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Application Note AN 2014-06

V1.1 January 2015

E V A L P F C - 3 k W - I P Z 6 5 R 0 1 9 C 7

3 k W P F C E v a l u a t i o n B o a r d

IPZ 6 5 R 0 1 9 C 7 wit h C C M P F C c o n t r o l l e r

Stückler Franz (IFAT PMM APS SE SL)

Siu Ken (IFHK PMM SMD AP APC)

Summary of content (23 pages)

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Application Note AN 2014-06 V1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 Edition 2011-02-02 Published by Infineon Technologies Austria AG 9500 Villach, Austria © Infineon Technologies Austria AG 2011. All Rights Reserved.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 General safety instruction Warning: The evaluation board works with high voltage which could be deadly for the users. Furthermore all circuits on the board are not isolated from the line input. Due to the high power density, the components on the board as well as the heat sink can be heated to a very high temperature which can cause a burning risk when touched directly.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 Table of contents 1 Introduction .................................................................................................................................................. 5 1.1 Evaluation Board ................................................................................................................................ 5 1.2 CoolMOS™ C7 ......................................................................................
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 1 1.1 V1.1 January 2015 Introduction Evaluation Board This document describes the evaluation board EVALPFC-3kW-IPZ65R019C7, which is designed for the customers to evaluate the performance of the TO247-4pin CoolMOSTM C7 family.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 characteristics and a lower figure of merit (Q c*Vf). More than this it offers also increased dv/dt robustness up TM to 100V/ns which enables very fast switching. This is perfect fit to the fast switching CoolMOS C7 family. 1.4 CCM-PFC Controller The evaluation board presented here is a 3kW power factor correction (PFC) circuit with 85~265VAC universal input and output of 400VDC.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 2 V1.1 January 2015 Application The demo board described within this document is based on a CCM PFC (continuous conduction mode power factor correction) as shown the principle schematic below.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 3 3.1 V1.1 January 2015 Circuit Description 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 high precisely power metering. The choke L3, X2-capacitor C4/C5/C23 and Y1-capacitors C17/CY18 are used to suppress common mode noise as well as differential mode noise.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 is possible to optimize this fan between noise generation and cooling effect by changing the changeable resistor R28 nearby the fan for the bridge rectifier. The main heat sink for the DUT offers cooling and heating functionality in parallel.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 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.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 4.3.4 V1.1 January 2015 IC supply under voltage lockout When VCC voltage is below the under voltage lockout threshold VCCUVLO, typical 11V, IC is off and the gate drive is internally pull low to maintain the off state. The current consumption is down to 1.4mA only. 4.3.5 Bulk Voltage Monitor and Enable Function (VBTHL_EN) The IC monitors the bulk voltage status through VSENSE pin and output a TTL signal to enable PWM IC or control inrush relay.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 5 V1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 6 V1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 7 V1.1 January 2015 Component List Value Description B1, B2 closed with 0Ohm Placeholder for Ferrite Bead, 0Ohm resitor Bias1 12V Bias Bias adapter C1 10µ 25V C2 4n7 25V C3 10n 25V C4, C5 1µ x-capacitor C6 4.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 IC1 TDA2030 Mount with M2.5x6 IC2 LM4040 LM4040D20IDBZRG4 IC3 ICE3PCS01G PFC_CCM_Controller IC4 1EDI60N12AF 6A_isolated_MOSdriver IC5 IFX91041 1.8A Step down switching regulator J1, J11 Jumper_3Pin SPC20486 J2 Strombruecke 1.25mm isolated copper wire J3 BOHRUNG U-schape-Cu-wire 1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 X5 np (MOS2) Thermal measurement connector X6 Rg_4pin SPC20485 X7 Rg_3pin SPC20485 X8, X9 KL_STANDARD_2 SPC20485 X12 np for adapter power supply 8 Boost Choke Layout The boost choke on this evaluation board is self winded since this is not a volume production. It consists of 2 stacked “Kool Mμ” toroids cores with the partnumber 77083A7. As a result of the 64windings with 1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 10 V1.1 January 2015 Test report All test condition are based on 60°C heat sink temperature. For the efficiency test it is important to take the voltage sensing on the input and output power with the Vin_sense and Vout_sense right beside the power connections. 10.1 Load and Line Test VIN IIN PIN UOUT IOUT POUT 400.89 400.9 400.86 400.89 400.89 400.87 400.87 400.89 400.88 400.89 400.89 400.89 400.89 400.88 400.85 400.87 400.88 400.87 400.82 400.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 Figure 10: High line efficiency with IPW65R019C7 & IDH16G65C5 @ 100kHz 1.8ohms Figure 11: Low line efficiency with IPW65R019C7 & IDH16G65C5 @ 100kHz 1.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 10.2 V1.1 January 2015 Conductive EMI Test EMI is a very important quality factor for a power supply. The EMI has to consider the whole SMPS and is splitted into radiated and conductive EMI consideration. For the described evaluation PFC board, it is more important to investigate on the conducted EMI-behavior since a PFC is the input stage of any SMPS with input power above 75 watts or greater.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 V1.1 January 2015 Figure 13: Conductive EMI Measurement of the Board with resistive load after modification 10.3 Startup behavior During power up when the VOUT is less than 96% of the rated level, internal voltage loop output increases from initial voltage under the soft-start control.
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Application Note AN 2014-06 EVALPFC-3kW-IPZ65R019C7 11 V1.1 January 2015 Conclusion The 3kW PFC Evaluation Board described in this document is aimed to analyze the switching performance of different variants of packages in a very common used PFC topology. It helps to understand the switching behavior and parasitic influences. With the various option settings via “solder jumper” it is possible to modify the circuit without changing any layout.