User's Guide
SLUU316 – August 2008
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
The UCC28061 is a dual-phase, transition-mode Power Factor Correction (PFC) pre-regulator. The
UCC28061EVM is an evaluation module (EVM) with a 390-V, 300-W, dc output that operates from a
universal input of 85 VRMS to 265 VRMS and provides power-factor correction.
Throughout this document, the acronym EVM and the phrases evaluation board and evaluation module
are synonymous with the UCC28061EVM.
1
Description
The pre-regulator uses the UCC28061 PFC interleaved controller to shape the input current wave to
provide power-factor correction. This device uses TI’s Natural Interleaving™ technology to interleave
boost phases.
This user’s guide provides the schematic, List of Materials, assembly drawing for a single-sided printed
circuit board application, and test set-up information necessary to evaluate the UCC28061 in a typical
PFC application.
2
Thermal Requirements
This evaluation module will operate up to 300 W without external cooling in ambient tempatures of 25°C.
3
Electrical Characteristics
Table 1 summarizes the electrical specifications of the UCC28061EVM.
Table 1. UCC28061EVM Electrical Specifications
PARAMETER
CONDITIONS
RMS input voltage (ac line)
UCC28061EVM
MIN
TYP
85
Output voltage, VOUT
265
47
Power factor (PF) at maximum load
0.9
Output power
4
UNITS
VRMS
390
Line frequency
Full load efficiency
MAX
AC line = 115 V
94%
AC line = 230 V
97%
V
63
Hz
300
W
Schematics
Figure 1 and Figure 2 show the schematics for this EVM. See the List of Materials for specific values.
To evaluate inductor ripple currents, resistors R25 and R26 can be removed and replaced with current
loops.
Natural Interleaving is a trademark of Texas Instruments.
All other trademarks are the property of their respective owners.
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
1
Schematics
+
+
www.ti.com
Figure 1. Interleaved PFC Power Stage
2
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
Schematics
+
www.ti.com
Figure 2. Controller Circuitry
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
3
Test Setup and Power-Up/Power-Down Instructions
5
www.ti.com
Test Setup and Power-Up/Power-Down Instructions
WARNING
There are high voltages present on the pre-regulator. It should only
be handled by experienced power supply professionals. To
evaluate this board as safely as possible, the following test
configuration should be used:
• Connect an isolation transformer between the source and unit
• Attach a voltmeter and a resistive or electronic load to the unit
output before supplying power to the EVM.
A separate 13-V bias supply is required to power the UCC28061 control circuitry. The unit will start up
under no-load conditions. However, for safety, a load should be connected to the output of the device
before it is powered up. The unit should also never be handled while power is applied to it or when the
output voltage is above 50-V dc. Refer to Figure 3 for a recommended test setup diagram.
CAUTION
There are very high voltages on the board. Components can and will reach
temperatures greater than 100°C. Use caution when handling the EVM.
4
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
Test Setup and Power-Up/Power-Down Instructions
www.ti.com
VM
0 to 300W Load
Isolation
Transformer
+
13V Bias Supply
Figure 3. Test Setup
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
5
Typical Performance Data
6
www.ti.com
Typical Performance Data
Figure 4 through Figure 7 present characteristic performance data for the UCC28061EVM.
Efficiency
Efficiency at Vin = 115Vrms
100.0
100.0
99.0
99.0
98.0
97.0
Efficiency (%)
Efficiency (%)
98.0
96.0
95.0
94.0
93.0
97.0
96.0
95.0
94.0
93.0
92.0
92.0
91.0
91.0
90.0
10
20
30
40
50
60
70
80
90
100
90.0
10
Output Power (%)
20
30
40
50
60
70
80
90
100
Output Power (%)
Efficiency at Vin 85Vrms
Efficiency at Vin 265Vrms
Phase Management Disabled
Figure 5. Efficiency at 115 VRMS, Without
Phase Management
Figure 4. Efficiency at 85VRMS and 265VRMS
Efficiency at Vin = 230Vrms
Current Harmonics
Vin = 230V RMS, Pout = 300W
100.0
1.40706
99.0
1.17256
97.0
EN61000-3-2 SPEC
96.0
Amplitude
Efficiency (%)
98.0
95.0
94.0
93.0
0.93805
0.70354
0.46904
92.0
91.0
0.23453
90.0
10
20
30
40
50
60
70
80
90
100
Output Power (%)
Phase Management Disabled
Figure 6. Efficiency at 230 VRMS, Without
Phase Management
6
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
0.00002
0
3
6
9 12 15 18 21 24 27 30 33 36 39 42 45 48
Harmonic Number
Figure 7. Current Harmonics
SLUU316 – August 2008
Submit Documentation Feedback
Typical Performance Data
www.ti.com
6.1
Output Ripple Voltage at Full Load
Figure 8 illustrates the output ripple voltage.
Figure 8. VOUT Ripple, POUT = 300 W
6.2
Input Ripple Current Cancellation
Figure 9 through Figure 14 show the input current (M1= IL1 + IL2), Inductor Ripple Current (IL1, IL2) versus
rectified line voltage. From these graphs, it can be observed that interleaving reduces the magnitude of
input ripple current caused by the inductor ripple current.
Figure 9. Inductor and Input Ripple Current at
85 VRMS at Peak of Line Voltage
SLUU316 – August 2008
Submit Documentation Feedback
Figure 10. Inductor and Input Ripple Current
at 85 VRMS Input at Half the Line Voltage
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
7
Typical Performance Data
8
www.ti.com
Figure 11. Inductor and Input Ripple Current
at 265 VRMS Input at Peak Line Voltage
Figure 12. Inductor and Input Ripple Current
at 265 VRMS Input at Half Peak Line Voltage
Figure 13. Inductor and Input Ripple Current
at VIN = 85 VRMS, POUT = 300 W
Figure 14. Inductor and Input Ripple Current
at VIN = 265 VRMS, POUT = 300 W
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
Typical Performance Data
www.ti.com
6.3
Startup Characteristics
Figure 15 and Figure 16 illustrate the UCC28061EVM startup characteristics.
Figure 15. Start-Up at VIN = 85 VRMS,
POUT = 300 W
6.4
Figure 16. Start-Up at VIN = 265 VRMS,
POUT = 0 W
Brownout Protection
The UCC28061 has a brownout protection that shuts down both gate drives (GDA and GDB) when the
VINAC pin detects that the RMS input voltage is too low. This EVM was designed to go into a brownout
state when the line drops below 64 VRMS. Once the UCC28061 control device has determined that the
input is in a brownout condition, a 400-ms timer starts to allow the line to recover before shutting down the
gate drivers. After 400 ms of brownout, both gate drivers turn off, as shown in Figure 17 and Figure 18.
VOUT
C3
15.2VPP
Rectified Line Voltage After the Bridge Rectifier C3
9.67VRMS
GDA
GDB
Figure 17. Brownout at 85 VRMS
SLUU316 – August 2008
Submit Documentation Feedback
Figure 18. Brownout at 265 VRMS
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
9
Typical Performance Data
6.5
www.ti.com
Line Transient
A line transient test was conducted with an ac source on the reference design. The line was varied from
230 VRMS to 115 VRMS to 230 VRMS and the transient response was evaluated in each case. From the
oscilloscope image in Figure 19, it can be observed that the output recovered from line transients within
300ms at full load.
Figure 19. Line Transient, POUT = 300W
10
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
Reference Design Assembly Drawing
www.ti.com
7
Reference Design Assembly Drawing
Figure 20 and Figure 22 show the top and bottom layers (respectively) of the UCC28061EVM.
Note:
Board layouts are not to scale. These figures are intended to show how the board is laid out;
they are not intended to be used for manufacturing UCC28061EVM PCBs.
Figure 20. Top Layer Assembly
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
11
Reference Design Assembly Drawing
www.ti.com
Figure 21. Bottom Layer Copper
12
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
Reference Design Assembly Drawing
www.ti.com
Figure 22. Bottom Layer Assembly
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
13
List of Materials
8
www.ti.com
List of Materials
Table 2 lists the EVM components as configured according to the schematics (see Section 4).
Table 2. List of Materials
COUNT
14
REF DES
DESCRIPTION
PART NUMBER
MFR
4
AC_LINE,
AC_NEUTRAL,
RETURN, VOUT
Connector, banana jack, uninsulated, 3267,
0.500 dia. inch
3267
Pomona
1
C1
Capacitor, film, 275VAC, 20%, 0.1 µF, 0.689 x
0.236 inch
ECQU2A104BC1
Panasonic
1
C11
Capacitor, ceramic, 16 V, X7R, 10%, 220 nF,
1206
Std
Std
2
C12, C13
Capacitor, ceramic, 16 V, X7R, 10%, 2.2 µF,
0805
Std
Std
1
C14
Capacitor, aluminum, 35 V, 20%, 22 µF, 0.200 *
0.435 inch
ECA-1VM220
Panasonic
1
C15
Capacitor, ceramic, 25 V, X7R, 10%, 1 nF, 0805
Std
Std
1
C17
Capacitor, ceramic, 25 V, X7R, 10%, 10 nF,
0805
Std
Std
1
C2
Capacitor, polyester, 630 V, 10%, 0.047 µF,
0.256 x 0.650 inch
ECQ-E6473KZ
Panasonic
2
C3, C4
Capacitor, aluminum, 450 VDC, 20% , 100 µF,
18 x 40 mm
EKXG451ELL101
MM40S
Nippon
Chemi-con
2
C5, C6
Capacitor, film, 275 VAC, 20%, 0.47 µF, 0.236 X
0.591
ECQ-U2A474MG
Panasonic
2
C7, C10
Capacitor, ceramic, 25 V, X7R, 10%, 22 pF,
0805
Std
Std
3
C8, C9, C16
Capacitor, ceramic, 25 V, X7R, 10%, 1.2 nF,
0805
Std
Std
3
D1, D2, D4
Diode, 3000 mA, 600 V, SMC
MURS360T3
On Semi
1
D3
Diode, bridge, 6 A, 600 V, BU6
GBU6J
Vishay
2
F1
Fuse clip, 5x20 mm
0100056H
Wickmann
3
HS1, HS2, HS3
Heatsink, universal-mount TO-220, 7-345-2PP,
1.500 x 2.000 inch
7-345-2PP
IERC-CTS
1
J1
Terminal block, 2 pin, 15 A, 5.1 mm,
ED1609-ND, 0.40 x 0.35 inch
ED1609
OST
3
JP1, JP2, JP3
Jumper, 2.000 inch length, PVC insulation, AWG
22, 0.035 inch dia.
923345-20-C
3M
1
JP4
Jumper, 2.100 inch length, PVC insulation, AWG
22, 0.035 inch dia.
923345-21-C
3M
1
JP5
Jumper, 0.500 inch length, PVC insulation, AWG
22, 0.035 inch dia
923345-05-C
3M
2
JP6, JP8
Jumper, 0.700 inch length, PVC insulation, AWG
22
923345-07-C
Belden
1
JP7
Jumper, 0.100 inch length, non-insulated, AWG
22
923345-01-C
Belden
1
JP10
Header, 2-pin, 100-mil spacing, (36-pin strip),
PTC36SAAN, 0.100 inch x 2
PTC36SAAN
Sullins
1
JP9
Jumper, 1.2 inch length, PVC insulation, AWG
22, 0.035 inch dia.
923345-20-C
3M
2
L1, L2**
Inductor, boost PFC with aux. 330 uH @ 5.3 A
PK, 1.555 Dia. inch
CTX16-17769R
Cooper
2
Q1, Q2
MOSFET, N-channel, 500 V, 11 A, 520 mΩ,
TO-220V
IRFB11N50APbF
IR
1
R1
Resistor, chip, 1/10 W, 1%, 51.1 Ω, 0805
Std
Std
2
R11, R14
Resistor, chip, 1/10 W, 1%, 20.5 kΩ, 0805
Std
Std
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
SLUU316 – August 2008
Submit Documentation Feedback
List of Materials
www.ti.com
Table 2. List of Materials (continued)
COUNT
REF DES
DESCRIPTION
PART NUMBER
MFR
2
R12, R13
Resistor, chip, 1/10 W, 1%, 47.0 kΩ, 0805
Std
Std
1
R15
Resistor, chip, 1/10 W, 1%, 121 kΩ, 0805
Std
Std
2
R16, R19
Resistor, chip, 1/10 W, 1%, 5.11 Ω, 0805
Std
Std
1
R18
Resistor, chip, 1/10 W, 1%, 6.19 kΩ, 0805
Std
Std
3
R2, R4, R17
Resistor, chip, 1/10 W, 1%, 10.0 kΩ, 0805
Std
Std
1
R23
Resistor, chip, 1/10 W, 1%, 30.1 kΩ, 0805
Std
Std
1
R24
Resistor, chip, 1/10 W, 1%, 100 Ω, 0805
Std
Std
2
R25, R26
Resistor, chip, 1 W, 5%, 0 Ω, 2512
Std
Std
1
R3
Resistor, chip, 1/2 W, 1%, 0.015 Ω, 2010
WSL2010R0150F
EA
Vishay
9
R5, R6, R7, R8, R9,
R10, R20, R21, R22
Resistor, chip, 1/10 W, 1%, 1.00 MΩ, 0805
Std
Std
1
RT1
Thermistor, NTC, 5 Ω, 6 A, 5 Ω, 0.180 X 0.550
inch
CL-40
Thermometrics
2
TP1, TP2
Pin, thru hole, tin plate, for 0.062 PCB's,
K24A/M, 0.039 inch
K24A/M
Vector
1
U1
Interleave PFC Controller, SO16
UCC28061D
TI
1
VAR1
Varistor 275 V RMS, 0.472 x 0.213 inch
S10K275E2
Epcos
1
PCB
HPA343 printed circuit board
HPA343
1
X1 @ F1
4 A, fast acting fuse, BK/GDA-4A, 5mmX20mm
BK/S501-4-R
Cooper/Bussman
6
"X1 @ HS1 and D3,
HS2 and Q1, HS3 and
Q2"
Nut #4-40 (steel)
Std
Std
6
"X1 @ HS1 and D3,
HS2 and Q1, HS3 and
Q2"
Pan head screw #4-40X3/8 (steel)
Std
Std
1
X1 D3 and HS1
Thermal grease
Std
Std
6
"X1 @ HS1 and D3,
HS2 and Q1, HS3 and
Q2"
Split lock washer #4(steel)
Std
Std
6
"X1 @ HS1 and D3,
HS2 and Q1, HS3 and
Q2"
Nylon shoulder washer #4
3049
Keystone
Electronics
2
"X1 @ HS2 and Q1,
HS3 and Q2"
Thermal pad silicon TO220
3223-07FR-51
BERQUIST
4
1903C
Standoff hex .500/6-32THR nylon
1903C
Keystone
Electronics
4
4824
Nut
4824
Keystone
Electronics
Note 9
RTV, adhesive sealant
RTV 167
GE
AR
SLUU316 – August 2008
Submit Documentation Feedback
UCC28061EVM 300-W Interleaved PFC Pre-Regulator
15
EVALUATION BOARD/KIT IMPORTANT NOTICE
Texas Instruments (TI) provides the enclosed product(s) under the following conditions:
This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES
ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have
electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete
in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental
measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does
not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling
(WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives.
Should this evaluation board/kit not meet the specifications indicated in the User’s Guide, the board/kit may be returned within 30 days from
the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY SELLER TO BUYER
AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies TI from all claims
arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all
appropriate precautions with regard to electrostatic discharge.
EXCEPT TO THE EXTENT OF THE INDEMNITY SET FORTH ABOVE, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
TI currently deals with a variety of customers for products, and therefore our arrangement with the user is not exclusive.
TI assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or
services described herein.
Please read the User’s Guide and, specifically, the Warnings and Restrictions notice in the User’s Guide prior to handling the product. This
notice contains important safety information about temperatures and voltages. For additional information on TI’s environmental and/or
safety programs, please contact the TI application engineer or visit www.ti.com/esh.
No license is granted under any patent right or other intellectual property right of TI covering or relating to any machine, process, or
combination in which such TI products or services might be or are used.
FCC Warning
This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES
ONLY and is not considered by TI to be a finished end-product fit for general consumer use. It generates, uses, and can radiate radio
frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are
designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may
cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may
be required to correct this interference.
EVM WARNINGS AND RESTRICTIONS
It is important to operate this EVM within the input voltage range of 85VRMS to 265VRMS and the output voltage range of 375V to 450V.
Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are questions
concerning the input range, please contact a TI field representative prior to connecting the input power.
Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the EVM.
Please consult the EVM User's Guide prior to connecting any load to the EVM output. If there is uncertainty as to the load specification,
please contact a TI field representative.
During normal operation, some circuit components may have case temperatures greater than +100°C. The EVM is designed to operate
properly with certain components above +100°C as long as the input and output ranges are maintained. These components include but are
not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of devices can be identified
using the EVM schematic located in the EVM User's Guide. When placing measurement probes near these devices during operation,
please be aware that these devices may be very warm to the touch.
Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265
Copyright 2008, Texas Instruments Incorporated
IMPORTANT NOTICE
Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements,
and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should
obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are
sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment.
TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI’s standard
warranty. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. Except where
mandated by government requirements, testing of all parameters of each product is not necessarily performed.
TI assumes no liability for applications assistance or customer product design. Customers are responsible for their products and
applications using TI components. To minimize the risks associated with customer products and applications, customers should provide
adequate design and operating safeguards.
TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right, copyright, mask work right,
or other TI intellectual property right relating to any combination, machine, or process in which TI products or services are used. Information
published by TI regarding third-party products or services does not constitute a license from TI to use such products or services or a
warranty or endorsement thereof. Use of such information may require a license from a third party under the patents or other intellectual
property of the third party, or a license from TI under the patents or other intellectual property of TI.
Reproduction of TI information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied
by all associated warranties, conditions, limitations, and notices. Reproduction of this information with alteration is an unfair and deceptive
business practice. TI is not responsible or liable for such altered documentation. Information of third parties may be subject to additional
restrictions.
Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all
express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice. TI is not
responsible or liable for any such statements.
TI products are not authorized for use in safety-critical applications (such as life support) where a failure of the TI product would reasonably
be expected to cause severe personal injury or death, unless officers of the parties have executed an agreement specifically governing
such use. Buyers represent that they have all necessary expertise in the safety and regulatory ramifications of their applications, and
acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements concerning their products
and any use of TI products in such safety-critical applications, notwithstanding any applications-related information or support that may be
provided by TI. Further, Buyers must fully indemnify TI and its representatives against any damages arising out of the use of TI products in
such safety-critical applications.
TI products are neither designed nor intended for use in military/aerospace applications or environments unless the TI products are
specifically designated by TI as military-grade or "enhanced plastic." Only products designated by TI as military-grade meet military
specifications. Buyers acknowledge and agree that any such use of TI products which TI has not designated as military-grade is solely at
the Buyer's risk, and that they are solely responsible for compliance with all legal and regulatory requirements in connection with such use.
TI products are neither designed nor intended for use in automotive applications or environments unless the specific TI products are
designated by TI as compliant with ISO/TS 16949 requirements. Buyers acknowledge and agree that, if they use any non-designated
products in automotive applications, TI will not be responsible for any failure to meet such requirements.
Following are URLs where you can obtain information on other Texas Instruments products and application solutions:
Products
Amplifiers
Data Converters
DSP
Clocks and Timers
Interface
Logic
Power Mgmt
Microcontrollers
RFID
RF/IF and ZigBee® Solutions
amplifier.ti.com
dataconverter.ti.com
dsp.ti.com
www.ti.com/clocks
interface.ti.com
logic.ti.com
power.ti.com
microcontroller.ti.com
www.ti-rfid.com
www.ti.com/lprf
Applications
Audio
Automotive
Broadband
Digital Control
Medical
Military
Optical Networking
Security
Telephony
Video & Imaging
Wireless
www.ti.com/audio
www.ti.com/automotive
www.ti.com/broadband
www.ti.com/digitalcontrol
www.ti.com/medical
www.ti.com/military
www.ti.com/opticalnetwork
www.ti.com/security
www.ti.com/telephony
www.ti.com/video
www.ti.com/wireless
Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265
Copyright © 2008, Texas Instruments Incorporated
