Author Topic: STNRGPF01 - 3-channel interleaved CCM PFC digital controller  (Read 4022 times)

Offline Mads Barnkob

  • Administrator
  • High Voltage Expert
  • *****
  • Posts: 1323
  • Karma: +21/-0
  • 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: 7
  • Karma: +0/-0
    • 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 Expert
  • *****
  • Posts: 1323
  • Karma: +21/-0
  • 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

Offline futurist

  • Global Moderator
  • High Voltage Technician
  • *****
  • Posts: 125
  • Karma: +1/-0
    • 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 Engineer
  • *****
  • Posts: 302
  • Karma: +9/-0
    • 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 Expert
  • *****
  • Posts: 1323
  • Karma: +21/-0
  • 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 Engineer
  • *****
  • Posts: 302
  • Karma: +9/-0
    • 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 Expert
  • *****
  • Posts: 1323
  • Karma: +21/-0
  • 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 Engineer
  • *****
  • Posts: 302
  • Karma: +9/-0
    • 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 :)

Offline TCWilliamson

  • High Voltage Enthusiast
  • *
  • Posts: 7
  • Karma: +0/-0
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #9 on: September 12, 2017, 09:14:06 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 :)

Please let me know how that comes along... could be quite nice.

Offline Hydron

  • Administrator
  • High Voltage Engineer
  • *****
  • Posts: 302
  • Karma: +9/-0
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #10 on: September 12, 2017, 11:25:29 PM »
I will be making stuff public, but I cannot guarantee how good the documentation will be (I don't have the best record), but I will try my best!

I've bought one of the ADP1048 chips to test, but realistically the PFC design is behind a few other things on the to-do list.

Offline futurist

  • Global Moderator
  • High Voltage Technician
  • *****
  • Posts: 125
  • Karma: +1/-0
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #11 on: September 13, 2017, 12:08:35 AM »
Do all Dell server/workstation PSUs have separate PFC?
I have 3x 750W Dell PE 2950 server PSUs which became useless when server died

Offline Mads Barnkob

  • Administrator
  • High Voltage Expert
  • *****
  • Posts: 1323
  • Karma: +21/-0
  • Denmark
    • View Profile
    • Kaizer Power Electronics
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #12 on: September 14, 2017, 08:44:35 AM »
Futurist, did you ever get a BOM made? and found a total price?

Hydron, you have to make a good documentation! I got 6 of these 1000 Watt server power supplies, which actually was meant to be pit in series for 3x 12VDC for a royer IH.

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

Offline futurist

  • Global Moderator
  • High Voltage Technician
  • *****
  • Posts: 125
  • Karma: +1/-0
    • View Profile
Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #13 on: September 14, 2017, 03:26:21 PM »
I didn't manage to import BOM, mouser asks for manufacturer part numbers which aren't included in pdf
So you need to search for ~120 parts manually

Here is pdf bom converted to excel if someone wants to make project at mouser
* pfc_bom.zip

High Voltage Forum

Re: STNRGPF01 - 3-channel interleaved CCM PFC digital controller
« Reply #13 on: September 14, 2017, 03:26:21 PM »

 


* Recent Topics and Posts

post Re: A few (stupidly basic) questions
[Beginners]
Mads Barnkob
Today at 02:53:24 PM
post Re: A few (stupidly basic) questions
[Beginners]
John123
Today at 11:46:07 AM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
John123
Today at 11:40:55 AM
post Re: Power MOSFETs with fast recovery body diodes
[Electronic Circuits]
John123
Today at 11:32:19 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ritaismyconscience
Today at 03:48:55 AM
post Re: Class E SSTC Topology
[Solid State Tesla Coils (SSTC)]
ZakW
April 01, 2020, 09:47:42 PM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
April 01, 2020, 09:31:49 PM
post Re: Power MOSFETs with fast recovery body diodes
[Electronic Circuits]
davekni
April 01, 2020, 08:47:11 PM
post Re: Fishing for atmospheric electricity
[Static Electricity]
johnf
April 01, 2020, 08:45:14 PM
post Re: Homemade HV transformer
[Transformer (Ferrite Core)]
johnf
April 01, 2020, 08:37:29 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
davekni
April 01, 2020, 08:24:06 PM
post Re: Pt100 oddities
[Electronic Circuits]
davekni
April 01, 2020, 08:16:59 PM
post Re: Pt100 oddities
[Electronic Circuits]
johnf
April 01, 2020, 07:50:16 PM
post Re: Fishing for atmospheric electricity
[Static Electricity]
haversin
April 01, 2020, 07:42:47 PM
post Re: Homemade HV transformer
[Transformer (Ferrite Core)]
John123
April 01, 2020, 07:39:48 PM
post Re: Fishing for atmospheric electricity
[Static Electricity]
John123
April 01, 2020, 06:07:44 PM
post Photographing/filming high voltage arcs
[DSLR]
John123
April 01, 2020, 05:17:04 PM
post Power MOSFETs with fast recovery body diodes
[Electronic Circuits]
John123
April 01, 2020, 02:01:30 PM
post Re: Pt100 oddities
[Electronic Circuits]
kamelryttarn
April 01, 2020, 01:38:47 PM
post Re: Pt100 oddities
[Electronic Circuits]
T3sl4co1l
April 01, 2020, 12:49:21 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
John123
April 01, 2020, 10:29:06 AM
post Pt100 oddities
[Electronic Circuits]
kamelryttarn
April 01, 2020, 09:48:37 AM
post Re: Class E SSTC Topology
[Solid State Tesla Coils (SSTC)]
Weston
April 01, 2020, 07:01:51 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ritaismyconscience
April 01, 2020, 04:15:41 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
April 01, 2020, 04:05:20 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ritaismyconscience
April 01, 2020, 01:51:05 AM
post Re: A few (stupidly basic) questions
[Beginners]
davekni
April 01, 2020, 01:32:54 AM
post Re: Class E SSTC Topology
[Solid State Tesla Coils (SSTC)]
ZakW
March 31, 2020, 11:03:36 PM
post Re: Class E SSTC Topology
[Solid State Tesla Coils (SSTC)]
Weston
March 31, 2020, 10:13:13 PM
post Class E SSTC Topology
[Solid State Tesla Coils (SSTC)]
ZakW
March 31, 2020, 09:15:23 PM
post Re: Homemade HV transformer
[Transformer (Ferrite Core)]
AlexanderHun
March 31, 2020, 12:05:40 PM
post Re: A few (stupidly basic) questions
[Beginners]
Mads Barnkob
March 31, 2020, 08:54:35 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
March 31, 2020, 04:58:16 AM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
davekni
March 31, 2020, 04:44:05 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ritaismyconscience
March 31, 2020, 01:33:16 AM
post Fishing for atmospheric electricity
[Static Electricity]
haversin
March 31, 2020, 12:48:56 AM
post Re: Corona lockdown thread, tell about your situation
[General Chat]
Mads Barnkob
March 30, 2020, 08:08:54 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
John123
March 30, 2020, 07:20:08 PM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
March 30, 2020, 06:46:02 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
davekni
March 30, 2020, 06:35:13 PM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Mads Barnkob
March 30, 2020, 05:00:11 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
John123
March 30, 2020, 04:30:55 PM
post Re: TVS diode selection for 400v transistor
[Electronic Circuits]
SteveN87
March 30, 2020, 01:16:47 PM
post Re: Conical pulse skip DRSSTC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Acid Byte
March 30, 2020, 07:23:21 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ritaismyconscience
March 30, 2020, 06:13:52 AM
post Re: A few (stupidly basic) questions
[Beginners]
MRMILSTAR
March 30, 2020, 05:31:27 AM
post Re: synchronous motors up for bid
[General Chat]
klugesmith
March 30, 2020, 02:55:41 AM
post Re: A few (stupidly basic) questions
[Beginners]
davekni
March 30, 2020, 02:23:23 AM
post Re: Skm100 coil
[Dual Resonant Solid State Tesla coils (DRSSTC)]
oneKone
March 30, 2020, 02:22:33 AM
post Re: GDT keeps on killing IGBTs
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
March 30, 2020, 02:10:26 AM

Sitemap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 
SimplePortal 2.3.6 © 2008-2014, SimplePortal