PMP21366: 3.5KW Design

Venkatesh B

Part Number: PMP21366
Other Parts Discussed in Thread: PMP40988

Hi ti Team,

Can i use this IC for 3.5KW power rating (EV charger Front end PFC Purpose) and Higher switching frequency say 150KHZ to 300KHZ range to reduce form factor (Reactive elements)

Suggest/advice design procedure and possibility of implementations

Thank you

venkatesh B

over 2 years ago

0 Venkatesh B over 2 years ago

Intellectual 793 points

HI ti expert

could you please advice on this

Regards

venkatesh B

0 Robert Taylor1 over 1 year ago in reply to Venkatesh B

TI__Expert 6670 points

Hi Venkat, sorry for the delay here I am reaching out to the original designer to help.

In general the design is using transition mode, so the switching frequency is changing. Going to the 150KHz to 300KHz range is going to increase the losses so if you plan correctly it could be possible.

The original design was for 700W, so it would need to be completely redesigned to reach 3.5kW.

Thanks,

Robert

0 Venkatesh B over 1 year ago in reply to Robert Taylor1

Intellectual 793 points

Thank you,Robert

I have one doubt will this DCM mode make Inductor size bigger?

Could you please guide me for design procedure please

Thank you

+1 Sheng-yang Yu1 over 1 year ago in reply to Venkatesh B

TI__Expert 4830 points

If you want to have PFC operates at a higher frequency to reduce inductor inductance and size, you will likely need to make it soft-switching to minimize the switching loss on the MOSFETs. Operates at 150kHz with a continuous conduction mode (CCM) PFC (hard-switching) is still doable. But usually people will limit the PFC switching frequency to 130kHz or below because conduction EMI regulation usually starts from 150kHz.

Going higher frequency, likely you will have to make it soft-switching like PMP40988 did.

https://www.ti.com/tool/PMP40988

PMP40988 and UCC2806x uses variable frequency control to maintain inductor current always go through zero every switching cycle. The inductor current ripple will be higher than CCM PFC, thus, different inductor core material is generally chosen. Ex: Ferrite core.

I have a CRM PFC paper attached might help you better understand how it works.

https://www.ti.com/lit/an/slyt599/slyt599.pdf

Hope that solves your questions.

Regards,

Sheng-Yang Yu

0 Venkatesh B over 1 year ago in reply to Sheng-yang Yu1

Intellectual 793 points

Thank you sheng,

i will go through it

Thank you

venkatesh B

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PMP21366: 3.5KW Design