How to use the 3 kW three-channel interleaved PFC based on ......3. The green LED D2 on the control...

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Introduction The STEVAL-IPFC01V1 3 kW interleaved PFC reference design is based on the STNRGPF01 digital controller and includes a separate power board, control board and programming board. The STNRGPF01 is a digital configurable ASIC developed by STMicroelectronics, which can drive up to three channels in an interleaved PFC for industrial applications. The STNRGPF01 digital controller 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 non- time critical operations. You can use the eDesignSuite software available on the ST website to configure the STNRGPF01 to satisfy the specifications of each interleaved PFC. Figure 1. STEVAL-IPFC01V1 3 kW interleaved PFC reference design How to use the 3 kW three-channel interleaved PFC based on the STNRGPF01 digital controller UM2520 User manual UM2520 - Rev 3 - October 2019 For further information contact your local STMicroelectronics sales office. www.st.com

Transcript of How to use the 3 kW three-channel interleaved PFC based on ......3. The green LED D2 on the control...

  • IntroductionThe STEVAL-IPFC01V1 3 kW interleaved PFC reference design is based on the STNRGPF01 digital controller and includes aseparate power board, control board and programming board. The STNRGPF01 is a digital configurable ASIC developed bySTMicroelectronics, which can drive up to three channels in an interleaved PFC for industrial applications.

    The STNRGPF01 digital controller on the control board implements mixed signal (analog/digital) average current mode controlin CCM at fixed frequency. The analog section ensures cycle-by-cycle current regulation, while digital control manages the non-time critical operations. You can use the eDesignSuite software available on the ST website to configure the STNRGPF01 tosatisfy the specifications of each interleaved PFC.

    Figure 1. STEVAL-IPFC01V1 3 kW interleaved PFC reference design

    How to use the 3 kW three-channel interleaved PFC based on the STNRGPF01 digital controller

    UM2520

    User manual

    UM2520 - Rev 3 - October 2019For further information contact your local STMicroelectronics sales office.

    www.st.com

    https://www.st.com/en/product/stnrgpf01?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520http://www.st.com/edesignsuitehttps://www.st.com/en/product/stnrgpf01?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520

  • 1 Safety instructions

    Danger:The evaluation board uses voltage levels that can cause serious injury and even death.Do not touch any of the boards immediately after disconnecting the input power supply as thecharged capacitors need time to discharge.Due to the high power density, the board components and the heat sink can become very hot andcause severe burns when touched.

    This board is intended for use by skilled technical personnel who are suitably qualified and familiar with theinstallation, use and maintenance of power electronic systems. The same personnel must be aware of and mustapply national accident prevention rules.The electrical installation shall be completed in accordance with the appropriate requirements (e.g., cross-sectional areas of conductors, fusing, and GND connections).

    UM2520Safety instructions

    UM2520 - Rev 3 page 2/28

  • 2 STEVAL-IPFC01V1 evaluation kit overview

    Figure 2. STEVAL-IPFC01V1 block diagram1. I/O measurement signals2. Analog circuitry3. Power stage4. Digital control section with STNRGPF01 digital controller

    EMI filter&

    rectification

    3-channelinterleaved

    PFC

    Driver Driver Driver

    Currentcompensator

    Triangularwave

    generator

    Analogfilter

    STNRGPF01

    SIN_REF PWM0

    flip-flop

    SET1 RESET1

    OUT_PI[2],[3]

    TRIANG_REF

    CLOCK

    VIN

    VDD

    VSS

    IOUT

    VOUT

    flip-flop

    SET2 RESET2

    Load

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    The STEVAL-IPFC01V1 implements mixed signal (analog/digital) control, so the converter can manage a range ofinput and output conditions and still remain highly responsive to fast transients in input signals. The inner currentloop is a hardware analog proportional-integral (PI) compensator that ensures the highest possible bandwidth andcycle-by-cycle sensing and regulation. The outer voltage loop is performed by a digital PI controller with fastdynamic response.

    2.1 Features

    • Input voltage range: 90 to 265 VAC• Line frequency range: 47 to 63 Hz• Maximum output power: 3 kW at 230 V• Output voltage: 400 V• Power factor: > 0.98 at 20% load• Total Harmonic Distortion:

  • 3 How to use the STEVAL-IPFC01V1 evaluation board

    To perform functional and efficiency testing, you need the following equipment:• Programmable AC source with power > 3 kW• DC electronic load/or load resistor > 3 kW• Power analyzer• Digital oscilloscope

    The STEVAL-IPFC01V1 board can be tested at up to 3 kW at 230 VRMS and 1.5 kW at 115 VRMS, in a frequencyrange between 47 and 63 Hz.

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

    3.1 How to connect and start the STEVAL-IPFC01P1 power board

    Step 1. Insert the STEVAL-IPFC01C1 control board in connector J301 on the STEVAL-IPFC01P1 power board.

    Figure 3. STEVAL-IPFC01C1 insertion in STEVAL-IPFC01P1 J301 connector

    J301Step 2. Connect a 230 V/50 Hz or 115 V/60 Hz AC source to the J2 connector on the STEVAL-IPFC01P1

    power board.

    Figure 4. STEVAL-IPFC01V1 AC source connection

    GND

    AC IN

    UM2520How to use the STEVAL-IPFC01V1 evaluation board

    UM2520 - Rev 3 page 4/28

  • Step 3. Connect the load wires to the J1 output terminals on the STEVAL-IPFC01P1 power board.The actual load (electronic dc load, load resistors, inverter, etc.) must remain disconnected until thesoft startup sequence has completed.The correct polarity is indicated on the board.

    Figure 5. STEVAL- IPFC01V1 DC output connection

    GND+400V

    Step 4. Supply one of the following input voltage and frequency ranges while no load is connected on theoutput:– 185 – 265 VAC at 47 - 53 Hz– 90 – 140 VAC at 57 – 63 Hz

    Step 5. Wait for the green LED D2 on the STEVAL-IPFC01C1 control board to light up.The LED indicates that the startup sequence has finished.

    Step 6. Connect the load.Do not connect the load before the green LED indicates that the board is ready or you may damage theboard.

    3.1.1 STEVAL-IPFC01P1 power board startup sequence1. The appropriate AC input voltage is applied under a no load condition.

    – 185 – 265 VAC at 47 - 53 Hz– 90 – 140 VAC at 57 – 63 Hz)

    2. When the input voltage rises above 60 V, the auxiliary power supply starts and generates the auxiliaryvoltages (15 VDC and 5 VDC) for the drivers and the signal conditioning circuitry.

    3. Once the auxiliary voltages are nominal, the inrush current limiter phase begins by charging the outputcapacitor until the DC voltage reaches the peak input voltage. The charge current is limited by resistor R101.

    UM2520How to connect and start the STEVAL-IPFC01P1 power board

    UM2520 - Rev 3 page 5/28

  • Figure 6. STEVAL-IPFC01V1 DC input connection

    1nF

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    1. The STNRGPF01 then checks for any output current flow:– If there is no current, the STNRGPF01 closes the contacts of a mechanical relay in parallel with

    resistor R101.– If any current is detected, the STNRGPF01 will keep the relay contacts on R101 open (so the board

    cannot start) until the current falls to zero.2. After the inrush limiter phase, the soft startup 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.3. The green LED D2 on the control board indicates that the sequence has finished and the PFC is ready for

    the load to be connected:– the output voltage is regulated to 400 V ±2 V.– for 185 – 265 V 50 Hz mains, the maximum output power is 3000 W– for 90 – 140 V 60 Hz mains, the maximum output power is 1500 W

    Warning:If the load is connected before the Inrush current limiter phase, a very high current will flow intothe PFC and possibly damage the board when the relay closes the contacts across resistor R101.

    UM2520How to connect and start the STEVAL-IPFC01P1 power board

    UM2520 - Rev 3 page 6/28

  • 4 PFC controller customization with eDesign Suite

    The eDesignSuite suite software tool developed by STMicroelectronics helps you configure ST products powerconversion applications. You can use it to customize the PFC controller for a specific application: you start byentering the main specifications for your design and then generate an automatic design or follow a sequentialprocess to build a highly customized design.

    Figure 7. PFC specifications

    UM2520PFC controller customization with eDesign Suite

    UM2520 - Rev 3 page 7/28

    http://www.st.com/edesignsuite

  • Figure 8. PFC step-by-step design

    RELATED LINKS See RM0446 for details on how to use eDesignSuite to generate specialized firmware

    UM2520PFC controller customization with eDesign Suite

    UM2520 - Rev 3 page 8/28

    https://www.st.com/en/product/stnrgpf01

  • 5 Status LEDs and fault conditions

    The STEVAL-IPFC01C1 control board has a green LED and a red LED connected to STNRGPF01 pin 15(PFC_OK) and pin 14 (PFC_FAULT), respectively.

    5.1 Normal operation

    During normal operation, the green LED (D1) on the STEVAL-IPFC01C1 control board remains lit to indicate thatthe PFC is operating under allowable conditions.

    5.2 Fault conditions

    When a fault is detected, the red LED (D2) on the STEVAL-IPFC01C1 control board is lit and the green LED (D1)is switched 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 outputcapacitors.

    Warning:Do not short the output terminals to discharge the capacitors as the high discharge current maydamage the output current sensing circuitry.

    The following conditions will trigger fault protection:• Frequency or voltage out of range or highly irregular input voltage waveforms that inhibit frequency

    measurement. For example, if the input voltage is 230 Vrms but the mains frequency is 60 Hz, or if the inputvoltage is 115 Vrms and the mains frequency is 50 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 VDC• Overvoltage protection on input voltage:

    – for 115 V nominal supply: above 140 V– for 230 V nominal supply: above 265 V

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

    5.3 Wait conditions

    The following conditions are signaled when both the green LED (D1) and the red LED (D2) on the STEVAL-IPFC01C1 control board switched 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 V at 60 Hz or 185 V at 50 Hz.• Input voltage dropout when the input voltage signal disappears for more than 25 ms.

    Under these conditions, the STNRGPF01 will drive both LEDs on the control board off and will wait until theconditions have cleared before repeating the startup sequence.

    UM2520Status LEDs and fault conditions

    UM2520 - Rev 3 page 9/28

  • 6 STEVAL-IPFC01P1 power board schematics

    Figure 9. STEVAL-IPFC01P1 schematic - input section

    1nF

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    R112

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    UM

    2520 - Rev 3

    page 10/28

    UM

    2520STEVA

    L-IPFC01P1 pow

    er board schematics

  • Figure 10. STEVAL-IPFC01P1 schematic - auxiliary power supply

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    UM

    2520 - Rev 3

    page 11/28

    UM

    2520STEVA

    L-IPFC01P1 pow

    er board schematics

  • Figure 11. STEVAL-IPFC01P1 schematic - boost interleaving section

    C310

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    OC

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    UM

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    UM

    2520STEVA

    L-IPFC01P1 pow

    er board schematics

  • 7 STEVAL-IPFC01C1 control board schematic

    Figure 12. STEVAL-IPFC01C1 schematic

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    11

    RED

    PWM[0]

    FAN

    7

    13

    C28

    O+in

    U1

    16

    7

    100pF

    25

    47µF

    VDD

    OUT_PI[2]

    10

    C10

    150pF

    5

    ZVD

    10k

    C27

    OUT_PI

    REF SIN

    14

    RTX_RX

    VDD

    SWIM

    VDD

    O-in

    100nF

    1

    PIN29

    34

    VDD

    10k

    R14

    WE-CBF

    21

    TSV911ILT 10k

    10k

    VSSA

    12

    RESET2

    PTX

    3

    2

    VCOUTSYNCR[1] 6

    OCP1

    74HC132

    10nF

    100nF

    I_in2

    VDD

    22k

    C33

    FAN

    VBUS

    4

    R38 100k

    21

    36

    20

    OUT_PI[3]

    1125

    A

    14

    R27

    100

    31

    CON4

    U2C

    VIN

    VDD

    CCO_clk

    1.5nF

    PWM1

    1

    12

    C34

    56k

    +

    R10

    TRIANG REF

    TEMPPTX_TX

    26

    100pF

    RESET1

    14PFC_FAULT

    OCP

    N.M.

    VIN

    OCP1

    n.c.

    C11

    14

    C30

    150pF

    10nF

    100

    R21R28

    220nF

    4

    A

    TRIANG_REF

    A

    R31

    2LMV358IDT 4

    3

    R29 0

    3.3k

    37

    A

    6.2k

    35

    12

    R25 220K

    30

    31VIN

    9

    U2B

    +

    U5A

    RESET1

    150pF

    R8

    R16

    C16

    GREEN LED

    VSS

    10k

    J1

    R7

    100pF

    100

    9

    VDD

    A

    16 SIN_REFSET2

    C23

    12

    12

    4.7µF10V

    C2

    15nF

    U5B

    VDD

    7

    7

    14

    C17

    8

    R11

    CLOCK

    GREEN LED

    RESET2

    C4I_0

    D2

    C36

    27

    14

    I_1

    O+in

    100nF

    R39 100k

    TEMP

    C15

    100nF

    C8

    A

    3

    A

    R[1]

    R[3]

    23

    RELAY

    VDD

    37

    PRX

    34

    7

    220nF

    100pF

    6

    10nF

    5

    TRIANG REF

    R35 3.3k

    SET1

    OCP[0]

    2

    910

    6

    R15

    12

    OCP1

    74HC132

    U2A

    C29 100pF

    R12

    220nF

    15

    1k

    38

    100nF

    A

    10

    74HC132

    VDD

    A

    -

    I_LOAD

    R33

    R[2]

    100pF

    33pF

    56k

    14

    TEMP

    NC[1]ZVD

    32

    +

    8

    I_in1

    9

    RTX_RX

    VDD

    1

    R22

    4

    VDD

    R40 100k

    C7

    R30

    VDD

    R4

    74HC132

    35

    10nF

    RELAY

    C9

    2.2k

    18

    10nF

    N.M.

    NC[2]

    PWM0

    74HC132

    R2

    PWM0

    C39

    7

    FAN

    10nF

    CCO_clk

    -

    1k

    36

    C40

    ZVD

    D1

    0

    I_in2

    A

    28

    10k

    C3

    27

    VDD

    38

    2

    74HC1327

    C21

    13

    39

    -

    VDD

    +

    3

    4

    1nF

    100pF

    C26

    40

    GREEN

    74HC132

    IOUT

    10pF

    TEMP

    I_2

    1

    24

    R36

    VDD

    10k 0.1%

    VDD

    8

    A

    8

    NRST

    J3

    A

    13

    I_2

    7.5k

    6

    C24

    C14

    OCP[1]28

    13

    5.1k

    C19

    32

    PTX_TX

    7

    100

    R34

    330pF

    CON40AOUT_PI

    17

    4

    PWM0

    22

    220nFU3B

    34

    33pF

    30

    U3C

    A

    5

    R1

    R[4]

    10

    U3D

    STNRGPF01

    U3A

    R32

    ZVD

    14

    VBUS

    6

    R20

    I_1

    11

    L1

    C5

    15

    100nF

    18

    C35

    I_LOAD

    RELAY

    7

    J2

    4

    LMV358IDT

    33

    14

    C22

    29

    C18

    PWM2

    R13

    15k

    19

    C25

    7

    PWM2

    VBUS

    17

    24

    C20

    I_0

    PROGRAMMING PORT

    SYNCR[2]

    RESET1

    1

    5

    UM

    2520 - Rev 3

    page 13/28

    UM

    2520STEVA

    L-IPFC01C

    1 control board schematic

  • 8 STEVAL-IPFC01A1 adapter board schematic

    Figure 13. STEVAL-IPFC01A1 schematic

    J

    2

    YELL

    OW

    R4031k

    LED

    1

    RED

    YELL

    OW

    401

    Q400

    470k

    J400

    RED

    R401 330

    4 3 2 1

    BLAC

    K

    MMBT2222ALT1G

    R402

    1 2 3 4 5 6

    8 7 6 5

    D400

    CON4CON6

    GR

    EEN

    BRO

    WN

    3

    OR

    ANG

    E

    OR

    ANG

    E

    UM

    2520 - Rev 3

    page 14/28

    UM

    2520STEVA

    L-IPFC01A

    1 adapter board schematic

  • 9 STEVAL-IPFC01V1 3 kW interleaved PFC bill of materials

    Table 1. STEVAL-IPFC01V1 bill of materials

    Item Q.ty Ref. Part / Value Description Manufacturer Order code

    1 1 - STEVAL-IPFC01P1 Power board ST not available separately

    2 1 - STEVAL-IPFC01C1 Control board ST not available separately

    3 1 - STEVAL-IPFC01A1 adapter board ST not available separately

    9.1 STEVAL-IPFC01P1 power board bill of materials

    Table 2. STEVAL-IPFC01P1 bill of materials

    Item Q.ty Ref. Part / Value Description Manufacturer Order code

    1 1 C100 100nF, 275Vac,±20%

    POLYPROPILENEFILM CAP, throughhole lead spacing15mm

    PANASONIC ECQUAAF104MA

    2 1 C101 100nF, 50V,±10% 0603 ANY ANY

    3 1 C102 1nF, 500Vdc,±20%

    Ceramic disc cap,through hole leadspacing 7.5mm

    VISHAY BCCOMPONENTS VY1102M35Y5UG63V0

    4 3 C200, C204,C208470nF, 50V,±20%

    X7R CeramicCapacitor, 0805 TDK CGA4J3X7R1H474M125AE

    5 3 C201, C202,C203470µF, 25V,±20%

    Electrolyticcapacitor +105°, TH8mm diameter,3.5mm lead spacing

    ANY ANY

    6 1 C205 10µF, 25V,±20%

    Electrolyticcapacitor +105°,through hole leadspacing 2.5mm

    ANY ANY

    7 2 C206, C207 4.7µF, 50V,±10%Ceramic Capacitor,1210 MULTICOMP MULTICOMP

    8 1 C209 4.7nF, 50V,±10%X7R CeramicCapacitor, 0603 ANY ANY

    9 2 C210, C340 1nF, 50V, ±10% X7R CeramicCapacitor, 0603 ANY ANY

    10 4 C300, C301,C302, C303470µF, 450V,±20%

    Electrolyticcapacitor +105°,through hole leadspacing 10mm

    Nichicon LGL2W471MELC35

    11 1 C304 0.56µF, 450V,±10%

    POLYPROPILENEFILM CAP, throughhole lead spacing22.5mm

    EPCOS B32673P6564K000

    12 1 C305 1µF, 520V,±10%

    POLYPROPILENEFILM CAP, throughhole lead spacing22.5mm

    EPCOS B32673Z5105K000

    UM2520Bill of materials

    UM2520 - Rev 3 page 15/28

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    13 11

    C306, C328,C329, C330,C334, C307,C323, C324,C325, C332,C339

    10nF, 50V,±10%

    X7R CeramicCapacitor, 0603 ANY ANY

    14 3 C308, C309,C310100pF, 630 Vdc,±5%

    POLYPROPILENEFILM CAP, throughhole lead spacing5mm

    KEMET PFR5101J630J11L4BULK

    15 4 C311, C312,C313, C326100pF, 50V,±5%

    COG CeramicCapacitor, 0603 ANY ANY

    16 11

    C316, C317,C319, C322,C331, C335,C336, C337,C338, C318,C320

    100nF, 50V,±10%

    X7R CeramicCapacitor, 0603 ANY ANY

    17 1 C327 3.3nF, 50V, ±5% C0G CeramicCapacitor, 0603 ANY ANY

    18 3 C328, C329,C330150 pF, 50V,±5%

    C0G CeramicCapacitor, 0603 ANY ANY

    19 1 C333 1nF, 50V, ±5% C0G CeramicCapacitor, 0603 ANY ANY

    20 18

    D100, D203,D303, D304,D305, D306,D307, D308,D309, D310,D311, D312,D313, D314,D316, D317,D318, D319

    30V, 1A Power schottkydiode, SMA ST STPS1L30A

    21 1 D101 50A, 1000V, 50A Single Phase BridgeRectifier, GBJHY ElectronicCorp GBJ5010

    22 3 D102, D103,D104GF1M, 1000V,1A

    General PurposeRectifier Diode,SMA

    ONSemiconductor GF1M

    23 1 D200 220V TRANSIL, SMB ST SM6T220A

    24 1 D201 150V, 2A Power schottkydiode, SMA ST STPS2150A

    25 1 D202 1000V, 1ATurbo 2 ultrafasthigh voltagerectifier, SMA

    ST STTH1L06A

    26 1 D204 100V, 150mASmall signalSchottky diode,SMD Minimelf

    ST TMMBAT46FILM

    27 3 D300, D301,D302 600V, 12ASilicon carbide highvoltage rectifier,TO220AC

    ST STPSC12065D

    28 1 D315 100V, 150mASmall signalSchottky diode,SOD-323

    ST BAT46JFILM

    29 1 F100 20A, 250Vac,20A, 0%

    Cylindrical FuseClass gG/gL andaM, SMD 10x3 mm

    Bel Fuse Inc. SMM 20

    UM2520Bill of materials

    UM2520 - Rev 3 page 16/28

    https://www.st.com/en/product/stps1l30?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/sm6t?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/stps2150?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/stth1l06?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/tmmbat46?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/stpsc12065?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/bat46?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    30 1 ISO100 80V, 50mA , 0% Optocoupler, SMD Toshiba TLP385

    31 1 J100 VIN, 630V,17.5A

    PCB terminal block,through hole leadspacing 7.5mm

    Phoenix Contact 1717033

    32 1 J300 VOUT, 300Vac,25A

    PCB terminal block,through hole leadspacing 7.62mm

    RS Pro 790-1130

    33 1 J301 CON40A,550Vca, 6.9A

    PCB terminal blockfemale, through holelead spacing 2.54mm

    Samtec ESQ12037GD

    34 1 L1002x 4.5 mH,250V, 18A,±20%

    Common ModePower Line Choke,through hole

    WURTHELEKTRONIK 7448051804

    35 1 L200 4.7uH, 1.7A,±20%SMD Inductor, SMD4.5x4mm

    NICCOMPONENTS NPI43C4R7MTRF

    36 1 L201 2.2mH, 0.47A,±10%

    Switch ModeTransformer,through hole

    AQ Magnetica

    OR

    Würth Elektronik

    2198.0037

    OR

    750 318 675

    37 3 L300, L301,L302 ±10%Power inductor,through hole PQ32

    AQ Magnetica

    OR

    Würth Elektronik

    2083.0011

    OR

    750316867

    38 2 Q100, Q304 18V, 1AN-channel 20 V,Power MOSFET,SO8

    ST STS6NF20V

    39 3 Q300, Q301,Q302 600V, 40AMDmesh II Plus™low Qg, TO-247 ST STW40N60M2

    40 1 Q303 45V, 200 mABJT NPN smallsignal transistor,SOT-23

    ONSemiconductor MMBT6429LT1G

    41 1 RL100 250Vac-16A,250V, 16A, 0%RELAY SPST,through hole

    SCHRACK - TECONNECTIVITY RT314018

    42 1 RV100 S14K275,275Vac, ±10%

    METAL OXIDEVARISTORS,through hole leadspacing 6mm

    EPCOS B72214S0271K101

    43 2 R100, R360 22, 200V, ±1% Metal film resistor,1206 ANY ANY

    44 1 R101 150, 350V, ±5%High power ceramicresistors, throughhole

    TE Connectivity SQMW5150RJ

    45 4 R102, R203,R362 33k, 50V, ±1%Metal film resistor,0603 ANY ANY

    46 7

    R103, R104,R112, R113,R301, R304,R308

    470k, 200V,±1%

    Metal film resistor,1206 ANY ANY

    47 3 R105, R108,R109 33k, 200V, ±1%Metal film resistor,1206 ANY ANY

    48 1 R106 100k, 200V,±1%Metal film resistor,1206 ANY ANY

    UM2520Bill of materials

    UM2520 - Rev 3 page 17/28

    https://www.st.com/en/product/sts6nf20v?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/stw40n60m2?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    49 2 R107, R111 10M, 50V, ±1% Metal film resistor,0603 ANY ANY

    50 1 R110 47k, 50V, ±1% Metal film resistor,0603 ANY ANY

    51 1 R114 3k ±0.1%, 50V,0%Metal film resistor,0603 ANY ANY

    52 1 R200 3.3k, 200V, ±1% Metal film resistor,1206 ANY ANY

    53 1 R202 100, 200V, ±1% Metal film resistor,1206 ANY ANY

    54 1 R204 12k, 50V, ±1% Metal film resistor,0603 ANY ANY

    55 1 R205 24k, 50V, ±1% Metal film resistor,0603 ANY ANY

    56 2 R206, R207 2.7, 200V, ±1%Professional MELFResistors, MELF0204

    Vishay MMA02040C2708FB300

    57 1 R208 24k, 50V, ±1% Metal film resistor,0603 ANY ANY

    58 1 R300 30m, ±1%

    Ultra PrecisionCurrent SensingChip Resistor, SMD4527

    StackpoleElectronics Inc. CSS4527FT30L0

    59 11

    R302, R303,R332, R334,R336, R339,R341, R343,R351, R352,R367

    100, 50V, ±1% Metal film resistor,0603 ANY ANY

    60 3 R305, R306,R307 510, 50V, ±1%Metal film resistor,0603 ANY ANY

    61 10

    R309, R310,R333, R335,R337, R340,R342, R344,R356, R358

    2.2k ±0.1%,75V, 0%

    Metal film resistor,0603 ANY ANY

    62 2 R311, R325 10k ±0.1%, 50V,0%Metal film resistor,0603 ANY ANY

    63 3 R312, R313,R314 33, 200V, ±1%High Power ThickFilm Resistor, 1206 ANY ANY

    64 2 R315, R316 10, 200V, ±1% High Power ThickFilm Resistor, 1206 ANY ANY

    65 1 R317 10, 200V, ±1% High Power ThickFilm Resistor, 1206 ANY ANY

    65 3 R318, R322,R320 10k, 200V, ±1%High Power ThickFilm Resistor, 1206 ANY ANY

    67 3 R319, R321,R323 10m, ±1%Wirewound Res.,Precision, SMD2512

    OHMITE MCS3264R010FER

    68 1 R324 3.3k ±0.1%,75V, 0%Metal film resistor,0603 ANY ANY

    69 1 R326 4m, ±1% Metal film resistor,SMD 3921 Vishay WSLP39214L000FEA

    UM2520Bill of materials

    UM2520 - Rev 3 page 18/28

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    70 6R327, R328,R329, R346,R347, R348

    62k ±0.1%, 75V,0%

    Metal film resistor,0603 ANY ANY

    71 2 R330, R353 6.8k, 50V, ±1% Metal film resistor,0603 ANY ANY

    72 1 R331 2k, 50V, ±1% Metal film resistor,0603 ANY ANY

    73 1 R338 4.7k, 50V, ±1% Metal film resistor,0603 ANY ANY

    74 1 R345 47k, 50V, ±1% Metal film resistor,0603 ANY ANY

    75 1 R349 3.3k, 50V, ±1% Metal film resistor,0603 ANY ANY

    76 1 R350 10k, 50V, ±1% Metal film resistor,0603 ANY ANY

    77 1 R354 330k, 50V, ±1% Metal film resistor,0603 ANY ANY

    78 2 R355, R359 82k ±0.1%, 75V,0%Metal film resistor,0603 ANY ANY

    79 1 R357 470, 50V, ±1% Metal film resistor,0603 ANY ANY

    80 1 R361 11k, 50V, ±1% Metal film resistor,0603 ANY ANY

    81 1 R363 10k, 50V, ±1% Metal film resistor,0603 ANY ANY

    82 3 R364, R365,R366 0, 200V, ±1%Metal film resistor,1206 ANY ANY

    83 3 R368, R369,R370 1k, 50V, ±1%Metal film resistor,0603 ANY ANY

    84 1 U200 5V, 0.25AVery low dropvoltage regulatorswith inhibit, SO8

    ST L4931ABD50, TR

    85 1 U201 900VOff-line all-primary-sensing switchingregulator, SO16N

    ST ALTAIR05T, 800

    86 5U300, U301,U302, U303,U305

    -rail to rail input/output 5V CMOSOp-Amp, SOT23-5L

    ST TSV911ILT

    87 1 U304 -Rail-to-rail high-speed comparator,SOT23-5L

    ST TS3011ILT

    88 1 U306 5V

    Ultra-low current 2.4V precision analogtemperature sensor,SOT323-5L

    ST STLM20W87F

    89 3 U307, U308,U309 18V, 4A4 A dual low sideMOSFET driver,SO8

    ST PM8834TR

    90 2 Y100, Y101 2.2nF, 250V,±20%

    Ceramic disc cap, TH lead spac. 7.5mm

    MURATA DE2E3KH222MA3B

    UM2520Bill of materials

    UM2520 - Rev 3 page 19/28

    https://www.st.com/en/product/l4931?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/altair05t-800?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/tsv911?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/ts3011?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/stlm20?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/pm8834?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    91 1 Y300 FAN2, 12V,0.25A

    DC Axial Fan,through hole40X40X20

    ARX FD1240-A0241D0AL

    92 1 HEATSINK -HEATSINK 220mm,standard finishingsize length: 220 mm

    PADA 8411

    93 1 PLEXIGLASSSPACER -PLEXIGLASSSPACER, DIM:240X40x3mm

    ANY ANY

    94 6 SPACER - Nylon spacer 10mmM3 - -

    95 6 NUT - Nylon NUT M3 - -

    96 3 INSULATOR KIT1 -INSULATOR KITTO-220 MULTICOMP MK3306/S

    97 3 INSULATOR KIT2 -INSULATORTO-247 - -

    98 2 Screw M3 - M3 steel screws -10 mm length - -

    99 7 Screw M2.5 - M2.5 steel screws -20 mm length - -

    100 7 NUT - M2.5 STEEL NUT - -

    101 7 Plain Washer - M2.5 Steel PlainWasher - -

    9.2 STEVAL-IPFC01C1 control board bill of materials

    Table 3. STEVAL-IPFC01C1 bill of materials

    Item Q.ty Ref. Part / Value Description Manufacturer Order code

    1 1 C1 4.7µF, 0805, 16V, 10 %X7R CeramicCapacitor ANY ANY

    2 2 C2, C5 100nF, 0603, 50V, 10 %X7R CeramicCapacitor ANY ANY

    3 4 C3, C4, C15,C1710nF, 0603, 50V, 10 %

    X7R CeramicCapacitor ANY ANY

    4 1 C6 47µF, 1206, 6.3V, 20 %Polarized tantalumchip capacitor AVX TAJA476K006RNJ

    5 1 C7 1µF, 0603, 25 V,10 %X7R CeramicCapacitor ANY ANY

    6 6 C8, C21, C22,C25, C26, C27100pF, 0603, 25V, 10 %

    X7R CeramicCapacitor ANY ANY

    7 3 C9, C19, C20 150pF, 0603, 25V, 5 %C0G CeramicCapacitor ANY ANY

    8 2 C10, C37 33pF, 0603, 50V, 5 %C0G CeramicCapacitor ANY ANY

    9 1 C11 100nF, 0603, 50V, 10 %X7R CeramicCapacitor ANY ANY

    10 1 C12 15nF, 0603, 50V, 10 %X7R CeramicCapacitor ANY ANY

    11 4 C13, C38, C39,C40220nF, 0603, 50V, 10 %

    X7R CeramicCapacitor ANY ANY

    UM2520Bill of materials

    UM2520 - Rev 3 page 20/28

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    12 2 C14, C16 100nF, 0603, 25V, 10 %X7R CeramicCapacitor ANY ANY

    13 3 C18, C24, C32 100nF, 0603, 50V, 10 %X7R CeramicCapacitor ANY ANY

    14 2 C23, C33 10nF, 0603, 25V, 10 %X7R CeramicCapacitor ANY ANY

    15 1 C28 1.5nF, 0603, 25V, 10 %X7R CeramicCapacitor ANY ANY

    16 1 C29 100pF, 0603, 25V, 5 %COG CeramicCapacitor ANY ANY

    17 1 C30 10pF, 0603, 50V, 5 %COG CeramicCapacitor ANY ANY

    18 1 C31 15nF, 0603, 50V, 10 %X7R CeramicCapacitor ANY ANY

    19 1 C34 1nF, 0603, 25 V,10 %X7R CeramicCapacitor ANY ANY

    20 1 C35 2.2nF, 0603, 25V, 10 %C0G CeramicCapacitor ANY ANY

    21 1 C36 330pF, 0603, 50V, 5 %COG CeramicCapacitor ANY ANY

    22 1 D1 RED, 0805, N.A.%,

    High efficiency reddiffused LED 2mA3mm

    Kingbright KP-2012SRC-PRV

    23 1 D2 GREEN, 0805,N.A. %,

    High efficiencygreen diffused LED2mA 3mm

    Kingbright KPHCM-2012CGCK

    24 1 J1 CON40A, /, / V, /%,

    Right angleconnector 2 ways2.54mm

    Stelvio Kontek 4.74975E+12

    25 1 J2 SWIM I/F, generic male stripline connector ANY ANY

    26 1 J3 CON4, generic male stripline connector ANY ANY

    27 1 L1 WE-CBF, SMD Inductor, 0603 Wurth Elektronik 74279262

    28 2 R1, R2 1k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    29 3 R4, R7, R36 10k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    30 2 R6, R35 3.3k, 50 V, 1 % Metal film resisto,0603r ANY ANY

    31 3 R8, R9, R32 10k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    32 4 R10, R11, R16,R17 100, 50 V, 1 %Metal film resistor,0603 ANY ANY

    33 4 R12, R13, R18,R19 N.M., 50 V, 1 %Metal film resistor,0603 ANY ANY

    34 2 R14, R15 10k, 50 V, 0.1%,Metal film resistor,0603 ANY ANY

    35 2 R20, R30 22k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    UM2520Bill of materials

    UM2520 - Rev 3 page 21/28

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    36 1 R21 10k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    37 1 R22 2.2k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    38 1 R23 7.5k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    39 1 R24 2.4k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    40 1 R25 220K, 50 V, 1 % Metal film resistor,0603 ANY ANY

    41 2 R26, R27 56k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    42 1 R28 6.2k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    43 2 R29, R31 0, 50 V, 1 % Metal film resistor,0603 ANY ANY

    44 1 R33 N.M., 50 V, 1 % Metal film resistor,0603 ANY ANY

    45 1 R34 15k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    46 1 R37 5.1k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    47 3 R38, R39, R40 100k, 50 V, 1 % Metal film resistor,0603 ANY ANY

    48 1 U1 -

    Three-channelinterleaved CCMPFC digitalcontroller, TSSOP38

    ST STNRGPF01

    49 2 U2,U3 -Quad 2-InputSchmitt NANDGate, SO14

    ST M74HC132YRM13TR

    50 1 U4 -rail to rail input/output 5V CMOSOp-Amp, SOT23-5L

    ST TSV911ILT

    51 1 U5 -Low power rail-to-rail input/output op-amp, SO8

    ST LMV358IDT

    9.3 STEVAL-IPFC01A1 adapter board bill of materials

    Table 4. STEVAL-IPFC01A1 bill of materials

    Item Q.ty Ref. Part / Value Description Manufacturer Order code

    1 1 D400 LEDHigh Efficiency RedLED 3mm, throughhole

    Kingbright L-7104ID

    2 1 J400 CON4

    4-contact 2.54mmfemale SIL Board-to-board Socket,through hole

    HARWIN M20-7890446

    UM2520Bill of materials

    UM2520 - Rev 3 page 22/28

    https://www.st.com/en/product/stnrgpf01?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/M74HC132?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/tsv911?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520https://www.st.com/en/product/lmv358?ecmp=tt9470_gl_link_feb2019&rt=um&id=UM2520

  • Item Q.ty Ref. Part / Value Description Manufacturer Order code

    3 1 J401 CON6

    Right angle maleconnector 1 way 6circuits 2.54mm,through hole

    ANY ANY

    4 1 Q400 40 V, 0.6 AGeneral PurposeTransistors, NPNSilicon

    ONSemiconductor SMMBT2222ALT1G

    5 1 R401 330 Metal film resistor,0805 ANY ANY

    6 1 R402 470k Metal film resistor,0805 ANY ANY

    7 1 R403 1K Metal film resistor,0805 ANY ANY

    UM2520Bill of materials

    UM2520 - Rev 3 page 23/28

  • Revision history

    Table 5. Document revision history

    Date Version Changes

    18-Dec-2018 1 Initial release.

    09-Sep-2019 2

    Throughout document: minor text edits

    Updated Figure 10. STEVAL-IPFC01P1 schematic - auxiliary power supply

    Updated Table 2. STEVAL-IPFC01P1 bill of materials

    11-Oct-2019 3 Updated Table 2. STEVAL-IPFC01P1 bill of materials

    UM2520

    UM2520 - Rev 3 page 24/28

  • Contents

    1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

    2 STEVAL-IPFC01V1 evaluation kit overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

    2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    3 How to use the STEVAL-IPFC01V1 evaluation board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    3.1 How to connect and start the STEVAL-IPFC01P1 power board . . . . . . . . . . . . . . . . . . . . . . . . 4

    3.1.1 STEVAL-IPFC01P1 power board startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    4 PFC controller customization with eDesign Suite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    5 Status LEDs and fault conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

    5.1 Normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    5.2 Fault conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    5.3 Wait conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    6 STEVAL-IPFC01P1 power board schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

    7 STEVAL-IPFC01C1 control board schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

    8 STEVAL-IPFC01A1 adapter board schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

    9 STEVAL-IPFC01V1 3 kW interleaved PFC bill of materials. . . . . . . . . . . . . . . . . . . . . . . . . .15

    9.1 STEVAL-IPFC01P1 power board bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

    9.2 STEVAL-IPFC01C1 control board bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

    9.3 STEVAL-IPFC01A1 adapter board bill of materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

    Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

    UM2520Contents

    UM2520 - Rev 3 page 25/28

  • List of figuresFigure 1. STEVAL-IPFC01V1 3 kW interleaved PFC reference design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Figure 2. STEVAL-IPFC01V1 block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Figure 3. STEVAL-IPFC01C1 insertion in STEVAL-IPFC01P1 J301 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Figure 4. STEVAL-IPFC01V1 AC source connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Figure 5. STEVAL- IPFC01V1 DC output connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Figure 6. STEVAL-IPFC01V1 DC input connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 7. PFC specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Figure 8. PFC step-by-step design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Figure 9. STEVAL-IPFC01P1 schematic - input section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Figure 10. STEVAL-IPFC01P1 schematic - auxiliary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure 11. STEVAL-IPFC01P1 schematic - boost interleaving section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Figure 12. STEVAL-IPFC01C1 schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Figure 13. STEVAL-IPFC01A1 schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

    UM2520List of figures

    UM2520 - Rev 3 page 26/28

  • List of tablesTable 1. STEVAL-IPFC01V1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Table 2. STEVAL-IPFC01P1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Table 3. STEVAL-IPFC01C1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Table 4. STEVAL-IPFC01A1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Table 5. Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

    UM2520List of tables

    UM2520 - Rev 3 page 27/28

  • IMPORTANT NOTICE – PLEASE READ CAREFULLY

    STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, enhancements, modifications, and improvements to STproducts and/or to this document at any time without notice. Purchasers should obtain the latest relevant information on ST products before placing orders. STproducts are sold pursuant to ST’s terms and conditions of sale in place at the time of order acknowledgement.

    Purchasers are solely responsible for the choice, selection, and use of ST products and ST assumes no liability for application assistance or the design ofPurchasers’ products.

    No license, express or implied, to any intellectual property right is granted by ST herein.

    Resale of ST products with provisions different from the information set forth herein shall void any warranty granted by ST for such product.

    ST and the ST logo are trademarks of ST. For additional information about ST trademarks, please refer to www.st.com/trademarks. All other product or servicenames are the property of their respective owners.

    Information in this document supersedes and replaces information previously supplied in any prior versions of this document.

    © 2019 STMicroelectronics – All rights reserved

    UM2520

    UM2520 - Rev 3 page 28/28

    http://www.st.com/trademarks

    Introduction1 Safety instructions2 STEVAL-IPFC01V1 evaluation kit overview2.1 Features

    3 How to use the STEVAL-IPFC01V1 evaluation board3.1 How to connect and start the STEVAL-IPFC01P1 power board3.1.1 STEVAL-IPFC01P1 power board startup sequence

    4 PFC controller customization with eDesign Suite5 Status LEDs and fault conditions5.1 Normal operation5.2 Fault conditions5.3 Wait conditions

    6 STEVAL-IPFC01P1 power board schematics7 STEVAL-IPFC01C1 control board schematic8 STEVAL-IPFC01A1 adapter board schematic9 STEVAL-IPFC01V1 3 kW interleaved PFC bill of materials9.1 STEVAL-IPFC01P1 power board bill of materials9.2 STEVAL-IPFC01C1 control board bill of materials9.3 STEVAL-IPFC01A1 adapter board bill of materials

    Revision history