Specifications
EVALPFC-3kW-IPZ65R019C7
8
Application Note AN 2014-06
V1.1 January 2015
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 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. R_NTC2 is placed in series to limit inrush
current during each power on. A relay is mounted across the R_NTC2 to short the resistor when V
OUT
is
higher than ~60V.
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, IPZ65R019C7,
IDH16S65C5, C30, C8, C21 and C24,. The seventh generation CoolMOS™ IPZ65R019C7 and the SiC
Diode IDH16S65C5 share the same heat sink so that the system heat can be equably spread. Output
capacitor C30, C8, C21 and C24 provides energy buffering to reduce the output voltage ripple (100Hz at
50Hz AC input) to the acceptable level and meet the holdup time requirement.
3.2.1 Separate Source Power MOSFET
Infineon’s TO-247 4pin package enables significant efficiency improvements in hard switching topologies for
CoolMOS™ 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 3,5W of saved power in a CCM Mode
PFC running at 1.2KW, which is equal to 0,3% extra full load efficiency compared to the same MOSFET in
the standard 3pin TO-247 package.
The evaluation board is available to test the physical same device in either 3 pins or 4 pins (with sense
source) configuration. The standard setting of the set-up is 4 pin configuration. To change the testing device
to 3 pins configuration, it is necessary to open the connection point J7 and connect the solder point J8 or J6.
Please check chapter 9 on page 17 for more detail information.
3.3 PWM Control of Boost Converter
The ICE3PCS01G is a 14-pins control IC for power factor correction converters. It is suitable for wide range
line input applications from 85 to 265 V
AC
with overall efficiency above 97%. The IC supports converters in
boost topology and it operates in continuous conduction mode (CCM) with average current control.
The IC operates with a cascaded control; the inner current loop and the outer voltage loop. The inner current
loop of the IC controls the sinusoidal profile for the average input current. It uses the dependency of the
PWM duty cycle on the line input voltage to determine the corresponding input current. This means the
average input current follows the input voltage as long as the device operates in CCM. Under light load
condition, depending on the choke inductance, the system may enter into discontinuous conduction mode
(DCM) resulting in a higher 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 which controls the
amplitude of the average input current.
The IC is equipped with various protection features to ensure safe operating condition for both the system
and 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 concept for the input bridge rectifier is designed only for cooling with adjustable fan speed. It