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UCC28019: PFC for three phase PMSG from 500W - 2kW

Part Number: UCC28019
Other Parts Discussed in Thread: PMP20873, UCC28070, UCC28180, LM5122,

Hi

This is a follow-up question regarding my first attempt to get power from a 3 phase PMSG to a grid-tied solar inverter. The first question is posted here: e2e.ti.com/.../lm5122-bode-plot-in-manual-possible-mixup-with-frequency-and-rad-s-where-does-an-output-lc-filter-come-in-the-tf-feedforward-of-rectifier-ripple-additional-risk-of-floating-ground-plane
To recap: for this application (a water turbine) I'm trying to convert the energy of of a 3 phase 48VAC PMSG to a stable 80V output with minimal ripple that can be delivered to an off the shelf solar grid-tied inverter (max input 600VDC, minimum input = 70V).

So Brigitte suggested that maybe a PFC would be a better solution for this setup. After looking at these seminars: https://training.ti.com/power-factor-correction-pfc-circuit-basics and this seminar: https://training.ti.com/choosing-right-pfc-topology-100w-several-kw I can only agree with Brigitte's suggestion.

I'm having some trouble with determining which chip I should use. 
Here are the design considerations:

  1. Space: isn't that important there is plenty of room
  2. EMI on the generator side isn't that important. Off course On the DC side we want a quite clean signal and there are other electronics on the board so it shouldn't interfere with these.
  3. Efficiency and cost are equally important. But I rather spend more money on silicon than on aluminium, with which I mean that a high efficiency design with smaller heatsinks are prefered over lower efficiency and larger heatsinks
  4. not too much complexity
  5. Power: currently 500W, but for the future up to 2kW. The 2kW will be with another generator with higher voltages, but also 3 phase.

Questions:

  1. Most PFC's are designed for 1phase, 94VAC - 240VAC,  ~50/60Hz. Is this a problem for the 12VAC - 48VAC and the 18Hz - 72Hz from the PMSG? I guess that the voltages are only important in regard to the ratio to the output voltage, so 12V/70V is probably a stretch, but then we start at a higher input voltage. I think these frequency is wihtin the bandwith of the 'standard' implementation for the compensator. 
  2. I also plan to use a digital potentiometer in the feedbackloop in order to control the output voltage. Will this cause a possible problem?
  3. At first glance I think that the single phase CCM would be good for my  the UCC28019 would be a good and simple solution, or would you suggest something else?
  4. I checked the bridgeless PFC's, the totempole design (PMP20873) and the bi-directional bridgeless PFC, but if I need to add the two other phases from the generator this will be too complex and expensive I think.
  • Hi,

    Thank you for the query.

    UCC28019/UCC28180/UCC28070 CCM controllers could be used for the power levels which you are designing for. But again these are designed/optimized for performance of line input voltages from 85-25Vac/single phase.

    So TI does not have any analog PFC controller optimized for 3 phase input.  We have digital solutions such as our C2000 MCU that can be optimized for 3 phase input.

    But you can try the following architecture with the UCC28070 as it supports external synchronization in the following way in case you want to add flexibility of increasing power by adding other phases but is expensive. Otherwise from a single phase point of view we have customers designing 2KW power stage using UCC28180/UCC28019.

    Since your AC input voltage 48V(l-l) I think can also try this configuration using UCC28180

    The other two CCM family controllers do not support synchronization and hence cannot be extended to three phases. 

    Please let us know if you have any questions.

    Regards,

    Harish

  • Hi 

    Thank you for your fast reply. So I was preferring the UCC28019 because it is available in stock. The UCC28180 and UCC28070 both have a leadtimes of 1 year, which is not an option.

    The 48VAC is L-L, because with my current setup (with the LM5122) I get a rectified voltage of 65V.

    Would it be possible to have the second setup (where you suggested the UCC28180), but using the UCC28019? What's the main difference between these two chips?

  • Hi

    Yes, you can use UCC28019 instead of UCC28180. UCC28180 (programmable freq) is an enhanced version of UCC28019 (fixed frequency of 65Khz). You could use UCC28019A which is a more closer in features to UCC28180 but for fixed frequency.

    Thank you

    Regards,

    Harish