13 April 2011 Data Sheet No. PD97152 IRAC1155-300W Reference Design Kit for IR1155 (One Cycle Control PFC IC) Product Summary REFERENCE DESIGN KIT FEATURES * * * * * * * * * * * IEC61000-3-2 Class D Standards Compliant Less than 10% Total Harmonic Distortion (115230VAC/300W) Power Factor higher than 0.99 (115-230VAC/300W) Universal AC Input Voltage capability Fully regulated 388V DC bus Full load start-up, no minimum load requirements Current loop controlled soft-current limit protection for overpower limitation at minimum VAC Cycle-by-Cycle Peak Current Limit Output Over Voltage Protection Open Feedback Loop Protection 100kHz Switching Frequency AC Input Voltage 85-264VAC AC Input Line Frequency 47-63Hz DC Bus Output Voltage 388V +/- 4% Maximum output power 300W Minimum Load Requirement None Power Factor (115-230VAC/300W) Total Harmonic Distortion (115-230VAC/300W) <10% Start-up time 50ms >0.99 IR1155 PFC IC FEATURES * * * * * * * * * * * * PFC IC with "One Cycle Control" Continuous conduction mode boost type PFC Programmable switching frequency Average current mode control DC bus overvoltage protection (Dedicated) DC bus open feedback loop protection Cycle-by-cycle peak current limit (DC bus voltage foldback type) Soft-current limit protection VCC under voltage lockout Programmable soft-start Micropower startup & sleep mode (user-initiated) 1.5A peak gate drive Introduction IRAC1155-300W is a full function AC-DC reference design showcasing the operation of IR1155 PFC IC in a continuous conduction mode boost converter for achieving power factor correction, sub-10% harmonic current distortion and EN61000-3-2 Class D harmonic current limits standard compliance. Designed to be operated from 85-264VAC universal input voltage, IRAC1155-300W delivers 300W continuous output power via a fully regulated 388V DC bus. Thanks to IR1155 PFC IC, the reference design is rendered with a very high level of safety against system abnormalities such as DC bus voltage loop feedback loss, system overcurrent & overvoltage protection. The IRAC1155-300W reference design is an excellent design example that can be seamlessly imported & integrated by system designers that require a high-performance PFC stage at the AC-DC front-end of their designs in a variety of applications. Rev 1.0 (c) 2010 International Rectifier 1 IRAC1155-300W Table of Contents Introduction .........................................................................................................................................................1 Description of Hardware & Key Operating Features ...........................................................................................4 Hardware Installation & Operating Procedure ....................................................................................................5 Performance Characterization ............................................................................................................................6 IRAC1155-300W Schematics ...........................................................................................................................13 IRAC1155-300W Bill of Materials (BoM) ..........................................................................................................14 IRAC1155-300W Components Layout .............................................................................................................15 List of Figures Figure 1 IRAC1155-300W test set-up.................................................................................................................5 Figure 2 Efficiency over line/load of IRAC1155-300W ........................................................................................6 Figure 3. Power factor vs. Line/Load Variation of IRAC1155-300W...................................................................7 Figure 4. THD across 85-264VAC for IRAC1155-300W ....................................................................................7 Figure 5. 2X AC frequency ripple in DC bus capacitor at 85VAC, 300W ...........................................................9 Figure 6. 2X AC frequency ripple in DC bus capacitor at 264VAC, 300W .........................................................9 www.irf.com (c) 2010 International Rectifier 2 IRAC1155-300W Safety Precautions ! ATTENTION: The ground potential of the IRAC1155-300W is biased to a negative DC bus voltage potential. In order to be able to safely measure voltage waveform by oscilloscope, the use of an isolation transformer at the AC input is recommended. Though floating the ground potential of the scope is often practiced, it is not recommended. Failure to follow these guidelines so may result in personal injury or death. ATTENTION: The IRAC1155-300W system contains dc bus capacitors & capacitors on the rectified AC line (C3, C14, C18), which take time to discharge after removal of main supply. Remove and lock out power from the IRAC1155-300W board before you attempt to disconnect or reconnect wires or perform service. Wait at least one minute after removing power to discharge the capacitor voltages. Do not attempt to service the reference design until all capacitor voltages have discharged to zero. Failure to do so may result in bodily injury or death. ! ! ! ! ! ATTENTION: Only personnel familiar with the IRAC1155-300W system should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: The surface temperatures of the IRAC1155-300W board & heatsink may become hot, which may cause injury. A fan is recommended to cool the board whenever operating at the full rated power for prolonged periods. ATTENTION: The IRAC1155-300W system contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference applicable ESD protection handbook and guideline. ATTENTION: An incorrectly applied or installed board can result in component damage or reduction in product life. Wiring errors, supplying an incorrect AC supply, or excessive ambient temperatures may result in system malfunction. www.irf.com (c) 2010 International Rectifier 3 IRAC1155-300W Description of Hardware & Key Operating Features The key features of the IRAC1155-300W hardware are listed below. The user is referred to IRAC1155-300W schematics provided later in the document for the following discussions and also to "300W PFC Converter Design Example" section in IR1155 Application Note AN-1166 for the design details. AC Input Stage (before bridge rectifier) * EMI Stage is comprised of 2X 0.47uF X-capacitors & one common-mode EMI choke with 2.8mH rated magnetic impedance. * In rush current limitation is provided by a NTC (negative thermal co-efficient) resistor offering 1ohm impedance at 25C. * A 250V, 5A fuse is included for current protection. Power Stage * Bridge Rectifier: 600V, 10A bridge rectifier (D1) is employed. * Boost Inductor: A 850uH Boost inductor (L2) based on Cool-Mu EE40 core is employed. With 850uH of boost inductance, the ripple current factor is about 0.18 (18% current ripple) near peak of AC sinusoid at 85VAC, 300W (DC bus voltage=388V). * Boost Switch & Gate Drive Circuit: CoolMOS 650V/165mohm (Q1) is used for boost switch. With +/1.5A gate drive capability, IR1155S can directly drive the MOSFET without using external buffer. Localized gate resistor & diode networks (R7, R9, D7) is used to preferentially adjust turn-on & turnoff dV/dt. Turn-on is slower to control reverse recovery behavior of boost diode. Finally a Schottky diode, D6 between GATE & COM pins of IR1155 is used to clamp any negative voltage spikes that can cause IC latch-up. * Boost Diode: A 600V, 8A Q-speed diode (D3) is employed as boost diode. * DC Bus Capacitor: 270uF, 450V capacitor (C14) is employed on the DC bus for acceptable ripple at 300W power rating at 388VDC. A 1W, 470kohm bleed resistor (R10) is used across C10 to discharge the bus voltage. * Current Sense Resistor: IRAC1155-300W employs a 70mohm, 3W current sense resistor (Rs). CAUTION: If the user attempts to modify the power level of the PCB by changing the current sense resistor, attention must be paid to the component ratings - semiconductors (bridge rectifier, boost switch, boost diode), boost inductor, fuse, DC bus capacitor - and system thermal performance (use a fan to cool heatsink, run at lower ambient temperature etc). * Current Monitoring: A Jumper at the bottom side of the PCB is provided for monitoring the PFC switch current. Vcc bias * User should provide IR1155 VCC bias using an external DC supply connected to J2. The recommended DC supply voltage range is 12V~15V. IR1155 IC Control Circuit * VFB Pin - The DC bus voltage is programmed using the resistor divider comprised of R11, R3 & R6. By adjusting R6, user can modify the DC bus voltage. Increasing R6 will decrease DC bus voltage. Decreasing R6 will increase DC bus voltage. * OVP Pin - OVP pin resistor divider (R13, R5 & R20) program the over-voltage protection level. www.irf.com (c) 2010 International Rectifier 4 IRAC1155-300W IRAC1155-300W Default Set-point DC Bus Regulation Voltage Overvoltage Protection Set-point (OVP pin) Overvoltage Protection Reset Set-point (OVP pin) Typical Level 388V 419V 402V * FREQ Pin - The capacitor that connected between FREQ pin and COM (C15) defines the switching frequency of IR1155. The frequency can be programmed between 48kHz to 200kHz with capacitor value from 500pF to 2nF. In this design, a 1nF cap is used and the switching frequency is set to 100kHz. Please refer to IR1155S datasheet to get the frequency setup curve. * VCOMP Pin - C5, C11 & R8 are involved in the following functions: o Voltage loop compensation (location of pole & zero in voltage loop feedback response & phase margin) o C11 primarily determines the system soft-start time during start-up The user is recommended to review "Voltage Loop Compensation" section in AN-1166 before modifying any of these components, since such an explanation is outside the scope of this document. * ISNS Pin -The VISNS signal from the current sense resistor is filtered using RC network created by R4 & C8 in order to provide a clean signal to the IR1155 IC. * VCC Pin - Two 0.47uF ceramic capacitors (located as close as possible to VCC & COM pins) are used to provide optimum decoupling for the VCC bias to IR1155 IC. A 15V zener diode, Z1 is used to clamp overvoltage spikes on VCC pin & protect IR1155 IC. * COM Pin - A STAR connection point located very close to the COM pin of the IC is used to individually terminate all the control signal return loops (VCC, VCOMP, VFB, OVP, BOP & power GND). Please refer to PCB Layout Features section of this document for more information. * GATE Pin - Please refer to Boost Switch & Gate Drive Circuit section of this document for more information. Hardware Installation & Operating Procedure The recommended test set-up for IRAC1155-300W is shown in Figure 1. (V out) Power Analyzer Vin Vin Vout Vout AC1 AC Prog Source or Variac (0 - 265Vac) AC2 DMM V DC source (12V Vcc) (J1) L (J3) + N - + E-Load - (J2) Figure 1 IRAC1155-300W test set-up www.irf.com (c) 2010 International Rectifier 5 IRAC1155-300W Load Connection Connect high voltage resistive or electronic load, capable of 300W continuous power to connector J3 as shown in Figure 1. Pay attention to the polarity of the terminals in the connector. There is no minimum load requirement for operating IRAC1155-300W. The DC bus voltage is monitored at test-points VOUT and VO_RTN. Always monitor the DC bus voltage to ensure that the capacitor voltage is discharged completely prior to adding or removing load connections from the demo board. AC Input Connection Connect a 60Hz AC power source, capable of operation up to 264VAC to connector J1 as shown in Figure 1. The AC input voltage can be monitored at test points L and N. Once power is applied to demo board, potentially lethal high voltages will be present on board and necessary precautions should be taken to avoid serious injury. The use of an isolation transformer on the AC side is highly recommended, so that all the control signals on the test points can easily be probed by using regular oscilloscope probes. Though floating the ground potential of the scope is often practiced, it is not recommended. Failure to follow these guidelines so may result in personal injury or death. DC supply Connection Connect a 12V~15V DC power supply to connector J2. This will provide the bias voltage to IR1155. Power-up Once all the connections are made the system can be powered up. There is no minimum load requirement during power-up and the system can be powered-up at any load from 0W to 300W. There is no strict biasing sequence for VAC and DC supply. It is OK to supply either voltage first. Performance Characterization DC Bus Voltage Regulation DC bus voltage is regulated to 388V. The output voltage will have some variation form part to part due to device tolerance. The statistic variation is within +/-4%. For a specific board, the output voltage variation over line and load is within +/-0.2%. Efficiency The efficiency of IRAC1155-300W demo board is in 94% ~97% at 150W the 50% load over the input line range. The efficiency is tested with NTC thermistor in circuit. If the NTC resistor is shorted, the efficiency can be improved further, especially at low line. A 0.5% efficiency improvement is seen at 85Vac at 50% and 100% load. 100% 99% Efficiency 98% 97% 96% 95% 94% 93% 100% Load 300W 50% Load 92% 23% Load 91% 90% 85 105 125 145 165 185 205 225 245 265 VAC (V) Figure 2 Efficiency over line/load of IRAC1155-300W www.irf.com (c) 2010 International Rectifier 6 IRAC1155-300W Power Factor IRAC1155-300W delivers power factor greater than 0.99 at 300W, 85-250VAC. At light load condition, there is some drop in power factor which is primarily due to X-capacitors in EMI filter. Figure 3. Power factor vs. Line/Load Variation of IRAC1155-300W Total Harmonic Distortion IRAC1155-300W delivers less than 10% of Total Harmonic Distortion at the rated 300W output power. Total Harmonic Distortion (%) 14.00 23% Load 12.00 50% Load 100% Load 10.00 8.00 6.00 4.00 2.00 0.00 85 105 125 145 165 185 205 225 245 265 VAC (V) Figure 4. THD across 85-264VAC for IRAC1155-300W www.irf.com (c) 2010 International Rectifier 7 IRAC1155-300W Steady-state Input Current Waveforms (Ch 4: Input Voltage, Ch3: Input Current) 85VAC, 300W 115VAC, 300W 230VAC, 300W 264VAC, 300W www.irf.com (c) 2010 International Rectifier 8 IRAC1155-300W DC Bus Capacitor Ripple Voltage The sizing of the DC bus capacitor, load condition, AC input voltage frequency etc determine the 2X AC frequency ripple in the DC bus capacitor. The DC bus capacitor ripple in IRAC1155-300W at 300W is less than 10V as seen in Figure 5 and 6. Figure 5. 2X AC frequency ripple in DC bus capacitor at 85VAC, 300W Figure 6. 2X AC frequency ripple in DC bus capacitor at 264VAC, 300W www.irf.com (c) 2010 International Rectifier 9 IRAC1155-300W Start-up Current Waveforms at 100% load The maximum time for system start-up, about 50msec, is encountered when IRAC1155-300W is powered up at minimum input voltage (85VAC) and maximum output power (300W). The soft-start feature of the IC allows for a linear ramp in the VCOMP voltage, which allows a smooth build-up of AC input RMS current admitted into the PFC converter and DC bus capacitor voltage. Since the PFC voltage loop is a slow loop, the converter goes through a period where the DC bus voltage is under hysteretic OVP condition (between 102.2% and 106.5% of regulation voltage set-point) before the VCOMP voltage stabilizes near the steady stage voltage value. 85VAC, 300W 115VAC, 300W 230VAC, 300W 264VAC, 300W www.irf.com (c) 2010 International Rectifier 10 IRAC1155-300W No Load Start-up Current Waveforms 85VAC, 0W 115VAC, 0W 230VAC, 0W 264VAC, 0W www.irf.com (c) 2010 International Rectifier 11 IRAC1155-300W Load Step Waveforms * No-Load to Full-Load Under a 0W to 300W load step at 115VAC, the maximum DC bus voltage undershoot is about 50V; the undershoot at 230Vac is 24V. 115VAC, 0W to 300W load step * 230VAC, 0W to 300W load step Full-load to No-Load 300W to 0W negative load step waveforms are presented below. At low line, the OVP protection feature is encountered. IR1155 immediately stops switching when output voltage reaches 419V the OVP threshold. IR1155 resumes boost operation when the DC bus capacitor voltage discharges back to the regulation voltage. At high line, the OVP is not triggered. As COMP pin voltage dropped to a very low level when the load is removed (below Vcomp_start), the gate stops switching and prevents further increasing of Bus voltage. 115VAC, 300W to 0W load step 230VAC, 300W to 0W load step www.irf.com (c) 2010 International Rectifier 12 IRAC1155-300W IRAC1155-300W Schematics www.irf.com (c) 2010 International Rectifier 13 IRAC1155-300W IRAC1155-300W Bill of Materials (BoM) Sl.No Designator Qty Description Value X cap input Footprint Radial 8.5 mm W x 25.5 mm L x 17.5 mm H Radial 7.8 mm W x 26 mm L x 17 mm H 0805 Panasonic -ECG / Epcos Cornell Dubilier / Panasonic -ECG AVX Manufacturer Part Number ECQ-U2A474ML / B32024A3474M DME6P33K-F / ECQE6334KF 08055C152KAT2A AVX AVX AVX Panasonic AVX 08055A470KAT2A 12065C334KAT2A 12065C474KAT2A EET-HC2W271EA 08055C102KAT2A Manufacturer 1 C1,C2 2 2 3 C3,C18 C5 2 1 0.47 uF, X1, 275 VAC 0.33 uF, 630 VDC METAL Polyester Film Capacitors POLY Ceramic MLCC X7R 1.5 nF, 50V, 10% 4 5 6 7 9 C4 C11 C9,C19,C20 C14 C8, C15 1 1 3 1 2 Ceramic MLCC NPO Ceramic MLCC X7R Ceramic MLCC X7R Bulk Cap Ceramic MLCC X7R 47 pF, 50V, 10% 0.33 uF,50V, 10% 0.47 uF,50V, 10% 270 uF, 450V, 105 deg. 1000 pF, 50V, 10% 10 C13 1 Ceramic MLCC X7R 0.1 uF, 50V, 10% 0805 AVX 08055C104JAT2A 11 C12 1 Ceramic MLCC X7R 100 pF, 50V, 10% 0805 AVX 08055C101KAT2A 12 D1 1 Bridge Rectifiers 600 V, 10A 13 14 15 D3 D5 D6, D7 1 1 2 Rectifiers H-Series 600V 8A Super-Low Qrr 600 V, 8 A (QH08TZ600) Standard Diode Rectifiers 600 V, 5 A (S5JC-13-F) Schottky Diode 20 V, 1 A 16 17 18 19 F1 F1 J1,J3 J2, 1 1 2 1 Fuse Holder Fuses Connector Connector 20 Vcc RTN, Vo RTN 2 TEST POINT Black 21 N 1 TEST POINT Yellow 22 GATE 1 TEST POINT Blue 23 L 1 TEST POINT White 24 25 26 VCC, VOut L2 Q1 2 1 1 TEST POINT Red Boost inductor MOSFET 250VAC, 5A, Fast Acting 3-Pin Header Vertical 2-Pin Header Vertical TEST POINT PC COMPACT .063"D BLK TEST POINT PC COMPACT .063"D YLW TEST POINT PC COMPACT .063"D blue TEST POINT PC COMPACT .063"D WHT TEST POINT PC COMPACT .063"D RED 1mH / 3.35A N-CH 600V 27 28 29 30 31 32 33 34 35 36 37 38 39 RT1 RV1 Rs R1,R2 R3,R11,R13 R5 R4 R6, R20 R7 R10 R8 R9 R14 1 1 1 2 3 2 1 2 1 1 1 1 1 Thermistors - NTC Varistors - MOV Sense resistor 0.07E SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor SMD- Resistor 1R, 9A 14mm/ 300V AC 0.070, 3 W 249k, 1/4 W, 1% 487k, 1/8W, 1% 499k,1/8W, 1% 100E, 1/4W, 1% 12.7k,1/8W, 1% 6.2E,1/8W, 1% 10k,1/8W, 1% 6.8k, 1/8W, 1% 2.7E,1/8W, 1% 100,1/8W, 1% 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 R21 L1 U1 Z1 HS 1 HS 2 Jumper PCB Heat sink PCB Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink Heat sink 1 1 1 1 1 1 1 1 1 8 1 1 1 1 1 4 1 1 2 1 2 4 CFR Resistor 470k, 1W EMI Common Mode Choke 2.2 mH, 5 A Control IC IR1155 Zener Diodes 15V, 500mW Heat sink LSI 182RD 40mm Heat sink LSI 182RD 90mm Wire PVC 1 Sq mm ( 50 mm L) PCB IRAC1155 demo board, Rev-A Screws M3x15 Philips head (Nickel) Screws M3x10 Philips head (Nickel) Screws M3x8 Philips head (Nickel) Screws M2.5x15 Philips head (Nickel) Insulating Bush TO 220 M2.5 Insulating Bush Sil-Pad TO 220 Sil-Pad insulating Washer M2.5 Plain washer(Nickel) Spacer M3x12 Hexagonal Nylon spacer Nut M2.5 Nut Spring washer M2.5 (Nickel) Plain washer M3 (Nickel) Nut M3 (Nickel) Spring washer M3 (Nickel) Fiber washer M3 (Nickel) Assly (D1) Assly (D3) Assly (Q1) Assly Assly Assly Assly Assly Assly Assly Assly Assly Assly www.irf.com 0805 1206 1206 35x30 0805 Through Hole, KBU, L- 22.3 mm,W- 18mm,H-18.8mm Taiwan Semi KBU1005 TO-220 AC SMC SOD-323 QH08TZ600 S5JC-13-F NSR0320MW2T3G Power Integrations Diodes Inc. ON Semiconductor PCB-Mounting Vertical type Elcom 5.20mm x 20.00mm Little Fuse Through Hole Molex Through Hole Molex Keystone Through Hole Electronics/Kobiconn Keystone Through Hole Electronics/Kobiconn Keystone Through Hole Electronics/Kobiconn Keystone Through Hole Electronics/Kobiconn Keystone Through Hole Electronics/Kobiconn Custom Prismatic TO-220 Infineon Radial 15 mm Dia. x 7 mm W x 22 mm H EPCOS Radial EPCOS Through Hole IRC 1206 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) 1206 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) 0805 Yageo (VA) PBF-2M 0217005.H 26-60-4030 22-23-2021 Through Hole Through Hole Custom SO-8 SMD SOD-123 Custom Custom PR01000104703JR500 019-4119-00 IR1155 MMSZ5245BT1G BC/ Vishay PRECISION IR ON Semiconductor LSI LSI 5006k /151-103-RC 5009k/151-102-RC 5122k/151-105-RC 5007k/151-101-RC 5005k/151-107-RC 9404189501 IPP60R165CP B57237S0109M000 B72214S2301K101 LOB3R070JLF RC1206FR-07249KL RC0805FR-07487KL RC0805FR-07499KL RC1206FR-07100RL RC0805FR-0712K7L RC0805FR-076R2L RC0805FR-0710KL RC0805FR-076K8L RC0805FR-072R7L RC0805FR-07100RL (c) 2010 International Rectifier 14 IRAC1155-300W IRAC1155-300W Components Layout Top Layer Bottom Layer The information provided in this document is believed to be accurate and reliable. However, International Rectifier assumes no responsibility for the consequences of the use of this information. International Rectifier assumes no responsibility for any infringement of patents or of other rights of third parties which may result from the use of this information. No license is granted by implication or otherwise under any patent or patent rights of International Rectifier. The specifications mentioned in this document are subject to change without notice. This document supersedes and replaces all information previously supplied. For technical support, please contact IR's Technical Assistance Center http://www.irf.com/technical-info/ WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 www.irf.com (c) 2010 International Rectifier 15 IRAC1155-300W Revision History Date 4/13/2011 Comment Original document www.irf.com (c) 2010 International Rectifier 16