Texas Instruments UCC28780EVM-021 User manual

Using the UCC28780EVM-021, 45-W, 20-V High-
Density Silicon (Si) Based, Active-Clamp
Flyback Converter/Evaluation Module
User's Guide
Literature Number: SLUUBV6
August 2018

WARNING
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General Texas Instruments High Voltage Evaluation (TI HV EVM) User Safety Guidelines
Always follow TI’s setup 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 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 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 suitable qualified, you should
immediately stop from further use of the HV EVM.
1. Work Area Safety
1. Keep work area clean and orderly.
2. Qualified observer(s) must be present anytime circuits are energized.
3. 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.
4. All interface circuits, power supplies, evaluation modules, instruments, meters, scopes and other
related apparatus used in a development environment exceeding 50Vrms/75VDC must be
electrically located within a protected Emergency Power Off EPO protected power strip.
5. Use stable and nonconductive work surface.
6. Use adequately insulated clamps and wires to attach measurement probes and instruments. No
freehand testing whenever possible.
2. Electrical Safety
As a precautionary measure, it is always a good engineering practice to assume that the entire EVM
may have fully accessible and active high voltages.
1. 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.
2. With the EVM confirmed de-energized, proceed with required electrical circuit configurations,
wiring, measurement equipment connection, and other application needs, while still assuming the
EVM circuit and measuring instruments are electrically live.
3. After 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
1. Wear personal protective equipment (for example, latex gloves or safety glasses with side shields)
or protect EVM in an adequate lucent plastic box with interlocks to protect from accidental touch.
Limitation for safe use:
EVMs are not to be used as all or part of a production unit.

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Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,
Active-Clamp Flyback Converter/Evaluation Module
User's Guide
SLUUBV6–August 2018
Using the UCC28780EVM-021, 45-W, 20-V High-Density
Silicon (Si) Based, Active-Clamp Flyback
Converter/Evaluation Module
1 Description
The UCC28780EVM-021 is a 45-W evaluation module (EVM) for evaluating an off-line active-clamp
flyback adapter for notebook charging and other applications. The EVM meets CoC Tier 2 and DoE Level
6 efficiency requirements. It is intended for evaluation purposes and is not intended to be an end product.
The UCC28780EVM-021 converts input voltage of 90-VRMS to 264-VRMS down to 20-VDC, with a 2.25-A
nominal output current rating and a 160-ms limit for over-power capability. The main devices used in this
design are active clamp flyback controller UCC28780, SR controller UCC24612, and Si MOSFETs.
Figure 1. UCC28780EVM-021 Top View

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Figure 2. UCC28780EVM-021 Bottom View

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2 Electrical Performance Specifications
(1) The performance listed in this table is achieved using secondary resonance and based on the test results from a single board.
(2) Average efficiency of four load points, IOUT = 25%, 50%, 75% and 100% nom.
Table 1. UCC28780EVM-021 Electrical Performance Specifications(1)
PARAMETER TEST CONDITIONS MIN NOM MAX UNIT
INPUT CHARACTERISTICS
VIN Input line voltage (RMS) 90 115 / 230 264 V
fLINE Input line frequency 47 50 / 60 63 Hz
PSTBY Input power at no-load VIN = 115 VRMS, IOUT = 0 A 37.2 mW
PSTBY Input power at no-load VIN = 230 VRMS, IOUT = 0 A 40.1 mW
P0.25W Input power at 0.25W load VIN = 115 VRMS, POUT = 237mW 330 mW
P0.25W Input power at 0.25W load VIN = 230 VRMS, POUT = 237 mW 392 mW
OUTPUT CHARACTERISTICS
VOUT Output voltage VIN = 115 VRMS, IOUT = 2.249 A 19.928 V
VIN = 230VRMS, IOUT = 2.249 A 19.924 V
VOUT Output voltage VIN = 115 VRMS, IOUT = 0 A 19.937 V
VIN = 230VRMS, IOUT = 0 A 19.936 V
IOUT Full load rated output current VIN = 90 to 264 VRMS 2.25 A
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 to 2.25 652/600 mVpp
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 2.25 A 20/28 mVpp
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 A 20/21 mVpp
POUT_opp Over-power protection power
limit VIN = 90 to 264 VRMS 55 W
tOPP Over-power protection duration VIN = 90 to 264 VRMS, POUT = POUT_opp 160 ms
VOUT_ΔOutput voltage deviation due to
load step up IOUT step between 0 A and 2.25A < 5%
SYSTEMS CHARACTERISTICS
ηFull-load efficiency VIN = 115 VRMS, IOUT = 2.25A 94.06% VIN = 230 VRMS, IOUT = 2.25A 93.82%
VIN = 90V RMS, IOUT = 2.25A 93.08%
η4-point average efficiency(2) VIN = 115 VRMS 92.82%
VIN = 230 VRMS 91.71%
ηEfficiency at 10% Load VIN = 115 VRMS, IOUT = 10% rated current 88.09%
VIN = 230 VRMS, IOUT = 10% rated current 85.08%
TAMB Ambient operating temperature
range VIN = 90 to 264 VRMS, IOUT = 0 to 2.25A 25 °C

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3 Schematic Diagram
Figure 3. UCC28780EVM-021 Schematic Diagram

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4 Test Setup
4.1 Test Setup Requirements
Safety: This evaluation module is not encapsulated and there are accessible voltages that are greater
than 50 VDC.
Isolation Input Transformer: A suitably rated 1:1 isolation transformer shall be used on the input(s) to
this EVM and be constructed in a manner in which the primary winding(s) are separated from the
secondary winding(s) by reinforced insulation, double insulation, or a screen connected to the protective
conductor terminal.
WARNING
If you are not trained in the proper safety of handling and testing
power electronics please do not test this evaluation module.
Read this user's guide thoroughly before making test.
Voltage Source: Isolated AC source or variable AC transformer capable of 264 VRMS cable of handling
100 W
Voltmeter: Digital voltage meter
Power Analyzer: Capable of measuring 1 mW to 100 W of input power and capable of handling 264-VRMS
input voltage. Some power analyzers may require a precision shunt resistor for measuring input current to
measure input power of 5 W or less. Please read the power analyzer’s user manual for proper
measurement setups for full power and for stand-by power.
Oscilloscope:
• 4-Channel, 500 MHz bandwidth.
• Probes capable of handling 600 V.
Output Load: Resistive or electronic load capable of handling 100 W at 20 V.
Recommended Wire Gauge: Insulated 22 AWG to 18 AWG.
WARNING
Caution: Do not leave EVM powered when unattended

UCC28780EVM-021
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4.2 Test Setup Diagram
Figure 4. UCC28780EVM-021 Test Setup Diagram
4.3 Design Notes
In Table 6, a component list shows critical components to achieve stable ABM operation with secondary
resonance which provides better efficiency and output voltage ripple performance. Details on secondary
resonance can be found in the UCC28780 datasheet.
4.4 Test Points
Table 2. Test Point Functions
TEST POINTS NAME DESCRIPTION
J1-L Location J1 Terminal L AC line voltage input
J1-N N AC neutral input
J2+ Location J2 Terminal VOUT + Output supply
J2- VOUT – Output return

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5 Performance Data and Typical Characteristic Curves
5.1 Efficiency Typical Result of 4-Point Average
Table 3. Efficiency Test Data
VIN RMS PIN VOUT IOUT POUT(%) EFFICIENCY EFFICIENCY 4pt-
AVERAGE
Switching
Frequency @
Full Load
90 48.210 19.927 2.252 100% 93.08% 92.57% 179kHz
90 35.875 19.930 1.680 75% 93.33%
90 24.240 19.932 1.123 50% 92.34%
90 12.720 19.935 0.584 25% 91.53%
115 47.670 19.928 2.250 100% 94.06% 92.82% 224kHz
115 35.760 19.930 1.680 75% 93.63%
115 24.290 19.931 1.123 50% 92.15%
115 12.710 19.935 0.583 25% 91.44%
230 47.780 19.924 2.250 100% 93.82% 91.71% 288kHz
230 36.130 19.925 1.681 75% 92.70%
230 24.970 19.926 1.131 50% 90.25%
230 12.950 19.933 0.585 25% 90.04%
264 47.930 19.923 2.249 100% 93.48% 91.47% 291kHz
264 36.310 19.924 1.683 75% 92.35%
264 24.870 19.93 1.131 50% 90.63%
264 13.060 19.93 0.586 25% 89.44%
5.2 Efficiency Typical Results
Figure 5. Efficiency Over Load Figure 6. Efficiency Over Input Voltage

19.4
19.58
19.76
19.94
20.12
20.3
20.48
75 105 135 165 195 225 255
Vout, V
AC Input Voltage, Vac
Full Load
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5.3 VI Characteristics
Figure 7. VOUT Line Regulation Figure 8. VOUT Load Regulation
5.4 Switching Frequency
Figure 9. Switching Frequency Over Input at Full Load
Figure 10. Maximum switching frequency about 500kHz at
high line and entering ABM
CH1 = PWML, CH4 = Transformer Primary Winding Current, CH3 = Switch Node Voltage
5.5 Key Switching Waveforms and Operation Mode Load Current
This section shows typical operation modes in Table 4 along with typical load currents in this design and
with Vin = 115Vac as an example.
• AAM: Adaptive Amplitude Modulation
• ABM: Adaptive Burst Mode
• LPM: Lower Power Mode
• SBP: Standby Power Mode
Table 4. Operation Mode and Load Current
Mode AAM AAM to ABM ABM End LPM SBP
Typical Load Current 1.50 A to 2.25 A 1.30 A to 1.60 A 0.15 A to 0.18 A 0.05 A to 0.15 A < 0.08 A
Typical Load % 67% to 100% 58% to 71% 6.7% to 8% 2.2% to 6.7% < 3.5%

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Figure 11. AAM Mode at Heavy Loads (CH1 = PWML, CH4
= Transformer Primary Winding Current, CH2 = Switch
Node Voltage, CH3 = PWMH)
Figure 12. ABM Mode at Medium Loads (CH1 = PWML,
CH4 = Transformer Primary Winding Current, CH2 =
Switch Node Voltage)
Figure 13. ABM Mode and SR (CH1 = PWML, CH4 =
Transformer Primary Winding Current, CH2 = Switch Node
Voltage, CH3 = SR Vgs)
Figure 14. Recovery after OPP with 3 Stages of Peak
Current (CH1 = PWML, CH4 = Transformer Primary
Winding Current, CH2 = Switch Node Voltage)
Figure 15. LPM Mode Operation (when a burst packet
contains 2 pulses and the interval between 2 packets is
around 40µs, and peak current starts to reduce. CH3 =
PWML, CH4 = Transformer primary winding current.)
Figure 16. SBP Mode Operation
(when a burst packet contains 2 pulses and the interval
between 2 packets is > 40 µs. CH3 = PWML, CH4 =
Transformer primary winding current.)

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5.6 Start Up
CH1 = PWML, CH2 = Switch Node Voltage, CH3 = Output Voltage, CH4 = Transformer Primary Current.
Figure 17. 115 VAC and Full Load Startup Figure 18. 230 VAC and Full Load Startup
5.7 Line Transient Response
CH1 = Vout, CH2 = Line voltage.
Figure 19. Output Voltage Response to Line Transient with
Full Load. Figure 20. Output Voltage Response to Line Transient with No Load.

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5.8 Output Ripple Voltage
CH3 = Output Voltage Ripple
Figure 21. VOUT_pp = 40.0mV, VIN = 115 VRMS, IOUT = 2.25 A Figure 22. VOUT_pp = 38.6mV, VIN = 230 VRMS, IOUT = 2.25 A
Figure 23. VOUT_pp < 80 mV, VIN = 115VRMS, IOUT = 1.125 A Figure 24. VOUT_pp < 80mV, VIN = 230VRMS, IOUT = 1.125 A
Figure 25. VOUT_pp = 24.3 mV, VIN = 115VRMS, IOUT = 0 A Figure 26. VOUT_pp = 24.3mV, VIN = 230VRMS, IOUT = 0 A

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5.9 Over Power Protection
Figure 27 shows the converter Over Power Protection (OPP) with respect to input voltage. Figure 28
shows the converter auto-retry to resume operation after OPP.
Figure 27. OPP with Respect to Input Voltage Figure 28. OPP Auto Retry (CH1 = PWML, CH2 = Switch
Node Voltage, CH3 = Transformer Primary Current)

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5.10 Load Transient Response
Figure 29 and Figure 30 show output voltage Vout deviation < 5% for 0 and 2.25A load step change.
CH3 = Vout, CH4 = Load Current.
Figure 29. Vout Load Transient Response at VIN = 115 VRMS Figure 30. Vout Load Transient Response at VIN = 230 VRMS
Figure 31 and Figure 32 show the switching node voltage response for 0 and 2.25A load step change.
CH2 = PWML, CH3 = Switch Node Voltage, CH4 = Load Current.
Figure 31. Load Transient Step-Up (0A to 2.25A) Figure 32. Load Step-Down (2.25A to 0A)

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5.11 Conducted EMI Output Not Grounded to LISN ground
Figure 33. Peak EMI, VIN = 115 VRMS, Load = 9.3 ΩFigure 34. Peak, VIN = 230 VRMS, Load = 9.3 Ω
NOTE: Please note this was evaluated on an EMI station for pre-qualification purpose only. It is
recommended that all final designs be verified by an agency qualified EMI test house.

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5.12 Thermal Images at Full Load (2.25 A)
Figure 35. VIN = 90 VAC, Top Side (Transformer: 60 °C) Figure 36. VIN = 90 VAC, Bottom Side (Q1: 64 °C; U7: 63 °C;
DB1: 64 °C)
Figure 37. VIN = 115 VAC, Top Side (Transformer: 59 °C) Figure 38. VIN = 115 VAC, Bottom Side (Q1: 59 °C; U7: 56 °C)
Figure 39. VIN = 230 VAC, Top Side (Transformer: 66 °C) Figure 40. VIN = 230 VAC, Bottom Side (Q1: 76 °C)

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Figure 41. VIN = 265 VAC, Top Side (Transformer: 69 °C) Figure 42. VIN = 265 VAC, Bottom Side (Q1: 79 °C)

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6 Transformer Details
Precision Inc transformer part number 019-8916-00R is used on this design and wound on a low profile
RM8/ILP core set (11.6 mm height).
Figure 43. Transformer Schematic Diagram
Sh1 and Sh2 are the terminals for EMI shields. Their optimal connections are to be determined and their
current connections are to pin P1.
Table 5. Transformer Specifications at 25°C
PARAMETER VALUE PINS/LEADS TEST CONDITIONS
Inductance (µH) 104 to 127 P1 – P2 Open all other pins
Leakage Inductance (µH) 2.5 Max. P1 – P2 Tie S1 - S2, 0.1 V, 200 kHz
D.C. resistance (Ω) 0.147 Max. P1 – P2
D.C. resistance (Ω) 0.014 Max. S1 – S2
D.C. resistance (Ω) 0.16 Max. Pa1 – Pa2
D.C. resistance (Ω) 0.168 Max. Sa1 – Sa2
Dielectric (VAC) 1500 P1 – S1 1 mA, 60 Hz, 1 s
Dielectric (VAC) 500 P1, S1 to Core 1 mA, 60 Hz, 1 s
Turns ratio 1:0.19:0.14:0.1 (P1-P2):(S1-S2):(Pa1-Pa2):(Sa1-Sa2)

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7 List of Materials
UCC28780EVM-021 (secondary resonance approach as default) list of materials for the schematic
diagram shown in Figure 3.
Table 6. UCC28780EVM-021 List of Materials
QTY DES DESCRIPTION PART NUMBER MANUFACTURER
2 C1, C2 Capacitor, aluminum, 39 µF, 400 V, ±20%, AEC-
Q200 Grade 2, TH EKXJ401ELL390MU2 0S Chemi-Con
4 C3, C4, C5, C17 Capacitor, ceramic, 0.1 uF, 450 V, ±10%, X7T,
1206_190 C3216X7T2W104K16 0AA TDK
3 C6, C24, C33 Capacitor, ceramic, 0.33 µF, 250 V, ± 10%, X7T,
1210 C3225X7T2E334K200 AA TDK
1 C7 Capacitor, ceramic, 10 pF, 50 V, ±5%, C0G/NP0,
0402 885012005055 Wurth Elektronik
2 C8, C9 Capacitor, ceramic, 33 uF, 25 V, ± 20%, X5R, 1206 C3216X5R1E336M16
0AC TDK
1 C10 Capacitor, ceramic, 330 pF, 50 V, ±1%, C0G/NP0,
0402 GRM1555C1H331FA 01J MuRata
1 C11 Capacitor, ceramic, 180 pF, 50 V, ±1%, C0G/NP0,
0402 04025A181FAT2A AVX
1 C12 Capacitor, film, 0.068 µF, X2 275 VAC, ±10%, TH 890324022017CS Wurth Elektronik
1 C13 Capacitor, ceramic, 330 pF, 250 V, ±5%, C0G/NP0,
0805 GRM21A5C2E331JW 01D MuRata
1 C14 Capacitor, ceramic, 33 pF, X1 250 VAC/Y2 250 VAC,
±5%, SL, 8x5mm DE21XKY330JN3AM0 2F MuRata
2 C15, C25 Capacitor, ceramic, 22 uF, 35 V, ±20%, X5R, 0805 C2012X5R1V226M12
5AC TDK
1 C16 Capacitor, aluminum polymer, 680 µF, 25 V, ± 20%,
0.29256 ohm, TH 687AVG025MGBJ Illinois Capacitor
1 C18 Capacitor, ceramic, 2200 pF, 50 V, ± 10%, X7R,
AEC-Q200 Grade 1, 0402 CGA2B2X7R1H222K 050BA TDK
1 C19 Capacitor, ceramic, 2.2 uF, 50 V, ±10%, X7R, 0805 C2012X7R1H225K12
5AC TDK
1 C20 Capacitor, ceramic, 22 pF, 50 V, ± 5%, C0G/NP0,
0402 GRM1555C1H220JA0 1D MuRata
1 C21 Capacitor, ceramic, 0.1 uF, 25 V, ± 10%, X7R, 0402 GRM155R71E104KE
14D MuRata
1 C22 Capacitor, ceramic, 4700 pF, 50 V, ± 10%, X7R,
AEC-Q200 Grade 1, 0402 CGA2B2X7R1H472K 050BA TDK
2 C23, C26 Capacitor, ceramic, 680 pF, X1 250 VAC/Y2 250
VAC, ±10%, X7R, 2211 GA352QR7GF681KW 01L MuRata
1 C27 Capacitor, ceramic, 3.3 pF, 50 V, ±8%, C0G/NP0,
0603 06035A3R3CAT2A AVX
1 C28 Capacitor, ceramic, 0.01 uF, 50 V, ± 5%, C0G/NP0,
AEC-Q200 Grade 1, 0603 CGA3E2C0G1H103J0 80AA TDK
1 C29 Capacitor, ceramic, 1 uF, 50 V, ±10%, X7R, AEC-
Q200 Grade 1, 0805 CGA4J3X7R1H105K1 25AB TDK
1 C30 Capacitor, ceramic, 1 uF, 25 V, ± 10%, X7R, 0603 C1608X7R1E105K08
0AB TDK
1 C31 Capacitor, ceramic, 0.047 uF, 50 V, ±10%, X7R,
1206 C1206C473K5RACTU Kemet
2 C34, C35 Capacitor, ceramic, 100 pF, 50 V, ± 5%, C0G/NP0,
0402 CC0402JRNPO9BN1 01 Yageo America
1 D1 Diode, superfast rectifier, 600 V, 1 A, 3.5x1.6mm CSFMT108-HF Comchip
Technology
1 D2 Diode, ultrafast, 100 V, 0.15 A, SOD-123 1N4148W-7-F Diodes Inc.
1 D4 Diode, TVS, Uni, 18 V, 45 Vc, SOD-323 CDSOD323-T18 Bourns