Application Note Addendum to 300W general purpose wide-range SMPS

I CE3P CS 01 G PF C+ TT F c on tr ol c a r d
Addendum to ANEVAL_201410_PL52_002
Addendum
About this document
Scope and purpose
This document is and addendum to the Infineon application note “300 W General Purpose wide-range
SMPS” (ANEVAL_201410_PL52_002), which describes a 300 W switched mode power supply design using
ICE1CS02G combi controller IC to implement the PFC and TTF function.
This addendum describes in technical details the alternative control card, which consist in a circuit using the
Infineon ICE3PCS01G CCM PFC controller IC in combination with the Texas Instruments LM5021-2 TTF
controller IC.
The power board hardware is compatible with both the control cards with minor changes, which are
described in this document.
Attention: This board is intended for evaluation purposes only and is not intended to be an end product.
Intended audience
Design engineers who are developing a PFC + TTF switched mode power supply.
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ICE3PCS01G PFC+TTF control card
Addendum to ANEVAL_201410_PL52_002
Board description
Table of Contents
1
1.1
1.2
1.3
1.3.1
1.3.2
Board description .......................................................................................................................... 3
Block diagram...................................................................................................................................... 3
Hardware description ......................................................................................................................... 3
Power board required changes .......................................................................................................... 5
PFC current sense – shunt replacement ...................................................................................... 5
TTF current sense – shunt replacement ....................................................................................... 5
2
2.1
2.2
2.3
2.4
Protections..................................................................................................................................... 7
Brown-Out Protection ......................................................................................................................... 7
Bus Over-Voltage protection .............................................................................................................. 7
Bus Under-Voltage protection ............................................................................................................ 7
PFC Overcurrent protection and TTF overcurrent protection ........................................................... 7
Addendum
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Board description
1
Board description
The “300 W general purpose wide-range SMPS” application note is the document where most of the
information is described. Please refer to this document when replacing the original ICE1CS02G combi IC
control card with the ICE3PCS01G control IC card which is described below.
1.1
Block diagram
The following pictures represent the board topology and its partitioning with indication of the main
components.
For a better explanation, the power supply can be divided into five parts, shown in Figure 1.
1.
2.
3.
4.
5.
The input filter
The PFC stage  Originally controlled by combi IC ICE1CS02G  Now replaced by ICE3PCS01G
The TTF stage  Originally controlled by combi IC ICE1Cs02G  Now replaced by LM5021-1
The output stage
The auxiliary supply
Rapid 2 Diode
2
3
CoolMOS™ C6
1
CoolMOS™ CE
4
ICE3PCS01G
LM5021-2
2EDL05I06BF
Controller ICs
EiceDRIVER™ Compact
ICE QR/FF
5
Figure 1
CoolSET™
300 W SMPS evalualtion board - simplified schematic
The new control card is put in evidence in green in Figure 1.
1.2
Hardware description
The following sections gives a detailed description of the hardware and how it can be used.
Addendum
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Addendum to ANEVAL_201410_PL52_002
Board description
Figure 2
Hardware TOP overview – ICE3PCS01G in evidence
Figure 3
Control card schematic
Addendum
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Addendum to ANEVAL_201410_PL52_002
Board description
The connector is described in the following table:
Table 1
1
Control card connector
2
3
4
VBUS
VCC
5
6
PWMout PFCout
7
8
VCC
9
GND PWMcs
10
FB
11
12
13
PFCcs GND
14
RECac+
Pin1 and Pin14 are connected to high voltage, please be careful when handling the control cards while
connected to the power board.
1.3
Power board required changes
The use of the alternative control card requires a hardware change in the power board, which is the one
hosting the power active components and magnetics.
The only hardware changes needed are the re-sizing of the shunt current sense resistors for both the PFC
and the TTF circuits.
1.3.1
PFC current sense – shunt replacement
The PFC current sense sizing is described in chapter 3.3 of the “300 W General Purpose wide-range SMPS”
application note.
We are then goin to follow the same rules.
The power board is designed for a typical shunt voltage threshold VCSTH=0.2 V giving the following result:
| |
| |
0.2 
=
=
∆1
20% ∙ 1 5.82  ∙ (1.1)
1 +
1 +
2
2
= 312 Ω
_ ≤
Eq 1
A second point to keep in mind is the power dissipation:
_ = | | ∙ ()1 = 0.2 ∙ 3.55  = 0.71 
Eq 2
In order to fulfill both requirements, three shunt resistors of 100 mΩ in parallel have been used. The choice
is on 1 W SMD resistors, type “2512” resistors to keep also low the stray inductance, which would cause
spikes on the sensed voltage.
Chosen values are R6=R7=R11=0.1Ω.
1.3.2
TTF current sense – shunt replacement
The same procedure as explained in chapter 4 in “300 W General Purpose wide-range SMPS” application
note is applied here.
The power board is designed for a shunt voltage threshold Vcsth=0.5 V giving the following result:
_ ≤
| |
()
=
0.5 
= 190 Ω
2.63 
Eq 3
A second point to keep in mind is the power dissipation:
Addendum
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ICE3PCS01G PFC+TTF control card
Addendum to ANEVAL_201410_PL52_002
Board description
_ = | | ∙ () = 0.5  ∙ 2  = 1 
Eq 4
In order to fulfill both requirements, and to keep some flexibility, two shunt resistors of 0.402 mΩ in parallel
have been used. The choice is on 1 W SMD resistors, type “2512” to keep also low the stray inductance,
which would cause spikes on the sensed voltage.
Addendum
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Addendum to ANEVAL_201410_PL52_002
Protections
2
Protections
2.1
Brown-out protection
Brown-out protection is set by: R13=R23=2.1 Meg; R12=1.96 Meg; R9=82 K.
See below the brown-out input DC voltages
13 + 23 + 12
6.16 
) = 1.25  ∙ (1 +
) = 95 
9
82 
13 + 23 + 12
6.16 
= _2 ∙ (1 +
) = 1  ∙ (1 +
) = 76 
9
82 
Eq 5
 = _2 ∙ (1 +

2.2
Eq 6
Bus over-voltage protection
Bus overvoltage protection is set by: R1=R3= 2.05 Meg; R5=1.1 Meg; R10=31 K.
See below the BUS Overvoltage values:
1 + 3 + 5
5.2 
) = 2.7  ∙ (1 +
) = 455 
10
31 
1 + 3 + 5
5.2 
= _2 ∙ (1 +
) = 2.5  ∙ (1 +
) = 421 
10
31 
Eq 7
 = _2 ∙ (1 +

2.3
Eq 8
Bus under-voltage protection
TTF stage is turned on via VB_OK digital signal. ICE3PCS01G monitors the bus voltage and turns off VB_OK
when VSense is below VBTHL_EN pin voltage.
In this controller card VBTHL_EN is set to disable the TTF stage at Vbus=330 V:
15
200 
_ =  ∙ (
)=5∙(
) = 2.13 
15 + 11
200  + 270 
2 + 4 + 6
5.2 
 = _ ∙ (1 +
) = 2.13 ∙ (1 +
) = 330 
8
31 
2 + 4 + 6
5.2 
 = _ ∙ (1 +
) = 2.375  ∙ (1 +
) = 368 
8
31 
2.4
Eq 9
Eq 10
Eq 11
PFC overcurrent protection and TTF overcurrent protection
ICE3PCS01G protects the power supply by interrupting the PWM pattern at each cycle if overcurrent is
detected. As soon as Bus voltage drops, the VB_OK pin is pulled-down and the TTF stage stopped. This
protection is not latched.
TTF is protecting the power supply by interrupting the PWM pattern and enters hic-up mode in case of
continuous overload condition. Please see ICE3PCS01G and LM5021-2 datasheets for more details.
Addendum
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ICE3PCS01G PFC+TTF control card
Addendum to ANEVAL_201410_PL52_002
References and proposed links
3
References and proposed links
[1] CoolMOS™ high voltage MOSFETs product main page
www.infineon.com/coolmos
[2] thinQ™! Silicon Carbide Schottky Diodes main page
www.infineon.com/sic
[3] Rapid Silicon Diodes main page
http://www.infineon.com/cms/en/product/transistor-and-diode/diode/silicon-powerdiode/channel.html?channel=ff80808112ab681d0112ab6a527f04a6
[4] CoolSET™ auxiliary and SMPS controller ICs main page
www.infineon.com/coolset
[5] ICE1CS02G application note: “300W Evaluation board using ICE1CS02”:
http://www.infineon.com/dgdl?folderId=5546d4694909da4801490a2652e6286a&fileId=db3a30431c69a
49d011c8e8e3df1048f
[6] ICE1CS02G datasheet from Infineon product page
http://www.infineon.com/dgdl?folderId=5546d4694909da4801490a07012f053b&fileId=db3a30431c69a
49d011c8e917a2d0494
[7] Application Note - 300 W general purpose wide range SMPS
http://www.infineon.com/dgdl?fileId=5546d4624e765da5014eced06bd44911
Revision History
Major changes since the last revision
Page or Reference
--
Addendum
Description of change
First Release
8
Revision 1.0, 2015-09-17
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Document reference
AN_201509_PL52_023
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