Texas Instruments UCC29950EVM-631 User manual

Using the UCC29950EVM-631
User's Guide
Literature Number: SLUUB69A
March 2015–Revised March 2015

User's Guide
SLUUB69A–March 2015–Revised March 2015
Using the UCC29950EVM-631
300-W PFC/LLC Off-Line PSU Module
1 Introduction
The UCC29950EVM-631 evaluation module is a 300-W nominal, two-stage off-line converter. The EVM
consists of a Continuous Conduction Mode (CCM) PFC input stage followed by a half-bridge LLC output
and isolation stage. It provides a 12-V constant-voltage output with overload and short circuit protection.
The UCC29950 incorporates a wide range of protection features to ensure safe system operation. The
EVM may be operated without an external bias supply in Self Bias Mode, or with an external bias supply
in Aux Bias Mode.
2 Description
This evaluation module uses the UCC29950 CCM PFC and LLC Combo Controller in a 300-W converter
The input accepts a voltage range of 90 VAC to 265 VAC. It has an output voltage of 12 V and a maximum
output current of 25 A. Refer to the UCC29950 datasheet, (TI Literature Number SLUSC18), for full specs
and details about the controller features. This EVM makes use of the device features to control a two-
stage power supply that is rated for 300-W output power.
An overload timer tracks the extent and duration of overload and trips the overload protection when the
current exceeds the over-current protection profile described in the datasheet. The overload protection
turns the power stages off and then attempts restarts at 1 second intervals.
If the VCC level at the UC29950 controller falls below the UVLO threshold the controller shuts down. It will
attempt a restart when VCC recovers.
The over-temperature protection feature of the UCC29950 trips If the temperature of the device exceeds
the thermal shutdown temperature. The device restarts once the temperature falls to the restart
temperature.
The UCC29950 employs frequency dithering to reduce conducted emissions and therefore reduce the size
and cost of the EMI filter.
This user’s guide provides the schematic, component list, assembly drawing, art work and test set up
necessary to evaluate the UCC29950EVM-631.
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www.ti.com Description
2.1 Features
UCC29950EVM-631 features include:
• AC Input Range 90 VAC to 264 VAC
• DC Output of 12 V, 25 A
• A CCM Boost Power Factor Correction Input Stage for High-Power Factor and High Efficiency
• An LLC Output Stage for High Efficiency
• Low Start-Up Current, with Integrated High-Voltage Start-Up Control
• On/Off Control of PFC Stage and PFC / LLC Stages
• Current Sense Inputs for PFC / LLC Overload Protection
• Line Brownout Protection
• PFC Bus Over-Voltage and Under-Voltage Protection
• X-Cap Discharge Function for Reduced System Standby Power Consumption
• Three Level LLC Over-Current Protection for Loads with High-Peak Power Requirements
• Short Circuit Protection
• Over Temperature Protection
• Operation in Self Bias or Aux Bias Modes
CAUTION
High voltage levels are present on the evaluation module whenever it is
energized. Proper precautions must be taken when working with the EVM. The
large bulk capacitor, C6, and the output capacitors C17, C20, C21, C22, C23,
C24, C20 and C12, must be completely discharged before the EVM can be
handled. Serious injury can occur if proper safety precautions are not followed.
2.2 Typical Applications
The UCC29950 is suited for use in mid-to-high power off-line converters. It is simple to use and has a low-
external component count with extensive fault protection features.
• Televisions
• High Efficiency AC-to-DC server power supplies
• High Density Adapters
• 80+ SILVER PC Silver Box
• Gaming
• Audio
• Lighting Drivers
• Industrial Power
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Electrical Performance Specifications www.ti.com
3 Electrical Performance Specifications
Table 1. UCC29950EVM-631 Performance Summary
PARAMETER TEST CONDITION MIN TYP MAX UNIT
Input Characteristics
VIN Input voltage 90 115/230 265 VAC
fLINE Input frequency 47 63 Hz
VIN = 115 V
PIN(115V_no-load) No-load input power fLINE = 60 Hz, 200 mW
IOUT = 0 A
VIN = 230 V
PIN(230V_no-load) No-load input power fLINE = 50 Hz, 200 mW
IOUT = 0 A
VIN = 90 V),
IIN(peak) Peak input current fLINE = 60 Hz, 5.4 A
IOUT = 25 A
AC turn-on voltage 80 VAC
AC turn-off voltage 75
Output Characteristics
VIN(min) < VIN < VIN(max),
VOUT Output voltage fLINE(min) < fLINE < fLINE(max), 11.9 12.0 12.1 VDC
IOUT(min) < IOUT < IOUT(max)
VIN(min) < VIN < VIN(max),
VOUT(line) Line regulation 0.1%
IOUT = IOUT(max)
VIN = 115 VAC,
fLINE = 60 Hz, 0.1%
IOUT(min) < IOUT < IOUT(max)
VOUT(load) Load regulation VIN = 230 VAC,
fLINE = 50 Hz, 0.1%
IOUT(min) < IOUT < IOUT(max)
VIN(min) < VIN < VIN(max)
IOUT Output load current 0 25 A
fLINE(min) < fLINE < fLINE(max)
VIN(min) < VIN < VIN(max)
POUT Output power 0 300 W
fLINE(min) < fLINE < fLINE(max)
VIN = 115 VAC,
High-frequency output voltage ripple fLINE = 60 Hz 400 mVP-P
(measured with of a 10-µF aluminum IOUT = IOUT(max)
VRIPPLE(SW) electrolytic capacitor and a 1-µF high- VIN = 230 VAC,
frequency ceramic capacitor across the fLINE = 50 Hz 400 mVP-P
output terminals.) IOUT = IOUT(max)
IOCC Steady-state output over current threshold VIN(min) ≤VIN ≤VIN(max) 28 A
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www.ti.com Electrical Performance Specifications
Table 1. UCC29950EVM-631 Performance Summary (continued)
PARAMETER TEST CONDITION MIN TYP MAX UNIT
System Characteristics
Switching frequency – including ±2-kHz
fSW(PFC) TJ= 25°C 87 100 109 kHz
dither VIN = 115 VAC,
60 Hz, 0.999
IOUT = IOUT(max)
PF Power factor VIN = 230 VAC,
50 Hz, 0.995
IOUT = IOUT(max)
VIN = 115 VAC,
fLINE = 60 Hz, 3% 10%
IOUT = IOUT(max)
THD Total harmonic distortion VIN = 230 VAC,
fLINE = 50 Hz 6% 10%
IOUT = IOUT(max)
fSW(LLC) LLC stage switching frequency 70 110 350 kHz
VIN = 115 VAC,
fLINE = 60 Hz, 88.3%
IOUT = IOUT(max)
ηFL Full load efficiency VIN = 230 VAC,
fLINE = 50 Hz, 90.5%
IOUT = IOUT(max)
VIN = 115 VAC,
fLINE = 60 Hz, 87.8%
IOUT = IOUT(max)
ηAV Average efficiency VIN = 230 VAC,
fLINE = 50 Hz, 90.2%
IOUT = IOUT(max)
tAMB Ambient temperature 25 °C
5
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TP10
10µF C34
0.1µF
C33
3.32k R56
470pF
C36
0.1µF
C40
Q4
10.0k
R41
0.1µF
C39
2.21k
R55
3.09Meg
R49
3.09Meg
R50
3.09Meg
R51
10.0Meg
R42
3.3Meg
R46
75.0k
R45
0
R36
1000pF
C41
470
R52
D18
AGND
ACDET1
AC1
PGND
ACDET1
FB
MOSI
MOSI
PSON VCC
PSON
PGND
PGND
AGND
AGND
AGND
AGND
TP9
10µF C35
10.0Meg
R43
10.0Meg
R44
D16
D15
0
R37
0
R48
Green D17
12 34 56 78 910
J6
5103308-1
470pF
C37
AGND
D19
470
R53
AGND
470pF
C38
AGND
3.09Meg
R39
3.09Meg
R40
3.09Meg
R38
100k
R47
100k
R54
AGND
PSON
TP16
TP17
TP12
TP13
TP15
VCC
VCC
BULK
AC1 AC2
PFCCS
LLC_RCS
FB
GD1
0
R35
TP14
PFCGD GD2
46
3 1
S1
46
3 1
S2
100pF
C46
AGND
R61
1.00k
TP11
0 R19
GD2 2
VCC
3
SUFG 4
SUFS
5
AGND 6
MD_SEL/PS_ON
7
VBULK
8
AC2
9AC1
10
LLC_CS
11
FB
12
PFC_CS
13
GD1 14
AC_DET 15
PFC_GD 16
GND 1
U6
UCC29950D
375Vdc
Schematic www.ti.com
4 Schematic
Figure 1. UCC29950EVM-631 Schematic - Control
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H1 HEATSINK D2, D3, Q1
H3 HEATSINK D4, D6
H2 HEATSINK Q1, Q2
V1
C28
NF
Q2
AOW25S65
49.9
R24
10.0k R12 10.0k R18
1 Fμ C18
1000pF
C10
0.047μF
C29
C30
NF
C31
NF
1000μF
C21
D5
NF
D9
NF
R27
NF
18.0k
R26
3.30
R10
3.30
R17
R29
NF
R32
NF
R16
NF
330μF
C20
1.5μH
L4
L3
0.47μF
C1
0.47μF
C2
t°
5 ohm
RT1
0.33μF
C3
0.1
R4
0.1
R6
D1
1
3 2
Q1
3.3
R2
270μF
C6
0.1μF
C4
0.1μF
C5
0.012μF
C13
10.0
R1
1.20k
R23
R34
NF
220μF
C26
0.1μF
C27
TP5
NF R21
R20
NF 5.10k
R22 10.0k
R25
0.1μF C8
47μF
C7
0
R30
D13 D12
1
2
3
D7
1
2
3
D8 STPS40L45CT
0.1μF
C32
TP8
TP2
51.1 R11
R28
NF
51.1
R13
0 R31
TP1 TP4
TP3
100pF
C45
100pF
C44 1 Fμ
C25
BULK
LLC_RCS
PGND SEC_0V
SEC_0V
AGND
SEC_0V
PGND
D3
C3D04060A
~
+
~
-
D2
250V 8A
F1
Q3
AOW25S65
1 2
4 3
U3 ACPL-217-56AE
1 2
4 3
U4 ACPL-217-56AE
1 Fμ C9
1 2 3
J1
1.20
R7
D6
0.012μF
C14
0.016μF
C11
0.047μF
C15
1000μF
C22
1000μF
C23
1000μF
C24
330μF
C17
18V
D11 12V
D14
BZX384-C12,115
2.2mH
L1
46
3 1
S3
NF
LINE
NEUTRAL +PFC BULK
PFC BULK RTN
1 Fμ C16
NT1
Net-Tie
AGND
+VOUT
+VOUT
TP6 TP7
10K R33
VCC VCC
VCC
OUTPUT: 12 VDC, 25 A
+VOUT
VOUT RTN
NOMINAL VBULK: 390VDC
AC1
AC2
PFCCS
PFCGD
GD2 GD1
FB
VCC
LLC_RCS
BULK
PGND
1.00 R57
2.2
R58
L2
1 2 3 4
J3
1 2 3
J2
1 2 3 5 6
13 14 15 16 17 18 19 20
T1
TP19 TP27
TP24
TP21
TP26
TP18
TP23
TP20
TP22
TP28
1 2 3
HS1
1 2 3
HS2
1 2 3
HS3
PGND
TP25
TP29
TP30
TP31 TP32 TP33
10.0M R14 1.10M
R15
AGND
10μF C43
1 2 3
J4
D20
OUT
1
FB
2PG
3
4
EN 5
NC
6DELAY 7
IN 8
9
EPGND
U7
TPS7A1601DGNT 0.1μF
C42
VCC
10μF C47
0.01μF
C48
1.0 R3
J5
D4
0.1 R5
1.20
R8 1.20 R9
D10
100k
R59
0
R60
10.0k R62
SEC_0V
HIGH VOLTAGE
HIGH VOLTAGE
HI
1
LI
2
VSS 3
NC/EN
4
COM 5
LO 6
VDD
7
NC
8
NC
9
NC
10
HS 11
HO 12
HB 13
NC
14
U2 UCC27714D
PGND
0.1μF
C12
3
2
1
U5 TL431AIDBZR
VDD 1
OUTH 2
OUTL 3
GND
4
IN-
5
IN+
6
U1 UCC27511DBVR
90VAC to 264VAC
385V to 450VDC
90VAC to 264VAC
MECH
Tinned Copper
H33
296 SV005
i
LV
0.016μF
C19
www.ti.com Schematic
Figure 2. UCC29950EVM-631 Schematic - Power
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Fan
62 k:,
5W
Electronic
Load
+-
V1
-+ A1
-
+
V2
-+
AC Source
L N
Power Meter
+
-
+
-
Voltage
Current
The 62-k:resistor and the
V2 Meter provide monitoring
and an automatic discharge
of the PFC stage output
capacitance (C6). They are
recommended but are not
necessary for operation and
may be omitted. Remember
to discharge C6 when
finished.
The voltage on the bulk
capacitor, C6, may be
monitored at J2 as shown
or at TP31 (pos) and TP
32 (neg)
Test Setup www.ti.com
5 Test Setup
Figure 3 shows the test setup recommended in order to evaluate the UCC29950EVM-631 in Self Bias
Mode. Figure 4 shows the test setup recommended in order to evaluate the UCC29950EVM-631 in Aux
Bias Mode.
Figure 3. UCC29950EVM-631 Recommended Self Bias Test Set Up
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Fan
62 k:,
5 W
Electronic
Load
+-
V1
-
+A1
-
+
13 V Bias
Supply
+-
V2
-
+
AC Source
L N
Power Meter
+
-
+
-
Voltage
Current
The 62-k:resistor and the
V2 Meter provide monitoring
and an automatic discharge
of the PFC stage output
capacitance (C6). They are
recommended but are not
necessary for operation and
may be omitted. Remember
to discharge C6 when
finished.
The voltage on the bulk
capacitor, C6, may be
monitored at J2 as shown
or at TP31 (pos) and TP
32 (neg)
www.ti.com Test Setup
Figure 4. UCC29950EVM-631 Recommended Aux Bias Test Set Up
WARNING
High voltages that may cause injury exist on this evaluation
module (EVM). Please ensure all safety procedures are followed
when working on this EVM. Never leave a powered EVM
unattended.
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Test Setup www.ti.com
5.1 Test Equipment
AC Source: (for example, Hewlett Packard 6813B 300 VRMS, 1750 VA AC Power Source/Analyzer) or
VARIAC. The input voltage shall be a transformer isolated variable AC source capable of supplying
between 90 VAC and 264 VAC, at 50 Hz and 60 Hz, at no less than 10-A peak.
13-V Bias Supply: The bias supply to the device shall be capable of supplying up to 13 VDC at no less
than 100 mA. Connect the bias supply to the negative and positive terminals of J5, shown in Figure 3 and
Figure 4.
Output Load: One Electronic Load (for example TDI RBL 488 600-40-800). A programmable electronic
load set to constant current mode and capable of sinking 0 A to 25 A at 12 VDC shall be used. Connect the
load to J3 as shown in Figure 3 and Figure 4.
Power Meter: For highest accuracy, a power analyzer shall be used to measure the input power, THD,
and power factor. An example of such an analyzer is the Voltech PM100 Single Phase Power Analyzer or
the Yokogawa WT210/WT230 Digital Power Meter.
Multimeters: For highest accuracy, the output voltage of the UCC29950EVM-631 shall be monitored by
connecting a digital voltmeter, V1, directly across TP18 and TP27 with the positive terminal at TP18 and
the negative terminal at TP27. A dc current meter, A1, should be placed in series with the electronic load
for accurate output current measurements.
Oscilloscope: A digital or analog oscilloscope with 500-MHz scope probes is recommended.
Fan: A fan, capable of 200 LFM to 400 LFM, should be used to maintain component temperatures within
safe operating ranges at all times during operation of the UCC29950EVM-631. Position the fan so as to
blow along the length of the heatsink as shown in Figure 3 and Figure 4.
Recommended Wire Gauge: All electrical connections to the EVM must be made using appropriately
rated wire. The line connections at J1, the PFC Output connections at J2 and the Aux Bias connections at
J5 may be made using 22 AWG (0.5 mm2) Tri Rated wire. The output connections at J3 may be made
with 16 AWG (1.5 mm2) Tri Rated wire. Use two conductors for the positive output and two for the
negative output. The normal output load current of 25 A causes a voltage drop of about 250 mV per meter
in both the positive and negative connections.
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