300W Evaluation board using ICE1PCS02

Application Note, V1.0, June 2005
ICE1PCS02
300W PFC Evaluation Board with CCM PFC
controller ICE1PCS02
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2005-06-17
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2004.
All Rights Reserved.
Attention please!
The information herein is given to describe certain components and shall not be considered as a guarantee
of characteristics.
Terms of delivery and rights to technical change reserved.
We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement,
regarding circuits, descriptions and charts stated herein.
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
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ICE1PCS02
Revision History:
Previous Version:
Page
2005-06
none
Subjects (major changes since last revision)
300W PFC Evaluation Board with CCM PFC controller ICE1PCS02
License to Infineon Technologies Asia Pacific Pte Ltd
Wang Qing
Luo Junyang
Jeoh Meng Kiat
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]
V1.0
ANP0055
ICE1PCS02
Table of Contents
Page
1
Content ...............................................................................................................5
2
Evaluation Board ...............................................................................................5
3
List of Features ..................................................................................................6
4
Technical Specifications ...................................................................................6
5
Circuit Description.............................................................................................6
5.1
Line Input .......................................................................................................................................6
5.2
Power Stage − Boost Type PFC Converter.................................................................................6
5.3
PWM Control of Boost Converter ................................................................................................7
6
Circuit Operation ...............................................................................................7
6.1
Soft Startup....................................................................................................................................7
6.2
Enhanced Dynamic Response.....................................................................................................7
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
Protection Features ......................................................................................................................7
Input brown-out protection ..............................................................................................................7
Open loop protection.......................................................................................................................8
Output over-voltage protection........................................................................................................8
Soft over current control (SOC) and peak current limit...................................................................8
IC supply under voltage lockout......................................................................................................8
7
Circuit Diagram ..................................................................................................9
8
PCB Layout Top Layer ....................................................................................10
9
PCB layout Bottom Layer................................................................................11
10
Component List ...............................................................................................12
11
Boost Choke Layout ........................................................................................13
12
Test report ........................................................................................................14
12.1
Load test (table and figure) ........................................................................................................14
12.2
12.2.1
12.2.2
12.2.3
12.2.4
12.3
12.3.1
12.3.2
12.3.3
12.3.4
12.3.5
12.3.6
12.3.7
12.3.8
12.3.9
Harmonic test according to EN61000-3-2 Class D requirement.............................................17
85VAC, full load (300W output).....................................................................................................17
85VAC, 9.3% of full load (28W output) .........................................................................................17
265VAC, full load (300W output) ..................................................................................................18
265VAC, 9.3% of full load (28W output) .......................................................................................18
Test Waveforms ..........................................................................................................................19
Startup test at 85VAC, full load (300W) ........................................................................................19
Startup test at 85VAC, open load .................................................................................................19
Load jump test at 85VAC, Iout from 0A to 0.75A ..........................................................................19
Load jump test at 85VAC, Iout from 0.75A to 0A ..........................................................................20
Voltage jump test at full load, from 85V to 265V...........................................................................20
Voltage jump test at full load, from 265V to 85V...........................................................................20
Enter brown-out at Iout=0.3A, 68VAC...........................................................................................21
Leave brown-out at Iout=0.3A, 80VAC .........................................................................................21
Open Loop protection at 265V, Iout=0.1A ....................................................................................21
13
References: ......................................................................................................22
Application Note
4
2005-06-17
ICE1PCS02
1
Content
The evaluation board presented here is a 300W power factor correction (PFC) circuit with 85~265VAC
universal input and 390VDC fixed output. The continuous conduction mode (CCM) PFC controller
ICE1PCS02 is employed in this board to achieve the unity power factor. This ICE1PCS02 is a design
variant of ICE1PCS01 to incorporate the new input brown-out protection function and optimized to have a
faster startup time with controlled peak startup current. Appreciated for its high integrated design,
ICE1PCS02 can achieve full requirements of the PFC application implemented in the 8-pin DIP8 and SO8
packages. At the same time the number of peripheral components is minimized. The operation frequency
is fixed at 65kHz due to internal oscillator of ICE1PCS02. In order to improve the power conversion
efficiency, the CoolMOSTM C3 series and high voltage silicon carbide (SiC) schottky diode thinQ!TM are
used into this boost type PFC circuit.
2
Evaluation Board
Application Note
5
2005-06-17
ICE1PCS02
3
List of Features
Ease of use with few external components
Supports wide input range
Average current control
External current and voltage loop compensationfor greater user flexibility
Trimmed internal fixed switching frequency (65kHz±7.7% at 25 )
Direct sensing, input brown-out detection with hysteresis
Short startup (soft start) duration
Max duty cycle of 97% (typ)
Trimmed internal reference voltage (5V±2%)
VCC under voltage lockout
Cycle by cycle peak current limiting
Over voltage protection
Open loop detection
Soft over current protection
Enhanced dynamic response
Fulfills Class D requirements of IEC 1000-3-2
4
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
50Hz
Output voltage and current
390VDC, 0.76A
Output power
300W
Efficiency
>90% at full load
Switching Frequency
65kHz
5
Circuit Description
5.1
Line Input
The AC line input side comprises the input fuse F1 as over-current protection. The high frequency current
ripple is filtered by R1, L1 and CX1. The choke L2, X2-capacitors CX1 and CX2 and Y1-capacitor CY1
and CY2 are used as radio interference suppressors. RT1 is placed in series to limit inrush current during
each power on.
5.2
Power Stage − Boost Type PFC Converter
After the bridge rectifier BR1, there is a boost type PFC converter consisting of L3, Q1, D1 and C2. The
third generation CoolMOS™ SPP20N60C3 is used as the power switch Q1. BR1, Q1 and SiC Diode D1
Application Note
6
2005-06-17
ICE1PCS02
share the same heat sink so that the system heat can be equably spread. Output capacitor C2 provides
energy buffering to reduce the output voltage ripple (100Hz) to the acceptable level.
5.3
PWM Control of Boost Converter
The PWM control is realized by 8-Pin CCM PFC IC ICE1PCS02. It is a variant design of ICE1PCS01 with
preserving most of the features. Unlike the conventional PFC controller, ICE1PCS02 does not need direct
sine wave reference signal. The switching frequency is fixed at 65kHz by the IC internal oscillator. There
are two control loops in the circuit, voltage loop and current loop. The output voltage is sensed by the
voltage divider of R5, R5A, R5B and R6 and sent to internal error amplifier. The output of error amplifier is
used to control current in the inner current loop. The compensation network C4, C5, R7 constitutes the
external circuitry of the error amplifier. This circuitry allows the feedback to be matched to various load
conditions, thereby providing stable control. In order not to make the response for 100Hz ripple, the
voltage loop compensation is implemented with low bandwidth. The inner loop, current control loop, is
implemented with average current mode strategy. The instant current is adjusted to be proportional to
both of MOSFET off duty DOFF and the error amplifier output voltage of voltage loop. The current is
sensed by shunt resistors R2, R2A and R2B and fed into IC through R9. The current sense signal is
averaged by an internal operating amplifier and then processed in the PWM generator which drives the
gate drive. The averaging is realized by charging and discharging an external capacitor C7 at pin ICOMP.
The IC supply is provided by external voltage source and filtered and buffered by C8 and C9. The IC
output gate driver is a fast totem pole gate drive. It has a built-in cross conduction current protection and a
Zener diode to protect the external transistor switch against undesirable over voltages. The gate drive
resistor R4 is selected to limit and gate pulse current and drive MOSFET for fast switching.
6
Circuit Operation
6.1
Soft Startup
When Vcc pin is higher than turn-on threshold, typical 11.2V, PFC is going to start. The unique soft start
is integrated. Input current keeps sinusoidal and is increasing gradually until output voltage reaches 80%
of rating. Because the peak current limit is not activated, the boost diode is not stressed with large diode
duty cycle under high current.
6.2
Enhanced Dynamic Response
Due to inherent low bandwidth of PFC dynamic, in case of load jump, regulation circuit can not response
fast enough and it will lead to large output voltage overshoot or drop. To solve this problem in PFC
application, enhanced dynamic response is implemented in the IC. Whenever output voltage exceeds by
±5%, it will bypass the slow compensation operating amplifier and act on the nonlinear gain block to affect
the duty cycle directly. The output voltage can be recovered in a short time.
6.3
Protection Features
6.3.1
Input brown-out protection
The dedicated input voltage brown-out VINS pin is the most distinct new feature brought by ICE1PCS02.
This VINS pin senses a filtered input voltage divider and detects for the input voltage brown-out condition.
If the detected VINS is below 0.8V, then IC output will be shut down. Only when VINS voltage reaches
1.5V can awake the IC again. Be informed that it will still have the soft start property when the IC is
recovered from brown-out situation.
Application Note
7
2005-06-17
ICE1PCS02
6.3.2
Open loop protection
The open loop protection is available for this IC to safe-guard the output. Whenever VSENSE voltage falls
below 0.8V, or equivalently VOUT falls below 16% 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 0.8V.
6.3.3
Output over-voltage protection
Output over-voltage protection is also available by the same integrated blocks of enhanced dynamic
response. Whenever VOUT exceeds the rated value by 5%, the over-voltage protection OVP is active.
This is implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 5.25V.
A VSENSE voltage higher than 5.25V will immediately reduce the output duty cycle even down to zero,
bypassing the normal voltage loop control. This results in a lower input power and the output voltage
VOUT is reduced.
6.3.4
Soft over current control (SOC) and peak current limit
When the amplitude of current sense voltage reaches 0.73V, Soft Over Current Control (SOC) is
activated. This is a soft control does not directly switch off the gate drive but acts on the internal blocks to
result in a reduced PWM duty cycle.
The IC also provides a cycle by cycle peak current limitation (PCL). It is active when the voltage at current
sense voltage reaches -1.08V. The gate output is immediately off after 300ns blanking time.
6.3.5
IC supply under voltage lockout
When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 10.2V, IC is off the
gate drive is internally pull low to maintain the off state. The current consumption is down to 200uA only.
Application Note
8
2005-06-17
9
N
85~265VAC
L
VAR1
S10K275
F1
5A
GND
Vcc
2*3.9mH
L2
C8
0.1u
C9
47u/25V
CY1
2.2nF, Y2, 250V
Earth
0.47u/275V
L1* CX1
R1*
1nF
C7
D3
R8
220nF
C6
GND
ICE1PCS02
IC1
Vcomp
Vsense
C5
1uF
5
6
8
R7
33k
C4
0.1uF
3.3
I-Sense
R4
R2B
0.22/1W
220
Gate
R2A
0.22/1W
C1
0.1u/630V
R2
0.33/1W
R3
10k
Q1
SPP20N60C3
L3
1.24mH
R9
BR1
8A, 400V
Brown Out
Icomp
Vcc
1N4007
120k, 1%
2
7
3.9M, 1%
R11
3.9M, 1%
R10
CY2
2.2nF, Y2, 250V
0.47u/275V
CX2
RT1
S237/5
4
Application Note
3
C2
C3*
* Optional Components
220u/450V
D1
SDT04S60
10k, 1%
R6
R5B
200k, 1%
270k, 1%
R5A
R5
300k, 1%
Gnd
390V/300W
Vo
7
1
D2
1N5408
ICE1PCS02
Circuit Diagram
2005-06-17
ICE1PCS02
8
PCB Layout Top Layer
Application Note
10
2005-06-17
ICE1PCS02
9
PCB layout Bottom Layer
Application Note
11
2005-06-17
ICE1PCS02
10
Component List
Designator
Part Type
Description
BR1
C1
C2
C3*
C4
C5
C6
C7
C8
C9
CX1
CX2
CY1
CY2
8A, 400V
0.1uF/630V
220uF/450V
Not Connected
0.1uF/50V
1uF/50V
220nF/50V
1nF/50V
0.1uF/50V
47uF/25V
0.47uF, X1, 275V
0.47uF, X1, 275V
2.2nF, Y2, 250V
2.2nF, Y2, 250V
Bridge Rectifier
Ceramic Cap
Electrolytic Cap
D1
D2
D3
F1
SDT04S60
1N5408
1N4007
5A
IC1
JP1
JP2
JP3
JP4
L1*
L2
L3
Q1
ICE1PCS02
12.5mm, Ф0.7mm
20mm, Ф0.7mm
12mm, Ф1.2mm
17.5mm, Ф0.7mm
Shorted
2*3.9mH
1.24mH
SPP20N60C3
R1*
R2
R2A
R2B
R3
R4
R5
R5A
R5B
R6
Not Connected
0.33/1W, 5%
0.22/1W, 5%
0.22/1W, 5%
10k/0.25W, 5%
3.3/0.25W, 5%
300k/0.25W, 1%
270k/0.25W, 1%
200k/0.25W, 1%
10k/0.25W, 1%
Application Note
Ceramic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Electrolytic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Connector
Diode
Diode
Diode
Fuse
Fuse Holder
Jumper
Jumper
Jumper
Jumper
CM Choke
Choke
Power MOSFET
Heat Sink
TO220 Clip
TO247 Clip
TO220 Isolation Pad
3mm Screw
Metal Film Resistor
Metal Film Resistor
Metal Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
12
Quantity
1
1
1
0
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
2
1
1
1
1
1
0
1
1
1
1
2
1
2
3
0
1
1
1
1
1
1
1
1
1
2005-06-17
ICE1PCS02
R7
R8
R9
R10
R11
RT1
VAR1
11
33k/0.25W, 5%
120k/0.25W, 1%
220/0.25W, 5%
3.9M/0.25W, 1%
3.9M/0.25W, 1%
S237/5
S10K275
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
NTC Thermistor
Varistor
1
1
1
1
1
1
1
Boost Choke Layout
Core: CS468125 toriod
Turns: 83
Wire: 1 x Φ1.0mm, AWG19
Inductance: L=1.24mH
Application Note
13
2005-06-17
ICE1PCS02
12
Test report
12.1
Load test (table and figure)
Vin
(VAC)
Iin (A)
Pin (W)
Vo (V)
Io (A)
Po (W)
PF
85
3.866
3.043
2.517
2.000
1.495
0.996
0.506
0.267
0.151
0.083
0.062
327.9
258.1
213.4
169.7
126.9
84.4
42.7
22.4
12.5
6.4
4.5
397.1
397.1
397.1
397.1
397.0
397.0
397.0
397.0
397.1
397.1
397.0
0.754
0.600
0.501
0.399
0.300
0.199
0.100
0.052
0.029
0.014
0.006
299.4
238.3
198.9
158.4
119.1
79.0
39.7
20.6
11.5
5.6
2.4
0.998
0.998
0.998
0.998
0.998
0.998
0.994
0.987
0.966
0.911
0.851
Efficiency
(%)
91.3%
92.3%
93.2%
93.4%
93.9%
93.6%
93.0%
92.2%
92.1%
86.9%
52.9%
110
2.906
2.302
1.913
1.526
1.145
0.767
0.389
0.210
0.122
0.071
0.058
318.9
252.5
209.9
167.5
125.5
84.0
42.4
22.4
12.5
6.4
4.6
396.9
397.0
397.0
397.0
397.0
397.0
397.1
397.1
397.1
397.0
397.0
0.755
0.600
0.501
0.400
0.300
0.200
0.100
0.053
0.029
0.014
0.006
299.7
238.2
198.9
158.8
119.1
79.4
39.7
21.0
11.5
5.6
2.4
0.997
0.998
0.998
0.998
0.997
0.995
0.991
0.972
0.935
0.820
0.720
94.0%
94.3%
94.8%
94.8%
94.9%
94.5%
93.7%
94.0%
92.1%
86.8%
51.8%
230
1.360
1.085
0.905
0.726
0.551
0.376
0.205
0.130
0.099
0.085
0.082
309.9
247.1
206.2
165.4
124.7
83.8
42.8
23.3
13.4
7.3
5.3
397.0
397.0
397.1
397.1
397.1
397.1
397.1
397.0
397.0
397.0
397.0
0.755
0.600
0.501
0.399
0.300
0.200
0.100
0.052
0.029
0.014
0.006
299.7
238.2
198.9
158.4
119.1
79.4
39.7
20.6
11.5
5.6
2.4
0.991
0.990
0.990
0.990
0.984
0.969
0.910
0.780
0.585
0.373
0.274
96.7%
96.4%
96.5%
95.8%
95.5%
94.8%
92.8%
88.6%
85.9%
76.1%
44.9%
Application Note
14
2005-06-17
ICE1PCS02
Vin
(VAC)
Iin (A)
Pin (W)
Vo (V)
Io (A)
Po (W)
PF
265
1.180
0.942
0.787
0.635
0.482
0.333
0.190
0.129
0.106
0.095
0.093
309.2
246.7
206.0
165.3
124.6
84.0
43.5
23.8
13.8
7.7
5.7
397.0
397.0
397.1
397.0
397.0
397.0
397.0
396.9
396.9
396.9
396.9
0.755
0.601
0.501
0.400
0.300
0.199
0.100
0.053
0.029
0.014
0.005
299.7
238.6
198.9
158.8
119.1
79.0
39.7
21.0
11.5
5.6
2.0
0.989
0.989
0.988
0.983
0.975
0.951
0.865
0.693
0.495
0.309
0.231
Application Note
15
Efficiency
(%)
96.9%
96.7%
96.6%
96.1%
95.6%
94.1%
91.3%
88.4%
83.4%
72.2%
34.8%
2005-06-17
ICE1PCS02
98.0%
Efficiency
96.0%
94.0%
Full Load
Half Load
92.0%
90.0%
88.0%
85
110
230
265
Input Voltage (V)
1
0.9
Power Factor
0.8
0.7
85V
110V
230V
265V
0.6
0.5
0.4
0.3
0.2
0.1
0
2.4
11.5
39.7
119.1
198.9
299.4
Output Power (W)
Application Note
16
2005-06-17
ICE1PCS02
12.2
Harmonic test according to EN61000-3-2 Class D requirement
12.2.1
85VAC, full load (300W output)
IACin
12.2.2
85VAC, 9.3% of full load (28W output)
IACin
Application Note
17
2005-06-17
ICE1PCS02
12.2.3
265VAC, full load (300W output)
IACin
12.2.4
265VAC, 9.3% of full load (28W output)
IACin
Application Note
18
2005-06-17
ICE1PCS02
12.3
Test Waveforms
12.3.1
Startup test at 85VAC, full load (300W)
IACin
Vout
Vcc
12.3.2
Vcomp
Startup test at 85VAC, open load
IACin
Vout
Vcc
12.3.3
Vcomp
Load jump test at 85VAC, Iout from 0A to 0.75A
Vout
Vsense
Iout
Vgate
Application Note
19
2005-06-17
ICE1PCS02
12.3.4
Load jump test at 85VAC, Iout from 0.75A to 0A
Vout
Vsense
Iout
Vgate
12.3.5
Voltage jump test at full load, from 85V to 265V
VACin
Vout
IACin
VIsense
12.3.6
Voltage jump test at full load, from 265V to 85V
VACin
Vout
IACin
VIsense
Application Note
20
2005-06-17
ICE1PCS02
12.3.7
Enter brown-out at Iout=0.3A, 68VAC
AC line voltage change
IACin VACin
Vbrown_out
Vgate
12.3.8
Leave brown-out at Iout=0.3A, 80VAC
AC line voltage change
IACin
VACin
Vbrown_out
Vgate
12.3.9
Open Loop protection at 265V, Iout=0.1A
Vout
IACin
Vsense
Vgate
Application Note
21
2005-06-17
ICE1PCS02
13
References:
[1]
ICE1PCS02 Datasheet V1.1, Infineon Technologies, Munich, Germany, Dec. 2004
[2]
Luo Junyang, Jeoh Meng Kiat, ICE1PCS02 Based Boost Type CCM PFC Design Guide,
Application Note, Infineon Technologies, Singapore, Oct. 2004
[3]
Junyang Luo, Meng Kiat Jeoh and Ming Lik Yew, 300W CCM PFC Evaluation Board with
ICE1PCS01, CoolMOSTM and SiC Diode thinQ!TM, Infineon Technologies, Singapore
Application Note
22
2005-06-17
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