FAN9612 Boost Converter Design Tool

This design tool is used for a PFC pre-regulated boost converter design using the FAN9612 Interleaved Dual BCM PFC Controller. It complements the Quick Setup Guide procedure in the FAN9612 datasheet and the design procedure described in AN-8086 the application note for FAN9612. This tool is meant to be used with both documents. The FAN9612 Design Tool consists of three steps. Each step is contained in a separate worksheet that can be accessed from the tabs at the bottom. Step 1: Enter their desired power supply performance specifications. The worksheet then calculates the ideal component values based on the input specifications. Step 2: Select real component values based on the ideal component values calculated in Step 1. The worksheet then calculates the real power supply performance specifications. Final Step: The third and final step provides an overview of the schematic and components selected. A loop gain Bode Plot is shown as well to conclude the design.

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, CIRCUIT OR TOOL DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.

Note: No macros or code was used in the Design Tool in an effort to provide simple, efficient and safe tools.

Project

For Designer Use Only

Designer Date

2009 Fairchild Semiconductor Corporation. All rights reserved. Rev. 2.0.0 07/24/2009 Smith, Guo

www.fairchildsemi.com

FAN9612 Boost Converter (Ideal Values)

Step 1: Enter power supply parameters and calculate ideal component values. This sheet calculates the ideal component values based on the power supply specifications that are entered. Enter the specifications in the 'From Power Supply Specification' section. The 'Pre-calculated Power Stage Parameters' section allows the user to adjust the estimated conversion efficiency and the turns ratio of the boost inductor to auxiliary winding. This section also displays the power stage components and parameters that result from the specification, and will be used to calculate the remaining component values. The 'Calculated Component Values' section displays the remaining ideal component values that result from the entered power supply specification. These values will be used as a guide in selecting the real component values.

From Power Supply Specification: Min. AC RMS Input (turn-on) Min. AC RMS Input (turn-off) Nominal AC RMS Input Max. AC RMS Input Min. Line Frequency Nominal DC Output Output Voltage Ripple (2 fLINE) Latching Output OVP Full Load Output Power Soft Start dVOUT/dt Desired Hold Up Time Pre-Calculated Parameters: Estimated Conversion Efficiency Turns Ratio (NBOOST / NAUX) Output Capacitance Boost Inductance per Channel Output Power per Channel Max. Output Power per Channel Max. On-Time per Channel Other Variables Used During the Calculations: Peak Inductor Current Max. DC Output Current (to load) Calculated Component Values: Zero Current Detect Resistor Bypass Capacitor for 5V Bias Maximum On-time Set Soft-Start Capacitor Compensation Capacitor Compensation Resistor Compensation Capacitor Feedback Divider Feedback Divider Over Voltage Sense Divider VLINE.ON VLINE.OFF VLINE.Norminal VLINE.MAX fLINE,MIN VOUT VOUT,RIPPLE VOUT,LATCH POUT dVOUT/dt tHOLD N COUT L POUT,CH PMAX,CH tON,MAX 73 V 70 V 110 V 265 V 50 Hz 400 V 8V 468 V 400 W 1.500 V/ms 20.00 ms 0.95 10 398 F 175 H 200 W 260 W 19.565 s Line OVP Voltage Min. Allowable Brown-Out Hysteresis VLINE,OVP Vline,Hyst 280 V 3.1 V Min. DC Output (end of tHOLD) Min. Switching Frequency Max. DC Bias (for FAN9612) Voltage Loop Crossover Frequency Feedback Pole Frequency Feedback Power Dissipation OVP Network Power Dissipation VIN Sense Power Dissipation Power Supply Over design VOUT,MIN fSW,MIN VDDMAX 330 V 50 kHz 15.00 V 6.0 Hz 150 Hz 0.150 W 0.100 W 0.070 W 1.30

fc

fHFP PFB POVP PINSNS KMAX

IL,PK IO,MAX RZCD1, RZCD2 C5VB RMOT CSS CCOMP,LF RCOMP CCOMP,HF RFB1 RFB2 ROV1

11.059 A 1.300 A 46.80 k 0.220 F 85.07 k 444 nF 336 nF 78.85 k 13.5 nF 1058.7 k 8.00 k 2173.9 k Over Voltage Sense Divider Input Voltage Sense Divider Input Voltage Sense Divider Brown-Out Hysteresis Set Input Voltage Sense Filter Capacitor Gate Drive Resistor Bypass Capacitor for VDD - HF Startup Energy Storage for VDD Current Sense Resistor Current Sense Resistor Power ROV2 RIN1 RIN2 RINHYST CINF RG1, RG2 CVDD1 CVDD2 RCS1, RCS2 PRCS1, PRCS2 16.38 k 2219.1 k 20.93 k 0.00 k 9.6 nF 15.00 2.2 F 22 F 0.0181 0.437 W

Note: Cells that have white text on a red background indicate that there is an error. Certain parts of the circuit will not operate properly if these items are not addressed.

Project

For Designer Use Only

Designer Date

2009 Fairchild Semiconductor Corporation. All rights reserved. Rev. 2.0.0 07/24/2009 Smith, Guo

www.fairchildsemi.com

FAN9612 Boost Converter (Actual Values)

Step 2: Select real component values based on the ideal component values calculated in Step 1 and verify the real power supply performance specifications. This sheet calculates the actual parameter values that result from the selected components. Ensure that all parameters were entered properly in the Step 1 worksheet before working on this step. Enter the component values into the column named 'Selection'. Calculated component values from the parameters entered in Step 1 and Step 2 appear in the ' Calculated' column. These values provide a recommended component value to obtain the input parameters desired. The 'Actual Value' column provides the parameter values that result from the components selected in the 'Selection' column. For reference and comparison, the 'Input Value' column displays the parameters that were selected in the Step 1 worksheet.

1 - Select the feedback components

Component RFB1 RFB2 Component ROV1 ROV2 Component RIN1 RIN2 RINHYST CINF Component RMOT Component L Selection 1066.0 k 8.06 k Selection 2190.0 k 16.50 k Selection 2226.0 k 21.00 k 0.00 k 10.0 nF Selection 84.50 k Selection 180 H Calculated 1058.7 k 8.00 k Calculated 2173.9 k 16.38 k Calculated 2219.1 k 20.93 k 0.00 k 9.5 nF Calculated 85.1 k Calculated 175 H Parameter VOUT PFB Parameter VOUTLATCH POVNOM Parameter VLINEOFF VLINEON PINSNSMAXLINE fcINF Parameter tONMAX Parameter PMAXCH IOPK fSWMIN Parameter ILPK Parameter VOUTRIPPLE tHOLD VOUTMIN Parameter fc fHFP Actual Value 399.8 V 0.149 W Actual Value 468.0 V 0.072 W Actual Value 70.0 V 73.1 V 0.063 W 757.9 Hz Actual Value 19.435 s Actual Value 251 W 1.257 A 50.3 kHz Actual Value 10.000 A Actual Value 7.238 V 28.006 ms 351.4 V Actual Value 6.0 Hz 155.8 Hz Input Value 400.0 V 0.150 W Input Value 468.0 V 0.100 W Input Value 70.0 V 73.0 V 0.070 W 795.8 Hz Input Value 19.565 s Input Value 260 W 1.300 A 50 kHz Input Value 11.059 A Input Value 8.000 V 20.000 ms 330.0 V Input Value 6.0 Hz 150.0 Hz

2 - Select the latching output OVP components

3 - Select the input sense components

4 - Select the maximum on time resistor

5 - Select the boost inductors

6 - Select the current sense resistors

Component RCS1, RCS2 Component COUT Selection 0.020 Selection 440 F Calculated 0.0187 Calculated 398 F

7 - Select the output capacitance

8 - Select the compensation network components

Component CCOMP,LF RCOMP CCOMP,HF Component CSS Component RG1, RG2 Component RZCD1, RZCD2 Selection 390 nF 68.1 k 15 nF Selection 470 nF Selection 15.00 Selection 47.50 k Calculated 368 nF 68.01 k 16 nF Calculated 444 nF Calculated 15.00 Calculated 46.80 k Parameter dVOUT/dt Parameter IGD Parameter IZCD Actual Value 1.418 V/ms Actual Value 1.00 A Actual Value 0.985 mA Input Value 1.500 V/ms Input Value 1.00 A Input Value 1.000 mA

9 - Select the soft start capacitor

10 - Select the gate drive resistors

11 - Select the zero current detect resistors

Note: Cells that have white text on a red background indicate that there is an error. Certain parts of the circuit will not operate properly if these items are not addressed. Cells with red text indicate that the parameter values calculated differ greatly from the desired value. Project Designer Date
www.fairchildsemi.com

For Designer Use Only

2009 Fairchild Semiconductor Corporation. All rights reserved. Rev. 2.0.0 07/24/2009 Smith, Guo

FAN9612 Boost Converter (Final Components)

Final Step: Review the final component values. This sheet provides a schematic and an overview of the components selected through Steps 1 and 2. Ensure that both steps have been completed properly before using the component values displayed below.

VIN VLINE RIN1 RZCD2 RZCD1 AC IN FAN9612

1

L2a D2 L2b L1a

VOU

CIN

D1

L1b RFB1

EMI Filter RIN2 C5VB

ZCD1 ZCD2 5VB MOT AGND SS COMP FB

CS1 16 CS2 15 VDD 14 DRV1 13 DRV2 12 PGND 11 VIN 10 OVP

9 RCS1 RCS2

2 3 4

VBIAS
Q1

RFB2

RINHYST

RMOT CSS RCOMP CCOMP,LF CCOMP,HF

8 5 6 7

RG1 RG2

Q2

ROV1

CVDD1 CINF

CVDD2

ROV2

Selected Component Values: Output Capacitance (total) Boost Inductance (per channel) Zero Current Detect Resistor Bypass Capacitor for 5V Bias Maximum On-time Set Soft-Start Capacitor Compensation Capacitor Compensation Resistor Compensation Capacitor Feedback Divider Feedback Divider COUT L1, L2 RZCD1, RZCD2 C5VB RMOT CSS CCOMP,LF RCOMP CCOMP,HF RFB1 RFB2 440 F 180 H 47.5 k 0.220 F 84.5 k 470 nF 390 nF 68.1 k 15.0 nF 1066 k 8.1 k Over Voltage Sense Divider Over Voltage Sense Divider Input Voltage Sense Divider Input Voltage Sense Divider Brown-Out Hysteresis Set Input Voltage Sense Filter Capacitor Gate Drive Resistor Bypass Capacitor for VDD - HF Startup Energy Storage for VDD Current Sense Resistor Current Sense Resistor Power ROV1 ROV2 RIN1 RIN2 RINHYST CINF RG1, RG2 CVDD1 CVDD2 RCS1, RCS2 PRCS1, PRCS2

Note: Cells that have white text on a red background indicate that there is an error and the component value cannot be displayed.

Project

For Designer Use Only

Designer Date

2009 Fairchild Semiconductor Corporation. All rights reserved. Rev. 2.0.0 07/24/2009 Smith, Guo

www.fairchildsemi.c

ost Converter (Final Components)

mponents selected through Steps 1 and 2. e using the component values displayed below.

L2a D2 L2b L1a VOUT

D1 COUT

FAN9612
CS1 16 CS2 15 VDD 14 DRV1 13 DRV2 12 PGND 11 VIN 10 OVP
9

L1b RFB1

VBIAS
Q1

RFB2

RG1 RG2

Q2

ROV1

RCS1

RCS2

CVDD1 CINF

CVDD2

ROV2

Selected Component Values: 2190 k 16.5 k 2226 k 21.0 k 0.0 k 10 nF 15.00 2.2 F 22 F 0.0200 0.395 W

there is an error and the component value cannot be displayed.

www.fairchildsemi.com

FAN9612 Boost Converter

Final Step: Review the loop transmission Bode Plot. This sheet provides colsed-loop gain Bode Plot based on components being calculated in step 1 and 2. DC Output Current 1.0 A

Loop Transmission Bode Plot - Magnitude

60
40 20

Magnitude (dB)

0 -20

-40
-60 -80 -100 -120 0.1 1 10 100 Frequency (Hz) 1000 10000

Loop Transmission Bode Plot - Phase

100 90

80 70 Phase (deg) 60
50 40 30 20 10 0 0.1 1 10 100 Frequency (Hz)
6.31 Hz 59.67 deg

1000

10000

Crossover Frequency Phase Margin

Note: This spreadsheet uses complex number, so Analysis ToolPak installation is required. Project

For Designer Use Only

Designer Date

2009 Fairchild Semiconductor Corporation. All rights reserved. Rev. 2.0.0 07/24/2009 Smith, Guo

www.fairchildsemi.com