1. 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)

2. 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)

3. 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
is 16.7A at Unity Power Factor but 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)

4. 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

5. 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.

6. 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

7. 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

8. 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

9. 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

10. 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)

11. 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

12. 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

13. 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)

14. 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

15. 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

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

17. 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

18. 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

19. Resources
J. Betten. (2011, Q2) “Benefits of a coupled-inductor SEPIC converter” Analog Applications Journal [Online] Available: [October ].
G. Sharp. “Sepic Converter Design and Operation.” BS, WPI, Worcester, MA, 2014.
ST. “TM sepic converter in PFC pre-regulator.” Internet: 34/73/b9/27/48/65/CD pdf/files/CD pdf/jcr:content/translations/en.C D 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,pp , [ 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: [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,pp
Consistent w/ citations
Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

20. Additional information can be found on our website:
Questions?
Additional information can be found on our website: