Welcome Back!
DIY SMPS 1.4 Kw WITH CCM PFC
- Thread starter crazifunguy
- Start date
Welcome Back!
daneloctober
Future Earthmaker
Any updates?... Please help!
Hello! I'm kind of late player here, but what the hey.
I'm also supposed to make a 2.2kW PFC. The highest rated output I've found so far is 1700W by MicrosiM. I'm hoping some of you guys could shed some light on this as well. I've already posted this on his thread about the 1kW PFC, so I'm not sure if this is legal. Just inform me and I'll stop. Or you can direct me to a helpful thread. Hehe. Anyway, here it is:
I need to design a 2.2kW PFC using the UCC28019 with the following specs:
Input Voltage: 230VAC, 60Hz
Output: 385V, 5.7A
I'm having trouble getting past the 1kW output. Mosfet keeps blowing up. I'm thinking I need to change the inductor. I'm currently using the ETD-59 ferrite core with no gap, which means about 9 turns. I'm getting the required 0.43mH (according to the component calculator from TI) but the inductor current (which I think is supposed to be a regular triangular waveform from upclose) distorts when output current gets higher than 500mA (that's about 200W). I'm getting a relatively stable 385V output though. Can any of you please help? Thank you very much. =)
Hello! I'm kind of late player here, but what the hey.
I'm also supposed to make a 2.2kW PFC. The highest rated output I've found so far is 1700W by MicrosiM. I'm hoping some of you guys could shed some light on this as well. I've already posted this on his thread about the 1kW PFC, so I'm not sure if this is legal. Just inform me and I'll stop. Or you can direct me to a helpful thread. Hehe. Anyway, here it is:
I need to design a 2.2kW PFC using the UCC28019 with the following specs:
Input Voltage: 230VAC, 60Hz
Output: 385V, 5.7A
I'm having trouble getting past the 1kW output. Mosfet keeps blowing up. I'm thinking I need to change the inductor. I'm currently using the ETD-59 ferrite core with no gap, which means about 9 turns. I'm getting the required 0.43mH (according to the component calculator from TI) but the inductor current (which I think is supposed to be a regular triangular waveform from upclose) distorts when output current gets higher than 500mA (that's about 200W). I'm getting a relatively stable 385V output though. Can any of you please help? Thank you very much. =)
Post your schematic and transformer specs.
daneloctober
Future Earthmaker
Schematic and Issues
I think it's ok now. I've changed the inductor. I placed an airgap which resulted in more turns but a more stable inductor. I've gone to about 800W, but the output voltage starts to lower the higher i go. The system is designed for 380V output but at 800W it's at 365V. What could be going wrong?... Here's my schematic:
I think it's ok now. I've changed the inductor. I placed an airgap which resulted in more turns but a more stable inductor. I've gone to about 800W, but the output voltage starts to lower the higher i go. The system is designed for 380V output but at 800W it's at 365V. What could be going wrong?... Here's my schematic:
Attachments
-
Bullzip PDF Printer.jpg
Last edited:
Your schematic shows a boost converter making your 385VDC. Boost converters are practically only good for 150 watts and for safety reasons are not used for power supplies over 40VDC because they are not isolated. This is an extremely dangerous design.
I have not studied boost converters so i can not give you any practical advice, but because you are trying to push the capability of the boost converter circuit so far you will have extreme component values in your design.
When you start talking about 2.2KW of power you should be using a full bridge isolated circuit.
I have not studied boost converters so i can not give you any practical advice, but because you are trying to push the capability of the boost converter circuit so far you will have extreme component values in your design.
When you start talking about 2.2KW of power you should be using a full bridge isolated circuit.
Attachments
-
full bridge basic circuit image154a.png
daneloctober
Future Earthmaker
Hehe. You should've started with that thought... hehehe...
I don't think Texas Instruments would post some bogus claims on their site. Check out the UCC28019 and maybe brush up on the latest boost converter technology. =D
FULLY agree.
Sorry about that, i miss read your post. I thought you were trying to make a 2.2kw SMPS with a boost converter. Now i see you said you are just trying to make a 2.2kw PFC stage, you are right this can be done. Now whether this is the best chip or method to do this is another story.
I have been studying the best way to do high power PFC and i found that “two phase interleaved CCM PFC” is the best choice for PFC over 1KW. If you goggle for that phrase a lot of information will come up.
I have been studying the best way to do high power PFC and i found that “two phase interleaved CCM PFC” is the best choice for PFC over 1KW. If you goggle for that phrase a lot of information will come up.
daneloctober
Future Earthmaker
Progress
Hey guys! Thanks for all your responses! =)
MicrosiM, I would have to agree with Kanwar and TBDz. I asked TI about the limitations of UCC28019 and UCC28019A and this was their reply:
"Realistically a controller is just that, it sends control signals to the rest of the circuit. The power stage is what limits the power. Theoretically you can use either one of these device for a gigawatt design but realistically, wouldn't you want to have more control features than what any 8-pin controller can offer for something that massive? The 2kW is an arbitrary limit that we would recommend as a practical application for this device, but neither is limited to this value." -Lisa Dinwoodie, TI Employee
I was able to reach about 1400W so far and the device is starting to make a buzzing noise. From 1300W and below, it's been really silent. I'm going to try to increase the boost inductor core gap to increase the saturation current. =)
I used to have an ungapped ETD-59, N87 core inductor with 9 turns. Now I put a gap of about 1mm, which resulted in 28 turns. No problems so far, so I'm going to try to increase the load. I'll keep you guys updated!
By the way, I'm attaching a file that presents the differences between the UCC28019 and UCC28019A. =) When I used the UCC28019, it made a short, but disturbing noise whenever I switched on the load. The noise was totally eliminated, though, when replaced it with UCC28019A. You should try it! =D
Hey guys! Thanks for all your responses! =)
MicrosiM, I would have to agree with Kanwar and TBDz. I asked TI about the limitations of UCC28019 and UCC28019A and this was their reply:
"Realistically a controller is just that, it sends control signals to the rest of the circuit. The power stage is what limits the power. Theoretically you can use either one of these device for a gigawatt design but realistically, wouldn't you want to have more control features than what any 8-pin controller can offer for something that massive? The 2kW is an arbitrary limit that we would recommend as a practical application for this device, but neither is limited to this value." -Lisa Dinwoodie, TI Employee
I was able to reach about 1400W so far and the device is starting to make a buzzing noise. From 1300W and below, it's been really silent. I'm going to try to increase the boost inductor core gap to increase the saturation current. =)
I used to have an ungapped ETD-59, N87 core inductor with 9 turns. Now I put a gap of about 1mm, which resulted in 28 turns. No problems so far, so I'm going to try to increase the load. I'll keep you guys updated!
By the way, I'm attaching a file that presents the differences between the UCC28019 and UCC28019A. =) When I used the UCC28019, it made a short, but disturbing noise whenever I switched on the load. The noise was totally eliminated, though, when replaced it with UCC28019A. You should try it! =D
szhighstar
New member
For PFC inductor, we can use ferrite and lamination core, however we must open enough air gap, so that inductor can handle necessary DC current, we can also select toroidal core, e.g. powder iron( very cheaper, power loss is big), Fe-Si-AL or Fe-Si (price is middle and loss is not bigger), MPP(price is expensiver and loss is less), and high-Flux