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. 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. 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 Any information within this document that you feel is wrong, unclear or missing at all? Your feedback will help us to continuously improve the quality of this document. Please send your proposal (including a reference to this document) to: [email protected] 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