February 22, 2012 IRS2500S TRANSITION MODE PFC CONTROL IC Features • • • • • • • • • • • • PFC Control IC Boost or Flyback Converter Modes Critical-conduction / Transition mode operation Over-current protection Static and Dynamic DC bus overvoltage protection Micropower startup (<50μA) Low quiescent current (2.5mA) Latch immunity and ESD protection Wide range PFC for universal AC line input Low THD Open load Over voltage protection Noise immunity Typical Applications • • • Product Summary Topology Boost / Flyback Io+ & I o- (typical) 500 / 500 mA tr & tf (typical) 60 / 30 nS Packages 8-Lead SOIC Switched Mode Power Supplies Electronic Ballasts LED Drivers Typical Connection Diagram www.irf.com © 2012 International Rectifier IR's IRS2500 µPFC Control IC Reduces Noise Sensitivity for Cost Sensitive Electronic Ballast and SMPS Applications IR’s IRS2500 µPFC™ Control IC Reduces Noise Sensitivity for Cost Sensitive Electronic Ballast and SMPS Applications Part Search EL SEGUNDO, Calif. — International Rectifier, IR® (NYSE: IRF), a world leader in power management technology, today announced the introduction of the IRS2500 µPFC™ power factor correction (PFC) control IC for switch mode power supply (SMPS), LED drivers, fluorescent and HID electronic ballast applications. The IRS2500 µPFC controller can be configured to operate in critical conduction boost PFC or flyback configuration. The new device also features a total harmonic distortion (THD) optimization circuit to reduce line current harmonics. The controller has high noise immunity, simplifying design and reducing system cost. Site Search AC-DC Appliances Automotive DC-DC Lighting NetCom A&D/HiRel Audio Desktop/Server Enterprise Power Motor Control Portables About IR Careers Contact Us Investor Relations Site Index Press Room Corporate Social Responsibility Awards Featured Articles Print Advertising Request Literature Trade Show Calendar Editorial Contacts All News Releases New Product Releases New Catalog Additions Investor News E-Mail News RSS Feeds “The IRS2500 PFC control IC expands IR’s existing SMPS and general lighting device portfolios. The new device reduces noise sensitivity, eases PCB layout and provides a cost- effective alternative to existing solutions,” said Peter Green, LED Group Manager, IR’s Energy Saving Products Business Unit. Available in an SO-8 package, the IRS2500 also features micro power start up current of less than 50µA, quiescent current of 2.5mA, drive capability of +800mA/-600mA as well as static and dynamic over-voltage protection and over-current protection. The short minimum on time of the device allows wide input range power factor correction for universal input operation. Specifications Part Number IRS2500SPBF Package Standby Current Vref Io SO-8 < 50µA 2.5V +/- 500mA Design Tools A datasheet and application note are available via the part number link above. Availability and Pricing Pricing for the IRS2500 begins at US $0.33 each in quantities of 10,000-units. Production quantities are available immediately. The devices are lead free and RoHS compliant. Prices are subject to change. International Sites: | Chinese ???? | Korean ??? | Japanese ??? | http://www.irf.com/whats-new/nr111117.html[2012-06-27 11:16:48] About International Rectifier | Contact Us | Privacy ©1995- 2012 International Rectifier Application Note AN-1173 Power Factor Correction using the IRS2500 By Peter B. Green Table of Contents Page 1. Introduction ......................................................................................2 2. Power Factor and THD.....................................................................3 3. PFC Boost Pre-regulator ..................................................................5 4. Design Equations .............................................................................11 5. Factors affecting PF and THD..........................................................12 6. PCB Layout Considerations .............................................................14 7. Example Schematic .........................................................................15 8. Bill of Materials.................................................................................16 9. Test Results .....................................................................................17 10. Replacing Alternative Controllers ...................................................19 Safety Warning! The IRS2500 based power factor correction pre-regulator is based on a non-isolated Boost SMPS circuit topology. The output typically ranges from 400 to 500VDC. When operating the output produces potentially dangerous voltages!The IRS2500 and associated circuitry should be handled by qualified electrical engineers only! www.irf.com AN-1173 1 IRS2500 PFC Pre-regulator 1. Introduction Many offline applications require power factor correction circuitry in order to minimize transmission line losses and stress on electrical generators and transformers created by high harmonic content and phase shift. Appliances often incorporate switching power supplies (SMPS) which include capacitive filter circuitry followed by a bridge rectifier and bulk capacitor supplying a load. Without power factor correction circuitry a SMPS draws a high peak current close to the line voltage peak and almost no current over much of the cycle, resulting in a power factor of around 0.5 and a high total harmonic distortion. Power factor correction circuitry is added which enables the appliance to draw a sinusoidal current from the AC line with negligible phase shift and very low harmonic distortion. This allows optimization of the load seen by the power grid such that power can be supplied without creating additional conductive losses in transmission lines or additional burden on transformers and generators. Costs to electricity providers are therefore reduced, which are hopefully passed on to the consumer. Although not explicitly specified in standards such as IEC 61000-3-2 relating to power factor and line current harmonics, it is generally a requirement for the total harmonic distortion (THD) of the line input current supplying a PFC pre-regulator to be as low as possible. As is normally the case a tradeoff exists between cost and performance where more expensive high end products rated at higher power typically incorporate active power factor correction circuits, while low cost passive circuits often suffice in cheaper consumer products. This is a market trend in power supplies used in a variety of appliances as well as electronic lighting ballasts for Fluorescent, high intensity discharge (HID) lamps and LED lighting. For a product incorporating active power factor correction a THD of less than 20% over a wide input voltage range, normally 100VAC to 305VAC is expected. In many cases THD can be less than 10% over much or all of this voltage range. Important Safety Information The IRS2500 based PFCpre-regulator does not provide galvanic isolation of the output from the line input. Therefore if the system is supplied directly from a non-isolated input, an electrical shock hazard exists.The DC output voltage is highenough to produce a potentially lethal electrical shock! It is recommended that for laboratory evaluation that the IRS2500PFC board be used with an isolated AC or DC input supply. The IRS2500 series Boost topology is suitable only for front end applications where isolation is either not necessary or provided elsewhere in the system. www.irf.com AN-1173 2 2. Power Factor and THD THD is the RMS of harmonic distortion from all components of an AC signal excluding the fundamental, expressed as a percentage of the RMS of the fundamental. In other words it quantifies the amount by which the signal deviates from a pure sinusoid. ∞ THD = ∑ An n =2 A1 2 = ( ARMS − A1 2 A1 where, A1 is the RMS amplitude of the fundamental and ARMS is the total RMS value of the complete signal. It should be noted that THD is not directly related to power factor (PF) since phase shift between current and voltage inputs are not factored into the THD calculation. Power factor is defined as the ratio of the real power, which is utilized by the load, to the apparent power which also includes energy stored in the load and returned to the source as well as current harmonics created by non-resistive loads. In an off line AC system real power is derived from the voltage and the fundamental component of the current only as a function of the phase shift between them. Distortion power is derived from all other harmonics of the current. It is therefore possible for a circuit to obtain a very low THD without a high power factor if a phase shift exists. The European standard IEC 61000-3-2 class C limits (applicable to lighting ballasts rated above 25W) specifies maximum allowable levels for individual odd harmonics up to the 39th. A THD of less than 10% will normally provide compliance to these limits. Figure 1. Power Vector Diagram www.irf.com AN-1173 3 A general formula for power factor is: PF = PRMS V RMS ⋅ I RMS where PRMS is the real power consumed by the load. The displacement power factor is given the formula: PF = COS(φ ) where Ф is the phase shift between the voltage and sinusoidal current. The following formula gives the distortion power factor: DF = 1 1 + THD 2 The following formula combines these to give the total power factor: PF = COS (φ1 ) 1 + THD 2 where Ф1 refers to the phase shift between the voltage and the fundamental component of the current and THD is expressed as a fraction. www.irf.com AN-1173 4 3. PFC Boost Pre-regulator Figure 1 shows the schematic for a PFC pre-regulator based on a critical conduction mode Boost circuit. The IRS2500 pinout conforms to most industry standard power factor controllers and can be used as a drop in replacement for alternative parts in many applications. The Boost PFC pre-regulator circuit consists of an EMI filter followed by a bridge rectifier which provides a full wave rectified voltage at the input to the Boost inductor LPFC. CIN provides an essential path for the circulating high frequency switching current. Both CF and CIN are critical to prevent excessive conducted emissions back onto the AC line, however CF produces a phase leading component of input current and CIN contributes to cross over distortion since it never fully discharges at the line zero crossing. In critical conduction mode (also known as transition or boundary mode) the PWM gate drive signal to MPFC maintains a constant on time during the line cycle apart except where additional on time is added near the zero crossing and a variable off time. Each new cycle starts when the energy stored in LPFC has been fully transferred to the output. LPFC DPFC DC Bus (+) RBUS1 RS DVCC IC1 RBUS2 VBUS COMP 2 RDC2 VDC 3 LF AC Line CF Input OC CIN 4 CDC 8 IRS2500 CCOMP RDC1 BR VCC 1 OUT 7 6 COM CVCC CBUS + LOAD ZX 5 RZX ROUT MPFC ROC1 COC ROC DC Bus (-) Figure 2: PFC Pre-regulator Schematic www.irf.com AN-1173 5 The on and off times not taking into account the additional on time modulation can be calculated by the following formulae: L.IL ( pk ) 2 .Vin ( rms ) L.IL ( pk ). sin θ = Vout − 2 .Vin ( rms ). sin θ TON = TOFF A feedback loop regulates the output voltage by adjusting the PWM on time gradually over many line cycles so that the input current follows the shape of the input voltage and remains sinusoidal. When the switch MPFC is turned on, the inductor LPFC is connected between the rectified line input (+) and (-) causing the current in LPFC to increase linearly. When MPFC is turned off, LPFC is connected between the rectified line input (+) and the DC bus capacitor CBUS through diode DPFC. The stored energy in LPFC is transferred to the output, supplying a current into CBUS. MPFC is turned on and off at a high frequency and the voltage on CBUS charges up to a specified voltage. The voltage feedback loop of the IRS2500 regulates the output to the desired voltage by continuously monitoring the DC output and adjusting the on-time of MPFC accordingly. If the output voltage is too high the on-time is decreased and if it is too low the on-time is increased. This negative feedback control loop operates with a slow loop speed and a low loop gain such that the average inductor current smoothly follows the low-frequency line input voltage to obtain high power factor and low THD. The loop speed is intentionally slow with respect to the AC line frequency so that there is no appreciable change in the on time during a single line half cycle. This allows the current to follow shape of the sinusoidal voltage. V, I t Figure 3: Sinusoidal line input voltage (solid line), triangular PFC Inductor current and smoothed sinusoidal line input current (dashed line) over one halfcycle of the AC line input voltage. www.irf.com AN-1173 6 Corrections to the output voltage therefore require several line cycles. With a fixed on-time, and an off-time determined by the inductor current discharging to zero, the result is a system where the switching frequency is free-running and constantly changing from a high frequency near the zero crossing of the AC input line voltage, to a lower frequency at the peaks (Figure 3). When the line input voltage is low (near the zero crossing), the inductor current will increase only a small amount and the discharge time will be short resulting in a high switching frequency. When the input line voltage is high (near the peak), theinductor current will charge up to a much higher level and the discharge time will be longer giving a lower switching frequency. The PFC control circuit of the IRS2500 (Figure 4) includes six control pins: VBUS, COMP, ZX, OUT, VDC and OC. The VBUS pin measures the DC bus voltage through an external resistor voltage divider. The COMP pin voltage determines the on-time of MPFC and sets the feedback loop response speed with an external RC integrator. The ZX pin detects when the inductor current discharges to zero each switching cycle using a secondary winding from the PFC inductor. The OUT pin is the low-side gate driver output for the external MOSFET, MPFC. The VDC pin senses the line input cycle providing phase information to control the on time modulation described in the next section. The OC pin senses the current flowing through MPFC and performs cycle-by-cycle over-current protection. Figure 4: IRS2500 simplified PFC control circuit. The VBUS pin is compared with a fixed internal 2.5V reference voltage for regulating the DC output voltage. The feedback loop error amplifier increases or decreases the COMP pin voltage. The resulting voltage on the COMP pin sets www.irf.com AN-1173 7 the threshold for the charging of the internal timing capacitor shown in Figure 5 and therefore determines the on-time of MPFC. The error amplifier operates at a slow loop speed preventing rapid changes in PWM duty cycle during a single input line cycle. This prevents distortion achieving high power factor and low THD. VCC OC 4 VOCTH COM 6 8 200 ns Blank Time UVLO VBUS 1 VCLAMP OVP VVBUS VCC VVBUSOV 7 COMP 2 VDC ON TIME MODULATOR 3 S Q R Q CT S Q OUT Watchdog Timer R1 R2 Q ZX 5 VZXCLAMP VZX Figure 5: IRS2500 Internal Block Diagram. The off-time of MPFC is determined by the time it takes the LPFC current to discharge to zero. The zero current level is detected by a secondary winding on LPFC that is connected to the ZX pin through an external current limiting resistor RZX. This winding normally has close to a 1:10 turns ratio relative to the main winding. A positive-going edge exceeding the internal threshold VZX+ signals the beginning of the off-time. A negative-going edge on the ZX pin falling below VZXwill occur when the LPFC current discharges to zero, which signals the end of the off-time and MPFC is turned on again (Figure 12). The ZX pin is internally biased to ensure that the voltage detected from the inductor drops fully to zero before triggering the next PWM cycle. A wide hysteresis prevents false triggering by ringing oscillations. The ZX pin current should not exceed 0.5mA as excessive current can cause incorrect triggering and possible damage to the IRS2500. The cycle repeats itself indefinitely until the IRS2500 is disabled through an overvoltage condition on the DC bus or if the negative transition of ZX pin voltage does not occur. Should the negative edge on the ZX pin not occur, MPFC will remain off until the watch-dog timer forces a turn-on of MPFC for an on-time duration programmed by the voltage on the COMP pin. The watch-dog pulses occur every 300-400us (tW) indefinitely until a correct positive and negativegoing signal is detected at the ZX pin and normal operation is resumed. Should the OC pin voltage exceed the VOCTH over-current threshold during the on-time www.irf.com AN-1173 8 the gate drive output will turn off. The circuit will then wait for a negative-going transition on the ZX pin or a forced turn-on from the watch-dog timer to turn the output on again. ILPFC ... OUT ... ZX ... VOCTH OC ... Figure 6: Inductor current, OUT pin, ZX pin and OC pin timing diagram. A fixed on-time of MPFC over an entire cycle of the line input voltage produces a peak inductor current which naturally follows the sinusoidal shape of the line input voltage. The smoothed, averaged line input current is in phase with the line input voltage for high power factor but a high total harmonic distortion (THD), as well as individual higher harmonics of the current are still possible. This is mostly due to cross-over distortion of the line current near the zero-crossings of the line input voltage. To achieve low harmonics that are acceptable for compliance with international standards and general market requirements, an additional on-time modulation circuit has been added to the PFC control. This circuitdynamically increases the on-time of MPFC as the line input voltage nears the zero-crossings (Figure 7). This causes the peak LPFC current, and therefore the smoothed line input current, to increase near the zero-crossings of the line input voltage. This reduces the amount of cross-over distortion in the line input current which reduces the THD and higher harmonics. On time modulation is controlled by sensing the full wave rectified voltage at the bridge rectifier output through a resistor divider (RDC1, RDC2). This is scaled such that the peak voltage will be close to 1V at 120VAC and 3V at 265VAC. This function can be disabled by connecting a resistor from pin 3 to VCC in place of the input signal. www.irf.com AN-1173 9 ILPFC 0 OUT pin 0 near peak region of rectified AC line near zero-crossing region of rectified AC line Figure 7: On-time modulation circuit timing diagram. The IRS2500 incorporates both static and dynamic overvoltage protection. Static over voltage protection monitors the feedback voltage at the VBUS pin and disables the gate drive output if this voltage exceeds the target voltage by 8%. This is activated by an internal comparator set to detect a threshold of 2.7V, which is 8% above the regulation threshold of 2.5V. However, under startup condition or when a load is removed from the output the error amplifier output voltage at the COMP pin swings low. Since the compensation capacitor CCOMP is connected from this output back to the VBUS input a current will flow during the COMP voltage transition. This pulls down the VBUS voltage, which allows the output voltage to exceed the desired regulation level during the transition and results in an overshoot before the voltage at the VBUS input exceeds the regulation threshold. In order to compensate for this effect, the IRS2500 includes dynamic detection of the error amplifier output current. During a swing in the negative direction the error amplifier output current peaks at a much high level than the level during steady state operation. This higher current is internally detected and triggers the overvoltage protection circuitry disabling the PWM output until the error amplifier output has settled to a new level. This prevents the output voltage from overshooting the desired level by a significant amount under the transient conditions described. For this reason the loop should be designed such that voltage ripple at COMP is minimized during steady state operation. www.irf.com AN-1173 10 4. Design Equations Step1: CalculatePFC inductor value: LPFC = 2 (VBUS − 2 ⋅ VAC MIN ) ⋅ VAC MIN ⋅η 2 ⋅ f MIN ⋅ POUT ⋅ VBUS [Henries] where, VBUS = DC bus voltage VAC MIN = Minimum RMS AC input voltage = PFC efficiency (typically 0.95) η f MIN = Minimum PFC switching frequency at minimum AC input voltage POUT = Output power Step 2: Calculate peak PFC inductor current: iPK = 2 ⋅ 2 ⋅ POUT VACMIN ⋅η [Amps Peak] Note: The PFC inductor must not saturate at i PK over the specified ballast operating temperature range. Proper core sizing and air-gapping should be considered in the inductor design. Step 3: Calculate PFC over-current resistor ROC value: ROC = VOCTH i PK where VOCTH = 1.1V [Ohms] ROC power rating can be approximated: 2 PROC ⎛ POUT ⎞ ⎟⎟ × ROC ≥ ⎜⎜ ⎝ VAC MIN .η ⎠ [Watts] Step 4: Calculate start-up resistor RVCC value: RVCC < VAC MIN IQCCUV PRVCC > www.irf.com [Ohms] 2 V ACMAX RVCC [Watts] AN-1173 11 RVCC is often comprised of two series resistors (RBUS1A and RBUS1B) in order to withstand the high voltage. In this case choose RVCC1 and RVCC2 to be the next preferred value down from RVCC/2 with power rating greater than PRVCC/2. Step 5: Calculate VBUS feedback resistor divider network: RBUS1 is often comprised of two series resistors (RBUS1A and RBUS1B) in order to withstand the high voltage. Select an initial value of 10K for RBUS2 RBUS1 = (VBUS − 2.5) × RBUS 1 A = RBUS 1B = 10000 2.5 [Ohms] RBUS 1 2 [Ohms] Choose the nearest preferred value for RBUS1A and RBUS1B. Then re-calculate RBUS2: RBUS 2 = 2.5 × ( RBUS 1 A + RBUS 1B ) VBUS − 2.5 [Ohms] Then choose the nearest E96 1% tolerance value for RBUS2. Step 6: Calculate VDC resistor divider network: RDC1 is often comprised of two series resistors (RDC1A and RDC1B) in order to withstand the high voltage. Select an initial value of 10K for RDC2 R DC 1 = ( 2.V ACMIN − 1) × 10000 [Ohms] Choose the nearest preferred value for RDC1A and RDC1B. Then re-calculate RDC2: RDC 2 = RDC1 A + RDC1B [Ohms] 2.V ACMIN − 1 Then choose the nearest E96 1% tolerance value for RDC2. www.irf.com AN-1173 12 Step 7: Calculate COMP capacitor: CCOMP should be selected to roll off the gain of the error amplifier at approximately 20Hz. CCOMP = 1 2π × 20 Hz × RBUS 2 [Farads] Choose the nearest preferred value for CCOMP. Step 8: Calculate RZX resistor: Choose Izx as 0.5mA and assume ZX winding maximum voltage VZX of 20V at the ZX winding as an approximation. If the actual VZX is higher than 20V use the true value. RZX ≤ VZX I ZX [Ohms] Choose the next lowest preferred resistor value for RZX. www.irf.com AN-1173 13 5. Factors affecting PF and THD The PFC pre-regulator circuit described above draws a current from the line input which follows the shape of the voltage, however the following limitations exist: 1. Phase shift produced by CF. The capacitance of CF draws current from the line input, which leads the voltage by 90º. The magnitude of this reactive current is dependent on the size of CF and the AC line input voltage. This is one reason why the power factor always drops as line input voltage increases. For this reason CF should be kept as small as possible while making sure the input filter is adequate for EMC compliance. This does not produce distortion and affects only the power factor. 2. Phase shift produced by CIN. CIN also causes some phase shift since the voltage across it is full wave rectified. This should also be kept to a minimum though it must be sufficient to provide a high frequency AC current source for the switching regulator. This is also essential for EMC compliance. 3. Cross over distortion produced by CIN. CIN also contributes to cross over distortion while CF does not. The circuit can be considered as a resistive load and therefore it is clear that as the AC line input voltage passes through each zero crossing, CIN will need to discharge through the load. Depending on the magnitude of CIN and the load the voltage on CIN never discharges completely to zero at each zero crossing always maintaining a residual voltage. This problem becomes worse in systems where the load is variable such as a dimmable electronic lighting ballast. As the load is reduced the residual voltage on CIN increases. Since the voltage at CIN does not reach zero, when the AC line input voltage drops below the minimum voltage at CIN there is no current drawn from the line input, which results in the characteristic dead band shown on the input current waveform in figure 7. It should be noted that the bridge rectifier (BR) also contributes to the cross over distortion to a small extent due to the forward voltage drop of two series diodes that always appears between the AC line voltage and the rectified voltage, therefore there will always be some cross over distortion no matter how small CIN is. www.irf.com AN-1173 14 Power Factor = 0.99 THD < 10% Traces: Green – Line Input Voltage Blue – Line Current Figure 8: Line input and current in a typical PFC pre-regulator 4. Minimal energy transfer at the zero crossing. At low line input voltage levels there may be insufficient energy stored in the Boost inductor LPFC to provide enough voltage at the drain of MPFC to forward bias the output diode DPFC. This is due to parasitic capacitances in the windings of LPFC as well as the drain to source capacitance of the MOSFET switch. This being the case it is necessary for the control IC to compensate for this by increasing the MOSFET on time when the voltage approaches zero in order to draw more current. Many PFC control ICs including the IRS2500 include circuitry that gradually increases the on time when the input voltage is close to a zero crossing. This functionality is referred to as on time modulation. The line input voltage is generally detected through the divided input signal provided at pin 3. It should be noted here that the residual voltage across CIN will be divided down through RDC1 and RDC2 so that it also appears at pin 3, which prevents the IC from detecting the input voltage below the level of the residual voltage. In order to limit this problem, the IRS2500 must produce sufficient on time modulation to discharge CIN as low as possible and introduce this before the residual voltage level is reached. 5. Ripple at the error amplifier output (COMP) The output bus voltage from the PFC pre-regulator circuit will always contain some ripple at twice the line frequency, ∆VOUT superimposed on top of the regulated DC output. The magnitude of ∆VOUT depends on the magnitude of the www.irf.com AN-1173 15 output storage capacitor CBUS. Since the output voltage is divided and fed back to the inverting input of the error amplifier, a component of ripple will also be fed to the input and compared with the internal 2.5V reference of the IRS2500. This may result in a component of ripple appearing at the error amplifier output (COMP) which determines the PWM on time. It is necessary for the compensation capacitor CCOMP to be large enough to roll off the error amplifier gain at a frequency well below twice the line frequency in order to eliminate this ripple as much as possible. Ripple at the COMP output results in modulation of the on time which causes distortion of the current waveform and should therefore be eliminated as far as possible. 6. Delay before next switching cycle In critical conduction mode an auxiliary wining on the Boost inductor provides a signal to the ZX (zero crossing) pin of the controller. This indicates when all of the energy from the inductor has been transferred to the output by transitioning from high to low. When this transition is detected the PWM output drive goes high to start the next cycle, however if there is delay then the converter is actually operating in discontinuous mode due to the dead time. This can cause some distortions in the current waveform. 6. PCB Layout Considerations For correct operation the following guidelines should be followed: 1. CVCC must be as close to IC1 as possible with short direct traces. 2. The feedback path should be kept to a minimum length and separated as much as possible from high frequency switching traces to minimize noise at the VBUS input. 3. The current sense filter components ROC and COC should be located close to the IRS2500 with short direct traces. 4. It is essential that all signal and power grounds should be kept separated from each other to prevent noise from entering the control environment. Signal and power grounds should be connected together at one point only, which must be at the COM pin of the IRS2500. The IRS2500 may not operate in a stable manner if these guidelines are not followed! All components associated with the IR2500 should be connected to the IC signal ground (COM) with the shortest path possible. 5. All traces carrying the load current need to be sized accordingly. 6. Gate drive traces should also be kept to a minimum length. www.irf.com AN-1173 16 www.irf.com AC Line CF Input LF BR CIN LPFC DBP MPFC ROC RDC1 DPFC RDC2 AN-1173 ROUT RZX ROC1 DOUT CDC RDC3 RBUS3 OC VDC 4 3 2 COMP 1 VBUS COC CCOMP RBUS2 RBUS1 IC1 DVCC 5 6 7 8 ZX COM OUT VCC CVCC1 DZVCC RVCC CVCC2 Q1 RS2 RS1 + + DC Output (-) CBUS2 CBUS1 DC Output (+) 7. Example Schematic IRS2500 Figure 9: 80W PFC Schematic 17 8. Bill of Materials Item Description Part # Manufacturer Qty Reference 1 2 Diode, 75V, 150mA, MiniMELF Diode, 1000V, 1A DL4148 1N4007 Diodes Inc Diodes Inc 2 1 DVCC, DOUT DBP 3 20V, ZenerDiode, 500mW, MiniMELF ZMM5250B-7 Diodes Inc 1 DZVCC 4 5 6 7 Diode, 600V, 3A, 250nS, SMB Bridge, 1000V, 1.5A, 4SDIP MOSFET, 650V, 0.38 Ohm, TO220 NPN Transistor, SOT23, 40V RS3JB-13-F DF10S SPP11N60C3 MMBT2222A-TP 1 1 1 1 DPFC BR1 MPFC Q1 8 IC, PFC Controller IRS2500SPBF Diodes Inc Fairchild Infineon Micro Com International Rectifier 1 IC1 9 Inductor CM Line Filter, 250V,0.70A ELF-15N007A Panasonic 1 LF 10 Inductor, 520uH, 4.2Apk SRW2620PQX22V102 TDK 1 LPFC 11 Capacitor, 0.10uF, 275VAC, X2/Y2,TH,.591” ECQ-U2A104ML Panasonic 1 CF 12 Capacitor, 0.10uF, 400VDC, 0.295” MKS4-.1/400/10 PCM 7.5 Wima 1 CIN 13 14 Capacitor, 100uF, 250V Capacitor, 1.0uF, 25V,X7R, 1206 C3216X7R1E105K TDK 2 1 CBUS1, CBUS2 CCOMP 15 Capacitor, 10nF, 1206 12061C103K4T2A AVX 1 CDC 16 Capacitor, 1nF, 50V, 1206 12065C102KAT2A AVX 1 COC 17 Capacitor, 10µF, 50V, 1210 GRM32DF51H106ZA 01L Murata 1 CVCC1 18 Capacitor, 2.2uF, 25V, X7R, 1206 C3216X7R1E225K TDK 1 CVCC2 19 Resistor, 0.33 Ohm, 0.5W, 2010 MCR50JZHFLR330 Rohm 1 ROC 20 Resistor, 470K, 5%, 1206 ERJ-8GEYJ474V Panasonic 2 RDC1, RDC2 21 Resistor, 5.6K, 5%, 1206 ERJ-8GEYJ562V Panasonic 1 RDC3 22 23 24 25 26 27 28 29 Resistor, 787K, 1%, 1206 Resistor, 9.1K, 1%, 1206 Resistor, 100K, 5%, 1206 Resistor, 18K, 5%, 1206 Resistor, 1.0K, 5%, 1206 Resistor, 3.3K, 5%, 1206 CONNECTOR, 2 POSITION PCB ERJ-8SENF7873V ERJ-8ENF9101V ERJ-8GEYJ104V ERJ-8GEYJ183V ERJ-8GEYJ102V ERJ-8GEYJ332V Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic 2 1 2 1 1 1 2 1 RBUS1, RBUS2 RBUS3 RS1, RS2 RZX ROC1 RVCC www.irf.com AN-1173 18 9. Test Results Figure 10: 80W ExampleWaveforms AC Input Voltage AC Current VDC Pin Input MPFC Gate Drive : Yellow : Green : Blue : Red Results for power factor and THD were measured over the input voltage range 90VAC to 260VAC (see table 1). In order for the THD results to be accurately measured an electronic AC source was used which produces a pure sinusoidal voltage supply to the board under test. Without using an electronic AC source the input voltage may be distorted as a result of auto-transformers and safety isolating transformers combined with the effects of other loads connected to the AC line. These effects can make THD results appear worse than they actually are. www.irf.com AN-1173 19 VAC VDCmax VDCmin P.F. T.H.D.i Vout Pout (W) 90 1 0 0.998 6.4% 440 83.5 100 1.2 0 0.998 5.5% 440 82.7 110 1.4 0 0.998 4.9% 440 82.1 120 1.6 0 0.999 4.4% 440 81.9 140 1.8 0 0.998 4.0% 440 80.9 160 2.0 0 0.998 4.4% 440 80.6 180 2.2 0 0.997 5.4% 440 80.6 200 2.4 0 0.995 6.8% 440 80.6 220 2.6 0 0.993 8.3% 440 80.6 240 2.8 0 0.99 9.8% 440 80.4 260 3 0 0.986 11.3% 440 80.4 Table 1: 80W Example PF and THD Results www.irf.com AN-1173 20 10. Replacing Alternative Controllers Competitor Part Number Manufacturer IR Direct Cross L6561(A) L6562(A) MC33262 UCC28810 UCC28811 FAN7527B STM STM On Semi TI TI Fairchild IRS2500 IRS2500 IR Close Cross IR Cross Possible IRS2500 IRS2500 IRS2500 IRS2500 Competitor Package SO8/DIP8 SO8/DIP8 SO8/DIP8 SO8/DIP8 SO8/DIP8 SO8/DIP8 IR Package SO8 SO8 SO8 SO8 SO8 SO8 Table 2: Alternative controllers The IRS2500 can be used as a direct drop in replacement for the controllers listed in table 2 indicated as a direct cross. In the case of controllers listed as close cross some minor modifications to the application circuit will be necessary in order to replace the existing controller with the IRS2500. Some controllers such as the MC33262 use a trans-conductance error amplifier where the compensation capacitor is connected from the output to 0V instead of back to the input as in the standard integrating configuration. When replacing this part with the IRS2500 the compensation capacitor must be disconnected from 0V and connected to pin 1. IR WORLD HEADQUARTERS: 101 N. SepulvedaBlvd., El Segundo, California 90245 Tel: (310) 252-7105 Data and specifications subject to change without notice. 8/17/2011 www.irf.com AN-1173 21 IRS2500S Table of Contents Page Description 3 Qualification Information 5 Absolute Maximum Ratings 6 Recommended Operating Conditions 6 Electrical Characteristics 7 Functional Block Diagram 9 Input/Output Pin Equivalent Circuit Diagram 10 Lead Definitions 11 Lead Assignments 11 Application Information and Additional Details 12 Package Details 19 Tape and Reel Details 20 Part Marking Information 21 Ordering Information 22 www.irf.com © 2012 International Rectifier 2 IRS2500S Description The IRS2500 is a fully integrated, fully protected PFC SMPS control IC designed to drive Boost or Flyback switching regulators providing high power factor. Typical applications are PFC pre-regulators for SMPS and electronic ballasts for fluorescent or HID lighting as well as single stage Flyback converters widely used in low power LED drivers. The IRS2500 is pin compatible with most industry standard critical conduction or transition mode PFC control IC with additional improvements to increase performance. The PFC circuitry provides high PF, low THD and stable DC bus regulation over a wide line/load range. The IRS2500 protection features include cycle by cycle over-current protection and output over voltage protection. www.irf.com © 2012 International Rectifier 3 IRS2500S Typical Application Diagram DBUS DIN RPU RSH RS DVCC IC2 VREG T1 OUT+ +5V CVCC RIN RV1 RZX CIN RFB1 INV 1 COMP CCOMP AC Line Input CVREG IC1 VDC OC 2 3 4 8 IRS2500 BR1 7 6 5 VCC CVOUT OUT RD1 COM ZX RPFC RPD IC3A RFB2 RD2 RVFB CVFB MPFC CF RDC OUTRV2 RF RII IC3B ROC RI CF RD3 RIFB www.irf.com CIFB © 2012 International Rectifier 4 IRS2500S † Qualification Information Qualification Level Moisture Sensitivity Level Machine Model ESD IC Latch-Up Test RoHS Compliant Human Body Model Industrial†† Comments: This family of ICs has passed JEDEC’s Industrial qualification. IR’s Consumer qualification level is granted by extension of the higher Industrial level. MSL2††† 260°C (per IPC/JEDEC J-STD-020) Class B (per JEDEC standard JESD22-A115) Class 2 (per EIA/JEDEC standard EIA/JESD22-A114) Class I, Level A (per JESD78) Yes † †† Qualification standards can be found at International Rectifier’s web site http://www.irf.com/ Higher qualification ratings may be available should the user have such requirements. Please contact your International Rectifier sales representative for further information. ††† Higher MSL ratings may be available for the specific package types listed here. Please contact your International Rectifier sales representative for further information. www.irf.com © 2012 International Rectifier 5 IRS2500S Absolute Maximum Ratings Absolute maximum ratings indicate sustained limits beyond which damage to the device may occur. All voltage parameters are absolute voltages referenced to COM, all currents are defined positive into any lead. The thermal resistance and power dissipation ratings are measured under board mounted and still air conditions. Symbol VCC Definition Supply Voltage † Min. Max. -0.3 VCLAMP Unit s VOUT Gate Driver Output Voltage -0.3 VCC + 0.3 V IOMAX Maximum allowable output current (OUT) due to external power transistor miller effect -500 500 mA 0 25 mA -0.3 VCC + 0.3 ICC VCOMP VOC VVBUS VCC current COMP Pin Voltage OC Pin Voltage VBUS Pin Voltage VDC VDC Pin Voltage VZX ZX Pin Voltage ICOMP V -0.3 7.0 -5 5 mA COMP Pin Current IZX ZX Pin Current IOC OC Pin Current PD Package Power Dissipation @ TA ≤ +25ºC --- 0.625 W Thermal Resistance, Junction to Ambient --- 128 ºC/W TJ Junction Temperature -55 150 TS Storage Temperature -55 150 TL Lead Temperature (soldering, 10 seconds) --- 300 Min. VCCUV+ Max. VCLAMP 0 10 -1 1 -25 125 RθJA ºC Recommended Operating Conditions For proper operation the device should be used within recommended conditions. Definition Symbol †: † VCC Supply Voltage ICC VCC Supply Current IOC OC Pin Current IZX ZX Pin Current TJ Junction Temperature Units V mA ºC This IC contains a zener clamp structure between the chip VCC and COM which has a nominal breakdown voltage of 20V. This supply pin should not be driven by a DC, low impedance power source greater than the VCLAMP specified in the Electrical Characteristics section. www.irf.com © 2012 International Rectifier 6 IRS2500S Electrical Characteristics VCC = 14 V +/- 0.25 V, COUT=1000 pF, CVCC=0.1 μF, TA=25 °C unless otherwise specified. Symbol Supply Characteristics Definition Min Typ Max 11.5 12.5 13.5 9.5 10.5 11.5 1.5 2.0 3.0 Units Test Conditions VUVHYS VCC Supply Undervoltage Positive Going Threshold VCC Supply Undervoltage Negative Going Threshold VCC Supply Undervoltage Lockout Hysteresis IQCCUV UVLO Mode VCC Quiescent Current --- 30 --- uA VCC Supply Current --- 2.3 5.0 mA VCC Zener Clamp Voltage --- 20.0 --- V --- 10 --- --- -23 --- --- 6.0 --- --- 0.25 --- --- 0 --- Input bias current --- --- -1 uA VBUS=0 to 3V Gv Voltage gain 60 80 --- dB Open loop GB Bandwidth --- 1 --- MHz 2.46 2.5 2.54 VCCUV+ VCCUV- ICC VCLAMP VCC = 8V VBUS=2.5V PFC off time = 5us ICC = 10mA Error Amplifier Characteristics ICOMP SOURCE ICOMP SINK COMP Pin Error Amplifier Output Current Sourcing COMP Pin Error Amplifier Output Current Sinking Error Amplifier Output Voltage Swing (high VCOMPOH state) Error Amplifier Output Voltage Swing (low VCOMPOL state) VCOMPFL Error Amplifier Output Voltage in Fault T Mode IVBUS mA V VVBUS = 2.4V VCOMP=4.0V VVBUS = 2.6V VCOMP=4.0V VBUS=2.0V ICOMP=-0.5mA VBUS=3.0V ICOMP=+0.5mA VBUS=3.0V Control Characteristics VVBUS VBUS Internal Reference Voltage VZX+ ZX Pin Threshold Voltage (Arm) --- 1.6 --- VZX- ZX Pin Threshold Voltage (Trigger) --- 0.7 --- VZXclamp ZX pin Clamp Voltage (high state) --- 5.2 --- VDCclamp VDC pin Clamp Voltage --- 5.2 --- tBLANK VCOMP = 4.0V V IZX = 1mA IDC = 1mA OC pin current-sensing blank time --- 320 --- ns PFC Watch-dog Pulse Interval --- 400 --- us tONMIN PFC Minimum ON time --- 0.3 --- us tONMAX PFC Maximum ON Time 10 50 --- us tWD www.irf.com VBUS=2.5V VCOMP=4.0V ZX = 0,VCOMP = 4.0V ZX = 0,VCOMP = 0.25V ZX = 0,VCOMP = 6.0V, VDC = 2V © 2012 International Rectifier 7 IRS2500S Electrical Characteristics (cont’d) VCC = 14V +/- 0.25V, COUT = 1000pF, VCOMP = VOC = VBUS = VZX = 0V, TA=25C unless otherwise specified. Protection Circuitry Characteristics VOCTH VVBUSOV VVBUSOV HYS ICOMPOV+ ICOMPOV- OC Pin Over-current Sense Threshold VBUS Over-voltage Comparator Threshold VBUS Over-voltage Comparator Hysteresis Dynamic Over-voltage detection threshold 0.93 1.1 1.22 V 2.7 50 100 150 30 Dynamic Over-voltage detection reset mV Guaranteed by design Guaranteed by design uA 8 Gate Driver Output Characteristics VOL Low-Level Output Voltage --- 0 100 mV IO = 0 VOH High-Level Output Voltage --- 0 11 V IO = 0 tr Turn-On Rise Time --- 60 110 tf Turn-Off Fall Time --- 30 70 I0+ Source Current --- 500 --- I0- Sink Current --- 500 --- www.irf.com ns mA © 2012 International Rectifier 8 IRS2500S Functional Block Diagram VCC OC 4 VOCTH COM 6 8 Blank Time UVLO VBUS 1 VCLAMP OVP VVBUS VCC VVBUSOV 7 COMP 2 VDC ON TIME MODULATOR 3 S Q R Q VDCCLAMP S Q OUT Watchdog Timer R1 R2 Q ZX 5 VZXCLAMP VZX www.irf.com © 2012 International Rectifier 9 IRS2500S Input/Output Pin Equivalent Circuit Diagrams www.irf.com © 2012 International Rectifier 10 IRS2500S Lead Definitions Symbol VBUS COMP VDC OC ZX COM OUT VCC Description DC Bus Sensing Input PFC Error Amplifier Compensation Full Wave Voltage Input PFC Current Sensing Input PFC Zero-Crossing Detection IC Power & Signal Ground Gate Drive Output Logic & Low-Side Gate Driver Supply VBUS COMP VDC OC 1 2 3 4 IRS2500 Lead Assignments www.irf.com 8 7 6 5 VCC OUT COM ZX © 2012 International Rectifier 11 IRS2500S When the switch MPFC is turned on, the inductor LPFC is connected between the rectified line input (+) and (-) causing the current in LPFC to increase linearly. When MPFC is turned off, LPFC is connected between the rectified line input (+) and the DC bus capacitor CBUS through diode DPFC. The stored energy in LPFC is transferred to the output, supplying a current into CBUS. MPFC is turned on and off at a high frequency and the voltage on CBUS charges up to a specified voltage. The voltage feedback loop of the IRS2500 regulates the output to the desired voltage by continuously monitoring the DC output and adjusting the on-time of MPFC accordingly. If the output voltage is too high, the on-time is decreased and if it is too low, the on-time is increased. This negative feedback control loop operates with a slow loop speed and a low loop gain such that the average inductor current smoothly follows the lowfrequency line input voltage to obtain high power factor and low THD. The loop speed is intentionally slow with respect to the AC line frequency so that there is no appreciable change in the on time during a single line half cycle. This allows the current to follow shape of the sinusoidal voltage. Application Information and Additional Details Power factor correction is required in many electrical appliances in order to minimize reactive current losses in AC power transmission lines. The degree to which an electronic circuit matches an ideal purely resistive load is measured by the phase shift (displacement) between the input voltage and input current and the amount of current waveform distortion. In other words how well the shape of the input current waveform matches the shape of the sinusoidal input voltage. The power factor (PF) is defined as the ratio between real power and apparent power with the maximum value of 1.0 representing a totally resistive load where the current waveform shape matches the voltage waveform shape exactly. The distortion of the input current waveform is quantified by the total harmonic distortion (THD), which is the sum of all harmonic content of the waveform expressed as a percentage. An ideal power factor of 1.0 corresponds to zero phase shift and a THD of 0% representing a purely sinusoidal input current waveform in phase with the line voltage. The lower the power factor the more current is needed to supply the same power to the load, which results is higher conduction losses in transmission lines. For this reason it is desirable to have a high PF and a low THD. To achieve this, the IRS2500 implements an active power factor correction (PFC) circuit. The control method implemented in the IRS2500 may be used in a Boost converter (Figure 8) or a low power single stage Flyback converter for small power supplies or LED drivers. The IRS2500 operates in critical-conduction mode (CrCM), also known as transition mode. This means that during each switching cycle of the PFC MOSFET, the circuit waits until the inductor current discharges to zero before turning the PFC MOSFET on again. The PFC MOSFET is turned on and off at a much higher frequency (>10KHz) than the line input frequency (50 to 60Hz). LPFC (+) DPFC V, I t Figure 9: Sinusoidal line input voltage (solid line), triangular PFC Inductor current and smoothed sinusoidal line input current (dashed line) over one half-cycle of the AC line input voltage. Corrections to the output voltage therefore require several line cycles. With a fixed on-time, and an offtime determined by the inductor current discharging to zero, the result is a system where the switching frequency is free-running and constantly changing from a high frequency near the zero crossing of the AC input line voltage, to a lower frequency at the peaks (Figure 9). When the line input voltage is low (near the zero crossing), the inductor current will increase only a small amount and the discharge time will be short resulting in a high switching frequency. When the input line voltage is high (near the peak), the inductor current will charge up to a much higher DC Bus + MPFC CBUS (-) Figure 8: Boost converter circuit. www.irf.com © 2012 International Rectifier 12 IRS2500S level and the discharge time will be longer giving a lower switching frequency. The PFC control circuit of the IRS2500 (Figure 10) includes six control pins: VBUS, COMP, ZX, OUT, VDC and OC. The VBUS pin measures the DC bus voltage through an external resistor voltage divider. The COMP pin voltage determines the ontime of MPFC and sets the feedback loop response speed with an external RC integrator. The ZX pin detects when the inductor current discharges to zero each switching cycle using a secondary winding from the PFC inductor. The OUT pin is the low-side gate driver output for the external MOSFET, MPFC. The VDC pin senses the line input cycle providing phase information to control the on time modulation described in the next section. The OC pin senses the current flowing through MPFC and performs cycle-by-cycle overcurrent protection. VBUS 1 VCC 2.75 5.1V RZX CBUS MPFC OC COM ROC RVBUS RDC (-) Figure 10: RS4 2.0V The off-time of MPFC is determined by the time it takes the LPFC current to discharge to zero. The zero current level is detected by a secondary winding on LPFC that is connected to the ZX pin through an external current limiting resistor RZX. A positive-going edge exceeding the internal threshold VZX+ signals the beginning of the offtime. A negative-going edge on the ZX pin falling below VZX- will occur when the LPFC current discharges to zero, which signals the end of the offtime and MPFC is turned on again (Figure 12). The ZX pin is internally biased to ensure that the voltage detected from the inductor drops fully to zero before triggering the next PWM cycle. A wide hysteresis prevents false triggering by ringing oscillations. The cycle repeats itself indefinitely until the IRS2500 is disabled through an over-voltage condition on the DC bus or if the negative transition of ZX pin voltage does not occur. Should the negative edge on the ZX pin not occur, MPFC will remain off until the watch-dog timer forces a turn-on of MPFC for an on-time duration programmed by the voltage on the COMP pin. The watch-dog pulses occur every 300-400us (tWD) indefinitely until a correct positive and negative-going signal is detected at the ZX pin and normal operation is resumed. Should the OC pin voltage exceed the VOCTH over-current threshold during the on-time the gate drive output will turn off. The circuit will then wait for a negative-going transition on the ZX pin or a forced turn-on from the watch-dog timer to turn the output on again. ZX COMP OC 1.2V Figure 11: IRS2500 detailed PFC control circuit. RVBUS2 RPFC 4 WATCH DOG TIMER M2 COMP3 ZX 5 RIN OUT OUT R Q S Q R1 R2 Q RVBUS1 PFC Control 7 Q On Time Modulator C1 DFPC VDC S M1 VDC 3 LPFC CCOMP RS3 COMP5 COMP 2 (+) VBUS COMP4 2.5V IRS2500 simplified PFC control circuit. The VBUS pin is compared with a fixed internal 2.5V reference voltage for regulating the DC output voltage (Figure 11). The feedback loop error amplifier increases or decreases the COMP pin voltage. The resulting voltage on the COMP pin sets the threshold for the charging of the internal timing capacitor (C1, Figure 11) and therefore determines the on-time of MPFC. The error amplifier operates at a slow loop speed preventing rapid changes in PWM duty cycle during a single input line cycle. This prevents distortion achieving high power factor and low THD. www.irf.com © 2012 International Rectifier 13 IRS2500S ILPFC ILPFC ... OUT 0 ... OUT pin 0 ZX near peak region of rectified AC line ... VOCTH OC near zero-crossing region of rectified AC line Figure 13: On-time modulation circuit timing diagram. ... Output Over-voltage Protection The IRS2500 incorporates both static and dynamic overvoltage protection. Static over voltage protection monitors the feedback voltage at the VBUS pin and disables the gate drive output if this voltage exceeds the target voltage by 8%. This is activated by an internal comparator set to detect a threshold of 2.7V, which is 8% above the regulation threshold of 2.5V. However, under startup condition or when a load is removed from the output the error amplifier output voltage at the COMP pin swings low. Since the compensation capacitor CCOMP is connected from this output back to the VBUS input a current will flow during the COMP voltage transition. This pulls down the VBUS voltage, which allows the output voltage to exceed the desired regulation level during the transition and results in an overshoot before the voltage at the VBUS input exceeds the regulation threshold. In order to compensate for this effect, the IRS2500 includes dynamic detection of the error amplifier output current. During a swing in the negative direction the error amplifier output current peaks at a much high level than the level during steady state operation. This higher current is internally detected and triggers the overvoltage protection circuitry disabling the PWM output until the error amplifier output has settled to a new level. This prevents the output voltage from overshooting the desired level by a significant amount under the transient conditions described. For this reason the loop should be designed such that voltage ripple at COMP is minimized during steady state operation. Figure 12: Inductor current, OUT pin, ZX pin and OC pin timing diagram. On-time Modulation Circuit A fixed on-time of MPFC over an entire cycle of the line input voltage produces a peak inductor current which naturally follows the sinusoidal shape of the line input voltage. The smoothed, averaged line input current is in phase with the line input voltage for high power factor but a high total harmonic distortion (THD), as well as individual higher harmonics, of the current are still possible. This is mostly due to cross-over distortion of the line current near the zero-crossings of the line input voltage. To achieve low harmonics that are acceptable for compliance with international standards and general market requirements, an additional on-time modulation circuit has been added to the PFC control. This circuit dynamically increases the on-time of MPFC as the line input voltage nears the zero-crossings (Figure 13). This causes the peak LPFC current, and therefore the smoothed line input current, to increase near the zero-crossings of the line input voltage. This reduces the amount of cross-over distortion in the line input current which reduces the THD and higher harmonics. The on time modulation function is controlled via the VDC input. The full wave rectified voltage from the bridge rectifier is divided down by RIN and RDC to provide an input with a peak voltage of approximately 1V at 90VAC input and 3V at 277VAC. CDC is added to remove noise from the signal, the value is typically 10nF. The on time modulation function is not required in some applications. In such cases the VDC input should be tied to VCC through a 10K resistor. www.irf.com © 2012 International Rectifier 14 IRS2500S PCB Layout Guidelines For correct operation of the IRS2500, the PCB should be designed to avoid noise coupling to the control inputs and ground loops. By following the recommendations listed here potential issues will be avoided: 1. The circuit signal and power grounds should be joined together at one point only. The signal ground should be a star point located close to the COM pin of the IRS2500. 2. The point at which the signal ground is connected to the power ground is recommended to be at the current sense resistor (ROC) ground. 3. A 0.1μF noise decoupling capacitor should be located between the VCC and COM pins of the IRS2500 located as close to the IC as possible. Figure 14: Layout Example 4. All traces to the VBUS input should be as short as possible. This means that resistors and capacitors that are connected to this input should be located as close to the IRS2500 as possible. The voltage feedback divider resistor connected to COM should be connected to a signal ground close to the COM pin. Figure 14 shows a layout where the IRS2500 is located on the bottom side of the PCB. The bottom side traces are shown in red and the top side traces in pale blue. The circuit power ground can be seen at the C2 GND node with the signal ground star point is located at the junction between RPFC6 and CPFC4 to the left of the IRS2500 (IC1). (Note that the component designators in this example are different from those used in the datasheet schematics) The traces from IC1 pin 6, RPFC3 and CPFC1 (the VDC divider low side) all run directly to the star point without crossing any other grounds. The signal ground is connected to the power ground at the current sense resistor. A large trace can be seen running from the star point off the left to where the MOSFET is situated (not shown). This is the single point where the signal and power grounds are connected. The VCC supply decoupling capacitor shown in this example is CPFC4, which is located very close to the IRS2500 and grounded directly to the signal ground star point. Traces leading to pin 1 (VBUS) are all short and components connected to pin 1 (RPFC5, RPFC6 and RPFC7) are all located close to IC1. There are no traces connected to high voltage switching nodes located anywhere close to pin 1. The board layout shown in figure 14 complies with all of the guidelines stated enabling optimum operation of the IRS2500. 5. Traces carrying high voltage switching signals such as those connected to the MOSFET drain or gate drive signals should not be located close to traces connected directly to the VBUS input. 6. The divider network resistor (RDC) and filter capacitor (CDC) connected to the VDC input of the IRS2500 should be located as closely to the IC as possible with the grounded end connected to the circuit signal ground. 7. The compensation capacitor CCOMP should be located close to the IRS2500 with short traces leading to the VBUS and COMP pins. 8. The over current detection filter resistor (ROC) and capacitor (COC) should be located as close to the IRS2500 as possible with COC connected to the circuit signal ground. 9. The zero crossing detection resistor should be located close to the IRS2500 if possible to prevent possible noise appearing at this input. www.irf.com © 2012 International Rectifier 15 IRS2500S PFC Design Equations (for Boost Converter) Step1: Calculate PFC inductor value: LPFC = 2 (VBUS − 2 ⋅ VACMIN ) ⋅VAC MIN ⋅η 2 ⋅ f MIN ⋅ POUT ⋅VBUS [Henries] (1) where, VBUS VAC MIN η f MIN POUT = = = = = DC bus voltage Minimum rms AC input voltage PFC efficiency (typically 0.95) Minimum PFC switching frequency at minimum AC input voltage Ballast output power Step 2: Calculate peak PFC inductor current: i PK = 2 ⋅ 2 ⋅ POUT VAC MIN ⋅η [Amps Peak] (2) Note: The PFC inductor must not saturate at i PK over the specified ballast operating temperature range. Proper core sizing and air-gapping should be considered in the inductor design. Step 3: Calculate PFC over-current resistor ROC value: ROC = VOCTH i PK [Ohms] where VOCTH = 1.1V (3) Step 4: Calculate start-up resistor RVCC value: RVCC = VAC MIN + 10 PK [Ohms] IQCCUV www.irf.com (4) © 2012 International Rectifier 16 IRS2500S 14 2.5 VCCUV+ 12 2 VCCUV‐ ICC ( mA) VCCUV (+/‐) 10 8 6 4 1.5 1 0.5 2 0 0 ‐25 ‐25 0 25 50 75 100 0 25 50 75 100 125 125 TEMP C TEMP C Graph 2: ICC vs. Temperature Graph 1: VCCUV+ vs. Temperature 22 120 21.8 21.6 100 VCLAMP (V) IQCCUV (uA) 21.4 80 60 40 21.2 21 20.8 20.6 20.4 20 20.2 0 20 ‐25 0 25 50 75 100 125 ‐25 0 25 50 75 100 125 TEMP C TEMP C Graph 4: VCLAMP vs. Temperature Graph 3: IQCCUV vs. Temperature www.irf.com © 2012 International Rectifier 17 IRS2500S 500 450 WATCH DOG INTERVAL (us) 3 2.9 2.8 VBUS (V) 2.7 2.6 2.5 2.4 2.3 2.2 2.1 400 350 300 250 200 150 100 50 2 0 ‐25 0 25 50 75 100 125 ‐25 0 25 50 75 100 125 TEMP C TEMP C Graph 6: Watch dog interval vs. Temperature Graph 5: VBUS reference vs. Temperature 50 49 PFC Ton max (US) 48 47 46 45 44 43 42 41 40 ‐25 0 25 50 75 100 125 TEMP C Graph 7: PFC Ton max (us) Package Details www.irf.com © 2012 International Rectifier 18 IRS2500S www.irf.com © 2012 International Rectifier 19 IRS2500S Tape and Reel Details LOADED TAPE FEED DIRECTION A B H D F C NOTE : CONTROLLING DIM ENSION IN M M E G CARRIER TAPE DIMENSION FOR Metric Code Min Max A 7.90 8.10 B 3.90 4.10 C 11.70 12.30 D 5.45 5.55 E 6.30 6.50 F 5.10 5.30 G 1.50 n/a H 1.50 1.60 8SOICN Imperial Min Max 0.311 0.318 0.153 0.161 0.46 0.484 0.214 0.218 0.248 0.255 0.200 0.208 0.059 n/a 0.059 0.062 F D C B A E G H REEL DIMENSIONS FOR 8SOICN Metric Code Min Max A 329.60 330.25 B 20.95 21.45 C 12.80 13.20 D 1.95 2.45 E 98.00 102.00 F n/a 18.40 G 14.50 17.10 H 12.40 14.40 www.irf.com Imperial Min Max 12.976 13.001 0.824 0.844 0.503 0.519 0.767 0.096 3.858 4.015 n/a 0.724 0.570 0.673 0.488 0.566 © 2012 International Rectifier 20 IRS2500S Part Marking Information www.irf.com © 2012 International Rectifier 21 IRS2500S Ordering Information Standard Pack Base Part Number Package Type Complete Part Number Form IRS2500 SOIC8 Quantity Tube/Bulk 95 IRS2500SPBF Tape and Reel 2500 IRS2500STRPBF The information provided in this document is believed to be accurate and reliable. However, International Rectifier assumes no responsibility for the consequences of the use of this information. International Rectifier assumes no responsibility for any infringement of patents or of other rights of third parties which may result from the use of this information. No license is granted by implication or otherwise under any patent or patent rights of International Rectifier. The specifications mentioned in this document are subject to change without notice. This document supersedes and replaces all information previously supplied. For technical support, please contact IR’s Technical Assistance Center http://www.irf.com/technical-info/ WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 www.irf.com © 2012 International Rectifier 22