3.6kW Totem-Pole PFC with active in-rush current limiting · Maximum input curent: 16 A RMS (POUT =...
Transcript of 3.6kW Totem-Pole PFC with active in-rush current limiting · Maximum input curent: 16 A RMS (POUT =...
![Page 1: 3.6kW Totem-Pole PFC with active in-rush current limiting · Maximum input curent: 16 A RMS (POUT = 3.6KW) Efficiency: > 97,5% THD < 10 % Remove two bulky relays and an NTC](https://reader033.fdocuments.in/reader033/viewer/2022042507/5f57ce6f1c2651196b3c5778/html5/thumbnails/1.jpg)
3.6kW Totem-Pole PFCwith active in-rush current limiting
Jeff Halbig
Power Discrete Group – Product Marketing Manager
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Agenda
2 ST AC-DC inrush current limiter solutions
3 PFC totem pole topology using SiC MOSFETs and thyristors
2
4 Evaluation board performance
1 3.6kW Totem Pole PFC Introduction
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Evaluation Board 3.6 kW Totem Pole PFC
3
Main
Features
▪ Input AC voltage: 85VAC up to 264VAC
▪ DC output voltage: 400VDC
▪ Switching frequency: 72 kHz
▪ Maximum input curent: 16 A RMS (POUT = 3.6KW)
▪ Efficiency: > 97,5%
▪ THD < 10 %
▪ Remove two bulky relays and an NTC resistor thanks
to SCRs progressive start-up
Key Products
▪ TN3050H-12WY → SCR in the Bridge
▪ SCTW35N65G2V → 650V SiC MOSFET
▪ STGAP2S → Isolated Gate Driver
▪ STM32 → 32-bit Microcontroller)
▪ VIPER26LD → HV Converter Controller
STGAP2S
STM32F334 STGAP2S
TN3050H-12WY
SCTW35N65G2V
▪ Compliant to :
• EN 55015 and IEC 61000-4-11 and IEC 61000-3-3
• IEC 61000-4-5 surge: 4kV
• IEC 61000-4-4 EFTY burst : criteria A @ 4kV min
▪ Design for operation with DC/DC converter
▪ Peak inrush current tuning
Available Q2/20
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Traditional PFC Totem Pole
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• A conventional PFC circuit:
• Consists of a full bridge rectifier and a boost pre-regulator
• A large portion of system losses are in the diode bridge
D1 D2
D4D3
L
SC
vIN(t)
iIN (t) Inrushcurrentlimiter
D1
S4
L1
S3
GND
D2
C
IIN
VIN
S2
S1
Inrush
current
limiter
SiC MOSFETs(High Frequency)
Diodes or
MOSFETs(Low Frequency)
• In a traditional totem pole PFC:
• The diode losses are eliminated
• Low frequency switches are diodes or MOSFETs
• Needs an Inrush current limiter (NTC + relays)
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Bridge-less TopologiesTotem Pole PFC
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Device Technology ST Proposal
S1/S2 1200V SiC MOS SCTxxN120
D1/D2 1200V Rectifier STBRxx12W
Driver STGAP2S/D
Control STM32
Device Technology ST Proposal
S1/S2 1200V SiC MOS SCTWxxN120
S3/S4 1200V SiC MOS SCTxxN120
Driver STGAP2S/D
Control STM32
Device Technology ST Proposal
S1/S2 1200V SiC MOS SCTxxN120
T3/T4 1200V SCR TNxx50-12PI
Driver STGAP2S/D
Control STM32
Var. 1 – Cost – Diode Leg Var. 2 – Performance – SiC MOS Leg Var. 3 – Relay-less – SCR Leg
Phase 1
S1
S2
D1
D2
Phase 2
Phase 3
S1
S2
S3
S4
Phase 1
Phase 2
Phase 3
Phase 1
Phase 2
Phase 3
S1
S2
T3
T4
SiC MOSFET mandatory due high DC Voltage and body diode robustness
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ST AC-DC Inrush Current Limiter solutions
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RLIM
S1
S2
• Programmable soft power up control
• Controlled multiple peak current
limitation
• Zero-current Switch
• No Contact Bounce: no spark, no EMI
• Faster line-drop recovery
• Increase switching life expectancy
Low profile design, smaller height thanks
to D²PAK package
SM
AR
TS
AF
ET
YC
OM
PA
CT
IHT008V1 ISF003V1
power500W 7kW2kW
SCR001V1
Latest topology trends
STEVAL-SCR001V1
TN5015H-6G
TN2010H-6G
DPSTPFC1
MCU
+
SCR
TRIAC
+
MCU SCR
+
SCR
Bridgeless PFC
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SCRs phase control
77
SCR1
VACHVDC
SCR2
T T T
T_OFF_1 T_OFF_2 T_OFF_3
T T TT
T_OFF_Max
2x∆t 3x∆t 4x∆t∆t 5x∆t
T_OFF_Min
• Bulk capacitor is charged according to time-depending pulse train driving SCR1
and SCR2
• SCR1 and SCR2 are synchronized according to the zero crossing (ZVS) of the
AC line
• SCR1 and SCR2 are alternatively controlled according to the AC line polarity by
reducing the turn-on delay (“T_OFF”) by a constant ∆t at each half AC line cycle
• SCR1 and SCR2 are controlled by phase angle up to the turn-on delay
(“T_OFF”) is lower than “T_OFF_Min”
• Control the inrush-current to charge a DC bus capacitor
• Disconnect the DC bus capacitor from the AC mains when it does not have to operate
LAOD
S2
VAC
IACSCR1
SCR2
S1
HVDC
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Evaluation board performanceDesign content
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Reference Name Description
STEVAL-DPSTPFC0 AC - DC power boardBridgeless Totem Pole boost with auxiliary
supply
STEVAL-DPS334M1 PFC control board 32-bit MCU control board
STEVAL-DPSADP01 Adapter BoardInterface for MCU debugging and USART
communication
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Evaluation board performancePFC Totem Pole start-up
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To ensure a smooth PFC start-up a soft start routines has
been implemented on the MCU firmware:
1) Inrush current limiter: SCRs are controlled with a
progressive phase control and the output capacitor can be
smoothly up to the AC line peak voltage.
2) PFC soft start: The output voltage reference is controlled
from AC line peak voltage to 400 Vdc with a smoothly
voltage ramp.
HVDCVAC
IAC
Inrush current limiter Steady StatePFC soft startPFC OFF
LAOD
S2
VAC
IACSCR1
SCR2
S1
HVDC
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Evaluation board performancePFC efficiency / THD measurement
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VAC = 230 VRMS @ 50 Hz
0
2
4
6
8
10
12
14
16
18
90
91
92
93
94
95
96
97
98
99
500 1000 1500 2000 2500 3000 3500
THD
(%
)
Effi
ien
y (%
)
POUT (W)
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Board features
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• Description of a 3.6kW bridgeless totem pole PFC evaluation board for telecom and industrial applications with an digital Inrush current limiter using SiC MOSFETs and Thyristors.
• The Evaluation board design includes
• A power board bridgeless totem pole boost with an inrush limiter circuit, SiC MOSFET and SCRs switch drivers and an auxiliary power supply
• A control board with its MCU, a PFC/ICL control firmware
• An adapter board for software debug
• Evaluate a full ST solution• SCRs: To control the inrush-current to charge a DC bus capacitor and to fulfill with the IEC 61000-3-3 standard
• SiC MOSFETs: To reduce passive components size and to provide a PFC with a very high efficiency thanks to low reverse recovery diode body
• STGAP2S driver: Dedicated and optimized to control SiC MOSFETs
• STM32 microcontroller: Embedded the PFC control algorithm
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DC/DC or motor inverter can
be connected to this
evaluation board
L
A
O
D
S2
VAC
IACSCR1
SCR2
S1
HVDC
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• Check the stand-by losses • Reduce drastically the stand-by losses of the traditional NTC/PTC Inrush-current limitation
• Disconnect the DC bus capacitor from the AC mains when it does not have to operate
• Without requiring a relay to be added to open the circuit during stand-by
• Check EMC• Immunity to fast transient and surge voltages
• Common mode noise
• This reference design offering:• A high efficiency: > 97,5%
• A low THD distortion lower than 5 % of maximum load
• A high switching lifetime with reduced EMI emissions
• A robust circuit that meets EMC standards up to 4 kV
• SCR allows achieving a smart inrush current limitation at power up or line drop recovery compare to the traditional NTC and relays solution
Benefits
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