Texas Instruments UCD3138LLCEVM-028 User manual

Using the UCD3138LLCEVM-028
User's Guide
Literature Number: SLUU979A
August 2012–Revised July 2013

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.
2SLUU979A–August 2012–Revised July 2013
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User's Guide
SLUU979A–August 2012–Revised July 2013
Digitally Controlled LLC Resonant Half-Bridge DC-DC
Converter
1 Introduction
This EVM, UCD3138LLCEVM-028 is to help evaluate the UCD3138 64-pin digital control device in an off-
line power converter application and then to aid in its design. The EVM is a standalone LLC resonant half-
bridge DC-to-DC power converter. The EVM is used together with its control card, UCD3138CC64EVM-
030, also an EVM on which is placed UCD3138RGC.
The UCD3138LLCEVM-028 together with UCD3138CC64EVM-030 can be used as they are delivered
without additional work, from either hardware or firmware, to evaluate an LLC resonant half-bridge DC-to-
DC converter. This EVM combination allows for some of its design parameters to be retuned using a GUI
based tool, called Texas Instruments Fusion Digital Power Designer. It is also possible to load custom
firmware with user’s own definition and development.
Three EVMs are included UCD3138LLCEVM-028, UCD3138CC64EVM-030, and USB-TO-GPIO.
This user’s guide provides basic evaluation instruction from a viewpoint of system operation in a
standalone LLC resonant half-bridge DC-to-DC power converter.
WARNING
• High voltages are present on this evaluation module during
operation and for a while even after power off. This module
should only be tested by skilled personnel in a controlled
laboratory environment.
• An isolated DC voltage source meeting IEC61010 reinforced
insulation standards is recommended for evaluating this EVM.
• High temperature exceeding 60°C may be found during EVM
operation and for a while even after power off.
• This EVM’s purpose is to facilitate the evaluation of digital
control in an LLC using the UCD3138, and cannot be tested
and treated as a final product.
• Extreme caution should be taken to eliminate the possibility of
electric shock and heat burn.
• Read and understand this user’s guide thoroughly before
starting any physical evaluation.
3
SLUU979A–August 2012–Revised July 2013 Digitally Controlled LLC Resonant Half-Bridge DC-DC Converter
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Description www.ti.com
2 Description
The UCD3138LLCEVM-028 along with the UCD3138CC64EVM-030 demonstrates an LLC resonant half-
bridge DC-DC power converter with digital control using the UCD3138 device. The UCD3138 device is
located on the UCD3138CC64EVM-030 board. The UCD3138CC64EVM-030 is a daughter card with
preloaded firmware that provides the required control functions for an LLC converter. For details of the
firmware please contact TI. UCD3138LLCEVM-028 accepts a DC input from 350 VDC to 400 VDC, and
outputs a nominal 12 VDC with full load output power of 340 W, or full output current of 29 A.
NOTE: This EVM does not have an input fuse and relies on the input current limit from the input
voltage source used.
2.1 Typical Applications
• Offline DC-to-DC Power Conversion
• Servers
• Telecommunication Systems
2.2 Features
• Digitally Controlled LLC Resonant Half-Bridge DC-to-DC Power Conversion
• DC Input from 350 VDC to 400 VDC
• 12 VDC Regulated Output from No Load to Full Load
• Full-Load Power 340 W, or Full-Load Current 29 A
• High Efficiency
• Constant Soft-Start Time
• Protection: Over Voltage, Over Current, Brownout and Output Short-Circuit Protection
• Test Points to Facilitate Device and Topology Evaluation
• Synchronous Rectification
• Automatic Mode Switching between LLC Mode and PWM Mode
• Cycle-by-Cycle Current Limiting with Duty Cycle Matching
• Constant Current and Constant Power Control Mode
• PMBUS Communication
• Current Sharing Capability (GUI Enable), Across Paralleled Units
4Digitally Controlled LLC Resonant Half-Bridge DC-DC Converter SLUU979A–August 2012–Revised July 2013
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www.ti.com Performance Specifications
3 Performance Specifications
Table 1. UCD3138LLCEVM-028 Performance Specifications
PARAMETER TEST CONDITIONS MIN TYP MAX UNITS
Input Characteristics
Voltage operation range 350 400 VDC
Input UVLO On 325
Input UVLO Off 310
Input current Input = 350 VDC, full load = 29 A 1.2 A
Input current Input = 380 VDC, full load = 29 A 1.1
Input current Input = 400 VDC, full load = 29 A 1.0
Output Characteristics
Output voltage, VOUT No load to full load 12 VDC
Output load current, IOUT 350 VDC to 400 VDC 29 A
Output voltage ripple 380 VDC and full load = 29 A 200 mVpp
Output over current Operation 10s then latch-off shutdown 30 A
Systems Characteristics
Switching frequency Resonant mode 35 150 kHz
PWM Mode 150
Peak efficiency 380 VDC, full load = 29 A 93.5%
Full-load efficiency 380 VDC, load = 20 A 94.0%
Operating temperature Natural convection 25 ºC
Firmware
Device ID (version) UCD3100ISO1 | 0.0.44.0000 | 120517
Filename UCD3138LLCEVM_028_0_0_44_120517.x0
5
SLUU979A–August 2012–Revised July 2013 Digitally Controlled LLC Resonant Half-Bridge DC-DC Converter
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0.312V/A Primary Current Sense
Output Capacitors
Load current sense
Diode Oring Control
R73 - 74 Bleeder R's
+Vout Ripple Test
+VOUT = +12VEXT
Iout = 29A max
SR gate drivers
1:1:1
1mV/1A
35A scaled to 1.6V
Output Current Sense
Current Share Compensation
+12V Monitoring and Protection
Parts not used.
+VIN = 350 to 400VDC.
14
23
11
1
1
Isolation Line
(J2-12)
(J3-11)
(J3-1)
(J3-2)
(J3-13)
(J2-36)
(J2-35)
(J2-14)
(J3-11)
(J3-4)
(J3-3)
(J3-25)
(J2-38)
Pout = 340W max
Pin_max = 340W
(J2-30)
Voltage Feedback
(J2-39)
(J2-40, 10)
Redundant OVP circuit.
J6: short to disable Ext OVP
(J3-11)
(J3-17)
1 2
3,4
5
6
7,8
11
1
TP10
R50
124
TP13
R46
1k
D15
BAT54S
R48
1
TP11
R44
1
TP12
R49
1k
R45
1
TP9
D14
BAT54S
R51
124
R47
1
HS1
HS2
C43
100pF
T2
Q8
IRLB3036GPbF
Q9
IRLB3036GPbF
Q10
IRLB3036GPbF
Q11
IRLB3036GPbF
C39
2.2nF
C36
15nF
C37
15nF
C38
15nF
C40
15nF
C41
15nF
C42
15nF
HS6 HS4
HS3
HS5
1
2
3
4
5
6
L1
33uH
T3
Q6
SPW20N60CFD
Q7
SPW20N60CFD
J9
TP5
J8
TP6 TP7
C31
1.5uF
+
C30
47uF
R74
1k
C72
47uF
C71
47uF
C70
47uF
C69
47uF
R73
1k
C68
47uF
1VDD
2RSET
3STAT
4FLTB
5OV
6UV
7GND 8
GATE
9
RSVD
10
C
11
A
12
FLTR
13
BYP
14
PG
U11
TPS2411PW
R69
10k
R72
10k
R71
100k
R70
549
R66
10k
R67
10
R68
5.11k
C60
10nF
C57
2200pF C58
100pF
C59
100pF
C61
10nF J12
J11
Q15
Q14
TP16
TP17 TP20
+
C66
470uF
+
470uF
+
C65
470uF
+
C64
470uF
+
C63 470uF
R75 3m R77 3m
R76 3m
C62
0.1uF
TP19 TP18 C73
4.7uF
SH2 SH3
SH1
TP14
C45
0.1uF
R58
10k
C44
2.2uF
1ENBA
2INA
3GND
4INB 5
OUTB
6
VDD
7
OUTA
8
ENBB
9PWPD
U9
UCC27424DGN
C52
0.1uF
TP15
R64
10k
1ENBA
2INA
3GND
4INB 5
OUTB
6
VDD
7
OUTA
8
ENBB
9PWPD
U10
UCC27424DGN
C51
2.2uF
C28
2.2uF
C29
0.1uF
C34
2.2uF
1ENBA
2INA
3GND
4INB 5
OUTB
6
VDD
7
OUTA
8
ENBB
9PWPD
U6
UCC27424DGN
1ENBA
2INA
3GND
4INB 5
OUTB
6
VDD
7
OUTA
8
ENBB
9PWPD
U7
UCC27424DGN
R43
10k
R38
10k
R42
5.11k
R40
0
C32
0.1uF
C27
0.1uF
R37
5.11k
D8
R35
0
R39 10
TP4
D10
TP8
D13
C33 2.2uF
R36
10
R41
10
D11
D9
D12
1 2
5 6
9
10
T1
C35
0.1uF
R17
1k
R23
35.7k
R19
35.7k C13
220pF
3
4
1
25
U3
C14
10nF
R22
1k
C11
0.1uF
R18
1k
C15
220pF
C12
0.1uF
R12
1k
R11
R26
10k
R28
1k
C20
2200pF
R27
100
R20 10k
R21
1k
C16
2200pF
R16
100
TP2 TP3
C17
2200pF
R24 10k
R25
1k
R13
549
R15
549
R14
549
D7
R32
20k
R30
100
R33
1k
R29
20k
R31
100
J6
C26
0.1uF
Q5
R34
10k
Q4-A
Q4-B
SH4
J10
1
1
1
1
1
11
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
IPS
SR1 SR2
SR_VDS1 SR_VDS2
GND_PWR
AGND
HSG
HSS
LSG
GND_PWR_PRI
GND_PWR_PRI GND_PWR_PRI
TRP1
TRP2 GND_PWR
BUS+_HV_PRI
VIN_HV_PRI
GND_PWR_PRI
+12V
ORING_CTRL
GND_PWR DGND
+12VEXT
+12V
DGND
12VS
+12VEXT
12V_RTN
12VS
SR1
DPWM1A
GND_PWR
GND_PWR
OVLATCH
SR2
DPWM1B
GND_PWR
GND_PWR
DPWM0A
12VS
DPWM0B
GND_PWR
GND_PWR
GND_PWR
OVLATCH
GND_PWR
GND_PWR_PRI
3_3VA
IO_SENSE
IO_SEN-
IO_SEN+
EADC_IOSENSE
AGND
AGND
AGND
AGND
PWM0
AGND
VOSADC12
ORING_GATE
+VO_SENSE
-VO_SENSE
AGND
12V_RTN
AGND
+12VEXT
+12V
ORING_GATE
OVLATCH
3_3VD
+12V
DGND
EXT_OVP_DISABLE
Schematics www.ti.com
4 Schematics
Figure 1. UCD3138LLCEVM-028 Schematic (image 1 of 2)
6Digitally Controlled LLC Resonant Half-Bridge DC-DC Converter SLUU979A–August 2012–Revised July 2013
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EAP1
12V_EXT
AD02 AD05
AD06 EAN1
EAN0
DPWM2B
DPWM1B
DPWM0B DPWM3B
DPWM2A
DPWM1A DPWM3A DPWM0A
EAP0
FAULT0
EAN2
EAP2 AD10 AD13
AD12
AD11 AD09
AD08
AD07 AD04
AD03 AD00
AD01
NC
SYNC PWM_0
PWM_1
TCAP
SCI_TX0
SCI_RX0
INT_EXT
/RESET SCI_TX1
SCI_RX1 3.3V DGND
DGND DGND
DGND
AGND
ADC_EXT FAULT3 NC
NC
NC
FAULT2
NC
NC
NC
NC
NC NC
NC DGND NC
NC AGND
AGND AGND AGND AGND AGND AGND AGND AGND AGND AGND AGND AGND AGND
AGND
FAULT1
NC
Control Card Connectors (PWR030)
DGND/AGND Damping
DGND Test Point
SCI Interface
V+ = +5.4V
V- = -5.4V
PFC Communication
On/off control
Device Address
I Share Bus
Temperature Sensor
Temperature =
SR body diode conduction detection circuits
Leading edge blanking pulse
External Power Input
Bias power generation
3.3VD LED Indicator
VAUX_P = +12V
VIN_MON=1.93V AT VIN=400V
VIN Operating Range: 300V to 400VDC.
Leading edge blanking pulse
Parts not used.
1
1
1
1
1
11
Isolation Line
(J2-22)
(J2-24)
(J2-28)
(J3-24)
(J3-23)
(J3-22)
(J2-8)
(J2-4)
(J3-32)
(J3-31)
(J3-33)
(J3-34) (J3-15) (J3-26)
(J3-5)
(J3-6)
159.6 C - TEMP * 85.5 C/V
OFF
ON
12Vp_on
(J2-6, 16)
1
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
J2
R5 10
TP1
C24
0.1uF
C22
0.1uF
C23
0.1uF C25
0.1uF
C21
0.1uF
1EN 2C1+ 3V+
4C1- 5C2+
6C2- 7V-
8RIN 9
ROUT
10
INVALID
11
DIN
12
FORCEON
13
DOUT
14
GND
15
VCC
16
FORCEOFF
U5
SN65C3221PW
J7
C8
0.1uF
R9 5.11k
SW1
R10 C10
1
2
3
J4
C9
10nF
C18
10nF
C19
10nF
1
NC
2
GND
3
VO
4V+
5GND
U4
LM20BIM7
R55 51.1
D19
C47
100pF
R52
1k
R54
3.01k
R57
301
C49
100pF
R53
C48
R56 10k
C46
0.01uF
C50
0.1uF
D16
Q12
D18
D17
1
2
7
5 8U8-A
D2
BAT54S
R4
301
C7
1uF
R1
1.74k
C2
0.1uF
R2
1
C5
0.1uF
R3 1
C6
0.1uF
C3
2.2uF
C4
0.1uF
C1
0.1uF
1IN 2NC
3NC 4GND 5
FB/NC
6
NC
7
NC
8
OUT
9PWPD
U2
TPS715A33DRBR
D1
D3
1
2
3
J1
VIN+
VAUX_P
-VAUX_-VIN
-VIN
GND
VIN_MONITOR
VAUX_S
U1 PWR050
R62 51.1
D23
C54
100pF
R59
1k
R61
3.01k
R65
301 C56
100pF
R60
C55
R63 10k
C53
0.01uF
D20 D21
D22
Q13
3
4
6
U8-B
R7
301
R8
301
Q2
R6
301
Q3
Q1
D6
D4 D5
1
2
3
4
5 6
7
8
9
10
11
J5
11
11
1
1
1
1
11
1
1
1
1
1
1
1
1
111
1
1
1
1
1
1
1
1
1
ADDRESS
EADC_IOSENSE
+VO_SENSE
DPWM0A
DPWM1A
OVLATCH P_GOOD
SCI_TX0
AC_P_FAIL_IN
12VS
DPWM0B
DPWM1B
ON/OFF AC_P_FAIL_OUT 3_3VD
SCI_RX0
+VO_SENSE
DPWM2A
DPWM2B
SRDET1
SRDET2
-VO_SENSE IPS
SCI_RX1
VIN_MON
DGND
IO_SENSE ISHARE
TEMP
PWM0
SCI_TX1 EXT_OVP_DISABLE VIN_MON
VOSADC12
ORING_CTRL
FAILURE IO_SEN-
IO_SEN+
AGND
DGND AGND
3_3VD
DGND
DGND
DGND
SCI_RX1
SCI_TX1
3_3VD
SCI_RX0
SCI_TX0
DGND
AC_P_FAIL_IN
3_3VD
ON/OFF
DGND
ADDRESS
AGND
ISHARE
AGND
TEMP
3_3VA
AGND
3_3VD
SR_VDS1 SRDET1
DPWM2A
AGND
DGND
GND_PWR
DGND
3_3VD
VAUX_P
12VS 3_3VA
VIN_MON
GND_PWR_PRI
GND_PWR
GND_PWR AGND
DGND
DGND
DGND
AGND
3_3VD
DGND
DGND
BUS+_HV_PRI
3_3VD
SR_VDS2
SRDET2
DPWM2B
AGND
DGND
GND_PWR
AC_P_FAIL_OUT
FAILURE P_GOOD
3_3VD
DGND
DGND
www.ti.com Schematics
Figure 2. UCD3138PFCEVM-026 Schematic (image 2 of 2)
7
SLUU979A–August 2012–Revised July 2013 Digitally Controlled LLC Resonant Half-Bridge DC-DC Converter
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RESET
Parts not used
1
1111
1
1
1
11
1
1
111
1
1
1
1
1
1
1
111
1
R14
1.5K
TP2
TP3
TP1
TP6
TP22
TP11
TP23
TP8 TP9
TP10
TP4
TP7
TP16
TP12 TP13
TP14 TP15 TP17 TP18
TP19 TP20
TP21 TP24
TP25
TP26 TP27
TP28
TP29
TP32
TP33
TP34
TP35 TP36
TP30
TP31
1
2
3
4
5
6
7
8
9
10
J1
J2
S1
D1
BAT54A
D2
BAT54A
C31
1000pF
C30
1000pF
C28
1000pF
C29
1000pF
C26
1000pF
C27
1000pF
C24
1000pF
C25
1000pF
C22
1000pF
C23
1000pF
C20
1000pF
C21
1000pF
C18
1000pF
C19
1000pF
C14
1000pF
C7
100pF
C8
1000pF
C17
33pF
C15
33pF
C16
33pF
C9 33pF
C10 33pF
C2
0.1uF
C3
0.1uF
C4
0.1uF
C5
0.1uF
C6
1uF
C11
0.1uF
C12
2.2uF
C1
1uF
C13
0.1uF
R13
1.5K
R12
1.65K
R9 100
R8 100
R7 100
R5 100
R6
0
R3
R1 R2 R4
R11 16K
R10
10K
R15
100K
R16 100
R17 100
R18 100 R20 100
R19 100
R25 100
R23 100
R26 100
R24 2K
R21 2K
R22 2K
R27 2K
R28 2K
R29 2K
NS1
1AGND
2AD13
3AD12 4AD10
5AD07 6AD06
7AD04 8AD03
9
V33DIO
10 DGND
11
RESET
12
ADC_EXT
13
SCI_RX0
14
SCI_TX0
15 PMBUS_CLK 16 PMBUS_DATA
17
DPWM0A
18
DPWM0B
19
DPWM1A
20
DPWM1B
21
DPWM2A
22
DPWM2B
23
DPWM3A
24
DPWM3B
25 DGND
26
SYNC
27 PMBUS_ALERT 28 PMBUS_CTRL
29
SCI_TX1
30
SCI_RX1
31 PWM0
32 PWM1
33 DGND
34
INT_EXT
35
FAULT0
36
FAULT1
37
TCK
38
TDO
39
TDI
40
TMS
41
TCAP
42
FAULT2
43
FAULT3
44 DGND 45
V33DIO
46
BP18
47
V33D
48 AGND
49 AGND
50 EAP0 51 EAN0 52 EAP1 53 EAN1 54 EAP2 55 EAN2
56 AGND
57
V33A
58 AD00
59 AD01
60 AD02
61 AD05 62 AD08
63 AD09
64 AD11
65 PWPD
U1
UCD3138RGC
TP5
R39 10
AD-00
SCI-RX1
SCI-TX1 SCI-TX0
SCI-RX0
EXT-TRIG
DPWM-2B
DPWM-2A
DPWM-1B
DPWM-1A
DPWM-0B
DPWM-0A
/RESET
TMS
TDI
TDO
TCK
PWM-1
PWM-0
AD-06
AD-05
AD-04
AD-03
AD-00
EADC-N1
EADC-P1
EADC-N0
DGND
AD-02
AD-07
DPWM-3A
DPWM-3B
EADC-P2
EADC-N2
SYNC
FAULT-0
TCAP
AD-09
AD-10
AD-12
AD-13
EADC-P0
AD-08
AD-01
AD-11 FAULT-3
FAULT-2
FAULT-1
DGND
/RESET
DGND
INT-EXT
DGND
DGND
PMBUS-CTRL
PMBUS-CLK
PMBUS-ALERT
PMBUS-DATA
3.3VD
3.3VD
3.3VD
3.3VD
DGND
DGND
DGND
3.3VA
AGND
AGND
AGND DGND
Schematics www.ti.com
Figure 3. UCD3138CC64EVM-030 Schematic (image 1 of 2)
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If needed, use this jumper
to provide 3.3VD to application board
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
PPPN202FJFN
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
PPPN202FJFN
1
IN
2
NC
3
NC
4
GND
5FB/NC
6NC
7NC
8OUT
9PWPD
U2
TPS715A33DRBR
TP37
C33
10uF
C32
1uF
R31
301
R30
0.5
R35
10K
R32
10K
R33
10K
R37 10K
R38 10K
R34
0
R36
0
D3
J6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J5
C34
0.1uF
EADC-N2
EADC-N1
EADC-N0
EADC-P0
EADC-P1
EADC-P2
AD-00
AD-01
AD-02
AD-03
AD-04
AD-05
AD-06
AD-07
AD-08
AD-09
AD-10
AD-11
AD-12
AD-13
DPWM-0A
DPWM-1A
DPWM-2A
DPWM-3A
FAULT-0
SYNC
FAULT-2
SCI-TX1
PWM-0
TCAP
SCI-TX0
INT-EXT
+12V_EXT
DPWM-0B
DPWM-1B
DPWM-2B
DPWM-3B
FAULT-3
SCI-RX1
PWM-1
SCI-RX0
EXT-TRIG
/RESET
3.3VD
TMS
TDI
TDO
TCK
DGND
+12V_EXT
FAULT-1
3.3VD
3.3VD
3.3VD
DGND
DGND
AGND
www.ti.com Schematics
Figure 4. UCD3138CC64EVM-030 Schematic (image 2 of 2)
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VM1
VM2
+
+
VINDC1
LOAD1
UART 1 (J5)
SW1
Test Setup www.ti.com
5 Test Setup
5.1 Test Equipment
DC Voltage Source: capable of 350 VDC to 400 VDC, adjustable, with minimum power rating of 400 W, or
current rating not less than 1.5 A, with current limit function. The DC voltage source to be used should
meet IEC61010 safety requirements.
DC Multimeter: One unit capable of 0-VDC to 400-VDC input range, four digits display preferred; and one
unit capable of 0-VDC to 15-VDC input range, four digits display preferred.
Output Load: DC load capable of receiving 0 VDC to 15 VDC, 0 A to 30 A, and 0 W to 360 W or greater,
with display such as load current and load power.
Current-meter, DC, optional in case the load has no display, one unit, capable of 0 A to 30 A. A low ohmic
shunt and DMM are recommended.
Oscilloscope: capable of 500-MHz full bandwidth, digital or analog, if digital 5 Gs/s or better.
Fan: 200 LFM to 400 LFM forced air cooling is recommended, but not a must.
Recommended Wire Gauge: capable of 30 A, or better than number 14 AWG, with the total length of
wire less than 8 feet (a four foot input and a four foot return).
5.2 Recommended Test Setup
Figure 5. UCD3138LLCEVM-028 Recommended Test Set Up
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www.ti.com Test Setup
Figure 6. Orientation of Board UCD3138CC64EVM-030 on Board UCD3138LLCEVM-028
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List of Test Points www.ti.com
6 List of Test Points
Table 2. UCD3138CC64EVM-030 Test Points
TEST POINTS NAME DESCRIPTION
TP1 DGND Digital GND
TP2 Not Used
TP3 Not Used
TP4 HSG Primary high-side MOSFET gate, Q6
TP5 Input + Input + after jumper J10
TP6 Input_P Input voltage positive terminal
TP7 Input_N Input voltage return terminal
TP8 LSG Primary low-side MOSFET gate, Q7
TP9 HSS Primary-side switch node, or the intersection of Q6 and Q7
TP10 SWC Primary side, the intersection of bridge capacitors
TP11 SR_VDS1 Drain of secondary side sync FET Q8 and Q9
TP12 SR_VDS2 Drain of secondary side sync FET Q10 and Q11
TP13 IPS Primary current sense
TP14 SR1 SR gate drive to Q8 and Q9
TP15 SR2 SR gate drive to Q10 and Q11
TP16 Vo_Ripple Output voltage ripple
TP17 Vo_P Output voltage positive terminal
TP18 Xmer_C Power transformer center point of the secondary side windings.
TP19 GND_PWR Power GND
TP20 Vo_N Output voltage return
7 List of Terminals
Table 3. List of Terminals
TERMINAL NAME DESCRIPTION
J1 Bias Input 3 pin, external power input, 12 V
J2 Analog Signal 40-pin header, analog signal to control card (UCD3138CC64EVM-030)
J3 Digital Signal 40-pin header, digital signal to control card
J4 AJ Analog signal connection, 40 pins
J5 UART1 Standard UART connection, RS232, 9 pin
J6 OVP-1 2-pin header, jump across to disable external OVP
J7 Not Used
J8 Input_P Input voltage positive terminal
J9 Input_N Input voltage return terminal
J10 Jumper Reserved to an input fuse substitution
J11 Output_P Output voltage positive terminal
J12 Output_N Output voltage return terminal
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www.ti.com Test Procedure
8 Test Procedure
8.1 Efficiency Measurement Procedure
WARNING
• Danger of electrical shock! High voltage present during the
measurement.
• Do not leave EVM powered when unattended.
• Danger of heat burn from high temperature.
1. Refer to Figure 5 for basic set up to measure power conversion efficiency. The required equipment for
this measurement is listed in Section 5.1.
2. Before making electrical connections, visually check the boards to make sure no shipping damage
occurred.
3. In this EVM package, three EVMs are included, UCD3138LLCEVM-028, UCD3138CC64EVM-030, and
USB-TO-GPIO. For this measurement, the UCD3138LLCEVM-028 and UCD3138CC64EVM-030
boards are needed.
4. First install the UCD3138CC64EVM-030 board onto the UCD3138LLCEVM-028. Care must be taken
with the alignment and orientation of the two boards, or damage may occur. Refer to Figure 6 for
UCD3138PFCEVM-030 board orientation.
5. Connect the DC voltage source to J8 (+) and J9 (-). The DC voltage source should be isolated and
meet IEC61010 requirements. Set up the DC output voltage in the range specified in Table 1, between
350 VDC and 400 VDC; set up the DC source current limit 1.2 A.
NOTE: The board has no fuse installed and relies on the external voltage source current limit for
circuit protection.
6. Connect an electronic load with either constant-current mode or constant-resistance mode. The load
range is from zero to 29 A.
7. Check and make sure a jumper is installed on J6.
8. It is recommended to use the switch SW1 to turn on the board output after the input voltage is applied
to the board. Before applying input voltage, make sure the switch, SW1, is in the OFF position.
9. If the load does not have a current or a power display, a current meter or low ohmic shunt and DMM is
needed between the load and the board for current measurements.
10. Connect a volt-meter across the output connector and set the volt-meter scale 0 V to 15 V on its
voltage, DC.
11. Turn on the DC voltage source output, flip SW1 to ON and vary the load. Record output voltage and
current measurements.
8.2 Equipment Shutdown
1. Shut down the DC voltage source.
2. Shut down the electronic load.
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11.300
11.500
11.700
11.900
12.100
12.300
5 10 15 20 25 30
Load Current (A)
Load Regulation (V)
400Vdc
380Vdc
350Vdc
80.0%
85.0%
90.0%
95.0%
5 10 15 20 25 30
Load Current (A)
Efficiency
400Vdc
380Vdc
350Vdc
Performance Data and Typical Characteristic Curves www.ti.com
9 Performance Data and Typical Characteristic Curves
Figure 7 through Figure 20 present typical performance curves for UCD3138LLCEVM-028.
9.1 Efficiency
Figure 7. UCD3138LLCEVM-028 Efficiency
9.2 Load Regulation
Figure 8. UCD3138LLCEVM-028 Load Regulation
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40.0
60.0
80.0
100.0
120.0
140.0
5 10 15 20 25 30
Load Current (A)
Switching Frequency (kHz)
400Vdc
380Vdc
350Vdc
www.ti.com Performance Data and Typical Characteristic Curves
9.3 Switching Frequency Control
Figure 9. Switching Frequency Control in LLC Mode
9.4 Load Operation with LLC and PWM
Figure 10. LLC Resonant Mode Operation at Full Load Figure 11. PWM Mode Operation after FSW = 150 kHz
(Ch1 = VGS of Q7, Ch2 = current in resonant network, 2 (Ch1 = VGS of Q7, Ch2 = VGS of Q6, Ch3 = VGS of SR2,
A/div, Ch3 = VDS of Q7, Ch4 = VOripple) Ch4 = VGS of SR3)
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Performance Data and Typical Characteristic Curves www.ti.com
9.5 Very Light-Load Operation at High Line of Input
Figure 12. PWM Control at 400VDC Input and Light Figure 13. PWM Control with SR Off and Pulse
Load (SR off) Skipping
(Ch1 = VGS, Q7, Ch2 = VGS, Q6, Ch3 = VGS, SR1, Ch4 = (Ch1 = VGS, Q7, Ch2 = VGS, Q6, Ch3 = VGS, SR1, Ch4 =
VGS, SR2) VGS, SR2)
9.6 Output Voltage Ripple
Figure 14. Output Voltage Ripple 380 VDC and Full Figure 15. Output Voltage Ripple 380 VDC and Half
Load Load
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www.ti.com Performance Data and Typical Characteristic Curves
9.7 Output Turn On
Figure 16. Output Turn On 380 VDC with Load Range Figure 17. Output Turn On 350 VDC with Load Range
9.8 Other Waveforms
Figure 18. 380 VDC and 30 A Before OCP Latch-Off Shutdown
(Ch1 = VDS of Q7, Ch2 = current of resonant network, Ch3 = VOripple)
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Gain and Phase verse Frequency
-50.00
-40.00
-30.00
-20.00
-10.00
0.00
10.00
20.00
30.00
40.00
50.00
0.10 1.00 10.00
F - Frequency - kHz
Gain - dB
-150.00
-120.00
-90.00
-60.00
-30.00
0.00
30.00
60.00
90.00
120.00
150.00
Gain Phase
Gain and Phase verse Frequency
-50.00
-40.00
-30.00
-20.00
-10.00
0.00
10.00
20.00
30.00
40.00
50.00
0.10 1.00 10.00
F - Frequency - kHz
Gain - dB
-150.00
-120.00
-90.00
-60.00
-30.00
0.00
30.00
60.00
90.00
120.00
150.00
Gain Phase
Performance Data and Typical Characteristic Curves www.ti.com
Figure 19. Control Loop Bode Plots at 380 VDC and Full Load
Figure 20. Control Loop Bode Plots at 400 VDC and Full Load
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www.ti.com EVM Assembly Drawing and PCB layout
10 EVM Assembly Drawing and PCB layout
The following figures (Figure 21 through Figure 26) show the design of the UCD3138LLCEVM-028 printed
circuit board. PCB dimensions: L x W = 8.0 inch x 6.0 inch, PCB material: FR4 or compatible, four layers
and 2-ounce copper on each layer
Figure 21. UCD3138LLCEVM-028 Top Layer Assembly Drawing (top view)
Figure 22. UCD3138LLCEVM-028 Bottom Assembly Drawing (bottom view)
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EVM Assembly Drawing and PCB layout www.ti.com
Figure 23. UCD3138LLCEVM-028 Top Copper (top view)
Figure 24. UCD3138LLCEVM-028 Internal Layer 1 (top view)
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