300W Evaluation board using ICE1CS02

Application Note, V2.0, April 2009
EVALCOMBI-ICE1CS02
300W PFC/PWM COMBI High Efficiency
Evaluation Board with ICE1CS02
Power Management & Supply
N e v e r
s t o p
t h i n k i n g .
Edition 2009-04-13
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2004.
All Rights Reserved.
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Application Note, V1.0, April 2009
EVALCOMBI-ICE1CS02
Revision History:
2009-04
Previous Version: V1.0
Page
Subjects (major changes since last revision)
300W PFC/PWM Combi Evaluation Board with ICE1CS02
License to Infineon Technologies Asia Pacific Pte Ltd
Liu Jianwei
We Listen to Your Comments
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V1.0
AN-PS0024
Page
Table of Content
1
Abstract.............................................................................................5
2
Evaluation Board..............................................................................5
3
Technical Specifications .................................................................6
4
Circuit Diagram ................................................................................7
5
Circuit Description ...........................................................................8
6
PCB Layout Top Layer.....................................................................9
7
PCB layout Bottom Layer ................................................................9
8
Components ...................................................................................10
8.1
Bill of Material...............................................................................................................10
8.2
PFC Boost Choke Layout ............................................................................................11
8.3
Forward Converter Transformer .................................................................................11
8.4
Output choke ................................................................................................................11
9
Test report ......................................................................................12
9.1
Load test .......................................................................................................................12
9.2
Waveforms ....................................................................................................................14
10
References:.....................................................................................16
Application Note
4
2009-04-13
1
Abstract
The evaluation board presented is a 300W CCM PFC/PWM Combi circuit employing the new combi
controller IC ICE1CS02. The circuit can operate from 85~265VAC universal input and achieve high
efficiency. The PFC section achieves near unity power factor and provides 390VDC to the down-stream
forward converter, which outputs 12V and 5VDC. The detailed application circuit, PCB drawing and
component list are included. Important specifications such as power factor and efficiency are tested and
some important features are demonstrated.
2
Evaluation Board
Application Note
5
2009-04-13
3
Technical Specifications
Input voltage
85VAC~265VAC
Input frequency
50Hz
Output voltage
12VDC
~ 5VDC
Output power
300W
Switching Frequency (internal)
65kHz PFC / 130kHz PWM
Efficiency at 115Vac
83.3% at full load
86.5% at half load
85.8% at 20% load
Application Note
6
2009-04-13
4
Circuit Diagram
300W2Tforward converter
0.7mH
L3
12V, 20A
Bus
1N5408
L2
D1_1
MBR2560CT
15
D2
+ C1
D3
STTH8R06D
G2
D1_2
D4
UF5406
Q2
SPP15N60C3
+ C7
3300uF/35V
1000uF/35V
MBR2560
14
R14
AC+
Rec AC+
FUSE 5A
C3
C2
0.47uF/X cap 0.47uF/X cap
BR1
SPP20N60C3/IPA
C10
CY2
2.2nF,Y2,250v
D7
UF5406
+ C5
3300uF/25V
Q3
SPP15N60C3
G3
12
R15
10k
CY3
2.2nF,Y2,250v
CS
R1
5V, 17A
D6_2
STPS3045CT
8
R11
10k
0.1uF/630V
D6_1
STPS3045CT
13
G1
AC-
VAR
S10K275
5
10k
+ C4
330uF/450V
Q1
8A/400V
Relay
L1
2x3.9mH
85~265VAC
S2
R12
0R33/2W
0.22
R2 0.1
PFC CS
TRAN_ICE1CES02
CY1
2n2/250V
R5
680R
IC1
SFH617
R109
R100
Bus
R101
R106
R102
R103
C111
PFC VSENSE
C101
C100
PFC OVP
R108
C102
IC GND
GND
R123
G1
PFC OUT
Vcc
+
6
Pulse T100
C105
R126
R117
S3&PWM CS
D103
R122
C108
IC101
S2
G3
VCC
8
PWM Out
C107
C106
R116
1
3
2
R112
D100
R111
IC2
TL431
Rec AC+
R113
C128
C109
C112
ext signal
R121
IC103
C113
R125
IC102
S3&PWM CS
Application Note
7
R7
7.5k
C8
68nF/50V
R6
1k
C104
VINS HYS
13
VREF
12
PWM FB
11
PWM PRESHORT
10
PWM SYNC
9
PWM CS
ICE1CS02
PFC VCOMP
G2
16
C129
PFC ISENSE
15
VINS
R110
14
PFC ICOMP
20k
R105
PFC CS
C103
R104
R107
4
R8
1.3k
C6
2.7nF/50V
2009-04-13
R10
4.3k
R9
15k
5
Circuit Description
Line Input
The high frequency current ripple and radio interference is suppressed by the choke L1, X2-capacitors
C2 and C3 and Y1-capacitor CY2 and CY3. NTC is placed in series to limit inrush current during
power on.
PFC Converter
The CCM boost type PFC converter consists of L2, Q1, D3 and C4. Bulk capacitor C4 provides
energy buffering to reduce the output voltage ripple (100Hz) to the acceptable level.
The PFC brown-out voltage is set at 59VAC. The recover voltage is 68VAC. The values can be
adjusted by changing the components at 14 and 15 pin.
The CoolMOSTM C3 series MOSFET SPP20N60 is usedas main switch in this boost type PFC circuit.
PWM Converter
This stage is a two_transistor (Q2 and Q3) forward converter. The two ultra-fast diodes D4 and D7
consists of the magnetic resetting circuit. The output inductors are coupled to improve cross regulation
and reduce phase-ripple current for transient response.
The pre-short protection blanking time is set as 10ms.
The CoolMOSTM C3 series MOSFET SPP15N60 are used.
Application Note
8
2009-04-13
6
PCB Layout Top Layer
7
PCB layout Bottom Layer
Application Note
9
2009-04-13
8
Components
8.1
Bill of Material
Part Type
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
C1
C2
C3
C4
C5
C6
C7
C8
C10
C100
C101
C102
C103
C104
C105
C106
C107
C108
C109
C111
C112
C113
C128
C129
CY2
CY3
D1_1
D1_2
D2
D3
D4
D6_1
D6_2
D7
D100
D103
L1
L2
Q1
Q2
Q3
Application Note
2200uF/35V
0.47uF
0.47uF
220uF/450V
2200uF/25V
2.7nF
1000uF/35V
68nF
0.1uF
0.1uF
1uF
0.1uF
3.3nF
680nF
1u/50V
47uF/50V
0.1uF
1nF
0.1uF
0.1uF
0.47nF
Empty
0.1uF
1nF
2.2nF,Y2,250v
2.2nF,Y2,250v
MBR2560CT
MBR2560CT
1N5408
STTH8R06D
UF5406
STPS3045CT
STPS3045CT
UF5406
1N4007
1N4148
2x3.9mH
0.71mH
SPP20N60C3
SPP15N60C3
SPP15N60C3
Part Type
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
IC1
IC2
R1
R2
R5
R6
R7
R8
R9
R10
R11
R12
R14
R15
R100
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R116
R117
R118
R119
R121
R122
R123
R125
R126
BR1
FUSE
NTC
TR
10
SFH617
TL431
0.22/1W
0.1/1W
Empty
1k
7.5k
1.3k
15k
4.3k
10k
0.33 /2W
10k
10k
2M
2M
2M
2M
33k
33k
270k
390k
33k
3.3
470k
5.6M
82k
3.6k
3.3
3.3
Empty
Empty
Empty
1k
3.3
180
6.8
8A/400V
5A
Shorted
TRAN_ICE1CES02
2009-04-13
42
IC101
BC548
87
43
44
45
IC102
IC103
IC104
BC557
BC548
ICE1CS02
88
89
90
8.2
VAR
Pulse
T100
Heatsink1
Heatsink2
S10K275
CD602
3.6C/W
2.9C/W
PFC Boost Choke Layout
Core size: ETD39 Core material N97 (Epcos)
Bobbin: ETD39 (16pin) Horizontal Version
Litz Wire: 80x0.1mm
Primary Inductance, Lp=710uH, measured between pin 1 and pin 4 (air gap)
8.3
Forward Converter Transformer
Core size: ETD39 Core material N97 (Epcos)
Bobbin: ETD39 (16pin) Horizontal Version
Primary Inductance, Lp=5.9mH, measured between pin 8 and pin 5 (no air gap)
8.4
Output choke
Core size: ETD39 Core material N97 (Epcos)
Bobbin: ETD39(16pin) Horizontal Version
Primary Inductance, Lp=12.4uH, measured between pin 1 and pin 3 (air gap)
Application Note
11
2009-04-13
9
Test report
Please note an electric fan (say of 11W) is used to help dissipate heat, otherwise the devices may get
overheated and damaged.
9.1
Vin(VAC)
100VAC
115VAC
230VAC
265VAC
Load test (NTC shorted)
Vout1(V)
Iout1(A)
Vout2(V)
Iout2(A)
Pout(W)
Pin(W)
(read)
Pin(W)
(overall)
Efficiency
PF
11.94
11.95
11.94
11.94
11.95
11.94
11.94
11.95
11.94
11.94
11.95
11.94
18.94
8.98
3.98
18.96
8.98
3.98
18.94
8.98
3.98
18.95
8.98
3.98
4.4
4.44
4.55
4.4
4.43
4.55
4.4
4.44
4.55
4.4
4.44
4.56
16.94
9.95
2.99
16.94
9.954
2.99
16.94
9.95
2.99
16.94
9.95
2.99
300.7
151.5
61.1
300.9
151.4
61.1
300.7
151.5
61.1
300.8
151.5
61.2
357.3
174.8
71.3
356.2
174.5
71.2
346.5
171.4
70.4
346.9
171.4
69.8
362.4
175.4
71.9
361.3
175.1
71.8
347.1
172
71
347.5
172
70.4
83.0%
86.4%
85.0%
83.3%
86.5%
85.1%
86.6%
88.1%
86.1%
86.6%
88.1%
86.9%
0.991
0.968
0.86
0.99
0.96
0.846
0.96
0.88
0.745
0.96
0.89
0.76
Application Note
12
2009-04-13
Efficiency Vs Output Power
89.0%
88.0%
Efficiency
87.0%
100VAC
86.0%
115VAC
230VAC
85.0%
265VAC
84.0%
83.0%
82.0%
0.0%
50.0%
100.0%
Pout(%)
PF Vs Output Power
1
0.95
PF
0.9
100VAC
115VAC
0.85
230VAC
265VAC
0.8
0.75
0.7
0.0%
50.0%
100.0%
Pout(%)
Application Note
13
2009-04-13
9.2
Waveforms
External Synchronization at 70kHz
Vext signal
Vsync
Vgate_pwm
Vgate _pwm
External Synchronization at 100kHz and 150kHz
Vext signal
Vsync
Vgate_pwm
Vgate _pwm
85Vac, Full load (300W) PFC softstart
Application Note
14
2009-04-13
V_12V
Vpfc_out
V_5V
I_choke
Full load (300W) PWM softstart
V_12V
VFB
I_forward
16 steps
Output 12V stable during the 20ms cycle drop out under full load
V12V
Vpfc_out
20ms
drop out
Application Note
Vin
15
2009-04-13
10
References:
[1]
Combi PFC/PWM Controller ICE1CS02 datasheet Preliminary datasheet; Infineon Technologies;
Munich
[2]
Liu Jianwei, Luo Junyang, Jeoh Meng Kiat, Design Guide for Boost Type CCM PFC with
ICE2PCSxx, Application note, Infineon Technologies, Munich, Germany, Feb. 2007
Application Note
16
2009-04-13
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