230-V 3.5-KW PFC With 98% Efficiency
230-V 3.5-KW PFC With 98% Efficiency
230-V 3.5-KW PFC With 98% Efficiency
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
± +
UCC27531D LMT01
(Low-side driver) (Temp sensor)
TIDUBE1C – January 2016 – Revised October 2017 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size 1
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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
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2 System Overview
± +
UCC27531D LMT01
(Low-side driver) (Temp sensor)
4 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size TIDUBE1C – January 2016 – Revised October 2017
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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.
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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
10 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size TIDUBE1C – January 2016 – Revised October 2017
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Table 3. Performance Data With MOSFET and Ultra-Fast Diode Under 230-V AC Input
VINAC (V) IINAC (A) PINAC (W) PF THDi (%) VOUT (V) IOUT (A) POUT (W) EFFICIENCY (%) REG (%)
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
Table 4. Performance Data With MOSFET and Ultra-Fast Diode Under 270-V AC Input
VINAC (V) IINAC (A) PINAC (W) PF THDi (%) VOUT (V) IOUT (A) POUT (W) EFFICIENCY (%) REG (%)
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
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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
VINAC (V) IINAC (A) PINAC (W) PF THDi (%) VOUT (V) IOUT (A) POUT (W) EFFICIENCY (%) REG (%)
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
12 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size TIDUBE1C – January 2016 – Revised October 2017
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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.
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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
Output Power (W) D004
Figure 2. Efficiency With Load Variation in Using Figure 3. Efficiency Compared Between MOSFET and
MOSFET IGBT
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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%
Figure 4. Efficiency versus AC Input Voltage in Using Figure 5. Efficiency Versus AC Input Voltage in Using
MOSFET IGBT
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
Output Power (W) D002
Output Power (W) D003
Figure 6. Power Factor With Load Variation Figure 7. THDi With Load Variation
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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
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Figure 12. Inrush Current Under 230-V AC Input With No Figure 13. Inrush Current Under 270-V AC Input With No
Load Load
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
18 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size TIDUBE1C – January 2016 – Revised October 2017
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Figure 16. Bus Voltage Ripple Under Half Load Figure 17. Bus Voltage Ripple Under Full Load
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)
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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
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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
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
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
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
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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.
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Revision History
NOTE: Page numbers for previous revisions may differ from page numbers in the current version.
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