/PWM Combo, DIP, FSID:
FAN4803CP-1
1 U1 Fairchild FAN4803CP-1
56 IC Shunt Regulator, TO-92, FSID: TL431CLP 1 U2 Fairchild TL431CLP
57 IC OptoIsolator, DIP-6, FSID: MOC8102 1 U3 Fairchild
Fairchild
MOC8102
MOC8112
Magnetics
58 Inductor 91µH, MicroMetals Powered Iron 1 L1 Premier Magnetics TSD-1273
59 Inductor 1.7mH, MicroMetals Powered Iron 1 L2 Premier Magnetics TSD-1274
60 Ferrite Bead 1 L3 Panasonic EXC-ELSA39
61 Transformer 100µH 1 T1 XFMRS, Inc. XF4317-00
62 Transformer - Gate Drive 450µH, 1:1:1 1 T2 Pulse Engineering P0584
Hardware
63 Fuse 5 A, 250 VAC, 5 x 20 mm 1 F1 Littlefuse DigiKey Series 216 F921-ND
64 Hardware Fuse Clips, PC Mount, for 5 x 20
mm fuse
1 F1 (ref.) Littelfuse, etc. 111501 or equiv.
65 Hardware 2-Screw terminal Strip .375" Pitch 1 J2 Tyco
Molex/Beau
Augat/RDI
RDI
Augat/RDI
3-1437652-5
71502-C
LC6-P107-02
6PCV-02
LC6-P107-02
66 Hardware 0.156" Square 3-Pin Header 1 J1 Molex 26-60-4030
67 Hardware Housing for 0.156" Square 3-Pin
Header
1 J1 Molex 09-50-3031
68 Hardware Terminal for 0.156" Square 3-Pin
Header
0 J1 (ref) -
not supplied
Molex 08-50-0106
69 Heat Sink .720" High Rise TO-220, AAVID
590102B00150
4 Ref. CR1, CR2,
Q2, Q5
AAVID 590102B00150
70 Hardware 8-32 Lock Washer 8 Ref. CR1, CR2,
Q2, Q5
Item Description Qty Ref. Vendor Part Number

© 2005 Fairchild Semiconductor Page 10 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
4.1 Vendors for parts
The components listed in the parts list are available from the following list:
Future Active Incorporated [phone]
Digi-Key Corporation [phone]
Mouser Electronics [phone]
Premier Magnetics [phone]
http://www.premiermag.com/
Xfmrs. Inc. [phone]
http://www.xfmrs.com/index.html
Pulse Engineering [phone]
http://www.pulseeng.com/default.cfm
5. Transformer Specification
FEB107-001 T1 Forward Transformer Spec.
1. SCHEMATIC DIAGRAM. (TOP VIEW)
71 Heat Sink Tube, Berquist SPT400
11-25
3 Ref. CR1, Q2,
Q5
Berquist SPT400 11-25
72 Heat Sink Tube, Berquist SPT400 13.5-25 1 Ref. CR2 Berquist SPT400 13.5-25
73 Heat Sink Twisted Fin, TO-220, AAVID
593002B03400
2 Ref. Q3, Q4 AAVID 593002B03400
74 Hardware Heatsink Assembly kit, Thermalloy
48805
2 Ref. Q3, Q4 Thermalloy 48805
75 Hardware 4-40 x .25" screws 8
76 Hardware Ground Plate, Paradigm Metals
PLATE, ref: P.O. 28678
0 Not supplied Paradigm Metals PLATE, ref: P.O. 28678
77 Hardware Round Aluminum 4-40 threaded
0.375" spacers
4 Digikey J170-ND
78 Hardware 6-32 X 0.25" Screw 8
79 PCB FAN4803EVAL P.C. Board Rev B 1 Fairchild Rev. B
80 Hardware 4-40 x .375" Philips screws 8 Ref. Q3, Q4
Item Description Qty Ref. Vendor Part Number
Primary
Bias
5
6
1
2
7
10
Secondary
Secondary
Secondary
Inside
Bobbin
8
11
9
12
Bias
Secondary
Primary A
Outside
Primary
FEB107-001 Evaluation Kit Parts List (continued)

© 2005 Fairchild Semiconductor Page 11 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
2. WINDING SPECIFICATION
3. CORE & BOBBIN
CORE: EE4035
BOBBIN: EE4035
6. Printed Circuit Board
The PCB is a single layer board constructed of FR4.
6.1 PCB Silkscreen
Figure 3: FEB107-001 PCB top silkscreen
PIN WIRE TURNS
Primary A 2 → 1 28AWG 84
Secondary 7,8,9 → 10,11,12 3 × 1 φ 7
Bias 5
→ 6 28AWG 4
Primary B 2
→ 1 28AWG 84

© 2005 Fairchild Semiconductor Page 12 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
6.2 Layout considerations
The FEB107-001 Evaluation board contains high impedance, low level signals and low impedance, high level
circuits. Consequently, it requires extra care in component placement, grounding and PC trace routing. In
order to shield low level circuits from the high level signals, the control circuits are placed in surface mount form
on the bottom side of the board. Since the current sense for the FAN4803 is not differential, care must be taken
to prevent large di/dt across the PCB trace joining the output capacitor and the current sense resistor. As the best
place to reference the IC is at the output capacitor 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
accomplished by “starring” all 400V return connections to the output capacitor, and/or “starring” very low
inductive/resistive paths from all power devices to the output capacitor return. Output common mode capaci-
tors C23 and C26, along with a ground plane, have been added as a low impedance path for shunting output
common mode currents back to the source through C20 and C19. Although it is not absolutely necessary for a
functioning FEB107-001 Evaluation Board, it does help to reduce high frequency output noise and improve
output voltage regulation.
The following list some general layout guidelines.
A. Bypass the VCC pin directly to the IC ground pin with a 1µF ceramic capacitor, located as close as possible
to the IC.
B. Return all compensation components directly to the IC ground pin, keeping the lead lengths as short as
possible.
C. Make sure that low level noise-free returns do not share return paths with high level, or noisy signals, e.g. ,
gate drive.
D. Isolate and or shield rapidly changing high voltage waveforms from sensitive, high impedance circuits, such
as the timing capacitor, PFC current sense input, error amplifier input/output, etc.
E. “Star” connect all power return paths to the boost output capacitor C1.
7. Featured Products
7.1 FAN4803 Description
The FAN4803 is a space-saving controller for power factor corrected, switched mode power supplies that offers
very low start-up and operating currents.
Power Factor Correction (PFC) offers the use of smaller, lower cost bulk capacitors, reduces power line loading
and stress on the switching FETs, and results in a power supply fully compliant to IEC1000-3-2 specifications.
The FAN4803 includes circuits for the implementation of a leading edge, average current "boost" type PFC and
a trailing edge, PWM.
The FAN4803-1’s PFC and PWM operate at the same frequency, 67kHz. The PFC frequency of the FAN4803-
2 is automatically set at half that of the 134kHz PWM. This higher frequency allows the user to design with
smaller PWM components while maintaining the optimum operating frequency for the PFC. An overvoltage
comparator shuts down the PFC section in the event of a sudden decrease in load. The PFC section also includes
peak current limiting for enhanced system reliability.
7.1.1 FAN4803 Features
•Internally synchronized PFC and PWM in one 8-pin IC
•Patented one-pin voltage error amplifier with advanced input current shaping technique
•Peak or average current, continuous boost, leading edge PFC (Input Current Shaping Technology)
•High efficiency trailing-edge current mode PWM
•Low supply currents; start-up: 150µA typ., operating: 2mA typ.
•Synchronized leading and trailing edge modulation

© 2005 Fairchild Semiconductor Page 13 of 14 Rev 2.0 March 2005
www.fairchildsemi.com
•Reduces ripple current in the storage capacitor between the PFC and PWM sections
•Overvoltage, UVLO, and brownout protection
•PFC V
CC
OVP with PFC Soft Start
8. Resources/References
8.1 Application Notes
Application Note AN-42043 - ML4803 240W Off-Line Power Supply with PFC
Application Note AN-42047 - Power Factor Correction (PFC) Basics

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