STMicroelectronics STEVAL-IPFC02V1 User Manual

UM2674

User manual

How to use the 2 kW two-channel interleaved PFC based on the STNRGPF02

digital controller

Introduction

The STEVAL-IPFC02V1 2 kW interleaved PFC kit is based on the STNRGPF02 digital controller and consists of a power board, control board and adapter board. The digital configurable ASIC can drive up to two channels in an interleaved PFC for industrial applications.

The STNRGPF02 embedded on the control board implements mixed signal (analog/digital) average current mode control in CCM at fixed frequency. The analog section ensures cycle-by-cycle current regulation, while digital control manages the nontime-critical operations. You can use the eDesignSuite software available on the ST website to configure the digital controller according to specific application requirements.

Figure 1. STEVAL-IPFC02V1 evaluation kit with power, control and adapter boards

UM2674 - Rev 3 - January 2021

For further information contact your local STMicroelectronics sales office.

www.st.com

1 Safety instructions

Danger:

The evaluation board uses voltage levels that can cause serious injury and even death.

Do not touch any components immediately after disconnecting the input power supply as the charged capacitors need time to discharge.

Due to the high power density, board components and heat sinks can become very hot and cause severe burns when touched.

This board is intended for use by skilled technical personnel who are suitably qualified and familiar with the installation, use and maintenance of power electronic systems. The same personnel must be aware of and must apply national accident prevention rules.

The electrical installation shall be completed in accordance with the appropriate requirements (e.g., crosssectional areas of conductors, fusing, and GND connections).

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Safety instructions

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2 STEVAL-IPFC02V1 evaluation kit overview

Figure 2. STEVAL-IPFC02V1 block diagram

1. I/O measurement signals

2. Analog circuitry

3. Power stages

4. Digital control section

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STEVAL-IPFC02V1 evaluation kit overview

2.1

The STEVAL-IPFC02V1 implements mixed signal (analog/digital) control, combining the flexibility of a programmable high end digital solution with the responsiveness and accuracy of analog componentry. The inner current loop consists of an analog proportional-integral (PI) compensator that ensures the highest possible bandwidth and cycle-by-cycle regulation. The outer voltage loop is performed by a digital PI controller with fast dynamic response.

Board features

The 2 kW interleaved PFC evaluation kit features:

• A modular design with the following separate boards:

– STEVAL-IPFC02P1 power board

– STEVAL-IPFC02C1 control board

– STEVAL-IPFC01A1 adapter board

• 2-channel interleaved PFC

• Input voltage range: 90 to 265 VAC (50 or 60 Hz)

• Maximum output power: 2 kW at 230 VAC; 1 kW at 115 VAC;

• Output voltage: 400 V

• Fixed frequency average current mode control and CCM operation

• Mixed-signal, semi-digital approach

• Programmable phase shedding

• Cooling System management

• Programmable fast overcurrent and thermal protection

• Digital inrush current limiter function performed with relay

• Soft startup and burst mode management

• Load current and input voltage feed forward

• Channel current balance function

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• Two status LEDs to signal nominal and fault conditions

• Browser GUI tool (eDesignSuite) for driver customization

• Serial communication port for

– STNRGPF02 programming

– PFC parameter monitoring

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Board features

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EARTH

AC LINE

How to use the STEVAL-IPFC02V1 evaluation board

3 How to use the STEVAL-IPFC02V1 evaluation board

To perform functional and efficiency testing, you need the following equipment:

• Programmable AC source with power > 2 kW

• DC electronic load or load resistor > 2 kW

• Power analyzer

• Digital oscilloscope

The STEVAL-IPFC02V1 board can be tested up to 2 kW at 230 V range between 47 and 63 Hz.

Note: Any load or passive oscilloscope probe must be isolated from the input source of the PFC.

3.1 How to connect and start the STEVAL-IPFC02P1 power board

Step 1. Insert the STEVAL-IPFC02C1 control board in connector J100 on the STEVAL-IPFC02P1 power board.

Figure 3. STEVAL-IPFC02P1 AC supply connection

and 1 kW at 115 V

RMS

, in a frequency

RMS

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+400V

GND

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How to connect and start the STEVAL-IPFC02P1 power board

Step 2. Connect the load wires to the output terminals on J300 of the STEVAL-IPFC02P1 power board.

The actual load (electronic dc load, load resistors, inverter, etc.) must remain disconnected until the soft startup sequence has completed.

The correct polarity is indicated on the board.

Figure 4. STEVAL-IPFC02P1 DC output connection

Step 3. Supply the following input voltage while no load is connected on the output:

– 90 – 265 VAC (50 or 60 Hz)

Step 4. Apply the load.

max: 2 kW at 230 VAC, 1 kW at 115 V

3.1.1 STEVAL-IPFC02P1 power board startup sequence

1. The appropriate AC input voltage is applied under a no load condition.

2. When the input voltage rises above 60 V, the auxiliary power supply starts and generates the auxiliary voltages (13 VDC and 5 VDC) for the drivers and the signal conditioning circuitry.

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13V

V_INPUT

A A A A A A

RELAY

ZVD

VIN_L1

R108

33k

R102 33k

RV100 S14K27 5

- +

D101 50A

D100 STPS 1L30A

D103

BAS70-04 FILM

R104 470k N.M.

R107 10M

D104 BAS70-04 FILM

ISO100 TLP385(E

R114 3k

0.1%

R106 100k

R123 3k

0.1%

R101

150

R112 470k

C111 100pF

R121 470k

C101

0.1uF

R103 470k N.M.

L100 2x4.5mH

2 1

3 4

C100 100nF

Y101

2.2nF

C110 100pF

R100 22

R113 470k

J100

VIN

1 2 3

R122 470k

R105

33k

Q100

STS6 NF20V

213 5

R111 10M

C102

1nF

D102

GF1M

RL100

250Vac -16A

Y100

2.2nF

R110 47k

F100

20A 250 Vac

R109

33k

AC-IN-L2

AC-IN-L1

L1 VDDIO

VIN_L2

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How to connect and start the STEVAL-IPFC02P1 power board

3. Once the auxiliary voltages are nominal, the inrush current limiter phase begins by charging the output capacitor until the DC voltage reaches the peak input voltage. The current is limited by resistor R101 until it is shorted by the relay RL100 at the end of inrush phase.

Figure 5. STEVAL-IPFC02P1 input section

4. After the inrush limiter phase, the soft startup procedure is activated and the output voltage rises up to 436 VDC, at which point the PFC enters burst mode to regulate the output voltage between 416 and 436 VDC.

5. The green LED D2 on the control board indicates when the sequence has finished and the PFC is ready for the load to be connected.

6. Once you connect the load:

– the output voltage is regulated to 400 V ±2 V.

– for 185 – 265 VAC, the maximum output power is 2000 W

– for 90 – 140 VAC, the maximum output power is 1000 W

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PFC controller customization with eDesignSuite

4 PFC controller customization with eDesignSuite

The eDesignSuite software tool developed by STMicroelectronics helps you configure ST products for power conversion applications. You can use it to customize the PFC controller for a specific application by entering the main specifications for your application and generating an automatic design, or by following a guided process for more specific designs.

Figure 6. PFC specifications

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Status LEDs and fault conditions

5 Status LEDs and fault conditions

The STEVAL-IPFC02C1 control board has the following status LEDs:

• a green LED connected to STNRGPF02 pin 15 (PFC_OK)

• a red LED connected to STNRGPF02 pin 14 (PFC_FAULT)

5.1 Normal operation

During normal operation, the green LED (D2) on the STEVAL-IPFC02C1 control board remains lit to indicate that the PFC is operating under allowable conditions.

5.2 Fault conditions

When a fault is detected, the red LED (D1) on the STEVAL-IPFC02C1 control board lights up and the green LED (D2) turns off. The device stops all switching activities and turns off the fan.

After a fault condition, the board must be reset by switching off the AC input voltage and discharging the output capacitors.

Note: Warning: Do not short the output terminals to discharge the capacitors as the high discharge current may

damage the output current sensing circuitry.

The following conditions will trigger a fault protection:

• Highly distorted input voltage waveforms that inhibit frequency measurement. For example, if the mains frequency out of the accepted range (e.g., 47-63 Hz).

• Overcurrent condition on at least one PFC channel. This protection prevents PFC inductor saturation.

• Overvoltage protection on output voltage if the output voltage exceeds 450 V

• Overvoltage protection on input voltage:

– for 115 VAC nominal supply: above 140 V

– for 230 VAC nominal supply: above 265 V

• Over-temperature protection when the ambient temperature of the board exceeds the threshold setting.

5.3 Wait conditions

In addition to the conditions that trigger PFC_OK and PFC_FAULT, there are other conditions that are indicated with both LEDs are off:

• Undervoltage condition on the output when the DC bus voltage falls below 340 V.

• Undervoltage condition on input when the input rms voltage falls below 90 VAC for 115 VAC nominal (or 185 VAC for 230 VAC nominal).

• Input voltage dropout when the input voltage signal disappears for more than 25 ms.

Under these conditions, the STNRGPF02 will drive both LEDs on the control board off and will wait until the conditions have cleared before repeating the startup sequence.

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