1
Hiper_PFS_Boost_04241
3; Rev.1.4; Copyright
Power Integrations 2011 INPUT INFO OUTPUT UNIT
Hiper_PFS_Boost_042413_Rev1-4.xls;
Continuous Mode Boost Converter Design
Spreadsheet
2
Enter Applications
Variables
Design Title
3
Input Voltage Range
High_
Line
High_Lin
e
Select Universal or High_Line option
4
VACMIN 180 V Minimum AC input voltage
5
VACMAX 265 265 V Maximum AC input voltage
6
VBROWNIN 172.56 Expected Minimum Brown-in Voltage
7
VBROWNOUT 156.24 V Specify brownout voltage.
8
VO 385.00 385.00 V Nominal Output voltage
9
PO 540.00 540.00 W Nominal Output power
10
fL 50 Hz Line frequency
11
TA Max 50.00 50 deg C Maximum ambient temperature
12
n 0.970 Info 0.97 !!! Info. Efficiency should be between 0.87 and 0.97
13
KP 0.420 0.42
Ripple to peak inductor current ratio at the peak of
VACMIN
14
VO_MIN 365.75 V Minimum Output voltage
15
VO_RIPPLE_MAX 20 V Maximum Output voltage ripple
16
tHOLDUP 20 ms Holdup time
17
VHOLDUP_MIN 310 V Minimum Voltage Output can drop to during holdup
18
I_INRUSH 40 A Maximum allowable inrush current
19
Forced Air Cooling
No No
Enter "Yes" for Forced air cooling. Otherwise enter "No"
20
21
22
PFS Parameters
23
PFS Part Number
PFS72
6
PFS726
Selected PFS device
24
IOCP min 6.80 A Minimum Current limit
25
IOCP typ 7.15 A Typical current limit
26
IOCP max 7.50 A Maximum current limit
27
RDSON 0.62 ohms Typical RDSon at 100 'C
28
RV 9.00
Mohm
s
Line sense resistor
29
C_VCC 1.00 uF Supply decoupling capacitor
30
C_V 47.00 nF V pin decoupling capacitor
31
C_FB 10.00 nF Feedback pin decoupling capacitor
32
FS_PK 89.5 kHz
Estimated frequency of operation at crest of input voltage
(at VACMIN)
33
FS_AVG 89.4 kHz
Estimated average frequency of operation over line cycle
(at VACMIN)
34
IP 5.61 A MOSFET peak current
35
PFS_IRMS 2.23 A PFS MOSFET RMS current
36
PCOND_LOSS_PFS 3.10 W Estimated PFS conduction losses
37
PSW_LOSS_PFS 2.78 W Estimated PFS switching losses
38
PFS_TOTAL 5.88 W Total Estimated PFS losses
39
TJ Max 100 deg C Maximum steady-state junction temperature
40
Rth-JS 3.00
degC/
W
Maximum thermal resistance (Junction to heatsink)
41
HEATSINK Theta-CA 5.50
degC/
W
Maximum thermal resistance of heatsink
42
43
44
Basic Inductor
Calculation
45
LPFC 373 uH Value of PFC inductor at peak of VACMIN and Full Load
46
LPFC (0 Bias) 2849 uH
Value of PFC inductor at No load. This is the value
measured with LCR meter
47
LPFC_RMS 3.39 A
Inductor RMS current (calculated at VACMIN and Full
Load)
1
Hiper_PFS_Boost_04241
3; Rev.1.4; Copyright
Power Integrations 2011 INPUT INFO OUTPUT UNIT
Hiper_PFS_Boost_042413_Rev1-4.xls;
Continuous Mode Boost Converter Design
Spreadsheet
48
LP_TOL 10 % Tolerance of PFC Inductor Value
49
50
Inductor Construction
Parameters
51
Core Type
Sendu
st
Sendust
Enter "Sendust", "Pow Iron" or "Ferrite"
52
Core Material
Auto 125u
Select from 60u, 75u, 90u or 125 u for Sendust cores.
Fixed at PC44 or equivalent for Ferrite cores. Fixed at 52
material for Pow Iron cores.
53
Core Geometry
Auto TOROID
Select from Toroid or EE for Sendust cores and from EE,
or PQ for Ferrite cores
54
Core
77324(
OD=36
.7)
77324(OD
=36.7)
Core part number
55
AE 67.8 mm^2 Core cross sectional area
56
LE 89.8 mm Core mean path length
57
AL 119 nH/t^2 Core AL value
58
VE 6088 cm^3 Core volume
59
HT 11.35 mm Core height/Height of window
60
MLT 43.4 mm Mean length per turn
61
BW N/A mm Bobbin width
62
NL 155 Inductor turns
63
LG N/A mm Gap length (Ferrite cores only)
64
ILRMS 3.39 A Inductor RMS current
65
Wire type
Litz Litz
Select between "Litz" or "Regular" for double coated
magnet wire
66
AWG 38 AWG Inductor wire gauge
67
Filar 90 Inductor wire number of parallel strands
68
OD 0.102 mm Outer diameter of single strand of wire
69
AC Resistance Ratio 1.70
Ratio of AC resistance to the DC resistance (using Dowell
curves)
70
J 4.64
A/mm
^2
Estimated current density of wires. It is recommended that
4 < J < 6
71
BM_TARGET N/A Gauss Target flux density at VACMIN (Ferrite cores only)
72
BM 2579 Gauss Maximum operating flux density
73
BP 6954 Gauss Peak Flux density (Estimated at VBROWNOUT)
74
LPFC_CORE_LOSS 1.40 W Estimated Inductor core Loss
75
LPFC_COPPER_LOSS 1.75 W Estimated Inductor copper losses
76
LPFC_TOTAL LOSS 3.14 W Total estimated Inductor Losses
77
78
79
Critical Parameters
80
IRMS 3.09 A AC input RMS current
81
IO_AVG 1.40 A Output average current
82
83
84
85
Output Diode (DO)
86
Part Number
STTH1
2R06
STTH12R
06
PFC Diode Part Number
87
Type
ULTRAFA
ST
Diode Type - Special - Diodes specially catered for PFC
applications, SiC - Silicon Carbide type, UF - Ultrafast
recovery type
88
Manufacturer ST Diode Manufacturer
89
VRRM 600 V Diode rated reverse voltage
90
IF 12 A Diode rated forward current
91
TRR 25 ns Diode Reverse recovery time
92
VF 1.1 V Diode rated forward voltage drop
93
PCOND_DIODE 1.54 W Estimated Diode conduction losses