300W Evaluation board using ICE2PCS03

Application Note, V1.0, October 2007
EVALPFC2-ICE2PCS03
300W PFC Evaluation Board with CCM PFC
controller ICE2PCS03
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2007-10-30
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2007 Infineon Technologies AG
All Rights Reserved.
Legal Disclaimer
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conditions or characteristics. With respect to any examples or hints given herein, any typical
values stated herein and/or any information regarding the application of the device,
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including without limitation, warranties of non-infringement of intellectual property rights
of any third party.
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For further information on technology, delivery terms and conditions and prices, please
contact the nearest Infineon Technologies Office (www.infineon.com).
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EVALPFC2-ICE2PCS03
Revision History:
Previous Version:
Page
2007-10
V1.0
Subjects (major changes since last revision)
300W PFC Evaluation Board with CCM PFC controller ICE2PCS03
License to Infineon Technologies Asia Pacific Pte Ltd
Liu Jianwei
He Yi
Jeoh Meng Kiat
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AN-PS0016
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 .....................................................................................................................14
Application Note
.......................................................................5
.....................................................................6
.........................................................................8
.................................................................12
.............................................................................12
4
2007-10-30
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 ICE2PCS03 is employed in this board to achieve the unity power factor. This ICE2PCS03 is
a design variant of ICE2PCS01 to incorporate the new input brown-out protection function.
Appreciated for its high integrated design, ICE2PCS03 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 ICE2PCS03. 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
2007-10-30
3
4
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
50Hz
Output voltage and current
393VDC, 0.75A
Output power
~ 300W
Efficiency
>91% at full load
Switching Frequency
100kHz
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 ICE2PCS03. It is a variant design of ICE2PCS01
with preserving most of the features. Unlike the conventional PFC controller, ICE2PCS03 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
2007-10-30
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
ICE2PCS03. 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
2007-10-30
6
Circuit Diagram
1
2
3
4
D
D
D2
1N5408
R1
120ohm
L
85~265VAC
VAR1
S10K275
N
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
SDP04S60
820uH
8A, 400V
S237/5
L2
L1
40uH
D1
L3
BR1
RT1
F1
5A
Gnd
C
R2A
0.22/1W
D3
1N4007
R5
R2B
0.22/1W
R4
220
3.3
I-Sense
R11
3.9M,1%
7
B
R9
R5A
390k, 1%
3
R10
3.9M, 1%
390k, 1%
2
Vcc
8
Gate
ICE2PCS03
Icomp
Vsense
6
Vcomp
5
PNP R
Brown Out
GND
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
2007-10-30
7
PCB Layout Top Layer
Application Note
9
2007-10-30
8
PCB layout Bottom Layer
Application Note
10
2007-10-30
9
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
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
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
ICE2PCS03
12.5mm, Ф0.7mm
20mm, Ф0.7mm
12mm, Ф1.2mm
17.5mm, Ф0.7mm
Shorted
2*3.9mH
820uH
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
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
11
Quantity
1
1
1
1
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
1
1
2007-10-30
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
1
1
1
1
1
Boost Choke Layout
Core: CS400125 toriod
Turns: 70
Wire: 1 x Φ1.0mm, AWG19
Inductance: L=820uH
11
Test report
11.1
Load test (table and figure)
Vin(VAC)
85VAC
110VAC
230VAC
Application Note
Pin
318
252.8
208
168.2
146.5
126.8
105.2
85.67
64.05
44.47
22.3
310.4
246.5
205.1
166.2
144.8
123.3
103.9
84.58
63
43.2
21.46
302.4
240.9
203.1
162.8
142.1
Iin
3.756
2.972
2.449
1.98
1.727
1.504
1.247
1.015
0.7578
0.533
0.278
2.84
2.251
1.871
1.514
1.324
1.128
0.951
0.776
0.581
0.406
0.22
1.328
1.061
0.896
0.723
0.631
Vout
388.3
388.6
388.9
389.2
389.4
389.5
389.8
390
390.3
390.7
391.4
389
389.3
389.5
389.8
389.9
390.1
390.3
390.4
390.7
391
391.7
390.6
390.8
390.9
391.1
391.2
Iout
0.75
0.6
0.5
0.4
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0.75
0.6
0.5
0.4
0.35
0.3
0.25
0.2
0.15
0.1012
0.05
0.75
0.6
0.5
0.4
0.35
12
Pout
291
233
194
156
136
117
97
78
59
39
20
292
234
195
156
136
117
98
78
59
40
20
293
234
195
156
137
Efficiency
91.58
92.23
93.49
92.56
93.03
92.15
92.63
91.05
91.41
87.86
87.76
93.99
94.76
94.95
93.81
94.24
94.91
93.91
92.31
93.02
91.6
91.26
96.88
97.33
96.23
96.09
96.35
PF
0.9986
0.9987
0.9988
0.9984
0.998
0.9976
0.9968
0.9953
0.9924
0.9855
0.938
0.9985
0.9983
0.9977
0.9969
0.9962
0.995
0.9934
0.9906
0.984
0.967
0.8892
0.9937
0.991
0.9883
0.9835
0.9789
2007-10-30
122.7
101.7
82.6
61.18
42.15
21.1
301.3
242.1
199.8
160
140.9
122.3
101.1
82.4
60.9
42
21
265VAC
0.551
0.463
0.383
0.295
0.216
0.136
1.15
0.927
0.768
0.62
0.551
0.482
0.405
0.338
0.263
0.208
0.17
391.3
391.4
391.5
391.7
391.9
392.1
390.8
391
391.1
391.3
391.4
391.5
391.6
391.7
391.8
392
392.2
0.3
0.25
0.2
0.15
0.1012
0.05
0.75
0.6
0.5
0.4
0.35
0.3
0.25
0.2
0.15
0.1012
0.05
117
98
78
59
40
20
293
235
196
157
137
117
98
78
59
40
20
95.67
96.21
94.79
96.04
94.09
92.91
97.28
96.9
97.87
97.83
97.22
96.03
96.83
95.07
96.5
94.45
93.38
0.9711
0.9575
0.94
0.9034
0.8522
0.674
0.9913
0.9879
0.984
0.975
0.9678
0.9588
0.9436
0.9209
0.8758
0.7612
0.47
1.0
0.9
PF
0.8
85VAC
110VAC
230VAC
265VAC
0.7
0.6
0.5
0.4
0
50
100
150
200
250
300
Pout(W)
Application Note
13
2007-10-30
11.2
Harmonic test according to EN61000-3-2 Class D requirement
85VAC, 7% of full load (22W output)
Iin
265VAC, 2% of full load (7W output)
Iin
Test Waveforms
Startup test at 85VAC, open load
Vout
Vgate
Vcomp
Vout
Iin
Application Note
14
2007-10-30
Load jump test at 85VAC, Iout from 0A to 0.75A
Load jump test at 85VAC, Iout from 0.75A to 0A
Vsense
Vout
Iin
Vgate
Enter brown-out at Iout=0.1A, 56VAC
Leave brown-out at Iout=0.1A, 74VAC
Vout
Iin
Vins
Vgate
Vins
Open Loop protection at 265V, Iout=0.1A
Vout
Vsense
Vgate
Application Note
15
2007-10-30
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