300W Evaluation board using ICE2PCS02

Application Note, V1.1, October 2009
EVALPFC2-ICE2PCS02
300W PFC Evaluation Board with CCM PFC
controller ICE2PCS02
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-ICE2PCS02
Revision History:
2009-10
Previous Version:
Page
8&9
V1.0
Subjects (major changes since last revision)
Cx1 size changed
15
Typo errors
300W PFC Evaluation Board with CCM PFC controller ICE2PCS02
License to Infineon Technologies Asia Pacific Pte Ltd
Liu Jianwei
Luo Junyang
Jeoh Meng Kiat
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V1.1
AN-PS0011
Page
Table of Content
...................................................................................5
1
Content
2
Evaluation Board
3
Technical Specifications ..............................................................6
4
Circuit Description
5
Circuit Operation........................................................................6
6
Circuit Diagram
7
PCB Layout Top Layer .................................................................9
8
PCB layout Bottom Layer ...........................................................10
9
Component List .......................................................................11
10
Boost Choke Layout
11
Test report
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
Application Note
.......................................................................5
.....................................................................6
.........................................................................8
.................................................................12
.............................................................................12
4
2009-10-13
1
Content
The evaluation board presented here is a 300W power factor correction (PFC) circuit with
85~265VAC universal input and 393VDC fixed output. The continuous conduction mode (CCM) PFC
controller ICE2PCS02 is employed in this board to achieve the unity power factor. This ICE2PCS02 is
a design variant of ICE2PCS01 to incorporate the new input brown-out protection function.
Appreciated for its high integrated design, ICE2PCS02 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 ICE2PCS02. 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
2009-10-13
3
4
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
50Hz
Output voltage and current
393VDC, 0.75A
Output power
~ 300W
Efficiency
>92% at full load
Switching Frequency
65kHz
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™ SPP20N60C3 is used as the power switch Q1. BR1, Q1 and SiC
Diode D1 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.
PWM Control of Boost Converter
The PWM control is realized by 8-Pin CCM PFC IC ICE2PCS02. It is a variant design of ICE2PCS01
with preserving most of the features. Unlike the conventional PFC controller, ICE2PCS02 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 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 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.
5
Circuit Operation
Soft Startup
Application Note
6
2009-10-13
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
80% of rating. 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, 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.
Protection Features
a. Input brown-out protection
The dedicated input voltage brown-out VINS pin is the most distinct new feature brought by
ICE2PCS02. 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.
b. Open loop 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.
c. Output over-voltage protection
Whenever VOUT exceeds the rated value by 8%, the over-voltage protection OVP is active. This is
implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 3.25V. A
VSENSE voltage higher than 3.25V will immediately block the gate signal.
d. 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.
e. IC supply under voltage lockout
When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11, 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
7
2009-10-13
6
Circuit Diagram
1
2
4
3
D
D
D2
1N5408
R1
120ohm
L
85~265VAC
VAR1
S10K275
N
RT1
F1
5A
S237/5
L2
L1
40uH
L3
D1
1.24mH
SDP04S60
390V/300W
Vo
Q1
CX1
SPP20N60C3
CX2
2*3.9mH
CY1
2.2nF, Y2, 250V
Earth
R3
10k
R2
0.33/1W
CY2
2.2nF, Y2, 250V
C2
C1
0.1u/630V
0.47u/275V
0.47u/275V
C
BR1
8A, 400V
1N4007
C
R5
R2B
0.22/1W
390k, 1%
R9
R4
220
3.3
R5A
390k, 1%
3
R10
3.9M, 1%
Gnd
R2A
0.22/1W
D3
IC?
I-Sense
R11
3.9M,1%
7
B
2
Vcc
8
Gate
ICE2PCS02
Icomp
Brown Out
GND
Vsense
6
Vcomp
5
B
R7
47u/25V
GND
C8
0.1u
C7
4.7nF
R8
120k
33k
1
C9
4
Vcc
C6
220nF
C5
C4
0.1uF
C3
0.1uF
R6
R6B
10k, 1%
15k,1%
1uF
A
A
1
Application Note
2
8
3
4
2009-10-13
7
PCB Layout Top Layer
Application Note
9
2009-10-13
8
PCB layout Bottom Layer
Application Note
10
2009-10-13
9
Component List
Designator
Part Type
Description
Manufacturer / Part No.
BR1
C1
C2
C3*
C4
C5
C6
C7
C8
C9
CX1
CX2
CY1
CY2
8A, 400V
0.1uF/630V
220uF/450V
0.1uF/50V
0.1uF/50V
1uF/50V
220nF/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
D3
F1
SDT04S60
1N5408
1N4007
5A
Bridge Rectifier
Ceramic Cap
Electrolytic Cap
Ceramic Cap
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
IC1
JP1
JP2
JP3
JP4
L1*
L2
L3
Q1
ICE2PCS02
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
R5A
R5B
R6A
R6B
R7
R8
Not Connected
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%
120k/0.25W, 1%
Application Note
Murata / RPER71H104K2K1A03B
Murata / RPER71H104K2K1A03B
Murata / RPER71H224K2K1C03B
Murata / RPER71H104K2K1A03B
Epcos / B32922C3474M
Epcos / B32922C3474M
Epcos / B81123C1222M000
Epcos / B81123C1222M000
Vishay / 1N5408
Vishay / 1N4007
Infineon
Jumper
Jumper
Jumper
Jumper
CM Choke
Choke
Power MOSFET
Heat Sink
TO220 Clip
TO247 Clip
TO220 Isolation Pad
3mm Screw
Epcos / B82725J2602N20
Infineon
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
11
2009-10-13
R9
R10
R11
RT1
VAR1
10
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
NTC Thermistor
Varistor
Epcos / B57237S509M
Epcos / B72210S271K101
Boost Choke Layout
Core: CS468125 toriod
Turns: 83
Wire: 1 x Φ1.0mm, AWG19
Inductance: L=1.24mH
11
Test report
11.1
Load test (table and figure)
Vin(VAC)
Pin
85VAC
110VAC
230VAC
Application Note
Iin
319
253
208
167
124
84
42
31
22
14.2
6.2
310
250
205
165
122
84
42
30
22
14.3
6.2
300
244
202
161
122
84
42
30.2
Vout
3.81
3.02
2.49
2
1.5
1.03
0.52
0.38
0.28
0.19
0.1
2.85
2.28
1.88
1.51
1.13
0.77
0.4
0.3
0.22
0.15
0.076
1.33
1.1
0.89
0.72
0.55
0.38
0.21
0.16
391
391
391
392
392
393
393
394
394
394
395
392
392
392
392
393
393
393
394
395
395
395
393
394
394
394
394
394
395
395
Iout
0.75
0.6
0.5
0.4
0.3
0.2
0.1
0.072
0.053
0.0337
0.014
0.75
0.6
0.5
0.4
0.3
0.2
0.1
0.072
0.053
0.0337
0.014
0.75
0.6
0.5
0.4
0.3
0.2
0.1
0.072
12
Pout
293.25
234.6
195.5
156.8
117.6
78.6
39.3
28.368
20.882
13.2778
5.53
294
235.2
196
156.8
117.9
78.6
39.3
28.368
20.935
13.3115
5.53
294.75
236.4
197
157.6
118.2
78.8
39.5
28.44
Efficiency
92%
93%
94%
94%
95%
94%
94%
92%
95%
94%
89%
95%
94%
96%
95%
97%
94%
94%
95%
95%
93%
89%
98%
97%
98%
98%
97%
94%
94%
94%
PF
1
1
1
1
1
0.99
0.98
0.96
0.93
0.9
0.82
1
1
1
0.99
0.99
0.98
0.95
0.92
0.89
0.86
0.74
0.99
0.99
0.98
0.98
0.96
0.93
0.84
0.78
2009-10-13
22
13.8
6.2
300
243
202
161
121
82
41
29
22
13.7
6.2
265VAC
0.13
0.1
0.09
1.16
0.99
0.781
0.63
0.48
0.34
0.19
0.18
0.15
0.12
0.1
395
395
396
394
395
395
396
396
397
397
396
396
396
396
0.053
0.0337
0.014
0.75
0.6
0.5
0.4
0.3
0.2
0.1
0.072
0.053
0.0337
0.014
20.935
13.3115
5.544
295.5
237
197.5
158.4
118.8
79.4
39.7
28.512
20.988
13.3452
5.544
95%
96%
89%
99%
98%
98%
98%
98%
97%
97%
98%
95%
97%
89%
0.7
0.58
0.3
0.99
0.99
0.98
0.97
0.96
0.92
0.82
0.74
0.5
0.35
0.21
98.0%
Efficiency
96.0%
300W Load
200W Load
150W Load
80W Load
94.0%
92.0%
90.0%
88.0%
85
110.00
220.00
265.00
Input Voltage (V)
1
0.9
0.8
0.7
85VAC
PF
0.6
110VAC
0.5
230VAC
0.4
265VAC
0.3
0.2
0.1
0
0
Application Note
100
200
13
Pout (W)
300
400
2009-10-13
11.2
Harmonic test according to EN61000-3-2 Class D requirement
85VAC, full load (300W output)
Iin
85VAC, 9.3% of full load (28W output)
Iin
265VAC, full load (300W output)
Iin
Application Note
14
2009-10-13
265VAC, 9.3% of full load (28W output)
Iin
11.3
Test Waveforms
Startup test at 85VAC, open load
Vout
IACin
Vcc
Vcomp
Load jump test at 85VAC, Iout from 0A to 0.75A
Load jump test at 85VAC, Iout from 0.75A to 0A
Vout
Vout
Iout
Vsense
Vsense
Iout
Vgate
Vgate
Application Note
15
2009-10-13
Enter brown-out at Iout=0.1A, 62VAC
Leave brown-out at Iout=0.1A, 76VAC
Vout
Vout
Iin
Iin
Vins
Vins
Vgate
Vgate
Open Loop protection at 265V, Iout=0.1A
Vout
Iin
Vsense
Vgate
12
References:
Application Note
16
2009-10-13
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