Towards a 99% Efficient Three-Phase Buck-Type PFC Rectifier for 400-V DC Distribution Systems

In telecom applications, the vision for a total power conversion efficiency from the mains to the output of point-of-load (PoL) converters of 95% demands optimization of every conversion step, i.e., the power factor correction (PFC) rectifier front-end should show an outstanding efficiency in the range of 99%. For recently discussed 400-V dc distribution bus voltages, a buck-type PFC rectifier is a logical solution. In this paper, an efficiency-optimized, 98.8% efficient, 5-kW three-phase buck-type PFC rectifier with 400-V output is presented. Methods for calculating losses of all components are described and are used to optimize the converter design for efficiency at full load. Special attention is paid to semiconductor losses, which are shown to be dominant, with the parasitic device capacitance losses being a significant component. The calculation of these parasitic capacitance losses is treated in detail, and the charge-balance approach used is verified. A prototype of the proposed rectifier is constructed which verifies the accuracy of the models used for loss calculation and optimization.