350W Power Factor Boost Converter for Inverter-Fed BLDC and PMSM Motors

This 350W power factor boost converter is designed for inverter-fed BLDC/PMSM motor appliances, A/C units, Refrigerators, and industrial power supplies. The circuit is a continuous-conduction-mode boost converter implemented using a UCC28180 PFC controller module which provides all the necessary built-in protections. It’s a robust output supply protected for output cover current, output over-voltage, and output under voltage conditions. The converter has two parts, the main power board and the UCC28180 PFC controller/Breakout board. PFC boost converter provides 380V_DC regulated output at 0.9A load current. The PFC converter accommodates an input voltage range of 85V_AC to 265 V_AC and uses average current mode control at a fixed programmable switching frequency of 120Khz.

Features

• Output 380V DC
• Output Load Current 0.9A
• Full Load Efficiency 94%
• Input AC Range 85V to 265V AC
• Input Frequency 47 to 63 Hz
• No Load Input Current 70mA
• Operating Frequency 120Khz
• Average Current Mode PWM Control
• No AC Line Sensing Needed
• Soft Over Current and Cycle-by-Cycle Peak Current Limiting
• VCC Under Voltage Lockout with Low Start-Up Current
• Voltage Regulation Open Loop Detection
• Output Over-Voltage Protection with Hysteresis Recovery
• Soft Start
• PCB Dimensions 97.79 x 89.22 mm
• 4 x 3mm Mounting Holes

UCC28180 – PFC Controller (Schematic and PCB Layout in Downloads below)

The UCC28180 module provides high performance and offers a series of benefits to address the next-generation requirement of low THD standards for appliances. The UCC28180 is a high-performance, compact continuous conduction mode (CCM), Frequency is programmed 120Khz using R11 and R15 The UCC28180 uses trimmed current loop circuits to achieve less than a 5% THD from a medium-to-full load (50% to 100%). A reduced current sense threshold enables the UCC28180 device to utilize a 50% smaller shunt resistor, resulting in lower power dissipation while maintaining low THD. The UCC28180 also consists of an integrated fast gate driver, with a drive of +2-A source current and −1.5-A sink current, which eliminates the requirement for an external gate driver.

The UCC28180 device also has a complete set of system protection features that significantly improve reliability and further simplify the design.

• Soft overcurrent
• Cycle-by-cycle peak current limit
• Output Overvoltage
• VCC undervoltage lockout (UVLO) protection
• Open pin protections (ISENSE and VSENSE pins)

Main Power Board

The main power board consists CN2 AC power input connector, Fuse F1 for short circuit protection, R4 Varistor for spike protection, EMI filter built using T1 choke, Capacitor C5, C6, C7, C8, C9, and C10. Resistor R3 NTC is provided to control the inrush current. BR1 bridge rectifier provides DC output from AC input. R5 is the current sense resistor, C4 acts as the filter capacitor, Q1 MOSFET acts as the switching transistor, and D2 high speed switching diode. C1, C2, and C3 are bulk storage capacitors. CN1 provides [email protected] output.

AC to DC Module (LS05-13B12R3)

This module provides 12V DC output from AC input. It is used to provide V_CC power supply to UCC28180 PFC controller module/Breakout Board.

Connection and Other Details

• CN1: Pin 1 = +DC Output 380V DC, Pin 2 = NC, Pin 3 = GND
• CN2: Pin 1 = AC Live Input, Pin 2 = AC Neutral, Pin 3 = Earth
• CN3: Pin 1 and 2 = VCC, Pin 3,4 = GND (Don’t Install)
• CN4: Pin 1 = GND, Pin 2 = VCC, Pin 3 = NC, Pin 4 = VINS, Pin 5 = ISENSE, Pin 6 = GND, Pin 7 = Out, Pin 8 = GND, Pin 9 = NC, Pin 10 = Voltage Feedback
• CN5: AC To DC Converter Pin 1 = AC Live, Pin 2 = AC Neutral, Pin 3 = High Voltage + Capacitor, Pin 4 = -Capacitor

Schematic

Parts List

Connections

Block Diagram

Gerber View

Photos

Video

IPW65R095C7XKSA1 Datasheet

UCC28180 Datasheet

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