ANALYSIS AND DESIGN FOR 5KW POWER FACTOR CORRECTED CONVERTER

LU Xiang
1. School of electric power South China University of Technology Guangzhou, CHINA 2. College of Physical Science and Technology Guangxi University Nanning, CHINA luxiang@gxu.edu.cn
Abstract In this paper, a 5KW power factor corrected (PFC) converter for wide voltage input range is designed. The converter, which is applied to frequency-variable conversion air conditioner, adopts two phase interleaved boost converter. The circuit operates in current continuous conduction mode (CCM), and use voltage outer loop and current inner loop control strategy, i.e., current inner loop using average current control, voltage outer loop using the PI control strategy with input voltage feedforward .In order to verify the feasibility of the proposed scheme, a 5KW boost PFC prototype, which converting universal ac input voltage to 400V dc output, is implemented by using a TI IC of UCC28070. The experimental results is satisfactory, which demonstrate a power factor greater than 0.97, THD less than 5% and efficiency more than 99.4% at 41.67 kHz switching frequency and 220V input voltage from 1.27KW to 4.889kW. Keywords- two phase interleaved; boost converter; CCM; power factor corrected; wide voltage input range

XIE YUN-xiang, LI Quang-jiao, CHENG Li, WANG Zhi-ping

School of electric power South China University of Technology Guangzhou, CHINA

include high power capability, modularity, and improved reliability [1-4]. This paper propose a 5KW converter at wide input voltage range, which use parallel interleaving technique and UCC28070 controller chip to achieve control for the converter. And it is used in frequency-variable conversion air conditioner. The boost PFC circuit topology and its control block diagram is shown in Fig. 1.

I.

INTRODUCTION
Vin

In order to meet the standards of IEC6l000-3-2 harmonic current limits, achieve high power factor and reduce harmonic pollution on power grid, power factor corrected is commonly used in various types of switching power supply. In which, continuous conduction mode boost converter have lots of advantage, such as: Low input current waveform distortion, high output voltage; In the entire input voltage range, it can maintain a high input power factor; It can effectively suppress EMI noise; Its circuit structure is simple and work at high reliability, etc. Therefore, it is widely used in the PFC converter. However, with the power level further increases, switching devices of the traditional PFC boost converter to bear a larger voltage and current stress. In the power device switching process, there will be too large du and di , which will give
dt

iL1
iref

iL 2

KVFF

verror
Vref

Vo

Fig.1. Diagram of 5KW PFC boost converter and its control

II.

PROPOSED BOOST TOPOLOGYASE AND CONTROLL STRATEGY

dt

A. Proposed Boost Topology The proposed staggered parallel boost PFC basic circuit consists of two boost PFC circuit in parallel with the same parameters, as shown in the red dotted frame of Fig.1. In o which, the drive signal of two switching Q1, Q2 is out of 180 , the two basic boost PFC is working in staggered condition[5].

rise to radiation and conducted EMI, bring pollution to the power grid. The use of parallel staggered boost PFC, can solve these deficiencies. Interleaved method used to improve power converter performance in terms of efficiency, conducted EMI, size, and transient response. The benefits of interleaving

This project is supported by Guangxi University Scientific Research Foundation (X071084)

978-1-4577-0547-2/12/$31.00 2012 IEEE

B. Circuit Operation Analysis In order to simplify the analysis, assume that: (1) All devices, including power switching tube Q1 and Q2, boost inductor L1 and L2, diode D1 and D2, capacitor C, etc., are ideal; (2) Boost inductor L1 = L2 = L, its value is large enough, so that it can be equivalent as constant current source in the switching cycle; (3) Output filter capacitor is large enough, so the output voltage is constant and equivalent to a constant voltage source. (4) The switching frequency is much higher than the power grid frequency, power grid vin and DC side voltage VO is constant in a switching cycle. In the instant for power on, the power source providing starting current via D0. Since then, D0 is off. The circuit turns into steady-state. In one cycle, the circuits operation can be divided into four working modes, as shown in Fig. 2. 1Mode1Switching tube Q1 and Q2 are on, diode D1 and D2 are off. The current in series inductor L1 and L2 increases linearly and stores the energy in these inductors, and the energy stored in C provides energy to the load, as shown in Fig.2(a). At this stage, the state differential equations of the circuit are given by:
diL1 L1 dt = Vin . diL 2 L V = 2 in dt dV0 V = 0 C R dt

energy to the load, as shown in Fig.2(d). At this stage, the state differential equations of the circuit are given by:
diL1 L1 dt = Vin V0 . diL 2 = Vin V0 L2 dt V0 dV0 C dt = iL1 + iL 2 R

L1

D1

Vin

L2

D2

C Vo

Q1

Q2

(a)
L1 D1

1
Vin
L2 D2 C Vo R

Q1

Q2

2Mode2Switching tube Q1 diode D2 are on, and Q2 and D1 are off. The current in series inductor L1 increases linearly while in series inductor L2 decreases, as shown in Fig.2(b). At this stage, the state differential equations of the circuit are given by:
diL1 L1 dt = Vin . diL 2 = V0 Vin L2 dt V0 dV0 C dt = iL 2 R

(b)

Vin

Vo

3Mode3Switching tube Q2 and diode D1 are on, and Q1 and D2 are off. The current in series inductor L1 decreases linearly while in series inductor L2 increases, as shown in Fig.2(c). At this stage, the state differential equations of the circuit are given by
diL1 L1 dt = Vin V0 . diL 2 = Vin L2 dt V0 dV0 C dt = iL1 R
Vin

(c)
L1 D1

L2

D2

Vo

3
Q1 Q2

(d) Fig.2. Four working mode for two phase interleaved PFC boost converter. (a) Mode 1. (b) Mode 2. (c) Mode 3. (d) Mode 4.

4Mode4Switching tube Q1 and Q2 are off, diode D1 and D2 are on. The power source and the energy stores in series inductor L1 and L2 charge the capacitor and provide

III.

CONTROLL STRATEGY FOR PROPOSE TOPOLOGY

A. Control Strategy of Conventional Average Current Mode The propose boost PFC converter adopt average current control, and use voltage control loop and current control loop, as shown in Fig.3. Input current iL is compared with the reference current iref, and its high frequency components pass by current error amplifier for average processing. Then, the average error current, which has been amplified, compared with the sawtooth wave, and provides the PWM drive signal for the switching tube Q. When the inductor current iL rises, the error current ierro decreases, the output duty cycle for PWM comparator decreases, resulting in reduced inductor current iL. On the contrary, the inductor current iL increases. When output voltage Vo increases, the output verro for voltage error comparator decreases error current ierro decreases the output duty cycle for PWM comparator decreases, resulting in reduced inductor current iL and output voltage Vo. On the contrary, the output voltage Vo increases.

equivalent KVFF within the eight ranges. These eight KVFF levels are spaced to accommodate the full universal line range from 85V to 265V. Tab.1 reflects the relationship between the various vin peak voltages and the corresponding KVFF terms for the multiplier equation. The propose controller can response to both increasing and decreasing changes in input voltage. So that, disturbances transmitted to the PFC output are minimized. The instantaneous multiplier current is dependent upon voltage VIN, error voltage verro and the feed-forward controller output KVFF. The reference current for CCM boost converter inner loop is decide by [6]

iref =

VIN (verror 1) 17 A KVFF

(5)

Tab.1. The relationship between the various vin peak voltages and the corresponding KVFF Level 1 2 3 4 5 6 7 8 vin (V) 133 133-160 160-187 187-220 220-260 260-300 300-345 345 VIN (V) 1.00V 1.00- 1.20 1.20- 1.40 1.40- 1.65 1.65- 1.95 1.95- 2.25 2.25- 2.60 2.60 KVFF(V2) 0.398 0.600 0.839 1.156 1.604 2.199 2.922 3.857

IV.

PARAMETERS DESIGN FOR PROPOSE TOPOLOGY

A. Design for Boost Inductor The inductor parameter is according to the minimum input voltage of circuit. In the case of full load, when the input voltage is minimum, the current flows through inductor is the biggest, the corresponding duty cycle is given by:
Fig.3. Average current control strategy for boost converter

B. Control Strategy for Average Current Mode with Feedforward Compensator In most switching mode power supply topologies, the output voltage is directly proportional to the input voltage When a transient occurs on the input voltage, the output voltage will change almost immediately. The control feedback loop is not fast enough to neutralize the effect of the transient [5]. To solve this problem, this paper proposes a feed-forward controller based on the average current control, as shown in Fig. 4.

d max =

Vo 2Vin (min) Vo

Where, Vin (min) is the minimum input voltage, Vo is output voltage, the parameters of L1L2 is given by:

L1 = L2 =

Vi (2min ) d max
Pout f

B. Design for Output Capacitor In the PFC rectifier, the output filter capacitor should be selected by according to the required of holding time. Hold time is determined by the output capacitor energy storage, load power, output voltage and the minimum voltage value of load. The parameter of Comin is given by:

Co min =
V.
Fig.4. Average current control strategy with feed-forward

2 Po t . V Vo2(min)
2 o

EXPERIMENTAL RESULTS

The propose feed-forward controller detects the transition of the peak of VIN through seven thresholds and generates an

An experimental prototype, which is control by UCC28070, is built to verify the operation of the proposed converter. The key circuit parameters and specifications are listed as bellow:

vin(t) 86V264V Vo 400VDC5% Po 5KW fs 41.67kHz 340H Lin Co 1650F where vin(t) is the input sinusoidal voltage, Vo is the output dc voltage, Po is the output power, fs is the switching frequency, Lin is the input inductor, Co is the output capacitance. Fig.5 show the experimental prototype for propose 5KW boost PFC converter. Input voltage and input current waveform is show in Fig.6, it show that input current can better track input

inductor current rise and decline also be staggered, and reduce the input current ripple. 2) Compare with the switching frequency, the frequency of the input current is twice for each phase. It reduces the input EMI filter size and enhance power density. 3) Reduce the output capacitance. Since high-frequency ripple current of output capacitor is reduced, making the output capacitance decreases. 4) Input current can better track input voltage, power factor is high.

voltage.

Fig.5. experimental prototype

Fig.7. Waveform of inductor current and drive signal Tab.2. Efficiencies and Power Factor of Proposed Converter

Pin(KW) 1.316 1.982 2.629 3.287 3.952 4.719 5.054

Vo(V)
397.83 397.88 397.94 397.44 397.99 397.99 397.99

Pout(KW) 1.270 1.920 2.551 3.193 3.838 4.584 4.889

Eff(%) 96.5 96.9 97.0 97.1 97.1 97.1 97.2

PF 0.979 0.984 0.988 0.990 0.992 0.993 0.993

THD(%) 4.5 4.3 4.2 4.1 4.1 4.0 4.0

REFERENCES
Fig.6. waveform of input voltage and input current [1] JIANG Zhi-hong, LI Hui, HUANG Li-pei, A New Current-Sharing Controller for Parallel-Connected Interleaving CCM PFC Converter Based on a Duty-Cycle Dynamic Distribution Controller, Journal of Beijing Institute of Technology, vol.29, no.3, pp. 240-244,278, 2009. HU Yah-shen, XIE Yun-xiang, Design and Implement of 3-Channels Interleaved Boost DC/DC Converter, Power Electronic, vol.40, no.2 , pp.45-47, 2006. Xiaojun Xu, Wei Liu, Alex Q. Huang, Two-phase interleaved critical mode PFC boost converter with closed loop interleaving strategy, IEEE TRANSACTIONS ON POWER ELECTRONICS, vol.24, no.12, pp.3003-3013, 2009. Huber,L., Irving, B.T., Jovanovic,M.M., Open-Loop Control Methods for Interleaved DCM/CCM Boundary Boost PFC Converters, IEEE Transactions on Power Electronics, vol.23, no.14, pp. 1649-1657, 2008. BEN Hong-qi, ZHANG Ji-hong, LIU Gui-hua, et al, Active power factor correction technology for switching power supply. Beijing: Mechanical Industry Press, 2010. UCC28707 Data Sheet. Texas Instruments.http://focus.ti.com/lit/ds/symlink/ucc28070.pdf

The waveform of inductor current and drive signal as shown in Fig.7, it show that the two-phase switching tube breakover by cross, the inductor current rise and decline also be staggered. Efficiencies and PF of proposed controller is provided in Tab. 2 for 220V input at 41.67 kHz switching frequency and 400V output. It show that the converters PF greater than 0.97, THD less than 5% and efficiency more than 99.4%, from 1.27KW to 4.889kW. VI. CONCLUSION The propose 5KW converter which using double phase interleaved boost PFC have the following characteristics: 1) Reduce input current high-frequency ripple by effective. As the two-phase switching tube breakover by cross, the

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