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High Power Isolated Converter with PFC

Mike Miles
Prodigy 130 points
Other Parts Discussed in Thread: UCC3895

I need help with selecting a control IC for a new design. This power supply will produce 200V-300V at about 5 or 10 amps max. (two versions, 1.5 kW and 3 kW max. output). Input is 120Vac or preferably 100-240Vac. The 3 kW version only produces full output with 240Vac input. Also we need a PFC circuit at the input, which may be combined or separate from the isolated converter.

I'm considering a resonant/ZVS forward converter and would like a control IC that is well supported with application design info and sample designs. Can someone recommend a suitable device for the application? Or would a traditional PWM forward converter be a better approach?

Options I’ve encountered for a ZVS design include the TI/Unitrode UCC3895 and Intersil ISL6551 or ISL6755. Does anyone have experience with any of these in a high-power application like this?

Thanks!
Mike

  • 0
    Prodigy 65 points

    Mike

    At these power levels, you are left with only one option--a full bridge converter.  We recently complted a 3.5 KW Full Bridge, dual, resonant-mode, ZCS converter that achieved 94% efficiency, though at different voltage levels.  Since our input was DC, we did not need PFC (though we are looking forward to the AC version of the same supply).

    There are few choices for control chips, including the PFC chips.  We used a TI DSP--and did everything in software.  It was very easy, but I wouldn't recommend this for anyone inexperienced in DSP design.  Certainly the UCC3895 is a good choice for the resonant mode controller, but there are other choices that will work.

    John Perlick
    Aria Corporation

    jperlick@ariacorp.com