Summary of PROGRAMMABLE FREQUENCY – CONTINUOUS CONDUCTION MODE (CCM) – BOOST POWER – FACTOR CORRECTION (PFC) CONTROLLER
This article describes a compact PFC controller module based on the Texas Instruments UCC28180. It implements average current mode control in CCM, programmable switching frequency (18–250 kHz, default 116 kHz), integrated gate drive, reduced current-sense thresholds, and multiple protections (soft OC, cycle-by-cycle peak limit, OV with hysteresis, soft-start). Designed for 100 W to multi-kW AC–DC front ends, it needs few external components and omits AC line sensing for low component count and low input-current distortion.
Parts used in the PFC controller module:
- UCC28180 PFC controller IC (Texas Instruments)
- Power MOSFET or IGBT (external switch)
- Gate drive output circuitry (integrated but uses PCB connections)
- Shunt resistor for current sensing
- Resistors R9 and R12 for frequency programming
- Supply decoupling capacitors (12 to 15 V DC supply)
- Soft-start components (external capacitor/resistor as required)
- PCB footprint (29.21 x 16.67 mm)
The circuit described here is a simple PFC controller using the UCC28180 chip from Texas instruments. 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 module is a flexible and easy-to-use, active Power-Factor Correction (PFC) controller that operates under Continuous Conduction Mode (CCM) to achieve high Power Factor, low current distortion, and excellent voltage regulation of boost pre-regulators in AC – DC front-ends. The controller is suitable for universal AC input systems operating in 100-W to few-kW range with the switching frequency programmable between 18 kHz to 250 kHz, to conveniently support both power MOSFET and IGBT switches. An integrated 1.5-A and 2-A (SRC-SNK) peak gate drive output, clamped internally at 15.2 V (typical), enables fast turn-on, turn-off, and easy management of the external power switch without the need for buffer circuits. Low-distortion wave shaping of the input current using average current mode control is achieved without input line sensing, reducing the external component count.
In addition, the controller features reduced current sense thresholds to facilitate the use of small-value shunt resistors for reduced power dissipation, especially important in high-power systems. To enable low current distortion, the controller also features trimmed internal current loop regulation circuits for eliminating associated inaccuracies. The module requires few external components to create a complete PFC Controller. In the future, we will publish few PFC drivers using this module. Refer to the datasheet of UCC28128 to configure the board as per requirement.
FEATURES
- Supply 12 to 15V DC
- Default Frequency 116Khz (Programable 18Khz to 250Khz Resistor R9, R12)
- Average Current Mode PWM Control
- NO AC Line Sensing Needed
- Soft Over Current and Cycle by Cycle Peak Current Limiting
- Voltage Regulation Open Loop Detection
- Output Over-Voltage Protection with Hysteresis Recovery
- Enhanced Dynamic Response
- Soft-Start
- PCB Dimensions 29.21 x 16.67 mm
- What controller IC is used in the PFC module?
The module uses the UCC28180 PFC controller IC from Texas Instruments. - What switching frequency does the controller use by default and can it be changed?
The default switching frequency is 116 kHz and it is programmable from 18 kHz to 250 kHz using resistors R9 and R12. - Does the controller require AC line sensing for low-distortion current shaping?
No, low-distortion wave shaping of the input current is achieved without input line sensing. - What conduction mode does the controller operate in?
The controller operates in Continuous Conduction Mode (CCM). - What protections are included in the controller?
It includes soft over current, cycle-by-cycle peak current limiting, output over-voltage protection with hysteresis recovery, voltage regulation open-loop detection, and soft-start. - What supply voltage does the module require?
The module requires a 12 to 15 V DC supply. - Is the gate drive integrated or external?
The module provides an integrated gate drive output with 1.5-A and 2-A peak source and sink capability, clamped internally at about 15.2 V. - For what power range is the controller suitable?
It is suitable for universal AC input systems in the 100-W to few-kW range. - Does the controller minimize current-sense power dissipation?
Yes, it features reduced current sense thresholds to allow use of small-value shunt resistors and reduce power dissipation. - How large is the PCB for the module?
The PCB dimensions are 29.21 x 16.67 mm.
