One cycle control PFC boost converter integrated circuit with inrush current limiting, fan motor speed control and housekeeping power supply controller

1. A power factor corrected boost converter circuit comprising:

a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus;

an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier;

an integrated circuit comprising a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal coupled to an output of the converter circuit, and a second control input terminal coupled to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

a boost rectifier diode having a first terminal, the first terminal of the diode coupled to the second terminal of the inductor, the diode having a second terminal; and

a storage capacitor connected to the second terminal of the diode;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising an inrush current limiting circuit for limiting the current through the inductor to a value below a predetermined level.

2. The converter circuit of claim 1 , wherein the integrated circuit includes the switch and a gate driver for driving the switch receiving an output from the control circuit; and the output terminal of the integrated circuit comprises a main terminal of the switch.

3. The converter of claim 1 , wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

4. The converter circuit of claim 1 , wherein the converter circuit operates in continuous conduction mode.

5. The converter circuit of claim 1 , further comprising a sense resistor in one leg of said dc bus, one terminal of the sense resistor being coupled to the second control input terminal, said sense resistor providing a signal indicative of the inrush current.

6. The converter circuit of claim 1 , wherein the inrush current limiting circuit comprises a resistor in series with the inductor and a controlled bypass circuit for bypassing the resistor when the inrush current is below the predetermined level.

7. A power factor corrected boost converter circuit comprising:

a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus;

an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier;

an integrated circuit comprising a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal coupled to an output of the converter circuit, and a second control input terminal coupled to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

a boost rectifier diode having a first terminal, the first terminal of the diode coupled to the second terminal of the inductor, the diode having a second terminal; and

a storage capacitor connected to the second terminal of the diode;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising a fan motor speed control circuit, the fan motor speed control circuit regulating the fan motor speed as a function of the current sensed at said second control input terminal.

8. The converter circuit of claim 7 , wherein the fan motor speed control circuit comprises a control device receiving a pulse width modulated drive signal from said integrated circuit.

9. The converter circuit of claim 7 , wherein the integrated circuit includes the switch and a gate driver for driving the switch receiving an output from the control circuit and the output terminal of the integrated circuit comprises a main terminal of the switch.

10. The converter circuit of claim 7 , wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

11. The converter circuit of claim 7 , wherein the converter circuit operates in continuous conduction mode.

12. The converter circuit of claim 7 , further comprising a sense resistor in one leg of said dc bus, one terminal of the sense resistor being coupled to the second control input terminal.

13. A power factor corrected boost converter circuit comprising:

a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus;

an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier;

an integrated circuit comprising a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal coupled to an output of the converter circuit, and a second control input terminal coupled to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

a boost rectifier diode having a first terminal, the first terminal of the diode coupled to the second terminal of the inductor, the diode having a second terminal; and

a storage capacitor connected to the second terminal of the diode;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising a housekeeping power supply controller, said housekeeping power supply controller being controlled by a feedback voltage comprising the voltage level on said power terminal.

14. The converter circuit of claim 13 , wherein the integrated circuit includes the switch and a gate driver for driving the switch receiving an output from the control circuit and the output terminal of the integrated circuit comprises a main terminal of the switch.

15. The converter circuit of claim 13 wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

16. The converter circuit of claim 13 , wherein the converter circuit operates in continuous conduction mode.

17. The converter circuit of claim 13 , further comprising a sense resistor in one leg of said dc bus, one terminal of the sense resistor being coupled to the second control input terminal.

18. The converter circuit of claim 13 , wherein the housekeeping power supply controller comprises a controlled device controlled by a PWM signal from the integrated circuit to generate a housekeeping power supply voltage derived from the output voltage of the converter circuit.

19. An integrated circuit for a power factor corrected boost converter circuit, the boost converter circuit including a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus; an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier; a boost rectifier diode having a first terminal coupled to the second terminal of the inductor and having a second terminal; and a storage capacitor connected to the second terminal of the diode; the integrated circuit comprising:

a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal for coupling to an output of the converter circuit, and a second control input terminal for coupling to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising an inrush current limiting circuit for limiting the current through the inductor to a value below a predetermined level.

20. The integrated circuit of claim 19 , further wherein the switch is integrated in the integrated circuit and further comprising a gate driver for driving the switch receiving an output from the control circuit, the output terminal of the integrated circuit comprising a main terminal of the switch.

21. The integrated circuit of claim 19 , wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

22. The integrated circuit of claim 19 , wherein the boost converter circuit operates in continuous conduction mode.

23. The integrated circuit of claim 19 , further wherein the boost converter circuit includes a sense resistor in one leg of said dc bus, one terminal of the sense resistor for coupling to the second input terminal, said sense resistor providing a signal indicative of the inrush current.

24. The converter circuit of claim 19 , wherein the inrush current limiting circuit comprises a resistor in series with the inductor and a controlled bypass circuit for bypassing the resistor when the inrush current is below the predetermined level.

25. An integrated circuit for a power factor corrected boost converter circuit, the boost converter circuit including a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus; an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier; a boost rectifier diode having a first terminal coupled to the second terminal of the inductor and having a second terminal; and a storage capacitor connected to the second terminal of the diode; the integrated circuit comprising:

a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal for coupling to an output of the converter circuit, and a second control input terminal for coupling to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising a fan motor speed control circuit, the fan motor speed control circuit regulating the fan motor speed as a function of the current sensed at said second control input terminal.

26. The integrated circuit of claim 25 , wherein the fan motor speed control circuit comprises a control device receiving a pulse width modulated drive signal from said integrated circuit.

27. The integrated circuit of claim 25 , further wherein the switch is integrated in the integrated circuit and further comprising a gate driver for driving the switch receiving an output from the control circuit, the output terminal of the integrated circuit comprising a main terminal of the switch.

28. The integrated circuit of claim 25 , wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

29. The integrated circuit of claim 25 , wherein the boost converter circuit operates in continuous conduction mode.

30. The integrated circuit of claim 25 , further wherein the boost converter circuit includes a sense resistor in one leg of said dc bus, one terminal of the sense resistor for coupling to the second control input terminal.

31. An integrated circuit for a power factor corrected boost converter circuit, the boost converter circuit including a rectifier connectable to an ac input and having a rectified dc output provided across a dc bus; an inductor having first and second terminals connected in one leg of the dc bus, a first terminal of the inductor coupled to the output of said rectifier; a boost rectifier diode having a first terminal coupled to the second terminal of the inductor and having a second terminal; and a storage capacitor connected to the second terminal of the diode; the integrated circuit comprising:

a control circuit for controlling a switch, the integrated circuit comprising a housing enclosing the control circuit, the integrated circuit having a power terminal, a ground terminal, a first control input terminal for coupling to an output of the converter circuit, and a second control input terminal for coupling to a sensor for sensing current in the dc bus and further having an output terminal connected to the switch;

wherein the control circuit comprises a one cycle control circuit having an integrator reset by a clock signal for each cycle of the clock signal, the integrator receiving as an input a signal provided on said first control input terminal;

further comprising a housekeeping power supply controller;

said housekeeping power supply controller being controlled by a feedback voltage comprising the voltage level on said power terminal.

32. The integrated circuit of claim 31 , wherein the switch is integrated into the integrated circuit and further comprising a gate driver for driving the switch receiving an output from the control circuit, the output terminal of the integrated circuit comprising a main terminal of the switch.

33. The integrated circuit of claim 31 , wherein the output terminal of the integrated circuit is coupled to a control terminal of the switch.

34. The integrated circuit of claim 31 , wherein the boost converter circuit operates in continuous condition mode.

35. The integrated circuit of claim 31 , further wherein the boost converter circuit includes a sense resistor in one leg of said dc bus, one terminal of the sense resistor for coupling to the second control input terminal.

36. The integrated circuit of claim 31 , wherein the housekeeping power supply controller comprises a controlled device controlled by a PWM signal from the integrated circuit to generate a housekeeping power supply voltage derived from the output voltage of the converter circuit.