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480VAC PFC 1kW controller recommendation

Stefan Herteg
Prodigy 120 points
Other Parts Discussed in Thread: UCC28180, UCC28070A, UCC28051, UCC28063A, UCC28810

Hi,

Could anyone recommend a PFC controller for 1kw and 480VAC line input? Any demo boards available?

Thank you!

  • 0
    TI__Expert 3200 points
    Hi Stefan,

    An Applications Engineer will help you shortly.
  • 0 in reply to Brian Johnson96
    TI__Mastermind 25570 points
    Hi Stefan

    At 1kW power level you should probably look at a CCM PFC. The choices are either a single CCM controller - for example the UCC28180 for which the reference design TIDA00443 is close to what you need - although designed for 264Vac max. Alternatively an interleaved CCM design using the UCC28070A.
    The current levels at 480Vac are much, much lower than the normal low line condition (90Vac) so it may be worthwhile looking at a Transition Mode converter - use the UCC28063A - this is an interleaved TM controller. I think a single phase TM controller, like the UCC28051 would not really be suitable here.
    The output of the boost stage will probably be at about 630V or so - at this voltage level you may need to consider SiC MOSFETs and SiC boost diodes - or possibly IGBTs. In any case - to a first approximation the controller IC itself has no direct 'knowledge' of the external circuit because its inputs (CS and VSENSE for example) always have to be scaled before being presented to the controller inputs.

    Other factors such as the light load / no load performance you expect, the overall produce size (height, weight,), the input voltage range (max, min) and the line frequency all play a role in the choice of controller and the system design.

    Please feel free to re-post with any further questions you may have.
    Regards
    Colin
  • 0 in reply to Colin Gillmor
    Intellectual 895 points
    I would also recommend the UCC28180 for CCM or the UCC28063A for transition mode interleaving boost converters.
    I have just completed a design with the UCC28063A and will be laying out my PCBs soon. I am confident it will work very well.
  • 0 in reply to Stephen Oberholzer
    Prodigy 120 points

    Thank you so much!
    Actually I've used UCC28810 in flyback configuration extensively, but I never think outside the box.
    The UCC28180 is tempting but likely, the UCC28063A will be a better fit as downstream, I need to provide 4x250W independent DC to DC convertors to 50V/5A for an LED application ( initially considering 1PFC+ 4xLLC's).
    I may use 4 x UCC28063A, I have to see if I could synchronize them.

    I'll do the math and check if the parameters are realistic.

    Does TI have a Mathcad app note on this UCC28063A?

    Regards,
    Stefan

  • 0 in reply to Stefan Herteg
    TI__Expert 3200 points
    Hi Stefan,

    No Mathcad file I am aware of but there is an Excel file. Look in the "Tools & software" tab on the UCC28063A TI web page and towards the bottom you should see one file in the Software section. The web link should be: www.ti.com/.../toolssoftware
  • 0 in reply to Brian Johnson96
    Prodigy 120 points
    Thank you Brian,
    I've already tried the xcel file. It has the generic calculation and is not solution orientated. I'm looking for transformer calculation, switching and conduction losses for switching element selection.... SiC vs IGBT
    No problem. I'll build my own.