ST UM2520 User manual

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

1Safety 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 the
charged capacitors need time to discharge.
Due to the high power density, the board components and the heat sink 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).
UM2520
Safety instructions
UM2520 - Rev 3 page 2/28

2STEVAL-IPFC01V1 evaluation kit overview
Figure 2. STEVAL-IPFC01V1 block diagram
1. I/O measurement signals
2. Analog circuitry
3. Power stage
4. Digital control section with STNRGPF01 digital controller
EMI filter
&
rectification
3-channel
interleaved
PFC
Driver Driver Driver
Current
compensator
Triangular
wave
generator
Analog
filter
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
Auxiliary
Power
Supply
AC
input
DC
output
PWM0 PWM1 PWM2
Itot_fb
1
1
1
1
2
22
33
333
3
3
4
4 4
The STEVAL-IPFC01V1 implements mixed signal (analog/digital) control, so the converter can manage a range of
input and output conditions and still remain highly responsive to fast transients in input signals. The inner current
loop is a hardware analog proportional-integral (PI) compensator that ensures the highest possible bandwidth and
cycle-by-cycle sensing and regulation. The outer voltage loop is performed by a digital PI controller with fast
dynamic 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: <5% at 20% load
• Mixed-signal average current mode control, CCM fixed frequency operation
• Switching Frequency: 111 kHz
• Cycle-by-cycle regulation (analog current control loop)
• Input voltage and load feed-forwards
• Phase shedding
• Burst-mode operation
• Overvoltage protection
• Thermal protection
• Status indicator LEDs
• Inrush current limiter function
• Cooling function
UM2520
STEVAL-IPFC01V1 overview
UM2520 - Rev 3 page 3/28

3How 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 frequency
range 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
J301
Step 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
UM2520
How 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 the
soft 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 the
output:
– 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 the
board.
3.1.1 STEVAL-IPFC01P1 power board startup sequence
1. 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 auxiliary
voltages (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 output
capacitor until the DC voltage reaches the peak input voltage. The charge current is limited by resistor R101.
UM2520
How to connect and start the STEVAL-IPFC01P1 power board
UM2520 - Rev 3 page 5/28

Figure 6. STEVAL-IPFC01V1 DC input connection
1nF
0
100 nF
R112
AC-IN-L1
VIN
1
3
47k
4
L100
AC-IN-L2
2.2nF
R104
470k
250Vac-16A
2
F100
N.M.
R102
-+
3
33k - 1206
D103
20A
470k
GF1M
A1
33k - 1206
R113
VDD
N.M.S14K275
R109
2
ZVD
R105
3
1
2
3
C102
R108
R111
D104
R106
GF1M
A
100nF
V_INPUT
33k
15V
1
2
2
5
TLP385
50A
A2
2.2nF
D102
Y100
R114
150
D101
1
3k 0.1%
C100
C101
R101
1
10M
10M
7 8
RV100
3
RL100
3
VIN
2x 4.5 mH
2
Y101
Q100
D100
GF1M
6
0
14
STS6NF20V
ISO100
4
11
470k
STPS1L30A
J100
1
1
100k - 1206
R110
4
RELAY
12
2
4
R100 22
33k - 1206
R103
470k
R107
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 into
the PFC and possibly damage the board when the relay closes the contacts across resistor R101.
UM2520
How to connect and start the STEVAL-IPFC01P1 power board
UM2520 - Rev 3 page 6/28

4PFC controller customization with eDesign Suite
The eDesignSuite suite software tool developed by STMicroelectronics helps you configure ST products power
conversion applications. You can use it to customize the PFC controller for a specific application: you start by
entering the main specifications for your design and then generate an automatic design or follow a sequential
process to build a highly customized design.
Figure 7. PFC specifications
UM2520
PFC controller customization with eDesign Suite
UM2520 - Rev 3 page 7/28

Figure 8. PFC step-by-step design
RELATED LINKS
See RM0446 for details on how to use eDesignSuite to generate specialized firmware
UM2520
PFC controller customization with eDesign Suite
UM2520 - Rev 3 page 8/28

5Status 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 that
the 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 output
capacitors.
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 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 input
voltage 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 the
conditions have cleared before repeating the startup sequence.
UM2520
Status LEDs and fault conditions
UM2520 - Rev 3 page 9/28

6STEVAL-IPFC01P1 power board schematics
Figure 9. STEVAL-IPFC01P1 schematic - input section
1nF
0
100 nF
R112
AC-IN-L1
VIN
1
3
47k
4
L100
AC-IN-L2
2.2nF
R104
470k
250Vac-16A
2
F100
N.M.
R102
-+
3
33k - 1206
D103
20A
470k
GF1M
A1
33k - 1206
R113
VDD
N.M.S14K275
R109
2
ZVD
R105
3
1
2
3
C102
R108
R111
D104
R106
GF1M
A
100nF
V_INPUT
33k
15V
1
2
2
5
TLP385
50A
A2
2.2nF
D102
Y100
R114
150
D101
1
3k 0.1%
C100
C101
R101
1
10M
10M
7 8
RV100
3
RL100
3
VIN
2x 4.5 mH
2
Y101
Q100
D100
GF1M
6
0
14
STS6NF20V
ISO100
4
11
470k
STPS1L30A
J100
1
1
100k - 1206
R110
4
RELAY
12
2
4
R100 22
33k - 1206
R103
470k
R107
UM2520 - Rev 3 page 10/28
UM2520
STEVAL-IPFC01P1 power board schematics