Using the UCC28070EVM
User's Guide
Literature Number: SLUU312B
May 2008 – Revised May 2009
User's Guide
SLUU312B – May 2008 – Revised May 2009
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
1
Introduction
The UCC28070 evaluation module is a 300-W, two phase interleaved, PFC pre-regulator that uses
average current mode control techniques to achieve near unity power factor. The pre-regulator was
designed to operate off a universal ac line input of 85 V to 265 V and provides a regulated 390-V dc
output. This evaluation module demonstrates TI's interleaved PFC control technology.
2
Description
The pre-regulator uses the UCC28070 PFC interleaved controller to shape the input current wave form to
provide power factor correction.
3
Thermal Requirements
•
4
The evaluation module works up to 300 W without external cooling in ambient temperature of 25°C.
Electrical Specifications
Table 1. Specification Table
DEFINITION
RMS Input Voltage (ac line)
MINIMUM
TYPICAL
85
Output Voltage (VOUT)
47
Power Factor (PF) at Maximum Load
0.9
Output Power
2
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
UNITS
265
V
63
Hz
300
W
390
Line Frequency
Full Load Efficiency
MAXIMUM
90
%
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Schematics
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5
Schematics
+
U1
UCC27324D
+
+
To evaluate inductor ripple currents jumpers JP1 and JP2 can be removed and replaced with current
loops.
Figure 1. Interleaved PFC Power Stage (Mother Board HPA225)
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User's Guide
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Schematics
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Figure 2. Controller Circuitry (Daughter Board HPA284)
4
UCC28070 300-W Interleaved PFC Pre-Regulator
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Warning
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6
Warning
There are high voltages present on the pre-regulator and it should only be handled by experienced power
supply professionals. To evaluate this board as safely as possible the following test set up should be
used. An isolation transformer should be connected between the source and unit. Before power is
supplied a voltmeter and a resistive or electronic load should be attached to the unit’s output.
7
Test Setup and Power Up/Power Down Instructions
A separate 14-V bias supply is required to power the UCC28070 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. It is advised that resistive loads be used. Constant current or constant power
loads could damage the evaluation board. The unit should also never be handled when power is applied
to it or the output voltage is above 50-V dc. Please refer to Figure 3 for the test setup diagram.
Note:
There are very high voltages on the board and components can and will reach temperatures
above 100 °C, so caution must be taken in handling the board.
VM
0 to 300W Load
IsolationTransformer
+
14VBiasSupply
Figure 3. Test Setup
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Performance Data
8
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Performance Data
POWER FACTOR
vs
OUTPUT POWER
EFFICIENCY
vs
OUTPUT POWER
98
1.00
VIN = 230 V
0.99
96
VIN = 230 V
0.98
h - Efficiency - %
PF - Power Factor - V
94
0.97
VIN = 115 V
0.96
0.95
0.94
VIN = 115 V
92
90
88
0.93
86
0.92
84
0.91
10
20
30
40
50
60
70
80
90
10
100 110
20
30
40
50
60
70
80
90
100 110
POUT - Output Power - %
POUT - Output Power - %
Figure 4. Power Factor at VIN = 115 V
and 230 V RMS
Figure 5. Efficiency at VIN = 115 V
and 230 V RMS
AMPLITUDE
vs
CURRENT HARMONICS
1.41473
VIN = 230 V
POUT = 300 W
1.17894
Amplitude - A
0.94316
0.70737
EN61000-3-2 Class D
Specifications
0.47159
0.23580
0.00001
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
Current Harmonics - V/W
Figure 6. Input Current Harmonics
at VIN = 230 V, POUT = 300 W
6
UCC28070 300-W Interleaved PFC Pre-Regulator
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Performance Data
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8.1
Input Current and Output Ripple Voltage at Full Load
VOUT
VOUT
VIN
VIN
Figure 7. Input Ripple Current (IIN), Output
Ripple Voltage (VOUT), VIN = 85 V RMS,
POUT = 300 W
8.2
Figure 8. Input Ripple Current (IIN), Output
Ripple Voltage (VOUT), VIN = 265 V RMS,
POUT = 300 W
Input Ripple Current Cancellation
The following waveforms show input current (M1 = IL1+IL2), Inductor Ripple Current (IL1, IL2) verses
rectified line voltage. From these curves it can be observed that interleaving reduces the magnitude of
input ripple current caused by the inductor ripple current.
M1 = IL1 + IL2
M1 = IL1 + IL2
CH2 = IL1
CH2 = IL1
CH3 = IL2
CH3 = IL2
Figure 9. Inductor and Input Ripple Current at
VIN = 85 V RMS at the Peak of Line
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Figure 10. Inductor and Input Ripple Current
at 265 V RMS Input at the Half Output Voltage
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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Performance Data
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M1 = IL1 + IL2
M1 = IL1 + IL2
CH2 = IL1
CH2 = IL1
CH3 = IL2
CH3 = IL2
Figure 11. Inductor and Input Ripple Current
at 265 V RMS Input at Peak of the Line
Voltage
Figure 12. Input and Inductor Ripple Current
at VIN = 85 V RMS, POUT = 300 W
M1 = IL1 + IL2
CH2 = IL1
CH3 = IL2
Figure 13. Input and Inductor Ripple Current
at VIN = 265 V RMS, POUT = 300 W
8
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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Performance Data
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8.3
Startup Characteristics
CH4 = VOUT
CH4 = VOUT
CH2 = IL1
CH2 = IL1
CH3 = IL2
CH3 = IL2
Figure 14. Start Up at VIN = 85 V,
POUT = 300 W
8.4
Figure 15. Start Up at VIN = 265 V,
POUT = 300 W
Line Dropout
CH4 = VOUT
CH4 = VOUT
CH1 = Referenced
Line Voltage
CH1 =
Referenced
Line Voltage
CH2 = IL1
CH2 = IL1
CH3 = IL2
CH3 = IL2
Figure 16. Line Dropout at 115 V RMS
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Figure 17. Line Dropout at 230 V RMS
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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Performance Data
8.5
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Frequency Dithering
Frequency dithering has shown to reduce EMI. The UCC28070 EVM was design to operate in frequency
dithering mode and none frequency dithering mode. When the JP1 and JP2 jumpers on the daughter
board are shorted the PWM is operating in a fix frequency mode. The fixed frequency was set to 200 kHz
per phase. When Jumpers JP1 and JP2 are open the converter is running in frequency dither mode. The
single phases switching frequency was set to vary from roughly 190 kHz per phase to 210 kHz per phase.
When frequency dithering was applied to the EVM a 4.35 dBuV reduction in the Quasi Peak (QP) EMI
measurement was observed.
Note:
A filter was added to the front end of the EVM to clean up some of the noise to take EMI
data. Depending on the filter the amount of EMI will vary. Also, this filter was not setup to
pass EMI requirements but to show frequency dithering can reduced EMI.
Figure 18. EMI Quasi Peak (QP) Measurement Without Frequency Dithering, No EMI Filter Present
Figure 19. EMI Quasi Peak (QP) Measurement With Frequency Dithering, No EMI Filter Present
10
UCC28070 300-W Interleaved PFC Pre-Regulator
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Reference Design Assembly Drawing
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9
Reference Design Assembly Drawing
VOUT
RETURN
C5
HS1
C2
L1
D3
L2
C6
D5
T1
C7
.
.
T2
D6
C2
Q1
J1
RT1
Q1
VAR1
F1
HS3
HS2
C11
AC LINE
VCC
AC NEUTRAL
J2
SYNC
GND
Figure 20. Mother Board, Top Assembly and Copper Layer
VOUT
RETURN
RETURN
RETURN
JP2
D1
JP2
D3
D7 R6
C4 D8
R3
R14
D10
R12
C3
D4
R4
R9 R10
C8
C12
R13 R1
D13
C9
R8
U1
R11
R15
C10 D12
D11 R16
R18
R5
D2
R19
D9
R7
R17
R2
AC NEUTRAL
AC LINE
Figure 21. Mother Bottom, Assembly and Copper Layer
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UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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Reference Design Assembly Drawing
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U1
Figure 22. Daughter Board, Top Assembly and Copper Layer
Figure 23. Daughter Board, Top Assembly and Copper Layer
12
UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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List of Materials
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10
List of Materials
10.1 Mother Board List of Materials
Table 2. Mother Board
COUNT
REF DES
DESCRIPTION
MFR
4
AC_LINE, AC_NEUTRAL, Connector, banana jack, uninsulated,
RETURN, VOUT
3267, 0.500 dia. inch
1
C1
1
PART NUMBER
Pomona
3267
Capacitor, film, 275 VAC, 20%, 0.1 µF,
0.689 x 0.236 inch
Panasonic
ECQU2A104BC1
C11
Capacitor, aluminum, 35 V, 20%, 22 µF,
0.200 * 0.435 inch
Panasonic
ECA-1VM220
1
C2
Capacitor, film, 275 VAC, 20%, 0.47 µF,
0.236 X 0.591
Panasonic
ECQ-U2A474MG
2
C3, C9
Capacitor, ceramic, 25 V, X7R, 10%, 4.7 pF,
805
Std
Std
2
C4, C10
Capacitor, ceramic, 25 V, X7R, 10%, 47 nF, 805 Std
Std
1
C5
Capacitor, polyester, 630 V, 10%, 0.047 µF,
0.256 x 0.650 inch
Panasonic
ECQ-E6473KZ
2
C6, C7
Capacitor, aluminum, 450 VDC, 20%, 100 µF,
18 x 40 mm
Nippon
Chemi-con
EKXG451ELL101MM4
0S
2
C8, C12
Capacitor, ceramic, 25 V, X7R, 10%, 100 nF,
805
Std
Std
1
D1
Diode, 3000 mA, 600 V, SMC
Vishay
S3J-E3/57T
1
D13
Diode, zener, 13 V, 300 mW, SOT-23
Diodes
BZX84C13-7-F
2
D2, D9
Diode, Schottky Rectifier, 2 A, 600 V, TO-263-2
CREE
CSD02060G
1
D3
Diode, bridge, 6 A, 600 V, BU6
Vishay
GBU6J
6
D4, D7, D8, D10, D11,
D12
Diode, signal, 200 mA, 100 V, 350 mW,
SOD-123
Diodes
1N4148W-7-F
2
D5, D6
Diode, signal, 600 V, 1 A , DO-41
Diodes
1N4005
1
F1
Fuse clip, 5x20 mm, 4 A/250 V fuse,
0.205 x 0.220 inch x2
Wickmann
0100056H
3
HS1, HS2, HS3
Heat sink, universal-mount TO-220,
1.500 x 2.000 inch
Aavid
Thermalloy
600703U01500G
1
J1
Receptacle, 10 pins, 0.200 x 0.472 inch
HRS
DF11-10DS-2DSA(05)
1
J1
Assembled daughter board controller, HPA284
Std
Std
1
J2
Terminal block, 2 pin, 15 A, 5.1 mm,
0.40 x 0.35 inch
OST
ED1609
2
JP1, JP2
Resistor, chip, 1 W, 5%, 0, 2512
Std
Std
2
L1, L2
Inductor, 140 µH at 3.2 A pk, 0.828 dia. inch
Cooper
CTX16-18405R
1
PCB
Printed circuit board, HPA225
Std
Std
2
Q1, Q2
MOSFET, N-channel, 500 V, 7.1 A, 520 mΩ,
TO-220V
Infineon
IPP50R520CP
2
R1, R13
Resistor, chip, 1/10 W, 1%, 2.05 kΩ, 805
Std
Std
1
R17
Resistor, chip, 1/10 W, 1%, 20.5 Ω, 805
Std
Std
4
R2, R7, R11, R12
Resistor, chip, 1/10 W, 1%, 1.00 MΩ, 805
Std
Std
2
R3, R14
Resistor, chip, 1/8 W, 1%, 33.2 Ω, 1206
Std
Std
2
R4, R15
Resistor, chip, 1/10 W, 1%, 1.00 kΩ, 805
Std
Std
2
R5, R18
Resistor, chip, 1/10 W, 1%, 5.11 Ω, 805
Std
Std
2
R6, R16
Resistor, chip, 1/10 W, 1%, 2.49 kΩ, 805
Std
Std
4
R8, R9, R10, R19
Resistor, chip, 1/10 W, 1%, 10.0 kΩ, 805
Std
Std
RT1
Thermistor, NTC, 5 Ω, 6 A, 5 Ω,
0.180 X 0.550 inch
Thermometrics
CL-40
1
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List of Materials
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Table 2. Mother Board (continued)
COUNT
REF DES
DESCRIPTION
MFR
PART NUMBER
2
T1, T2
Inductor, 140 µH at 3.2 A PK, 0.360 X 0.520
inch
1
U1
Device, High Speed Low Side Power MOSFET
Driver, SO8
TI
UCC27324D
1
VAR1
Varistor 275 V RMS, 0.472 x 0.213 inch
Epcos
S10K275E2
Cooper
CTX16-18294-R
Additional Hardware
14
1
X1 @ F1
4 A, fast acting fuse, 5 mm X 20 mm
Cooper/Bussm
an
BK/S501-4-R
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
4
X1 @ HS1 and D3, HS2
and Q1, HS3 and Q2
Nylon shoulder washer #4
Keystone
Electronics
3049
2
X1 @ HS2 and Q1, HS3
and Q2
Thermal pad silicon TO220
BERQUIST
3223-07FR-51
4
X1 @ HS2, HS3 None
FET Side, Top and
Bottom
External tooth washer #4
Std
Std
UCC28070 300-W Interleaved PFC Pre-Regulator
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List of Materials
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10.2 Daughter Board List of Materials
Table 3. Daughter Board
COUNT
REF DES
DESCRIPTION
PART NUMBER
MFR
1
C1
Capacitor, ceramic, 25 V, X7R, 10%, 1 µF, 805
Std
Std
2
C11, C12
Capacitor, ceramic, 25 V, X7R, 10%, 100 nF, 805
Std
Std
2
C13, C14
Capacitor, ceramic, 25 V, X7R, 10%, 330 pF, 805
Std
Std
1
C2
Capacitor, ceramic, 25 V, X7R, 10%, 1.2 nF, 805
Std
Std
1
C3
Capacitor, ceramic, 25 V, X7R, 10%, 150 pF, 805
Std
Std
1
C4
Capacitor, ceramic, 25 V, X7R, 10%, 1.5 µF, 805
Std
Std
1
C5
Capacitor, ceramic, 25 V, X7R, 10%, 150 nF, 805
Std
Std
1
C6
Capacitor, ceramic, 25 V, X7R, 10%, 3.3 nF, 805
Std
Std
2
C7, C8
Capacitor, ceramic, 25 V, X7R, 10%, 220 pF, 805
Std
Std
2
C9, C10
Capacitor, ceramic, 25 V, X7R, 10%, 2.2 nF, 805
Std
Std
1
J1
Header, right angle 10 pins, DF11-10DP-2DSxx, 0.394 DF11-10DPx 0.472 inch
2DSxx
HRS
2
JP1, JP2
Header, 2 pin, 100 mil spacing, (36-pin strip), 0.100
inch x 2
PTC36SAAN
Sullins
2
JP1, JP2
Sockets jumper closed black
151-8010
Kobiconn
1
PCB
Daughter board PCB, HPA284
Std
Std
2
R1, R2
Resistor, chip, 1/10 W, 1%, 1.00 MΩ, 805
Std
Std
1
R11
Resistor, chip, 1/10 W, 1%, 3.65 kΩ, 805
Std
Std
1
R12
Resistor, chip, 1/10 W, 1%, 19.6 kΩ, 805
Std
Std
1
R13
Resistor, chip, 1/10 W, 1%, 38.30 kΩ, 805
Std
Std
1
R14
Resistor, chip, 1/10 W, 1%, 5.62 kΩ, 805
Std
Std
2
R15, R16
Resistor, chip, 1/10 W, 1%, 4.02 kΩ, 805
Std
Std
2
R3, R4
Resistor, chip, 1/10 W, 1%, 1.00 kΩ, 805
Std
Std
2
R5, R10
Resistor, chip, 1/10 W, 1%, 23.20 kΩ, 805
Std
Std
1
R6
Resistor, chip, 1/10 W, 1%, 46.40 kΩ, 805
Std
Std
1
R7
Resistor, chip, 1/10 W, 1%, 34.80 kΩ, 805
Std
Std
1
R8
Resistor, chip, 1/10 W, 1%, 37.40 kΩ, 805
Std
Std
1
R9
Resistor, chip, 1/10 W, 1%, 100.00 kΩ, 805
Std
Std
U1
Device, Two- Phases Interleaved CCM PFC
Controller, TSSOP-20
UCC28070PW
TI
1
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UCC28070 300-W Interleaved PFC Pre-Regulator
User's Guide
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
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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 85 to 265 VRMS and the output voltage range of 390 V ±15% .
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 50°C. The EVM is designed to operate
properly with certain components above 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.
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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
DLP® Products
DSP
Clocks and Timers
Interface
Logic
Power Mgmt
Microcontrollers
RFID
RF/IF and ZigBee® Solutions
amplifier.ti.com
dataconverter.ti.com
www.dlp.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
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