Application Note, V1.1, October 2009 EVALPFC2-ICE2PCS02 300W PFC Evaluation Board with CCM PFC controller ICE2PCS02 Power Management & Supply N e v e r s t o p t h i n k i n g . Edition 2009-10-13 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. EVALPFC2-ICE2PCS02 Revision History: 2009-10 Previous Version: Page 8&9 V1.0 Subjects (major changes since last revision) Cx1 size changed 15 Typo errors 300W PFC Evaluation Board with CCM PFC controller ICE2PCS02 License to Infineon Technologies Asia Pacific Pte Ltd Liu Jianwei 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] V1.1 AN-PS0011 Page Table of Content ...................................................................................5 1 Content 2 Evaluation Board 3 Technical Specifications ..............................................................6 4 Circuit Description 5 Circuit Operation........................................................................6 6 Circuit Diagram 7 PCB Layout Top Layer .................................................................9 8 PCB layout Bottom Layer ...........................................................10 9 Component List .......................................................................11 10 Boost Choke Layout 11 Test report 11.1 11.2 11.3 Load test (table and figure) ..............................................................................12 Harmonic test according to EN61000-3-2 Class D requirement ...................14 Test Waveforms .................................................................................................15 12 References: ............................................................................16 Application Note .......................................................................5 .....................................................................6 .........................................................................8 .................................................................12 .............................................................................12 4 2009-10-13 1 Content The evaluation board presented here is a 300W power factor correction (PFC) circuit with 85~265VAC universal input and 393VDC fixed output. The continuous conduction mode (CCM) PFC controller ICE2PCS02 is employed in this board to achieve the unity power factor. This ICE2PCS02 is a design variant of ICE2PCS01 to incorporate the new input brown-out protection function. Appreciated for its high integrated design, ICE2PCS02 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 ICE2PCS02. 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 2009-10-13 3 4 Technical Specifications Input voltage 85VAC~265VAC Input frequency 50Hz Output voltage and current 393VDC, 0.75A Output power ~ 300W Efficiency >92% at full load Switching Frequency 65kHz Circuit Description 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 Y1capacitor CY1 and CY2 are used as radio interference suppressors. RT1 is placed in series to limit inrush current during each power on. Power Stage − Boost Type PFC Converter After the bridge rectifier BR1, there is a boost type PFC converter consisting of L3, Q1, D1 and C2. The third generation CoolMOS™ SPP20N60C3 is used as the power switch Q1. BR1, Q1 and SiC Diode D1 share the same heat sink so that the system heat can be equably spread. Output capacitor C2 provides energy buffering to reduce the output voltage ripple (100Hz) to the acceptable level. PWM Control of Boost Converter The PWM control is realized by 8-Pin CCM PFC IC ICE2PCS02. It is a variant design of ICE2PCS01 with preserving most of the features. Unlike the conventional PFC controller, ICE2PCS02 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 R5A, R5B, R6A and R6B 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. 5 Circuit Operation Soft Startup Application Note 6 2009-10-13 When Vcc pin is higher than turn-on threshold, typical 11V, 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. The boost diode is not stressed with large diode duty cycle under high current. 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. Protection Features a. Input brown-out protection The dedicated input voltage brown-out VINS pin is the most distinct new feature brought by ICE2PCS02. 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. b. Open loop protection The open loop protection is available for this IC to safe-guard the output. Whenever VSENSE voltage falls below 0.6V, or equivalently VOUT falls below 20% of its rated value, it indicates an open loop condition (i.e. VSENSE pin not connected). In this case, most of the blocks within the IC will be shutdown. It is implemented using a comparator with a threshold of 0.6V. c. Output over-voltage protection Whenever VOUT exceeds the rated value by 8%, the over-voltage protection OVP is active. This is implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 3.25V. A VSENSE voltage higher than 3.25V will immediately block the gate signal. d. Soft over current control (SOC) and peak current limit When the amplitude of current sense voltage reaches 0.68V, 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 -1.04V. The gate output is immediately off after 300ns blanking time. e. IC supply under voltage lockout When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11, 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 7 2009-10-13 6 Circuit Diagram 1 2 4 3 D D D2 1N5408 R1 120ohm L 85~265VAC VAR1 S10K275 N RT1 F1 5A S237/5 L2 L1 40uH L3 D1 1.24mH SDP04S60 390V/300W Vo Q1 CX1 SPP20N60C3 CX2 2*3.9mH CY1 2.2nF, Y2, 250V Earth R3 10k R2 0.33/1W CY2 2.2nF, Y2, 250V C2 C1 0.1u/630V 0.47u/275V 0.47u/275V C BR1 8A, 400V 1N4007 C R5 R2B 0.22/1W 390k, 1% R9 R4 220 3.3 R5A 390k, 1% 3 R10 3.9M, 1% Gnd R2A 0.22/1W D3 IC? I-Sense R11 3.9M,1% 7 B 2 Vcc 8 Gate ICE2PCS02 Icomp Brown Out GND Vsense 6 Vcomp 5 B R7 47u/25V GND C8 0.1u C7 4.7nF R8 120k 33k 1 C9 4 Vcc C6 220nF C5 C4 0.1uF C3 0.1uF R6 R6B 10k, 1% 15k,1% 1uF A A 1 Application Note 2 8 3 4 2009-10-13 7 PCB Layout Top Layer Application Note 9 2009-10-13 8 PCB layout Bottom Layer Application Note 10 2009-10-13 9 Component List Designator Part Type Description Manufacturer / Part No. BR1 C1 C2 C3* C4 C5 C6 C7 C8 C9 CX1 CX2 CY1 CY2 8A, 400V 0.1uF/630V 220uF/450V 0.1uF/50V 0.1uF/50V 1uF/50V 220nF/50V 4.7nF/50V 0.1uF/50V 47uF/25V 0.47uF, X1, 305V 0.47uF, X1, 305V 2.2nF, Y2, 250V 2.2nF, Y2, 250V Vishay / KBU8G Epcos / B32652A6104J Epcos / B43304C5227M D1 D2 D3 F1 SDT04S60 1N5408 1N4007 5A Bridge Rectifier Ceramic Cap Electrolytic Cap Ceramic Cap 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 IC1 JP1 JP2 JP3 JP4 L1* L2 L3 Q1 ICE2PCS02 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 R5A R5B R6A R6B R7 R8 Not Connected 0.33/1W, 5% 0.22/1W, 5% 0.22/1W, 5% 10k/0.25W, 5% 3.3/0.25W, 5% 390k/0.25W, 1% 390k/0.25W, 1% 10k/0.25W, 1% 15k/0.25W, 1% 33k/0.25W, 5% 120k/0.25W, 1% Application Note Murata / RPER71H104K2K1A03B Murata / RPER71H104K2K1A03B Murata / RPER71H224K2K1C03B Murata / RPER71H104K2K1A03B Epcos / B32922C3474M Epcos / B32922C3474M Epcos / B81123C1222M000 Epcos / B81123C1222M000 Vishay / 1N5408 Vishay / 1N4007 Infineon Jumper Jumper Jumper Jumper CM Choke Choke Power MOSFET Heat Sink TO220 Clip TO247 Clip TO220 Isolation Pad 3mm Screw Epcos / B82725J2602N20 Infineon 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 Carbon Film Resistor Carbon Film Resistor 11 2009-10-13 R9 R10 R11 RT1 VAR1 10 220/0.25W, 5% 3.9M/0.25W, 1% 3.9M/0.25W, 1% S237/5 S10K275 Carbon Film Resistor Carbon Film Resistor Carbon Film Resistor NTC Thermistor Varistor Epcos / B57237S509M Epcos / B72210S271K101 Boost Choke Layout Core: CS468125 toriod Turns: 83 Wire: 1 x Φ1.0mm, AWG19 Inductance: L=1.24mH 11 Test report 11.1 Load test (table and figure) Vin(VAC) Pin 85VAC 110VAC 230VAC Application Note Iin 319 253 208 167 124 84 42 31 22 14.2 6.2 310 250 205 165 122 84 42 30 22 14.3 6.2 300 244 202 161 122 84 42 30.2 Vout 3.81 3.02 2.49 2 1.5 1.03 0.52 0.38 0.28 0.19 0.1 2.85 2.28 1.88 1.51 1.13 0.77 0.4 0.3 0.22 0.15 0.076 1.33 1.1 0.89 0.72 0.55 0.38 0.21 0.16 391 391 391 392 392 393 393 394 394 394 395 392 392 392 392 393 393 393 394 395 395 395 393 394 394 394 394 394 395 395 Iout 0.75 0.6 0.5 0.4 0.3 0.2 0.1 0.072 0.053 0.0337 0.014 0.75 0.6 0.5 0.4 0.3 0.2 0.1 0.072 0.053 0.0337 0.014 0.75 0.6 0.5 0.4 0.3 0.2 0.1 0.072 12 Pout 293.25 234.6 195.5 156.8 117.6 78.6 39.3 28.368 20.882 13.2778 5.53 294 235.2 196 156.8 117.9 78.6 39.3 28.368 20.935 13.3115 5.53 294.75 236.4 197 157.6 118.2 78.8 39.5 28.44 Efficiency 92% 93% 94% 94% 95% 94% 94% 92% 95% 94% 89% 95% 94% 96% 95% 97% 94% 94% 95% 95% 93% 89% 98% 97% 98% 98% 97% 94% 94% 94% PF 1 1 1 1 1 0.99 0.98 0.96 0.93 0.9 0.82 1 1 1 0.99 0.99 0.98 0.95 0.92 0.89 0.86 0.74 0.99 0.99 0.98 0.98 0.96 0.93 0.84 0.78 2009-10-13 22 13.8 6.2 300 243 202 161 121 82 41 29 22 13.7 6.2 265VAC 0.13 0.1 0.09 1.16 0.99 0.781 0.63 0.48 0.34 0.19 0.18 0.15 0.12 0.1 395 395 396 394 395 395 396 396 397 397 396 396 396 396 0.053 0.0337 0.014 0.75 0.6 0.5 0.4 0.3 0.2 0.1 0.072 0.053 0.0337 0.014 20.935 13.3115 5.544 295.5 237 197.5 158.4 118.8 79.4 39.7 28.512 20.988 13.3452 5.544 95% 96% 89% 99% 98% 98% 98% 98% 97% 97% 98% 95% 97% 89% 0.7 0.58 0.3 0.99 0.99 0.98 0.97 0.96 0.92 0.82 0.74 0.5 0.35 0.21 98.0% Efficiency 96.0% 300W Load 200W Load 150W Load 80W Load 94.0% 92.0% 90.0% 88.0% 85 110.00 220.00 265.00 Input Voltage (V) 1 0.9 0.8 0.7 85VAC PF 0.6 110VAC 0.5 230VAC 0.4 265VAC 0.3 0.2 0.1 0 0 Application Note 100 200 13 Pout (W) 300 400 2009-10-13 11.2 Harmonic test according to EN61000-3-2 Class D requirement 85VAC, full load (300W output) Iin 85VAC, 9.3% of full load (28W output) Iin 265VAC, full load (300W output) Iin Application Note 14 2009-10-13 265VAC, 9.3% of full load (28W output) Iin 11.3 Test Waveforms Startup test at 85VAC, open load Vout IACin Vcc Vcomp Load jump test at 85VAC, Iout from 0A to 0.75A Load jump test at 85VAC, Iout from 0.75A to 0A Vout Vout Iout Vsense Vsense Iout Vgate Vgate Application Note 15 2009-10-13 Enter brown-out at Iout=0.1A, 62VAC Leave brown-out at Iout=0.1A, 76VAC Vout Vout Iin Iin Vins Vins Vgate Vgate Open Loop protection at 265V, Iout=0.1A Vout Iin Vsense Vgate 12 References: Application Note 16 2009-10-13