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AN_201408_PL11_027
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
About this document
Scope and purpose
The 2.5 kW evaluation board is a great example of a full Infineon solution, and includes a PFC Controller,
MOSFET Driver and Silicon Carbide (SiC) Diode in order to evaluate the 4pin functionality with its advantages for efficiency and signal quality.
Furthermore, the reader will be presented with additional information on how to use the evaluation board, how the 600 V CoolMOS™ C7 behaves in this PFC application and the benefits that will be achieved by using the
TO-247 4pin package.
Intended audience
This document is intended for qualified engineers and technicians who are experienced in power electronics technology and want to improve their PFC applications by using 4pin devices.
Table of contents
Application Note www.infineon.com
Please read the Important Notice and Warnings at the end of this document
Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Table of contents
Application Note 2 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Introduction
General safety instruction
Attention: The evaluation board contains high voltages that could be deadly for the users. Furthermore no circuits on the board are isolated from the line input. Due to the high power density, the components on the board and/or the heatsink can reach a very high temperature that can cause a burning risk when touched directly. Users should be qualified engineers and technicians who are experienced in power electronics technology and make sure that no danger or risk may occur while operating this board.
Note:
Note:
Note:
Note:
Note:
After the operation of the evaluation board, the DC-Link capacitors C21 and C24 may still store a high energy for several minutes, which is indicated by the illumination of LED1. The Capacitors C21 and
C24 must be discharged until the LED1 is not lit before touching the board directly.
The board is designed for a maximum input current of 14 A. To operate it at a mains input of 90 V
AC
, the output power must be correspondingly reduced so that the maximum current limit is not exceeded.
The normal output power of the board is designed for up to 2.5 kW so that the device temperature remains below 80°C. Users can operate the board to a peak output power of 3000 W. However, it is not recommended to operate at this output power level for longer than 2 minutes. In this case, the device temperature of the MOSFET (DUT1) and/or diode (DUT1) can exceed 100°C which presents a risk of burning!
The EMC filter on the board is designed to cover a wide range of applications according to the standard CISPR 22. Nevertheless, the EMC performance of the board is very dependent on the application settings and load conditions. Users may modify the EMC filter using methods like wire shielding to make their own applications comply with the standard. To fulfill other standards required by different applications, users may need to apply extra or different components.
The evaluation board is designed to meet any certification requirements. Infineon Technologies will not guarantee any compliance with local certificate requirements or recommendations. The usage of the evaluation board is strictly at your own risk.
To get started
Step 1: Complete connections “V in
”, “V out
”, “KL01”, “J11”& “J11a”
− V out
: Connect with an output load which is able to operate at 400 V
DC
− V in
: Connect L, N and Earth to the 90 V
AC
…265 V
AC
main power supply
− KL01 : Optional DC-Power that is used to power-up the cooling fans externally see: Thermal concept
Step 2: Switch on the main power supply and check V out
for the presence of 400 V
DC
Step 3: For more instructions please refer to the following guidelines.
Application Note 3 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Introduction
1 Introduction
1.1 Evaluation board
This document describes the evaluation board EVAL_2.5KW_CCM_4PIN, which is designed to evaluate the performance of the TO-247 4pin CoolMOS™ C7 family. The board is developed for laboratory use only and does not serve any commercial purpose. Before operating the evaluation board, please read the general safety instruction section.
The aim of this document is to help the customers to get familiar with the evaluation board, and to investigate the different behavior of conventional 3pin devices compared to the high performance TO-247 4pin CoolMOS™ devices within a PFC application.
The following table gives the main technical specifications of the evaluation board:
Table 1
Power switch
Technical specifications of the 2.5 kW CCM PFC evaluation board
Input voltage
Input current
Input frequency
Output voltage and current
Output power
Average efficiency
Switching frequency
85 V
AC
14 A eff
~265 V
47~63 Hz
400 V
DC
AC
, 6.25 A
~ 2.5 kW (at V in
=230 V
AC
)
>95% at 115 V
AC
Possible range: 40 kHz~250 kHz;
Board frequency is set to 65 kHz;
Changeable by R20
4pin and 3pin MOSFET
1.2 CoolMOS
TM
C7
CoolMOS
TM
C7 ( IPZ60R040C7 ) achieves extremely low conduction and switching losses per package. The extremely low switching losses enable the designer to operate with higher switching frequencies in order to shrink the magnetic components and increase the power density.
E oss
reduction brings efficiency benefits at light load, the low Q
G
correlates to faster switching and also lower E on and E off
which gives efficiency benefits across the whole load range.
The CoolMOS TM C7 balances several parameters to give best-in-class performance improves the implementation and ease of use behavior when compared to other fast switching MOSFET families. Moreover, with its broad product portfolio, C7 can address the specific needs of hard switching applications for server, PC power, telecom rectifiers and solar. C7 offers the best-in-class performance on the market today with the lowest R
DS(on)
per package.
1.3 thinQ!
TM
SiC Diode Generation 5
The thinQ!
TM
Generation 5 Silicon Carbide Diode ( IDH16G65C5 ) represents Infineon’s leading edge technology for SiC Schottky Barrier Diodes. The Infineon proprietary diffusion soldering process, already introduced with generation 3, is now combined with a new, more compact design and thin wafer technology. The result is a new
Application Note 4 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Introduction family of products showing improved efficiency over all load conditions, resulting from both the improved thermal characteristics and a lower figure of merit (Q c
*V f
). It also offers improved dv/dt robustness up to
100 V/ns which enables very fast switching. This is a perfect fit to the fast switching CoolMOS
TM
C7 family.
1.4 CCM-PFC Controller
The evaluation board presented here is a 2.5 kW power factor correction (PFC) circuit with 85~265 V
AC
universal input and an output of 400 V
DC
. The continuous conduction mode (CCM) PFC Controller ( employed in this board to achieve a unity power factor.
ICE3PCS01G) is
The ( ICE3PCS01G) is specially designed for applications of power supplies used in PC, server, and telecom, requiring high efficiency and an excellent power factor. The voltage loop compensation is integrated digitally for better dynamic response and lower design effort. Recognized for its highly integrated design,( ICE3PCS01G) can achieve the full requirements of the PFC application implemented in the 14pin in DSO14 package while minimizing the number of peripheral components. The gate switching frequency is adjustable from 21 kHz to
250 kHz and is able to synchronize with an external switching frequency from 50 kHz to 150 kHz.
1.5 Gate Driver ICs (EiceDRIVER
TM
Compact)
The Infineon EiceDRIVER
TM
family (IEDI60N12AF) offers a wide range of CT (Coreless Transformer) based Gate
Drivers that support all topologies using CoolMOS
TM
in 3 and 4pin packages. CT utilizes on-chip coupled inductors realized in the existing metal layers to transmit the gate drive signals from the input to the output stage with isolation of more than 1200 V provided by a thick inter-metal oxide. This approach offers high speed and very good common-mode transient immunity, which is crucial to drive the MOSFET with fast voltage transients.
With the use of IEDI60N12AF on this evaluation board, the benefits of Infineon’s TO-247 4pin package demonstrates very fast switching behavior alongside clean gate waveforms. Based on the CT technique, the
Kelvin source can be completely isolated from the power source and higher efficiency and better system stability can be achieved.
The 6 A capability of the driver output is necessary to switch the 19 mΩ CoolMOS
TM
very quickly. Even if the board is used with higher ohmic devices, it is an advantage to have a very strong drive capability in order to minimize gate oscillation at fast switching.
The output of the driver features separate positive and negative outputs for easy tuning. The turn-on and turnoff behavior of the MOSFET can be changed by using different gate resistors. This is connected to the different outputs without any diode for separating the turn-on and turn-off phases.
In the evaluation board the two output pins are joined together. When creating a parallel design for 3 and 4pin devices two different changeable gate resistors are created. In order to keep the complexity low, the design did not take the opportunity to separate turn-on and turn-off gate resistors as this is not highly relevant for efficiency analysis.
This driver is the only currently known driver that has a CMTI (common mode transient immunity) of dv/dt ≥
100 V/ns which is required for high transition noise feedback from the drain to the gate signal in a fast switching mode.
Application Note 5 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Application
2 Application
The evaluation board described within this document is based on a CCM PFC (continuous conduction mode power factor correction). The principal schematic is shown below.
Figure 1 Schematic of the topology
Figure 2 EVAL_2.5kW_CCM_4PIN evaluation board
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2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit description
3 Circuit description
3.1 Line input
The AC line input side does not include any input fuse. Please ensure proper external over-current protection.
The input is fitted with 2 connectors in order to offer proper input voltage measurement for precise power metering. The choke L3, X2-capacitor C4/C5/C23 and Y1-capacitors C17/CY18 are used to suppress common and differential mode noise. R_NTC2 is placed in series to limit inrush current during each power on. A relay is mounted across the R_NTC2 to short the resistor when V
OUT
is higher than ~60 V.
3.2 Power stage
boost type PFC converter
After the bridge rectifier GL1 and GL2, there is a boost type PFC converter consisting of L1, IPZ60R040C7,
IDH16S65C5, C30, C8, C21 and C24. The seventh generation CoolMOS
TM
IPZ60R040C7 and the SiC Diode
IDH16S65C5 share the same heat sink so that the system heat can be equally spread. Output capacitor C30, C8,
C21 and C24 provides energy buffering to reduce the output voltage ripple (100 Hz at 50 Hz AC input) to an acceptable level and to meet the hold-up time requirement.
3.2.1 Separate source Power MOSFET
Infineon’s TO-247 4pin package enables significant efficiency improvements in hard switching topologies for
CoolMOS
TM
high voltage Power MOSFETs. The fourth pin acting as a Kelvin source can be used to reduce the parasitic inductance of the source lead of the Power MOSFET.
The benefit will be seen in various hard switching topologies such as Continuous Conduction Mode Power
Factor Correction (CCM PFC), Boost and Two Transistor Forward (TTF). The new package offers improved efficiency by reducing switching losses up to 8% which equates to 3.5 W of saved power in a CCM Mode PFC running at 1.2 kW, which is equal to 0.3% extra full load efficiency compared to the same MOSFET in the standard TO-247 3pin package.
The evaluation board is available to test the physically identical devices in either 3pin or 4pin (with sense source) configuration. The standard setting of the set-up is 4pin configuration. To change the testing device to
3pin configuration, it is necessary to open the connection point J7 and connect the solder point J8 or J6. Please
check chapter 9 on page 18 for more detailed information.
3.3 PWM control of boost converter
The ICE3PCS01G is a 14pin control IC for power factor correction converters and is suitable for wide range line input applications from 85 to 265 V
AC
with overall efficiency above 97%. The IC supports converters in boost topology and it operates in continuous conduction mode (CCM) with average current control.
The IC operates with a cascaded control; the inner current loop and the outer voltage loop. The inner current loop of the IC controls the sinusoidal profile for the average input current. It uses the dependency of the PWM duty cycle on the line input voltage to determine the corresponding input current. This means the average input current follows the input voltage as long as the device operates in CCM. Under light load condition, depending on the choke inductance, the system may enter into discontinuous conduction mode (DCM) by enlarging the harmonics, but still meeting the Class D requirement of IEC 1000-3-2.
The outer voltage loop controls the output bulk voltage, integrated digitally within the IC. Depending on the load condition, internal PI compensation output is converted to an appropriate DC voltage that controls the amplitude of the average input current.
Application Note 7 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit description
The IC is equipped with various protection features to ensure safe operating condition for both the system and the device.
3.4 Thermal concept
The evaluation board is fitted with different thermal management for the two different heat sinks mounted on the board. The thermal concept for the input bridge rectifier is managed by an adjustable-speed cooling fan.
The fan speed is adjustable to optimize between noise generation and cooling by changing resistor R28 near the fan for the bridge rectifier.
The main heat sink for the DUT offers cooling and heating functionality in parallel. To heat up the heat sink to target temperature (standard setting = 50°C), it is necessary to:
Set Jumper “J11a” to “Extern”
Set Jumper “J11” to “Extern”
Supply a galvanically isolated 12 V to connector KL01 between GND and +12 V with current limit of 1 A
Supply 17 V to connector KL01 between GND and heating with current limit of 3.5 A
Set R4 according to the temperature, which is intended for the devices
The control circuit will then heat up the heat sink to the adjusted temperature that is set by the variable resistor
R4. Once the temperature is reached it will start the fan to cool the system. Thus, it is possible to operate the application with regulated heat sink temperature for the MOSFET and the diode.
3.4.1 Operate without thermal control feature
If one wants to operate the evaluation board without any external heating it is recommended to use the internal cooling option through the following setting:
Change the wire connected to “J11a” to the bottom layer and insert 3pin connector for jumper into the PCB.
Set Jumper “J11a” to “Intern”
Set Jumper “J11” to “Intern”
Figure 3 Wire change from top layer to bottom layer
Application Note 8 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit description
Figure 4 Setting for internal cooling powering
With this setting the board will permanently cool the input bridge rectifier and keep the temperature of the diode and the MOSFET below the temperature setting by the changeable resistor R4.
If the board has been modified as described above and one wants to investigate the efficiency without the thermal power losses, please set the Jumper “J11” and “J11a” to the “Extern” position.
Application Note 9 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit operation
4 Circuit operation
4.1 Soft startup
During power up when the V
OUT
is less than 96% of the rated voltage, the internal voltage loop output of the IC increases from initial voltage under soft-start control. This results in a controlled linear increase of the input current from 0 A, thus reducing the current stress in the power components.
Once V
OUT
has reached 96% of the rated level, the soft-start control is released to achieve good regulation and dynamic response and the VB_OK pin delivers 5 V indicating the PFC output voltage is in the normal range.
4.2 Gate switching frequency
The switching frequency of the PFC converter can be set with an external resistor R
FREQ
at pin FREQ with reference to pin SGND. The voltage at pin FREQ is typically 1 V. The corresponding capacitor for the oscillator is integrated into the device and the R
FREQ
/frequency is given in Figure 3. The recommended operating frequency range is from 21 kHz to 250 kHz. As an example, a R
FREQ
of 43 kΩ at pin FREQ will typically set a switching frequency f
SW
of 100 kHz.
Frequency vs Resistance
260
240
220
200
180
160
80
60
40
20
140
120
100
Resistance
/kohm
15
17
20
30
40
50
60
70
80
90
100
Frequency
/kHz
278
249
211
141
106
86
74
62
55
49
43
Resistance
/kohm
110
120
130
140
150
169
191
200
210
221
232
Frequency
/kHz
40
36
34
31.5
29.5
26.2
25
23
21.2
20.2
19.2
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Resistance/kohm
Figure 5 Frequency setting
The switching frequency can be changed by the variable resistor R31. For easy adjustment please use the X8 connection pins to measure the value. Please make sure to connect the positive cable of the measurement tool to the left (towards the side of the fan) pin of X8. To use the table and plot in Figure 5 you have to subtract 10 kΩ from the serial resistance R15. If the polarity of the measurement tool is flipped compared to the way described above, please subtract 23 kΩ due to additional internal resistance from the controller itself. Please make sure the board is not connected to the main supply when connecting the measuring instrument to X8!
Application Note 10 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit operation
Therefore, the measureable resistance on X8 for the standard setting of 65 kHz will be 56 kΩ with positive polarity on the left pin and 43 kΩ with positive polarity on right pin.
4.3 Protection features
4.3.1 Open loop protection (OLP)
Open-loop protection is available for this IC to safeguard the output. Whenever voltage V
SENSE
falls below 0.5 V, or V
OUT
falls below 20% of its rated value, it indicates an open loop condition (i.e. V
SENSE
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 0.5 V.
4.3.2 First over-voltage protection (OVP1)
Whenever V
OUT
exceeds the rated value by 8%, the first over-voltage protection OVP1 is active. This is implemented by sensing the voltage at pin V
SENSE
with respect to a reference voltage of 2.7 V. A V
SENSE
voltage higher than 2.7 V will immediately block the gate signal. After the bulk voltage falls below the rated value, the gate drive resumes switching again.
4.3.3 Peak current limit
The IC provides a cycle-by-cycle peak current limitation (PCL) that is active when the voltage at pin I
SENSE reaches -0.2 V. This voltage is amplified by a factor of -5 and connected to the comparator with a reference voltage of 1.0 V. A 200 ns deglitcher after the comparator improves noise immunity to the activation of this protection. In other words, the current sense resistor should be designed for lower than -0.2 V PCL in normal operation.
4.3.4 IC supply under voltage lockout
When the voltage V
CC
is below the under voltage lockout threshold V
CCUVLO
(typically 11 V) the IC will turn off the gate for safety reasons. The current consumption reduces to 1.4 mA.
4.3.5 Bulk voltage monitor and enable function (VBTHL_EN)
The IC monitors the bulk voltage status through the V
SENSE
pin and outputs a TTL signal to enable the PWM IC or control the inrush relay. During soft-start, once the bulk voltage is higher than 95% rated value, pin VB_OK outputs a high level. The threshold to trigger the low level is determined by the pin VBTHL where the voltage is adjustable externally.
When pin VBTHL is pulled down externally to lower than 0.5 V, most function blocks are turned off and the IC enters into a standby mode for low power consumption. When the disable signal is released the IC recovers by soft-start.
Application Note 11 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Circuit diagram
5 Circuit diagram
Figure 6 Whole evaluation board schematic
Application Note 12 Revision 1.2
2015-11-02
6
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
PCB layout
PCB layout
Figure 7 PCB top layer view
Figure 8
Application Note
PCB bottom layer view
13 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Component list
7 Component list
C21, C24
C22, C23
C26
C27
C28
C29
D1
D2, D3
D4
D6
D10
DUT1
D_Z3
EMI_1
GL1, GL2
IC1
IC2
IC3
IC4
Application Note
Table 2
Designator
Component list
B1, B2
Bias1
C1
C2
C3
C4, C5
C6
C7
C8, C30
C10, C31
C11
C12, C25, C32
C13
C14, C15
C16
C17, C18, C19, C20
Value closed with 0 Ω
1 nF
10 µF
100 nF
100 nF
1 µF
100 µF
2.2 nF
12 V Bias
10 µF
4n7 F
10 nF
1 µF
4.7 nF
10 nF
100 nF / 500 V
560 µF
1 µF / 400 V
220 nF
10 µF
470 pF
22 nF
SS26
1N4148
1N5408
Short
ES1C
IPZ60R040C7
ZMM15
Not placed
GSIB2580
TDA2030
LM4040
ICE3PCS01G
1EDI60N12AF
14
Description
Placeholder for ferrite bead, 0Ω resistor
Bias adapter
25 V
25 V
25 V x-capacitor
25 V
25 V
VJ1825Y104KXEAT
25 V
25 V
25 V
25 V
25 V
25 V
Y-capacitor
EETHC2G561KA or
EKMR421VSN561MR50S
BFC237351105; Farnell 1215540
25 V
25 V
25 V
25 V
0 Ω
1 A 150 V fast diode
1N4734A
EMI adapter
GSIB2580
Mount with M2.5x6
LM4040D20IDBZRG4
PFC CCM controller
6 A isolated MOS driver
Revision 1.2
2015-11-02
J8, J10
J9
K1
L1
L2
L3
L4
K2
KL1
KL01
KL01-S
LED1
LED2, LED3, LED4, LED5
M1, M2
M1, M2
PWM-Signal
R1, R3, R13, R20, R56
R2, R8, R15, R44
R4
R5
R6
R7, R11
R9, R16
R10, R25
R12, R42
R14, R19
R17
Application Note
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Component list
Designator
IC5
J1, J11
J2
J3
J6
J7, J12
Value
IFX91041
Jumper_3pin
Current measurement bridge
Drilling
Open
Close with solder or 0 Ω resistance
Open
Close with solder or 0 Ω resistance
SK426
680 Ω
220 Ω
10 Ω
20 Ω
47 Ω
330 kΩ
2 MΩ
27 kΩ
KM75-1
BNC
Heating
Complement
L_PFC
10 A 100 µH
8120-RC
33 µH
Red
Blue
Fan 60 mm
Finger guard for Fan 60 mm
SMA
1 kΩ
10 kΩ
5 kΩ
15
Description
1.8 A step down switching regulator
SPC20486
1.25 mm isolated copper wire
U-shape-Cu-wire 1.25 mm 2 cm distance
Solder jumper; 4pin as 3pin
Solder jumper; driver ground to
SS, Solder jumper; isolated driver power
Solder jumper; 3pin ground,
Solder jumper; driver power none isolated
Solder jumper; isolated driver power
100 mm long; mound with
2xM4x15
KM75-1 +4clip 4597; Fischer
Oscilloscope_function_generator
MSTBA 2,5/ 3-G
MSTB 2,5/3-ST
2times 77083A7 64wind_1.15mm
Würth 744824101
BOURNS_8120-RC_2m4H_17A
74454133
Power on LED
Power on LED
PMD1206PTB1-A
LZ28CP
Oscilloscope_Function_generator
5%
5%
67WR20KLF
5%
5%
5%
3314G-1-200E
5%
5%
5%
5%
Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Component list
V out
V out_sense
X1
X2
X3
X4
X5
X6
X7
X8, X9
X12
Designator
R18
R21
R29
R30
R31
R35
R22, R23
R24
R27
R28
R36
R37
R45
REL1
REL2
R_NTC1
R_NTC2
S1, S2, S3, S4, S5, S6
S1, S2, S3, S4, S5, S6
S1, S2, S3, S4, S5, S6
V in
Value
36 kΩ
LTO100 4R7
500 kΩ
0R005
Np
20 kΩ
22 kΩ
1 kΩ
100 kΩ
2 RΩ
Np
Np 500 kΩ
200 kΩ
AZ762
G6D_1A_ASI
5 kΩ
3R3 Ω
SCREW_M4
Mother M4
Washer M4
HV in
V out
V out_sense
Np (Heat sink)
Np (MOS1)
Np (Diode)
Np (Choke)
Np (MOS2)
R g
_4pin
R g
_3pin
KL_STANDARD_2
Np
Description
5%
Include two 20F2617 Bürklin connector
10%
FCSL90R005FE
23AR20KLFTR
5%
10 V
67WR100KLF
5%
5%
5%
12 V
12 V
B57560G502F mound in K1 under
MOS
R_SL22
3 cm distance holder
M4 screw nut washer M4
GMSTBA 2,5/ 3-G-7,62 and
GMSTB 2,5/ 3-ST-7,62
GMSTBA 2,5/ 2-G-7,62 and
GMSTB 2,5/ 2-ST-7,62
GMSTBVA 2,5/ 2-G-7,62 and
GMSTB 2,5/ 2-ST-7,62
Thermal couple connector
Thermal couple connector
Thermal couple connector
Thermal couple connector
Thermal couple connector
SPC20485
SPC20485
SPC20485
For adapter power supply
Application Note 16 Revision 1.2
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EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Boost choke layout
8 Boost choke layout
The boost choke on this evaluation board is hand-wound as this is not volume production. It consists of 2 stacked “Kool Mμ” toroid cores with the part number 77083A7. As a result of the 64 windings with 1.15 mm copper wire the inductance at 100 kHz is about 600 µH. As the optimum value of the inductance and magnetic flux depend on the switching frequency and the output power, a change might be needed if the evaluation board is used for different values of power and frequency.
Figure 9 Main inductor
Application Note 17 Revision 1.2
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2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Source connection options
9 Source connection options
The source connection for the MOSFET Gate Driver can be set to different options. It is important to make sure that only one of the jumpers J6, J7 or J8 is closed at any time. In Figure 10 the possibilities on the top side of the PCB are shown. For standard through hole packages one can put a 0 Ω resistor or a solder bridge on the two surface areas of J6 so that there is an electrical connection if a low inductance gate drive is desired. For standard gate drive inductance it is possible to close J8 (see Figure 11) on the bottom side of the PCB instead
J6.
To investigate the performance advantages of the 4pin solution please activate J7 on the top side of the PCB.
This will completely separate the gate drive circuit from the power path and therefore result in the cleanest gate drive waveforms.
Figure 10 Source connection setting on top side for source sense and low inductance 3pin option
Application Note 18 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Source connection options
Figure 11 Source connection setting on bottom side for standard 3pin
Application Note 19 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
10 Test report
All test conditions are based on a 60°C heat sink temperature.
For the efficiency test it is important to monitor the voltage sensing directly on the input and output power with the V in_sense and V out_sense
right beside the power connections.
Table 3
Input
85 V
AC
230 V
AC
V
Efficiency results of IPZ60R040C7 (4pins) under different line input and loading condition at 100 kHz switching frequency
IN
I
IN
P
IN
V
OUT
I
OUT
P
OUT
Eff.
84.94 V
84.89 V
84.82 V
84.75 V
84.68 V
84.61 V
84.54 V
84.47 V
1.4644 A 123.08 W
2.9198 A 247.12 W
4.4044 A 372.57 W
5.895 A 498.4 W
7.398 A
8.924 A
625.3 W
753.7 W
10.475 A 884 W
12.034 A 1014.6 W
84.39 V
84.31 V
13.616 A 1146.8 W
15.215 A 1280.2 W
229.84 V 1.1775 A 254.23 W
229.96 V 2.2443 A 507 W
229.88 V 3.3473 A 763.2 W
229.82 V 4.4451 A 1016.3 W
229.83 V 5.567 A
229.77 V 6.677 A
1274.6 W
1529.3 W
229.72 V 7.807 A
229.67 V 8.923 A
1789 W
2044.7 W
229.61 V 10.054 A 2304.5 W
229.56 V 11.178 A 2561.5 W
401.49 V 0.2877 A 115.5 W
401.46 V 0.5867 A 235.53 W
401.45 V 0.8872 A 356.17 W
401.45 V 1.1866 A 476.3 W
401.42 V 1.4857 A 596.4 W
401.45 V 1.7855 A 716.8 W
401.4 V 2.0852 A 837 W
401.36 V 2.3852 A 957.3 W
401.38 V 2.6852 A 1077.7 W
401.34 V 2.9842 A 1197.6 W
401.42 V 0.6178 A 247.99 W
401.42 V 1.2376 A 496.8 W
401.34 V 1.8663 A 749 W
401.32 V 2.4872 A 998.2 W
401.29 V 3.1173 A 1250.9 W
401.22 V 3.7388 A 1500 W
401.24 V 4.3698 A 1753.2 W
401.18 V 4.9897 A 2001.6 W
401.19 V 5.615 A
401.15 V 6.235 A
2252.5 W
2500.9 W
93.8414%
95.30997%
95.59814%
95.56581%
95.37822%
95.10415%
94.68326%
94.35245%
93.97454%
93.54788%
97.54553%
97.98817%
98.13941%
98.21903%
98.14059%
98.08409%
97.99888%
97.89211%
97.74355%
97.6342%
In Figures 10 and 11 it can be seen that the full load efficiency is improved by simply changing from 3pin to 4pin configuration. Due to this it is possible to replace a current 3pin PFC MOSFET with a MOSFET of one step higher
R
DS(on)
. This will help to increase the efficiency all over the power range except full load at low line and will help to meet the Titanium Standard for server SMPS.
Application Note 20 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 12
Efficiency high line (230 V
ac
)
98,3
98,2
98,1
98
97,9
97,8
97,7
97,6
4pin_100kHz
3pin_100kHz
4pin_65kHz
3pin_65kHz
97,5
97,4
0 500 1000 1500 2000 2500 3000
Pout [W]
High line efficiency curve with the device IPZ60R040C7 & IDH16G65C5 @ 65 kHz & 100 kHz 3.3 Ω
Efficiency low line (85 V
ac
)
96,5
96
95,5
95
4pin_100kHz
3pin_100kHz
4pin_65kHz
3pin_65kHz
94,5
94
93,5
93
92,5
0 200 400 600 800 1000 1200 1400
Pout [W]
Low line efficiency curve with the device IPZ60R040C7 & IDH16G65C5 @ 65 kHz & 100 kHz 3.3 Ω Figure 13
10.1 Conductive EMI test
EMI is a very important quality factor for a power supply. The EMI data includes the whole spectrum of the
SMPS behavior and is split into radiated and conducted EMI. It is most important to investigate the conducted
EMI behavior for the described evaluation PFC board, as it is the input stage of any SMPS below a certain power range.
Application Note 21 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 14 Conductive EMI measurement of the evaluation board at 100 kHz with a resistive load (4 pin configuration)
Based on the EN55022 standard, the line filter can be modified as shown in Figure 15, in order to further improve the EMI quality and provide enough design margin (6 dB) under the standard line requirement:
Change the X2-capacitor C23 from value 1 µF to 1.5 µF
Application Note 22 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 15 Conductive EMI measurement of the evaluation board at 100 kHz with a resistive load and filter modification (4pin configuration)
Application Note 23 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 16 Conductive EMI measurement of the evaluation board at 100 kHz with a resistive load and filter modification (3pin configuration)
Application Note 24 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 17 Conductive EMI measurement of the evaluation board at 65 kHz with a resistive load and filter modification (4pin configuration)
Application Note 25 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 18 Conductive EMI measurement of the evaluation board at 65 kHz with a resistive load and filter modification (3pin configuration)
10.2 Startup behavior
During power up, when V
OUT
is less than 96% of the rated level, the internal voltage loop of the IC increases from the initial voltage under soft-start control. This results in a controlled linear increase of the input current from 0
A, thus reducing the current stress in the power components as can be seen in the yellow waveform in Figure
19.
Application Note 26 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Test report
Figure 19 Soft startup at low line with 1 kW output power
Application Note 27 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Conclusion
11 Conclusion
The 2.5 kW PFC evaluation board described in this document is aimed at analyzing the switching performance of different variants of packages in a very commonly used PFC topology. It helps to understand the switching behavior and parasitic influences. With the various option settings via jumpers it is possible to modify the circuit without changing the PCB layout. Therefore the evaluation board offers several investigation opportunities. Furthermore, it shows how to boost the efficiency in a standard PFC topology.
Application Note 28 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
References
12 References
1. ICE3PCS01G datasheet, Infineon Technologies AG, 2010.
2. 600V CoolMOS™ C7 Power MOSFET , Product Brief, Infineon Technologies AG, 2013.
3. IDH16G65C5 , datasheet, Infineon Technologies AG, 2012.
Application Note 29 Revision 1.2
2015-11-02
EVAL_2.5KW_CCM_4PIN
2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G
Revision History
Major changes since the last revision
Page or Reference Description of change
-- First Release
Application Note 30 Revision 1.2
2015-11-02
Trademarks of Infineon Technologies AG
AURIX™, C166™, CanPAK™, CIPOS™, CoolGaN™, CoolMOS™, CoolSET™, CoolSiC™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, DrBlade™, EasyPIM™,
EconoBRIDGE™, EconoDUAL™, EconoPACK™, EconoPIM™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, Infineon™, ISOFACE™, IsoPACK™, i-Wafer™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OmniTune™, OPTIGA™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™,
PrimeSTACK™, PROFET™, PRO-SIL™, RASIC™, REAL3™, ReverSave™, SatRIC™, SIEGET™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, SPOC™, TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™.
Trademarks updated August 2015
Other Trademarks
All referenced product or service names and trademarks are the property of their respective owners.
Edition 2015-11-02
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2015 Infineon Technologies AG.
All Rights Reserved.
Do you have a question about this document?
Email: [email protected]
Document reference
AN_201408_PL11_027
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