Application Note Evaluation Board 300W CCM PFC P6 Jun 20, 2013 | PDF | 631 kb

Application Note AN 2013-03
V1.0 03 2013
EVALPFC-300W-IPP60R190P6
300W PFC Evaluation Board
IPP60R190P6 with CCM PFC controller
ICE3PCS01G
IFAT PMM APS SE SL
Steiner Alois
(IFAT PMM APS SE AC)
Stückler Franz
(IFAT PMM APS SE AC)
Zechner Florian
(IFAT PMM APS SE AC)
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
Application Note AN 2013-03
V1.0 03 2013
Edition 2011-02-02
Published by
Infineon Technologies Austria AG
9500 Villach, Austria
© Infineon Technologies Austria AG 2011.
All Rights Reserved.
Attention please!
THE INFORMATION GIVEN IN THIS APPLICATION NOTE IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED
AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY
OF THE INFINEON TECHNOLOGIES COMPONENT. THE RECIPIENT OF THIS APPLICATION NOTE
MUST VERIFY ANY FUNCTION DESCRIBED HEREIN IN THE REAL APPLICATION. INFINEON
TECHNOLOGIES HEREBY DISCLAIMS ANY AND ALL WARRANTIES AND LIABILITIES OF ANY KIND
(INCLUDING WITHOUT LIMITATION WARRANTIES OF NON-INFRINGEMENT OF INTELLECTUAL
PROPERTY RIGHTS OF ANY THIRD PARTY) WITH RESPECT TO ANY AND ALL INFORMATION
GIVEN IN THIS APPLICATION NOTE.
Information
For further information on technology, delivery terms and conditions and prices please contact your
nearest Infineon Technologies Office (www.infineon.com).
Warnings
Due to technical requirements components may contain dangerous substances. For information on the
types in question please contact your nearest Infineon Technologies Office. Infineon Technologies
Components may only be used in life-support devices or systems with the express written approval of
Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of
that life-support device or system, or to affect the safety or effectiveness of that device or system. Life
support devices or systems are intended to be implanted in the human body, or to support and/or maintain
and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or
other persons may be endangered.
AN 2013-03
Revision History: date (13-06-07)
Previous Version: none
st
Subjects: 1 revision
Authors: Steiner Alois
, V1.0
(IFAT PMM APS SE AC)
Stückler Franz
(IFAT PMM APS SE AC)
Zechner Florian
(IFAT PMM APS SE AC)
We Listen to Your Comments
Any information within this document that you feel is wrong, unclear or missing at all? Your feedback will
help us to continuously improve the quality of this document. Please send your proposal (including a
reference to this document) to: [[email protected]]
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300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
Application Note AN 2013-03
V1.0 03 2013
Table of contents
1 Introduktion ..................................................................................................... Error! Bookmark not defined.
1.1
CoolMOS™ P6 .................................................................................................................................. 4
1.2
thinQ!™ SiC Diode Generation 5 ....................................................................................................... 4
1.3
CCM-PFC Controller .......................................................................................................................... 4
2 Evaluation Board ......................................................................................................................................... 5
3 Technical Specifications............................................................................................................................. 5
4 Circuit Description ...................................................................................................................................... 5
4.1
Line Input ........................................................................................................................................... 5
4.2
Power Stage  Boost Type PFC Converter ....................................................................................... 6
4.3
PWM Control of Boost Converter....................................................................................................... 6
5 Circuit Operation ......................................................................................................................................... 6
5.1
Soft Startup ........................................................................................................................................ 6
5.2
Boost Follower ................................................................................................................................... 6
5.3
Gate Switching Frequency ................................................................................................................. 7
5.4
Protection Features ............................................................................................................................ 7
5.4.1 Input brown-out protection (BOP) .................................................................................................. 7
5.4.2 Open loop protection (OLP) ........................................................................................................... 8
5.4.3 First over-voltage protection (OVP1) ............................................................................................. 8
5.4.4 Second over-voltage protection (OVP2) ........................................................................................ 8
5.4.5 Peak current limit ........................................................................................................................... 8
5.4.6 IC supply under voltage lockout ..................................................................................................... 8
5.4.7 Bulk Voltage Monitor and Enable Function (VBTHL_EN) .............................................................. 8
6 Circuit Diagram ............................................................................................................................................ 9
7 PCB Layout ................................................................................................................................................10
7.1
Top layer view ..................................................................................................................................10
7.2
Bottom layer view .............................................................................................................................10
8 Component List .........................................................................................................................................11
9 Boost Choke Layout ..................................................................................................................................12
12
10 Test report ..................................................................................................................................................13
10.1 Load and Line Test ..........................................................................................................................13
10.2 14
11 References .................................................................................................................................................14
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300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
Application Note AN 2013-03
V1.0 03 2013
Introduktion
1.1
CoolMOS™ P6
CoolMOS™ P6 IPP60R190P6 achieves extremely low conduction and switching losses especially in light
load condition enabling switching applications to work more efficient and be designed more compact, lighter
and cooler.
Moreover, with its granular portfolio, P6 can address the specific needs of applications such as server, PC
power, telecom rectifiers and consumer applications, while additionally offering the best price/performance
ratio on the market today.
CoolMOS™ P6 closes the gap between technologies which focus on delivering ultimate performance, such
as the high performance CoolMOS™ CP, and those which concentrate more on ease of use, for example
CoolMOS™ C6/E6.
1.2
thinQ!™ SiC Diode Generation 5
thinQ!™ Generation 5 IDH02G65C5 represents Infineon’s leading edge technology for SiC Schottky Barrier
diodes. The Infineon proprietary diffusion soldering process, already introduced with G3, is now combined
with a new, more compact design and thin wafer technology. The result is a new family of products showing
improved efficiency over all load conditions, coming from both the improved thermal characteristics and a
lower figure of merit (Q c x V f).
1.3
CCM-PFC Controller
The evaluation board presented here is a 300W power factor correction (PFC) circuit with 85~265VAC
universal input and output of 395VDC rated voltage or 333VDC in boost follower mode. The continuous
conduction mode (CCM) PFC controller ICE3PCS01G is employed in this board to achieve the unity power
factor.
This ICE3PCS01G is specially designed for applications of power supplies used in PC, server, LCD/PDP TV
and Telecom, requesting high efficiency and power factor. The voltage loop compensation is integrated
digitally for better dynamic response and less design effort. Appreciated for its high integrated design,
ICE3PCS01G can achieve full requirements of the PFC application implemented in the 14-pin in DSO14
package. At the same time the number of peripheral components is minimized. The gate switching frequency
is adjustable from 21kHz to 250kHz and able to synchronize with external switching frequency from 50kHz to
150kHz.
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300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
2
4
4.1
V1.0 03 2013
Evaluation Board
Figure 1
3
Application Note AN 2013-03
IPP60R190P6 Demoboard
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
47~63Hz
Output voltage and current
395VDC, 0.75A
Output power
~ 300W
Average efficiency
>95% at 115VAC
Switching Frequency
Possible Range: 21kHz~250kHz;
set by R20 to 100kHz
Circuit Description
Line Input
The AC line input side comprises the input fuse F1 as over-current protection. The choke L1, X2-capacitors
CX1/CX2 and Y1-capacitor CY1/CY2 are used to suppress common mode noise as well as differential mode
noise. RT1 is placed in series to limit inrush current during each power on. A relay is mounted across the
RT1 to short the resistor when VOUT is higher than 95% rated voltage.
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300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
4.2
Application Note AN 2013-03
V1.0 03 2013
Power Stage  Boost Type PFC Converter
After the bridge rectifier BR1, there is a boost type PFC converter consisting of L2, Q2, D3 and C3. The
seventh generation CoolMOS™ IPP60R190P6 is used as the power switch Q2. BR1, Q2 and SiC Diode D3
share the same heat sink so that the system heat can be equably spread. Output capacitor C3 provides
energy buffering to reduce the output voltage ripple (100Hz at 50Hz AC input) to the acceptable level and
meet the holdup time requirement.
4.3
PWM Control of Boost Converter
The ICE3PCS01G is a 14-pins control IC for power factor correction converters. It is suitable for wide range
line input applications from 85 to 265 VAC with overall efficiency above 97%. The IC supports converters in
boost topology and it operates in continuous conduction mode (CCM) with average current control.
The IC operates with a cascaded control; the inner current loop and the outer voltage loop. The inner current
loop of the IC controls the sinusoidal profile for the average input current. It uses the dependency of the
PWM duty cycle on the line input voltage to determine the corresponding input current. This means the
average input current follows the input voltage as long as the device operates in CCM. Under light load
condition, depending on the choke inductance, the system may enter into discontinuous conduction mode
(DCM) resulting in a higher harmonics but still meeting the Class D requirement of IEC 1000-3-2.
The outer voltage loop controls the output bulk voltage, integrated digitally within the IC. Depending on the
load condition, internal PI compensation output is converted to an appropriate DC voltage which controls the
amplitude of the average input current.
The IC is equipped with various protection features to ensure safe operating condition for both the system
and device.
5
5.1
Circuit Operation
Soft Startup
During power up when the VOUT is less than 96% of the rated level, internal voltage loop output increases
from initial voltage under the soft-start control. This results in a controlled linear increase of the input current
from 0A thus reducing the current stress in the power components.
Once VOUT has reached 96% of the rated level, the soft-start control is released to achieve good regulation
and dynamic response and VB_OK pin outputs 5V indicating PFC output voltage in normal range.
5.2
Boost Follower
The IC provides adjustable lower step of bulk voltage in case of low line input and light output power. The
low line condition is determined when pin BOP voltage is less than 2.3V. Pin BOFO is connected to PWM
feedback voltage through a voltage divider, representing the output power. The light load condition is
determined when pin BOFO voltage is less than 0.5V. Once these two conditions are met in the same time,
a 20uA current source is flowing out of pin VSENSE so that the bulk voltage should be reduced to a lower
level in order to keep the VSENSE voltage same as the internal reference 2.5V.
The reduced bulk voltage can be designed by upper side resistance of voltage divider from pin VSENSE.
Thus the low side resistance is designed by the voltage divider ratio from the reference 2.5V to the rated bulk
voltage. An internal 300kΩ resistor will be paralleled with external low side resistor of BOFO pin to provide
the adjustable hysteresis for entry/exit power when boost follower is activated.
The boost follower feature will be disabled internally during PFC soft-start in order to prevent bulk voltage
oscillation due to the unstable PWM feedback voltage. This feature is disabled on this demo board externally
by pulling up pin BOFO higher than 0.5V continuously by R26 and closed Jumper1 between pin 1 and pin2.
To use the boost follower feature as described above, please just remove the jumper 1 connection between
pin 1 and pin 2.
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300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
5.3
Application Note AN 2013-03
V1.0 03 2013
Gate Switching Frequency
The switching frequency of the PFC converter can be set with an external resistor R FREQ at pin FREQ with
reference to pin SGND. The voltage at pin FREQ is typical 1V. The corresponding capacitor for the oscillator
is integrated in the device and the RFREQ/frequency is given in Figure 2. The recommended operating
frequency range is from 21 kHz to 250 kHz. As an example, a R FREQ of 43kΩ at pin FREQ will set a switching
frequency FSW of 100 kHz typically.
Frequency vs Resistance
260
240
Resistance
/kohm
Frequency
/kHz
Resistance
/kohm
Frequency
/kHz
220
15
278
110
40
17
249
120
36
20
211
130
34
30
141
140
31.5
160
40
106
150
29.5
140
50
86
169
26.2
120
60
74
191
25
70
62
200
23
80
55
210
21.2
80
90
49
221
20.2
60
100
43
232
19.2
200
Frequency/kHz
180
100
40
20
0
10
20
30
40
50
60
70
80
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Resistance/kohm
Figure 2
Frequency setting
The switching frequency can be synchronized to the external pulse signal after 6 external pulses delay once
the voltage at the FREQ pin is higher than 2.5V. The synchronization means two points. Firstly, the PFC
switching frequency is tracking the external pulse signal frequency. Secondly, the falling edge of the PFC
signal is triggered by the rising edge of the external pulse signal. The external R20 combined with R21 and
the external diode, D6 can ensure FREQ pin voltage to be kept between 1.0V (clamped internally) and 5V
(maximum pin voltage). If the external pulse signal has disappeared longer than 108us (typical) the switching
frequency will be synchronized to internal clock set by the external resistor R20.
5.4
5.4.1
Protection Features
Input brown-out protection (BOP)
ICE3PCS01G provides a new BOP feature whereby it senses directly the input voltage for Input Brown-Out
condition via an external resistor/capacitor/diode network. This network provides a filtered value of VIN which
turns the IC on when the voltage at pin 9 (BOP) is more than 1.25V. The IC enters into the fault mode when
BOP goes below 1.0V. The hysteresis prevents the system to oscillate between normal and fault mode. Note
also that the peak of VIN needs to be at least 20% of the rated VOUT in order to overcome open loop
protection and power up system.
7
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
5.4.2
Application Note AN 2013-03
V1.0 03 2013
Open loop protection (OLP)
The open loop protection is available for this IC to safe-guard the output. Whenever voltage at pin VSENSE
falls below 0.5V, or equivalently VOUT falls below 20% of its rated value, it indicates an open loop condition
(i.e. VSENSE pin not connected). In this case, most of the blocks within the IC will be shutdown. It is
implemented using a comparator with a threshold of 0.5V.
5.4.3
First over-voltage protection (OVP1)
Whenever VOUT exceeds the rated value by 8%, the first over-voltage protection OVP1 is active. This is
implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 2.7V. A VSENSE
voltage higher than 2.7V will immediately block the gate signal. After bulk voltage falls below the rated value,
gate drive resumes switching again.
5.4.4
Second over-voltage protection (OVP2)
The second OVP (OVP2) is provided in case that the first one fails due to the aging or incorrect resistors
connected to the VSENSE pin. This is implemented by sensing the voltage at pin OVP with respect to a
reference voltage of 2.5V. When voltage at OVP pin is higher than 2.5V, the IC will immediately turn off the
gate, thereby preventing damage to bus capacitor.
When the bulk voltage drops out of the hysteresis, which is below 2.3V the IC can be latched further or begin
auto soft-start. These two protection modes are distinguished through detecting the external equivalent
resistance connecting to VBTHL_EN pin after VCC is higher than UVLO threshold. If the equivalent resistance
is higher than 100kΩ the IC selects latch mode for second OVP, otherwise auto soft-start mode.
In normal operation the trigger level of OVP2 should be designed higher than OVP1. However in the
condition of mains transient overshoot the bulk voltage may be pulled up to the peak value of mains that is
higher than the threshold of OVP1 and OVP2. In this case the OVP1 and OVP2 are triggered in the same
time the IC will shut down the gate drive until bulk voltage falls out of the two protection hysteresis, then
resume the gate drive again
5.4.5
Peak current limit
The IC provides a cycle by cycle peak current limitation (PCL). It is active when the voltage at pin ISENSE
reaches -0.2V. This voltage is amplified by a factor of -5 and connected to comparator with a reference
voltage of 1.0V. A deglitcher with 200ns after the comparator improves noise immunity to the activation of
this protection. In other words, the current sense resistor should be designed lower than -0.2V PCL for
normal operation.
5.4.6
IC supply under voltage lockout
When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11V, IC is off and the gate
drive is internally pull low to maintain the off state. The current consumption is down to 1.4mA only.
5.4.7
Bulk Voltage Monitor and Enable Function (VBTHL_EN)
The IC monitors the bulk voltage status through VSENSE pin and output a TTL signal to enable PWM IC or
control inrush relay. During soft-start once the bulk voltage is higher than 95% rated value, pin VB_OK
outputs a high level. The threshold to trigger the low level is decided by the pin VBTHL voltage adjustable
externally.
When pin VBTHL is pulled down externally lower than 0.5V most function blocks are turned off and the IC
enters into standby mode for low power consumption. When the disable signal is released the IC recovers by
soft-start.
8
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
6
Circuit Diagram
9
Application Note AN 2013-03
V1.0 03 2013
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
7
PCB Layout
7.1
Top layer view
7.2
Bottom layer view
10
Application Note AN 2013-03
V1.0 03 2013
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
8
Application Note AN 2013-03
V1.0 03 2013
Component List
Part Type
Description
BR1
8A, 400V
Bridge Rectifier
C1
10uF/50V
Electrolytic Cap
C2
0.1uF/630V
Ceramic Cap
Epcos / B32652A6104J
C3
220uF/450V
Electrolytic Cap
Epcos / B43304C5227M
C4
1.5 uF/50V
Ceramic Cap
C5
1.5 uF/50V
Ceramic Cap
C6
100pF/50V
Ceramic Cap
C7
100uF/25V
Electrolytic Cap
C8
1uF/25V
Ceramic Cap
C9
4.7nF/50V
Ceramic Cap
C10
10nF/50V
Ceramic Cap
C11
10pF/50V
Ceramic Cap
C13
4.7nF/50V
Ceramic Cap
CX1
0.68uF, X1, 275V
Ceramic Cap
CX2
0.68uF, X1, 275V
Ceramic Cap
Epcos / B32922C3474M
CY1
2.2nF, Y2, 250V
Ceramic Cap
Epcos / B81123C1222M000
CY2
2.2nF, Y2, 250V
Ceramic Cap
Epcos / B81123C1222M000
D1
1N4148
Diode
D2
1N5408
Diode
Vishay / 1N5408
D3
IDH02G65C5
Diode
Infineon Technologies
D4
1N4007
Diode
Vishay / 1N4007
D5
1N4007
Diode
Vishay /1N4007
D6
1N4148
Diode
F1
5A
Fuse
IC1
ICE3PCS01G
DSO-14
J1
Jumper
Connector (BOFO)
J2
Jumper
Connector (SYNC)
J3
Jumper
Connector (VCC)
J4
Jumper
Connector (VIN)
J5
Jumper
Connector (VOUT)
L1
2*3.9mH
CM Choke
L2
750uH
PFC Choke
Q1
BC517
NPN Transistor
Q2
IPP60R190P6
Power MOSFET
R1
100R/0.25W, 5%
Carbon Film Resistor
R2
10k/0.25W, 1%
Carbon Film Resistor
R3
3.9M/0.25W, 1%
Carbon Film Resistor
R4
68/0.25W, 1%
Carbon Film Resistor
Designator
11
Manufacturer/ Part No.
Vishay / KBU8G
Epcos / B32922C3474M
Infineon Technologies
Epcos / B82725J2602N20
Infineon Technologies
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
R5A
0.33/0.5W, 5%
Metal Film Resistor
R5
0.1/0.5W, 5%
Metal Film Resistor
R6
0.1/0.5W, 5%
Metal Film Resistor
R7
0.1/0.5W, 5%
Metal Film Resistor
R8
3.3/0.25W, 1%
Carbon Film Resistor
R9
10k/0.25W, 5%
Carbon Film Resistor
R10
1.8M/0.25W, 1%
Carbon Film Resistor
R11
2M/0.25W, 1%
Carbon Film Resistor
R12
130k/0.25W, 1%
Carbon Film Resistor
R13
3.9M/0.25W, 1%
Carbon Film Resistor
9
Application Note AN 2013-03
V1.0 03 2013
Boost Choke Layout
Manufacturer: Kaschke
Choke: AI1-KASCHKE-750UH-PQ3535
Inductance: L=750uH
Windings
1
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Start
1
TOP VIEW
End
3
Pin 12
Pin 11
Pin 10
Pin 9
Pin 8
Pin 7
Wire
100x0.1mm Litz
Pin 1
Pin 3
Turns
70
Layers
4 or 5
Method
Tight
Winding 1: 70 turns//100x0.1mm Litz//tight
Core Center Limb
Remove Pin
No
Margin
tape
12
Length 20.8mm
No
Margin
tape
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
10
Application Note AN 2013-03
V1.0 03 2013
Test report
All test condition are supply with Vcc=12V
10.1
Load and Line Test
VIN
IIN
PIN
UOUT
IOUT
POUT
Eff.
PF
Input
85Vac
230Vac
89,706
3,49803
313,3
379,84
0,78582
298,4859
95,272
0,99841
89,74
3,1073
278,39
379,819
0,70019
265,9455
95,53
0,99836
89,767
2,78335
249,41
379,788
0,62859
238,7309
95,718
0,99823
89,799
2,39961
215,1
379,761
0,54338
206,3545
95,934
0,99821
89,827
2,08104
186,58
379,755
0,47205
179,2634
96,079
0,99811
89,859
1,70004
152,46
379,74
0,3863
146,6936
96,218
0,99798
89,886
1,38571
124,26
379,728
0,3151
119,6523
96,292
0,99759
89,918
1,01081
90,61
379,741
0,2296
87,18853
96,224
0,99689
89,949
0,64084
57,34
379,766
0,14473
54,96353
95,855
0,99478
89,976
0,32995
29,31
379,791
0,07434
28,23366
96,328
0,9874
229,9
1,3258
303,2
379,8
0,786
298,51
98,454
0,99488
229,9
1,1823
270,19
379,8
0,701
266,07
98,474
0,99402
229,9
1,0623
242,65
379,8
0,629
239
98,495
0,99353
229,9
0,9203
209,86
379,8
0,544
206,72
98,502
0,99186
229,9
0,8013
182,43
379,8
0,473
179,66
98,483
0,99009
230
0,6585
149,39
379,8
0,387
147,17
98,511
0,98648
230
0,5429
121,98
379,8
0,316
120,07
98,435
0,977
230
0,4033
89,08
379,8
0,23
87,499
98,225
0,96031
230
0,2685
56,36
379,8
0,145
55,163
97,877
0,9125
230
0,1638
29,05
379,8
0,074
28,116
96,784
0,77109
13
Application Note AN 2013-03
300W PFC Evaluation Board IPP60R190P6
with CCM PFC controller ICE3PCS01G
V1.0 03 2013
Efficiency High Line
99
eta [%]
98,5
98
97,5
BT1 SPP20N60C3
97
BT3 IPP60R190C6
BT4 IPP60R190E6
BT5 IPP60R190P6
96,5
0
50
100
150
200
250
300
350
Pout[W]
Figure 3
Efficiency High Line
Efficiency Low Line
96,5
BT1 SPP20N60C3
BT3 IPP60R190C6
BT4 IPP60R190E6
BT5 IPP60R190P6
eta [%]
96
95,5
95
94,5
0
50
Figure 4
Efficiency Low Line
11
References
100
150
200
Pout[W]
250
300
350
[1]
ICE3PCS01G datasheet, Infineon Technologies AG, 2010.
[2]
600V CoolMOS™ P6 Power MOSFET, Product Brief, Infineon Technologies AG, 2012.
[3]
IDH02G65C5 , datasheet, Infineon Technologies AG, 2012.
14
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