ST STEVAL-IPFC02V1 User manual

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 non-
time-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
How to use the 2 kW two-channel interleaved PFC based on the STNRGPF02
digital controller
UM2674
User manual
UM2674 - Rev 3 - January 2021
For further information contact your local STMicroelectronics sales office.
www.st.com

1Safety 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., cross-
sectional areas of conductors, fusing, and GND connections).
UM2674
Safety instructions
UM2674 - Rev 3 page 2/28

2STEVAL-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
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.
2.1 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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STEVAL-IPFC02V1 evaluation kit overview
UM2674 - Rev 3 page 3/28

• 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
UM2674 - Rev 3 page 4/28

3How 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 VRMS and 1 kW at 115 VRMS, in a frequency
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
EARTH
AC LINE
AC LINE
UM2674
How to use the STEVAL-IPFC02V1 evaluation board
UM2674 - Rev 3 page 5/28

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
+400V
GND
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 VAC
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.
UM2674
How to connect and start the STEVAL-IPFC02P1 power board
UM2674 - Rev 3 page 6/28

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
0
13V
0
V_INPUT
5V
5V
A A A A A A
5V
RELAY
ZVD
VIN_L1
R108
33k
R102
33k
RV100
S14K275
- +
D101
50A
2
1
3
4
D100
STPS1L30A
D103
BAS70-04FILM
3
1 2
R104
470k
N.M.
R107
10M
D104
BAS70-04FILM
3
1 2
ISO100
TLP385(E
12 43
R114
3k
0.1 %
R106
100k
R123
3k
0.1 %
R101
150
R112
470k
C111
100pF
R121
470k
C101
0.1 uF
R103
470k
N.M.
L100
2x4.5mH
2 1 3 4
C100
100nF
Y101
2.2 nF
C110
100pF
R100 22
R113
470k
J100
VIN
1
2
3
R122
470k
R105
33k
Q100
STS6NF20V
6
4
2 1 3 5
7 8
R111
10M
C102
1nF
D102
GF1M
RL100
250Vac-16A
11
1
A1
A2
3
12
2
14
Y100
2.2 nF
R110
47k
F100
20A 250 Vac
R109
33k
AC-IN-L2
L1
L2
AC-IN-L1
L1 VDDIO
L2
VIN_L2
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
UM2674
How to connect and start the STEVAL-IPFC02P1 power board
UM2674 - Rev 3 page 7/28

4PFC 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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PFC controller customization with eDesignSuite
UM2674 - Rev 3 page 8/28

5Status 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 VDC
• 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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Status LEDs and fault conditions
UM2674 - Rev 3 page 9/28

6STEVAL-IPFC02V1 schematic diagrams
Figure 7. STEVAL-IPFC02P1 schematic - input section
0
13V
0
V_INPUT
5V
5V
A A A A A A
5V
RELAY
ZVD
VIN_L1
R108
33k
R102
33k
RV100
S14K275
- +
D101
50A
2
1
3
4
D100
STP S1L30A
D103
BAS 70-04FILM
3
1 2
R104
470k
N.M.
R107
10M
D104
BAS 70-04FILM
3
1 2
ISO100
TLP 385(E
12 43
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
STS 6NF20V
6
4
2 1 3 5
7 8
R111
10M
C102
1nF
D102
GF1M
RL100
250Vac-16A
11
1
A1
A2
3
12
2
14
Y100
2.2nF
R110
47k
F100
20A 250Vac
R109
33k
AC-IN-L2
L1
L2
AC-IN-L1
L1 VDDIO
L2
VIN_L2
UM2674 - Rev 3 page 10/28
UM2674
Schematic diagrams