AN_1911_PL52_1912_141352
3300 W CCM bi-directional totem pole with 650
V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
About this document
Authors
Matteo-Alessandro Kutschak
ee
c
David Meneses Herrera
Scope and purpose
This document presents a system solution based on Infineon superjunction (SJ) (CoolMOS™) and wide bandgap (CoolSiC™) power semiconductors, drivers and microcontroller for a bridgeless totem-pole Power Factor
Corrector (PFC) with bi-directional capability. The EVAL_3K3W_TP_PFC_SIC board is intended for those
applications which require the highest efficiency (99 percent) and high power density (73 W/in3), such as highend servers and telecoms. In addition, the bi-directional power flow capability would allow this design to be
used in battery chargers or battery formation applications. The totem pole implemented in the
EVAL_3K3W_TP_PFC_SIC board operates in Continuous Conduction Mode (CCM) in both rectifier (PFC) and
inverter mode, with full digital control implementation on the Infineon XMC™ 1000 series microcontroller.
The Infineon components used in the 3300 W bridgeless bi-directional totem-pole board are as follows:
•
•
•
•
•
600 V CoolMOS™ C7 SJ MOSFET and 650 V CoolSiC™ silicon carbide MOSFET
2EDF7275F isolated gate drivers (EiceDRIVER™)
XMC1404 microcontroller
ICE5QSAG CoolSET™ QR Flyback controller
950 V CoolMOS™ P7 SJ MOSFET
Figure 1
3300 W bridgeless totem-pole PFC with CoolSiC™, CoolMOS™ and XMC™ control
Application Note
Please read the Important Notice and Warnings at the end of this document
http://www.infineon.com/eval-3k3w-tp-pfc-sic
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
Table of contents
Table of contents
About this document ....................................................................................................................... 1
Table of contents ............................................................................................................................ 2
1
1.1
1.2
1.3
System description ........................................................................................................ 3
Board description .................................................................................................................................... 5
Signal conditioning for digital control of totem-pole CCM PFC ............................................................ 6
Graphical user interface (GUI)................................................................................................................. 7
2
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.4
PFC (AC-DC operation) specification and test results ......................................................... 9
Performance and steady-state waveforms ............................................................................................ 9
Power line disturbance ......................................................................................................................... 11
Line Cycle Drop-Out ......................................................................................................................... 11
Voltage sag ....................................................................................................................................... 13
Output voltage dynamic behavior ........................................................................................................ 15
Load-transient response in PFC mode ............................................................................................ 15
AC voltage variation in PFC mode ................................................................................................... 17
In-rush current and PFC start-up .......................................................................................................... 18
3
3.1
3.2
3.3
3.3.1
3.3.2
Inverter (DC-AC operation) specification and test results .................................................. 20
Performance and steady-state waveforms .......................................................................................... 21
Inverter mode load change ................................................................................................................... 22
Power line disturbance and AC voltage variation ................................................................................ 23
Inverter mode LCDO ......................................................................................................................... 23
Voltage sag and AC voltage variation .............................................................................................. 24
4
Thermal measurements................................................................................................. 26
5
Summary ..................................................................................................................... 27
6
Schematics .................................................................................................................. 28
7
Bill of Materials (BoM) ................................................................................................... 30
8
References ................................................................................................................... 32
Revision history ........................................................................................................................................................ 33
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
System description
1
System description
The EVAL_3K3W_TP_PFC_SIC board is a system solution enabled by Infineon Technologies power
semiconductors as well as drivers and microcontroller. The evaluation board consists of a bridgeless totempole topology and it is intended for high-end applications in which the highest efficiency is required.
Furthermore, the totem-pole topology is simple and offers a reduced part count and full utilization of the PFC
inductor and switches [1]. For these reasons, totem-pole PFC enables high power density at a limited system
cost for high-performance systems. In addition, the EVAL_3K3W_TP_PFC_SIC board provides reverse power
flow (inverter operation for grid-connected applications) due to the inherent bi-directional power flow
capability of the totem-pole topology.
The totem-pole topology in PFC applications with CCM operation is feasible by using wide band-gap
semiconductors [1]. In this case, the Infineon CoolSiC™ MOSFET in TO-247 four-pin package is used to push the
efficiency to 99 percent at half-load (Figure 2). The converter operates exclusively at high-line (176 Vrms
minimum, 230 Vrms nominal) in CCM with 65 kHz switching frequency.
Note:
Due to production variations and measurement set-up, efficiency variations up to ±0.2 percent can
be seen in the result shown.
100
Efficiency (%)
99,5
99
98,5
Eff_PFC_230V
98
97,5
97
300
Figure 2
800
1300
1800
2300
Output power (W)
2800
3300
Measured efficiency at 230 V (with applied line filter in the power analyzer) of the 3300 W
totem-pole PFC with 64 mΩ CoolSiC™ and 17 mΩ CoolMOS™
The PFC function to achieve bulk voltage regulation while demanding high-quality current from the grid is
implemented with an Infineon XMC1404 microcontroller [2]. Further detail on PFC control implementation in
the XMC™ 1000 family can be found in the application notes of other Infineon PSU and PFC evaluation boards
with classic boost or dual boost topologies [3][4][5].
The 3300 W bridgeless bi-directional (PFC/AC-DC and inverter/AC-DC) totem-pole presented in this application
note is a system solution developed with Infineon power semiconductors as well as Infineon drivers and
controllers. The Infineon devices used in the implementation of the EVAL_3K3W_TP_PFC_SIC board are listed
below.
64 mΩ 650 V CoolSiC™ (IMZA65R048M1) in TO-247 four-pin package, as totem-pole PFC high-frequency
switches
• 17 mΩ 600 V CoolMOS™ C7 (IPW60R017C7) in TO-247 package, for the totem-pole PFC return path (lowfrequency bridge)
•
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
System description
2EDF7275F isolated gate drivers (EiceDRIVER™)
• ICE5QSAG QR Flyback controller and 950 V CoolMOS™ P7 (IPU95R3K7P7) for the bias auxiliary supply
• XMC1404 microcontroller for PFC control implementation
•
A simplified block diagram of the bridgeless topology with the mentioned devices from the Infineon portfolio is
shown in Figure 3. The diode bridge in front of the totem-pole PFC converter is meant to be a current path for
start-up or surge conditions and it is not part of the current path during the steady-state converter operation.
The power flow direction, which will select the converter operation – forward power flow or PFC operation
versus reverse power flow or inverter operation – can be selecte y switch connecte to the XMC™
microcontroller as a digital input pin.
Note:
The power flow or operation mode is selected before the application starts and the power flow
cannot be reverted during operation. Therefore, the EVAL_3K3W_TP_PFC_SIC board is able to
operate as either PFC or inverter but the current version of the SW does not provide dynamic
change of operation mode.
Figure 3
3300 W bridgeless totem-pole PFC board (EVAL_3K3W_TP_PFC_SIC) simplified diagram
showing the topology and the Infineon semiconductors used
This document will describe the EVAL_3K3W_TP_PFC_SIC board implementation, as well as the specifications
and main test results. For further information on Infineon semiconductors visit the Infineon website, the
Infineon evaluation board search, and the websites for the different implemented components:
•
•
•
•
•
CoolMOS™ power MOSFET
CoolSiC™ MOSFET
Gate driver ICs
QR CoolSET™ (bias board KIT_6W_18V_P7_950V)
XMC™ microcontrollers
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
System description
1.1
Board description
Figure 4 shows the placement of the different sections of the EVAL_3K3W_TP_PFC_SIC bridgeless totem-pole
bi-directional PFC with Infineon 650 V CoolSiC™ silicon carbide MOSFET. The board is 208 mm long, with a
width of 89 mm and a height of 40 mm (1U), for a power density of 73 W/in3.
Inmediately after the AC input connector, a two-stage EMI filter is placed as well as a fuse and NTC in-rush
current limiter, together with the input relay. The DC output connector is placed on the same side of the board
as the AC connector. Close to the output connector, a single-stage filter (with differential and common mode
paths) is placed to guarantee proper aquisition of the output variables in efficiency measurements.
On the other side of the board, two daughter cards are introduced. They are the bias board and the control
card. The bias board uses a QR CoolSET™ controller n 950 V P7 CoolMOS™ switch to gener te the require
voltages for the control card, driving, relay and fan supply. The control card implements the required current,
voltage and polarity sensing. The full digital control is implemented in the Infineon XMC™ microcontroller,
which is in charge of the proper operation of the bridgeless totem-pole topology.
The rest of the board is occupied by the bridgeless totem-pole itself, which comprises the PFC choke, the bulk
capacitor and a bridge with 650 V CoolSiC™ MOSFET and 600 V C7 CoolMOS™. The bulk capacitance is
designed to comply with the hold-up time shown in Table 1. The semiconductors in TO-247 package are
mounted on a heatsink with attached fan, which blows air toward the PFC choke. The choke is designed with
high-flux material in EQ shape in order to comply with the height requirement, high efficiency performance and
high power density.
EMI Filter
NTC/Relay; Fuse
Control Board
Bias Board
AC in
DC out
Output Filter
Totem-pole PFC
Figure 4
Application Note
Placement of the different sections in the 3300 W bridgeless totem-pole PFC with Infineon
650 V CoolSiC™ and 600 V C7 CoolMOS™ MOSFETs and XMC™ control
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EVAL_3K3W_TP_PFC_SIC
System description
1.2
Signal conditioning for digital control of totem-pole CCM PFC
The evaluation board EVAL_3K3W_TP_PFC_SIC implements CCM average current mode control with Duty FeedForward (DFF) for both PFC and inverter operation. It follows a control structure similar to that implemented
for a classic PFC presented in [2] and [4] or the dual boost introduced in [5].
Unlike the classic PFC in which the AC voltage is rectified by the diode bridge, in the bridgeless totem-pole PFC
converter the inductor current is both positive and negative. The most simple and cost-effective way to sense
this current is to use a shunt resistor in series with the inductor as shown in Figure 5. In addition, in the
EVAL_3K3W_TP_PFC_SIC board, the control reference (GND_iso in Figure 5) is placed in the AC-line after the
shunt resistor. Therefore, the Current Sense voltage (CS+) is positive and negative according to the positive
reference current shown by the red arrow in Figure 5.
Since the ADC of the microcontroller used for the control implementation (XMC1404 from Infineon
Technologies [2]) only allows input voltages between zero and the supply voltage (Vcc_XMC in Figure 5), an
offset is included together with the CS gain in order to properly use the input spam of the ADC. In this case the
offset is 2.5 V, which corresponds to half the supply voltage for the XMC™ controller used. The differential gain
(Ki) is adjusted to consider not only inductor average current but also the switching frequency ripple, since this
signal is used for CCM average current control and peak current limitation [2].
In the totem-pole operation, for both PFC and inverter power flow, the return path transistors (HS_SR and
LS_SR on Figure 5) are switched at the AC zero crossing according to the AC polarity: HS_SR for positive AC and
LS_SR for negative AC cycle. The polarity of the input voltage is set according to the control reference GND_iso.
Since the control reference is in one of the AC input rails, the polarity detection is significantly simplified and
the internal ESD diode protection of the XMC™ controller is used to transform the input capacitor voltage into
a digital signal.
Figure 5
Block diagram of the sensing circuitry required for bi-directional totem-pole control with
XMC™ and control reference in the AC rail in series with the PFC choke
Due to the control reference location, the bulk voltage sense requires a differential amplifier with gain KDC, as
shown in Figure 5. In the case of the of AC voltage sensing, the control reference location allows simple sensing.
In this case, the voltage has been rectified (positive ADC input is required) and adapted to the ADC input range
with a differential gain KAC.
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
System description
Since the AC voltage is used for the current reference generation in the selected average current mode
structure (Figure 6), the current reference is a full wave rectified sinusoidal sequence. However, the current
sense after the ADC is a sinusoidal sequence with offset at half of the ADC spam. Therefore, the ADC result from
the CS first requires the offset to be removed and then rectified according to the AC polarity signal and the
operation mode: current in inverter mode is 180 degrees out of phase with the AC voltage, while current in PFC
mode is in phase with the AC voltage. These two steps, together with extra gain, are implemented by software
in the XMC™ controller.
The current loop controller and structure is kept the same for inverter operation. However, since the bulk
voltage is controlled by a DC-DC converter in DC-AC operation, the Vloop_output signal is substituted by a value sent
by the DC-DC stage which is the target power to be delivered into the grid.
Figure 6
Current loop structure with duty feed-forward and the required current manipulation
1.3
Graphical user interface (GUI)
The XMC™ controller inclu es a serial communication interface (UART) and a specific protocol, which allows
communication from a computer to the microcontroller. The user interface for Windows (Figure 7) has been
developed to communicate with the controller using XMC™ Link (UART to USB conversion).
Figure 7
Application Note
GUI for dead-time optimization and power target in inverter operation in the
EVAL_3K3W_TP_PFC_SIC board
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
System description
Two main sets of parameters can be updated in the controller using the GUI:
Dead-time between low-side and high-side CoolSiC™ switches in the totem-pole topology. The dead-time
can be modified in the controller following two linear regions with minimum and maximum limitation
(Figure 7).
• Power command, which sets the current level in inverter operation. This emulates the command sent by the
DC-DC stage in the final application. Figure 8 shows the relationship between the power command in the
GUI and the output power for different AC voltages.
•
3500
3000
Output power (W)
2500
2000
1500
Pac_176V(W)
1000
Pac_230V(W)
Pac_265V(W)
500
0
0
Figure 8
2000
4000
6000
8000
power_limit
10000
12000
14000
Measured output power (AC) according to the power_limit parameter from the GUI
The GUI shown is intended for development of the totem-pole platform, and the other functions displayed in
Figure 7 are not available.
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
2
PFC (AC-DC operation) specification and test results
This chapter presents the specifications, performance and behavior of the 3300 W bridgeless totem pole with
average current mode control in CCM for PFC operation. The results shown have been obtained with 64 mΩ 650
V CoolSic™ devices in TO-247 four-pin package and 17 mΩ 600 V CoolMOS™ in TO-247 as low-frequency
switches. Table 1 shows the demonstrator performance and specifications under several steady-state and
dynamic conditions. The converter operates at 65 kHz switching frequency and only for high-line AC input (176
V minimum RMS voltage).
Table 1
Summary of specifications and test conditions for the 3300 W bi-directional totem-pole
board in PFC mode
Test
Conditions
Specification
Efficiency test
230 Vrms, 50 Hz/60 Hz
ηpk = 99 percent at 1650 W (50 percent load)
Current THD
230 Vrms, 50 Hz/60 Hz
THDi less than 10 percent from 10 percent
load
Power factor
230 Vrms, 50 Hz/60 Hz
PF more than 0.95 from 20 percent load
Rated DC voltage
400 V
Steady-state Vout ripple
230 Vrms, 50 Hz/60 Hz, 100 percent
load
|∆Vout| less than 20 Vpk-pk
In-rush current
230 Vrms, 50 Hz/60 Hz, measured
on the first AC cycle
Iin_peak less than 30 A
AC lost
(hold-up
time)
230 Vrms, 50 Hz, 10 ms at 100
percent load, 20 ms at 50 percent
load
Vout_min = 300 V (UVP)
Voltage
sag
200 Vrms, 50 Hz/60 Hz, different sag
conditions, 100 percent load
Power line
disturbance
Brown-out
Load transient
AC
voltage
No damage:
* PFC soft-start if
bulk voltage under
300 V
* PFC soft-start if
AC out of range for
certain time
174 V on; 168 V off
7.4 A (90 percent) 0.8 A (10
percent), 0.2 A/µs
OCP
Vout_min = 300 V (UVP)
Vout_max = 450 V (OVP)
Peak current limit 40 A
AVG current limit 28 A
2.1
Performance and steady-state waveforms
The performance of the bi-directional totem pole presented in this document has been tested using the board
EVAL_3K3W_BIDI_PSFB [6] as load in PFC operation and voltage supplier for inverter mode. This board is a bidirectional ZVS phase-shift full-bridge converter which can be used together with the presented bi-directional
bridgeless PFC to build a full system solution using Infineon Technologies components. This set-up allows the
use of the high–frequency isolation transformer present in the DC-DC stage to properly interface a voltage
source to a grid emulator equipment, and it has been used to test the bi-directional capability and the steadystate performance of the bi-directional totem-pole. The presented measurements in this section comply with
the specifications presented in Table 1 and have been obtained with a WT3000 power analyzer.
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
Figure 9 shows the efficiency measurements for PFC operation at different AC voltages. The efficiency results
are the same regardless of the AC frequency (50 Hz/60 Hz) and do not include the fan consumption.
99,5
Efficiency (%)
99
98,5
98
Eff_PFC_176V
97,5
Eff_PFC_230V
Eff_PFC_265V
97
0
Figure 9
500
1000
1500
2000
2500
Output power (W)
3000
3500
4000
Measured efficiency (with applied line filter in the power analyzer) at different RMS
voltages (50/60 Hz) for PFC operation
Figure 9 depicts the Total Harmonic Distortion (THD) and power factor measured at different AC voltages at 50
Hz and 60 Hz for PFC operation. As can be seen, the results for THD and power factor have small differences.
These differences are within the measurement accuracy of the equipment used.
18
1
16
THD_PFC_265V_50Hz(%)
14
THD_PFC_265V_60Hz(%)
PF_PFC_265V_50Hz
THD_PFC_230V_60Hz(%)
Power factor
Current THD (%)
0,95
THD_PFC_230V_50Hz(%)
12
10
THD_PFC_176V_50Hz(%)
8
THD_PFC_176V_60Hz(%)
PF_PFC_265V_60Hz
0,9
PF_PFC_230V_50Hz
PF_PFC_230V_60Hz
6
PF_PFC_176V_50Hz
0,85
4
PF_PFC_176V_60Hz
2
0,8
0
0
500
Figure 10
1000
1500
2000
Output power (W)
2500
3000
0
3500
500
1000
1500
2000
Output power (W)
2500
3000
3500
Measured THD and power factor at different RMS voltages for 50 Hz and 60 Hz in PFC
operation
Figure 11 and Figure 12 show the PFC operation for different AC voltages in amplitude and frequency as well as
power levels.
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
Waveforms:
Figure 11
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current 10A/div
AC voltage
100V/div
Input current
10A/div
V_GS_LS
10V/div
V_DS_LS
200V/div
5ms/div
Steady-state waveforms at 230 V, 50 Hz AC voltage, 50 percent load (left) and 100 percent
load (right)
Waveforms:
Ch1
Ch2
Ch3
Ch4
time
Inductor current
10A/div
AC voltage
120V/div
Input current
10A/div
Vbulk_DC
10V/div
4ms/div
390Voffset
Figure 12
Steady-state waveforms at 265 V (left) and 176 V (right) for 60 Hz AC voltage and 80
percent load (2.7 kW)
2.2
Power line disturbance
Two main line disturbance conditions can occur when connected to the grid. On one side the AC can be lost
during a certain time – Line Cycle Drop-Out (LCDO) – and, on the other side, the AC voltage can suddenly
decrease to an abnormal value – voltage sag. This section introduces the test conditions for both disturbances
as well as the EVAL_3K3W_TP_PFC_SIC bridgeless board performance when those conditions are applied. For
these tests of the PFC operation a programmable AC source and a high-voltage electronic load have been used.
2.2.1
Line Cycle Drop-Out
The 3300 W totem-pole CCM PFC operates exclusively in high-line. Therefore the ACLCDO capability is tested
from 230 to 0 V. Different timing, related to the specified hold-up time and the line frequency, is applied as
shown in Table 2. The test results (Figure 13 and Figure 14) show that the output voltage is within the specified
dynamic variation regardless of the start angle of the voltage drop-out. In case the drop-out is longer than
specified, output voltage under-voltage (300 V) can be triggered and a turn-off and restart of the unit will occur.
Application Note
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
Table 2
Applied voltage cycles for LCDO test at different loads with 50 Hz AC input voltage
1st to 10th time (100 ms period)
Applied voltage
230 V AC
0 V AC
230 V AC
Timing at different load
conditions
50 percent load
20 percent (20 ms)
80 percent (80 ms)
100 percent load
10 percent (10 ms)
90 percent (90 ms)
Waveforms:
Figure 13
Ch1
Ch2
Ch3
Ch4
time
Detail of the fifth repetition in a 10 ms LCDO test at 230 V AC, 50 Hz and 100 percent load
with starting angle of 45 degrees
Waveforms:
Figure 14
Application Note
Inductor current
20A/div
AC voltage
100V/div
Input current
20A/div
V_bulk
50V/div
10ms/div (zoom)
Ch1
Ch2
Ch3
Ch4
time
Inductor current
20A/div
AC voltage
100V/div
Input current
20A/div
V_bulk
50V/div
20ms/div (zoom)
Detail of the fifth and sixth repetition in a 20 ms LCDO test at 230 V AC, 50 Hz and 50
percent load with starting angle of 0 degrees
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EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
2.2.2
Voltage sag
For high-line, two different voltage sag conditions are considered and tested, corresponding with Table 3.
Table 3
Voltage sag conditions for high-line applied to the EVAL_3K3W_TP_PFC_SIC board
1st to 10th time
AC input
Steady AC input
Voltage sag (time)
Period
200 V AC
130 V AC (0.5 s)
5s
200 V AC
150 V AC (2 s)
20 s
Figure 15 shows the totem-pole PFC behavior with 130 V voltage sag during 500 ms. As can be seen by the VDS
waveform, the output voltage cannot be regulated to 400 V in this condition since the inductor average current
is limited to 28 A. Not only is average current limitation applied in the EVAL_3K3W_TP_PFC_SIC board for both
power flow modes but also peak current limitation, which is set to 40 A (Figure 16).
Waveforms:
Figure 15
Application Note
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current
20A/div
AC voltage
130V/div
Input current
20A/div
Vds_HF-LS
150V/div
Vgs_HF-LS
10V/div
100ms/div
Main waveforms during a 500 ms and 130 Vrms voltage sag at full load
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
Waveforms:
Figure 16
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current
20A/div
AC voltage
130V/div
Input current
20A/div
Vds_HF-LS
150V/div
Vgs_HF-LS
10V/div
100us/div (zoom)
Peak current limitation when returning to nominal voltage after 130 V voltage sag in PFC
mode
However, if the voltage is under the nominal range for longer than specified in the table, the PFC turns off and
restarts with soft-start after an idle time. Figure 17 shows this behavior when a voltage sag to 130 V is applied
for longer than 500 ms (750 ms) at full load.
Note:
The electronic load used during the test is configured in such a way that it demands current only
when the voltage applied is over 300 V, which is the under-voltage setting of the bridgeless PFC.
Waveforms:
Figure 17
Application Note
Ch1 Inductor current
20A/div
Ch2 Bulk voltage
50V/div
Ch3 Input current
20A/div
time
200ms/div
PFC resumes operation after 130 Vrms voltage sag applied for 750 ms at full load
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EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
A similar behavior can be seen when 150 V is applied for 2s (Figure 18). The average inductor current, i.e. input
current, is limited to 28 A (Figure 18). In this case the demanded current is lower and therefore the average
current limitation occurs for a shorter time, and thus the bulk voltage decreases less than in the 130 V case.
Waveforms:
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current
20A/div
AC voltage
130V/div
Input current
20A/div
Vds_HF-LS
150V/div
Vgs_HF-LS
10V/div
6.25ms/div (zoom)
Figure 18
Detail of the voltage sag operation at 150 V for 2 s
2.3
Output voltage dynamic behavior
In addition to power line disturbance, two other dynamic perturbances can affect the performance of the
power supply shown: load and input voltage variation.
2.3.1
Load-transient response in PFC mode
As specified in Table 1, 10 percent load (0.8 A) to 90 percent load (7.4 A) steps (and vice versa) with 0.2 A/µs
slope are considered in PFC mode. Figure 19 and Figure 20 show the EVAL_3K3W_TP_PFC_SIC board behavior
under these load steps. The implemented voltage loop has a 35 Hz crossover frequency. In this SW version of
the totem-pole control, neither extra gain nor non-linear current variation have been implemented.
Application Note
15
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
Waveforms:
Figure 19
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current 10A/div
AC voltage
130V/div
Input current
10A/div
Vds_HF-LS
150V/div
Vgs_HF-LS
10V/div
50ms/div
3.3 kW SiC totem-pole CCM PFC response for 10 percent to 90 percent load steps every 150
ms with 0.2 A/µs current slope
The output voltage dynamic range for the specified load variation is within 375 V and 430 V. When the load is
removed (Figure 20) the overshoot reaches 440 V, which is under the over-voltage setting (450 V), and the
converter manages to reduce the voltage without PWM interruption. Furthermore, the converter regulates the
output voltage under no-load conditions by making the average inductor current close to zero. This is possible
since negative inductor current is allowed in a totem-pole configuration with complementary PWM signals, i.e.
if the MOSFET in diode function is not turned off when the inductor current gets close to zero to emulate the
diode behavior.
Waveforms:
Figure 20
Application Note
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current 10A/div
AC voltage
130V/div
Input current
10A/div
Vds_HF-LS
100V/div
Vgs_HF-LS
10V/div
50ms/div
3.3 kW SiC totem-pole CCM PFC response at full load to no-load step with 0.2 A/µs current
slope
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PFC (AC-DC operation) specification and test results
2.3.2
AC voltage variation in PFC mode
Input voltage variations, as seen in the power line disturbance section, can modify the bulk voltage. This can
also occur when the input voltage varies even within the normal operation range, as shown in Figure 21. In this
condition, the bulk voltage is in the range 330 to 430 V, as shown by the test result.
265V
176V
265V
430V
330V
Ch1
Ch2
Ch3
Ch4
Ch5
Ch6
Ch7
time
Figure 21
Inductor current
20A/div
AC voltage
200V/div
Input current
20A/div
Vds_HF-LS
200V/div
Vgs_HF-LS
20V/div
Vgs_LF-LS
20V/div
Vds_LF-LS
200V/div
50ms/div
Maximum (265 Vrms) to minimum (176 Vrms) line voltage variation at full-load operation
As introduced in section 2.2.2, a sudden increase in the input voltage leads to an immediate increase in the
inductor current until the voltage loop and the line feed-forward reduce the current demand. Figure 22 shows
this effect when the AC voltage changes from 176 to 265 V. The sudden change of the inductor current leads to
peak current limitation, which is set to 40 A for both positive and negative AC.
265V
176V
265V
Ch1 Inductor current
10A/div
Ch2 AC voltage
100V/div
time
250us/div (zoom)
40A
Figure 22
Application Note
Detail of the inductor peak current cycle-by-cycle limitation when the input voltage
changes from 176 to 265 V
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PFC (AC-DC operation) specification and test results
2.4
In-rush current and PFC start-up
Figure 23 shows the start-up of the bridgeless totem pole in PFC mode for full-load operation. The test has been
performed with programmable AC source and high-voltage electronic load. The load is configured with a 350 V
threshold to start sinking current. This threshold emulates the behavior of the DC-DC converter, which would
be the load for the PFC (Figure 24).
Waveforms:
Figure 23
EVAL_3K3W_TP_PFC_SIC start-up at full load for 230 V, 50 Hz input voltage
Waveforms:
Figure 24
Ch1 Inductor current 10A/div
Ch2 Vbulk
50V/div
Ch3 Input current
10A/div
time
200ms/div
Ch1 Inductor current 10A/div
Ch2 Vbulk
50V/div
Ch3 Input current
10A/div
time
20ms/div (zoom)
Detail of the bulk voltage soft-start from AC peak voltage to steady-state voltage after
relay is closed (230 V/50 Hz)
The in-rush current when connecting to the AC source is limited with a NTC. This resistor is short-circuited by a
parallel relay before start-up if the input and output voltage conditions to start the bridgeless PFC are met. The
in-rush current is measured at the first AC cycle and it is independent of the output load. Figure 25 shows the inApplication Note
18
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
PFC (AC-DC operation) specification and test results
rush current at full-load start-up. According to the measurement the in-rush current is significantly under the
specified 30 A in Table 1.
Waveforms:
Figure 25
Application Note
Ch1 Inductor current 10A/div
Ch2 Vbulk
50V/div
Ch3 Input current
10A/div
time
10ms/div (zoom)
In-rush current of EVAL_3K3W_TP_PFC_SIC at full-load start-up
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Inverter (DC-AC operation) specification and test results
3
Inverter (DC-AC operation) specification and test results
The bridgeless totem-pole topology offers inherent bi-directional power flow capability, which has been
explored in the EVAL_3K3W_TP_PFC_SIC. The inverter operation mode can be selected before the application
starts by choosing the “INV” option in the available switch (SW1) on the main board.
Note:
The power flow or operation mode is selected before the application starts and the power flow
cannot be reverted during operation in this version of the SW. Therefore, the
EVAL_3K3W_TP_PFC_SIC board is able to operate as either PFC or inverter but the SW is not ready
for dynamic change of operation mode.
INV/PFC
Switch
Figure 26
Switch to select the operation mode (PFC or inverter) in the EVAL_3K3W_TP_PFC_SIC
The inverter operates at 65 kHz switching frequency for high-line AC input (176 V minimum RMS voltage), as in
the rectifier operation. The specifications in inverter operation regarding efficiency, THD, PF, AC voltage ranges
and OCP are the same as those shown in Table 1. Table 4 shows those specifications which are different for
inverter operation.
Table 4
Summary of specifications and test conditions for the 3300 W bi-directional totem-pole
board in inverter mode
Test
Conditions
Specification
Rated DC voltage
AC voltage
400 V
Relay off after 100 ms
174 V on; 168 V off
DC voltage
Low range: 390 V on, 350 V off/latching
High range: 410 V on, 450 V off/latching
Load transient
Power line
disturbance
Soft change between received power
commands
AC lost
230 Vrms, 50 Hz, 2 ms, load
independent
Inverter resumes operation with soft-start
after AC returns to range
Voltage sag
100 ms under 170 V, load
independent
Inverter off and restarts after a defined time
with soft-start when AC returns to range
As introduced in section 2.1, the EVAL_3K3W_TP_PFC_SIC board has been tested using
EVAL_3K3W_BIDI_PSFB as the voltage supplier for inverter mode (Figure 27).
Application Note
20
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EVAL_3K3W_TP_PFC_SIC
Inverter (DC-AC operation) specification and test results
Note:
Since the DC-DC board has been designed as stand-alone, changes in the control loop have been
implemented to operate with the SiC bridgeless totem pole as a load.
Figure 27
EVAL_3K3W_BIDI_PSFB and EVAL_3K3W_TP_PFC_SIC set-up for inverter test connected to
a grid emulator
3.1
Performance and steady-state waveforms
The totem-pole bi-directional converter with Infineon CoolSiC™ presente in this pplication note has been
tested in steady-state up to 3 kW output power. The power limitation is necessary because of the thermal
limitation of EVAL-3K3W_BIDI_PSFB operating in boost mode [6]. Figure 28 shows the efficiency measurements
(without fan consumption) for inverter operation at different AC voltages at 50 Hz. AC current performance for
inverter operation of the bi-directional totem pole is presented in Figure 29.
99,2
99
98,8
Efficiency (%)
98,6
98,4
98,2
98
Eff_INV_176V(%)
97,8
Eff_INV_230V(%)
97,6
Eff_INV_265V(%)
97,4
0
Figure 28
500
1000
1500
2000
Output power (W)
2500
3000
3500
Measured efficiency for inverter operation of the EVAL_3K3W_TP_PFC_SIC board at
different RMS voltages (50 Hz)
20
1
16
INV_176V
14
INV_230V
12
INV_265V
0,975
Power factor
Current THD (%)
18
10
8
6
4
0,95
INV_176V
0,925
INV_230V
0,9
INV_265V
0,875
2
0,85
0
0
500
Figure 29
Application Note
1000
1500
2000
Output power (W)
2500
3000
0
3500
500
1000
1500
2000
Output power (W)
2500
3000
3500
Measured THD (left) and power factor (right) for inverter operation of
EVAL_3K3W_TP_PFC_SIC board at different RMS voltages (50 Hz)
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Inverter (DC-AC operation) specification and test results
The inductor current of the bridgeless totem-pole topology in inverter operation is 180 degrees out of phase in
comparison with the PFC operation. Therefore, current is actually injected into the AC grid. This main difference
can be seen in Figure 30, which shows the main waveforms of the EVAL_3K3W_TP_PFC_SIC board in rectifier
and inverter operation for the same power level, 50 percent load.
Waveforms:
Ch1
Ch2
Ch3
Ch4
Ch5
time
Inductor current
AC voltage
Input current
V_DS_LS
V_GS_LS
10A/div
130V/div
10A/div
100V/div
10V/div
4ms/div
Figure 30
Steady-state waveforms at 230 V 50 Hz for 50 percent load (1.65 kW) in PFC (left) and
inverter (right) mode
3.2
Inverter mode load change
In inverter mode, the EVAL_3K3W_TP_PFC_SIC board behaves as a current source connected between two
voltage sources: the bulk voltage and the AC grid. In that case, the power to be injected into the grid is set by
the DC-DC stage, which also regulates the bulk voltage (input voltage for the inverter). Therefore, the DC-DC
stage would send a power command to the DC-AC converter, which in the presented tests has been substituted
by a power command sent from the computer using a GUI (section 1.3).
When a new power command is received, the power is modified following a ramp as shown in Figure 31, where
a power change from 300 W to 2500 W is received. A similar behavior would be observed in case of a power
command reduction.
Waveforms:
Figure 31
Application Note
Ch1
Ch2
Ch3
Ch4
time
DC/AC Inductor current
AC voltage
LV DC/DC Input current
Vbulk(350V offset)
1s/div
10A/div
100V/div
10A/div
20V/div
Load increase (300 W to 2.5 kW) in inverter mode; 230 V, 50 Hz AC voltage
22
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Inverter (DC-AC operation) specification and test results
3.3
Power line disturbance and AC voltage variation
3.3.1
Inverter mode LCDO
In the case of inverter operation, the hold-up time does not apply since the DC-DC stage is controlling the bulk
voltage, i.e. the supply voltage to the DC-AC stage. Therefore, when an AC voltage loss is detected (AC close to
zero for more than 2 ms) the inverter prepares for soft-start operation when the voltage returns. This behavior,
which is independent of the injected power, can be seen in Figure 32 for a 20 ms line drop-out to 0 V, or in
Figure 33 when the AC goes to 0 V for 50 ms.
Waveforms:
Figure 32
Ch1
Ch2
Ch3
Ch4
Ch4
time
Inverter behavior under AC-line drop-out of 20 ms for 800 W power
Waveforms:
Figure 33
Application Note
Inductor current 3A/div
AC voltage
100V/div
Input current
3A/div
Vbulk_DC
50V/div
LS_pulses_uC
2V/div
100ms/div
Ch1
Ch2
Ch3
Ch4
time
Inductor current 3A/div
AC voltage
120V/div
Input current
3A/div
Vbulk_DC
50V/div
25ms/div (zoom)
Detail of the inverter behavior under AC-line drop-out of 50 ms for 800 W power
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Inverter (DC-AC operation) specification and test results
3.3.2
Voltage sag and AC voltage variation
The behavior shown previously occurs when the AC voltage drops to zero. In case the AC voltage is under the AC
voltage limit specified in Table 4, the inverter will stop operation and open the NTC relay. After a defined time
the inverter resumes operation with soft-start after closing the relay, provided that the AC voltage has returned
to the nominal range. Figure 34 shows a voltage sag from 230 to 115 V for 200 ms with 2.5 kW injected into the
grid emulator, in which the sequence shown can be recognized.
OFF after
100ms
Wait time
(relay Off)
Waveforms:
Figure 34
Soft-start to power
level before AC lost
Ch1
Ch2
Ch3
Ch4
time
DC/AC Inductor current
AC voltage
LV DC/DC Input current
Vbulk(350V offset)
500ms/div
10A/div
100V/div
10A/div
20V/div
115 V/200 ms voltage sag from 230 V at 2.5 kW inverter operation
In case the AC voltage is out of range for a time shorter than 100 ms, when the AC voltage returns to range a
higher current is momentarily demanded by the inverter. This increase in the current, together with the slow
voltage loop of the DC-DC supplying the bulk voltage, produces an over-current in the DC-DC low-voltage side.
This over-current can trigger Over-Current Protection (OCP) in the DC-DC stage. Figure 35 – left, shows a
successful voltage sag of 100 ms from 230 to 115 V with 380 W output power. However, when the power is
increased to 880 W the increase in the AC current during the transition transfers into an increase in the lowvoltage current and DC-DC OCP (68 A) is triggered. After that, the DC-DC converter stops and bulk voltage
reaches down to 350 V, and thus the DC-AC totem-pole latches operation.
Application Note
24
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EVAL_3K3W_TP_PFC_SIC
Inverter (DC-AC operation) specification and test results
Waveforms:
Figure 35
Ch1
Ch2
Ch3
Ch4
time
DC/AC Inductor current
AC voltage
LV DC/DC Input current
Vbulk(350V offset)
50ms/div
10A/div
100V/div
10A/div
20V/div
115 V voltage sag from 230 V applied during 100 ms at 380 W (left) and 880 W (right)
The same behavior can be expected even with variations within the normal AC range. Figure 36 shows two
examples of 265 to 176 V steps in the AC voltage for different power levels. When the power increases, OCP in
the DC-DC stage can also be triggered, as shown above.
Waveforms:
Figure 36
Application Note
Ch1
Ch2
Ch3
Ch4
time
DC/AC Inductor current
AC voltage
LV DC/DC Input current
Vbulk(350V offset)
200ms/div
10A/div
100V/div
10A/div
20V/div
265 to 176 V AC voltage variation for 960 W (left) and 1200 W (right) in inverter operation
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Thermal measurements
4
Thermal measurements
The board shown in this document (EVAL_3K3W_TP_PFC_SIC) is not provided with an enclosure. The
implemented thermal concept uses a low-power fan attached to the main heatsink, in which the power
semiconductors dissipate their generated losses. The PFC choke is behind the heatsink and also receives the
airflow from the implemented fan.
As can be seen, especially for AC voltages in the lower part of the range, the hotspot of the board is the PFC
choke. As introduced above, the PFC choke is implemented with a high-flux EQ core and helical flat wire. The
obtained form factor of this design enables high efficiency and increased power density, while keeping the
height requirement. The main disadvantage is the heat dissipation, since there are only two small contacts to
dissipate the winding heat through the PCB and the enclosed core limits the airflow from the implemented fan.
Therefore, a more powerful fan in an enclosed environment might be required in the final application.
Figure 37
Thermal capture at room temperature of EVAL_3K3W_TP_PFC_SIC at nominal input (230 V)
and full-load (3.3 kW) conditions for PFC operation
Figure 38
Thermal capture at room temperature of EVAL_3K3W_TP_PFC_SIC at minimum AC voltage
(176 V) and full-load (3 kW) conditions for inverter operation
Application Note
26
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
Summary
5
Summary
This document introduced an Infineon system solution for bridgeless totem-pole PFC, which achieves a peak
efficiency of 99 percent with a 1U form factor and a power density of 73 W/in3. The totem-pole PFC topology is
enabled by using an Infineon 650 V CoolSiC™ silicon c r i e MOS ET. The com in tion of the wi e n -gap
switches and 600 V CoolMOS™ C7 enables high performance in a compact form factor, as presented in this
application note. The bridgeless topology implements full digital control on an XMC™ 1000 series Infineon
microcontroller.
The EVAL_3K3W_TP_PFC_SIC board has been tested using programmable AC source and electronic load to
demonstrate the power line disturbance behavior or dynamic load conditions in PFC operation. But the bidirectional DC-DC phase-shift full-bridge board from Infineon (EVAL_3K3W_BIDI_PSFB) has also been used for
both the PFC and inverter test.
Digital control enables the utilization of the inherent bi-directional power flow capability of the bridgeless
totem-pole topology of EVAL_3k3W_TP_PFC_SIC. The power flow must be selected before starting the board,
by using an incorporated switch in the main board. The bi-directional solution presented in this document is
not prepared for dynamic change in the power flow.
The performance of the board in PFC operation complies with power line disturbance and hold-up time. In the
case of inverter operation, the dynamic load and power line disturbance behavior has been adapted by
introducing soft transitions. The interaction with the DC-DC converter and the influence of AC variations in
inverter operation is also discussed in the application note.
Application Note
27
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EVAL_3K3W_TP_PFC_SIC
Schematics
6
Schematics
Figure 39
EVAL_3K3W_TP_PFC_SIC main board schematic, which includes control board, bias board
and fan connectors, as well as the PFC/inverter selection switch. Infineon devices are
highlighted.
Application Note
28
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Schematics
Figure 40
Application Note
Control card schematic in EVAL_3K3W_TP_PFC_SIC with XMC1404
29
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Bill of Materials (BoM)
7
Bill of Materials (BoM)
Table 5
Main board components in EVAL_3K3W_TP_PFC_SIC
Designator
T1, T2
T3, T4
IC1, IC3
BR1
C1
C2, C7, C11, C50
C3, C10
C4, C12, C20, C41
C5, C6, C13, C14
C8, C9
C15, C16
C17
C19, C48
C25
D1, D2, D4, D5, D9
D3, D6, D7, D8, D10, D13, D14
F1
H1
IC2
L1
L3, L4, L5
NTC1, NTC2
R1, R2, R3, R4, R16, R17, R18, R19,
R20, R21, R22, R23, R25, R26, R27,
R29, R30, R31, R32, R33
R5, R6
R10
R15
R24
R28, R49
R34, R38
R37, R54, R59
R50
R51, R62
R53, R66
REL1
SW1
X1
X2
X3
X4
Application Note
Value
IPW60R017C7
IMZA65R048M1
2EDF7275F
LVB2560
10 µF
4.7 nF
3.3 µF
1 µF
470 µF
1 µF X2
33 nF
470 µF
22 nF
1 µF
RSFJL
BAT165
25 A
LAM4K05024
L78L05ACUTR
500 µH
2.5 mH
14 R
Tolerance
750 k
2k7
0R
R003
820 R
390 R
6R8
10 R
0R
560 R
10 R
ALF1P24
2AS1T2A1M2RES
SQW-116-01-L-D
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
1 percent
MKDS 5/3-6,35 –
1714955
MKDS 5/3-6,35 –
1714968
30
X5R
Y2
10 percent
X7R
20 percent
20 percent
5 percent
20 percent
X7R
X7R
Voltage
600 V
650 V
600 V
25 V
300 V
305 V AC
25 V
450 V
305 V AC
630 V
25 V
50 V
25 V
600 V
40 V
24 V
25 percent
24 V
Description
MOSFET
N-channel MOSFET
Integrated circuit
Bridge diode
Ceramic capacitor
Ceramic capacitor
Foil capacitor
Ceramic capacitor
Polarized capacitor
Foil capacitor
Foil capacitor
Polarized capacitor
Ceramic capacitor
Ceramic capacitor
Diode
Schottky diode
Fuse
Heatsink
Integrated circuit
Inductor
Inductor
NTC resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Relais
Toggle switch
Pin header 2 x 16
Female header, 2 contacts
AC connector
DC connector
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3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
Bill of Materials (BoM)
Table 6
Control board components in EVAL_3K3W_TP_PFC_SIC
Designator
IC1
T1
C1, C2, C17, C28
C3, C7, C9, C11, C14, C16, C20, C22,
C25, C27
C4, C6, C8, C10
C5
C12, C15, C21, C23, C26, C33, C34
C13, C18, C19, C24, C29, C30, C31
D1, D2, D3
IC2
IC3, IC4
IC5
Value
XMC1404-LQFP-64
BSS138N
330 pF
Tolerance
Voltage
X7R
50 V
100 nF
1 nF
10 µF
10 µF
100 pF
Blue LED
OPA2376AIDR
LMH6642MF
X7R
X7R
X7R
X7R
X7R
25 V
25 V
6V3
25 V
50 V
L1
R1, R4, R7, R15, R17, R33
R2, R13, R25, R29, R30
TL431B
Ferrite bead 60 Ω at
100 MHz
1k
510 R
R3, R5, R10, R12
37k4
R6, R8, R9, R11
750 k
R14, R16, R26, R28
750 R
R18, R19, R27, R31
47 R
X1
TMM-116-03-L-D
Application Note
31
0.50
percent
1 percent
1 percent
0.10
percent
0.10
percent
0.10
percent
0.10
percent
Description
Integrated circuit
MOSFET
Ceramic capacitor
Ceramic capacitor
Ceramic capacitor
Ceramic capacitor
Ceramic capacitor
Ceramic capacitor
LED diode
Integrated circuit
Integrated circuit
Integrated circuit
Inductor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Pin header 2 x 16
contacts
Revision 1.0
2020-01-14
3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
References
8
References
[1] Q. Huang and A. Q. Huang, “Review of GaN totem-pole bridgeless PFC”, in CPSS Transactions on Power
Electronics and Applications, vol. 2, no. 3, pp. 187–196, Sept. 2017.
[2] “XMC1400 AA-Step Reference M nu l”, August 2016. Available online.
[3] “800 W Pl tinum® server power supply, using 600 V CoolMOS™ C7 and digital control with XMC™”.
AN_201707_PL52_022.
[4] “P C emo o r – system solution. High power ensity 800 W 130 Hz Pl tinum server esign”.
Application note.
[5] “High-efficiency 3 kW bridgeless dual-boost PFC demo board; 90 kHz digital control design based on 650 V
CoolMOS™ C7 in TO-247 4-pin”. AN_201708_PL52_025.
[6] “3300 W 54 V bi-directional phase-shift full- ri ge with 600 V CoolMOS™ C D7 n XMC™”,
EVAL_3K3W_BIDI_PSFB. AN_1809_PL52_1809_081412.
Application Note
32
Revision 1.0
2020-01-14
3300 W CCM bi-directional totem pole with 650 V CoolSiC™ and XMC™
EVAL_3K3W_TP_PFC_SIC
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Revision 1.0
2020-01-14
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