Power Factor Correction Input Circuit Kevin Wong, Paul Glaze, Ethan Hotchkiss, Jethro Baliao Advisor: Prof. Ali Bazzi Sponsored by: Lenze Americas 11/30/2016 JETHRO Introduce Ourselves Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Outline JETHRO Go over what the course of the presentation will be Background Power Factor (PF) Power Factor Correction (PFC) Problem Statement Importance for Lenze Specifications Constraints Approach Active vs passive rectification DC/DC Design Topologies Design simulation Options Semiconductor Options Control Options Timeline moving forward JETHRO Go over what the course of the presentation will be First we will discuss what what Power Factor and Power Factor Correction is Why this is important to Lenze, their specifications and what we’re limited to How we tackle the issue through various topologies Simulations Controller Options Our plans for the future Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

What is Power Factor? JETHRO The ratio of real power to apparent power in the circuit Another way of looking at this relationship is from the power triangle. The apparent power, S can be determined by taking the vector sum of the reactive power, Q and the real power. JETHRO So first of all Working Power(Actual Power, Active Power, or Real Power) is what runs equipment Reactive Power is Power that transformers and motors need to produce magnetic flux Apparent power is the vectorial summation of Reactive Power and Working Power Beer Analogy So I’m pretty sure everyone here has been to the bar at least once So take for an example you get your favorite beer on tap The foam you get is the Reactive Power, and the actual Beer is your Actual/Working Power Basically the Ratio between the Beer and the Beer plus the Foam is your Power Factor You want to get rid of that foam (unless you’re into that) and get the most out of your beer 2000W @120V is 16.7A at Unity Power Factor but 2000W @23.8A at a 0.7 Power Factor This would not trip a 20A breaker at Unity Power Factor but at a 0.7 Power Factor it would. Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

What is Power Factor Correction? Reducing the reactive power consumed by an inductive load improves power factor Power factor correction methods: Capacitor Banks Pros: Simple, inexpensive, quiet Cons: Large size, limited adjustment Synchronous Condenser Pros: Extensive adjustment Cons: Large size, noise, expensive Power Electronics Switching Converter Pros: Extensive adjustment, small size, quiet Cons: Expensive JETHRO Simply Put, Power Factor Correction is comparable to Reducing the Foam from the Beer you get Examples of improving PF is the following Capacitor Banks store electrical energy and corrects power supply error in electric motors and transformers but are too big and adjustability is limited Synchronous Condenser would absorb reactive power but they too are big and expensive Power Electronics are small, generate no noise which is one of our approaches to this project

Why is this important for Lenze? Looking for a circuit to improve the Power Factor in one of their drives due to more consumer market requests. PFC creates less distortion on the line for the customer Design and manufacture affordable Variable Frequency Drives(VFDs). VFDs control the frequencies and voltages to motors. This is important because: Reduction in Energy Consumption and Costs Increase Longevity and Reduce Maintenance on Equipment Efficiency saves on power component and thermal management, and therefore Size and Cost JETHRO Lenze manufactures VFDs in Uxbridge, MA VFDs work in Appliances which include Heating, Ventilation and Air Conditioning (HVAC), Drills, and Pumps. Importance of VFD’s Reduction in Energy Consumption If an application does not have to function at full load, a VFD can cut down on the extra costs by controlling the motor. The VFD will match the load and the input to maximize efficiency. Electric Motor systems account for more than 60% of the power consumption in industry. Having one can potentially reduce wasted energy consumption by 70% depending on the application Longevity and Maintenance The VFD will have the motor operate at its optimal speed preventing any overloads, under voltage, over voltage, etc.

Block Diagram KEVIN Simple Block Diagram showing how we plan on approaching this project First the AC input runs through a Diode Bridge Rectifier That DC output will run into our choice of topology: Boost, Buck-Boost, Flyback, and SEPIC That output will feedback into the Switch/MOSFET using either: PID Controller Analog Controller Microcontroller KEVIN NEXT Color code the Block Diagram

Specifications Input Requirements Output Requirements Voltage Input: 90Vac-132Vac Power Factor: >0.95 Frequency: 48-62Hz Inrush Current: <40A Output Requirements Voltage Output: 325Vdc Max Continuous Power: 1472 Voltage Ripple: 20Vpk-pk System Requirements Operating Temperature: -10 to 55 °C Switching Frequency: >20KHz Efficiency: above 95% Kevin

Constraints Lenze is looking for Low Cost Small Footprint High Efficiency PCB Design Possible Three-Phase Circuit 230Vac to 325Vdc KEVIN Something Cheap, they plan on mass producing this product Small Footprint is a plus, this will be going to be working with one of their VFDs High Efficiency is Key to saving money and energy PCB design would be great for Lenze, although a hardwired project would also be helpful too before working with the final design Three-Phase is one of the extra goals for this project Three-Phase is advantageous over Single-Phase because Due to the Instantaneous Power (power consumed and power generated at anytime during a cycle) Consistent Power Delivery and more efficient

Active vs Passive Rectification Pros: Lower voltage drop Bi-directional current Higher efficiency Cons: Requires control More expensive More complex Passive Pros: No external control Simple Inexpensive Cons: Uni-directional current Higher voltage drop Lower efficiency KEVIN PASSIVE

Possible DC/DC Topologies Flyback SEPIC Buck Boost Boost ETHAN We considered four topologies for DC/DC conversion Boost is most common in practice Still wanted to explore others Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

DC/DC Converter Pros & Cons Topologies Pros/Cons Factors Boost Buck-Boost Flyback SEPIC Simplicity 1st 4th 2nd 3rd Size Cost Power Level Voltage Regulation ETHAN Boost outperforms in all categories except voltage regulation Voltage regulation is less relevant due to Vin = 0-170VDC

Boost Converter Diagram ETHAN Boost Converter is a step-up converter step up voltage step down current *Describe how it works if there is time

Ideal Boost Waveforms ETHAN 0-0.75s = 100W load 0.75-1.5s = 1.5kW load Power factor is good after system stabilizes Current transient response is good, Voltage transient response needs work All visible ripples are at fundamental frequency(60Hz) Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Semiconductor Options IGBT Voltage Rating: >1kv Current Rating: >500A Slower switching More expensive MOSFET Voltage Rating: <1kV Current Rating: <200A Faster switching Less expensive PAUL

No reliance on a 3rd party chip Lower production costs Control Options DSP Adjustability Expansion No reliance on a 3rd party chip Infineon ICE3PCS01G Existing control chip Greater stability Lower production costs PAUL

What is next? Begin physical prototyping Continue PCB design Continue coding microcontroller Optimize transient response EMI considerations PAUL

Fall Timeline PAUL -This is our Current Fall timeline -So far everything has been completed as of Today -Our next tasks are just the completing the Final Report and working on the Prototype Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL) 10/20/16

Spring Timeline PAUL How out next semester looks Mostly Testing and Delivering Weekly reports (assuming we get the prototype functional by the end of december) This is still subject to change however

Resources J. Betten. (2011, Q2) “Benefits of a coupled-inductor SEPIC converter” Analog Applications Journal [Online] Available: http://www.ti.com/lit/an/slyt411/slyt411.pdf [October 14 2016]. G. Sharp. “Sepic Converter Design and Operation.” BS, WPI, Worcester, MA, 2014. ST. “TM sepic converter in PFC pre-regulator.” Internet: http://www.st.com/content/ccc/resource/technical/document/application_note/48/9d/ 34/73/b9/27/48/65/CD00134778.pdf/files/CD00134778.pdf/jcr:content/translations/en.C D00134778.pdf, March 2007[October 10, 2016]. J.W. Kolar and T. Friedli. “The Essence of Three-Phase PFC Rectifier Systems-Part I.” IEEE Transactions on Power Electronics, Vol. 28, No.1,pp176-198, [ September 20, 2016]. H. Wei, and I. Batarseh. (1998) “Comparison of Basic Converter Topologies For Power Factor Correction.” [September 20, 2016] "The Flyback Converter," in University of Colorado. [Online]. Available: http://ecee.colorado.edu/~ecen4517/materials/flyback.pdf. [Oct. 27, 2016]. De Nardo et al, “Power Stage Design of Fourth-Order DC-DC Converters by Means of Principal Components Analysis.”IEEE Transactions on power Electronics, Vol. 23 No. 6,pp2867-2877 Consistent w/ citations Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Additional information can be found on our website: Questions? Additional information can be found on our website: http://ecesd.engr.uconn.edu/ecesd1703/