Site rules, must be read before posting! (Updated August 8th 2017): https://highvoltageforum.net/index.php?topic=31.0

Author Topic: STNRGPF01 - 3-channel interleaved CCM PFC digital controller  (Read 421 times)

Offline Mads Barnkob

  • Administrator
  • High Voltage Engineer
  • *****
  • Posts: 250
  • Denmark
    • View Profile
    • Kaizer Power Electronics
STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« on: April 04, 2017, 07:56:20 PM »
From the STMicroelectronics newsletter from today, there was a new interesting PFC controller that is well within the power range for use in fairly large Tesla coils, especially easy to make a design with their eDesignSuite (online circuit designer) that gives you a complete schematic after giving it components values for like 10 key parts. It does seem that you need a ST account to use it though!

The new product: http://www.st.com/content/st_com/en/products/power-management/ac-dc-converters/pfc-controllers/stnrgpf01.html?ecmp=tt4938_gl_enews_mar2017

Digikey got it in stock: https://www.digikey.com/products/en?WT.z_cid=sp_497_0928_buynow&Enterprise=44&lang=en&Vendor=497&mpart=STNRGPF01

Quote
The STNRGPF01 is a digital controller designed specifically for interleaved PFC boost topologies and intended for use in high power applications.

The controller is capable of driving up to 3 interleaved channels, generating the proper signals in each condition. Moreover, it implements a flexible phase shedding strategy that enables the correct number of PFC channels based on the actual load condition. With this function, the STNRGPF01 is always able to guarantee the highest power efficiency across a wide range of load current requirements.

The device works in CCM at fixed frequency with average current mode control, and implements mixed signal (analog/digital) control. The inner current loop is performed by hardware, ensuring cycle-by-cycle regulation. The outer voltage loop is performed by a digital PI controller with fast dynamic response.

The controller implements several functions: inrush current control, soft start-up, burst mode cooling management and status indicators.

It also features a full set of embedded protections against overvoltage, overcurrent, and thermal faults.

The STNRGPF01 is configured through a visual dedicated software tool (eDesignSuite) to match a wide range of specific applications. Using eDesignSuite, the user can customize the PFC conversion configuration and all the relevant electrical components. As a result, the tool will automatically generate a full schematic which includes a complete list of material and the final binary object code (FW) to be downloaded to the STNRGPF01.

Key Features

    Interleaved boost PFC
    Up to 3 interleaved channels
    CCM, fixed frequency
    Average current control, cycle-by-cycle
    Inrush current control
    Burst mode support
    Overcurrent and thermal protection
    Soft start-up
    Flexible phase-shedding strategy
        High operating frequency with small PFC inductor, suitable for high power-density applications
        Low ripple current (input/output)
        Simpler integration with other applications
    Flexible design customization to meet specific customer needs
    Firmware
        Turnkey solution for quick design
        eDesign Suite graphical user interface (GUI) for application configuration
    Embedded memory data retention 15 years with ECC
    Communication interfaces
        UART asynchronous protocol for bootloader support
    Operating temperature: -40 °C to 105 °C

http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline TCWilliamson

  • High Voltage Enthusiast
  • *
  • Posts: 6
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #1 on: May 21, 2017, 12:41:18 PM »
From the STMicroelectronics newsletter from today, there was a new interesting PFC controller that is well within the power range for use in fairly large Tesla coils, especially easy to make a design with their eDesignSuite (online circuit designer) that gives you a complete schematic after giving it components values for like 10 key parts. It does seem that you need a ST account to use it though!

The new product: http://www.st.com/content/st_com/en/products/power-management/ac-dc-converters/pfc-controllers/stnrgpf01.html?ecmp=tt4938_gl_enews_mar2017

Digikey got it in stock: https://www.digikey.com/products/en?WT.z_cid=sp_497_0928_buynow&Enterprise=44&lang=en&Vendor=497&mpart=STNRGPF01

Quote
The STNRGPF01 is a digital controller designed specifically for interleaved PFC boost topologies and intended for use in high power applications.

The controller is capable of driving up to 3 interleaved channels, generating the proper signals in each condition. Moreover, it implements a flexible phase shedding strategy that enables the correct number of PFC channels based on the actual load condition. With this function, the STNRGPF01 is always able to guarantee the highest power efficiency across a wide range of load current requirements.

The device works in CCM at fixed frequency with average current mode control, and implements mixed signal (analog/digital) control. The inner current loop is performed by hardware, ensuring cycle-by-cycle regulation. The outer voltage loop is performed by a digital PI controller with fast dynamic response.

The controller implements several functions: inrush current control, soft start-up, burst mode cooling management and status indicators.

It also features a full set of embedded protections against overvoltage, overcurrent, and thermal faults.

The STNRGPF01 is configured through a visual dedicated software tool (eDesignSuite) to match a wide range of specific applications. Using eDesignSuite, the user can customize the PFC conversion configuration and all the relevant electrical components. As a result, the tool will automatically generate a full schematic which includes a complete list of material and the final binary object code (FW) to be downloaded to the STNRGPF01.

Key Features

    Interleaved boost PFC
    Up to 3 interleaved channels
    CCM, fixed frequency
    Average current control, cycle-by-cycle
    Inrush current control
    Burst mode support
    Overcurrent and thermal protection
    Soft start-up
    Flexible phase-shedding strategy
        High operating frequency with small PFC inductor, suitable for high power-density applications
        Low ripple current (input/output)
        Simpler integration with other applications
    Flexible design customization to meet specific customer needs
    Firmware
        Turnkey solution for quick design
        eDesign Suite graphical user interface (GUI) for application configuration
    Embedded memory data retention 15 years with ECC
    Communication interfaces
        UART asynchronous protocol for bootloader support
    Operating temperature: -40 °C to 105 °C


Oooh, now that sounds pretty interesting... Is this only for single phase or do they offer an idea for 3 phase too?



Offline Mads Barnkob

  • Administrator
  • High Voltage Engineer
  • *****
  • Posts: 250
  • Denmark
    • View Profile
    • Kaizer Power Electronics
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #2 on: May 21, 2017, 07:09:39 PM »
Looking at the schematics from their 3kW evaluation board: http://www.st.com/content/ccc/resource/technical/document/data_brief/group1/ae/c8/2d/88/84/ab/4d/02/DM00379111/files/DM00379111.pdf/jcr:content/translations/en.DM00379111.pdf

On page 2 there is a ZVD (zerocrossing voltage detection) taken from one of the AC inputs, all 3 interleaved PFC stages are run from the same DC bus, so as it can only detect zero crossing on one phase, looking on page 5, the current sensing resistor is placed on the grounded output, as with many other PFC IC solutions, so they can not just be paralleled.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Online futurist

  • Global Moderator
  • High Voltage Enthusiast
  • *****
  • Posts: 45
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #3 on: May 24, 2017, 10:11:42 PM »
It looks great! They even give you gerbers and BOM for the 3kW eval board
I'll try to import BOM to Mouser to see total part cost, but I suppose it won't be cheap as STW40N60M2 MOSFETs alone are 8€ each

Offline Hydron

  • Administrator
  • High Voltage Enthusiast
  • *****
  • Posts: 10
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #4 on: July 06, 2017, 01:31:36 PM »
I had a quick look at that chip and the reference design the other day. Didn't price it up but did notice that it uses SiC diodes - when I eventually build a PFC I intend to do the same so I can basically ignore diode switching losses.

I'm personally more interested in the ADP1047/8, similarly they are digital, but with an I2C interface that allows for current/voltage/power measurement during operation and (I believe) changing control parameters (e.g. output voltage) on the fly.

Offline Mads Barnkob

  • Administrator
  • High Voltage Engineer
  • *****
  • Posts: 250
  • Denmark
    • View Profile
    • Kaizer Power Electronics
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #5 on: July 06, 2017, 01:42:34 PM »
I found the STNRGPF01 interesting because it comes in a 3 kW development board, I can only find a few notes about the ADP1047 that says its a 300 Watt rated controller and ADP1048 is 600 Watt.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline Hydron

  • Administrator
  • High Voltage Enthusiast
  • *****
  • Posts: 10
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #6 on: July 07, 2017, 10:54:44 AM »
300W and 600W are simply the available demo boards, rather than max output. The chip itself is just a controller so is capable of significantly higher power - in fact both the ST and ADI parts need external MOSFET drivers, and the ST part even needs some external logic (flip-flops) to generate PWM for channels 2 and 3.
I looked at the 3kW board (and the ST part) because the power level is about right to use as a start for a DIY design. Even if you don't use the same chip, the design is a good place to start - there won't be significant differences in topology between PFC controllers unless you go to bridgeless or similarly exotic configurations.

Offline Mads Barnkob

  • Administrator
  • High Voltage Engineer
  • *****
  • Posts: 250
  • Denmark
    • View Profile
    • Kaizer Power Electronics
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #7 on: July 07, 2017, 11:17:26 AM »
300W and 600W are simply the available demo boards, rather than max output. The chip itself is just a controller so is capable of significantly higher power - in fact both the ST and ADI parts need external MOSFET drivers, and the ST part even needs some external logic (flip-flops) to generate PWM for channels 2 and 3.
I looked at the 3kW board (and the ST part) because the power level is about right to use as a start for a DIY design. Even if you don't use the same chip, the design is a good place to start - there won't be significant differences in topology between PFC controllers unless you go to bridgeless or similarly exotic configurations.

I have tried, and failed, to scale up a PFC IC to 2kW that was not made for it, mostly it messes up the feedback loops and prevents it from even running or or melts down fairly fast. I do want to give my 2kW unit another try soon, with a change to the voltage and current feedbacks. I will make a separate thread for that :)
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline Hydron

  • Administrator
  • High Voltage Enthusiast
  • *****
  • Posts: 10
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #8 on: July 07, 2017, 12:23:40 PM »
I have 2x 800W and 2x 875W output Dell workstation power supplies which I'm thinking of tearing down and using for PFC experiments. Each PSU has a 2 board construction, with separate PFC and DC-DC PCBs, and thus are relatively easy to re-purpose. I'm hoping that I can remove the existing PFC chips and rewire for operation as a 1600W+ interleaved PFC converter with a new ADP1048 controller.

As for feedback loops, one of the reasons I'm looking at the ADP104x parts is that it can all be setup in software then flashed into the chip, in a nice GUI with graphs etc no less! Hopefully if I'm cautious and use a bulb in series or something to limit fault current I'll get away without blowing up too much silicon :)

High Voltage Forum

Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #8 on: July 07, 2017, 12:23:40 PM »

 


* Recent Topics and Posts

post Re: Futurist's DRSSTC1
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
Today at 12:23:57 PM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
kamelryttarn
Today at 08:44:02 AM
post Re: Boxing up the Loneoceans' midi2 controller
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
Today at 07:12:15 AM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
petespaco
Today at 05:44:31 AM
post Re: Secondary Coil Design Decisions
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 21, 2017, 03:39:14 PM
post Secondary Coil Design Decisions
[Dual Resonant Solid State Tesla coils]
sparkydownunder
August 21, 2017, 12:58:30 PM
post Boxing up the Loneoceans' midi2 controller
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 20, 2017, 09:32:01 PM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
kamelryttarn
August 20, 2017, 08:06:42 PM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
Mads Barnkob
August 20, 2017, 07:50:59 PM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
kamelryttarn
August 20, 2017, 09:07:33 AM
post Re: Royer induction heater and high current power supply
[Electronic circuits]
kamelryttarn
August 18, 2017, 09:32:26 PM
post Re: Royer induction heater
[Electronic circuits]
afk
August 18, 2017, 03:56:05 PM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 18, 2017, 06:14:26 AM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 17, 2017, 01:50:34 PM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
Mads Barnkob
August 17, 2017, 10:41:25 AM
post Re: DRSSTC inverter vs. secondary impedance inequality discussion
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 16, 2017, 01:36:24 PM
post Re: DRSSTC inverter vs. secondary impedance inequality discussion
[Dual Resonant Solid State Tesla coils]
Uspring
August 16, 2017, 12:32:48 PM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 16, 2017, 07:52:09 AM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 15, 2017, 10:55:39 PM
post Re: DRSSTC inverter vs. secondary impedance inequality discussion
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 15, 2017, 09:45:22 AM
post Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 15, 2017, 09:22:03 AM
post Re: Ebay: Electronics / high voltage items for sale on ebay
[Sell / Buy / Trade]
Mads Barnkob
August 15, 2017, 08:55:51 AM
post Sell / Buy / Trade rules - read before posting!
[Sell / Buy / Trade]
Mads Barnkob
August 15, 2017, 08:52:53 AM
post Re: [WTS] [world] HUGE Arduino/shield/sensor/components lot
[Sell / Buy / Trade]
Mads Barnkob
August 15, 2017, 08:48:26 AM
post Re: Hacking the IKEA 2000 Watt induction stove (5 parts)
[Electronic circuits]
futurist
August 14, 2017, 05:13:46 PM
post Re: Tardief's DRSSTC
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 14, 2017, 01:52:43 PM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 14, 2017, 11:35:30 AM
post Re: Tardief's DRSSTC
[Dual Resonant Solid State Tesla coils]
Tardief
August 14, 2017, 11:09:23 AM
post Tektronix 30-page guide to do measurements on SMPS/Inverters
[Beginners]
Mads Barnkob
August 14, 2017, 10:42:42 AM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
Mads Barnkob
August 14, 2017, 09:00:33 AM
post Re: My 160 (?)mm sstc
[Solid state Tesla coils]
Mads Barnkob
August 14, 2017, 08:50:22 AM
post Re: My 160 (?)mm sstc
[Solid state Tesla coils]
oneKone
August 14, 2017, 03:22:26 AM
post Re: Hacking the IKEA 2000 Watt induction stove (5 parts)
[Electronic circuits]
Mads Barnkob
August 13, 2017, 01:47:51 PM
post Re: Tardief's DRSSTC
[Dual Resonant Solid State Tesla coils]
futurist
August 12, 2017, 11:19:16 PM
post Re: Tardief's DRSSTC
[Dual Resonant Solid State Tesla coils]
Tardief
August 12, 2017, 10:06:07 PM
post Re: Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
Uspring
August 11, 2017, 12:46:33 PM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
ldm314
August 11, 2017, 09:54:15 AM
post Re: Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 10, 2017, 01:41:47 PM
post DRSSTC inverter vs. secondary impedance inequality discussion
[Dual Resonant Solid State Tesla coils]
Uspring
August 10, 2017, 12:44:12 PM
post Re: My 160 (?)mm sstc
[Solid state Tesla coils]
oneKone
August 10, 2017, 08:43:27 AM
post Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 09, 2017, 10:11:42 AM
post Re: Very high voltage, series connected, electrolytic capacitor bank
[Capacitor banks]
Mads Barnkob
August 09, 2017, 09:08:45 AM
post Re: Very high voltage, series connected, electrolytic capacitor bank
[Capacitor banks]
Bartos
August 09, 2017, 08:10:12 AM
post Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
TCWilliamson
August 08, 2017, 07:52:36 PM
post Re: AGFA PMT module AGFA-IUP3, reverse engineering
[Detection, counting and measurements]
RickyTerzis
August 08, 2017, 06:47:38 PM
post Re: Royer induction heater
[Electronic circuits]
petespaco
August 08, 2017, 04:41:52 PM
post Re: Futurist's DRSSTC1
[Dual Resonant Solid State Tesla coils]
futurist
August 08, 2017, 12:30:40 PM
post Re: Futurist's DRSSTC1
[Dual Resonant Solid State Tesla coils]
Uspring
August 08, 2017, 09:52:06 AM
post Re: The Procrastinator's DRSSTC
[Dual Resonant Solid State Tesla coils]
Mads Barnkob
August 08, 2017, 09:36:54 AM
post Re: Wifi SSTC attempt 1...
[Solid state Tesla coils]
Mads Barnkob
August 08, 2017, 08:27:00 AM