Application Note, V1.0, June 2005 ICE1PCS02 300W PFC Evaluation Board with CCM PFC controller ICE1PCS02 Power Management & Supply N e v e r s t o p t h i n k i n g . Edition 2005-06-17 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. ICE1PCS02 Revision History: Previous Version: Page 2005-06 none Subjects (major changes since last revision) 300W PFC Evaluation Board with CCM PFC controller ICE1PCS02 License to Infineon Technologies Asia Pacific Pte Ltd Wang Qing Luo Junyang Jeoh Meng Kiat 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 ANP0055 ICE1PCS02 Table of Contents Page 1 Content ...............................................................................................................5 2 Evaluation Board ...............................................................................................5 3 List of Features ..................................................................................................6 4 Technical Specifications ...................................................................................6 5 Circuit Description.............................................................................................6 5.1 Line Input .......................................................................................................................................6 5.2 Power Stage − Boost Type PFC Converter.................................................................................6 5.3 PWM Control of Boost Converter ................................................................................................7 6 Circuit Operation ...............................................................................................7 6.1 Soft Startup....................................................................................................................................7 6.2 Enhanced Dynamic Response.....................................................................................................7 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 Protection Features ......................................................................................................................7 Input brown-out protection ..............................................................................................................7 Open loop protection.......................................................................................................................8 Output over-voltage protection........................................................................................................8 Soft over current control (SOC) and peak current limit...................................................................8 IC supply under voltage lockout......................................................................................................8 7 Circuit Diagram ..................................................................................................9 8 PCB Layout Top Layer ....................................................................................10 9 PCB layout Bottom Layer................................................................................11 10 Component List ...............................................................................................12 11 Boost Choke Layout ........................................................................................13 12 Test report ........................................................................................................14 12.1 Load test (table and figure) ........................................................................................................14 12.2 12.2.1 12.2.2 12.2.3 12.2.4 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 12.3.6 12.3.7 12.3.8 12.3.9 Harmonic test according to EN61000-3-2 Class D requirement.............................................17 85VAC, full load (300W output).....................................................................................................17 85VAC, 9.3% of full load (28W output) .........................................................................................17 265VAC, full load (300W output) ..................................................................................................18 265VAC, 9.3% of full load (28W output) .......................................................................................18 Test Waveforms ..........................................................................................................................19 Startup test at 85VAC, full load (300W) ........................................................................................19 Startup test at 85VAC, open load .................................................................................................19 Load jump test at 85VAC, Iout from 0A to 0.75A ..........................................................................19 Load jump test at 85VAC, Iout from 0.75A to 0A ..........................................................................20 Voltage jump test at full load, from 85V to 265V...........................................................................20 Voltage jump test at full load, from 265V to 85V...........................................................................20 Enter brown-out at Iout=0.3A, 68VAC...........................................................................................21 Leave brown-out at Iout=0.3A, 80VAC .........................................................................................21 Open Loop protection at 265V, Iout=0.1A ....................................................................................21 13 References: ......................................................................................................22 Application Note 4 2005-06-17 ICE1PCS02 1 Content The evaluation board presented here is a 300W power factor correction (PFC) circuit with 85~265VAC universal input and 390VDC fixed output. The continuous conduction mode (CCM) PFC controller ICE1PCS02 is employed in this board to achieve the unity power factor. This ICE1PCS02 is a design variant of ICE1PCS01 to incorporate the new input brown-out protection function and optimized to have a faster startup time with controlled peak startup current. Appreciated for its high integrated design, ICE1PCS02 can achieve full requirements of the PFC application implemented in the 8-pin DIP8 and SO8 packages. At the same time the number of peripheral components is minimized. The operation frequency is fixed at 65kHz due to internal oscillator of ICE1PCS02. In order to improve the power conversion efficiency, the CoolMOSTM C3 series and high voltage silicon carbide (SiC) schottky diode thinQ!TM are used into this boost type PFC circuit. 2 Evaluation Board Application Note 5 2005-06-17 ICE1PCS02 3 List of Features Ease of use with few external components Supports wide input range Average current control External current and voltage loop compensationfor greater user flexibility Trimmed internal fixed switching frequency (65kHz±7.7% at 25 ) Direct sensing, input brown-out detection with hysteresis Short startup (soft start) duration Max duty cycle of 97% (typ) Trimmed internal reference voltage (5V±2%) VCC under voltage lockout Cycle by cycle peak current limiting Over voltage protection Open loop detection Soft over current protection Enhanced dynamic response Fulfills Class D requirements of IEC 1000-3-2 4 Technical Specifications Input voltage 85VAC~265VAC Input frequency 50Hz Output voltage and current 390VDC, 0.76A Output power 300W Efficiency >90% at full load Switching Frequency 65kHz 5 Circuit Description 5.1 Line Input The AC line input side comprises the input fuse F1 as over-current protection. The high frequency current ripple is filtered by R1, L1 and CX1. The choke L2, X2-capacitors CX1 and CX2 and Y1-capacitor CY1 and CY2 are used as radio interference suppressors. RT1 is placed in series to limit inrush current during each power on. 5.2 Power Stage − Boost Type PFC Converter After the bridge rectifier BR1, there is a boost type PFC converter consisting of L3, Q1, D1 and C2. The third generation CoolMOS™ SPP20N60C3 is used as the power switch Q1. BR1, Q1 and SiC Diode D1 Application Note 6 2005-06-17 ICE1PCS02 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. 5.3 PWM Control of Boost Converter The PWM control is realized by 8-Pin CCM PFC IC ICE1PCS02. It is a variant design of ICE1PCS01 with preserving most of the features. Unlike the conventional PFC controller, ICE1PCS02 does not need direct sine wave reference signal. The switching frequency is fixed at 65kHz by the IC internal oscillator. There are two control loops in the circuit, voltage loop and current loop. The output voltage is sensed by the voltage divider of R5, R5A, R5B and R6 and sent to internal error amplifier. The output of error amplifier is used to control current in the inner current loop. The compensation network C4, C5, R7 constitutes the external circuitry of the error amplifier. This circuitry allows the feedback to be matched to various load conditions, thereby providing stable control. In order not to make the response for 100Hz ripple, the voltage loop compensation is implemented with low bandwidth. The inner loop, current control loop, is implemented with average current mode strategy. The instant current is adjusted to be proportional to both of MOSFET off duty DOFF and the error amplifier output voltage of voltage loop. The current is sensed by shunt resistors R2, R2A and R2B and fed into IC through R9. The current sense signal is averaged by an internal operating amplifier and then processed in the PWM generator which drives the gate drive. The averaging is realized by charging and discharging an external capacitor C7 at pin ICOMP. The IC supply is provided by external voltage source and filtered and buffered by C8 and C9. The IC output gate driver is a fast totem pole gate drive. It has a built-in cross conduction current protection and a Zener diode to protect the external transistor switch against undesirable over voltages. The gate drive resistor R4 is selected to limit and gate pulse current and drive MOSFET for fast switching. 6 Circuit Operation 6.1 Soft Startup When Vcc pin is higher than turn-on threshold, typical 11.2V, PFC is going to start. The unique soft start is integrated. Input current keeps sinusoidal and is increasing gradually until output voltage reaches 80% of rating. Because the peak current limit is not activated, the boost diode is not stressed with large diode duty cycle under high current. 6.2 Enhanced Dynamic Response Due to inherent low bandwidth of PFC dynamic, in case of load jump, regulation circuit can not response fast enough and it will lead to large output voltage overshoot or drop. To solve this problem in PFC application, enhanced dynamic response is implemented in the IC. Whenever output voltage exceeds by ±5%, it will bypass the slow compensation operating amplifier and act on the nonlinear gain block to affect the duty cycle directly. The output voltage can be recovered in a short time. 6.3 Protection Features 6.3.1 Input brown-out protection The dedicated input voltage brown-out VINS pin is the most distinct new feature brought by ICE1PCS02. This VINS pin senses a filtered input voltage divider and detects for the input voltage brown-out condition. If the detected VINS is below 0.8V, then IC output will be shut down. Only when VINS voltage reaches 1.5V can awake the IC again. Be informed that it will still have the soft start property when the IC is recovered from brown-out situation. Application Note 7 2005-06-17 ICE1PCS02 6.3.2 Open loop protection The open loop protection is available for this IC to safe-guard the output. Whenever VSENSE voltage falls below 0.8V, or equivalently VOUT falls below 16% 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 0.8V. 6.3.3 Output over-voltage protection Output over-voltage protection is also available by the same integrated blocks of enhanced dynamic response. Whenever VOUT exceeds the rated value by 5%, the over-voltage protection OVP is active. This is implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 5.25V. A VSENSE voltage higher than 5.25V will immediately reduce the output duty cycle even down to zero, bypassing the normal voltage loop control. This results in a lower input power and the output voltage VOUT is reduced. 6.3.4 Soft over current control (SOC) and peak current limit When the amplitude of current sense voltage reaches 0.73V, Soft Over Current Control (SOC) is activated. This is a soft control does not directly switch off the gate drive but acts on the internal blocks to result in a reduced PWM duty cycle. The IC also provides a cycle by cycle peak current limitation (PCL). It is active when the voltage at current sense voltage reaches -1.08V. The gate output is immediately off after 300ns blanking time. 6.3.5 IC supply under voltage lockout When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 10.2V, IC is off the gate drive is internally pull low to maintain the off state. The current consumption is down to 200uA only. Application Note 8 2005-06-17 9 N 85~265VAC L VAR1 S10K275 F1 5A GND Vcc 2*3.9mH L2 C8 0.1u C9 47u/25V CY1 2.2nF, Y2, 250V Earth 0.47u/275V L1* CX1 R1* 1nF C7 D3 R8 220nF C6 GND ICE1PCS02 IC1 Vcomp Vsense C5 1uF 5 6 8 R7 33k C4 0.1uF 3.3 I-Sense R4 R2B 0.22/1W 220 Gate R2A 0.22/1W C1 0.1u/630V R2 0.33/1W R3 10k Q1 SPP20N60C3 L3 1.24mH R9 BR1 8A, 400V Brown Out Icomp Vcc 1N4007 120k, 1% 2 7 3.9M, 1% R11 3.9M, 1% R10 CY2 2.2nF, Y2, 250V 0.47u/275V CX2 RT1 S237/5 4 Application Note 3 C2 C3* * Optional Components 220u/450V D1 SDT04S60 10k, 1% R6 R5B 200k, 1% 270k, 1% R5A R5 300k, 1% Gnd 390V/300W Vo 7 1 D2 1N5408 ICE1PCS02 Circuit Diagram 2005-06-17 ICE1PCS02 8 PCB Layout Top Layer Application Note 10 2005-06-17 ICE1PCS02 9 PCB layout Bottom Layer Application Note 11 2005-06-17 ICE1PCS02 10 Component List Designator Part Type Description BR1 C1 C2 C3* C4 C5 C6 C7 C8 C9 CX1 CX2 CY1 CY2 8A, 400V 0.1uF/630V 220uF/450V Not Connected 0.1uF/50V 1uF/50V 220nF/50V 1nF/50V 0.1uF/50V 47uF/25V 0.47uF, X1, 275V 0.47uF, X1, 275V 2.2nF, Y2, 250V 2.2nF, Y2, 250V Bridge Rectifier Ceramic Cap Electrolytic Cap D1 D2 D3 F1 SDT04S60 1N5408 1N4007 5A IC1 JP1 JP2 JP3 JP4 L1* L2 L3 Q1 ICE1PCS02 12.5mm, Ф0.7mm 20mm, Ф0.7mm 12mm, Ф1.2mm 17.5mm, Ф0.7mm Shorted 2*3.9mH 1.24mH SPP20N60C3 R1* R2 R2A R2B R3 R4 R5 R5A R5B R6 Not Connected 0.33/1W, 5% 0.22/1W, 5% 0.22/1W, 5% 10k/0.25W, 5% 3.3/0.25W, 5% 300k/0.25W, 1% 270k/0.25W, 1% 200k/0.25W, 1% 10k/0.25W, 1% Application Note Ceramic Cap Ceramic Cap Ceramic Cap Ceramic Cap Ceramic Cap Electrolytic Cap Ceramic Cap Ceramic Cap Ceramic Cap Ceramic Cap Connector Diode Diode Diode Fuse Fuse Holder Jumper Jumper Jumper Jumper CM Choke Choke Power MOSFET Heat Sink TO220 Clip TO247 Clip TO220 Isolation Pad 3mm Screw Metal Film Resistor Metal Film Resistor Metal Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor 12 Quantity 1 1 1 0 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 1 1 1 1 1 0 1 1 1 1 2 1 2 3 0 1 1 1 1 1 1 1 1 1 2005-06-17 ICE1PCS02 R7 R8 R9 R10 R11 RT1 VAR1 11 33k/0.25W, 5% 120k/0.25W, 1% 220/0.25W, 5% 3.9M/0.25W, 1% 3.9M/0.25W, 1% S237/5 S10K275 Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor NTC Thermistor Varistor 1 1 1 1 1 1 1 Boost Choke Layout Core: CS468125 toriod Turns: 83 Wire: 1 x Φ1.0mm, AWG19 Inductance: L=1.24mH Application Note 13 2005-06-17 ICE1PCS02 12 Test report 12.1 Load test (table and figure) Vin (VAC) Iin (A) Pin (W) Vo (V) Io (A) Po (W) PF 85 3.866 3.043 2.517 2.000 1.495 0.996 0.506 0.267 0.151 0.083 0.062 327.9 258.1 213.4 169.7 126.9 84.4 42.7 22.4 12.5 6.4 4.5 397.1 397.1 397.1 397.1 397.0 397.0 397.0 397.0 397.1 397.1 397.0 0.754 0.600 0.501 0.399 0.300 0.199 0.100 0.052 0.029 0.014 0.006 299.4 238.3 198.9 158.4 119.1 79.0 39.7 20.6 11.5 5.6 2.4 0.998 0.998 0.998 0.998 0.998 0.998 0.994 0.987 0.966 0.911 0.851 Efficiency (%) 91.3% 92.3% 93.2% 93.4% 93.9% 93.6% 93.0% 92.2% 92.1% 86.9% 52.9% 110 2.906 2.302 1.913 1.526 1.145 0.767 0.389 0.210 0.122 0.071 0.058 318.9 252.5 209.9 167.5 125.5 84.0 42.4 22.4 12.5 6.4 4.6 396.9 397.0 397.0 397.0 397.0 397.0 397.1 397.1 397.1 397.0 397.0 0.755 0.600 0.501 0.400 0.300 0.200 0.100 0.053 0.029 0.014 0.006 299.7 238.2 198.9 158.8 119.1 79.4 39.7 21.0 11.5 5.6 2.4 0.997 0.998 0.998 0.998 0.997 0.995 0.991 0.972 0.935 0.820 0.720 94.0% 94.3% 94.8% 94.8% 94.9% 94.5% 93.7% 94.0% 92.1% 86.8% 51.8% 230 1.360 1.085 0.905 0.726 0.551 0.376 0.205 0.130 0.099 0.085 0.082 309.9 247.1 206.2 165.4 124.7 83.8 42.8 23.3 13.4 7.3 5.3 397.0 397.0 397.1 397.1 397.1 397.1 397.1 397.0 397.0 397.0 397.0 0.755 0.600 0.501 0.399 0.300 0.200 0.100 0.052 0.029 0.014 0.006 299.7 238.2 198.9 158.4 119.1 79.4 39.7 20.6 11.5 5.6 2.4 0.991 0.990 0.990 0.990 0.984 0.969 0.910 0.780 0.585 0.373 0.274 96.7% 96.4% 96.5% 95.8% 95.5% 94.8% 92.8% 88.6% 85.9% 76.1% 44.9% Application Note 14 2005-06-17 ICE1PCS02 Vin (VAC) Iin (A) Pin (W) Vo (V) Io (A) Po (W) PF 265 1.180 0.942 0.787 0.635 0.482 0.333 0.190 0.129 0.106 0.095 0.093 309.2 246.7 206.0 165.3 124.6 84.0 43.5 23.8 13.8 7.7 5.7 397.0 397.0 397.1 397.0 397.0 397.0 397.0 396.9 396.9 396.9 396.9 0.755 0.601 0.501 0.400 0.300 0.199 0.100 0.053 0.029 0.014 0.005 299.7 238.6 198.9 158.8 119.1 79.0 39.7 21.0 11.5 5.6 2.0 0.989 0.989 0.988 0.983 0.975 0.951 0.865 0.693 0.495 0.309 0.231 Application Note 15 Efficiency (%) 96.9% 96.7% 96.6% 96.1% 95.6% 94.1% 91.3% 88.4% 83.4% 72.2% 34.8% 2005-06-17 ICE1PCS02 98.0% Efficiency 96.0% 94.0% Full Load Half Load 92.0% 90.0% 88.0% 85 110 230 265 Input Voltage (V) 1 0.9 Power Factor 0.8 0.7 85V 110V 230V 265V 0.6 0.5 0.4 0.3 0.2 0.1 0 2.4 11.5 39.7 119.1 198.9 299.4 Output Power (W) Application Note 16 2005-06-17 ICE1PCS02 12.2 Harmonic test according to EN61000-3-2 Class D requirement 12.2.1 85VAC, full load (300W output) IACin 12.2.2 85VAC, 9.3% of full load (28W output) IACin Application Note 17 2005-06-17 ICE1PCS02 12.2.3 265VAC, full load (300W output) IACin 12.2.4 265VAC, 9.3% of full load (28W output) IACin Application Note 18 2005-06-17 ICE1PCS02 12.3 Test Waveforms 12.3.1 Startup test at 85VAC, full load (300W) IACin Vout Vcc 12.3.2 Vcomp Startup test at 85VAC, open load IACin Vout Vcc 12.3.3 Vcomp Load jump test at 85VAC, Iout from 0A to 0.75A Vout Vsense Iout Vgate Application Note 19 2005-06-17 ICE1PCS02 12.3.4 Load jump test at 85VAC, Iout from 0.75A to 0A Vout Vsense Iout Vgate 12.3.5 Voltage jump test at full load, from 85V to 265V VACin Vout IACin VIsense 12.3.6 Voltage jump test at full load, from 265V to 85V VACin Vout IACin VIsense Application Note 20 2005-06-17 ICE1PCS02 12.3.7 Enter brown-out at Iout=0.3A, 68VAC AC line voltage change IACin VACin Vbrown_out Vgate 12.3.8 Leave brown-out at Iout=0.3A, 80VAC AC line voltage change IACin VACin Vbrown_out Vgate 12.3.9 Open Loop protection at 265V, Iout=0.1A Vout IACin Vsense Vgate Application Note 21 2005-06-17 ICE1PCS02 13 References: [1] ICE1PCS02 Datasheet V1.1, Infineon Technologies, Munich, Germany, Dec. 2004 [2] Luo Junyang, Jeoh Meng Kiat, ICE1PCS02 Based Boost Type CCM PFC Design Guide, Application Note, Infineon Technologies, Singapore, Oct. 2004 [3] Junyang Luo, Meng Kiat Jeoh and Ming Lik Yew, 300W CCM PFC Evaluation Board with ICE1PCS01, CoolMOSTM and SiC Diode thinQ!TM, Infineon Technologies, Singapore Application Note 22 2005-06-17