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User guide 

22 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 

Quantity 

Ref 

Designator 

Value 

Description 

Manufacturer  Manufacturer P/N 

6.90mm W X 5.00mm H 
body / SMD / - 

2 

L5, L6 

220R 

Chip Ferrite Bead 

Wurth Elektronik 

742792031 

1 

NTC1 

AYN-MF56-503F-3950FB-
28#-100 

Header, 2-Pin 

 

 

AYN-MF56-503F-3950FB-
28#-100 

2 

P1, P2 

66100211622 

CONNECTOR HEADER 
VERT 2POS 2.54MM 

Wurth Elektronik 

66100211622 

1 

Q1 

IRLML6402TRPBF 

HEXFET P-Channel 
Power MOSFET, 20V, 
3.7A 

Infineon 
Technologies 

IRLML6402TRPBF 

2 

Q2, Q3 

IKW40N65WR5 

High speed fast IGBT in 
TRENCHSTOPTM 5 
technology, VCE 650V, IC 
40A 

Infineon 
Technologies 

IKW40N65WR5 

1 

Q5 

IPP90R340C3 

900V CoolMOS C3 Power 
Transistor, RDS(on) 
340mOhm 

Infineon 
Technologies 

IPP90R340C3 

3 

R1, R15, R81 

4.7k 

General Purpose Chip 
Resistor 

Yageo 

RC0603FR-074K7L 

4 

R2, R14, R108, 
R109 

0R 

0R/75V 

Panasonic 

ERJ3GEY0R00V 

1 

R3 

NC 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW0603115KFK, 

1 

R11 

NC 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW060310K0FK 

1 

R97 

NC 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW06031K20FK 

2 

R4, R27 

1.82k 

Standard Thick Film 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 Film Chip 
Resistor 

Vishay 

CRCW060322K6FK 

3 

R8, R66, R67 

1k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW12061K00FK 

1 

R9 

1.5k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW06031K50FK 

8 

R10, R32, R33, 
R35, R38, R45, 
R48, R100 

10k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW060310K0FK 

1 

R12 

118k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW0603118KFK 

1 

R13 

1k 

1k/200V/1% 

TT Electronics 

ASC1206-1K0FT5 

1 

R16 

124k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW0603124KFK 

1 

R17 

33k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW060333K0FK 

1 

R18 

84.5k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW060384K5FK 

4 

R20, R21, R22, 
R23 

62R 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW121062R0FK 

1 

R24 

3.65k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW06033K65FK 

2 

R25, R26 

5.62k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW06035K62FK 

1 

R28 

5.49k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW06035K49FK 

1 

R29 

200k 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW0603200KFK 

3 

R30, R43, R51 

100k 

General Purpose Chip 
Resistor 

Yageo 

RC0603FR-07100KL 

18 

R31, R34, R36, 
R37, R41, R42, 
R56, R57, R59, 
R63, R64, R65, 
R73, R74, R75, 
R78, R79, R80 

1MEG 

Standard Thick Film Chip 
Resistor 

Vishay 

CRCW12061M00FK 

Содержание 1ED44175

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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