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Infineon IKW40N65WR5 Manual

5 kw two-channel interleaved ccm pfc eval board
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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
www.infineon.com
Please read the Important notice and the Safety precautions and the Warnings
page 1 of 41
2021-03-05

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Summary of Contents for Infineon IKW40N65WR5

  • Page 1: About This Document

    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.

  • Page 2: Important Notice

    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.

  • Page 3: Safety Precautions

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application Safety precautions 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.

  • Page 4: Table Of Contents

    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 The board at a glance ......................

  • Page 5: The Board At A Glance

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application The board at a glance The 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.

  • Page 6: Block Diagram Of The Eval-Pfc5Kikwwr5Sys

    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™...
  • Page 7 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 • IDW60C65D1 Iout IKW40N65WR5 IKW40N65WR5 1ED44175 1ED44175 UCC28070 interleaved CCM PFC controller...

  • Page 8: System And Functional Description

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System and functional description System and functional description 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.

  • Page 9: Ucc28070 - Analogy Controller

    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...

  • Page 10: 1Ed44175 - Low Side Gate Driver

    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%.

  • Page 11: System Design

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design System design To meet individual customer requirements and make the EVAL-PFC5KIKWWR5SYS evaluation board a basis for development or modification, all necessary technical data like schematics, layout and components are included in this chapter.
  • Page 12 In Figure 7, two-channel boost converters connect 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 paratical applications, customers can also select two seprated silicon fast- recovery diodes or two SiC diodes to replace this common cathode diode, and put them as D21 and D22.
  • Page 13 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, 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 with traditional powder materials.
  • Page 14 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high 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 frequency, it is very easy for customer to adjust switching frequency.
  • Page 15 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Great care was taken to select the proper value for RC filters applied to V and V , as it may be beneficial in...
  • Page 16 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Because UCC28070 already has an integrated output over voltage protection via the continuous monitoring of the intput over-voltage protection and under-voltage protection in this converter are implemented by an VSENSE, external comparator, both of which are also connected to the SS pin of UCC28070.

  • Page 17: Layout

    As a default, the PCB has four electrical layers with 70 µm of copper and diemensions of 244 mm × 142 mm. The PCB board thickness is 2 mm. Please check Infineon’s website or contact Infineon’s technical support team to obtain more detailed information and the latest Gerber files.
  • Page 18 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 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-layer 1 routing of EVAL-PFC5KIKWWR5SYS Figure 13 depicts the mid-layer 1 routing of this evaluation board.
  • Page 19 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 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-layer routing of EVAL-PFC5KIKWWR5SYS Figure 15 illustrates the bottom-layer routing of this evaluation board.

  • Page 20: Bill Of Material

    IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design 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...
  • Page 21 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Quantity Value Description Manufacturer Manufacturer P/N Designator Chip Monolithic Ceramic MuRata GRM319R71H102JA01 Capacitor 220pF Chip Monolithic Ceramic MuRata GRM188R71H221KA01 Capacitor Multilayer Ceramic Chip...
  • Page 22 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Quantity Value Description Manufacturer Manufacturer P/N Designator 6.90mm W X 5.00mm H body / SMD / - L5, L6 220R Chip Ferrite Bead...
  • Page 23 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Quantity Value Description Manufacturer Manufacturer P/N Designator General Purpose Chip Yageo RC1206FR-0710KL Resistor R40, R44 Standard Thick Film Chip Vishay CRCW06031K00FK Resistor 5.1k...

  • Page 24: Connector Details

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System design Quantity Value Description Manufacturer Manufacturer P/N Designator ICE5QSAG Quasi-Resonant PWM Infineon ICE5QSAG Controller Technologies SFH617A-3 Optocoupler, Vishay SFH617A-3 Phototransistor Output, High Reliability, 5300 VRMS, 110 °C Rated...

  • Page 25: System Performance

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance System performance Efficiency and PFC measurements All test conditions are based on a 25℃ ambient temperature For the efficiency test it is important to monitor the voltage directly on the input connector X2 and output connector X8.

  • Page 26: Start-Up Behavior

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance Power factor 1,0000 0,9950 0,9900 0,9850 0,9800 0,9750 0,9700 0,9650 0,9600 0,9550 1000 1500 2000 2500 3000 3500 4000 4500 5000...

  • Page 27: Input Current And Inductor Current Cancellation

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance Vout=Blue, V =Yellow, I =Red,V =Green Figure 19 Full load start-up at V =264 V Input current and inductor current cancellation The next six waveforms show the input AC current and two inductor current waveforms of the converter at full load.
  • Page 28 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance = Green, I =Yellow, I =Red,V =Blue Figure 21 Detail view of interleaving operation at full load at V =180 V...
  • Page 29 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance = Green, I =Yellow, I =Red,V =Blue Figure 23 Detail view of interleaving operation at full load at V =230 V...

  • Page 30: Switching Performance Of Igbt At Steady State

    The design for this board is aimed at achieving high efficiency by using 650V TRENCHSTOP™ 5 WR5 IGBT IKW40N65WR5 as the main switch in a high-frequency interleaved PFC application. Compared to Infineon’s H3 IGBT, the WR5 IGBT has lower conduction and switching losses, enabling the MOSFET to be replaced by a WR5 IGBT in up to 100 kHz applications.

  • Page 31: Output Ripple Voltage

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance = Green, V =Yellow, I =Red,V =Blue Figure 27 Switching waveforms of IGBT at V =200 V at full load (continue current at high point of...
  • Page 32 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance =Blue, I = Red Figure 29 PFC output ripple voltage at V =180 V at full load =Blue, I = Red...

  • Page 33: Input Voltage And Input Current

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance =Blue, I = Red Figure 31 PFC output ripple voltage at V =264 V at full load Input voltage and input current The line current in the following figures are nearly perfect sinusoidal waves, in phase with the line voltage, while the output voltage is regulated at 400 V at full load.

  • Page 34: Load Step Tests

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance =Blue, I = Red Figure 33 PFC input voltage and input current at V =230 V at full load =Blue, I...
  • Page 35 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance =Blue, I = Green Figure 35 Load step :0%→100% at V =180 V =Blue, I = Green Figure 36 Load step :0%→100% at V...

  • Page 36: Thermal Measurements

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance =Blue, I = Green Figure 37 Load step :100%→0% at V =180 V Figure 37 illustrates the response of the voltage control loop during a load step from 100% to 0% with a voltage overshoot up to 425 V.
  • Page 37 5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application System performance Figure 38 Thermal capture at room temperature at nominal input (180 V) and full load condition for PFC operation Due to two powerful fans in an enclosed environment, the PFC chokes are not the hotspot of the board, as can be seen in Figure 38.

  • Page 38: Conclusions

    This user guide describes the implementation of an analog-controlled, single-phase, two-channel interleaved PFC converter that operates in continuous conduction mode. This interleaved PFC converter achieves a peak efficiency of 97.804% by using an Infineon 650 V TRENCHSTOP™ 5 WR5 IGBT IKW40N65WR5 and rapid1 power silicon diode IDW60C65D1.

  • Page 39: References And Appendices

    Report, SLUA479B, August 2008. Infineon Technologies, “Fifth-generation QR design guide for ICE5QSAG and ICE5QRXXXXAX”, Application Report, DG_201609_PL83_026, September 2017. Additional information In the following links you can find more detailed information about the used devices from Infineon. TRENCHSTOP™ 5 WR5 IGBT IKW40N65WR5 ⚫...

  • Page 40: Revision History

    5 kW two-channel interleaved CCM PFC EVAL board IKW40N65WR5, IDW60C65D1 and 1ED44175 in high frequency PFC application Revision history Revision history Document Date of release Description of changes version V1.0 March 5,2021 User guide-initial release User guide 40 of 41 v1.0...
  • Page 41 WARNINGS 81726 Munich, Germany Due to technical requirements products may contain dangerous substances. For information on the types in question please contact your nearest Infineon © 2021 Infineon Technologies AG. Technologies office. All Rights Reserved. Except as otherwise explicitly approved by Infineon...
  • Page 42 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Infineon EVALPFC5KIKWWR5SYSTOBO1...

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