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 About this document ............................................................................................................................................. 1 Table of contents ................................................................................................................................................... 1 General safety instruction...................................................................................................................................... 3 To get started ........................................................................................................................................................ 3 1 1.1 1.2 1.3 1.4 1.5 Introduction ....................................................................................................................................... 4 Evaluation board ..................................................................................................................................... 4 CoolMOSTM C7 .......................................................................................................................................... 4 thinQ!TM SiC Diode generation 5.............................................................................................................. 4 CCM-PFC Controller ................................................................................................................................. 5 Gate Driver ICs (EiceDRIVERTM Compact) ................................................................................................ 5 2 Application ......................................................................................................................................... 6 3 3.1 3.2 3.2.1 3.3 3.4 3.4.1 Circuit description.............................................................................................................................. 7 Line input ................................................................................................................................................. 7 Power stage boost type PFC converter ............................................................................................... 7 Separate source Power MOSFET ....................................................................................................... 7 PWM control of boost converter ............................................................................................................. 7 Thermal concept ..................................................................................................................................... 8 Operate without thermal control feature ......................................................................................... 8 4 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 Circuit operation .............................................................................................................................. 10 Soft startup ............................................................................................................................................ 10 Gate switching frequency ..................................................................................................................... 10 Protection features ............................................................................................................................... 11 Open loop protection (OLP)............................................................................................................. 11 First over-voltage protection (OVP1) ............................................................................................... 11 Peak current limit ............................................................................................................................. 11 IC supply under voltage lockout ...................................................................................................... 11 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 4.3.5 Bulk voltage monitor and enable function (VBTHL_EN) ................................................................ 11 5 Circuit diagram ................................................................................................................................ 12 6 PCB layout........................................................................................................................................ 13 7 Component list ................................................................................................................................ 14 8 Boost choke layout .......................................................................................................................... 17 9 Source connection options .............................................................................................................. 18 10 10.1 10.2 Test report ....................................................................................................................................... 20 Conductive EMI test............................................................................................................................... 21 Startup behavior ................................................................................................................................... 26 11 Conclusion ....................................................................................................................................... 28 12 References ....................................................................................................................................... 29 Revision History ................................................................................................................................................... 30 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: 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. Note: The board is designed for a maximum input current of 14 A. To operate it at a mains input of 90 VAC, the output power must be correspondingly reduced so that the maximum current limit is not exceeded. Note: 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! Note: 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. Note: 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 “Vin”, “Vout”, “KL01”, “J11”& “J11a” − Vout : Connect with an output load which is able to operate at 400 VDC − Vin : Connect L, N and Earth to the 90 VAC…265 VAC 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 Vout for the presence of 400 VDC 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 Technical specifications of the 2.5 kW CCM PFC evaluation board Input voltage 85 VAC~265 VAC Input current 14 Aeff Input frequency 47~63 Hz Output voltage and current 400 VDC, 6.25 A Output power ~ 2.5 kW (at Vin=230 VAC) Average efficiency >95% at 115 VAC Switching frequency Possible range: 40 kHz~250 kHz; Board frequency is set to 65 kHz; Changeable by R20 Power switch 4pin and 3pin MOSFET 1.2 CoolMOSTM C7 CoolMOSTM 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. Eoss reduction brings efficiency benefits at light load, the low QG correlates to faster switching and also lower Eon and Eoff which gives efficiency benefits across the whole load range. The CoolMOSTM 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 RDS(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 2015-11-02 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 (Qc*Vf). 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 CoolMOSTM 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 VAC universal input and an output of 400 VDC. The continuous conduction mode (CCM) PFC Controller (ICE3PCS01G) is employed in this board to achieve a unity power factor. 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 (EiceDRIVERTM Compact) The Infineon EiceDRIVERTM family (IEDI60N12AF) offers a wide range of CT (Coreless Transformer) based Gate Drivers that support all topologies using CoolMOSTM 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 CoolMOSTM 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 2015-11-02 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 Application Note 6 Revision 1.2 2015-11-02 EVAL_2.5KW_CCM_4PIN 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 VOUT 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 CoolMOSTM 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 CoolMOSTM 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 VAC 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 2015-11-02 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 Application Note Wire change from top layer to bottom layer 8 Revision 1.2 2015-11-02 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 2015-11-02 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 VOUT 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 VOUT 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 RFREQ 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 RFREQ/frequency is given in Figure 3. The recommended operating frequency range is from 21 kHz to 250 kHz. As an example, a RFREQ of 43 kΩ at pin FREQ will typically set a switching frequency fSW of 100 kHz. Frequency vs Resistance 260 240 Resistance /kohm Frequency /kHz Resistance /kohm Frequency /kHz 220 15 278 110 40 17 249 120 36 20 211 130 34 30 141 140 31.5 160 40 106 150 29.5 140 50 86 169 26.2 120 60 74 191 25 70 62 200 23 80 55 210 21.2 80 90 49 221 20.2 60 100 43 232 19.2 200 Frequency/kHz 180 100 40 20 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 2015-11-02 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 VSENSE falls below 0.5 V, or 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 0.5 V. 4.3.2 First over-voltage protection (OVP1) Whenever VOUT exceeds the rated value by 8%, the first over-voltage protection OVP1 is active. This is implemented by sensing the voltage at pin VSENSE with respect to a reference voltage of 2.7 V. A VSENSE 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 ISENSE 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 VCC is below the under voltage lockout threshold VCCUVLO (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 VSENSE 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 2015-11-02 EVAL_2.5KW_CCM_4PIN 2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G Circuit diagram 5 Figure 6 Application Note Circuit diagram Whole evaluation board schematic 12 Revision 1.2 2015-11-02 EVAL_2.5KW_CCM_4PIN 2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G PCB layout 6 PCB layout Figure 7 PCB top layer view Figure 8 PCB bottom layer view Application Note 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 Table 2 Component list Component list Designator Value B1, B2 closed with 0 Ω Bias1 12 V Bias C1 10 µF 25 V C2 4n7 F 25 V C3 10 nF 25 V C4, C5 1 µF x-capacitor C6 4.7 nF 25 V C7 10 nF 25 V C8, C30 100 nF / 500 V C10, C31 1 nF 25 V C11 10 µF 25 V C12, C25, C32 100 nF 25 V C13 100 nF 25 V C14, C15 1 µF 25 V C16 100 µF 25 V C17, C18, C19, C20 2.2 nF Y-capacitor C21, C24 560 µF EETHC2G561KA or EKMR421VSN561MR50S C22, C23 1 µF / 400 V C26 220 nF 25 V C27 10 µF 25 V C28 470 pF 25 V C29 22 nF 25 V D1 SS26 D2, D3 1N4148 D4 1N5408 D6 Short 0Ω D10 ES1C 1 A 150 V fast diode DUT1 IPZ60R040C7 D_Z3 ZMM15 EMI_1 Not placed EMI adapter GL1, GL2 GSIB2580 GSIB2580 IC1 TDA2030 Mount with M2.5x6 IC2 LM4040 LM4040D20IDBZRG4 IC3 ICE3PCS01G PFC CCM controller IC4 1EDI60N12AF 6 A isolated MOS driver Application Note Description Placeholder for ferrite bead, 0Ω resistor Bias adapter VJ1825Y104KXEAT BFC237351105; Farnell 1215540 1N4734A 14 Revision 1.2 2015-11-02 EVAL_2.5KW_CCM_4PIN 2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G Component list Designator Value IC5 IFX91041 J1, J11 Jumper_3pin J2 Current measurement bridge J3 Drilling J6 Open J7, J12 Close with solder or 0 Ω resistance Solder jumper; driver ground to SS, Solder jumper; isolated driver power J8, J10 Open Solder jumper; 3pin ground, Solder jumper; driver power none isolated J9 Close with solder or 0 Ω resistance K1 SK426 100 mm long; mound with 2xM4x15 K2 KM75-1 KM75-1 +4clip 4597; Fischer KL1 BNC KL01 Heating MSTBA 2,5/ 3-G KL01-S Complement MSTB 2,5/3-ST L1 L_PFC L2 10 A 100 µH L3 8120-RC L4 33 µH LED1 Red Power on LED LED2, LED3, LED4, LED5 Blue Power on LED M1, M2 Fan 60 mm M1, M2 Finger guard for Fan 60 mm PWM-Signal SMA Oscilloscope_Function_generator R1, R3, R13, R20, R56 1 kΩ 5% R2, R8, R15, R44 10 kΩ 5% R4 5 kΩ 67WR20KLF R5 680 Ω 5% R6 220 Ω 5% R7, R11 10 Ω 5% R9, R16 20 Ω 3314G-1-200E R10, R25 47 Ω 5% R12, R42 330 kΩ 5% R14, R19 2 MΩ 5% R17 27 kΩ 5% Application Note 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; isolated driver power Oscilloscope_function_generator 2times 77083A7 64wind_1.15mm Würth 744824101 BOURNS_8120-RC_2m4H_17A 74454133 PMD1206PTB1-A 15 LZ28CP Revision 1.2 2015-11-02 EVAL_2.5KW_CCM_4PIN 2.5 kW PFC evaluation board with CCM PFC Controller ICE3PCS01G Component list Designator Value Description R18 36 kΩ 5% R21 LTO100 4R7 R22, R23 500 kΩ 10% R24 0R005 FCSL90R005FE R27 Np R28 20 kΩ 23AR20KLFTR R29 22 kΩ 5% R30 1 kΩ 10 V R31 100 kΩ R35 2 RΩ R36 Np R37 Np 500 kΩ 5% R45 200 kΩ 5% REL1 AZ762 12 V REL2 G6D_1A_ASI 12 V R_NTC1 5 kΩ B57560G502F mound in K1 under MOS R_NTC2 3R3 Ω R_SL22 S1, S2, S3, S4, S5, S6 SCREW_M4 3 cm distance holder S1, S2, S3, S4, S5, S6 Mother M4 M4 screw nut S1, S2, S3, S4, S5, S6 Washer M4 washer M4 Vin HVin GMSTBA 2,5/ 3-G-7,62 and GMSTB 2,5/ 3-ST-7,62 Vout Vout GMSTBA 2,5/ 2-G-7,62 and GMSTB 2,5/ 2-ST-7,62 Vout_sense Vout_sense GMSTBVA 2,5/ 2-G-7,62 and GMSTB 2,5/ 2-ST-7,62 X1 Np (Heat sink) Thermal couple connector X2 Np (MOS1) Thermal couple connector X3 Np (Diode) Thermal couple connector X4 Np (Choke) Thermal couple connector X5 Np (MOS2) Thermal couple connector X6 Rg_4pin SPC20485 X7 Rg_3pin SPC20485 X8, X9 KL_STANDARD_2 SPC20485 X12 Np Application Note Include two 20F2617 Bürklin connector 67WR100KLF 5% For adapter power supply 16 Revision 1.2 2015-11-02 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 Application Note Main inductor 17 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 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 Application Note Source connection setting on top side for source sense and low inductance 3pin option 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 Application Note Source connection setting on bottom side for standard 3pin 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 Vin_sense and Vout_sense right beside the power connections. Table 3 Input 85 VAC 230 VAC Efficiency results of IPZ60R040C7 (4pins) under different line input and loading condition at 100 kHz switching frequency VIN IIN PIN VOUT IOUT POUT Eff. 84.94 V 1.4644 A 123.08 W 401.49 V 0.2877 A 115.5 W 93.8414% 84.89 V 2.9198 A 247.12 W 401.46 V 0.5867 A 235.53 W 95.30997% 84.82 V 4.4044 A 372.57 W 401.45 V 0.8872 A 356.17 W 95.59814% 84.75 V 5.895 A 498.4 W 401.45 V 1.1866 A 476.3 W 95.56581% 84.68 V 7.398 A 625.3 W 401.42 V 1.4857 A 596.4 W 95.37822% 84.61 V 8.924 A 753.7 W 401.45 V 1.7855 A 716.8 W 95.10415% 84.54 V 10.475 A 884 W 401.4 V 2.0852 A 837 W 94.68326% 84.47 V 12.034 A 1014.6 W 401.36 V 2.3852 A 957.3 W 94.35245% 84.39 V 13.616 A 1146.8 W 401.38 V 2.6852 A 1077.7 W 93.97454% 84.31 V 15.215 A 1280.2 W 401.34 V 2.9842 A 1197.6 W 93.54788% 229.84 V 1.1775 A 254.23 W 401.42 V 0.6178 A 247.99 W 97.54553% 229.96 V 2.2443 A 507 W 401.42 V 1.2376 A 496.8 W 97.98817% 229.88 V 3.3473 A 763.2 W 401.34 V 1.8663 A 749 W 98.13941% 229.82 V 4.4451 A 1016.3 W 401.32 V 2.4872 A 998.2 W 98.21903% 229.83 V 5.567 A 1274.6 W 401.29 V 3.1173 A 1250.9 W 98.14059% 229.77 V 6.677 A 1529.3 W 401.22 V 3.7388 A 1500 W 98.08409% 229.72 V 7.807 A 1789 W 401.24 V 4.3698 A 1753.2 W 97.99888% 229.67 V 8.923 A 2044.7 W 401.18 V 4.9897 A 2001.6 W 97.89211% 229.61 V 10.054 A 2304.5 W 401.19 V 5.615 A 2252.5 W 97.74355% 229.56 V 11.178 A 2561.5 W 401.15 V 6.235 A 2500.9 W 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 RDS(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 Efficiency high line (230 Vac) 98,3 4pin_100kHz eta [%] 98,2 3pin_100kHz 98,1 4pin_65kHz 98 3pin_65kHz 97,9 97,8 97,7 97,6 97,5 97,4 0 500 1000 1500 2000 2500 3000 Pout [W] Figure 12 High line efficiency curve with the device IPZ60R040C7 & IDH16G65C5 @ 65 kHz & 100 kHz 3.3 Ω Efficiency low line (85 Vac) 96,5 4pin_100kHz eta [%] 96 3pin_100kHz 95,5 4pin_65kHz 95 3pin_65kHz 94,5 94 93,5 93 92,5 0 200 400 600 800 1000 1200 1400 Pout [W] Figure 13 10.1 Low line efficiency curve with the device IPZ60R040C7 & IDH16G65C5 @ 65 kHz & 100 kHz 3.3 Ω 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 Application Note Conductive EMI measurement of the evaluation board at 100 kHz with a resistive load and filter modification (4pin configuration) 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 Application Note Conductive EMI measurement of the evaluation board at 100 kHz with a resistive load and filter modification (3pin configuration) 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 Application Note Conductive EMI measurement of the evaluation board at 65 kHz with a resistive load and filter modification (4pin configuration) 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 10.2 Conductive EMI measurement of the evaluation board at 65 kHz with a resistive load and filter modification (3pin configuration) Startup behavior During power up, when VOUT 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 Application Note Soft startup at low line with 1 kW output power 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 -- Application Note Description of change First Release 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 ©ifx1owners. 2015 Infineon Technologies AG. All Rights Reserved. Do you have a question about this document? Email: [email protected] Document reference AN_201408_PL11_027 IMPORTANT NOTICE The information contained in this application note is given as a hint for the implementation of the product only and shall in no event be regarded as a description or warranty of a certain functionality, condition or quality of the product. Before implementation of the product, the recipient of this application note must verify any function and other technical information given herein in the real application. 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