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
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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
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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
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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 (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
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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
Application Note
6
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
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
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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
Application Note
Wire change from top layer to bottom layer
8
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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 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
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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 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
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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
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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
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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
Application Note
Main inductor
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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
Application Note
Source connection setting on top side for source sense and low inductance 3pin option
18
Revision 1.2
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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
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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
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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
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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
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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
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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
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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
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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: erratum@infineon.com
Document reference
AN_201408_PL11_027
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