IRAC1152-350W Infineon

18 Feb 2011 Data Sheet No. PD97152 IRAC1152-350W Reference Design Kit for IR1152 (Fixed 66kHz Frequency, One Cycle Control PFC IC with Brown-Out Protection) Product Summary REFERENCE DESIGN KIT FEATURES IEC61000-3-2 Class D Standards Compliant AC Input Voltage 85-264VAC Less than 10% Total Harmonic Distortion (115- 230VAC/350W) AC Input Line Frequency 47-63Hz Universal AC Input Voltage capability DC Bus Output Voltage 388V +/- 2% Fully regulated 388V DC bus Full load start-up, no minimum load requirements Maximum output power 350W Current loop controlled soft-current limit protection for overpower limitation at minimum VAC Minimum Load Requirement None High Efficiency Si Superjunction MOSFET boost switch Power Factor >0.98 Hyper-fast recovery Si boost diode (115-230VAC/350W) On-board Flyback SMPS for 15V VCC supply (option to Total Harmonic Distortion disable for external VCC bias supply) <10% (115-230VAC/350W) Single layer PCB illustrating layout best-practices Start-up time 60ms IR1152 PFC IC FEATURES PFC IC with IR proprietary One Cycle Control Continuous conduction mode boost type PFC Fixed 66kHz switching frequency Average current mode control Input line sensed brownout protection DC bus overvoltage protection (Dual & 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) 750mA peak gate drive Optimized pin-out for single layer PCB layout Introduction IRAC1152-350W is a full function AC-DC reference design showcasing the operation of IR1152 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, IRAC1152-350W delivers 350W continuous output power via a fully regulated 388V DC bus. Thanks to IR1152 PFC IC, the reference design is rendered with a very high level of safety against system abnormalities such as AC line sag, DC bus voltage loop feedback loss, system overcurrent & overvoltage. Combining the cost-advantage of single layer PCB and ferrite-core boost inductors with optimized PCB layout, the IRAC1152-350W 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 2010 International Rectifier 1 IRAC1152-350W Table of Contents Introduction ......................................................................................................................................................... 1 Description of Hardware & Key Operating Features ........................................................................................... 4 Hardware Installation & Operating Procedure .................................................................................................... 7 Performance Characterization ............................................................................................................................ 9 IRAC1152-350W Schematics ........................................................................................................................... 19 IRAC1152-350W Bill of Materials (BoM) .......................................................................................................... 22 IRAC1152-350W PCB & Component Layout ................................................................................................... 24 List of Figures Figure 1 IRAC1152-350W test set-up................................................................................................................. 7 Figure 2: IRAC1152-350W external Vcc connection .......................................................................................... 8 Figure 3. Power factor vs. Line/Load Variation of IRAC1152-350W................................................................... 9 Figure 4. Current Harmonics at 85-264VAC, 350W ......................................................................................... 10 Figure 5. Current Harmonics at 85-264VAC, 87.5W (25% of rated power)...................................................... 10 Figure 6. THD at 350W across 85-264VAC for IRAC1152-350W .................................................................... 11 Figure 7. EMI filter stage causes phase-shift in Input Current Waveform (264VAC, 350W) ............................ 13 Figure 8. Power factor vs. Line/Load for modified IRAC1152-350W with single stage EMI filter ..................... 13 Figure 9. 2X AC frequency ripple in DC bus capacitor at 85VAC, 350W ......................................................... 14 Figure 10. 2X AC frequency ripple in DC bus capacitor at 264VAC, 350W ..................................................... 14 www.irf.com 2010 International Rectifier 2