Texas Instruments UCC28600 User manual

UCC28600 120-W Evaluation Module
User's Guide
October 2006 Power Supply MAN
SLUU256A

UCC28600 120-W Evaluation Module
User's Guide
Literature Number: SLUU256AAugust 2006 – Revised October 2006

1 Description
1.1 Applications
User's GuideSLUU256A – August 2006 – Revised October 2006
UCC28600 120-W Evaluation Module
The UCC28600 evaluation module (EVM) is a 120-W off-line quasi-resonant flybackconverter providing a 19.4-V regulated output at 6.2 A of load current, operating from auniversal ac input. The front-end power factor correction (PFC) stage is controlled bythe UCC28051 and accommodates an input line voltage range of 85 VRMS to 265VRMS and is designed to meet EIC61000-3-2 harmonic emissions requirements. Themodule uses the UCC28600 Quasi-Resonant Flyback Green-Mode Controller whichintegrates built-in state of the art energy saving features with high level protectionfeatures to provide cost effective solutions for energy efficient power supplies.
The UCC28600EVM highlights the many benefits of using the UCC28600 Quasi-Resonant FlybackGreen-Mode Controller. Low system parts count and multifunction pins in this green-mode controllerprovide a cost-effective solution while meeting stringent world-wide energy efficiency requirements. Lowvoltage switching reduces switching losses and improves efficiency. Green-mode and frequency-foldbackmode operation reduces the operating frequency at light loads and no-load operation. A dedicatedSTATUS pin is used to disable the PFC controller when the converter has entered standby.
This user’s guide provides the schematic, component list, assembly drawing for a single-sided PCBapplication, artwork, and test set up necessary to evaluate the UCC28600 in a typical off-line converterapplication.
The UCC28600 is suited for use in isolated off-line systems requiring high-efficiency and advanced faultprotection features including:•Bias supplies for LCD monitors, LCD TV, PDP TV, and set top boxes•AC/DC adapters•Offline battery chargers•Energy efficient power supplies up to 200 W
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1.2 Features
Description
The UCC28600EVM features include:•120-W, 19.4-V output•Universal off-line input voltage range•Power factor correction controlled by the UCC28051•Multi-mode operation•Current-mode control– Cycle-by-cycle power limit•Programmable over voltage protection•Internal over temperature protection•Less than 500-mW input power during standby•Programmable soft start•PFC disable using the STATUS pin of the UCC28600•Regulation down to zero output current•Single-sided board layout
CAUTION
High voltage levels are present on the evaluation module whenever it isenergized. Proper precautions must be taken when working with the EVM. Thelarge bulk capacitor across the +DC IN and -DC IN terminals, and the outputcapacitor bank must be completely discharged before the EVM can be handled.Serious injury can occur if proper safety precautions are not followed.
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2 UCC28600EVM Electrical Performance Specification
UCC28600EVM Electrical Performance Specification
Table 1. UCC28600EVM Performance Summary
PARAMETERS TEST CONDITION MIN TYP MAX UNITS
Input Characteristics
Input voltage range V
IN
85 265 V
RMS
Maximum input V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 1.3
A
RMScurrent
V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 0.7Input power factor V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 0.998correction
V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 0.972
Output Characteristics
Output voltage 85 V
RMS
≤V
IN
≤265 V
RMS
, 0 A ≤I
OUT
≤6.2 A 19.0 19.4 19.8 VOutput load current 85 V
RMS
≤V
IN
≤265 V
RMS
0 6.2 ALine regulation 85 V
RMS
≤V
IN
≤265 V
RMS
, I
OUT
= 3 A 3Load regulation 0 A ≤I
OUT
≤6.2 A, V
IN
= 115 V
RMS
15 mV0 A ≤I
OUT
≤6.2 A, V
IN
= 230 V
RMS
15Output voltage ripple V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 190V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 190
mV
pk=pkOutput voltage noise V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 190V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 190Output over voltage V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 23.4
Vlimit
V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 23.6
Control Loop Characteristics
Control loop V
IN
= 115 V
RMS
, I
OUT
= 3 A
2.6 kHzbandwidth
Phase margin 70 degrees( °)
Efficiency
Peak efficiency V
IN
= 265 V
RMS
, I
OUT
= 6 A 87.4%Full load efficiency V
IN
= 115 V
RMS
, I
OUT
= 6.2 A 82.7%V
IN
= 230 V
RMS
, I
OUT
= 6.2 A 86.4%No load power V
IN
= 115 V
RMS
, I
OUT
= 0 A 230
mWconsumption
V
IN
= 230 V
RMS
, I
OUT
= 0 A 420
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3 Schematic
Schematic
A schematic of the UCC28600EVM is shown in Figures 1 and 2. Terminal block J1 is the ac input voltagesource connector, J2 is the 19.4-V output, and J3 is the output voltage return. The +DC IN and –DC INconnectors are used to monitor the PFC output voltage or can be used to supply a dc input voltage whenthe PFC stage is disabled.
Figure 1 shows the PFC controller, the UCC28051, with all the discrete circuitry for configuring the powerfactor correction at the universal line input range. The bias to the UCC28051 controller is provided by theauxiliary winding of the quasi-resonant flyback inductor and controlled by the STATUS output of theUCC28600 controller. During light load operation, the bias to the PFC controller is removed, enabling theconverter to operate at high efficiencies.
Figure 2 shows the green-mode controller, the UCC28600, with all the discrete circuitry for configuring theisolated quasi-resonant flyback converter using the PFC output voltage as its input. The auxiliary windingprovides the bias to the controllers and provides over voltage protection and valley switching information,as well as bias to the UCC28600 and UCC28051. The series resistor connected between the currentsense pin and the current sense resistor programs the power limit of the converter. The seriescombination of R41 and D18 adds an offset voltage to the current sense signal that effectively reducesaudible noise during standby operation by limiting the current in the transformer during operation in theaudible frequency range.
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4A Fuse
F1
+
Schematic
Figure 1. PFC Portion of the UCC28600EVM
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+
+
+ +
+
Schematic
Figure 2. Quasi-Resonant Flyback Portion of the UCC28600EVM
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4 EVM Test Setup
AC SOURCE
POWER METER DMM 1VOUT
DMM 2IOUT
Electronic Load
++++++ −
−
−
−
−
−
−
+
DMM3
VBULK
+ −
Ripple Scope
AHIAEXT ALO
VHI VLO
FAN
EVM Test Setup
Figure 3 shows the basic test set up recommended to evaluate the UCC28600EVM with a load. Figure 4shows the equipment set up when measuring the input power consumption when the EVM is in standbymode. Note the addition of the 10- Ωshunt in Figure 4. The power analyzer should also be set for longaveraging in order to include several cycles of operation and an appropriate current scale factor for usingthe external shunt must be used.
Figure 3. Recommended HPA126 EVM Test Configuration for Operation with a Load.
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AC SOURCE
POWER METER DMM 1
VOUT
+ + ++ −
−
−−
−
+
DMM3VBULK
+ −
AHI AEXT
ALO
VHI VLO
FAN
10
EVM Test Setup
Figure 4. Equipment Set Up for HPA126 Evaluation During No-Load.
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4.1 Power Meter
4.2 AC Input Source
4.3 Digital Multimeters
4.4 Output Load
4.5 Recommended Wire Gauge
4.6 Fan
EVM Test Setup
The power analyzer shall be capable of measuring low input current, typically less than 10 mA, and a longaveraging mode if low power standby mode input power measurements are to be taken. An example ofsuch an analyzer is the Voltech PM100 Single Phase Power Analyzer. To measure the intermittent burstsof current and power drawn from the line during no-load operation, an external 10- Ωshunt, with a currentscale factor of 10 V/A, was used at a high sample rate over an extended period of time in order to displaythe averaged results (refer to Figure 4).
The input source shall be a variable ac source capable of supplying between 85 V
RMS
and 265 V
RMS
at noless than 5-A peak and connected to the AC LINE IN terminal on the EVM, as shown in Figure 2. Foraccurate efficiency calculations, a power meter should be inserted between the neutral line of the acsource and the NEUTRAL terminal of the EVM. For highest accuracy, connect the voltage terminals of thepower meter directly across the AC LINE IN and NEUTRAL terminals.
Digital multimeters are used to measure the bulk dc voltage into the quasi-resonant converter stage(DMM
3
), the output load current (DMM
2
), and the regulated output voltage (DMM
1
).
For the output load, a programmable electronic load set to constant current mode and capable of sinking 0to 7 A
DC
at 20 V
DC
shall be used. For highest accuracy, V
OUT
can be monitored by connecting a dcvoltmeter, DMM
1
, directly across the VOUT and VOUT RTN test points as shown in Figure 2. A dc currentmeter, DMM
2
, should be placed in series with the electronic load for accurate output currentmeasurements.
The connection between the source voltage and the EVM input terminals can carry as much as 2 A peak.The minimum recommended wire size is AWG #20 with the total length of wire less than 8 feet (4 feetinput, 4 feet return). The connection between the EVM output terminals and the load can carry as much as6.2 A. The minimum recommended wire size is AWG #16, with the total length of wire less than 8 feet (4feet output, 4 feet return).
Because this evaluation module is not enclosed, allowing probing of circuit nodes, a small fan capable of200 LFM to 400 LFM should be used to reduce component temperatures when operating at or above 50%maximum rated load current.
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5 Power-Up/Power-Down Procedure
Power-Up/Power-Down Procedure
The following test procedure is recommended primarily for power up and shutting down the evaluationmodule. The fan should be turned on whenever the EVM is running. Also, never leave a powered EVMunattended for any length of time.1. Working at an ESD workstation, make sure that an ionizer is on before the EVM is removed from theprotective packaging and power is applied to the EVM. Electrostatic smock and safety glasses shouldalso be worn. Because voltages in excess of 400 V may be present on the EVM, do not connect theground strap from the smock to the bench.2. Power Upa. Prior to connecting the ac input source, it is advisable to limit the source current to 5 A maximum.Make sure the ac source is initially set between 85 V
RMS
and 265 V
RMS
prior to turning on. Connectthe ac source to the AC LINE IN and NEUTRAL terminals of the EVM as shown in Figure 3.b. Connect the voltage terminals of the power analyzer across AC LINE IN and NEUTRAL as shownin Figures 3 and 4.c. Connect the current meter terminals of the power analyzer in series with the NEUTRAL line asshown in Figure 3.a. If no-load input power measurements are to be made, set the power analyzer to long averagingand external shunt mode. Insert a shunt, such as a 10- Ωresistor as shown in Figure 4, in serieswith the NEUTRAL terminal of the EVM. Set the appropriate current scale on the poweranalyzer.
d. Connect DMM
1
across VOUT and VOUT RTN as shown in Figures 3 and 4.e. For operation with a load, connect the positive terminal of the LOAD to the VOUT terminal of theEVM and the negative terminal of the LOAD to the VOUT RTN terminal of the EVM, as shown inFigure 3. Connect DMM
2
in series with the negative terminal as shown in Figure 3. Set the LOAD toconstant current mode to sink 0 A.f. Connect DMM
3
across +DC IN and – DC IN as shown in Figures 3 and 4.g. Make sure the output capacitor bank is completely discharged prior to power up.h. Turn on the ac source and observe that the output is regulating to 19.4 V.i. Increase load from 0 A up to 6.2 A.3. Power Downa. Turn off ac source.b. Discharge the output capacitor bank.c. Turn off the load.
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6 UCC28600EVM Performance Data and Characteristic Curves
5 V/div.
t − Time − 5.0 ms/div.
VOUT(os) = 1.1 V at IOUT = 6.2 A
5 V/div.
t − Time − 5.0 ms/div.
VOUT(os) = 1.1 V at IOUT = 6.2 A
t − Time − 2.0 ms/div.
200 mV/div.
200 mV/div.
t − Time − 2.0 ms/div.
UCC28600EVM Performance Data and Characteristic Curves
V
OUT
Start-Up Overshoot. V
IN
= 115 V
RMS
, I
OUT
= 6.2 A V
OUT
Start-Up Overshoot. V
IN
= 230 V
RMS
, I
OUT
= 6.2 A
Figure 5. Figure 6.Output Load Transient, 10% to 90% Load Step Output Load Transient, 10% to 90% Load StepChange, V
IN
= 115 V
RMS
Change, V
IN
= 230 V
RMS
Figure 7. Figure 8.
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20 mV/div.
t − Time − 200 ms/div.
20 mV/div.
t − Time − 200 ms/div.
50 mV/div.
t − Time − 5.0 µs/div.
20 mV/div.
t − Time − 5.0 ms/div.
UCC28600EVM Performance Data and Characteristic Curves
Output Voltage Ripple and Noise, Green Mode, V
IN
= Output Voltage Ripple and Noise, V
IN
= 115 V
RMS
, I
OUT230 V
RMS
, I
OUT
= 0.5 A = 0.5 A
Figure 9. Figure 10.Output Voltage Ripple and Noise, V
IN
= 230 V
RMS
, I
OUT= 6.2 A No Load Output Voltage Ripple, V
IN
= 230 V
RMS
Figure 11. Figure 12.
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20 mV/div.
t − Time − 5.0 ms/div.
Drain
CH1: 200 V/div.
Gate
CH2: 10 V/div.
FB
CH3: 1.0 V/div.
CS
CH4: 500 mV/div.
t − Time − 25 µs/div.
Drain
CH1: 200 V/div.
Gate
CH2:10 V/div.
FB
CH3: 5.0 V/div.
CS
CH4:1.0 V/div.
t − Time − 2.5 µs/div.
Drain
CH1: 200 V/div.
Gate
CH2: 10 V/div.
FB
CH3: 1.0 V/div.
CS
CH4: 500 mV/div.
t − Time − 200 µs/div.
UCC28600EVM Performance Data and Characteristic Curves
Green Mode, Burst Pulses at 40 kHz, V
IN
= 115 V
RMS
,No Load Output Voltage Ripple, V
IN
= 115 V
RMS
I
OUT
= 0.2 A
Figure 13. Figure 14.Green Mode Showing Frequency of Burst Packets Frequency Foldback Mode, Switching Frequency =Equal to 900 Hz , V
IN
= 115 V
RMS
, I
OUT
= 0.2 A 115 kHz, V
IN
= 115 V
RMS
, I
OUT
= 1.6 A
Figure 15. Figure 16.
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Drain
CH1: 200 V/div.
Gate
CH2: 10 V/div.
FB
CH3: 5.0 mV/div.
CS
CH4: 1.0 V/div.
t − Time − 2.5 µs/div.
Drain
CH1:
200V/div.
Gate
CH2: 10V/div.
FB
CH3: 5 V/div.
CS
CH4: 1.0 V/div.
t − Time − 2.5 µs/div.
−20
0
10
30
−15
−5
5
20
25
1E + 02 1E + 041E + 03
−10
15
Gain
Phase
−80
0
40
120
−60
−20
20
80
100
−40
60
PHASE/GAIN
vs.
FREQUENCY
f− Frequency − Hz
Gain − dB
Phase − O
0.0
10
15
25
20
0.0 122 104 6 8
5
OUTPUT VOLTAGE
vs.
OUTPUT CURRENT
IOUT − Output Current − A
VOUT − Output Voltage − V
UCC28600EVM Performance Data and Characteristic Curves
Discontinuous Current Mode, Switching Frequency = Quasi-Resonant Mode, Switching Frequency = 116130 kHz, V
IN
= 115 V
RMS
, I
OUT
= 4.6 A kHz, V
IN
= 115 V
RMS
, I
OUT
= 5.6 A
Figure 17. Figure 18.
Figure 19. Figure 20.
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EFFICIENCY
vs.
OUTPUT LOAD
IOUT − Output Load− A
Efficiency − %
0
100
20
0.5 2.5 3.51.5 4.5 5.5
40
60
80
VIN = 85 VRMS
VIN = 115 VRMS
VIN = 230 VRMS
VIN = 265 VRMS
UCC28600EVM Performance Data and Characteristic Curves
Figure 21.
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7 EVM Assembly Drawing and Layout
EVM Assembly Drawing and Layout
Figures 22 and 23 show the layout of the single-sided printed circuit board used for the evaluation module.
Figure 22. Top Layer of EVM
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R31
R32
EVM Assembly Drawing and Layout
Figure 23. Bottom Layer of EVM
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8 List of Materials
List of Materials
Table 2. Material List for EVM
(1) (2)
REF QT
DESCRIPTION MANUFACTURE PART NUMBERDESIGNATOR Y
C1 Capacitor, metal poly, 0.39 µF, 630 V, -40/+85 °C, ±10%, ST Microelectronics ECQ-E6394KF1
0.236 x 1.043C2 Capacitor, metal poly, 0.047 µF, 630 V, -40/+85 °C, ±10%, ST Microelectronics ECQ-E6473KF1
0.709 x 0.236C3, C6 2 Capacitor, ceramic, 1 nF, 50 V, X7R, ±10%, 0805 ON Semiconductor C0805C102K5RACTUC4 1 Capacitor, ceramic, 2.2 µF, 16 V, X7R, ±10%, 1206 Diodes Inc ECJ-3YB1C225KC5 1 Capacitor, ceramic, 10 nF, 50 V, X7R, ±10%, 0805 Littelfuse C0805C103K5RACTUC7 Capacitor, ceramic, 47 pF, 50 V, C0G, ±5%, 0805 Cooper Electronic C0805C470J5GACTU1
TechnologiesC8 Capacitor, ceramic, 0.1 µF, 25 V, X7R, ±10%, 0805 Cooper Electronic ECJ-2VB1E104K1
TechnologiesC9 Capacitor, aluminum electrolytic, 82 µF, 450 V
DC
, -40/+85 Coilcraft EET-ED2W820CA1
°C, ±20%, 0.984 inch Dia.C10 Capacitor, ceramic, 0.022 µF, 25 V, X7R, ±10%, 0603 Infineon ECJ-1VB1E223K1
TechnologiesC11 Capacitor, ceramic, 390 pF, 50 V, X7R, ±10%, 0603 Infineon GRM188R71H391KA01D1
TechnologiesC12 Capacitor, ceramic, 100 pF, 100 V, C0G, ±5%, 0603 infineon GRM1885C2A101JA01D1
TechnologiesC13 Capacitor, electrolytic, 10 µF, 100 V, -40/+105 °C, ±20%, Yageo America EEU-FC2A1001
0.200 inchC14 Capacitor, ceramic, 1 µF, 50 V, X7R, ±10%, 0.200 x 0.256 Yageo America B37984M5105K0001
inchC15 Capacitor, ceramic, 0.1 µF, 50 V, X7R, ±10%, 0.200 x Yageo America B37987F5104K0541
0.256 inchC16 Capacitor, ceramic disc, 1 nF, 1 kV, X5R, ±10%, 0.265 x Panasonic - ECG 562R-10TSD101
0.472 inchC17 Capacitor, polyester Film, 0.01 µF, 630 V, -40/+85 °C, Panasonic - ECG ECQ-E6103KF1
±10%, 0.472 x 0.177 inchC18 1 Capacitor, ceramic, 0.1 µF, 16 V, X7R, ±10%, 0603 Kemet C0603C104M4RACTUC19 Capacitor, ceramic disc, 4.7 nF, 250 V, -25/+85 °C, ±20%, Panasonic - ECG ECK-ANA472ME1
0.394 x 0.315 inchC20 1 Capacitor, ceramic, 220pF, 100 V, C0G, ±5%, 0603 Murata Electronics GRM1885C2A221JA01DC21 Capacitor, ceramic, 0.22 µF, 25 V, X7R, ±10%, 0603 AVX 06033D224KAT2A1
CORPORATIONC22, C23, Capacitor, ceramic, 1 µF, 25 V, X5R, ±10%, 0805 Panasonic - ECG ECJ-2FB1E105KC25, C27, 6C29, C30C24, C26, C28 Capacitor, aluminum electrolytic, 1800 µF, 25 V, ±20%, United Chemi-Con EKZE250ELL182MK30S3
0.571 inchC31 1 Capacitor, electrolytic, 33 µF, 50 V, ±20%, 0.200 inch Panasonic - ECG EEU-FC1H330D1, D2, D3, D4 4 Diode, rectifer GPP, 3 A, 600 V, SMC Diodes Inc S3J-13-FD5 1 Diode, rectifier, 6 A, 400 A peak surge, 600 V, P600 Diodes Inc 6A6-TD6, D7 2 Diode, fast recovery, 2 A, 600 V, SMA ST Microelectronics STTH2R06AD8 1 Diode, ultra fast, 3 A, 600 V, SMC ON Semiconductor MURS360T3D9 1 Diode, zener, 500 mW, 18 V, SOD-123 ON Semiconductor MMSZ18T1D11 Diode, schottky, 1 A, 40 V, SOT-23 Central ZHCS10001
SemiconductorD12, D17 2 Diode, ultra fast rectifier, 1 A, 100 V, SMA ON Semiconductor MURA110T3
(1)
These assemblies are ESD sensitive, ESD precautions shall be observed.(2)
These assemblies must comply with workmanship standards IPC-A-610 Class 2.
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