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DN05107/D

Design Note – DN05107/D

3.3KW On Board EV Charger
DeviceApplication

Input Voltage

Output Power

Topology

I/O Isolation

3.3KW

2CH
Interleave
PFC+
Full BridgeLLC+
QR Flyback+
Buck DCDC

Yes

FAN9672Q
FAN7688SJX
NCP1340B3D1R2G

FAN6224M
FAN3224TUMX-F085

NCV890100PDR2G
NCV51460SN33T1GOn Board EV Charger

90-264Vac

NCV210SQT2G
NCV2003SN2T1G
SC431AVSNT1G

FODM8801C…

Other Specification
Output Voltage
RippleNominal Current
Max Current
Min Current

Output 1

Output 2

200-450Vdc
5% (Meet QCT 895 2011)
14
0

12Vdc
1% (Meet QCT 895 2011)10
0.1

PFC (Yes/No)
Minimum Efficiency
Inrush Limiting
Operating Temp. Range
Cooling Method
Signal Level Control

Yes
90%
24A
-20-85˚CForce Air or Liquid cooling. Depend on
the Heatsink
On/Off, CC, CV.

Photo Graph of the Evaluation Board

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Key Features
Whole Solution:
 2CH Interleave PFC to get high efficiency and power density. Decrease the current ripple at mean time Full bridge LLC to boost efficiency by high bus voltage usage
 QR flyback to boost the efficiency on the 12V/10A LV output and the auxiliary power Hardware PFC and LLC control approach for easily designing and less malfunction.
 Active inrush current limit circuit to decrease the PCB footprint Full functional solution including input/output current/voltage sensing and CC/CV PWM control interface. CAN interface will
be available on next version
PFC Controller FAN9672
 Continuous Conduction Mode with Average Current Mode Control
 Two-Channel Interleave Operation
 Programmable Operation Frequency Range: 18 kHz~40 kHz or 55 kHz~75 kHz
 Programmable PFC Output Voltage
 Two Current-Limit Functions
 TriFault Detect™ Protects Against Feedback Loop Failure SAG Protection
 Programmable Soft-Start Under-Voltage Lockout (UVLO)
 Differential Current Sensing
LLC Controller FAN7688
 Secondary Side PFM Controller for LLC Resonant Converter with Synchronous Rectifier Control
 Charge Current Control for Better Transient Response and Easy Feedback Loop Design
 Adaptive Synchronous Rectification Control with Dual Edge Tracking
 Closed Loop Soft-Start for Monotonic Rising Output
 Wide Operating Frequency (39 kHz ~ 690 kHz) Green Functions to Improve Light-Load Efficiency
 Symmetric PWM Control at Light-Load to Limit the Switching Frequency while Reducing Switching Losses
 Protection Functions( with Auto-Restarto Over-Current Protection (OCP)o Output Short Protection (OSP)o NON Zero-Voltage Switching Prevention (NZS) by Compensation Cutback (Frequency Shift)o Power Limit by Compensation Cutback (Frequency Shift)o Overload Protection (OLP) with Programmable Shutdown Delay Timeo Over-Temperature Protection (OTP) Programmable Dead Times for Primary Side Switches and Secondary Side Synchronous Rectifiers
 VDD Under-Voltage Lockout (UVLO)
 Wide Operating Temperature Range -40°C to +125°C
QR PWM Controller NCP1340
 QR Frequency Jittering to Reduces EMI Signature New Quiet-Skip Technology Ensures Operation Outside Audible Range Integrated HV Startup with Brownout Protection Provides an efficient power-on source and protects ageists drops in input
mains voltage
 Valley Switching Operation with Valley Lockout. Maximizing the efficiency over the entire power range
 Integrated X2 Capacitor Discharge Capability Eliminates the need for a X2 resistors
 NTC Compatible Fault Pin Extra protection against high temperature or other fault conditions
 High Drive Capability: -500 mA / +800 mA Enables faster switching of primary-side MOSFET Latch input for OVP and OTP implementations Simple implementation of required protection functions
Synchronous Rectification Controller FAN6224
 mWSaver™ Technology
 Internal Green Mode to Stop SR Switching for Lower No-Load Power Consumption
 300 µA Ultra-Low Green Mode Operating Current
 Suited for High-Side and Low-Side of Flyback Converters in QR, DCM, CCM Operation and Forward Freewheeling
Rectification
 PWM Frequency Tracking with Secondary-Side Winding Voltage Detection
 140 kHz Maximum Operation Frequency
 VDD Pin Over-Voltage Protection (OVP)
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DN05107/D
 LPC Pin Open/Short Protection
 RES Pin Open/Short Protection
 RP Pin Open/Short Protection
 Internal Over-Temperature Protection (OTP)

Schematics1and Circuit Description
The system diagram is on Figure 1. The key elements of the OBC are marked in the color blocks.
AC in90-265V
16A max.

2Ch Interleave PFC
FCH077N65F_F085
FFSP3065A_F085

400VdcFull Bridge LLC

Full Bridge Rectifier

FCH104N60F_F085

FFSP3065A_F085

Drivers
FAN3224TUMX-F085
MJD200G x 2
MJD210G x 2
NJT4030PT1G X 4

Io Sensing

HV Output
200-450Vdc
14A max.

Iin Sensing
NCV210SQT2G

2Ch PFC Controller& Vin Sensing

NCV210SQT2GManual control
version is ready
Current mode LLC
Controller
CC/CV Control

FAN9672Q

Io Monitor

Control andInterface add on
Board

12Vdc

FAN7688SJX
NCV2003SN2T1G

Vo Monitor

Software control
version is coming

PWM signal
for CC/CV
ControlVin, Iin
Monitor
Auxiliary Power
15Vdc

NCP1340B3D1R2G
FCB290N80
FAN6224M
NVMFS5C628NL

LV Output
12Vdc
10A max.

Figure 1. System diagram of the 3.3KW OBC
Following the AC input is the PFC stage. It’s marked in light green. The detail schematic is shown on figure 2. The key
elements of the PFC stage are the controller FAN9672 and the dual boost power devices. They are in the right hand of the
figure 2. More details of the FAN9672 please refer the datasheet and the application notes of the device on the web site
https://www.onsemi.cn/PowerSolutions/product.do?id=FAN9672. Among others, to avoid the CS+ signals are short circuit
equivalent by C42 and C43, we placed the decouple inductors L21 and L31on the Vcc of the Totem poles.
On left hand of figure 2, there are 3 blocks in red dash line. The upper block is the inrush current limit circuit. On thisreference design, there are two options: NTC and Active mode. The NTC is a traditional method to limit the charge current of
the bulk E-capacitor during power on moment. RT1 and RT2 are those NTCs. After the E-cap C7, C8 are fully charged, therelay RL1 is turned on to short circuit the NTCs to decrease the power loss. On the NTC mode, the D3 is unnecessary. Thismethod is simple but the performance is limit. So we provided an active mode for choice. The most circuits of the active
inrush current limit beside D3 are on a daughter board which connects to the SW_MODE_IRCLA. The detail schematic andthe operating theory we will descript later.

1© 2018, SCILLC.
Disclaimer: Semiconductor Components Industries, LLC (SCILL) dba ON Semiconductor is providing this design note “AS IS” and does notassume any liability arising from its use; nor does SCILLC convey any license to its or any third party’s intellectual property rights. This document isprovided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associatedwith its use, including, but not limited to, compliance with all regulatory standards. SCILLC reserves the right to make changes without further notice
to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose,nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability,
including without limitation special, consequential or incidental damages.

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Figure 2. Schematic of the PFC
The middle block is the input current sensing circuit. The standard of the OBC required the input current must be under asafety level to prevent the power cord and the connector overheat in every condition. So the charger system must monitor
the input current continually. If the input current over the limit by the reason of the input voltage get lower or any others, thesystem must decrease the output power. The U10 is the 200X fix-gain current sense amplifier. Co-operate with the R7 andR8, the voltage on pin6 of U10 will be 200 x 0.001x Iin. If Iin=16Arms, at peak point of the sin wave, the output of U10 is4.525V.
The lower block is the interface of the PFC stage. The 10pin connector CON30 connects the PFC stage to the interface
board. The table 1 shows the signals on the CON30.
Pin No.
1
2

Direction
Output
-

3
4
5
6
7
8
9
10

Input
Input
OutputOutputOutputOutputDescription
Input voltage sensing.
Return of PFC enable signal. Connect to GND of FAN9672 in differential path with
Pin5.
Relay Control signal.
PFC enable signal. Control CM1 of FAN9672.
+18V.
Input current sensing signal.
GND
GND
+18V.
PFC output voltage sensing.
Table 1. Signals of the CON30

Another key element of the OBC is the DCDC stage. It was marked in dark green in figure 1. The schematic of the DCDC
stage is shown in figure 3. We adopt the full bridge LLC topology to get the high efficiency and suitable cost. It composed by
U60 and Q60, Q61, Q70, Q71 etc. The FAN7688 (U60) is a current mode advanced LLC controller. More details of the
FAN7688 please refer the datasheet and the application notes on the web site
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https://www.onsemi.cn/PowerSolutions/product.do?id=FAN7688. Because of the high output voltage (200-450Vdc), theSynchronous Rectifier cannot help too much on the rectifier conduction loss. So we omitted the SR function of the FAN7688.
Find a suitable power transformer and resonate inductor on the 3KW power level is not easy. We used 2pcs EPC54 dual slot
bobbin and core to make the transformer. It integrates the resonate inductor to save the room and conduction loss. On the
primary side the two transformers are in series and on the secondary side, the two transformers are in parallel. Thus thevoltage and current between the two transformers is balance automatically.

Figure 3. Schematic of the DCDC
Driving the full bridge MOSFETs with the half bridge LLC controller like FAN7688 is not difficult. Just drive the diagonal
MOSFETs by the same signal is okay. To drive the low Rdson MOSFETs need strong driver ability. The PROUT signals of
FAN7688 amplified by the U61 (FAN3224) and expend the current driving ability by the totem pole (Q64-Q67) then delivery
to primary side trough pulse transformers T62 and T72. Emitter followers Q62, Q63, Q72 and Q73 are to speed up theturning off of the MOSFETs.
The FAN7688 integrated a voltage reference and an error amplifier inside. For the CV (Constant Voltage) control, we justfollow the typical application of the FAN7688 is okay. What we need to do in the OBC application is just to add a CC
(Constant Current) control loop. The U80 rail to rail amplifier and peripheral components acted as this role. During the CV
mode, the U80 is in saturation. The voltage drops on the output of U80 can be ignored. On the close loop state, the output
voltage determined by the voltage dividing resisters (R93, R94, R95, R96, R78, R91 and R92. We ignore the effect of R98
here for easy calculation) and the PWM duty of CV control signal CVPWM. If CVPWM duty=100%, the output voltage will be
2.4 X {R93 + R94 + R95 + R96 + [R78// (R91 + R92)}/ [R78// (R91 + R92) ] . And if the CVPWM duty=0, the output voltage
will be 2.4 X (R93 + R94 + R95 + R96 + R78)/ R78. Fill the value of the resistors; the output voltage will change from 458.8V
to 200.4V if the CVPWM duty decreases from 100% to 0. The purpose of R98 is to add a small bias voltage on the FB pin.
Without it the current on the resonate tank may increase too fast during the start up moment and trigger the over current
protection. The R98 is also makes the output voltage lower a little bit than we calculate above. Please make an alignment on
whichever of R93, R94, R95, R96 or R78 if necessary.
The circuit around the U120 and R124 is to sense the output current. I’s quit same with the block of U10 which we discussed
above. CN60 is the interface of the DCDC stage. The table 2 shows the signals on the CON30.
The FAN7688 get VDD when both of the PFC RDY and the LLC enable signal are active.

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Pin No.
1
2
3
4
5
6
7
8
9
10

Direction
Output
Input
Input
OutputOutput
Input
Input

Description+12VHV.
GND
CCPWM. PWM signal for content current setting.
GND+5VHV.
VOM. Output voltage sensing.
COM. Output current sensing.
GND
CVPWM. PWM signal for content voltage setting.
LLC enable signal.
Table 2. Signals of the CON60

The third key element of the OBC is the Low Voltage and Auxiliary power. Figure 4 show the schematic.

Figure 4. Schematic of the Low Voltage and Auxiliary power.
The main topology of the LV and auxiliary power is the QR fly-back. The LV output is 12V 10A. To increase the efficiency,
we adopt the synchronous rectification. The detail of the PWM controller NCP1340 and the SR controller FAN6224 pleaserefer the datasheet and application note on the web site: https://www.onsemi.cn/PowerSolutions/product.do?id=NCP1340
and https://www.onsemi.cn/PowerSolutions/product.do?id=FAN6224.
This OBC has 3 separate GNDs. They are primary GND, LV output GND, and HV output GND. They are isolating eachother. The can bus connect to LV GND. The DCDC controller connects to HV GND. Besides the LV output, the fly-backconverter also provides the Vcc to PFC and DCDC controllers. So it has 3 isolating outputs. The feedback output of thePWM controller is the LV output because it’s the heaviest load. But the load of LV output is uncertain. So the crossregulation is a problem. To avoid the voltage of +18V and +18VHV too high on the LV heavy load situation, we placed theactive dummy load on the both output. They are Q152 and D157 and their peripheral components. Both of above dummy

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load can adjust the load current according to the output voltage automatically then save the power loss during the LV output
light load moment.
Both of the PFC controller and LLC controller need the relative regulate Vcc for stable operating. The +18V and +18VHV
output cannot meet regulation requirement due to the LV output’s uncertainty. So the sub-regulator is necessary. For
efficiency reason, we select the buck converters made by NCV890100PDR2G. This is a non-SR buck switching regulator
with SO8-EP package. The switching frequency is up to 2MHz. The performance cost ratio is high and easy for application.
On the typical application circuit of NCV890100, the Bootstrap is powered by the internal 3.3V regulator. This method has aproblem on this OBC design. In case of the load of LV is very light, the voltage of 18V and +18VHV will drop and close to
15V and 12V. The duty of the buck converter will be very large. Then the bootstrap voltage will drop below the DRV POR
Stop Threshold and the device stop working. To save this problem we connect the bootstrap diodes (D159, D161) to Vin of
the buck converters instead of the DRV pin. And insert a 3.3V LDO (U158, U159) from the bootstrap voltage to BST pin.
This way extends the maxima duty range of the converter. And if the device stops working by Vin drop, once the Vin-Vo
goes up to 3.3V, the device will re-work again. But in the typical application circuit, if the device stops working, It will keep
stop until the Vo drop to 0V.
The connector CN1 deliveries the +12V voltage to the interface board.
In this design, we put the interface circuits on an add-on board for the flexibility. The features of the full function interface
board will include the (1) Can communication with the BMS system to report the information like: Input voltage, Input current,
Output voltage, Output current, Bus voltage, Output miss-connection, LV voltage, Temperature of the Bridge Rectifier,Temperature of the PFC MOFETs and Diodes, Temperature of the PFC Inductors, Temperature of the LLC transformers,
Temperature of the LLC Diodes. (2) Can communication with the BMS to receive the following command: Power-up, Output
voltage, Output current, Power off. (3) Output the CC, CV PWM signals and the power-on and relay-on signals to the mainboard. But, the full function interface board is not ready so far. We use a simple manual control board instead of the fullfunction one. Figure 5 show the schematic of the manual control interface board.

Figure 5. Schematic of the manual control interface board.

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The SW1 powers ON/OFF the PFC and LLC stage in the secondary side for safety. It is delivery to the primary and HVstage by U223 and U224. The Vcc of the U223 and U224 is powered by the REY signal, thus the power-up will be AND withthe relay active. The REY signal is 3 second delayed by U200 from the 12V LV active moment to guarantee the Bus Caps isfull charged. The CC and CV PWM signals are generated by the U246 and U247 and the peripherals components. The
variable resistors CC and CV control the duty of the PWM signals. The sensing signals like Vin, Iin, Vbus, Vo and Io wasconnected to the test points for customer testing by the voltage meter.
During the description of the PFC stage, we mentioned we provided two methods to limit the inrush current which charge thebus-caps on the power cord plug-in moment. The NTC is one of the most popular solutions. We will not discuss here. What
we will high-light is the active inrush current limit circuit which is shown in figure 6.

Figure 6. Schematic of switch mode inrush current limit circuit.
The circuits in the red dash-line box locate on the switch mode inrush current limit add-on board. The add-on board connects
to the main board with two paths. The left path connect to the Source pin of the MOSFET Q2 through the current sense
resistor R9. And the right path connects to the Drain pin of Q2 directly. The Q2 is controlled by the PWM controller U1. The
U1 turns on in a fixed switching frequency and turns off triggered by the current sense signal with a fixed level. So the wholeadd-on board can be tread as a fixed frequency, fixed turn off current threshold switch. The circuits around Q1 provide the
Vcc to U1. The switch Q2 and the freewheel diode D3; inductors L20 and L30 composed a buck converter. This buckconverter charges the bus capacitors C7, C8 during the moments when the rectifier AC voltage is higher than the bus
voltage. The charging speed depends on the peak current which can be programmed by the R9. If we set the peak current
to a reasonable level, inrush current is limited. This inrush current limit methodology is different from the traditional methods
witch use the NTC, PTC, fixed resistor or MOSFET or IGBT which working under the linear mode. It works on the switch
mode. The power loss of the devices is limited. So the footprint of the circuits is small than the traditional methods. Thisfeature is valuable for the OBC. By using the PFC inductors as the buck inductor, the cost of this solution is not higher than
the traditional method so much.

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MEGNATICS DESIGN DATA SHEETPFC Inductors: L20, L30.

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Auxiliary Transformer: T150.

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Pulse Transformer: T73, T74..

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Current Transformer: T72.

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2

LLC Transformers: T70, T71.

2

© 2014, SCILLC.
Disclaimer: Semiconductor Components Industries, LLC (SCILL) dba ON Semiconductor is providing this design note “AS IS” and does notassume any liability arising from its use; nor does SCILLC convey any license to its or any third party’s intellectual property rights. This document isprovided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associatedwith its use, including, but not limited to, compliance with all regulatory standards. SCILLC reserves the right to make changes without further notice
to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose,nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability,
including without limitation special, consequential or incidental damages.

January 2018, Rev. 0.1

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DN05107/D

Test Result
Power Factor
PF

Vin=90Vac

Vin=110Vac

Vin=220Vac

Vin=264Vac

Load=25%

0.991

0.982

0.976

0.867

Load=50%

0.996

0.996

0.987

0.912

Load=75%

-

-

0.992

0.976

Load=100%

-

-

0.996

0.995

Efficiency of PFC stageVin (Vac)Pin (W)

Vo (V)

Io (A)Po (W)

Efficiency

901256.6392.273.020

1184.66

94.27%

110

1609.2392.273.905

1531.8195.20%

220

3314.3392.308.280

3248.2498.00%

264

3296.0392.468.285

3251.53

98.60%

Waveforms of PFC stage. Yellow: Inductance current of CH1; Green: Vds of CH1; Cyan: Vds of CH2; Pink: Vbus.

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Vin=90Vac, Pin=1250W

Vin=110Vac, Pin=1610W

Vin=220Vac, Pin=3315W

Vin=264Vac, Pin=3296W

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DN05107/D
Efficiency of total set

Efficiency vs Vo curve @Vin=220Vac
97.00%
96.00%
95.00%

Efficiency

94.00%
93.00%
100% load
75% load
50% load
25% load

92.00%
91.00%
90.00%
89.00%
88.00%
200

220

240

260

280

300

320

340

360

380

400

420

440

Efficiency vs Po curve @Vo=430Vdc

96.50%
96.00%
95.50%
95.00%
94.50%
94.00%
93.50%
93.00%
92.50%
92.00%
91.50%
91.00%

96.50%
96.00%
95.50%
95.00%
94.50%
94.00%
93.50%
93.00%
92.50%
92.00%
0.5

1

1.5

2

2.5

3

3.5

0.5

1

1.5

Po (KW)
150

180

200

2

2.5

3

3.5

Po (KW)
220

264

150

180

200

220

264

Efficiency vs Po curve @Vo=400Vdc

Efficiency vs Po curve @Vo=380Vdc

96.00%

96.00%
95.50%
95.00%
94.50%
94.00%
93.50%
93.00%
92.50%
92.00%
91.50%
91.00%
90.50%

95.50%
95.00%
94.50%

Efficiency

Efficiency

Vo (V)

460

Efficiency vs Po curve @Vo=450Vdc

Efficiency

Efficiency

180

94.00%
93.50%
93.00%
92.50%
92.00%
91.50%
0.5

1

1.5

2

2.5

3

3.5

0.5

1

Po (KW)
150

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180

200

1.5

2

2.5

3

3.5

Po (KW)
220264

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150

180

200

220

264

15

Efficiency vs Po curve @Vo=350Vdc

Efficiency vs Po curve @Vo=320Vdc

95.50%
95.00%
94.50%
94.00%
93.50%
93.00%
92.50%
92.00%
91.50%
91.00%
90.50%

95.00%
94.50%
94.00%

Efficiency

Efficiency

DN05107/D

93.50%
93.00%
92.50%
92.00%
91.50%
91.00%
90.50%

0.5

1

1.5

2

2.5

3

3.5

0.5

1

1.5

Po (KW)
180

200

220

264

150

3

3.5

180

200

220

264

Efficiency vs Po curve @Vo=280Vdc

Efficiency vs Po curve @Vo=250Vdc

94.50%

93.50%

94.00%

93.00%

93.50%

92.50%

93.00%
92.50%
92.00%
91.50%

92.00%
91.50%
91.00%

91.00%

90.50%

90.50%

90.00%

90.00%

89.50%
0.5

1

1.5

2

2.5

3

0.5

3.5

1

1.5

Po (KW)
150

180

200

2

2.5

3

Po (KW)
220

264

150

180

200

220

264

Efficiency vs Po curve @Vo=220Vdc

Efficiency vs Po curve @Vo=200Vdc

91.50%

91.00%

91.00%

90.50%
90.00%

90.50%

Efficiency

Efficiency

2.5

Po (KW)

Efficiency

Efficiency

150

290.00%
89.50%

89.50%
89.00%
88.50%

89.00%

88.00%

88.50%

87.50%
0.5

1

1.5

2

2.5

0.5

1

Po (KW)
150

January 2018, Rev. 0.1

180

200

1.5

2

2.5

Po (KW)
220264

www.onsemi.com

150

180

200

220

264

16

DN05107/D
Waveforms of LLC stage. : Green: Current of the resonate tank; Yellow: Drain of Q61; Pink: Drain of Q71.

January 2018, Rev. 0.1

Vo=450Vdc, Load=10%

Vo=450Vdc, Load=50%

Vo=450Vac, Load=100%

Vin=350Vac, Load=10%

Vo=350Vac, Load=50%

Vin=350Vac, Load=100%

www.onsemi.com

17

DN05107/D

Vo=250Vac, Load=10%

Vin=250Vac, Load=50%

Vo=250Vac, Load=100%
Waveforms of start-up. Pink: AC input voltage; Green: AC input current; Cyan: Bus voltage: Yellow: Output voltage.

Switch mode inrush current limit board

January 2018, Rev. 0.1

NTC

www.onsemi.com

18

DN05107/D

PCB Layout
Top side of main board. 254x180.4x2mm. 2oz.

January 2018, Rev. 0.1

www.onsemi.com

19

DN05107/D
Bottom side of main board

January 2018, Rev. 0.1

www.onsemi.com

20

DN05107/D
View through of main board

January 2018, Rev. 0.1

www.onsemi.com

21

DN05107/D
Top side of manual control interface board. 163.1x 73.7x 1.2mm.

Bottom side of manual control interface board

View through of manual control interface board

January 2018, Rev. 0.1

www.onsemi.com

22

DN05107/D
Top, bottom side and view through of switch mode inrush current limit board. 45.7x 30.5x 1.6mm.

Bottom view and view through of bridge board. 28.2x 713.2x 1.6mm. Single layer.

January 2018, Rev. 0.1

www.onsemi.com

23

DN05107/D

Bill of Materials
Main board
Description

Manufacturer Part Number

Manufacturer

Qty.

Designator

IC PWM Controller, QR, SOIC9

NCP1340B3D1R2G

ON Semiconductor

1

U150,

IC ICCM PFC Controller, QFP32

FAN9672Q

ON Semiconductor

1

U20,

IC Current mode LLC Controller, SOP16

FAN7688SJXON Semiconductor

1

U60,

IC SR Controller, SO8

FAN6224M

ON Semiconductor

1

U151,

IC Dual 4A Low-Side Gate Drivers, SO8

FAN3224TUMX-F085

ON Semiconductor

1

U61,

IC Buck Switcher, 1.2 A, 2 MHz, SO8EP

NCV890100PDR2GON Semiconductor

2

U156, U157,

IC 3.3V Voltage Reference, SOT-23

NCV51460SN33T1G

ON Semiconductor

2

U158, U159,

IC Current Sense Amplifier, SC70-6

NCV210SQT2GON Semiconductor

2

U10, U120,

IC RRO OP Amplifier, SOT-23 5L

NCV2003SN2T1G

ON Semiconductor

1

U80,

IC Shunt Regulator, SOT23-3L

SC431AVSNT1G

ON Semiconductor

2

U81, U153,

IC Photo Coupler High Temp, MFP-4L

FODM8801C

ON Semiconductor

2

U50, U152,

MOSFET 259mΩ 800V, D2PAKFCB290N80

ON Semiconductor

1

Q150,

MOSFET 91mΩ 600V, TO-247

FCH104N60F_F085

ON Semiconductor

4

Q60, Q61, Q70, Q71,

MOSFET 2.4mΩ 60V, SO8-FL

NVMFS5C628NLT3G

ON Semiconductor

1

Q151,

MOSFET 68mΩ 650V, TO-247

FCH077N65F_F085

ON Semiconductor

2

Q20, Q30,

Transistor 40 V, 3.0 A PNP, SOT223

NJT4030PT1G

ON Semiconductor

4

Q62, Q63, Q72, Q73,

Transistor 25 V 5A NPN, DPAK

MJD200G

ON Semiconductor

2

Q64, Q66,

Transistor 25 V 5A PNP, DPAK

MJD210G

ON Semiconductor

2

Q65, Q67,

Transistor 40 V 3A NPN, DPAKNJVMJD31T4G

ON Semiconductor

1

Q152,

Transistor 40V 2A PNP, SOT23

NSV40200LT1G

ON Semiconductor

3

Q22, Q32, Q53,

Transistor 40V 2A NPN, SOT23

NSV40201LT1G

ON Semiconductor

3

Q3, Q21, Q31,

Transistor 40V 0.2A NPN, SOT23

MMBT3904LT1G

ON Semiconductor

1

Q50,

MOSFET 60V 7.5Ω, SOT23

2V7002LT1G

ON Semiconductor

2

Q80, Q90,

Bridge Rectifier 35A 600V, GBPC-4L

GBPC3506

ON Semiconductor

1

D1,

FR Diode 16A 600V 60nS, D2PAKNRVUB1660CTT4G

ON Semiconductor

1

D3,

SIC Diode 30A 650V, TO220

FFSP3065A

ON Semiconductor

6

D20, D30, D50, D51, D52, D53,

Diode 1A 1000V, SMA

NRVA4007T3G

ON Semiconductor

3

D5, D6, D152,

Schottky Diode 3A 100V, SMC

NRVBS3100T3G

ON Semiconductor

2

D153, D155,

Schottky Diode 3A 40V, SMA

MBRA340T3G

ON Semiconductor

2

D158, D160,

Schottky Diode 1A 20V, SOD123

NRVB120ESFT1G

ON Semiconductor

14

D21, D31, D60, D61, D62, D63, D64,
D65, D66, D67, D70, D71, D72, D73,

Switching Diode 0.2A 100V, SOD323

BAS16HT1G

ON Semiconductor

13

D4, D15, D68, D69, D74, D75, D76, D77,
D150, D151, D154, D159, D161,

ZENER Diode 0.5W 22V, SOD123SZMMSZ22T1G

ON Semiconductor

2

D156, D157,

Chip resister 0805 0ohm-J

Any

1

R68,

Chip resister 0805 10ohm-J

Any4

R13, R80, R126, R157,

Chip resister 0805 22ohm-J

Any

1

R158,

Chip resister 0805 47ohm-J

Any4

R104, R110, R116, R122,

Chip resister 0805 82ohm-J

Any2

R197, R200,

Chip resister 0805 100ohm-J

Any2

R150, R154,

Chip resister 0805 220ohm-J

Any2

R50, R56,

January 2018, Rev. 0.1

www.onsemi.com

24

DN05107/D
Chip resister 0805 470ohm-J

Any6

R41, R42, R43, R44, R188, R189,

Chip resister 0805 1Kohm-J

Any4

R63, R64, R130, R131,

Chip resister 0805 1.2Kohm-J

Any

1

R199,

Chip resister 0805 1.5Kohm-J

Any

1

R196,

Chip resister 0805 2.2Kohm-J

Any

7

R59, R60, R61, R86, R151, R153, R173,

Chip resister 0805 3Kohm-J

Any

1

R87,

Chip resister 0805 4.7Kohm-J

Any

1

R174,

Chip resister 0805 4.75Kohm-F

Any

7

R36, R82, R83, R89, R91, R92, R125,

Chip resister 0805 5.1Kohm-J

Any

1

R71,

Chip resister 0805 8.2Kohm-J

Any3

R11, R12, R35,

Chip resister 0805 10Kohm-J

Any

20

R19, R39, R47, R53, R57, R69, R75,
R81, R84, R85, R90, R105, R111, R117,
R123, R156, R159, R175, R177, R198,

Chip resister 0805 12.4Kohm-F

Any4

R33, R34, R78, R172,

Chip resister 0805 12.7Kohm-F

Any2

R14, R26,

Chip resister 0805 15Kohm-J

Any

1

R74,

Chip resister 0805 18Kohm-J

Any4

R30, R37, R38, R70,

Chip resister 0805 27Kohm-J

Any

1

R170,

Chip resister 0805 33Kohm-J

Any3

R31, R88, R96,

Chip resister 0805 36Kohm-J

Any2

R23, R72,

Chip resister 0805 39Kohm-J

Any3

R32, R176, R179,

Chip resister 0805 43Kohm-J

Any

1

R169,

Chip resister 0805 47Kohm-J

Any

1

R40,

Chip resister 0805 68Kohm-J

Any

1

R77,

Chip resister 0805 75Kohm-J

Any

1

R168,

Chip resister 0805 100Kohm-J

Any

1

R98,

Chip resister 0805 120Kohm-J

Any

1

R171,

Chip resister 0805 200Kohm-J

Any4

R22, R73, R79, R178,

Chip resister 0805 360Kohm-J

Any

1

R152,

Chip resister 1206 0ohm-J

Any

4

R102, R108, R114, R120,

Chip resister 1206 0.62ohm-J

Any4

R160, R161, R162, R163,

Chip resister 1206 1ohm-J

Any2

R128, R129,

Chip resister 1206 2.2ohm-J

Any

1

R167,

Chip resister 1206 4.7ohm-J

Any

8

R100, R101, R106, R107, R112, R113,
R118, R119,

Chip resister 1206 10ohm-J

Any4

R45, R46, R51, R52,

Chip resister 1206 68ohm-J

Any

1

R97,

Chip resister 1206 82ohm-J

Any

1

R193,

Chip resister 1206 1Kohm-J

Any2

R9, R10,Chip resister 1206 1.5Kohm-J

Any2

R180, R181,

Chip resister 1206 4.7Kohm-J

Any

1

R155,

Chip resister 1206 220Kohm-J

Any

4

R3, R4, R5, R6,

Chip resister 1206 330Kohm-J

Any3

R93, R94, R95,

Chip resister 1206 470Kohm-J

Any

6

R164, R165, R166, R185, R186, R187,

Chip resister 1206 750Kohm-J

Any3

R65, R66, R67,

Chip resister 1206 1Mohm-J

Any

6

R15, R16, R20, R21, R24, R25,

Chip resister 1206 2Mohm-F

Any3

R27, R28, R29,

Chip resister 2512 2mohm-F

SMA25A2FR002T

SART

3

R7, R8, R124,

Chip resister 2512 30mohm-J

SK25G1FR030T

SART

2

R49, R55

January 2018, Rev. 0.1

www.onsemi.com

25

DN05107/D
Chip resister 2512 20mohm-J

SK25G1FR020T

Chip resister 2512 470ohm-J

SART

2

R48, R54,

Any

3

R190, R191, R192,

NTC 100Kohm 1%, AEC-Q200

B57540G1104F000

TDK

1RT150,

Disk Varistor 320V D20

820423211

WURTH

1

RV1

MLCC 0805-50V-10pFK-NP0‘885012007051

WURTH

3

C70, C154, C170,

MLCC 0805-50V-100pFK-NP0

885012007057

WURTH

3

C30, C32, C156,

MLCC 0805-450V-100pFK-NP0

CGA4C4C0G2W101J060AA

TDK

3

C30, C32, C156,

MLCC 0805-50V-220pFK-NP0

885012007059

WURTH

1

C77,

MLCC 0805-450V-220pFK-NP0

CGA4C4C0G2W221J060AA

TDK

1

C77,

MLCC 0805-50V-471J-NP0

885012007061

WURTH

8

C23, C26, C27, C34, C71, C75, C82,
C155,

MLCC 0805-450V-471J-NP0

CGA4C4C0G2W471J060AA

TDK

8

C23, C26, C27, C34, C71, C75, C82,
C155,

MLCC 0805-50V-102M-X7R

885012207086

WURTH

8

C29, C31, C37, C40, C61, C83, C163,
C167,

MLCC 0805-100V-102M-X7R

CGA4C2C0G2A102J060AA

TDK

8

C29, C31, C37, C40, C61, C83, C163,
C167,

MLCC 0805-50V-222M-X7R

885012207088

WURTH

6

C36, C38, C39, C41, C174, C183,

MLCC 0805-50V-222M-X7R

CGA4C2C0G1H222J060AA

TDK

6

C36, C38, C39, C41, C174, C183,

MLCC 0805-50V-472M-X7R‘885012207090

WURTH

1

C72,

MLCC 0805-50V-472M-X7R

CGA4C2C0G1H472J060AA

TDK

1

C72,

MLCC 0805-50V-103M-X7R

885012207092

WURTH

7

C25, C28, C33, C35, C50, C81, C153,

MLCC 0805-50V-103M-X7R

CGA4C2C0G1H103J060AA

TDK

7

C25, C28, C33, C35, C50, C81, C153,

MLCC 0805-50V-473M-X7R’885012207096

WURTH

3

C20, C76, C165,

MLCC 0805-100V-473M-X7R

CGA4J2X7R2A473M125AA

TDK

3

C20, C76, C165,

MLCC 0805-25V-104M-X7R

885012207072

WURTH

9

C14, C22, C80, C86, C120, C172, C175,
C180, C182,

MLCC 0805-100V-104M-X7R

CGA4J2X7R2A104K125AA

TDK

9

C14, C22, C80, C86, C120, C172, C175,
C180, C182,

MLCC 0805-25V-224M-X7R

885012207074

WURTH

2

C24, C73,

MLCC 0805-25V-224M-X7R

CGA4J2X7R1H224K125AA

TDK

2

C24, C73,

MLCC 0805-25V-474M-X7R

885012207076

WURTH

6

C21, C42, C43, C63, C92, C164,

MLCC 0805-25V-474M-X7R

CGA4J2X7R1E474K125AA

TDK

6

C21, C42, C43, C63, C92, C164,

MLCC 0805-25V-225M-X7R’885012207079

WURTH

2

C84, C91,

MLCC 0805-25V-225M-X7R

CGA4J3X7R1E225K125AB

TDK

2

C84, C91,

MLCC 0805-16V-475M-X7R’885012207052

WURTH

1

C74,

MLCC 0805-16V-475M-X7R

CGA4J3X7R1C475K125AB

TDK

1

C74,

MLCC 1206-25V-106M-X7R

885012208069

WURTH

3

C46, C166, C181

MLCC 1206-25V-106M-X7R

CGA5L1X7R1E106K160AC

TDK

3

C46, C166, C181

MLCC 1206-50V-475M-X7R

885012208094

WURTH

4

C60, C62, C173, C179

MLCC 1206-630V-222M-X7R

CGA5H4X7R2J222K115AA

TDK

1

C151,

MLCC 2220-630V-105M-X7T

CKG57NX7T2J105M500JJ

TDK

4C6, C9, C67, C68,

E-Cap 25V-150uF-105(6.3X11mm)

860020473010

WURTH

1

C11,

E-Cap 35V-82uF-105-10Kh(6.3X15mm)860160573010

WURTH

1

C157,

E-Cap 35V-220uF-105-LI(8X16mm)

86080574011

WURTH

1

C169,

E-Cap 35V-1500uF-105-LI(13X35mm)

860080578024

WURTH

1

C158,

E-Cap 25V-560uF-105-LI(10X20mm)

860080475017

WURTH

6

C159, C160, C161, C162, C171, C176,

860241181007

WURTH

4

C93, C94, C95, C96,

861141486026

WURTH

2

C7, C8,

E-Cap 250V-150uF-105-10Kh(18X31.5mm)
E-Cap 450V-680uF-105 (35X57mm)

January 2018, Rev. 0.1

www.onsemi.com

26

DN05107/D
Film Cap 630V 1uF PP

ECWFD2J105K

Panasonic

1

C150,

Film Cap 630V 2.2uF PP

ECWFD2J225K

Panasonic

1

C3,

Film Cap 1600V 47nF MPPECWHA3C473J

Panasonic

2

C66, C69,

Film Cap 800V 20uF PP

EZPE80206MTA

Panasonic

1

C78,

X-Cap 275VAC 1uF X2890324026027CS

WURTH

2

C1, C2,

X-Cap 275VAC 1uF X2

ECQUAAF105K

Panasonic

2

C1, C2,

Y-Cap 400VAC 4700pF Y2

CD45-E2GA472M-NKA

TDK

3

C4, C5, C152,

Common Choke 1.0mH 25A

7448262510

WURTH

2

L1, L2

Common Choke 47uH 15A

744844470

WURTH

1

L72,

Common Choke 16uH 10A

7448421016

WURTH

1

L150,

Aux. Transformer PQ3230, 12-Pin, THT.

750343613

WURTH

1

T150,

HNDJ

2

T70, T71,

LLC Transformer EPC54
Current Transformer EE8750343741

WURTH

1

T72,

Pulse Transformer EF20/10/6, THT

750343786

WURTH

2

T73, T74,

SMD Inductor 7X7X3.5mm-22uH-1.6A

784778220

WURTH

2

L151, L152,

SMD Inductor 7X7X4.5mm-22uH-1.7A

SPM7045VT-220M-D

TDK

2

L151, L152,

Chip Inductor 2016-1uH

74438343010

WURTH

3

L21, L22, L31,

Chip Inductor 2016-1uH Automotive

TFM201610ALMA1R0MTAA

TDK

3

L21, L22, L31,

PFC Inductor PQ4040 150uH

750343627

WURTH

2

L20, L30,

Connector 5mm 2Pins Screw type691101710002

WURTH

1

12V

Connector 5mm Screw type. 200X300mil

74760050

WURTH

4VO+, VO-, L, N,

61300421821

WURTH

1

CON1,

61301021821

WURTH

2

CON30, CON60,

RELAY 25A 250VAC

PCF-11202M

OEG

1

RL1

RELAY 20A 250VAC
Spacer Plastic, metric, internal/external,
8mm
Spacer Brass, metric, internal/external,
8mm
FUSE 30A 250V 6X30mm

ALF1P12

Panasonic

1

RL1

971080365

WURTH

6

971080324

WURTH

1

Any

1

F1

Connector 2.54mm Dual Socket Header
4Pns
Connector 2.54mm Dual Socket Header
10Pns* The adjacent items in same shadow are optional in different manufacturer.
Manual control interface board.
Description

Manufacturer Part Number

Manufacturer

Qty.

Designator

IC Single Timer, SO8

NCV1455BDR2GON Semiconductor

3

U200, U246, U247,

IC 5V 0.5A Voltage Regulator, DPAK

NCV78M05BDTRKGON Semiconductor

1

U245,

Photo Coupler High Temp MFP-4L

FODM8801C

ON Semiconductor

3

U223, U224, U244,

Switching Diode 0.2A 100V, SOD323

BAS16HT1G

ON Semiconductor

1

D200,

Schottky Diode 0.2A 100V, SOT23

SBAV99LT3G

ON Semiconductor

2

D241, D242,

LED D=5mm THT Green

151051VS04000

WURTH

2

POWER, RELAY,

LED D=5mm THT Red

151051RS11000

WURTH

1

ON,

Chip resister 0805 1Kohm-J

Any3

R202, R255, R256,

Chip resister 0805 2.2Kohm-J

Any2

R203, R204,

Chip resister 0805 2.43Kohm-F

Any2

R222, R224,

Chip resister 0805 12.4Kohm-F

Any

6

R223, R225, R226, R243, R244, R245,

January 2018, Rev. 0.1

www.onsemi.com

27

DN05107/D
Chip resister 0805 100Kohm-J

Any2

R236, R241,

Chip resister 0805 150Kohm-J

Any

1

R201,

Potentiometer 50Kohm 10X11mm
VerticalAny

2

CC, CV,

MLCC 0805-50V-102M-X7R

885012207086

WURTH

5

C221, C225, C226, C242, C243,

MLCC 0805-100V-102M-X7R

CGA4C2C0G2A102J060AA

TDK

5

C221, C225, C226, C242, C243,

MLCC 0805-50V-222M-X7R

885012207088

WURTH

2

C252, C254,

MLCC 0805-50V-222M-X7R

CGA4C2C0G1H222J060AA

TDK

2

C252, C254,

MLCC 0805-50V-103M-X7R

885012207092

WURTH

3

C202, C251, C253,

MLCC 0805-50V-103M-X7R

CGA4C2C0G1H103J060AA

TDK

3

C202, C251, C253,

MLCC 0805-25V-104M-X7R

885012207072

WURTH

3

C201, C250, C255,

MLCC 0805-100V-104M-X7R

CGA4J2X7R2A104K125AA

TDK

3

C201, C250, C255,

MLCC 1206-25V-106M-X7R

885012208069

WURTH

1

C240,

MLCC 1206-25V-106M-X7R

CGA5L1X7R1E106K160AC

TDK

1

C240,

E-Cap 35V-10uF-105(5X11mm)

860020572003

WURTH

1

C203,

2.54mm Dual Socket Header 4Pns

61300421821

WURTH

1

CON200,2.54mm Dual Socket Header 10Pns

61301021821

WURTH

2

CON220, CON240,

Any7

TP_PFCO, TP_IIN, TP_VIN,
TP_GND_PR, TP_GND_HV, TP_IO,
TP_VO,

Any

1

SW1,

WURTH

6

Test Pin
Switch 1 Connecter 2 Position,
8.6X4.4mm
Spacer Plastic, metric, internal/external,
15mm

971150365* The adjacent items in same shadow are optional in different manufacturer.
Switch mode inrush current limit board.
Description

Manufacturer Part Number

Manufacturer

Qty.

Designator

IC Current Mode PWM Controller SO8

NCV3843BVD1R2G

ON Semiconductor

1

U1,

MOSFET 11.5Ω 600V QFET, SOT223

FQT1N60CTF-WS

ON Semiconductor

1

Q1,

MOSFET 173m Ω 600V SuperFET,
D2PAK

FCB20N60-F085

ON Semiconductor

1

Q2,

Switching Diode 0.2A 100V, SOD323

BAS16HT1G

ON Semiconductor

3

D1, D2, D4,

ZENER Diode 0.5W 15V, SOD323

MM5Z15VT1GON Semiconductor

1

D3,

Chip resister 0805 4.7ohm-J

Any

1

R6,

Chip resister 0805 10ohm-J

Any

2

R7,

Chip resister 0805 22ohm-J

Any

1

R3,

Chip resister 0805 1Kohm-J

Any

1

R5,

Chip resister 0805 22Kohm-J

Any

1

R8,

Chip resister 0805 100Kohm-J

Any

1

R4,

Chip resister 1206 330Kohm-J

Any2

R1, R2,Chip resister 2512 0.1ohm-F

Any

1

R9,

MLCC 0805-50V-100pFK-NP0

885012007057

WURTH

2

C5, C6,MLCC 0805-450V-100pFK-NP0

CGA4C4C0G2W101J060AA

TDK

2

C5, C6,MLCC 0805-50V-103M-X7R

885012207092

WURTH

1

C2,

MLCC 0805-50V-103M-X7R

CGA4C2C0G1H103J060AA

TDK

1

C2,

MLCC 0805-25V-105M-X7R

885012207078

WURTH

2

C1, C4,January 2018, Rev. 0.1

www.onsemi.com

28

DN05107/D
MLCC 0805-25V-105M-X7R

CGA4J3X7R1E105K125AB

TDK

2

C1, C4,MLCC 1206-25V-106M-X7R

885012208069

WURTH

3

C46, C166, C181

MLCC 1206-25V-106M-X7R

CGA5L1X7R1E106K160AC

TDK

3

C46, C166, C181

2.54mm Header 10Pns 90Deg

61301011021

WURTH

1

* The adjacent items in same shadow are optional in different manufacturer.
Bridge board.
Description

Manufacturer Part Number

Manufacturer

Qty.

Designator

2.54mm THT Angled Dual Pin Header 10P

61301021021

WURTH

2

CON1, CON2,

January 2018, Rev. 0.1

www.onsemi.com

29