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User guide 

20 of 41 

v1.0  

 

 

2021-03-05 

5 kW two-channel interleaved CCM PFC EVAL board 

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application 

   

System design 

3.3

 

Bill of material 

 

The complete bill of material is available on the download section of the Infineon homepage. A log-in is 
required to download this material. 

Table 3

 

BOM of evaluation board 

Quantity 

Ref 

Designator 

Value 

Description 

Manufacturer  Manufacturer P/N 

15 

C1, C5, C6, C8, 
C13, C28, C30, 
C33, C35, C39, 
C46, C48, C58, 
C59, C73 

100nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71E104KA01,  

2 

C2, C18 

180nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GCM188R71E184JA55 

6 

C3, C9, C27, 
C76, C89, C90 

1nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71E102KA01,  

4 

C4, C34, C36, 
C37 

2.2uF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R61E225KA12 

18 

C7, C29, C31, 
C56, C57, C61, 
C62, C63, C66, 
C67, C70, C71, 
C72, C82, C83, 
C84, C86, C88 

10uF 

Commerical Grade 
Multilayer Ceramic Chip 
Capacitor 

TDK Corporation 

C3216X7R1E106K160AB 

2 

C10, C81 

100pF 

Multilayer Ceramic Chip 
Capacitor, C Series, 
Commercial Grade, 
General 

TDK Corporation 

C1608X7R1H101M 

3 

C11, C21, C23 

2.2nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71E222KA01 

1 

C12 

51nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GCM188R71E473KA37 

4 

C14, C32, C38, 
C68 

1uF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71E105KA12 

1 

C15 

470nF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71C474KA88 

2 

C16, C91 

330pF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM216R71H331KA01 

3 

C17, C53, C54 

330pF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71H331KA01 

4 

C19, C20, C25, 
C26 

470pF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM188R71H471KA01 

2 

C22, C24 

560pF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM1885C1E561JA01 

2 

C40, C41 

1uF 

Metallized Polypropylene 
Film Capacitor 

TDK Corporation 

B32923C3105M000 

1 

C42 

1uF 

Metallized Polyester Film 
Capacitor 

Epcos 

B32522N6105K000 

1 

C43 

NC 

Metallized Polyester Film 
Capacitor 

Epcos 

B32522N6105K000 

5 

C44, C45, C47, 
C55, C80 

2.2nF 

AC Line Rated Ceramic 
Disc Capacitor Class X1, 
760 VAC / Class Y1, 500 
VAC 

Vishay 

440LD22-R 

4 

C49, C50, C51, 
C52 

680uF 

CAP / ELCO / 680uF / 
450V / 20% / - / -40

℃

 to 

105

℃

 /  10.00mm Pitch X 

35.00mm Dia X 62.00 mm 
H body / - / - 

Aishi 

ELP2WM681R60KT 

1 

C60 

68uF 

Miniature Aluminum 
Electrolytic Capacitor 

Aishi 

EHL2WM680W50OT 

4 

C64, C65, C85, 
C87 

470uF 

Aluminum Electrolytic 
Capacitor / FC Series 

Aishi 

SPD1CM102G12O00RAXX
X 

1 

C69 

220uF 

Miniature Aluminium 
Electrolytic Capacitor 

Aishi 

EML1EM221F09OT 

1 

C74 

12pF 

Chip Monolithic Ceramic 
Capacitor 

MuRata 

GRM31A5C2H120JW01 

Summary of Contents for 1ED44175

Page 1: ...ery effective example of design with Infineon s low side gate driver 1ED44175 and rapid1 power silicon diode IDW60C65D1 The evaluation board has a flexible input AC voltage between 180 264 V and provi...

Page 2: ...hey are operated by the customer The customer shall ensure that all Evaluation Boards and Reference Boards will be handled in a way which is compliant with the relevant requirements and standards of t...

Page 3: ...y become hot during testing Hence necessary precautions are required while handling the board Failure to comply may cause injury Caution Only personnel familiar with the drive power electronics and as...

Page 4: ...g WR5 IGBT 9 2 1 3 IDW60C65D1 rapid1 power silicon diode 9 2 1 4 1ED44175 low side gate driver 10 2 2 Board specifications 10 3 System design 11 3 1 Schematics 11 3 2 Layout 17 3 3 Bill of material 20...

Page 5: ...tion with 120 out of phase the interleaved operation shares the same load capacitors and reduces input current ripple significantl It also eases the burden of filtering conducted EMI noise and helps r...

Page 6: ...y optimized for full rated hard switching applications with an excellent price performance ratio and is recommended for use in AC DC PFC stage for cost sensitive applications The EVAL PFC5KIKWWR5SYS i...

Page 7: ...1ED44175 in high frequency PFC application The board at a glance External force cooling for high power application IL2 IL1 ID2 ID1 Ic IQ2 IQ1 Iout CT1 CT2 UCC28070 interleaved CCM PFC controller GDA G...

Page 8: ...ajor home appliances Figure 4 EVAL PFC5KIKWWR5SYS board view The EVAL PFC5KIKWWR5SYS evaluation board design characteristics include Board performance High power factor PF 0 995 Low THDi High efficien...

Page 9: ...hard switching applications with a best price performance ratio and it is a good fit with mainstream designs of FSW 20 kHz The IKW40N65WR5 features the following key characteristics Very low VCEsat of...

Page 10: ...an OCP threshold tolerance of 5 Its features are listed as follows 0 246 V over current threshold with accurate 5 tolerance Over current detection with negative voltage input Single pin for fault out...

Page 11: ...on the same board All surface mounted devices are mounted on the bottom layer enabling customers to modifiy parameters if necessary 3 1 Schematics There are a total of 6 schematic diagrams in its des...

Page 12: ...ect in parallel with 180 out of phase control Each channel has a WR5 IGBT IKW40N65WR5 as main switch a rapid1 fast recovery diode IDW60C65D1 with common cathode as boost diodes for both channels in pa...

Page 13: ...5WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application System design 1ED44715 matches one IGBT Two boost inductors with NPH L material comes from POCO have better performance than inductors wi...

Page 14: ...h frequency PFC application System design Figure 8 depicts the UCC28070 analog control and its parameter settings with external resistors and capacitors Potentiometer R115 sets converter switching fre...

Page 15: ...plied the RC time constant for these two pins should not exceed 100 us More information about how to control the UCC28070 with external components can be found in 1 Figure 9 shows the fault protection...

Page 16: ...ng of VVSENSE the intput over voltage protection and under voltage protection in this converter are implemented by an external comparator both of which are also connected to the SS pin of UCC28070 Fig...

Page 17: ...is 13 8V therefore as shown in Figure 11 two LDO chips IFX1963 provide about 13 6 V voltage to fans directly without fan speed regulation Figure 11 Low dropout regulator for fans of EVAL PFC5KIKWWR5S...

Page 18: ...D1 and 1ED44175 in high frequency PFC application System design Figure 12 Top layer routing of EVAL PFC5KIKWWR5SYS Figure 12 illustrates the top layer routing of this evaluation board Figure 13 Mid la...

Page 19: ...and 1ED44175 in high frequency PFC application System design Figure 14 Mid layer 2 routing of EVAL PFC5KIKWWR5SYS Figure 14 shows the mid layer 2 routing of this evaluation board Figure 15 Bottom lay...

Page 20: ...MuRata GRM188R71E222KA01 1 C12 51nF Chip Monolithic Ceramic Capacitor MuRata GCM188R71E473KA37 4 C14 C32 C38 C68 1uF Chip Monolithic Ceramic Capacitor MuRata GRM188R71E105KA12 1 C15 470nF Chip Monolit...

Page 21: ...n Technologies IDW60C65D1 1 D20 STTH10LCD06FP Turbo2 Ultrafast High Voltage Rectifier For Flat Panel Displays STMicroelectronic s STTH10LCD06FP 2 D21 D22 NC 650 V rapid 1 Diode 30A TO247 3 Infineon Te...

Page 22: ...Chip Resistor Vishay CRCW06031K82FK 1 R5 3MEG Standard Thick Film Chip Resistor Vishay CRCW06033M00FK 2 R6 R50 82k Standard Thick Film Chip Resistor Vishay CRCW060382K0FK 2 R7 R19 22 6k Standard Thick...

Page 23: ...30k Standard Thick Film Chip Resistor Vishay CRCW060330K0FK 2 R85 R86 680R Standard Thick Film Chip Resistor Vishay CRCW0603680RFK 2 R87 R105 3k 3k 50V 1 ROHM Semiconductors MCR03EZPFX3001 3 R88 R91 R...

Page 24: ...5 X1 X3 X6 X7 X9 7460307 WP BUTR Redcube Press Fit with Internal Thread and Two Rows Pin Plate Wurth Elektronik 7460307 2 X2 X8 691311500102 Terminal Block 2Pins 5 08mm Pitch Board to Cable Wurth Ele...

Page 25: ...FC5KIKWWR5SYS including the aux supply for cooling fans at different input voltages between 180 VAC and 264 VAC The efficiency curves show that WR5 IGBTcan support customers to increase the PFC switch...

Page 26: ...voltage rectifier and the inrush current is limited by two NTC resistors Once output voltage reaches about 230 VDC K1 relay turns on and two NTC are shorted enabling the converter works with high effi...

Page 27: ...ed VCE Green Figure 19 Full load start up at VIN 264 VAC 4 3 Input current and inductor current cancellation The next six waveforms show the input AC current and two inductor current waveforms of the...

Page 28: ...0N65WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application System performance IIN Green IL1 Yellow IL2 Red VIN Blue Figure 21 Detail view of interleaving operation at full load at VIN 180 VAC I...

Page 29: ...0N65WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application System performance IIN Green IL1 Yellow IL2 Red VIN Blue Figure 23 Detail view of interleaving operation at full load at VIN 230 VAC I...

Page 30: ...itching losses enabling the MOSFET to be replaced by a WR5 IGBT in up to 100 kHz applications The following three waveforms show switching performances of IKW40N65WR5 with the low side gate driver 1ED...

Page 31: ...VCE Green VGE Yellow IL1 Red VOUT Blue Figure 28 Switching waveforms of IGBT at VIN 200 VAC at full load discontinue current at low point of input voltage 4 5 Output ripple voltage Due to the limitati...

Page 32: ...PFC EVAL board IKW40N65WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application System performance VOUT Blue IIN Red Figure 29 PFC output ripple voltage at VIN 180 VAC at full load VOUT Blue IIN...

Page 33: ...UT Blue IIN Red Figure 31 PFC output ripple voltage at VIN 264 VAC at full load 4 6 Input voltage and input current The line current in the following figures are nearly perfect sinusoidal waves in pha...

Page 34: ...nput current at VIN 230 VAC at full load VIN Blue IIN Red Figure 34 PFC input voltage and input current at VIN 264 VAC at full load 4 7 Load step tests Figure 35 and Figure 36 illustrate the response...

Page 35: ...nnel interleaved CCM PFC EVAL board IKW40N65WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application System performance VOUT Blue IOUT Green Figure 35 Load step 0 100 at VIN 180 VAC VOUT Blue IOU...

Page 36: ...illustrates the response of the voltage control loop during a load step from 100 to 0 with a voltage overshoot up to 425 V A similar response can be observed at VIN 230 VAC and VIN 264 VAC 4 8 Thermal...

Page 37: ...far away from the cooling fans Accoding to temperature data collected by Keysight 34970A with thermal couples as shown in Table 5 the highest temperature of the IGBT is 84 2 at full load while input...

Page 38: ...peak efficiency of 97 804 by using an Infineon 650 V TRENCHSTOP 5 WR5 IGBT IKW40N65WR5 and rapid1 power silicon diode IDW60C65D1 The EVAL PFC5KIKWWR5SYS board has been tested using a programmable AC...

Page 39: ...Chinese powder core manufacturer NPH L A powder core material from POCO 6 2 References 1 Texas instruments UCC28070 300W Interleaved PFC Pre regulator Design Review Rev B Application Report SLUA479B A...

Page 40: ...channel interleaved CCM PFC EVAL board IKW40N65WR5 IDW60C65D1 and 1ED44175 in high frequency PFC application Revision history Revision history Document version Date of release Description of changes...

Page 41: ...contain dangerous substances For information on the types in question please contact your nearest Infineon Technologies office Except as otherwise explicitly approved by Infineon Technologies in a wri...

Page 42: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information Infineon EVALPFC5KIKWWR5SYSTOBO1...

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