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  • 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size Reference Design

    • TIDUBE1D January   2016  – August 2024

       

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  • 230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size Reference Design
  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. 1System Description
    1. 1.1 Key System Specifications
  8. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 Highlighted Products and Key Advantages
      1. 2.2.1 UCC28180 – PFC Controller
      2. 2.2.2 UCC27524 – Dual Low-Side Gate Driver
      3. 2.2.3 UCC28881 – 700-V Off-Line Converter
    3. 2.3 System Design Theory
      1. 2.3.1 Selecting Switching Frequency
      2. 2.3.2 Calculating Output Capacitance
      3. 2.3.3 Calculating PFC Choke Inductor
      4. 2.3.4 Selecting Switching Element
      5. 2.3.5 Boost Follower Control Circuit
      6. 2.3.6 Bias Power
      7. 2.3.7 On-Off Switch
      8. 2.3.8 Thermal Design
  9. 3Hardware, Testing Requirements, and Test Results
    1. 3.1 Required Hardware
      1. 3.1.1 Test Conditions
      2. 3.1.2 Recommended Equipment
      3. 3.1.3 Procedure
    2. 3.2 Test Results
      1. 3.2.1 Performance Data
        1. 3.2.1.1 Efficiency and iTHD
        2. 3.2.1.2 Standby Power and Output Voltage
      2. 3.2.2 Performance Curves
        1. 3.2.2.1 Efficiency Curve
        2. 3.2.2.2 Voltage Follower Performance
      3. 3.2.3 Functional Waveforms
        1. 3.2.3.1 Power On Sequence
        2. 3.2.3.2 Inrush Current Protection
        3. 3.2.3.3 Switching Node
        4. 3.2.3.4 Waveform Under 3.5kW, 230VAC
      4. 3.2.4 Thermal Measurements
  10. 4Design Files
    1. 4.1 Schematics
    2. 4.2 Bill of Materials
  11. 5Documentation Support
  12. 6Trademarks
  13. 7About the Author
  14. 8Revision History
  15. IMPORTANT NOTICE
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Design Guide

230-V, 3.5-kW PFC With >98% Efficiency, Optimized for BOM and Size Reference Design

Description

This design guide is a 3.5-kW, cost competitive PFC designed for room air conditioners and other major appliances. This reference design is a continuous-conduction-mode (CCM) boost converter implemented using TI’s UCC28180 PFC controller provided with all of the necessary built-in protections. The hardware is designed and tested to pass surge and EFT testing as per the IEC 61000 requirements for household appliances. This design guide provides a ready platform for front-end PFCs to address power level requirements for appliances up to 3.5kW. The design also provides up to 98% peak efficiency under 230-V input enable a competitive high power density and small heat sink design.

 
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