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UCC28180: phase current is not sinusoidal under light load

Part Number: UCC28180

Tool/software:

Hi, 

I am designing a 3.5kW PFC with UCC28180, current is sinusoidal when load >2.3A, but current is not sinusoidal when load is light, see below waveforms, could you help to check the possible reason? and how to make the current in sinusoidal even in light load?

Regards

Hely

  • Hello Hely, 

    The first waveform with no significant high-frequency ripple appears to be at no-load condition.  All of the sinusoidal current seen is reactive current through the line-filter X-caps. 

    The last waveform seen is higher load, where the inductor ripple current is predominantly CCM.  THDi is low. 

    The middle two waveforms are at some unspecified light load, and the ripple current is relatively high plus much of the current is X-cap current.  
    I believe the inductor is operating mostly in DCM, and THDi is high when inductor current is not CCM.  The UCC28180 controller is designed for CCM-PFC. 

    The sudden step in the current is caused by charge stored on Cin.  At light loads, inductor current is so low that it cannot discharge Cin to zero at the crossings, so input current through the diode bridge is zero for a time interval. 

    To reduce the zero-crossing step distortion, reduce the Cin value.  To reduce the light-load reactive current, reduce the X-cap values.  However X-caps are used for Differential-Mode EMI filtering, so there is a practicable limit to reducing X-cap size. 

    To improve light load THDi, increase boost inductance to reduce the amount of DCM during the line-cycle.  There is a practicable limit to inductance increase, too, so some level of DCM at some light load must be acceptable. 

    Regards,
    Ulrich

  • HI, Ulrich

    Thanks for the answers.

    Here some other waveforms, seems there are a resonant current for some light load conditions.

    The PWM duty cycle of UCC28180 output is resonating, could you help to check the reason? and how to eliminate those current resonant?

    pink IAC is AC input current, green IL is boost inductor current.

    Regards

    Hely

  • Hello Hely, 

    These are very strange waveforms.  I've never seen the inductor current behave that way. 
    In the 40us/div zoom-in, you can see a resonant shape in the inductor current down-slope.  It should be a straight line, not sinusoidal. 

    I think that whatever is causing the current resonance is also causing the loop instability that leads to the larger resonance seen in the 800us/div zoom-in.
    It seems like there is a large capacitor across the inductor or from the switched node to PGND, or something like that.   

    Can you post a schematic diagram of your PFC stage, please?  

    Regards,
    Ulrich