Texas Instruments UCD3138PFCEVM-026 User manual

Using the UCD3138PFCEVM-026
User's Guide
Literature Number: SLUU885B
March 2012–Revised July 2012

www.ti.com
WARNING
Always follow TI’s set-up and application instructions, including use of all interface components within their
recommended electrical rated voltage and power limits. Always use electrical safety precautions to help
ensure your personal safety and the safety of those working around you. Contact TI’s Product Information
Center http://support/ti./com for further information.
Save all warnings and instructions for future reference.
Failure to follow warnings and instructions may result in personal injury, property damage, or
death due to electrical shock and/or burn hazards.
The term TI HV EVM refers to an electronic device typically provided as an open framed, unenclosed
printed circuit board assembly. It is intended strictly for use in development laboratory environments,
solely for qualified professional users having training, expertise, and knowledge of electrical safety risks in
development and application of high-voltage electrical circuits. Any other use and/or application are strictly
prohibited by Texas Instruments. If you are not suitably qualified, you should immediately stop from further
use of the HV EVM.
1. Work Area Safety:
(a) Keep work area clean and orderly.
(b) Qualified observer(s) must be present anytime circuits are energized.
(c) Effective barriers and signage must be present in the area where the TI HV EVM and its interface
electronics are energized, indicating operation of accessible high voltages may be present, for the
purpose of protecting inadvertent access.
(d) All interface circuits, power supplies, evaluation modules, instruments, meters, scopes and other
related apparatus used in a development environment exceeding 50 VRMS/75 VDC must be
electrically located within a protected Emergency Power Off (EPO) protected power strip.
(e) Use a stable and non-conductive work surface.
(f) Use adequately insulated clamps and wires to attach measurement probes and instruments. No
freehand testing whenever possible.
2. Electrical Safety:
(a) De-energize the TI HV EVM and all its inputs, outputs, and electrical loads before performing any
electrical or other diagnostic measurements. Revalidate that TI HV EVM power has been safely de-
energized.
(b) With the EVM confirmed de-energized, proceed with required electrical circuit configurations, wiring,
measurement equipment hook-ups and other application needs, while still assuming the EVM circuit
and measuring instruments are electrically live.
(c) Once EVM readiness is complete, energize the EVM as intended.
WARNING: while the EVM is energized, never touch the EVM or its electrical circuits as they
could be at high voltages capable of causing electrical shock hazard.
3. Personal Safety:
(a) Wear personal protective equipment e.g. latex gloves and/or safety glasses with side shields or
protect EVM in an adequate lucent plastic box with interlocks from accidental touch.
4. Limitation for Safe Use:
(a) EVMs are not to be used as all or part of a production unit.
2SLUU885B–March 2012–Revised July 2012
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User's Guide
SLUU885B–March 2012–Revised July 2012
Digitally Controlled Single-Phase PFC Pre-Regulator
1 Introduction
This EVM is to help evaluate the UCD3138 64-pin digital control device in off-line power converter
application and then to aid its design. The EVM is a standalone Power Factor Correction (PFC) pre-
regulator of single-phase AC input. The EVM UCD3138PFCEVM-026 is used together with its control
card, UCD3138CC64EVM-030, also an EVM on which is placed UCD3138RGC.
The EVM of UCD3138PFCEVM-026 together with UCD3138CC64EVM-030 can be used as they are
delivered without additional work, from either hardware or firmware, to evaluate PFC. The
UCD3138PFCEVM-026 together with the UCD3138CC64EVM-030 can also be re-tuned on its design
parameters through the operation of GUI, called Texas Instruments Fusion Digital Power Designer, or re-
loaded up with custom firmware with user’s definition and development.
The EVM system is in topology of single-phase boost converter at its delivery on both hardware and
firmware, but can be re-configured into two other PFC topologies: dual-phase interleaved, and bridgeless,
then corresponding operation can be made by reloading with that associated firmware. All necessity of
hardware and firmware for the two additional topologies are already developed and delivered with the
shipment. Please contact Texas Instruments to obtain the instructions how to make re-configuration.
In the package delivered, three EVMs are included UCD3138PFCEVM-026, UCD3138CC64EVM-030, and
USB-TO-GPIO. In the same package, also included is a hard copy of Evaluation Module Electrical Safety
Guideline.
This user’s guide provides basic evaluation instruction from a viewpoint of system operation in standalone
PFC in its boost configuration.
3
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Description www.ti.com
2 Description
UCD3138PFCEVM-026 together with UCD3138CC64EVM-030 is an EVM of PFC pre-regulator with digital
control using UCD3138 device in boost converter topology and in the application of single-phase AC input.
UCD3138 device is located on the board of UCD3138CC64EVM-030. UCD3138CC64EVM-030 is a
daughter card and serves all PFC required control functions with preloaded single-phase boost PFC
firmware. UCD3138PFCEVM-026 accepts universal AC line input from 90 VAC to 264 VAC, and outputs
nominal 390 VDC with full load output power 360 W, or full output current 0.92 A.
2.1 Typical Applications
• Single-Phase Universal AC Line Power Factor Correction Pre-Regulator
• Servers
• Telecommunication Systems
2.2 Features
• Digitally Controlled PFC Pre-Regulator
• Universal AC Line Input from 90 VAC to 264 VAC with AC Line Frequency 47 Hz to 63 Hz
• Regulated Output 390 VDC with Output from No-Load to Full-Load
• Full-Load Power 360 W, or full-Load Current 0.92 A
• High Power Factor Close to 0.999 and Low THD Below 5% in Most Operation Conditions
• High Efficiency
• Protection:
– Over Voltage
– Over Current
– Brownout
– Power-On Inrush Current
• Test Points to Facilitate Device and Topology Evaluation
• Re-Configurable to Dual-Phase Interleaved PFC or Bridgeless PFC (please contact TI for detail)
4Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012
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www.ti.com Electrical Performance Specifications
3 Electrical Performance Specifications
Table 1. UCD3138PFCEVM-026 Electrical Performance Specifications
PARAMETER TEST CONDITIONS MIN TYP MAX UNITS
Input Characteristics
Voltage range 90 264 VAC
Line frequency 47 63 Hz
Input current, peak Input = 90 VAC, 60 Hz, full load = 0.92 A 6.5 7.0 A
Input current, RMS Input = 90 VAC, 60 Hz, full load = 0.92 A 4.5 5.5
Input UVLO On PFC function start (no load) 86 90 VAC
Input UVLO Off PFC function stop (no load) 80 83
Power factor Half load 0.99 -
THD, input current 10% to 30% full load 10%
30% to 100% full load 5%
Output Characteristics
Output voltage, VOUT No load to full load 390 VDC
Output load current, IOUT 90 VAC to 264 VAC 0.92 A
Output voltage ripple Full load and 115 VAC, 60 Hz 13 Vpp
Full load and 230 VAC, 50 Hz 15
Output over current 0.95 A
Systems Characteristics
Switching frequency Normal operation 100 kHz
Peak efficiency 230 VAC, full load 96%
Full load efficiency 115 VAC, full load 94%
Operating temperature Natural convection 25 ºC
5
SLUU885B–March 2012–Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator
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DPWM_3B
FAULT_0
SCI_TX1
PWM-1
SCI_RX0
GND_Ext
FAULT_1
SYNC
SCI_RX1
PWM-0
SCI_TX0
3.3V
Ext Supply
AD_01
AD_02
AD_05 AD_07
AD_08
EADC_P2
EADC_P1
When U11 not installed, connect J14-1 and -3 to external source to get +12V_EXT
Vin = 90 to 264 Vac (47 to 63Hz)
Copper fill for heat-sink
AD_00 AD_03
AD_04
AD_06
EADC_P0
Isolated GND
OPTO Isolated Section
Isolated GND
R31 and R106 are preload resistors
If needed, connect J15-1 and -2 to use U11 to bias secondary side
External sync signal
Bridgeless PFC with CT_1 and CT_2 and Interleaved PFC with ISENSE_SHUNT.
Parts not used
AD_13
3
1
4
2
12
12
1
1
11
1
1
1
1
1
AGND
DGND
1
AC_Line
AC_Neutral
if use VAUX_P but not use VAUX_S
Secondary side
Isolation line
Fuse: T7A/250VAC
(J3-13)
(J3-25) (J3-26)
(J4-18)
(J4-20)
(J3-11)
(J3-8)
Secondary side
Secondary side
1
TP8
TP9
TP12
TP13
TP10
1
2
J7
R31
1.5k
C5
4.7nF
R19 4.7k
+C1
10uF
TP11
C3
47nF
D18
C37
0.47uF
D21
TP4
R14
3.83k
R13 200k
R27
200k
D20
C20
1nF
R16
3.83k
R29
200k
R15
200k
TP3
1
2
3
4
5
K1
R68
C25
R24 R78
1.1k
TP2 TP1
1
2
3
J10
F2
R20 4.7k
+
C21 10uF
R28
200k
R3 50
C17
R1
C8
0.1uF
C13
0.1uF
C27
0.1uF
R79
100
R36 R34
R72
1.5k
J11
R21 4.7k
Q8
MMBT3904TT1
D19
LN1371GTR
D24 MBR0530
C12
1nF
TP7
C2
47nF
C38
0.47uF
Q6
MMBT3904TT1
D6 BAT54S
TP14
R30
200k
R22
4.7k
C15
0.1uF
R35 0
R33 0
L5
2mH
J2
J1
3IN
1ADJ/GND 2
OUT
4
OUT
U7
TLV1117-33IDCY
L4
7.80uH
L3
7.80uH
C29
D5
1N4148W
C28
0.1uF
1
23
4
U9
SFH6156-2
C9 0.1uF
C14
0.1uF
1EN 2C1+
3V+
4C1-
5C2+
6C2-
7V-
8R1IN 9
R1OUT
10
INVALID
11
T1IN
12
FORCEON
13
T1OUT
14
GND
15
VCC
16
FORCEOFF
U2
SN75C3221DBR
1
2
3
4
5 6
7
8
9
10
11
J9
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
31
32
33
34
35
36
37
38
39
40
J3
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
31
32
33
34
35
36
37
38
39
40
J4
1VCC1
2OUTA
3INB
4GND1 5
GND2
6
OUTB
7
INA
8
VCC2
U8
ISO7221CD
Q7
MMBT3904TT1
D25
BAT54S
C6
4.7nF
1
2
3
4
5
6
J8
Q1
2N7002
Q4
2N7002
1VIN+
2VAUX_P
3-VAUX_-VIN 4-VIN
5
GND
6
VIN_MONITOR
7
VAUX_S
DB-1
PWR050
SH2
R23
3.3k
TP5
C30
330pF
R42 1k
R8
1k
R82
1k R81
1k
R80
1k
R32 0
R49 0
R77 0
R76 0
R75 0
R37 10k
R38 10k
R70
10k
R74
10k
R73
10k
1
1
1
1
1
1
1
1
1
SYNC_IN
LED_3
+12V_EXT
DPWM-1B
SCI_RX0
+3_3V
+3_3V
ISO_SCI_TX
ISO_SCI_RX
VAUX_P
+3_3V
DPWM-2B
+3_3V
+3_3V V33D_ISO
V33D_ISO
VAUX_S_RTN
1
VAUX_S
+12V_EXT
+12V_EXT
VAUX_S
VAUX_S_RTN
LED_1
AC_DROP
RLY_CTRL
LED_1
SCI_TX1
SCI_RX1
LED_3
+3_3V
DPWM-0A
DPWM-2A
DPWM-3A
SCI_TX0
IIN_SENSE
VBUS_OV
AC_N
SCI_TX1
SCI_RX1
CT_1
ISENSE_SHUNT
SCI_RX0
VAUX_P_RTN
VAUX_P
VAUX_S
LED_2
SYNC_IN
LED_2
DPWM-1A
RLY_CTRL
AC_L
+12V_EXT
CT_1
AC_L
CT_2
AC_DROP
V33D_ISO
SCI_TX0
AC_NEU_PFC
AC_L_PFC
+12V_EXT
3
3
3
1
IPM
VBUS_SENSE
CT_2
BUS+
VAUX_P
VAUX_P_RTN
2
2
2
VAUX_S_RTN
1
1
AC_N
1
1
GND_EARTH
GND_EARTH
1
1
Schematics www.ti.com
4 Schematics
Figure 1. UCD3138PFCEVM-026 Schematic
6Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012
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Interleaved PFC: Jump across E6 and E4, and E1 and E5.
PGND
Bridgeless PFC: Jump across E2 and E6, and E3 and E1.
Vbus = 390VDC, Iout = 0.92A
DGND
31
31
1
1
1
1
1
1
Parts not used
1
1
Single-phase PFC: default connection E6 to E4.
1
1
1
1
1 1
(J4-40)
(J3-15)
(J3-7)
+
-
Vbus
(J4-10)
(J4-16)
(J4-30)
(J3-3)
(J3-4)
(J3-5)
(J3-6)
(J4-12)
(J4-8)
(J4-6)
TP23
TP22
TP24
TP20
C18
0.1uF TP16
R71 910
SH1
R60
49.9k
TP21
E3 E2
R48
1.8k
C7 4.7nF
E4 E5
E1
E6
C32
150pF
R44 0
R43
R66
15
TP19
R64 10k
R55
5.23
TP26
D3
BAT54S
D14
C3D10060G
D13
C3D10060G
R50
1.8k
C24
0.1uF
TP17
C40
47nF
C19
0.1uF
R9
100k
TP15
R10
100k
J6
+C34
220uF
R4
5.01k
C23
0.1uF
TP6
R40
C26
1uF
TP25
HS3
C39
47nF
R47
1.8k
R25
100k
D4
BAT54S
R69
1.6k
C36
100pF
R39 2k
C16
0.01uF
R6 0.02 R7 0.02
C22
47nF
TP18
R18
100k
R17
100k
R11
100k
D2
BAT54S
R45 100
D7
MURS160T3
R63
15
D15
BAT54S
R53
5.23
D22 BAT54S
D11
MBR0530
L1
327uH
C33
47nF
R46
100k
R67
100k
R59 49.9k
U3
OPA350EA
D8
BAT54C
R2
3.3M
R58 2k
D23 BAT54S
R12
100k
D16 6A6-T
1N/C
2INA
3GND
4INB 5
OUTB
6
VDD
7
OUTA
8
N/C
U4
UCC27324D
R65 10k
HS2
Q2
IPP60R199CP
8
7
3
1
T2
PA1005.050
+
C31
47uF
L2
327uH
Q3
IPP60R199CP
8
7
3
1
T1
PA1005.050
R26
100k
R51
100k
R62
100k
C41
47nF
D1
BAT54S
C35 100pF
D12
MBR0530
2
3
6
4
7
U1
OPA350EA
Q5
2N7002
D17
GBU8J
C4
0.1uF
VDD
GND
IN+ IN-
OUT
U5
VDD
GND
IN+ IN-
OUT
U6
C10 C11
D9
ZHCS506
D10 ZHCS506
J5
HS1
12
JMP1
R61
1k
R5
1k
R54
0
R41 0
R52
0
R56
10k
R57
10k
1
1
AC_L_PFC
+3_3V
IIN_SENSE
IPM
DPWM-3A
SYNC_IN
+3_3V
CT_2
DPWM-1B
DPWM-1A
CT_1
SWITCH_NODE
+3_3V
AC_NEU_PFC
+3_3V
DPWM-2A
DPWM-2B
+3_3V
+3_3V
+3_3V
SWITCH_NODE
+3_3V
VBUS_SENSE
ISENSE_SHUNT
+12V_EXT
VBUS_OV
+12V_EXT
+12V_EXT
2
2
2
2
2
22
2
2
2
GND_EARTH
BUS+
1
1
www.ti.com Schematics
Figure 2. UCD3138PFCEVM-026 Schematic
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Electronic
Load
VM1
+
AC Source
J6 J5
TP17 TP22
J1 J2
LN
Test Setup www.ti.com
5 Test Setup
5.1 Test Equipment
AC Voltage Source:capable of single-phase output AC voltage 85 VAC to 265 VAC, 47 Hz to 63 Hz,
adjustable, with minimum power rating 400 W, the AC voltage source to be used should meet IEC60950
reinforced insulation requirement.
DC Multimeter: capable of 0-V to 500-V input range, four digits display preferred.
Output Load: DC load capable of 400 VDC or greater, 1 A or greater, and 400 W or greater, with display
such as load current and load power.
Oscilloscope: capable of 500-MHz full bandwidth, digital or analog, if digital 5 Gs/s or better.
Current probe: capable of 0 A to 10 A, 100-MHz or greater full bandwidth, AC coupling.
Fan: 200 LFM to 400 LFM forced air cooling is recommended, but not a must.
Recommended Wire Gauge: capable of 4-A RMS, or better than #16 AWG, with the total length of wire
less than 8 feet (4 feet input and 4 feet return).
5.2 Recommended Test Setup
Figure 3. UCD3138PFCEVM-026 Recommended Test Setup
8Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012
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UCD3138CC64EVM-030
www.ti.com Test Setup
Figure 4. EVM Orientation of UCD3138PFCEVM-030 on the UCD3138PFCEVM-026
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List of Test Points www.ti.com
6 List of Test Points
Table 2. List of Test Points
TEST POINTS NAME DESCRIPTION
TP1 T1OUT UART0 (J9-2) T1OUT
TP2 R1IN UART0 (J9-3) R1IN
TP3 DGND Digital GND of J3 connection
TP4 +3_3V 3.3-V LDO output on board from 12 V
TP5 RC-PWM-0A DPWM0A RC filter
TP6 CT_2 Second phase current sensing signal
TP7 AC_N Input voltage sensing signal of Neutral wire
TP8 DGND Digital GND and same as TP3
TP9 VAUX_S Secondary side 12 V on board. Not used, but can be used for external circuit.
TP10 VAUX_P 12-V output on board from DB-1, UCC28600EVM400V-12V
TP11 +12V_EXT 12 V on board from VAUX_P
TP12 K1 Relay K1 coil
TP14 AC_L Input sensing signal of Line wire
TP15 VBUS_SENSE PFC output voltage sensing signal
TP16 GND Analog GND
TP17 BUS- PFC output return
TP18 REC-1 Rectifier positive output
TP19 CT-1 Current sensing signal from current transformer T1
TP20 ISENSE Current sensing signal after conditioning
TP21 REC-2 Rectifier return
TP22 BUS+ PFC output positive, nominal 390VDC
TP23 SW2 Q2 Drain pin
TP24 SW1 Q3 Drain pin
TP25 Q2-Gate Gate pin of Q2 MOSFET
TP26 Q3-Gate Gate pin of Q3 MOSFET
7 List of Terminals
Table 3. List of Terminals
TERMINAL NAME DESCRIPTION
J1 Line Board AC input line, single-pin connection – screw type, J1 and J2 are AC input terminals,
rated up to 264 VAC and maximum 7.5 A, 47 Hz to 63 Hz.
J2 Neutral Board AC input neutral, single-pin connection – screw type
J3 DJ Digital signal connection, 40 pins
J4 AJ Analog signal connection, 40 pins
J5 BUS+ PFC output positive connection, single-pin connection – screw type, BUS+ and BUS- are DC
output terminals, rated maximum 400 VDC, and maximum current 1 A.
J6 BUS- PFC output return, single-pin connection – screw type
J7 12V_Sec 12-V auxiliary to supply to external circuit on the secondary side, 2 pins
J8 UART1 Isolated and communication to DC converter, not production tested, 6 pins
J9 UART0 Non-isolated connection, standard RS232, 9 pins,
J10 Sync External 12-V bias and sync signal, 3 pins
J11 Chassis Chassis ground, or earth connection, single-pin connection – screw type
10 Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012
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