MICROCHIP MSC750SMA170B High-Voltage Power Discretes and Modules User Guide
- June 12, 2024
- MICROCHIP
Table of Contents
Auxiliary Power Supply for Industrial and Solar
Applications Using 1.7 kV SiC MOSFET
Introduction
This document describes the design and performance of a 63W auxiliary power
supply with wide input voltage for industrial and solar applications using 1.7
kV Silicon Carbide (SiC) MOSFETs. The evaluation board is designed to evaluate
the performance of MSC750SMA170B for ease of use.
This document is for the users of MSC750SMA170B who want to create low-cost
and high-performance off-line Switch Mode Power Supply (SMPS) for auxiliary
power supply. This document provides the design details, including device
selection, control parameter determination, and transformer and hardware
designs.
Auxiliary power supply is an essential part of a power converter that converts
the electric power from High Voltage (HV) DC bus to a Low Voltage (LV) source
for powering control circuits, sensing circuits, cooling fans, and so on. A
low power (<100W) power converter with galvanic isolation is one of the most
important components in industrial and Photovoltaic (PV) applications. Due to
DC link voltage variation, many of these auxiliary power supplies must operate
from a wide input voltage range, typically ranging from 250V to 1000V. To
ensure the overall reliability of the power converter system, this converter
must have a simple topology and a low component count.
Due to its simple structure, low component count, and low cost, the single
switch flyback topology is a popular choice for such low power DC-DC
converters. However, due to the high peak voltage seen on the power switching
device, using silicon MOSFETs in the auxiliary power supply applications
presents many challenges.
For example, at the highest input voltage of 1 kV, the peak voltage on the
switching device can easily exceed 1.2 kV due to secondary side reflected
voltage and voltage across transformer leakage inductance, forcing the user to
use 1.5 kV–2 kV devices.
The options for the HV silicon MOSFETs are limited, and the specific on-state
resistance is much higher than for LV MOSFETs, reducing the converter
efficiency and complicating the cooling design. Furthermore, due to limited
resources, the cost of the HV silicon MOSFETs is significantly higher. To
utilize the lower rated voltage silicon MOSFETs, two-switch flyback or other
topologies can be used, but the design complexity and component count increase
significantly, reducing reliability and increasing design cost.
The following figure shows the topology of a single switch flyback converter
with a 1.7 kV SiC MOSFET for the auxiliary power supply applications.
Figure 1. Single Switch Flyback Converter for Auxiliary Power Supply
Applications![MICROCHIP MSC750SMA170B High-Voltage Power Discretes and Modules
- Auxiliary](https://manuals.plus/wp-content/uploads/2023/07/MICROCHIP- MSC750SMA170B-High-Voltage-Power-Discretes-and-Modules-Auxiliary.jpg)
1.7 kV SiC MOSFET is an excellent choice for using a single switch flyback
topology in an auxiliary power supply application that requires a wide input
voltage range. The 1.7 kV breakdown voltage provides sufficient voltage margin
for the 1 kV input voltage. The specific on-resistance of 1.7 kV SiC MOSFET is
much lower than that of HV silicon MOSFET, allowing for a smaller die size and
lower on-resistance in the same package. The smaller die size also
significantly reduces switching loss. This option allows to increase the
switching frequency of the auxiliary power supply in order to reduce
transformer size and weight.
Features
The evaluation board has the following key hardware features:
- Single Switch Flyback Topology
- 250V–1000V Wide Input Voltage
- +24V/2A and +15V/1A Dual Outputs, and Total 63W Output Power
- High-Power Conversion Efficiency Over Wide Power Range
- Current-Mode Pulse-Width Modulation (PWM) Controller-Based Closed Loop Control
Applications
The evaluation board has the following applications:
- ndustrial motor drives Solar inverters
- Uninterruptible power supplies
- General purpose inverters
- Cascaded H-bridge converters
- Modular multilevel converters
Electrical Specification
The following table lists the electrical specification of the evaluation
board.
Table 1-1. Electrical Specification—Evaluation Board
Symbol | Parameter | Ratings | Unit |
---|---|---|---|
Vin min | Minimum input voltage | 250 | V |
Vin max | Maximum input voltage | 1000 | |
Vout1 | Output voltage 1 | 24 | |
lout_maxl | Maximum output current 1 | 2 A | |
Vout2 | Output voltage 2 | 15 V | |
lout_max2 | Maximum output current 2 | 1 A | |
Pout max | Maximum output power | 63 | |
fs | Switching frequency | 45 kHz | |
Efficiency at >25% load | >80 | 0/0 | |
Eff max | Peak efficiency | 89 |
Evaluation Board
This chapter describes the evaluation board hardware, schematics, circuit, and
Printed Circuit Board (PCB) layout.
2.1 Evaluation Board Hardware
The main components of the evaluation board include input and output power
connectors, input and output capacitors, SiC MOSFET, isolation transformer,
output rectifier, driver IC, and analog closed-loop circuits.
The following figure shows the picture of the evaluation board hardware.
Figure 2-1. Evaluation Board Hardware 2.2 Schematic
The following components are included in the main power stage circuit:
- A DC input fuse and a Metal Oxide Varistor (MOV) (optional)
- An input capacitor
- A loss reduction startup circuit
- A Resistor Capacitor Diode (RCD) snubber circuit An isolation transformer
- SiC MOSFET A gate driving circuit
- An output rectification circuit
- An isolated output voltage feedback circuit
- An analog control circuit
The control circuit is based on a fixed frequency, high performance, and
current-mode PWM controller Integrated Circuit (IC) MIC38C44. The following
section describes the detailed design and parameter selection method. To
download the actual design files (schematic and gerber files), go to
microchip.com/sic.
The following figure shows the schematic of the evaluation board.
Note: The resistance units denoted by k, M, and R in the following figure
are kΩ, MΩ, and Ω respectively.
Figure 2-2. Schematic of the Evaluation Board 2.3 Circuit Description
The design of a SiC-based single switch flyback converter can be similar to
the traditional design of a flyback converter using MIC38C4x controllers.
However, some special considerations are discussed in the following sections.
2.3.1 Primary Side SiC Switching Device Selection
For a 1 kV maximum input voltage and the refected voltages at the transformer
from the secondary side 24V output voltage, the peak voltage on the primary
side switching device can exceed 1.2 kV; thus, 1.7 kV SiC MOSFETs are are
selected. The Root Mean Square (RMS) current through the primary side
switching device is very low for the rated 63W power, so 750 mΩ SiC MOSFET is
more than enough for such applications, while the smaller die size of the 750
mΩ SiC MOSFET can also help to reduce switching loss. Because the peak current
through the device is also relatively small, the 3L-TO247 package was chosen
for better thermal performance, allowing natural convection cooling to
eliminate the need for a fan. Therefore, a 1.7 kV, 750 mΩ SiC MOSFET in an
industry standard3L-TO247 package from Microchip (part number MSC750SMA170B)
is selected as the primary side switching power device.
2.3.2 Gate Driving Voltage and Gate Resistance Selection
The ultra low gate capacitance of the 1.7 kV, 750 mΩ SiC MOSFET enables direct
driving from the controller IC, eliminating the need for an additional gate
driver. It is recommended that the gate driving voltage for MSC750SMA170B be
+20V/-5V. However, as shown in the following figure, the device works well at
+18V with only a slight increase in on-state resistance; even at +15V, the on-
state resistance increase is less than 25% at higher junction temperatures.
The conduction loss in this application is very low due to the low RMS current
through the primary side switch.
Figure 2-3. Normalized On-State Resistance (RDSon) under Different Gate
VoltagesFurthermore, because MSC750SMA170B is a normally off device, a
negative voltage is not required to keep the device off in a steady state; the
recommended negative voltage is to avoid false turn on, which can cause shoot
through failure in a half-bridge circuit. There is no risk of shoot through
failure in a single switch flyback topology. Therefore, the negative off
voltage is not required.
Meanwhile, the controller IC MIC38C44 has an absolute maximum supply voltage
of +20V, with special precautions required for operations at ≥ 18V. To ensure
the controller IC safe operation, the driving voltage of the SiC MOSFET is set
to +17V/0V.
The selection of suitable gate resistance is determined by optimizing
switching losses, Electromagnetic Interference (EMI) noise emission, and
driving IC capability. A lower gate resistance
increases power MOSFET switching speed and reduces switching loss, while a
higher gate resistance reduces converter EMI noise emission. A turn on
resistance of 10Ω is selected based on the internal gate resistance of the SiC
MOSFET, the peak output current capability, and the output impedance of the
PWM controller.
The Undervoltage Lockout (UVLO) of the controller MIC38C44 is relatively low
when compared to the optimal gate voltage of the SiC MOSFETs. During the
startup process, the controller begins to operate once the supply voltage
exceeds the UVLO threshold. When the gate voltage is low, the SiC MOSFET may
operate in linear mode, and the maximum current through the device may be less
than the current required if the load is heavy. The UVLO can be bypassed, and
the threshold voltage can be set through an external circuit. For more
information on detailed implementation, contact Microchip technical support.
2.3.3 Control Power Supply and Active Startup
In steady-state operation, the control voltage is generated from the auxiliary
winding of the transformer through an 18V zener diode and an NPN transistor.
During the startup process, the control voltage is drawn directly from the DC
bus. To reduce converter loss and protect the controller from the high DC link
voltage, a HV N-channel MOSFET (part number CS3N150AHR) with a high resistance
branch is designed for control voltage during startup. Once the voltage on the
auxiliary winding of the transformer is built up, the circuit cuts the
connection to the HV DC bus to reduce power loss.
It is critical to optimize the gate loop layout design after determining the
gate driving parameters. To reduce gate ringing and avoid high peak gate
voltage, the key consideration is to reduce gate loop inductance and avoid
near-field coupling.
2.3.4 Switching Frequency
The switching frequency of the power converter is one of the most important
design parameters because it influences switching losses, transformer losses,
overall converter size/weight, and converter level EMI. SiC MOSFETs have low
switching loss energy and ultra-low gate charge when compared to Silicon (Si)
switches, allowing for higher switching frequency and a more compact
transformer design with lower power loss. For this evaluation board, a
switching frequency of fs = 45 kHz is selected considering the overall
optimization of the converter loss.
2.3.5 Output Voltage Regulation
This demonstration hardware is designed for industrial and solar applications
and has two output voltages: 24V/2A for fan loads and 15V/1A for main
converter level control circuits. The 24V/2A output is directly regulated by
feeding the output voltage back to the controller through an analog
compensation network and an opto isolator. The 15V/1A output has an optional
second stage power conversion based on the fixed frequency PWM/PFM synchronous
buck regulator (MCP16311). If a high precision 15V output is required, the
secondary winding of the transformer outputs 18V and feeds it into the buck
regulator, which converts it to a precision 15V output. The buck regulator can
also be bypassed for cost reduction. In this configuration, the transformer
secondary winding
is redesigned for 15V output to comply with the 24V regulation; this
transformer design is also available.
2.3.6 Transformer Design
The transformer is the key passive component in the circuit for providing
correct output voltages and galvanic isolation. The transformer power loss and
temperature rise are determined by the core material and winding wire
selection. The leakage inductance, which is determined directly by the winding
structure, influences the voltage ringing and peak voltage on the power
MOSFET, as well as the RCD clamping circuit design. The isolation capacitance
effects the Common Mode (CM) noise emission of the system.
The following table lists the transformer key parameters.
Table 2-1. Transformer Design Specification
Parameter | Specification |
---|---|
Core material | PQ3528 |
Turns ratio (Np-Ns1-Ns2-Na, Pri:Sec1:Sec2:Aux) | 60:7:5:5 |
Primary side inductance (LP) | 3.5 mH |
Isolation rating (pri-sec) | 3000 VAC, 3s, 2.0 mA |
Isolation resistance (Np-Ns) | 100 MΩ |
Working temperature | −25 °C–125 °C |
2.3.7 RCD Clamping
To avoid excessive voltage on the primary side switching devices, the flyback
topology requires an RCD clamping circuit to absorb the energy in the
transformer leakage inductance. When the device drain source voltage is higher
than the input plus reflected output voltage, the RCD snubber circuit absorbs
the energy from the leakage inductance resonance by forward biasing the diode.
The voltage can be assumed constant during one switching period if the snubber
capacitance is large enough. To absorb the energy from the transformer leakage
inductance, two high power 2W resistors are connected in parallel with one HV
630V/3.9 nF film capacitor.
2.3.7.1 Closed Loop Control Parameter
Closed loop control is used to eliminate steady-state error and reduce the
sensitivity of system parametric change. The gain and phase margin of the
converter are optimized over a specific frequency range to reduce the
influence of small signal load disturbances and improve system load dynamic
performance. The closed loop control has minimal influence on the steady state
performance. Because the drive IC is configured as a peak current mode PWM
controller, an external voltage feedback loop is required to stabilize the
converter.
The compensation loop is a typical dual loop design with TL431, the
phototransistor optocoupler FOD817A, and the error amplifier inside the
controller IC. A detailed RC value calculation for the voltage compensation
loop design is not included in this user guide because the purpose of this
evaluation board is to demonstrate the power stage performance. For more
details, contact the Microchip support team.
2.4 PCB Layout
To reduce system costs, a two-layer PCB configuration is selected. The power
loop on the primary side and the gate loop on the secondary side are both
minimized for the improved device switching performance and the overall
converter performance.
The following figures show the PCB layout design of the demo hardware.
Figure 2-4. PCB Layout Design Figure 2-5. PCB Layout Design—Top Layer Copper
and Top Side Component PlacementFigure 2-6. PCB Layout Design—Bottom Layer Copper and
Bottom Side Component Placement
Bill Of Materials (BOM)
The following table lists BOM of the evaluation board.
Table 3-1. BOM of the Evaluation Board
Type| Ratings/Part Number| Designator| Footprint|
Description| Quantity
---|---|---|---|---|---
Capacitor
| 3.9 nF/630V| C3| 1812| TDK, ‘X7R, ±10%| 1
100 nF/630V| C13, C14| 1812| TDK, ‘X7R, ±10%| 2
100 μF/35V| C7, C12, C32| C 811-3.5| AIHUA| 3
220 μF/35V| C44, C45| C 811-3.5| AIHUA| 2
1 μF| C8, C11, C16| C0603| TDK, ‘X7R, ±10%, 35V| 3
100 nF| C9, C15, C17, C21| C0603| TDK, ‘X7R, ±10%, 35V| 4
10 nF| C19| C0603| TDK, ‘X7R, ±10%, 35V| 1
1 nF| C22| C0603| TDK, ‘X7R, ±10%, 35V| 1
100 nF| C23| C0603| TDK, ‘X7R, ±10%, 35V| 1
200 pF| C24, C34, C35, C39, C41| C0603| TDK, ‘X7R, ±10%, 35V| 5
22 nF| C25| C0603| TDK, ‘X7R, ±10%, 35V| 1
NC| C26, C28, C33, C43| C0603| TDK, ‘X7R, ±10%, 35V| 4
10 nF| C27| C0603| TDK, ‘X7R, ±10%, 35V| 1
10 μF| C20, C40| C0805| TDK, ‘X7R, ±10%, 35V| 2
100 pF| C1, C10| C1206| TDK, ‘X7R, ±10%, 35V| 2
10 μF| C18| C1210| TDK, ‘X7R, ±10%, 35V| 1
3 μF/1100V| C6| C-18*6-15P| HJC| 1
2.2 μF/450V| C2, C4, C5| CY-222-4.5X14| ±10%| 3
2200 pF| C29, C30, C31, C36, C37, C38, C42| CY-222-4.5X14| KEMET| 7
………..continued
Type| Ratings/Part Number| Designator| Footprint| Description| Quantity
Resistor
| 510 kΩ| R22, R38| R0603| YAGEO, ±1%| 2
5.1 kΩ| R23| R0603| YAGEO, ±1%| 1
NC| R25, R37, R46, R47| R0603| YAGEO, ±1%| 4
23 kΩ| R26| R0603| YAGEO, ±1%| 1
10 kΩ| R27| R0603| YAGEO, ±1%| 1
1 kΩ| R28, R29, R33| R0603| YAGEO, ±1%| 3
0Ω| R30, R34, R39| R0603| YAGEO, ±1%| 3
5.6 kΩ| R31| R0603| YAGEO, ±1%| 1
21.5 kΩ| R32| R0603| YAGEO, ±1%| 1
14.3 kΩ| R35| R0603| YAGEO, ±1%| 1
2.43 kΩ| R36| R0603| YAGEO, ±1%| 1
68 kΩ| R40, R42| R0603| YAGEO, ±1%| 2
230 kΩ| R41| R0603| YAGEO, ±1%| 1
20 kΩ| R43| R0603| YAGEO, ±1%| 1
51Ω| R44| R0603| YAGEO, ±1%| 1
2.2Ω| R13| R0805| YAGEO, ±1%| 2
10Ω| R14| R0805| YAGEO, ±1%| 2
NC| R45| R1206| YAGEO, ±1%| 1
51Ω| R1| R1206| YAGEO, ±1%| 1
1.5 MΩ| R2, R6, R11, R12, R15, R16| R1206| YAGEO, ±1%| 6
0Ω| R8| R1206| YAGEO, ±1%| 1
NC| R10| R-6.8-LS| YAGEO, ±1%| 1
10Ω| R17| R1206| YAGEO, ±1%| 1
33Ω| R18| R1206| YAGEO, ±1%| 1
10 kΩ| R19| R1206| YAGEO, ±1%| 1
150 kΩ| R3, R7, R9, R48| R2512| YAGEO, ±1%| 4
1Ω| R20, R21| R2512| YAGEO, ±1%| 2
68 kΩ/2W| R4, R5| R-6.8-LS| YAGEO, ±1%| 2
200Ω/5W| R24, R49| R-6.8-LS| YAGEO, ±1%| 2
Diode
| ES1D| D7| SMA| ON, ST| 1
RS1M| D3, D4| SMB| ON, ST| 2
SS14| D6, D9| SOD123| ON, ST| 2
27V| ZD1| SOD123| UMZ27K| 1
18V| ZD2| SOD123| BZT52C18| 1
D4UB100| D1, D2| D3K| YJ| 2
DSA20C200PB| D5, D8| TO-220AB| Littelfuse| 2
………..continued
Type| Ratings/Part Number| Designator| Footprint| Description| Quantity
Integrated Circuit (IC)
| MIC38C44| U1| SOIC8| Microchip| 1
MCP16311| U4| SOIC8| Microchip| 1
817A| U2| OPTO-SMT| TI| 1
TL431| U3| SOT23| TI| 1
NPN transistor
| STN0214| Q2| SOT223| ST| 1
MMBT2222A| Q3, Q4, Q6| SOT23| ON, ST| 3
PNP transistor| MMBT4403| Q5| SOT23| ON, ST| 1
MOSFET| MSC750SMA170B| Q1| TO-247| MC| 1
Fuse| FUSE| FUSE1| AXIAL0.8| Littelfuse| 1
Header| Header 2H| J1, J2, J3| HDR1X2-7.5| TE| 3
Heat sink
| Heat sink| HS_D5, HS_D8| HS-TO220-1| —| 2
Heat sink| HS_Q1| HS-TO247-1| —| 1
Inductance
| 2.2 μH| L1, L2| IN-L| 3A| 2
10 μH| L3| IN-L| 2A| 1
70 mΩ/2A| T1| LL| PDMCAT1386-472ML| 1
MOV| —| MOV1, MOV2| MOV| Placeholder| 2
Negative Temperature Coefficient (NTC)|
NTC
|
N1
|
NTC
|
Placeholder
|
1
Transformer| Trans BB| T2| PQ3528| —| 1
Quick Startup and Test Procedure
Perform the following steps to quickly boot up and test the evaluation board:
- Visually inspect any damage to the board and the components. Examine for bending, breaking, or a change in shape.
- Connect the DC input to the DC power supply and the two DC outputs to passive or electronic loads, making sure to match the positive/negative connections.
- Connect all the measurement equipment, such as oscilloscope probes and Digital Multimeter (DMM).
- Start with a DC input of 10V/0.1A and monitor the DC source current. Make sure the DC source current is close to 0 to ensure there is no short circuit in the system. If the DC source current is 0.1A, there is a short circuit in the input. Stop the system and look for problems.
- Set the DC source to 250V/0.5A for normal testing, and the outputs setups after 0.5s.
Experimental Testing Results
This chapter describes the results of tests performed on SiC MOSFET.
5.1 Operation Waveforms
The converter operates at Continuous Conduction Mode (CCM) with a 250V input
voltage at 50% and 100% load and at Discontinuous Conduction Mode (DCM) with a
1 kV input voltage at 50% and 100% load. The drain-to-source peak voltage on
the MOSFET is well below the 1.7 kV device rated voltage.
The RCD circuit well clamps the device drain-to-source voltage, but there is
still some VDS ringing after device turn-off due to the relatively large
leakage inductance of the transformer. Because of the relatively large gate
resistance and good PCB layout design, the gate voltage has small voltage
overshoot and undershoot during device switching transient. The gate signal
VGS is clean during both the turn-on and turn-off transients. The measured
gate voltage on the device is 16.5V, and works well with 0V gate voltage
during turn-off.
The following figures show the operation waveforms for SiC MOSFET at different
input voltages and steady-state output power levels.
Note: In the following operation waveforms, drain-to-source voltage (VDS) is
blue, gate-to-source voltage (VGS) is red, and device current (IDS) is green.
Figure 5-1. Operation Waveform at Vin = 250V and 50% LoadFigure
5-2. Operation Waveform at Vin = 250V and 100% LoadFigure 5-3. Operation Waveform at Vin = 1000V and
50% LoadFigure
5-4. Operation Waveform at Vin = 1000V and 100% Load 5.2 Thermal Performance
With only a small heatsink and no fan cooling, the primary side MOSFET
temperature rise is only 25.8 °C in the worst case, demonstrating that the
MOSFETs can process much higher power and that the heatsink is not required in
some applications. The maximum temperature rise of the power transformer is
37.5 °C, which validates its effectiveness. At full load, the highest
temperature rise (47.6 °C) is measured on the rectifier diode of output 1. The
output diodes are connected to a small heatsink, and natural convection
cooling is used. The results validate the design effectiveness and show that
the temperature rise of all the major components in the converter design is
relatively low due to the small heatsink and natural convection cooling.
The following figure shows the thermal performance of the converter at full
load under different input voltage conditions.
Figure 5-5. Temperature Measurement Results Vout2 Diode, SiC FET, and Input
Diode
at Vin = 250V Power Transformer at Vin = 250V Vout1 Diode at Vin = 250V
5.3 Power
Loss and Efficiency
The switching loss of the converter increases significantly with high input
voltage, so the efficiency at 1 kV is lower than the efficiency at 400V and
250V. Above 25% load, the converter efficiency is more than 80% for 250V and
400V input voltages, with a peak efficiency of 89% at 100% load and 400Vinput
voltage.
The following figure shows the efficiency measurement results for the demo
converter at different input voltage and load conditions.
Figure 5-6. Measured Efficiency vs. Output Power Load Under Different Input
VoltageMore
test results are available, including the steady state output voltage ripple.
For more information on load and line regulations, start-up time, hold-up
time, and short circuit protection results for various working conditions,
contact the Microchip technical support team.
Reference Documents
The following document is referred in this user guide:
- MIC38C42/43/44/45 BiCMOS Current-Mode PWM Controllers Data Sheet
Revision History
The revision history describes the changes that were implemented in the document. The changes are listed by revision, starting with the most current publication.
Revision | Date | Description |
---|---|---|
B | 06/2023 | Replaced HV SiC MOSFETs with HV silicon MOSFETs and lower rated |
voltage SiC MOSFETs with lower rated voltage silicon MOSFETs in Introduction.
A| 02/2023| Initial revision
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©2023, Microchip Technology Incorporated and its subsidiaries. All Rights
Reserved. ISBN: 978-1-6683-2697-8
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User Guide
DS50003498B – 25
© 2023 Microchip Technology Inc. and its subsidiaries
Documents / Resources
|
MICROCHIP MSC750SMA170B High-Voltage Power Discretes and
Modules
[pdf] User Guide
MSC750SMA170B, MSC750SMA170B High-Voltage Power Discretes and Modules, High-
Voltage Power Discretes and Modules, Power Discretes and Modules, Discretes
and Modules, Modules
---|---
References
- Silicon Carbide (SiC) Power Modules | Microchip Technology
- Empowering Innovation | Microchip Technology
- Design Help and Other Services | Microchip Technology
- Microchip Lightning Support
- Empowering Innovation | Microchip Technology
- Empowering Innovation | Microchip Technology
- Client Support Services | Microchip Technology
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