230-V 3.5-KW PFC With 98% Efficiency

TI Designs: TIDA-00779
230-V, 3.5-kW PFC With >98% Efficiency, Optimized for

BOM and Size Reference Design
Description Features
This reference design is a 3.5-kW, cost competitive • High Efficiency of > 98% Over Entire Operating
PFC designed for room air conditioners and other Voltage Range, Allowing a Smaller Heat Sink
major appliances. This reference design is a • Wide Full Load Operating Input Range of 190-V to
continuous-conduction-mode (CCM) boost converter 270-V AC
implemented using TI’s UCC28180 PFC controller • High Power Factor > 0.99 and < 5% THD From
provided with all of the necessary built-in protections. Medium-to-Full Load (50 to 100%)
The hardware is designed and tested to pass surge
and EFT testing as per the IEC 61000 requirements • Up to 3.5-kW High Power Output to Cover Most of
for household appliances. Single-Phase Input PFC Application
The key highlights of this reference design are: • 8-Pin PFC Solution (No AC Line Sensing Needed)
Enable Very Simple Design
• Provides a ready platform for front-end PFCs to
address power level requirements for appliances • Reduced Current Sense Threshold Minimizes
up to 3.5 kW Power Dissipation
• Up to 98.6% peak converter efficiency under 230-V • High Power Density for Smaller Dimension
input enable a competitive high power density and • Robust Output Supply Protected for Output
small heat sink design Overcurrent, Output Overvoltage, and Output
• Robust output supply protected for output Undervoltage Conditions
overcurrent, output overvoltage, and output • Meets Requirements of EFT Norm IEC 6000-4-4
undervoltage conditions and Surge Norm IEC 61000-4-5
• Simple Use PCB Form Factor (215 × 145 mm)
Resources
Applications
TIDA-00779 Design Folder • Room Air Conditioners
UCC28180 Product Folder • Industrial AC/DC > 480 W
UCC27531 Product Folder • Single-Phase UPS
LMT01 Product Folder
• Other Major Appliances
ASK Our E2E Experts
± +
UCC27531D LMT01
(Low-side driver) (Temp sensor)
Boost follower UCC28180

(Optional) (PFC controller)
TIDUBE1C – January 2016 – Revised October 2017 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size 1
Submit Documentation Feedback Reference Design
Copyright © 2016–2017, Texas Instruments Incorporated
System Description www.ti.com
An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.
1 System Description
Major appliance equipment such as air conditioners, refrigerators, and washers use three-phase, pulse-
width modulated BLDC or PMSM drives. These motor drives typically have fractional or low horsepower
ratings ranging from 0.25 HP (186 W) to 5 HP (3.75 kW). An electronic drive is required to control the
stator currents in a BLDC or PMSM motor. A typical electronic drive consists of:
• Power stage with a three-phase inverter with the required power capability
• Microcontroller unit (MCU) to implement the motor control algorithm
• Motor voltage and current sensing for closed-loop speed or torque control
• Gate driver for driving the three-phase inverter
• Power supply to power up the gate driver and MCU
These drives require a front-end power PFC regulator to shape the input current of the power supply and
to meet the standards for power factor and current THD, such as IEC61000-2-3. A PFC circuit shapes the
input current of the power supply to be in phase with the mains voltage and helps to maximize the real
power drawn from the mains. The front-end PFC also offers several benefits:
• Reduces RMS input current
For instance, a power circuit with a 230-V/5-A rating is limited to about 575 W of available power with a
power factor (PF) of 0.5. Increasing the PF to 0.99 almost doubles the deliverable power to 1138 W,
allowing the operation of higher power loads.
• Facilitates power supply hold-up
The active PFC circuit maintains a fixed, intermediate DC bus voltage that is independent of the input
voltage so that the energy stored in the system does not decrease as the input voltage decreases. This
maintenance allows the use of smaller, cost effective bulk capacitors.
• Improves efficiency of downstream converters
The PFC reduces the dynamic voltage range applied to the downstream inverters and converters. As a
result, the voltage ratings of rectifiers can be reduced, resulting in lower forward drops. The operating
duty cycle can also be increased, resulting in lower current in the switches.
This reference design is a boost PF regulator implemented using the UCC28180 device as a PFC
controller for use in all appliances that demand a PF correction of up to 3.5 kW. The design provides a
ready platform of an active front-end to operate downstream inverters or DC/DC converters operating on a
hi-line AC voltage range from 190-V to 270-V AC.
This design demonstrates a high power density PF stage in a small form factor (215 × 145 mm) that
operates from 190-V to 270-V AC and delivers up to 3.5 kW of continuous power output to drive inverters
or converters at more than a 98% efficiency rate without an SiC device. This TI Design also provides
flexibility for the boost follower configuration, in which the boost voltage can be varied with AC input
voltage, but only can work on the boosted voltage when it is above the peak input voltage. The boost
follower configuration helps reduce switching losses in the PFC regulator and the downstream inverter or
converter. This design also gave an efficiency comparison in using MOSFET and IGBT, which can help
customer to choose efficiency or cost is preferred.
Above all, this TI Design meets the key challenges of appliances to provide safe and reliable power with
all protections built in while delivering a high performance with low power consumption and a very
competitive bill-of material (BOM) cost.
2 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size TIDUBE1C – January 2016 – Revised October 2017
Reference Design Submit Documentation Feedback
www.ti.com System Description
1.1 Key System Specifications
Table 1. Key System Specifications

PARAMETER SYMBOL TEST CONDITIONS MIN NOM MAX UNIT
INPUT CHARACTERISTICS
Input voltage VIN — 85 230 270 V AC
Frequency FAC — 47 — 64 Hz
Input UVLO VIN_UVLO IOUT = nom — 80 — V AC
Power factor PF VIN = nom, IOUT = max — 0.99 — —
Input current IIN VIN = nom, IOUT = max — 20 — A
OUTPUT CHARACTERISTICS
Output voltage VOUT VIN = nom, IOUT = min to max — 390 — V
Output current IOUT VIN = 190-V AC to max 0 — 9 A
Output power POUT VIN = 190-V AC to max — — 3.5 kW
Line regulation VIN = min to max, IOUT = nom — — 2 %
Load regulation VIN = nom, IOUT = min to max — — 3 %
Output voltage ripple VOUT_RIPPLE VIN = nom, IOUT = max — — 17 V
Output overvoltage VOVP IOUT = min to max — — 430 V
Output overcurrent IOCP VIN = min to max 12 — — A
SYSTEM CHARACTERISTICS
Switching frequency fSW — — 45 — kHz
Peak efficiency ηPEAK VIN = max, IOUT = 4 A, test with MOSFET — — 98.6 %
Operation temperature TNOM With air flow –25 — 65 °C
System Overview www.ti.com
2 System Overview
2.1 Block Diagram
± +
UCC27531D LMT01
(Low-side driver) (Temp sensor)
Boost follower UCC28180

(Optional) (PFC controller)
Figure 1. Block Diagram of PFC Regulator
2.2 Highlighted Products and Key Advantages

The following subsections detail the highlighted products used in this reference design, including the key
features for their selection. See their respective product datasheets for complete details on any highlighted
device.
2.2.1 UCC28180 – PFC Controller

The UCC28180 is a high performance, CCM, 8-pin programmable frequency PFC controller. The wide and
programmable operating frequency of the controller provides flexibility to design at a high frequency to
optimize the components. The UCC28180 uses trimmed current loop circuits to achieve less than a 5%
THD from a medium-to-full load (50% to 100%). A reduced current sense threshold enables the
UCC28180 to use a 50% smaller shunt resistor, resulting in lower power dissipation while maintaining low
THD. The UCC28180 also consists of an integrated fast gate driver, with a drive of 2-A source current and
−1.5-A sink current, which eliminates the requirement for an external gate driver.
The UCC28180 also has a complete set of system protection features that greatly improve reliability and
further simplify the design:
• Soft overcurrent
• Cycle-by-cycle peak current limit
• Output overvoltage
• VCC undervoltage lockout (UVLO) protection
• Open pin protections (ISENSE and VSENSE pins)
www.ti.com System Overview
2.2.2 UCC27531D – Low-Side Gate Driver

Obtaining a lower level of switching losses is important to achieve high efficiency. The switching losses of
a MOSFET are a function of the drive current that is required to quickly pass through the Miller plateau
region of the power-MOSFET's switching transition. Placing a high-current gate driver close to a FET
allows for a faster turn on and turnoff by effectively charging and discharging voltage across the
MOSFET’s gate-to-drain parasitic capacitor (CGD). This placement effectively reduces switching losses.
The UCC27531D is a single-channel, high-speed gate driver can effectively drive MOSFET and IGBT
power switch. Using a design that allows for a source of up to 2.5 A and a 5-A sink through asymmetrical
drive (split outputs), coupled with the ability to support a negative turn-off bias, rail-to-rail drive capability,
extremely small propagation delay (17 ns typical), the UCC27531D are ideal solutions for MOSFET and
IGBT power switches. The UCC27531D can also support enable, dual input, and inverting and non-
inverting input functionality. The split outputs and strong asymmetrical drive boost the devices immunity
against parasitic Miller turn-on effect and can help reduce ground debouncing.
Other key features that make the device ideal for this application are:
• Wide VDD range from 10 to 35 V
• Input and enable pins capable of withstanding up to –5-V DC below ground
• UVLO
• Output held low when input pins are floating or during VDD UVLO
Using an additional gate driver is an optional means to further reduce the switching losses because the
UCC28180 controller has an integrated fast gate driver of 2-A source current and −1.5-A sink current,
which is sufficient for this design.
2.2.3 LMT01 — Temperature Sensor

The LMT01 is a high-accuracy, 2-pin temperature sensor with an easy-to-use pulse count interface, which
makes it an ideal digital replacement for PTC or NTC thermistors both on and off board in industrial and
consumer markets. The LMT01 digital pulse count output and high accuracy over a wide temperature
range allow pairing with any MCU without concern for integrated ADC quality or availability, while
minimizing software overhead. The LMT01 achieves flat ±0.5°C accuracy with very fine resolution
(0.0625°C) over a wide temperature range of –20°C to 90°C without system calibration or hardware or
software compensation.
Unlike other digital IC temperature sensors, the LMT01’s single-wire interface is designed to directly
interface with a GPIO or comparator input, thereby simplifying hardware implementation. Similarly, the
LMT01's integrated EMI suppression and simple 2-pin architecture make it ideal for onboard and off-board
temperature sensing. The LMT01 offers all the simplicity of analog NTC or PTC thermistors with the added
benefits of a digital interface, wide specified performance, EMI immunity, and minimum processor
resources. This design uses the LMT01 as the temperature monitor for the MOSFET or IGBT.
Other key features that make the device ideal for this application are:
• Communication frequency: 88 kHz
• Continuous conversion plus data-transmission period: 100 ms
• Conversion current: 34 μA
• Floating 2- to 5.5-V (VP–VN) supply operation with integrated EMI immunity
2.3 System Design Theory

This reference design is a 3.5-kW boost PFC regulator that operates in continuous conduction mode and
is implemented using the UCC28180 PFC controller. The design is specifically tailored for inverter fed
drives for use in major appliances such as air conditioners. This design serves as a simple and superior
alternative to existing bulk, passive PFC circuits that are used to meet the power harmonic standards. The
system efficiency is greater than 98% over the wide input operating voltage range from 190-V to 270-V AC
under full load conditions. Additionally, this design includes several embedded protections including output
overvoltage protection and output short circuit protection.
The main focus of this design is a high efficiency, high PF, and protected DC power rail for targeted
applications.
2.3.1 Selecting Switching Frequency

The UCC28180 switching frequency is user programmable with a single resistor on the FREQ pin to GND.
This design uses a 45-kHz switching frequency. Calculate the suitable resistor value to program the
switching frequency using Equation 1:
f TYP ´ R TYP ´ R INT
R FREQ =
( ) ( )
f SW ´ R INT + R TYP ´ f SW - (R TYP ´ f TYP )
(1)
where
• fTYP, RTYP, and RINT are constants internally fixed to the controller that are based on the UCC28180
control logic
• fTYP = 65 kHz
• RTYP = 32.7 kΩ
• RINT = 1 MΩ
Applying these constants in Equation 2 yields the appropriate resistor that must be placed between the
FREQ and GND pins.
65 kHz ´ 32.7 kW ´ 1 MW
R FREQ = = 47.9 kW
(45 kHz ´ 1 MW ) (45 kHz ´ 32.7 kW ) - (65 kHz ´ 32.7 kW )
+ (2)
A typical value of 47 kΩ for the FREQ resistor results in a switching frequency of 44 kHz.
2.3.2 Calculating Output Capacitance

Assuming that the percentage of non-conducting period is minimal, the required output capacitance can
be calculated as Equation 3 shows:
2 ´ PLOAD
CO =
p ´ V O ´ DV O ´ f LINE (3)
Where
• ΔVO = The peak-to-peak voltage ripple on the output
• fLINE = The input line frequency
• PLOAD = The output load power
Insert the values into Equation 3 to obtain the following result:
space
2 ´ 3500
CO = = 2286 mF
p ´ 390 ´ 50 ´ 50
A capacitance of 2040 µF has been selected to accommodate overload conditions and effects caused by
aging.
www.ti.com System Overview
2.3.3 Calculating PFC Choke Inductor

The UCC28180 is a CCM controller; however, if the chosen inductor allows a relatively high ripple current,
the converter becomes forced to operate in discontinuous mode (DCM) at light loads and at the higher
input voltage range. High-inductor ripple current affects the CCM/DCM boundary and results in a higher
light-load THD. This type of current also affects the choices for the input capacitor, RSENSE, and CICOMP
values. Allowing an inductor ripple current, ΔIRIPPLE, of 20% or less enables the converter to operate in
CCM over the majority of the operating range. However, this low-inductor ripple current requires a boost
inductor that has a higher inductance value, and the inductor itself is physically large. This design takes
certain measures to optimize performance with size and cost. The inductor is sized to have a 40% peak-
to-peak ripple current with a focus on minimizing space and the knowledge that the converter operates in
DCM at the higher input voltages and at light loads; however, the converter is well optimized for a nominal
input voltage of 230-V AC at the full load.
Calculate the minimum value of the duty cycle, DMIN, as Equation 4 shows:
(
2 ´ V IN _ MIN ´ sin 2p ´ f LINE ´ t ) 2 ´ 190 ´ 1
D MIN = 1 - = = 0.31
VO 390 (4)
Based upon the allowable inductor ripple current of 40%, the PFC choke inductor, LBST, is selected after
determining the maximum inductor peak current, IPK, as Equation 5 shows:
2 ´ PO 2 ´ 3500
I PK = = = 26.6 A
h ´ V IN _ MIN 0.98 ´ 190 (5)
Calculate the minimum value of the c, LMIN, based upon the acceptable ripple current, IRIPPLE, as Equation 6
shows:
2 ´ V IN _ MIN ´ D MIN 2 ´ 190 ´ 0.31
L MIN ³ = = 174 mH
I PK ´ 0.4 ´ fSW 26.6 ´ 0.4 ´ 45 ´ 103 (6)
The actual value of the PFC choke inductor used is LMIN = 180 μH
2.3.4 Selecting Switching Element

The MOSFET switch is driven by a gate output that is clamped at 15.2 V internally for VCC bias voltages
greater than 15.2 V. An external gate drive resistor is recommended to limit the rise time and to dampen
any ringing caused by the parasitic inductances and capacitances of the gate drive circuit. This resistor
also helps by meeting any EMI requirements of the converter. This design uses a 22-Ω resistor; the final
value of any design depends on the parasitic elements associated with the layout of the design. To
facilitate a fast turnoff, place a standard 100-V, 1-A Schottky diode or switching diode anti-parallel with the
gate drive resistor. A 10-kΩ resistor is placed between the gate of the MOSFET and ground to discharge
the gate capacitance and protect from inadvertent dV/dT triggered activations.
The maximum voltage across the FET is the maximum output boost voltage (that is, 425 V), which is the
overvoltage set point of the PFC converter used to shut down the output. Considering a voltage de-rating
of 30%, the voltage rating of the MOSFET must be greater than 550-V DC.
This design uses an IPW60R099P6 MOSFET of 600 V with 37.9 A at 25°C and 24 A at 100°C. If cost is a
concern, this design also can use an IGBT (FGA4060ADF) to replace the MOSFET. This design needs a
heat sink of the appropriate size for the MOSFET or IGBT.
2.3.5 Boost Follower Control Circuit

The traditional design of PFC boost converters consists of a fixed output voltage greater than the
maximum peak line voltage to maintain boost operation and be able to shape the input current waveform
of the power supply. The boost voltage does not have to be fixed, but can be varied based on the AC
input voltage provided that the boosted voltage is above the peak input voltage. The boost follower control
circuit aids in setting the output voltage based on the peak input voltage.
Varying the output voltage with variations in the peak line voltage provides several benefits.
• Reduced boost inductor
The boost inductor is selected based on the maximum allowed ripple current, at maximum duty cycle,
at minimum line voltage, and at minimum output voltage. A decrease in VOUT results in a decrease in
the maximum duty cycle, which causes the boost inductor to decrease.
• Reduced boost switch losses at low line operation
In an offline PFC converter, a large amount of converter power loss is due to the switching losses of
the boost FET. The boost follower PFC has a much lower output voltage at the low-input line voltage
than a traditional PFC boost, which reduces the switching losses.
• Reduced switching losses in the downstream inverter stage and isolated DC/DC converter stage
The switching losses in a three-phase inverter drive or isolated DC/DC converter stage are proportional
to the boost regulated voltage. A lower output voltage results in lower switching losses, increasing the
overall efficiency of the system, which is more noticeable in the light-load efficiency of the power stage.
2.3.6 Bias Power

The TIDA-00779 design requires an external bias supply to power the UCC28180 PFC controller
UCC27531D gate driver, and relay, which is used to shunt the inrush current limiting resistor.
TI recommends powering these devices from a regulated auxiliary supply. These devices are not intended
to be used from a bootstrap bias supply. A bootstrap bias supply is fed from the input high voltage through
a resistor with sufficient capacitance on the VCC pin to hold the voltage on the VCC pin until the current
can be supplied from a bias winding on the boost inductor.
The UCC28180 has a UVLO of 11.5 V and the UCC27531D has a UVLO of 4.5 V, whereas the minimum
voltage required to turn on the relay is 9.6 V (for a 12-V relay), so the bias voltage for board operation
must be ≥ 12 V. The total current required for these devices is approximately 55 mA.
TI recommends using an external bias power supply of 12 V per 60 mA to power the board independently.
The board has been tested and validated with a 12-V bias supply.
www.ti.com Hardware, Testing Requirements, and Test Results
3 Hardware, Testing Requirements, and Test Results
3.1 Required Hardware
3.1.1 Test Conditions

For the input, the power supply source (VIN) must range from 190-V to 270-V AC. Set the input current
limit of the input AC source to 25 A.
For the output, use an electronic variable load or a variable resistive load, which must be rated for ≥ 400 V
and must vary the load current from 0 mA to 10 A.
3.1.2 Recommended Equipment

Use the following recommended test equipment:
• Fluke 287C (multimeter)
• Chroma 61605 (AC source)
• Chroma 63204 (DC electronic load)
• Voltech PM100 / WT210 (power analyzer)
• Tektronix DPO 3054 (oscilloscope)
3.1.3 Procedure
1. Connect input terminals (P1 and P2) of the reference board to the AC power source.
2. Connect output terminals (P4 and P5) to the electronic load, maintaining correct polarity (P4 is the 390-
V DC output and P5 is the GND terminal).
3. Connect an auxiliary supply of 12 V between pin-3 and pin-4 of connector J3, maintaining correct
polarity (pin-3 is the bias supply positive input and pin-4 is the GND terminal).
4. Turn on the auxiliary supply and set a voltage of 12 V.
5. Gradually increase the input voltage from 0 V to turn on the voltage of 190-V AC.
6. To test the board independently, short pin-3 and pin-5 of connector J3.
7. Turn on the load to draw current from the output terminals of the PFC.
8. Observe the startup conditions for smooth-switching waveforms.
Hardware, Testing Requirements, and Test Results www.ti.com
3.2 Test Results

The following test results cover the steady-state performance measurements, functional performance waveforms and test data, transient
performance waveforms, thermal measurements, surge measurements, and EFT measurements.
3.2.1 Performance Data
3.2.1.1 Efficiency and Regulation With Load Variation

Table 2, Table 3, and Table 4 show the data at inputs of 190-V AC, 230-V AC, and 270-V AC input in using MOSFET and an ultra-fast diode.
Table 2. Performance Data With MOSFET and Ultra-Fast Diode Under 190-V AC Input
VINAC (V) IINAC (A) PINAC (W) PF THDi (%) VOUT (V) IOUT (A) POUT (W) EFFICIENCY (%) REG (%)
190 0.60 81.7 0.716 15.82 392.8 0.20 78.2 95.68 0
190 0.97 165.9 0.901 11.94 392.7 0.41 160.7 96.84 –0.03
190 1.35 244.6 0.953 3.37 392.6 0.61 237.8 97.20 –0.05
190 1.75 323.1 0.971 5.07 392.6 0.80 314.9 97.45 –0.05
190 2.16 402.0 0.980 6.19 392.6 1.00 392.5 97.63 –0.05
190 4.25 801.0 0.991 4.55 392.6 2.00 784.8 97.98 –0.05
190 6.39 1202.0 0.990 3.28 392.6 3.00 1177.7 97.98 –0.05
190 8.54 1599.0 0.986 3.19 392.7 3.99 1565.8 97.92 –0.03
190 10.75 2003.0 0.981 3.35 392.9 4.99 1959.7 97.84 0.03
190 12.83 2419.4 0.993 1.64 392.9 6.02 2365.3 97.76 0.03
190 14.95 2822.7 0.994 1.76 393.0 7.02 2757.3 97.68 0.05
190 17.06 3225.4 0.995 2.62 393.0 8.01 3147.9 97.60 0.05
190 18.14 3435.1 0.996 2.39 393.1 8.52 3350.0 97.52 0.08
230 0.62 81.3 0.569 18.74 392.3 0.20 77.2 94.96 –0.05
230 0.90 165.6 0.802 22.51 392.3 0.41 160.2 96.75 –0.05
230 1.18 244.4 0.901 10.20 392.3 0.61 237.6 97.21 –0.05
230 1.49 322.4 0.941 6.39 392.3 0.80 314.8 97.65 –0.05
230 1.82 401.2 0.960 3.54 392.3 1.00 392.4 97.81 –0.05
230 3.52 799.0 0.987 4.88 392.3 2.00 784.6 98.20 –0.05
230 5.26 1198.0 0.990 4.00 392.4 3.00 1177.7 98.31 –0.03
230 7.00 1592.0 0.989 3.65 392.5 3.99 1565.4 98.33 0
230 8.78 1994.0 0.987 3.63 392.6 4.99 1958.5 98.22 0.03
230 10.56 2406.9 0.991 1.67 392.6 6.02 2363.8 98.21 0.03
230 12.30 2808.6 0.993 1.87 392.7 7.02 2755.2 98.10 0.05
230 14.04 3208.3 0.994 2.21 392.7 8.01 3145.9 98.06 0.05
230 15.78 3612.3 0.995 2.40 392.8 9.01 3537.6 97.93 0.08
270 0.72 81.5 0.421 44.76 392.3 0.20 76.9 94.39 –0.05
270 0.92 165.3 0.663 40.20 392.3 0.41 159.9 96.76 –0.05
270 1.13 243.8 0.801 29.18 392.4 0.61 237.4 97.38 –0.03
270 1.34 321.8 0.886 16.68 392.4 0.80 314.7 97.80 –0.03
270 1.60 400.3 0.927 7.87 392.4 1.00 392.4 98.02 –0.03
270 3.02 797.0 0.978 4.84 392.4 2.00 784.6 98.45 –0.03
270 4.48 1195.0 0.988 4.61 392.4 3.00 1177.6 98.54 –0.03
270 5.94 1588.0 0.990 4.17 392.5 3.99 1565.4 98.57 0
270 7.43 1987.0 0.990 4.10 392.6 4.99 1958.5 98.57 0.03
270 8.96 2399.2 0.992 1.99 392.6 6.02 2363.5 98.51 0.03
270 10.43 2798.1 0.993 2.06 392.6 7.02 2754.5 98.44 0.03
270 11.92 3198.5 0.994 2.35 392.7 8.01 3145.5 98.34 0.05
270 13.41 3599.4 0.994 2.51 392.7 9.01 3536.7 98.26 0.05
Table 5 shows the data at a 230-V AC input in using an IGBT and an ultra-fast diode.
Table 5. Performance Data With IGBT and Ultra-Fast Diode Under 230-V AC Input
230 0.55 45.0 0.354 16.39 392.5 0.10 41.1 91.33 –0.05
230 1.95 409.3 0.914 8.34 392.5 1.01 398.4 97.34 –0.06
230 3.61 807.2 0.971 5.86 392.4 2.01 790.0 97.87 –0.07
230 5.32 1206.2 0.985 3.90 392.5 3.01 1182.1 98.00 –0.05
230 7.09 1616.4 0.991 3.65 392.5 4.03 1584.8 98.04 –0.05
230 8.83 2017.6 0.993 3.63 392.7 5.02 1977.8 98.03 –0.01
230 10.58 2419.1 0.994 2.64 392.6 6.02 2369.6 97.95 –0.02
230 12.34 2823.2 0.995 1.86 392.8 7.02 2764.0 97.90 0.04
230 14.10 3227.3 0.995 2.47 392.8 8.01 3155.9 97.79 0.03
230 15.88 3637.1 0.996 2.24 393.3 9.00 3551.9 97.66 0.15
3.2.1.2 Efficiency and Regulation With Line Variation

Table 6 and Table 7 show the data for the efficiency and line regulation of the output with AC input voltage
variation in using a MOSFET.
Table 6. Performance Data With Fixed Output Voltage in Using MOSFET

VINAC (V) IINAC (A) PINAC (W) PF VOUT (V) IOUT (A) POUT (W) EFFICIENCY (%)
190 17.18 3247.7 0.995 392.9 8.01 3147.5 96.92
200 16.52 3288.1 0.995 393.1 8.13 3193.9 97.14
210 15.87 3316.6 0.995 393.2 8.21 3228.2 97.33
220 15.33 3356.9 0.995 393.2 8.32 3273.0 97.50
230 14.99 3432.6 0.996 393.3 8.52 3351.7 97.64
240 14.68 3508.1 0.995 393.3 8.72 3429.6 97.76
250 14.54 3619.1 0.996 393.2 9.00 3540.7 97.83
260 13.97 3614.5 0.995 393.3 9.00 3540.8 97.96
270 13.43 3610.5 0.996 393.3 9.00 3540.8 98.07
Table 7. Performance Data With Boost Follower Configuration in Using MOSFET

190 17.30 3267.6 0.994 333.1 9.51 3169.1 97.08
200 16.75 3331.4 0.994 340.2 9.52 3240.1 97.26
210 16.24 3392.2 0.995 347.2 9.52 3305.5 97.44
220 15.76 3450.0 0.995 353.5 9.52 3366.0 97.56
230 15.33 3508.5 0.995 360.0 9.52 3427.1 97.68
240 14.95 3568.2 0.995 366.6 9.52 3489.2 97.79
250 14.46 3597.0 0.995 373.2 9.43 3520.0 97.86
260 13.81 3570.0 0.995 380.0 9.20 3496.8 97.95
270 13.23 3552.6 0.995 386.9 9.00 3483.3 98.05
Table 8 and Table 9 show the data for the efficiency and line regulation of the output with AC input voltage
variation in using an IGBT.
Table 8. Performance Data With Fixed Output Voltage in Using IGBT

190 17.20 3253.0 0.995 392.8 8.01 3144.9 96.68
200 16.55 3295.3 0.995 393.1 8.12 3192.8 96.89
210 15.90 3324.4 0.995 393.3 8.21 3227.8 97.09
220 15.36 3364.5 0.995 393.3 8.32 3272.6 97.27
230 15.02 3439.9 0.996 393.3 8.52 3350.9 97.41
240 14.71 3515.2 0.995 393.3 8.72 3428.7 97.54
250 14.56 3625.3 0.996 393.2 9.00 3540.0 97.65
260 13.98 3620.8 0.996 393.2 9.00 3540.0 97.77
270 13.45 3616.2 0.996 393.2 9.00 3540.0 97.89
Table 9. Performance Data With Boost Follower Configuration in Using IGBT

190 17.05 3214.5 0.992 327.2 9.52 3113.6 96.86
200 16.57 3290.6 0.993 335.5 9.52 3192.6 97.02
210 16.12 3363.2 0.993 343.5 9.52 3267.9 97.17
220 15.71 3435.0 0.994 351.4 9.52 3343.6 97.34
230 15.32 3504.1 0.994 358.8 9.52 3414.4 97.44
240 14.97 3571.7 0.994 366.2 9.52 3484.7 97.56
250 14.51 3607.9 0.995 373.7 9.43 3524.0 97.67
260 13.88 3589.1 0.995 381.4 9.20 3509.6 97.79
270 13.31 3574.5 0.995 388.6 9.00 3498.6 97.88
3.2.1.3 No Load Power

The no load power was noted at multiple AC input voltages with the PFC controller enabled. Table 10 and
Table 11 show the tabulated results with the fixed output and boost follower configuration.
Table 10. No Load Power With Fixed Output

VINAC (VAC) IINAC (mA) PINAC (W) VOUT (V) POUT (W) NO LOAD POWER (W)
120 260.0 2.3 389.5 0.69 1.61
150 320.0 2.4 389.5 0.69 1.71
180 379.0 2.3 389.5 0.69 1.61
230 476.0 2.3 389.5 0.69 1.61
270 557.0 2.5 389.5 0.69 1.81
Table 11. No Load Power With Boost Follower Configuration

VINAC (VAC) IINAC (mA) PINAC (W) VOUT (V) POUT (W) NO LOAD POWER (W)
120 259.0 1.3 292.0 0.39 0.91
150 317.0 1.4 315.7 0.45 0.95
180 377.0 1.6 336.1 0.51 1.09
230 477.0 2.3 370.3 0.62 1.68
270 558.0 2.6 397.7 0.72 1.88
3.2.2 Performance Curves
3.2.2.1 Efficiency Curves

Figure 2, Figure 3, Figure 4, and Figure 5 show the measured efficiency in the system with AC input
voltage variation with and without boost follower configurations. These graphs also compare the efficiency
improvement between using a MOSFET and using an IGBT.
99% 98.5%
98.3%
98%
98.1%
97.9%
97%
97.7%
Efficiency
Efficiency
96% 97.5%
97.3%
95%
97.1%
190-V AC 96.9%
94%
230-V AC 96.7% IGBT
270-V AC MOSFET
93% 96.5%
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
Output Power (W) D001
Figure 2. Efficiency With Load Variation in Using Figure 3. Efficiency Compared Between MOSFET and
MOSFET IGBT
98.3% 98.1%
98.1% 97.9%
97.9%
97.7%
97.7%
97.5%
Efficiency
Efficiency
97.5%
97.3%
97.3%
97.1%
97.1%
96.9%
96.9%
96.7% Boost Follower 96.7% Boost Follower

Fixed Output Fixed Output
96.5% 96.5%
180 200 220 240 260 280 180 200 220 240 260 280
Input Voltage (VAC) D005
Input Voltage (VAC) D006
Figure 4. Efficiency versus AC Input Voltage in Using Figure 5. Efficiency Versus AC Input Voltage in Using
MOSFET IGBT
3.2.2.2 PF and THDi Curves

Figure 6 and Figure 7 show the measured PF value and THDi in the system with load variation.
1.1 9.25%
190-V AC
1 8.25% 230-V AC
270-V AC
7.25%
0.9
6.25%
Power Factor
0.8
5.25%
THDi
0.7
4.25%
0.6
3.25%
0.5 2.25%
190-V AC
0.4 230-V AC 1.25%
270-V AC
0.3 0.25%
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
Figure 6. Power Factor With Load Variation Figure 7. THDi With Load Variation
3.2.3 Functional Waveforms
3.2.3.1 Startup and Shutdown Waveform
Figure 8. Start-up With Fixed Output Under 230-V AC Figure 9. Shutdown With Fixed Output Under 230-V AC
Input Input
Figure 10. Input Voltage versus Input Current Under Half Figure 11. Input Voltage versus Input Current Under Full
Load Load
3.2.3.2 Inrush Current Waveform

Figure 12 and Figure 13 show the inrush current drawn by the system. The inrush current was observed
and recorded at a input voltage of 230-V and 270-V AC.
Figure 12. Inrush Current Under 230-V AC Input With No Figure 13. Inrush Current Under 270-V AC Input With No
Load Load
3.2.3.3 Input Voltage and Current Waveform

Figure 14 and Figure 15 show the input current waveform at 230-V AC with a half and full-load condition.
Figure 14. Input Voltage and Current With Half Load Figure 15. Input Voltage and Current With Full Load
Under 230-V AC Input Under 230-V AC Input
3.2.3.4 Output Ripple

As Figure 16 and Figure 17 show, the ripple was observed at a 390-V DC output with half load and full
load, respectively.
Figure 16. Bus Voltage Ripple Under Half Load Figure 17. Bus Voltage Ripple Under Full Load
3.2.3.5 Switching Node Waveform

Figure 18, Figure 19, Figure 20, and Figure 21 show the waveforms at the switching node, which were
observed along with the MOSFET and IGBT for 230-V AC under full-load conditions.
Figure 18. VDS1, VDS2, and PFC Choke Current Figure 19. VGS1 and VGS2 (MOSFET)
(MOSFET)
Figure 20. Turn on of VGS1 and VGS2 (IGBT) Figure 21. Turn off of VGS1 and VGS2 (IGBT)
3.2.3.6 Transient Waveform

The load transient performance was observed with the load switched at a 0.2-m wire length. The output
load is switched using an electronic load.
Figure 22 and Figure 23 show the load transient waveforms for VIN = 230-V AC and a step load transient
from 0.5 A to 8 A. Figure 22 shows a step change from 0.5 A to 8 A, and Figure 23 shows a load step
down from 8 A to 0.5 A.
Figure 22. DC Link Voltage versus DC Link Current Figure 23. DC Link Voltage versus DC Link Current
Under 0.5 A to 8 A Under 8 A to 0.5 A
3.2.4 Thermal Measurements

To better understand the temperature of power components and maximum possible operating
temperature, the thermal images were plotted at room temperature (25°C) with a closed enclosure, no
airflow, and at full-load conditions. The board was allowed to run for 30 minutes before capturing a thermal
image.
Figure 24 shows the temperature of power components at input voltage of 230-V AC with the 3.5-kW
power output.
Figure 24. Top-Side Temperatures at 230-V AC Input and 3.5-kW Output
Design Files www.ti.com
4 Design Files
4.1 Schematics
To download the schematics, see the design files at TIDA-00779.
VDCBUS
R35 R36
221k 221k
HS1
R34 R37
221k 221k
NOTES: Heatsink HS1 for BR1,
LINE INPUT VOLTAGE: 156VRMS - 265VRMS, 47Hz - 63Hz 1
Q1,Q6,D1,D3
PEAK INPUT CURRENT: 30.0A 2
PGND
OUTPUT VOLTAGE: 390VDC nominal TBD
D2 Bleeder Resistor to discharge output
MAXIMUM OUTPUT POWER: 3500W
When unit is turned-off
1N5406 D3 FFH30S60S
TP1 TP3 L1 TP5

P1 F1 L4 D1 FFH30S60S VDCBUS
BR1
L + 11 2 1 2 1
30A 029E1-001 C21 P4
R30 R32 R28
RV1 L3 62k 62k L2 2 300k
1 2 1 2 AC
275V C1 C22 C3 1000pF
2.2μF C2
3 1µF 390 VDC
2.2μF AC 9 Amps max
4 3 4 3 2.2μF
R29 R33 RTN
2.5 mH 2.5 mH
TP2 RLY-P RLY-N 62k 62k TP7 TP4 C4 C5 C18
2
Q1 Q6
IPW60R099P6
IPW60R099P6
P2 R2
- 4 680 uF 680 uF 680 uF
1 1
N GBJ3508 R6
B470N R5 R4 R45 R3 R24 332k
3
0.01 0.01 0.01 22 4.7 R1 R40 R41 R42
C8 C9 C6 C7 C23 C26 10.0k 22 4.7 10.0k TP6
2.2nF 2.2nF 2.2nF 2.2nF 2.2nF 2.2nF
CGRM4007-G
CGRM4007-G
1
P3
VCC P5
E D6 D7 PGND U2 C28 D11 PGND
1 6 MMDL914-TP D12 NOTES: R7
ENA VDD
For UCC27531D Configuration: 332k
2 7 1μ F R44 Populate R44=0 Ohm
GNDE INA OUTA
R11 0
221 4 5 For UCC27524A Configuration
INB OUTB
Do not populate R44
C27 8 ENB GND
3
220pF R8
UCC27531D 340k
PGND
PGND
Vsense
RLY-N RLY-P R20
K1 R25 332k
4 3 340k
PFC_ON U1
R43
BIAS
R21 1 GND GATE 8 TP9

Vsense
1 2 R26 332k 100
340k 2 ICOMP VCC 7 TP8
VCC
Q2
HF105F-1/12DT-1HS D10 R22 3 6 MMBT3906 R18
R13 ISENSE VSENSE BIAS VCC
BAT54 340k
BC847CLT1G
15.4
3
10 D5 R38
21.0k ACsense 4
FREQ VCOMP
5
1 Q4 C19
UCC28180D R15
1N4148W-7-F R39 D9 10uF
45kHz
3
R23 R10
BAT54
1.00k BZX384-C12,115 10.0k

2
10.0k D4 C15 C10 R12 10.0k

1 2.7nF S1
C17 Q5 3300pF 47.0k R9
C11 13.0k 1 2 R16
1uF 2N7002-7-F
C20 R14 C16 C12 C13 820pF KCD3-101N 6.8k
2
R27
R31 C25 10uF D8 13.7k 0.1μF 1μF 0.39μF PGND
221k
47.5k 10uF BAT54 TP10 C14 PFC_ON
8.2μF R19 Q3
10.0k 2N7002-7-F
PGND PGND PGND PGND PGND PGND PGND PGND

PGND
CURRENT LIMIT RESISTOR BYPASS CIRCUIT Switch ON delay 0.2s BOOST FOLLOWER CONTROL CIRCUIT C24 R17
0.47μF 6.8k
J3
VP 1 NOTES:
12-15 VDC VN 2 For MOSFET Configuration:
3 Bias Power input by 12 VDC
BIAS PGND PGND
4
5 For IGBT Configuration:
6 Bias Power input by 15 VDC PFC SHUTDOWN CIRCUIT
NOTES: PGND PFC_ON
For Boost Follower Configuration: PEC06SAAN
PFC_ON
Populate R14 and Q4 and set R9 = 21.5k
Populate R5 = 0.2 Ohm ACsense
For Fixed Output Boost PFC configuration

Do not populate R14 and Q4 and Set R9 = 13k
Do not populate R5 Recommended to use TIDA-00473 Design for Bias Supply Needs
Figure 25. TIDA-00779 Schematics
www.ti.com Design Files
4.2 Bill of Materials

To download the bill of materials (BOM), see the design files at TIDA-00779.
4.3 Layout Prints

To download the layout prints, see the design files at TIDA-00779.
4.4 Altium Project

To download the Altium project files, see the design files at TIDA-00779.
4.5 Gerber Files

To download the Gerber files, see the design files at TIDA-00779.
4.6 Assembly Drawings

To download the assembly drawings, see the design files at TIDA-00779.
5 References
1. Texas Instruments, 230-V, 900-W, Power Factor Regulator Converter (PFC) for Inverter-Fed Drives
and Appliances, TIDA-00443 Design Guide
2. Texas Instruments, Using the UCC28180EVM-573 360-W Power Factor Correction Module,
UCC28180EVM-573 User’s Guide
3. Texas Instruments, UCC28180 Programmable Frequency, Continuous Conduction Mode (CCM), Boost
Power Factor Correction (PFC) Controller, UCC28180 Datasheet
5.1 Trademarks
All trademarks are the property of their respective owners.
6 About the Author

YUAN (JASON) TAO is a systems engineer at Texas Instruments, where he is responsible for developing
reference design solutions for the industrial segment. Yuan brings to this role his extensive experience in
power electronics, high frequency DC/DC, AC/DC converters, and analog circuit design. Yuan earned his
master of IC design and manufacture from Shanghai Jiao Tong University in 2007.
Revision History www.ti.com
Revision History
NOTE: Page numbers for previous revisions may differ from page numbers in the current version.
Changes from B Revision (May 2016) to C Revision ...................................................................................................... Page
• Changed formatting to fit current design guide template............................................................................. 1

• Changed THD from more than 5% to less than 5% .................................................................................. 1
Changes from A Revision (March 2016) to B Revision .................................................................................................. Page
• Changed title ............................................................................................................................... 1
Changes from Original (January 2016) to A Revision .................................................................................................... Page
• Changed from preview page ............................................................................................................. 1
24 Revision History TIDUBE1C – January 2016 – Revised October 2017

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TI Designs: TIDA-00779

230-V, 3.5-kW PFC With >98% Efficiency, Optimized for

ASK Our E2E Experts

Boost follower UCC28180

1.1 Key System Specifications

Table 1. Key System Specifications

2.1 Block Diagram

Boost follower UCC28180

Figure 1. Block Diagram of PFC Regulator

2.2 Highlighted Products and Key Advantages

2.2.1 UCC28180 – PFC Controller

2.2.2 UCC27531D – Low-Side Gate Driver

2.2.3 LMT01 — Temperature Sensor

2.3 System Design Theory

2.3.1 Selecting Switching Frequency

2.3.2 Calculating Output Capacitance

2.3.3 Calculating PFC Choke Inductor

2.3.4 Selecting Switching Element

2.3.5 Boost Follower Control Circuit

2.3.6 Bias Power

3 Hardware, Testing Requirements, and Test Results

3.1 Required Hardware

3.1.1 Test Conditions

3.1.2 Recommended Equipment

3.2 Test Results

3.2.1 Performance Data

3.2.1.1 Efficiency and Regulation With Load Variation

3.2.1.2 Efficiency and Regulation With Line Variation

Table 6. Performance Data With Fixed Output Voltage in Using MOSFET

Table 7. Performance Data With Boost Follower Configuration in Using MOSFET

Table 8. Performance Data With Fixed Output Voltage in Using IGBT

Table 9. Performance Data With Boost Follower Configuration in Using IGBT

3.2.1.3 No Load Power

Table 10. No Load Power With Fixed Output

Table 11. No Load Power With Boost Follower Configuration

3.2.2 Performance Curves

3.2.2.1 Efficiency Curves

96.7% Boost Follower 96.7% Boost Follower

3.2.2.2 PF and THDi Curves

3.2.3 Functional Waveforms

3.2.3.1 Startup and Shutdown Waveform

3.2.3.2 Inrush Current Waveform

3.2.3.3 Input Voltage and Current Waveform

3.2.3.4 Output Ripple

3.2.3.5 Switching Node Waveform

3.2.3.6 Transient Waveform

3.2.4 Thermal Measurements

Figure 24. Top-Side Temperatures at 230-V AC Input and 3.5-kW Output

TP1 TP3 L1 TP5

R21 1 GND GATE 8 TP9

1.00k BZX384-C12,115 10.0k

10.0k D4 C15 C10 R12 10.0k

PGND PGND PGND PGND PGND PGND PGND PGND

For Fixed Output Boost PFC configuration

Figure 25. TIDA-00779 Schematics

4.2 Bill of Materials

4.3 Layout Prints

4.4 Altium Project

4.5 Gerber Files

4.6 Assembly Drawings