300W Evaluation board using ICE2PCS01

Application Note, V1.1, October 2009
EVALPFC2-ICE2PCS01
300W PFC Evaluation Board with CCM PFC
controller ICE2PCS01
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2009-10-13
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2004.
All Rights Reserved.
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EVALPFC2-ICE2PCS01
Revision History:
Previous Version:
Page
9&10
2009-10
V1.0
Subjects (major changes since last revision)
Capacitor CX1 size changed
300W PFC Evaluation Board with CCM PFC controller ICE2PCS01
License to Infineon Technologies Asia Pacific Pte Ltd
AN-PS0010
Liu Jianwei
Luo Junyang
Jeoh Meng Kiat
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3
Table of Content
1
Content................................................................................................................. 5
2
Evaluation Board ................................................................................................ 5
3
Technical Specifications .................................................................................... 6
4
Circuit Description.............................................................................................. 6
5
Circuit Operation................................................................................................. 6
6
Circuit Diagram ................................................................................................... 8
7
PCB Layout Top Layer ....................................................................................... 9
8
PCB layout Bottom Layer................................................................................. 10
9
Component List................................................................................................. 11
10
Boost Choke Layout ....................................................................................... 122
11
Test report ......................................................................................................... 12
11.1
11.2
11.3
Load test (table and figure).............................................................................. 12
Harmonic test according to EN61000-3-2 Class D requirement .................. 14
Test Waveforms ................................................................................................ 15
12
References:........................................................................................................ 16
4
1 Content
The evaluation board described here is a 300W power factor correction (PFC) circuit with 85~265VAC
universal input and 393VDC fixed output. Boost converter topology is employed in this board. The
continuous conduction mode (CCM) PFC controller ICE2PCS01 is employed in this board to achieve
the unity power factor. 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.
2 Evaluation board
5
3 Technical specifications:
Input voltage
Input frequency
Output voltage and current
Output power
Efficiency
Switching frequency
85VAC~265VAC
50Hz
393VDC, 0.75A
~ 300W
>90% at full load
62.5kHz (with R8=76K)
4 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 ICE2PCS01. Unlike the conventional PFC
controller, ICE2PCS01 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 R5A, R5B, R6A and R6B 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.
5 Circuit Operation
Soft Start
When Vcc pin is higher than turn-on threshold, typical 11V, PFC is going to start. The unique soft start
is integrated. Input current keeps sinusoidal and is increasing gradually until output voltage reaches
6
75% 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
a. 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 0.6V, 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 0.6V. Insufficient input voltage VIN
will also trigger this protection.
b. 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 3.15V.
A VSENSE voltage higher than 3.15V 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.
c. Soft over current control (SOC) and peak current limit
When the amplitude of current sense voltage reaches 0.68V, 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 -1.04V. The gate output is immediately off after 300ns blanking time.
d. IC supply under voltage lock out
When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11V, IC is off the
gate drive is internally pull low to maintain the off state. The current consumption is down to 200uA
only.
7
6 Circuit Diagram
1
2
4
3
D
D
D2
1N5408
F1
5A
L
85~265VAC
N
VAR1
S10K275
R1
120ohm
L2
L1
40uH
CX1
CY1
2.2nF, Y2, 250V
Earth
C
C2
C1
0.1u/630V
R2
0.33/1W
0.47u/275V
0.47u/275V
390V/300W
Vo
Q1
SPP20N60C3
CX2
2*3.9mH
D1
SDP04S60
L3
1.24mH
BR1
8A, 400V
RT1
S237/5
CY2
2.2nF, Y2, 250V
R3
10k
Gnd
R2A
0.22/1W
C
R5
390k, 1%
R2B
0.22/1W
R4
R5A
220
3.3
390k, 1%
3
R9
IC?
I-Sense
7
B
2
Vcc
ICE2PCS01
I-Comp
Freq
8
Gate
GND
Vsense
6
V-Comp
5
R7
GND
47u/25V
0.1u
C7
4.7nF
R8
76k
33k
1
C8
4
Vcc
C9
B
C5
C4
0.1uF
C3
0.1uF
R6
R6B
10k, 1%
15k,1%
1uF
A
A
1
2
3
8
4
7 PCB layout top layer
9
8 PCB layout Bottom:
10
9 Component List:
Designator
Part Type
Description
Manufacturer / Part No.
BR1
C1
C2
C3
C4
C5
C7
C8
C9
CX1
CX2
CY1
CY2
8A, 400V
0.1uF/630V
220uF/450V
0.1uF/50V
0.1uF/50V
1uF/50V
4.7nF/50V
0.1uF/50V
47uF/25V
0.47uF, X1, 305V
0.47uF, X1, 305V
2.2nF, Y2, 250V
2.2nF, Y2, 250V
Vishay / KBU8G
Epcos / B32652A6104J
Epcos / B43304C5227M
D1
D2
F1
SDT04S60
1N5408
5A
Bridge Rectifier
Ceramic Cap
Electrolytic Cap
Ceramic 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
ICE2PCS01
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
R5A
R5B
R6A
R6B
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%
390k/0.25W, 1%
390k/0.25W, 1%
10k/0.25W, 1%
15k/0.25W, 1%
33k/0.25W, 5%
75k/0.25W, 1%
220/0.25W, 5%
S237/5
S10K275
Murata / RPER71H104K2K1A03B
Murata / RPER71H104K2K1A03B
Murata / RPER71H104K2K1A03B
Epcos / B32922C3474M
Epcos / B32922C3474M
Epcos / B81123C1222M000
Epcos / B81123C1222M000
Vishay / 1N5408
Infineon
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
11
Epcos / B82725J2602N20
Infineon
Epcos / B57237S509M
Epcos / B72210S271K101
10 Boost Choke Layout
Core: CS468125 toriod
Wire: 1 x Φ1.0mm, AWG19
Turns: 83
Inductance: L=1.24mH
11 Test report
11.1 Load test (table and figure):
Vin
Pin (W)
Iin (A)
Vout (V)
(VAC)
320
3.8
393
211
2.51
393
165
1.96
393
124
1.47
393
83
0.99
393
43
0.52
394
31
0.39
394
20.3
0.26
395
12.2
0.17
396
85
4.2
0.07
396
316
2.9
393
208
1.91
393
163
1.5
393
123
1.13
393
83
0.77
393
42.3
0.4
393
30
0.29
394
22
0.22
394
14.2
0.15
394
110
6.2
0.076
394
307
1.4
394
204
1
394
161
0.8
394
120
0.63
394
82
0.45
394
41
0.29
394
29.5
0.16
395
21.7
0.133
395
14
0.1
395
220
6
0.093
395
265
305
1.2
394
203
0.79
394
161
0.63
394
120
0.48
395
81
0.34
395
41
0.21
395
Iout (A)
0.75
0.5
0.4
0.3
0.2
0.1
0.075
0.049
0.029
0.01
0.75
0.5
0.4
0.3
0.2
0.1
0.0718
0.0525
0.034
0.014
0.75
0.5
0.4
0.3
0.2
0.1
0.072
0.053
0.033
0.014
0.75
0.5
0.4
0.3
0.2
0.1
12
Pout
(W)
294.75
196.5
157.2
117.9
78.6
39.4
29.55
19.355
11.484
3.96
294.75
196.5
157.2
117.9
78.6
39.3
28.2892
20.685
13.396
5.516
295.5
197
157.6
118.2
78.8
39.4
28.44
20.935
13.035
5.53
295.5
197
157.6
118.5
79
39.5
efficiency
92%
93%
95%
95%
95%
92%
95%
95%
94%
94%
93%
94%
96%
96%
95%
93%
94%
94%
94%
89%
96%
97%
98%
99%
96%
96%
96%
96%
93%
92%
97%
97%
98%
99%
98%
96%
PF
1
1
1
0.99
0.99
0.97
0.95
0.91
0.87
0.71
1
0.99
0.99
0.99
0.98
0.94
0.89
0.86
0.82
0.63
0.99
0.99
0.97
0.95
0.92
0.83
0.77
0.67
0.53
0.22
0.99
0.98
0.97
0.95
0.91
0.73
29.5
21.7
13.8
5.83
0.17
0.16
0.15
0.1
395
395
395
395
0.072
0.053
0.033
0.014
96%
96%
94%
95%
28.44
20.935
13.035
5.53
0.64
0.45
0.38
0.15
98.0%
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
0.8
0.7
85VAC
0.6
PF
Efficiency
96.0%
110VAC
0.5
230VAC
0.4
265VAC
0.3
0.2
0.1
0
0
50
100
150
200
Pout (W)
13
250
300
11.2 Harmonic test according to EN61000-3-2 Class D requirement
85VAC, full load (300W output)
Iin
85VAC, 9% of full load (28W output)
Iin
265VAC, full load (300W output)
Iin
14
265VAC, 9% of full load (28W output)
Iin
11.3 Waveforms (soft start, load jump, open loop)
Soft start, test at 85VAC, Iout=0.2A
Iin
Vout
Vcc
Vcomp
Load jump test at 85VAC, Iout from 0A to 0.75A
Load jump test at 85VAC, Iout from 0.75A to 0A
Vgate
Vgate
Vout
Vout
Iout
Iout
15
Open loop test at 265VAC, Iout=0.1A
Vgate
Iin
Vout
Vsense
12 References:
16
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