300W Evaluation board using ICE3PCS02-03G

Application Note, V1.0, January 2011
EVALPFC-300W-ICE3PCS02/03G
300W PFC Evaluation Board with CCM PFC
controller ICE3PCS02/03G
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2010-12-31
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2010.
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
system. Life support devices or systems are intended to be implanted in the human body, or to support
and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health
of the user or other persons may be endangered.
EVALPFC-300W-ICE3PCS02/03G
Revision History:
Previous Version:
NA
V1.0
300W PFC Evaluation Board with CCM PFC controller ICE3PCS02/03G
License to Infineon Technologies Asia Pacific Pte Ltd
AN-PS0054
Lim Teik Eng
Liu Jianwei
Li Dong
3
Table of Content
1
Content .............................................................................................................................5
2
Evaluation Board.............................................................................................................5
3
Technical Specifications..................................................................................................6
4
Circuit Description..........................................................................................................6
Line Input .......................................................................................................................................................... 6
Power Stage − Boost Type PFC Converter ....................................................................................................... 6
PWM Control of Boost Converter ..................................................................................................................... 6
5
Circuit Operation ............................................................................................................7
5.1
Soft Startup.............................................................................................................................................. 7
5.2
Gate Switching Frequency ...................................................................................................................... 7
5.3
Protection Features................................................................................................................................. 8
5.3.1
Input brown-out protection (BOP)................................................................................................ 8
5.3.2
Open loop protection (OLP) ......................................................................................................... 8
5.3.3
First over-voltage protection (OVP1) ........................................................................................... 8
5.3.4
Second over-voltage protection (OVP2)....................................................................................... 8
5.3.5
Peak current limit.......................................................................................................................... 8
5.3.6
IC supply under voltage lockout ................................................................................................... 8
6
Circuit Diagram...............................................................................................................9
7
PCB Layout....................................................................................................................10
7.1
Top overlay view ................................................................................................................................... 10
7.2
Bottom layer view.................................................................................................................................. 10
8
Component List .............................................................................................................11
9
Boost Choke Layout ......................................................................................................12
10
Test report......................................................................................................................13
10.1
Load and Line Test........................................................................................................................... 13
10.2
Load and Line Test without NTC(5Ω).............................................................................................. 15
PFC stage efficiency Harmonic test according to EN61000-3-2 Class D requirement .................................. 16
Harmonic test according to EN61000-3-2 Class D requirement .................................................................... 17
11
Test Waveforms.............................................................................................................18
12
References:.....................................................................................................................19
4
1
Content
The evaluation board presented here is a 300W power factor correction (PFC) circuit with
85~265VAC universal input and output of 400VDC rated voltage. The continuous conduction mode
(CCM) PFC controller either ICE3PCS02G or ICE3PCS03G can be employed in this board to achieve
the unity power factor.
This ICE3PCS02G and ICE3PCS03G are specially designed for applications of power supplies used
in PC, server, LCD/PDP TV and Telecom, requesting high efficiency and power factor. The voltage
loop compensation is integrated digitally for better dynamic response and less design effort.
Appreciated for its high integrated design, ICE3PCS02G and ICE3PCS03G can achieve full
requirements of the PFC application implemented in the 8-pin in DSO8 package. At the same time the
number of peripheral components is minimized. The gate switching frequency is adjustable from
21kHz to 250kHz and able to synchronize with external switching frequency from 50kHz to 150kHz. In
order to improve the power conversion efficiency further, the CoolMOSTM CP series and high voltage
silicon carbide (SiC) schottky diode thinQ!TM are used into this boost type PFC circuit.
2
Evaluation Board
ICE3PCS01G Demoboard
5
3
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
47~63Hz
Output voltage and current
400VDC, 0.75A
Output power
~ 300W
Average efficiency
>95% at 115VAC
Switching Frequency
21kHz~250kHz
4
Circuit Description
Line Input
The AC line input side comprises the input fuse F1 as over-current protection. The choke L1, X2capacitors CX1/CX2 and Y1-capacitor CY1/CY2 are used to suppress common mode noise as well as
differential mode noise. 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™ IPP60R199P 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 and
meet the holdup time requirement.
PWM Control of Boost Converter
The ICE3PCS02G and ICE3PCS03G are 8-pins control IC for power factor correction converters. It is
suitable for wide range line input applications from 85 to 265 VAC with overall efficiency above 93.5%.
The IC supports converters in boost topology and it operates in continuous conduction mode (CCM)
with average current control.
The IC operates with a cascaded control; the inner current loop and the outer voltage loop. The inner
current loop of the IC controls the sinusoidal profile for the average input current. It uses the
dependency of the PWM duty cycle on the line input voltage to determine the corresponding input
current. This means the average input current follows the input voltage as long as the device operates
in CCM. Under light load condition, depending on the choke inductance, the system may enter into
discontinuous conduction mode (DCM) resulting in a higher harmonics but still meeting the Class D
requirement of IEC 1000-3-2.
The outer voltage loop controls the output bulk voltage, integrated digitally within the IC. Depending
on the load condition, internal PI compensation output is converted to an appropriate DC voltage
which controls the amplitude of the average input current.
The IC is equipped with various protection features to ensure safe operating condition for both the
system and device.
6
5
Circuit Operation
5.1
Soft Startup
During power up when the VOUT is less than 95% of the rated level, internal voltage loop output
increases from initial voltage under the soft-start control. This results in a controlled linear increase of
the input current from 0A thus reducing the current stress in the power components.
Once VOUT has reached 95% of the rated level, the soft-start control is released to achieve good
regulation and dynamic response.
5.2
Gate Switching Frequency
The switching frequency of the PFC converter can be set with an external resistor RFREQ at pin FREQ
with reference to pin SGND. The voltage at pin FREQ is typical 1V. The corresponding capacitor for
the oscillator is integrated in the device and the RFREQ/frequency is given in Figure 2. The
recommended operating frequency range is from 21 kHz to 250 kHz. As an example, a RFREQ of 68kΩ
at pin FREQ will set a switching frequency fSW of 65 kHz typically.
Frequency vs Resistance
260
240
Resistance
/kohm
Frequency
/kHz
Resistance
/kohm
Frequency
/kHz
220
15
278
110
40
17
249
120
36
20
211
130
34
30
141
140
31.5
160
40
106
150
29.5
140
50
86
169
26.2
120
60
74
191
25
70
62
200
23
80
55
210
21.2
80
90
49
221
20.2
60
100
43
232
19.2
200
Frequency/kHz
180
100
40
20
0
10
20
30
40
50
60
70
80
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Resistance/kohm
Frequency setting
The switching frequency can be synchronized to the external pulse signal after 6 external pulses
delay once the voltage at the FREQ pin is higher than 2.5V. The synchronization means two points.
Firstly, the PFC switching frequency is tracking the external pulse signal frequency. Secondly, the
falling edge of the PFC signal is triggered by the rising edge of the external pulse signal. The external
R8 combined with R9 and the external diode, D6 can ensure FREQ pin voltage to be kept between
1.0V (clamped internally) and 5V (maximum pin voltage). If the external pulse signal has disappeared
longer than 108us (typical) the switching frequency will be synchronized to internal clock set by the
external resistor R8.
7
5.3
Protection Features
5.3.1
Input brown-out protection (BOP)
ICE3PCS03G provides a new BOP feature whereby it senses directly the input voltage for InputBrown-Out condition via an external resistor/capacitor/diode network. This network provides a filtered
value of VIN which turns the IC on when the voltage at pin 5 (BOP) is more than 1.25V. The IC enters
into the fault mode when BOP goes below 1.0V. The hysteresis prevents the system to oscillate
between normal and fault mode. Note also that the peak of VIN needs to be at least 20% of the rated
VOUT in order to overcome open loop protection and power up system.
5.3.2
Open loop protection (OLP)
The open loop protection is available for this IC to safe-guard the output. Whenever voltage at pin
VSENSE falls below 0.5V, 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 0.5V.
5.3.3
First over-voltage protection (OVP1)
Whenever VOUT exceeds the rated value by 8%, the first over-voltage protection OVP1 is active. This
is implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 2.7V. A
VSENSE voltage higher than 2.7V will immediately block the gate signal. After bulk voltage falls below
the rated value, gate drive resumes switching again.
5.3.4
Second over-voltage protection (OVP2)
The second OVP (OVP2) is provided in case that the first one fails due to the aging or incorrect
resistors connected to the VSENSE pin. This is implemented by sensing the voltage at pin OVP with
respect to a reference voltage of 2.5V. When voltage at OVP pin is higher than 2.5V, the IC will
immediately turn off the gate, thereby preventing damage to bus capacitor. When the bulk voltage
drops out of the hysteresis, which is below 2.3V the IC begin auto soft-start.
In normal operation the trigger level of OVP2 should be designed higher than OVP1. However in the
condition of mains transient overshoot the bulk voltage may be pulled up to the peak value of mains
that is higher than the threshold of OVP1 and OVP2. In this case the OVP1 and OVP2 are triggered in
the same time the IC will shut down the gate drive until bulk voltage falls out of the two protection
hysteresis, then resume the gate drive again. This function is available in ICE3PCS02G.
5.3.5
Peak current limit
The IC provides a cycle by cycle peak current limitation (PCL). It is active when the voltage at pin
ISENSE reaches -0.4V. This voltage is amplified by a factor of -2.5 and connected to comparator with
a reference voltage of 1.0V. A deglitcher with 200ns after the comparator improves noise immunity to
the activation of this protection. In other words, the current sense resistor should be designed lower
than -0.4V PCL for normal operation.
5.3.6
IC supply under voltage lockout
When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11V, IC is off and the
gate drive is internally pull low to maintain the off state. The current consumption is down to 1.4mA
only.
8
6
Circuit Diagram
Schematic of 300W PFC demo board
9
7
PCB Layout
7.1
Top overlay view
7.2
Bottom layer view
10
8
Component List
Designator
BR1
C1
C2
C4
C4A
C5
C7
C8
C9
C10
C11
CX1
CX2
CY1
CY2
(Connecter) SYNC
Part Type
8A, 400V
0.1uF/630V
220uF/450V
1.5 uF/50V
1.5 uF/50V
4.7nF/50V
6.8nF/50V
0.1uF/50V
47uF/25V
10nF/50V
10pF/50V
0.47uF, X1, 275V
0.47uF, X1, 275V
2.2nF, Y2, 250V
2.2nF, Y2, 250V
SIP3-MOLEX
2-way PCB
(Connecter) VCC
connecter
2-way PCB
(Connecter) L N
connecter
2-way PCB
(Connecter) VOUT
connecter
D1
IDH04S60C
D2
1N5408
D4
1N4007
D5
1N4007
D6
1N4148
F1
5A
HEATSINK_KM100 Heatsink
ICE3PCS02G/
IC1
ICE3PCS02G
J1
jumper wire
J2
jumper wire
L1
2*3.9mH
L3
750uH
Q1
IPP60R199CP
R1
68/0.25W, 1%
R2
0.05/3W, 1%
R3
10k/0.25W, 1%
R4
3.3/0.25W, 1%
R5
1.5M/0.25W, 1%
R5A
1.5M/0.25W, 1%
R6
27k/0.25W, 1%
R6A
62k/0.25W, 1%
R8
68k/0.25W, 1%
R9
130k/0.25W, 1%
R10
3.9M/0.25W, 5%
R10A
3.9M/0.25W, 5%
Description
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
Ceramic Cap
Ceramic Cap
Connector (SYNC)
Manufacturer/ Part No.
Vishay / KBU8G
Epcos / B32652A6104J
Epcos / B32922C3474M
Epcos / B32922C3474M
Epcos / B81123C1222M000
Epcos / B81123C1222M000
Connector (VCC)
Connector (VIN)
Connector (VOUT)
Diode
Diode
Diode
Diode
Diode
Fuse
Infineon Technologies
Vishay / 1N5408
Vishay / 1N4007
Vishay /1N4007
DSO-8
Infineon Technologies
GATE signal
CM Choke
PFC Choke
Power MOSFET
Carbon 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
Carbon Film Resistor
11
Epcos / B82725J2602N20
Infineon Technologies
Vishay / LVR03R0500FE70
R11
R12
R12A
R13
R13A
RT1
SCREW1
SCREW2
SCREW3
SCREW4
SCREW5
SCREW6
SW1
VAR1
9
130k/0.25W, 1%
2M/0.25W, 1%
2M/0.25W, 1%
24k/0.25W, 1%
560k/0.25W, 1%
S237/5
Diameter:2mm
Diameter:2mm
Diameter:2mm
Diameter:2mm
Diameter:2mm
Diameter:2mm
3 pin PCB header
S10K275
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
Carbon Film Resistor
NTC Thermistor
PCB stand
PCB stand
PCB stand
PCB stand
Heatsink
Heatsink
Varistor
Boost Choke Layout
Core: PQ-core PQ3535 (TDK)
Material: PC95
Inductance: L=750uH
12
Epcos / B57237S509M
Epcos / B72210S271K101
10
Test report
10.1
Load and Line Test
Input
85V
115V
230V
265V
Vin(V)
Iin(I)
Vout(V)
Iout(I)
84.79
0.49
399.90
0.10
38.99
93.72
1.00
84.67
0.74
399.90
0.15
58.71
93.72
1.00
84.56
0.98
399.80
0.20
78.02
93.97
1.00
84.44
1.25
399.80
0.25
99.46
94.35
1.00
84.15
1.88
399.80
0.37
149.04
94.39
1.00
83.86
2.52
399.70
0.50
198.72
94.18
1.00
83.56
3.17
399.70
0.62
248.49
93.87
1.00
83.28
3.81
399.70
0.74
296.18
93.41
1.00
114.77
0.37
399.90
0.10
39.19
94.65
0.98
114.69
0.54
399.90
0.15
58.63
95.14
0.99
114.61
0.72
399.80
0.20
78.04
95.34
1.00
114.52
0.91
399.80
0.25
99.49
95.51
1.00
114.31
1.36
399.80
0.37
149.05
95.79
1.00
114.10
1.82
399.70
0.50
198.73
95.83
1.00
113.90
2.28
399.70
0.62
248.49
95.71
1.00
113.70
2.73
399.70
0.74
296.28
95.66
1.00
229.81
0.21
399.90
0.10
39.20
95.44
0.87
229.77
0.29
399.90
0.15
58.64
96.14
0.93
229.73
0.37
399.80
0.20
78.12
96.60
0.95
229.68
0.46
399.80
0.25
99.53
96.58
0.97
229.59
0.68
399.80
0.37
149.08
97.21
0.98
229.48
0.90
399.70
0.50
198.74
97.73
0.99
229.38
1.11
399.70
0.62
248.49
97.81
0.99
229.29
1.33
399.70
0.74
296.30
97.86
1.00
264.84
0.20
399.90
0.10
39.21
95.85
0.79
264.81
0.26
399.90
0.15
58.65
96.32
0.88
264.77
0.33
399.80
0.20
78.07
96.57
0.92
264.73
0.41
399.80
0.25
99.55
96.84
0.95
264.65
0.60
399.80
0.37
149.10
97.25
0.97
264.56
0.79
399.70
0.50
198.80
97.50
0.98
264.47
0.97
399.70
0.62
248.49
97.84
0.99
264.39
1.15
399.70
0.74
296.26
98.01
0.99
13
Pout(W) Efficiency
PF
ICE3PCS02/03G Efficiency
100.00
99.00
85V
115V
230V
265V
Efficiency(%)
98.00
97.00
96.00
95.00
94.00
93.00
92.00
0.00
50.00
100.00
150.00
200.00
250.00
300.00
Output Power (W)
PFC stage efficiency
ICE3PCS02/03G PF
1.00
0.95
PF
0.90
0.85
85V
0.80
115V
230V
265V
0.75
0.00
50.00
100.00
150.00
Output Power (W)
Power factor
14
200.00
250.00
300.00
10.2
Load and Line Test without NTC(5Ω)
Input
85V
115V
230V
265V
Vin(V)
Iin(I)
Vout(V)
Iout(I)
Pout(W)
Eff.
PF
84.78
0.48
399.90
0.10
38.79
95.44
1.00
84.67
0.73
399.90
0.15
58.59
95.49
1.00
84.53
1.02
399.90
0.21
82.26
95.76
1.00
84.43
1.23
399.90
0.25
99.40
95.84
1.00
84.14
1.85
399.90
0.37
148.97
95.77
1.00
83.84
2.48
399.90
0.50
198.55
95.51
1.00
83.51
3.16
399.90
0.63
250.37
95.10
1.00
83.22
3.79
399.90
0.75
298.09
94.65
1.00
114.77
0.36
399.90
0.10
39.20
96.14
0.98
114.68
0.53
399.90
0.15
58.61
96.56
0.99
114.58
0.74
399.90
0.21
82.28
96.69
1.00
114.51
0.90
399.90
0.25
99.43
96.67
1.00
114.30
1.35
399.90
0.37
149.03
96.77
1.00
114.09
1.80
399.90
0.50
198.58
96.73
1.00
113.85
2.28
399.90
0.63
250.41
96.60
1.00
113.64
2.72
399.90
0.75
298.07
96.43
1.00
229.81
0.21
399.90
0.10
39.20
96.28
0.86
229.76
0.28
399.90
0.15
58.62
96.92
0.92
229.72
0.39
399.90
0.21
82.31
97.28
0.95
229.68
0.46
399.90
0.25
99.57
97.37
0.97
229.58
0.68
399.90
0.37
149.08
97.68
0.98
229.48
0.89
399.90
0.50
198.35
98.10
0.99
229.36
1.12
399.90
0.63
250.37
98.24
0.99
229.24
1.33
399.90
0.75
298.09
98.24
1.00
264.84
0.20
399.90
0.10
39.20
96.64
0.78
264.80
0.26
399.90
0.15
58.61
97.02
0.88
264.76
0.34
399.90
0.21
82.31
97.31
0.93
264.73
0.41
399.90
0.25
99.58
97.54
0.95
264.64
0.59
399.90
0.37
149.11
97.80
0.97
264.55
0.78
399.90
0.50
198.73
98.11
0.98
264.45
0.98
399.90
0.63
250.45
98.35
0.99
264.35
1.15
399.90
0.75
298.05
98.47
0.99
15
ICE3PCS02/03G Efficiency - No NTC
100.00
99.00
Efficiency(%)
98.00
97.00
96.00
95.00
94.00
93.00
85V No NTC
92.00
0.00
50.00
115V No NTC
100.00
150.00
Output Power (W)
PFC stage efficiency without NTC (5Ω)
16
230V No NTC
200.00
265V No NTC
250.00
300.00
Harmonic test according to EN61000-3-2 Class D requirement
Test condition I: 85VAC input
measurement
class D
measurement
class D
0.25
1.2
1
0.2
0.8
current (A)
current (A)
0.15
0.6
0.1
0.4
0.05
0.2
0
0
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
3
5
7
9
11
harmonics (Vac=85V Po=300W Kp=1)
13
15
17
19
21
23
25
27
29
31
33
35
37
39
33
35
37
39
harmonics (Vac=85V Po=60W Kp=1)
Harmonics at 300W output
Harmonics at 60W output
Test condition II: 265VAC input
measurement
class D
measurement
1.2
class D
0.25
1
0.2
0.8
current (A)
current (A)
0.15
0.6
0.1
0.4
0.05
0.2
0
0
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
3
harmonics (Vac=265V Po=300W Kp=1, Boost Follower)
5
7
9
11
13
15
17
19
21
23
25
27
29
31
harmonics (Vac=265V Po=60W Kp=1, Boost Follower)
Harmonics at 300W output
Harmonics at 60W output
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11
Test Waveforms
BOP triggered startup
VCC triggered startup
Startup test at 85VAC, 300W
During startup the average current of PFC choke increases from zero to maximum limited by PCL and
PFC output voltage rises gradually with very slight overshoot.
Pout from 0W to 300W
Pout from 300W to 0W
Load jump test at 85VAC
The under shoot of output voltage is only 63V when load jump from no load to full load at 85Vac while the
overshoot is within 33V vice versa. The choke current shows no distortion during load dynamic change.
Enter brown-out and leave brown-out , Pout: 300W
Open Loop protection at 85V, Pout: 150W
Brownout and OLP test
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The gate drive is latched off once BOP pin voltage is lower than 1V and initiates another soft-startup once
BOP voltage is higher than 1.25V as shown in the left picture.
The gate drive can also be latched off once Vsense pin voltage is below 0.5V indicating an inadequate
output voltage and initiates another soft-startup once Vsense voltage is higher than 0.5V as shown in the
right picture.
Auto Restart Mode
OVP2 test
When OVP2 happens the gate drive the will shut down and enter auto startup when the voltage at OVP
pin drop below 2.3V.
12
References:
[1]
ICE3PCS02G and ICE3PCS03G datasheet, Infineon Technologies AG, 2010.
[2]
Luo Junyang, Liu Jianwei and Jeoh Meng Kiat, “Design tips for CCM PFC controller ICE2PCSxx”,
Application note, Infineon Technologies, 2008.
[3]
Lim Teik Eng, Li Dong and Liu Jian Wei, “300W PFC evaluation board with CCM PFC controller
ICE3PCS01G”, Application note, Infineon Technologies, 2010.
[4]
Luo Junyang, Liu Jianwei and Jeoh Meng Kiat, “ICE1PCS01 based boost type CCM PFC design
guide – control loop modeling”, Application note, Infineon Technologies, 2007.
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