300W Off-line Power Factor Correction (PFC) Boost Converter

  • Rajkumar Sharma
  • 788 Views
  • medium
  • Tested

The circuit presented here is a 300W off-line power factor correction (PFC) boost converter providing a nominal regulated output voltage of 375V @ 0.8A of load current. The project accommodates an input voltage range of 85V AC to 265VAC and uses average current mode control at a fixed programmable switching frequency of 116KHz. The project is based on UCCC28180 PFC controller module which incorporates a wide range of protection features to ensure safe system operation. The controller operates under average current mode control at a fixed programmable switching frequency of 116 kHz. Simple external current and voltage loop compensation, along with advanced protection features, make this controller ideal for server and desktop power supplies, industrial power supplies, and white goods. The project includes onboard fuse for short circuit protection, EMI filter, NTC to control inrush current, Bridge rectifier for DC rectification, high voltage/current MOSFET for switching, switching diode, high current inductor, high-value DC bus filter capacitor on the output. This project requires UCC28128 based controller board that can be mounted vertically on the PCB socket.

Heat Sink: Use appropriate heatsink for MOSFET and Switching Diode.

Fan: A fan, capable of 200 LFM to 400 LFM, should be used to maintain component temperatures within safe operating ranges at all times during operation.

Note: This project has 2 blocks, the power board and controller board, information about controller board is available here

UCCC28180 PFC controller module: https://www.electronics-lab.com/project/programmable-frequency-continuous-conduction-mode-ccm-boost-power-factor-correction-pfc-controller/

More Information about Power factor correction (PFC) is available here:

Safety precautions

The board operates at lethal voltages and has bulk capacitors that store significant charges. Accidental contact can lead to lab equipment damage, personnel injury, and may be fatal. Please be exceptionally careful when probing and handling this board. Always observe normal laboratory precautions.

Features

  • AC Input Range 85V AC to 265V AC
  • AC Frequency 47Hz to 63Hz
  • DC Supply for Logic Circuit 12V DC @ 100mA
  • 300W, 275V DC Output
  • Average Current Mode PWM Control
  • Fixed 116Khz Oscillator Frequency
  • 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
  • Enhanced Dynamic Response
  • Soft Start
  • PCB Dimensions 97.89  x 87.63 mm

Schematic

Parts List

NOQNTY.REF.DESC.MANUFACTURERSUPPLIERSUPPLIER PART NO
11BR1BRIDGE RECT. 600V 25AON SEMIDIGIKEYDFB2560-ND
21CN13 PIN SCREW TERMINALPHOENIXDIGIKEY277-1248-ND
31CN23 PIN SCREW TERMINALPHOENIXDIGIKEY277-1248-ND
41CN3UCC28128 MODULEELECTRONICS-LAB.COM
51CN44 PIN MALE HEADER PITCH 2.54MMWURTHDIGIKEY732-5317-ND
62C1,C20.1uF/630VPANASONICDIGIKEYP12158-ND
71C3470uF/450VNICHICONDIGIKEY493-3239-ND
81C40.22uF/630VNICHICONDIGIKEY493-3661-ND
92C5,C60.47uF/275VX2KEMETDIGIKEY399-12744-ND
104C7,C8,C9,C104.7K/3KVTDKDIGIKEY445-175519-ND
111C1147uF/35VNICHICONDIGIKEY493-9586-2-ND
121D11N5408ON SEMIDIGIKEY1N5408RLGOSTR-ND
131D2CVFD20065ACREEDIGIKEYCVFD20065A-ND
142D3,R4DNPOMIT
151F1FUSE HULDERWURTHDIGIKEY732-11376-ND
161F1FUSE HOLDER CLIP COVERWURTHDIGIKEY732-11379-ND
171F1FUSEWURTHDIGIKEY507-1270-ND
181L1300uH 5AmpABARCONDIGIKEY535-13508-ND
191Q1IPW65R095C7XKSA1INFINIONDIGIKEYIPW65R095C7XKSA1-ND
201R110K 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
211R23.3E 5% SMD SIZE 0805DMURATA/YAGEODIGIKEY
221R3SL22 5R012-BAMETHERMDIGIKEY570-1268-ND
231R50.033E 1% 4WOHMITEMOUSER588-14AFR033E
241T1COMMON MODE CHOKE 1MH 10AWURTHDIGIKEY732-1449-ND

Connections

Gerber View

Photos








Video


IPW65R095C7XKSA1 Datasheet

Infineon-IPW65R095C7-DS-v02_00-en-1227310

PCB

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