Infineon IKW40N65WR5 Manual de usuario

User guide Please read the Important notice and the Safety precautions and the Warnings

www.infineon.com page 1 of 41 2021-03-05

UG-2021-06

5 kW two-channel interleaved CCM PFC EVAL

board

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC

application

About this document

Scope and purpose

This user manual provides an overview of the reference design developed for the EVAL-PFC5KIKWWR5SYS board,

including its main features, key data, and mechanical dimensions.

EVAL-PFC5KIKWWR5SYS is a fast switching, analog-controlled two-channel interleaved 5 KW PFC converter with

Infineon’s TRENCHSTOP™ 5 WR5 IGBT IKW40N65WR5. It is designed to show case the use of WR5 IGBT with high

switching frequencies up to 60 kHz in an interleaved PFC application, which enables many system benefits such

as smaller size PFC choke, overall system size and BOM cost. This document also demonstrates a very 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 provides a 400 V output voltage

with maximum current up to 12.5 A. This document provides suggestions on how to develop interleaved PFC

converters in similar power ranges adapted to specific requirments, such as high-power SMPS, floor-standing

air conditioners in major home appliances.

Intended audience

This user guide is intended for all technical specialists who are familiar with high-speed AC-DC power stage

design and high-power interleaved PFC converters. The reference design is intended to be used under laboratory

conditions and only by trained specialists.

Evaluation Board

This board will be used during design in, for evaluation and measurement of characteristics, and proof of data

sheet specifications.

Note: PCB and auxiliary circuits are NOT optimized for final customer design.

Note: Boards do not necessarily meet safety, EMI, quality standards (for example UL, CE) requirements.

User guide 2 of 41 v1.0

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5 kW two-channel interleaved CCM PFC EVAL board

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application

Important notice

“Evaluation Boards and Reference Boards” shall mean products embedded on a printed circuit board

(PCB) for demonstration and/or evaluation purposes, which include, without limitation, demonstration,

reference and evaluation boards, kits and design (collectively referred to as “Reference Board”).

Environmental conditions have been considered in the design of the Evaluation Boards and Reference

Boards provided by Infineon Technologies. The design of the Evaluation Boards and Reference Boards

has been tested by Infineon Technologies only as described in this document. The design is not qualified

in terms of safety requirements, manufacturing and operation over the entire operating temperature

range or lifetime.

The Evaluation Boards and Reference Boards provided by Infineon Technologies are subject to functional

testing only under typical load conditions. Evaluation Boards and Reference Boards are not subject to the

same procedures as regular products regarding returned material analysis (RMA), process change

notification (PCN) and product discontinuation (PD).

Evaluation Boards and Reference Boards are not commercialized products, and are solely intended for

evaluation and testing purposes. In particular, they shall not be used for reliability testing or production.

The Evaluation Boards and Reference Boards may therefore not comply with CE or similar standards

(including but not limited to the EMC Directive 2004/EC/108 and the EMC Act) and may not fulfill other

requirements of the country in which they 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 the country in which they are operated.

The Evaluation Boards and Reference Boards as well as the information provided in this document are

addressed only to qualified and skilled technical staff, for laboratory usage, and shall be used and

managed according to the terms and conditions set forth in this document and in other related

documentation supplied with the respective Evaluation Board or Reference Board.

It is the responsibility of the customer’s technical departments to evaluate the suitability of the

Evaluation Boards and Reference Boards for the intended application, and to evaluate the completeness

and correctness of the information provided in this document with respect to such application.

The customer is obliged to ensure that the use of the Evaluation Boards and Reference Boards does not

cause any harm to persons or third party property.

The Evaluation Boards and Reference Boards and any information in this document is provided "as is"

and Infineon Technologies disclaims any warranties, express or implied, including but not limited to

warranties of non-infringement of third party rights and implied warranties of fitness for any purpose, or

for merchantability.

Infineon Technologies shall not be responsible for any damages resulting from the use of the Evaluation

Boards and Reference Boards and/or from any information provided in this document. The customer is

obliged to defend, indemnify and hold Infineon Technologies harmless from and against any claims or

damages arising out of or resulting from any use thereof.

Infineon Technologies reserves the right to modify this document and/or any information provided

herein at any time without further notice.

User guide 3 of 41 v1.0

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5 kW two-channel interleaved CCM PFC EVAL board

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application

Safety precautions

Note: Please note the following warnings regarding the hazards associated with development systems.

Table 1 Safety precautions

Warning: The DC link potential of this board is up to 400 VDC. When measuring voltage

waveforms by oscilloscope, high voltage differential probes must be used. Failure to do

so may result in personal injury or death.

Warning: The evaluation board contains DC bus capacitors which take time to

discharge after removal of the main supply. Before working on the drive system, wait

five minutes for capacitors to discharge to safe voltage levels. Failure to do so may

result in personal injury or death.

Warning: The evaluation board is connected to the grid input during testing. Hence,

high-voltage differential probes must be used when measuring voltage waveforms by

oscilloscope. Failure to do so may result in personal injury or death.

Caution: The heat sink and device surfaces of the evaluation or reference board may

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 associated

machinery should plan, install, commission and subsequently service the system.

Failure to comply may result in personal injury and/or equipment damage.

Caution: The evaluation board contains parts and assemblies sensitive to

electrostatic discharge (ESD). Electrostatic control precautions are required when

installing, testing, servicing or repairing the assembly. Component damage may result

if ESD control procedures are not followed. If you are not familiar with electrostatic

control procedures, refer to the applicable ESD protection handbooks and guidelines.

Caution: A drive that is incorrectly applied or installed can lead to component damage

or reduction in product lifetime. Wiring or application errors such as undersizing the

motor, supplying an incorrect or inadequate AC supply, or excessive ambient

temperatures may result in system malfunction.

Caution: The evaluation or reference board is shipped with packing materials that

need to be removed prior to installation. Failure to remove all packing materials that

are unnecessary for system installation may result in overheating or abnormal

operating conditions.

 
User guide 4 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 
Table of contents 
 
 
Table of contents 
About this document....................................................................................................................... 1 
Important notice ............................................................................................................................ 2 
Safety precautions.......................................................................................................................... 3 
Table of contents............................................................................................................................ 4 
1The board at a glance.............................................................................................................. 5 
1.1 Interleaved PFC .......................................................................................................................................5 
1.2 Block diagram of the EVAL-PFC5KIKWWR5SYS......................................................................................6 
2System and functional description........................................................................................... 8 
2.1 General overview.....................................................................................................................................8 
2.1.1 UCC28070 - analogy controller ..........................................................................................................9 
2.1.2 IKW40N65WR5 - fast switching 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 
3System design.......................................................................................................................11 
3.1 Schematics ............................................................................................................................................11 
3.2 Layout....................................................................................................................................................17 
3.3 Bill of material .......................................................................................................................................20 
3.4 Connector details ..................................................................................................................................24 
4System performance .............................................................................................................25 
4.1 Efficiency and PFC measurements .......................................................................................................25 
4.2 Start-up behavior ..................................................................................................................................26 
4.3 Input current and inductor current cancellation.................................................................................27 
4.4 Switching performance of IGBT at steady state...................................................................................30 
4.5 Output ripple voltage............................................................................................................................31 
4.6 Input voltage and input current............................................................................................................33 
4.7 Load step tests ......................................................................................................................................34 
4.8 Thermal measurements........................................................................................................................36 
5Conclusions..........................................................................................................................38 
6References and appendices ....................................................................................................39 
6.1 Abbreviations and definitions...............................................................................................................39 
6.2 References .............................................................................................................................................39 
6.3 Additional information..........................................................................................................................39 
Revision history.............................................................................................................................40 
 

User guide 5 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

The board at a glance

1The board at a glance

This section of the UG-2021-06 describes the basic concepts about interleaved PFC and a brief introduction about

the design of EVAL-PFC5KIKWWR5SYS board.

1.1 Interleaved PFC

The standard boost converter is the most popular topology for power factor correction due to a simple control

of the input current while keeping the output voltage constant. For medium power levels, increasing the output

power and improving overall efficiency leads to the use of several converters in a parallel connection, such as

two channles or three channels connected in parallel. Furthermore, if the switches operate at two-channel

connection with 180° out of phase or three-channel connection with 120° out of phase, the interleaved operation

shares the same load capacitors and reduces input current ripple significantl. It also eases the burdenof filtering

conducted EMI noise and helps reduce the EMI filter and CIN sizes.

This approach has several other benefits, such as ease of implementation, the use of more, but smaller

components and better heat distribution. Simultaneously, the output capacitor current ripple is also decreased

and evenly distributed in eachchannel, which can extend the life of the capacitors, help to reduce its size and

cost. Compared to a single boost converter, the inductors in interleaved PFC handle only half or one-third of the

current, inductors with much lower inductance values can reach the same high power, and lower inductance

means smaller inductors and higher power density for a given power rating.

Figure 1 is an example of two-channel interleaved PFC. Its detailed operation principles and key waveforms are

shown in Figure 2.

Iin

IL2

IL1

ID2

ID1

IQ2IQ1

Iout

Figure 1 Block diagram of two-channel interleaved PFC

User guide 6 of 41 v1.0

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5 kW two-channel interleaved CCM PFC EVAL board

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application

The board at a glance

Figure 2 Principles of operation for the two-channel interleaved PFC

1.2 Block diagram of the EVAL-PFC5KIKWWR5SYS

As we know, reduction the size of power converters by increasing switching frequency and reducing magnetic

component size is a goal that has been pursued for decades. This is especially true when using IGBTs in a

switching mode power supply.Higher switching frequency, means smaller size and lower cost. A high

performance IGBT is the key component in helping customers to gain a bigger market share. Fortunately,

Infineon’s WR5 IGBT is specifically 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 is an evaluation board for demonstrating the switching performance of TRENCHSTOP™

5 WR5 IGBT IKW40N65WR5 with high switching frequencies up to 60 kHz in interleaved PFC application.

The block diagram of EVAL-PFC5KIKWWR5SYS is depicted in Figure 3, which shows the high-performance analogy

controller UCC28070, TRENCHSTOP™ 5 IGBT IKW40N65WR5, low side gate driver 1ED44175 and rapid1 power

silicon diode IDW60C65D1.

This reference design includes:

•Two-channel boost converters

•High-speed 650 V, 40 A reverse conducting TRENCHSTOP™ 5 WR5 IGBT in TO-247 package

•Gate driver ICs for WR5 IGBTs

•Rapid1 power silicon diode for boost rectification

•Loss-free current monitering for switching current

•15 V auxiliary power supply

•Connectors for easy setup

User guide 7 of 41 v1.0

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5 kW two-channel interleaved CCM PFC EVAL board

IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application

The board at a glance

•External force cooling for high power application

IL2

IL1

ID2

ID1

IQ2IQ1

Iout

CT1CT2

UCC28070 interleaved CCM PFC controller

GDA GDB

CSA CSB

1ED44175 1ED44175

IKW40N65WR5

IDW60C65D1

Figure 3 Block diagram of EVAL-PFC5KIKWWR5SYS

User guide 8 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 and functional description

2System and functional description

2.1 General overview

EVAL-PFC5KIKWWR5SYS is a referene design for 5 kW interleaved PFC for, but not limited to, floor-standing air

conditioners in major 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 efficiency

Control technology incorporated:

•CCM (continuous conduction mode) average current control

•Frequency-dithering for enhanced EMI reduction

Fault protection:

•Input undervoltage protection and overvoltage protection

•Output overvoltage protection

•Open-circuit protection on AC input and DC output

•Cycle-by-cycle peak current limiting

•Thermal shutdown for power semiconducters

User guide 9 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 and functional description

2.1.1 UCC28070 - analogy controller

Infineon does not have a dedicated interleaved PFC controller, so we chose a UCC28070 from TI, which is a

popular choice in this field. Figure 5 is a simplified application diagram with UCC28070.

Figure 5 Simplified application diagram of UCC28070

2.1.2 IKW40N65WR5 - fast switching WR5 IGBT

IKW40N65WR5 is a high speed 650 V, 40 A reverse-conducting TRENCHSTOP™ 5 WR5 IGBT in TO-247 package. It

is optimized for 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 1.35 V @25°C

•Low Etot

•Soft recovery and low Qrr for diode

•Good R(G)off controllability

•Low T j& Tc for lower heatsink and cooling costs

2.1.3 IDW60C65D1 – rapid1 power silicon diode

IDW60C65D1 is a 650 V/ 60 A rapid1 diode, emitter controlled power silicon diode in common cathode

configuration and in a TO-247 package, allowing design optimization for more compact dimensions, easier

assembly and consequently lower costs. Here is summary of its features:

•Highest softness-factor for ultimate softness and low EMI filtering

•1.35 V temperature-stable forward voltage (VF)

•Lowest Irrm to provide lowest turn-on losses on the boost switch

User guide 10 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 and functional description

2.1.4 1ED44175 - low side gate driver

1ED44175 is an EiceDRIVER™ 25 V single-channel low-side non-inverting gate driver for IGBT with typical 2.6 A

source and sink currents in a tiny 6-lead PG-SOT23 package. 1ED44175N01B provides cost and space savings by

integrating the comparator. The new low-side gate driver utilizes Infineon’s proprietary latch immune CMOS

technologies to enable a rugged monolithic construction while achieving best-in-class fault reporting accuracy

with 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 output and enable

•Programmable fault-clear time

•Under voltage lockout for IGBTs

•CMOS Schmitt-triggered inputs

•3.3 V, 5 V and 15 V input logic compatible

•Output in phase with input

•-10 Vdc negative input capability of OCP pin

•3 kV ESD HBM

2.2 Board specifications

Table 2 depicts the key specifications of the reference design used in the EVAL-PFC5KIKWWR5SYS.

Table 2 EVAL-PFC5KIKWWR5SYS specifications

NO.

Parameters

Symbol

Value

Output power

Pout

5000 watt

Input voltage range (rms)

Vin

180 Vac to 264 Vac

Input frequency range

50 Hz or 60 Hz

Ouput voltage

VDC

400 V

Output ripple voltage

Vripple

20 V

Inductance

L1, L2

53 µH

Switching frequency

60 kHz

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