300W Evaluation board using ICE1PCS01

Application Note, V2.0, March 2006
EVALPFC2-ICE1PCS01
300W PFC Evaluation Board with CCM PFC
controller ICE1PCS01
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2006-03-27
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2004.
All Rights Reserved.
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EVALPFC2-ICE1PCS01
Revision History:
Previous Version:
Page
4 - 16
4 - 16
2006-03
V2.0
V1.0
Subjects (major changes since last revision)
Switching frequency
PCB layout
300W PFC Evaluation Board with CCM PFC controller ICE1PCS01
License to Infineon Technologies Asia Pacific Pte Ltd
Junyang Luo
Jeoh Meng Kiat
Jianwei Liu
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3
300W CCM PFC Evaluation Board
with
ICE1PCS01, CoolMOS™ and SiC Diode thinQ!™
The board described here was designed as a typical power factor correction (PFC) circuit in boost
topology. The controller ICE1PCS01 chip used for this application is an 8-pin wide range input IC for
active PFC converters. The IC operates in the CCM with average current control and in DCM only
under light load condition. The switching frequency is programmable by external resistor at one pin.
There are various protection features incorporated to ensure safe system operation conditions. The
device has a unique soft-start function which limits the start up inrush current thus reducing the stress
on the boost diode. To improve the efficiency, the third generation CoolMOS™ is used as the power
switch due to its lowest area specific Rdson. High voltage Silicon Carbide (SiC) Schottky diode
thinQ!™ is used as PFC boost diode. Because of its ideal reverse recovery behavior, SiC Schottky
diode is extremely suitable for high frequency CCM PFC application.
Evaluation board
4
Technical specifications:
Input voltage
Input frequency
Output voltage and current
Output power
Efficiency
Switching frequency
85VAC~265VAC
50Hz
400VDC, 0.75A
300W
>90% at full load
62.5kHz
Circuit Description
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 Y1capacitor CY1 and CY2 are used as radio interference suppressors. RT1 is placed in series to limit
inrush current during each power on.
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™ is used as the power switch Q1. Due to its low Rdson, the small heat
sink can fulfill the dissipation requirement. SiC Schottky diode thinQ!™ is used for D1. As SiC
Schottky diode does not show a reverse recovery behavior, the stress on the MOSFET will be reduced
due to very low current spike during turn on transient. Simultaneously higher reliability of the entire
system can be achieved. However, due to the poor pulse current capability of SiC Schottky diode, a
standard diode D2 is necessary to bypass the high inrush current during each power on transient.
Output capacitor C2 provides energy buffering to reduce the output voltage ripple (100Hz) to the
acceptable level.
PWM control of Boost Converter
The PWM control is realized by 8-Pin CCM PFC IC ICE1PCS01. Unlike the conventional PFC
controller, ICE1PCS01 does not need direct sine wave reference signal. The switching frequency is
fixed and programmed by R8. 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.
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 an in-built 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.
Circuit Operation
Soft Start
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
5
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.
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, enhance 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.
Protection Features
Open loop protection (OLP) / Mains under voltage 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. Insufficient input voltage
VIN will also trigger this protection.
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.
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.
IC supply under voltage lock out
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.
6
Circuit Diagram
1
2
3
4
D
D
D2
1N5408
L
85~265VAC
N
F1
5A
VAR1
S10K275
R1
120ohm
L2
L1
40uH
CX1
C1
0.1u/630V
R2
0.33/1W
0.47u/275V
0.47u/275V
CY1
2.2nF, Y2, 250V
Earth
C
Q1
SPP20N60C3
CX2
2*3.9mH
D1
SDP04S60
L3
1.24mH
BR1
8A, 400V
RT1
S237/5
CY2
2.2nF, Y2, 250V
390V/300W
Vo
C2
R3
10k
Gnd
R2A
0.22/1W
C
R5
300k, 1%
R2B
0.22/1W
R4
R5A
220
3.3
270k, 1%
3
R9
I-Sense
7
B
2
Vcc
ICE1PCS01
I-Comp
Freq
GND
Vsense
6
V-Comp
5
B
R7
C8
47u/25V
0.1u
C7
1nF
R8
76k
33k
1
C9
4
Vcc
GND
R5B
200k, 1%
8
Gate
C5
C4
0.1uF
C3
470p
R6
10k, 1%
1uF
A
A
1
2
3
4
7
PCB layout top layer
8
PCB layout Bottom:
9
Component List:
Designator
Part Type
Description
BR1
C1
C2
C4
C5
C7
C8
C9
CX1
CX2
CY1
CY2
8A, 400V
0.1uF/630V
220uF/450V
0.1uF/50V
1uF/50V
1nF/50V
0.1uF/50V
47uF/25V
0.47uF, X1, 275V
0.47uF, X1, 275V
2.2nF, Y2, 250V
2.2nF, Y2, 250V
D1
D2
F1
SDT04S60
1N5408
5A
Bridge Rectifier
Ceramic Cap
Electrolytic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Electrolytic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Ceramic Cap
Connector
Diode
Diode
Fuse
Fuse Holder
IC1
JP1
JP2
JP3
JP4
L1*
L2
L3
Q1
ICE1PCS01
12.5mm, Ф0.7mm
20mm, Ф0.7mm
12mm, Ф1.2mm
17.5mm, Ф0.7mm
Shorted
2*3.9mH
1.24mH
SPP20N60C3
R2
R2A
R2B
R3
R4
R5
R5A
R5B
R6
R7
R8
R9
RT1
VAR1
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%
33k/0.25W, 5%
76k/0.25W, 1%
220/0.25W, 5%
S237/5
S10K275
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
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
NTC Thermistor
Varistor
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
1
1
1
1
0
1
1
1
1
2
1
2
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
Boost Choke Layout
Core: CS468125 toriod
Turns: 83
Wire: 1 x Φ1.0mm, AWG19
Inductance: L=1.24mH
Test report
Load test (table and figure):
Vin (VAC)
Pin (W)
320
253
209
167
124
82
40
26
19
11
85
7.2
316
248
206
165
123
82
39
27
19
11
110
7.2
307
246
205
164
124
83
43
25.6
17.4
13.5
220
6.7
265
305
244
203
162
122
82
42
Iin (A)
3.8
3
2.5
2
1.5
0.99
0.51
0.37
0.29
0.18
0.13
2.9
2.3
1.9
1.5
1.2
0.78
0.43
0.31
0.24
0.15
0.11
1.4
1.2
1
0.8
0.63
0.45
0.29
0.21
0.15
0.13
0.093
1.2
0.96
0.81
0.67
0.52
0.39
0.26
Vout (V)
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
399
Iout (A)
0.75
0.59
0.49
0.39
0.29
0.19
0.09
0.06
0.043
0.024
0.015
0.75
0.59
0.49
0.39
0.29
0.19
0.09
0.06
0.043
0.024
0.015
0.75
0.6
0.5
0.4
0.3
0.25
0.2
0.1
0.04
0.03
0.015
0.75
0.6
0.5
0.4
0.3
0.2
0.1
Pout (W)
299.3
235.4
195.5
155.6
115.7
75.8
35.9
23.9
17.2
9.6
6.0
299.3
235.4
195.5
155.6
115.7
75.8
35.9
23.9
17.2
9.6
6.0
299.3
239.4
199.5
159.6
119.7
79.8
40.0
23.9
16.0
12.0
6.0
299.3
239.4
199.5
159.6
119.7
79.8
39.9
efficiency
94%
93%
94%
93%
93%
92%
90%
92%
90%
87%
83%
95%
95%
95%
94%
94%
92%
92%
89%
90%
87%
83%
97%
97%
97%
97%
97%
96%
93%
93%
92%
89%
89%
98%
98%
98%
99%
98%
97%
95%
PF
1
1
0.99
0.99
0.99
0.98
0.93
0.85
0.78
0.71
0.65
0.99
0.99
0.99
0.98
0.98
0.95
0.83
0.77
0.73
0.65
0.58
0.98
0.97
0.96
0.94
0.9
0.82
0.66
0.55
0.51
0.47
0.33
0.97
0.96
0.95
0.92
0.88
0.8
0.6
11
17
13.5
6.8
0.14
0.13
0.11
399
399
399
0.04
0.03
0.015
16.0
12.0
6.0
94%
89%
88%
0.49
0.41
0.22
98.0%
Efficiency
96.0%
300W Load
200W Load
150W Load
80W Load
94.0%
92.0%
90.0%
88.0%
85
110
220
265
Input Voltage (V)
1
0.9
Power Factor
0.8
0.7
85V
110V
220V
265V
0.6
0.5
0.4
0.3
0.2
0.1
0
5.6
40
120
200
300
Output Power (W)
12
Harmonic test according to EN61000-3-2 Class D requirement
1. 85VAC, full load (300W output)
Iin
2. 85VAC, 9% of full load (28W output)
Iin
3. 265VAC, full load (300W output)
Iin
13
4. 265VAC, 9% of full load (28W output)
Iin
Waveforms (soft start, load jump, open loop)
1.Soft start, test at 85VAC, Iout=0.2A
Iin
Vout
Vcc
14
2.Load jump test at 85VAC, Iout from 0A to 0.75A
Vout
Iout
Vgate
3. Load jump test at 85VAC, Iout from 0.75A to 0A
Vout
Iout
Vgate
15
4. Open loop test at 265VAC, Iout=0.1A
Vgate
Vout
Iin
Vsense
16
References:
[1]
Infineon Technologies: ICE1PCS01 - Standalone Power Factor Correction Controller in Continuous
Conduction Mode; Preliminary datasheet; Infineon Technologies; Munich; Germany; May 2003.
[2]
Junyang Luo, Meng Kiat Jeoh, Ming Lik Yew and Heng Cheong Huang, Novel Cost Effective CCM
PFC Controller, application note, Infineon Technologies, May 2003.
17
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