Using the UCC28250EVM-564
User's Guide
Literature Number: SLUU441A
September 2010 – Revised October 2011
User's Guide
SLUU441A – September 2010 – Revised October 2011
Half-Bridge DC-to-DC Converter
With Secondary-Side Control
1
Introduction
This EVM is to aid in evaluating UCC28250 PWM device with secondary-side control in DC-to-DC
symmetrical half-bridge converter topology. The targeted application is telecom module design with
nominal 48-V input. UCC28250 is a PWM controller that can be used for primary-side control or
secondary-side control. In this EVM, UCC28250 is placed at the secondary side to make secondary-side
control.
2
Description
The EVM is a 100-W symmetrical half-bridge DC-to-DC converter that converts 36 V to 75 V DC to a
regulated output voltage 3.3 V and maximum 30-A load current.
2.1
Typical Applications
•
•
•
•
2.2
Telecom Power Supplies with Secondary-Side Control
Server Systems
Datacom
DSP’s, ASIC’s, and FPGA’s
Features
•
•
•
•
•
•
•
•
•
•
•
Start up from telecom input voltage 36 V to 75 V DC with initial assistance of external auxiliary supply
on the secondary side.
Regulated output voltage 3.3 V with maximum 30-A load current.
Smooth and monotonic output voltage turn on with up to 90% pre-biased output voltage.
Output voltage regulation from no load to full load, and from low line to high line.
Secondary-side Enable ON/OFF function and manual switch.
Secondary-side control.
Voltage-mode control.
Control-driven synchronous rectifier.
Non-latching output over voltage protection.
Hiccup over current protection.
Telecom basic isolation from primary to secondary 1500 V.
CAUTION
Before doing any test with this EVM, please read this document especially
Section 3 through Section 6. Without a thorough reading of this document,
strange behavior of operation and possible damage may be resulted in the test.
2
Half-Bridge DC-to-DC Converter —With Secondary-Side Control
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Electrical Performance Specifications
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3
Electrical Performance Specifications
Table 1. UCC28250EVM-564 Electrical Performance Specifications
PARAMETER
TEST CONDITIONS
MIN
TYP
MAX
UNITS
Input Characteristics
Voltage range
36
48
75
V
Maximum input current
VIN = 36 V and IOUT = 30 A
3.5
A
No load input current
VIN = 75 V
90
mA
Output Characteristics
Output voltage, VOUT
Output current = 0 A
3.25
3.3
Output load current, IOUT
Output voltage regulation
Output voltage ripple
3.35
V
30
A
Line regulation: input voltage = 36 V to 75 V
0.15%
Load regulation: output current = 0 A to 23 A
0.15%
At IOUT = 30 A
50
Output over current
35
mVpp
A
Systems Characteristics
Switching frequency
200
Operation frequency
400
Peak efficiency
91%
Full load efficiency
Operating temperature
kHz
90%
Min 200 LFM force air flow
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°C
3
Schematic
Schematic
+
+
4
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Figure 1. UCC28250EVM-564 Schematic
4
Half-Bridge DC-to-DC Converter —With Secondary-Side Control
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Test Setup
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5
Test Setup
5.1
Test Equipment
Voltage source for main power: HP 6015A DC power supply
Voltage source for secondary initial bias: 8.0-V/0.1-A DC voltage source compatible
Multimeters: Fluke 45 dual display multimeter
Output load: HP 6060A DC electronic load
Oscilloscope: Tektronix TDS 460 A 400 MHz
Fan: 200 LFM minimum compatible
Recommended wire gauge: AWG #18 for input voltage connection. AWG #16 for output load connection.
+
A1
V1
_
Recommended Test Setup
DC
Source
5.2
V2
_
+
+
Load 1
3.3V/35A
_
A B
_
A
B
+
8V 2 nd Bias
EN ON
Enable
FAN
Figure 2. Recommended Test Set Up
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5
Test Setup
5.3
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List of Test Points
Table 2. Test Points Function
6
TEST POINTS
NAME
TP1
PGND
Input voltage negative test point, for efficiency test
TP2
Vin
Input voltage positive test point, for efficiency test
TP3
En_ON
Board Enable On, default low logic, jumper placed on the right
TP4
VOUT+
Output voltage positive test point for efficiency
TP5
VOUT-
Output voltage negative test point for efficiency
TP6
VLine
Primary side positive input after input filter
TP7
Loop+
Feedback loop injection
TP8
Loop-
Feedback loop injection
Primary side signal ground
TP9
GND
TP10
Prebias+
TP11
Vo_Ripple
DESCRIPTION
Prebias output positive input
Output voltage ripple test
J1
INPUT
J2
OUTPUT
Input voltage terminals
Output voltage terminals
J3
En_Logic
Set up enable high or low, default low, jumper cross pin 2 to 1
J4
2nd Bias
Secondary side initial bias, 8.0V
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Test Procedure
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6
Test Procedure
Set up the EVM based on Figure 2.
CAUTION
High voltage and high temperature present when the EVM is in operation!
6.1
Line/Load Regulation and Efficiency Measurement Procedure
1.
2.
3.
4.
Verify and confirm J3 jumper is placed across pin 2 to 1.
Verify switch S1 is on position A.
Connect the ammeter A1 (0 A to 10 A range) between DC source and J1 as shown in Figure 2.
Prior to connecting the DC source, it is advisable to limit the source current to 4 A maximum. Make
sure the DC source is initially set to 0 V and connected to J1 and A1 as shown in Figure 2.
5. Connect voltmeter, V1 across the DC source as shown in Figure 2.
6. Connect Load1 to J2 as shown in Figure 2. Set Load1 to constant current mode to sink 0 ADC before
the input voltage on J1 is applied.
7. Connect voltmeter, V2 to J2 as shown in Figure 2.
8. Connect 8.0 V 2nd Bias to J4. Turn its voltage into 8.0 V.
9. Turn on fan making sure to blow air directly on the EVM.
10. Increase the DC source voltage from 0 V to 36.0 VDC.
11. Snap switch S1 to position B.
12. Remove 8.0 V 2nd Bias.
13. Measure VOUT (V2), IOUT, VIN (V1) and Iin (A1).
14. Vary LOAD1 from 0 A to a higher value, up to 30 ADC.
15. Repeat step 10.
16. Increase input voltage to a different value, up to 75 V, and repeat step 10 and 11.
6.2
Equipment Shutdown
1.
2.
3.
4.
5.
6.3
Decrease Load1 to 0 A.
Snap switch S1 to position A.
Decrease VIN from 75.0 VDC to 0 V.
Shut down VIN and Fan.
Shut down the load.
Notes for Operating this EVM
1. This EVM relies on external auxiliary power supply (8.0 V/0.1 A) to start up. After start up, the board
can operate normally without the external auxiliary supply. If the auxiliary supply is removed, the board
cannot start up without adding the auxiliary supply back after Enable Off.
2. This EVM does not have line under voltage ON/OFF feature. Please follow 6.1 and 6.2 to turn on and
off the board. Strange behavior including damage may be observed if do not follow Section 6.1 and
Section 6.2.
3. In evaluating protection features (OVP and OCP, etc.), the external auxiliary power supply should
remain connected and setup at 8.0 V which is required to resume the EVM operation after a fault is
cleared or in order to operate in hiccup mode in that regarding.
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Performance Data and Typical Characteristic Curves
7
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Performance Data and Typical Characteristic Curves
Figure 3 through Figure 11 present typical performance curves for UCC28250EVM-564.
7.1
Efficiency
EFFICIENCY
vs
OUTPUT CURRENT
100
36 V
95
90
h - Efficiency - %
85
48 V
80
75
60 V
70
75 V
65
60
55
50
45
40
0
5
10
15
20
25
30
25
30
IOUT - Output Current - A
Figure 3. Efficiency
7.2
Load Regulation
OUTPUT VOLTAGE
vs
OUTPUT CURRENT
3.40
3.38
VOUT - Output Voltage - V
3.36
3.34
3.32
36 V
3.30
48 V
60 V
75 V
3.28
3.26
3.24
3.22
3.20
0
5
10
15
20
IOUT - Output Current - A
Figure 4. Load Regulation
8
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Performance Data and Typical Characteristic Curves
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7.3
Bode Plot
GAIN/PHASE
vs
FREQUENCY
50
150
Phase
120
30
90
20
60
10
30
Gain
0
0
-10
-30
-20
-60
-30
-90
-40
-120
Gain - dB
Gain - dB
40
-150
-50
0.1
1.0
10.0
100.0
f - Frequency - kHz
Figure 5. Loop Response Gain and Phase
7.4
Turn-On Waveform
Figure 6. Enable Turn-On Waveform
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Performance Data and Typical Characteristic Curves
7.5
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Turn-On Waveform with Pre-biased Output Voltage
Figure 7. Enable Turn-On Waveform
7.6
Turn-On Waveform with Pre-biased Output Voltage
Figure 8. Enable Turn-On Waveform
10
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7.7
Turn-On Waveform with Pre-biased Output Voltage
Figure 9. Enable Turn-On Waveform
7.8
Turn-Off Waveform
Figure 10. Enable Turn-Off Waveform
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Performance Data and Typical Characteristic Curves
7.9
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Output Ripple
Figure 11. Output Ripple
12
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EVM Assembly Drawing and PCB Layout
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8
EVM Assembly Drawing and PCB Layout
The following figures (Figure 12 through Figure 17) show the design of the UCC28250EVM-564 printed
circuit board. PCB dimensions: L x W = 4.0 in x 2.3 in, PCB material: FR406 or compatible, four layers
and 2-oz copper on each layer.
EN ON
A
B
A
B
Figure 12. Top Layer Assembly Drawing (top view)
Figure 13. Bottom Assembly Drawing (bottom view)
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EVM Assembly Drawing and PCB Layout
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Figure 14. Top Copper (top view)
Figure 15. Internal Layer 1 (top view)
14
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EVM Assembly Drawing and PCB Layout
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Figure 16. Internal Layer 2 (top view)
Figure 17. Bottom Copper (top view)
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List of Materials
9
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List of Materials
The EVM components list according to the schematic shown in Figure 1.
Table 3. UCC28250EVM-564 List of Materials
QTY
16
REF DES
DESCRIPTION
PART NUMBER
MFR
5
C1, C3,
C4, C6,
C9
Capacitor, ceramic, 50 V, X5R, ±10%, 1.0 µF, 603
Std
Std
1
C10
Capacitor, ceramic, 50 V, NP0, ±10%, 100 pF, 603
Std
Std
3
C11, C29,
Capacitor, ceramic, 50 V, X7R, ±10%, 2200 pF, 603
C30
Std
Std
2
C14, C28
Capacitor, ceramic, 50 V, X7R, ±10%, 470 pF, 603
Std
Std
1
C16
Capacitor, ceramic, 50 V, NP0, ±5%, 120 pF, 603
Std
Std
4
C17, C21,
Capacitor, ceramic, 100 V, X7R, ±10%, 2.2 µF, 1210
C24, C25
Std
Std
4
C2, C18,
C19, C23
Capacitor, ceramic, 6.3 V, X5R, ±10%, 100 µF, 1812
Std
Std
1
C20
Capacitor, ceramic, 100 V, X7R, ±10%, 1.0 µF, 1210
Std
Std
1
C22
Capacitor, ceramic, 2 kV, X7R, ±10%, 1000 pF, 1808
Std
Std
1
C31
Capacitor, aluminum, 100 V, 105°C, ±20%, 100 µF, 0.315
inch
EEU-PC2A101
Panasonic
1
C32
Capacitor, aluminum, 25 V, 105°C, ±20%, 470 µF, 0.315
inch
UVZ1E471MPD
Nichicon
0
C5
Capacitor, ceramic, 50 V, X7R, ±10%, Not used, 603
Std
Std
1
C7
Capacitor, ceramic, 50 V, X7R, ±10%, 680 pF, 603
Std
Std
7
C8, C12,
C13, C15,
Capacitor, ceramic, 50 V, X7R, ±10%, 0.1 µF, 603
C26, C27,
C33
Std
Std
2
D1, D7
Diode, switching, 90 V, 100 mA IFM, high speed,
SOD-323
1SS355TE-17
Rohm
2
D12, D13
Diode, switching, 150 mA, 75 V, 350 mW, SOT23
BAS16
Vishay-Liteon
3
D2, D10,
D11
Diode, Schottky, 350 mA, 40 V, SOD323
SD103AWS-7-F
Diodes Inc
1
D3
Diode, Zener, 8.2 V, 20 mA, 350 mW, 8.2V, SOT23
MMBZ5237B-7-F
Diodes Inc
Diodes
1
D4
Diode, fast switching, 80 V, 500 mA, SOT-363
MMBD44448HSDW7-F
1
D5
Diode, Schottky, 0.5 A, 20 V, SOD-123
MBR0520L
Fairchild
2
D8, D9
Diode, Zener, 11 V, 20 mA, 350 mW, 11V, SOT23
MMBZ5241B-7-F
Diodes Inc
2
J1, J4
Terminal block, 2 pin, 6 A, 3.5 mm, 0.27 inch x 0.25 inch
OSTTE020161
OST
1
J2
Terminal block, 4 -pin, 15 A, 5.1 mm, 0.80 inch x 0.35 inch ED120/4DS
OST
1
J3
Header, 3 pin, 2 mm spacing, 0.079 inch x 3 inch
TMM-103-01-T-S
Samtec Inc
1
L1
Inductor, SMT, 6 A, 8.8 mΩ, 1.0 µH, 0.287 inch x 0.268
inch
RLF7030T-1R0N6R4
TDK
1
L2
Inductor, power choke, ±20%, 1.3 µH, 18.2 mm x 18.3 mm 7443556130
Wurth Elektronik
3
Q1, Q2,
Q3
Transistor, NPN high voltage, VCE 100 V, IC1A, SOT89
FCX493TA
Zetex
2
Q4, Q7
MOSFET, N-channel, 100 V, 5.7 A, 25 mΩ, PWRPAK
S0-8
SI7456DP
Vishay
4
Q5, Q6,
Q8, Q9
MOSFET, N-channel, 30 V, 50 A, 2.6 mΩ, LFPAK
RJK0328DPB
Renesas
3
R1, R4,
R29
Resistor, chip, 1/16 W, ± 1%, 10.0 kΩ, 603
Std
Std
1
R10
Resistor, chip, 1/16 W, ± 1%, 2.32 kΩ, 603
Std
Std
3
R12, R14,
Resistor, chip, 1/16 W, ± 1%, 1.00 kΩ, 603
R30
Std
Std
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List of Materials
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Table 3. UCC28250EVM-564 List of Materials (continued)
QTY
REF DES
DESCRIPTION
PART NUMBER
MFR
1
R15
Resistor, chip, 1/16 W, ± 5%, 0 Ω, 603
Std
Std
1
R16
Resistor, chip, 1/16 W, ± 1%, 75.0 kΩ, 603
Std
Std
2
R17, R19
Resistor, chip, 1/16 W, ± 1%, 402 Ω, 603
Std
Std
1
R18
Resistor, chip, 1/16 W, ± 1%, 4.64 kΩ, 603
Std
Std
3
R2, R13,
R23
Resistor, chip, 1/16 W, ± 1%, 5.11 kΩ, 603
Std
Std
1
R20
Resistor, chip, 1/16 W, ± 1%, 6.81 kΩ, 603
Std
Std
1
R21
Resistor, chip, 1/16 W, ± 1%, 681 Ω, 603
Std
Std
1
R22
Resistor, chip, 1/16 W, ± 1%, 1.50 kΩ, 603
Std
Std
2
R24, R37
Resistor, metal film, 1/4 W, ± 1%, 17.8 Ω, 1206
Std
Std
1
R25
Resistor, metal film, 1/4 W, ± 1%, 36.5 Ω, 1206
Std
Std
1
R26
Resistor, metal film, 1/4 W, ± 1%, 60.4 kΩ, 1206
Std
Std
1
R28
Resistor, chip, 1/16 W, ± 1%, 20.0 kΩ, 603
Std
Std
2
R3, R6
Resistor, chip, 1/16 W, ± 1%, 23.2 kΩ, 603
Std
Std
1
R31
Resistor, metal film, 1/4 W, ± 1%, 90.9 Ω, 1206
Std
Std
2
R32, R33
Resistor, metal film, 1/4 W, ± 1%, 20 Ω, 1206
Std
Std
1
R34
Resistor, chip, 1/16 W, ± 1%, 47.5 kΩ, 603
Std
Std
2
R35, R36
Resistor, chip, 1/16 W, ± 1%, 1 Ω, 603
Std
Std
2
R5, R27
Resistor, chip, 1/16 W, ± 1%, 200 Ω, 603
Std
Std
1
R7
Resistor, chip, 1/16 W, ± 1%, 49.9 Ω, 603
Std
Std
1
R8
Resistor, chip, 1/16 W, ± 1%, 51.1 kΩ, 603
Std
Std
2
R9, R11
Resistor, chip, 1/16 W, ± 1%, 49.9 kΩ, 603
Std
Std
1
S1
Switch, Actuator SPDT, 0.500 inch x 0.260 inch
1101M2S3CQE2
C&K
1
T1
Transformer, Half-Bridge ± 30%, 270 µH, 1.120 inch x
1.273 inch
AF5096
Vitec Electronics
1
T2
Xfmr, Current Sense, 100:01:00, 0.315 inch x 0.320 inch
CST2-100L
Coilcraft
1
T3
Transformer, 1 primary, 1 secondary, 785 µH, 0.460 x
0.340 inch
PA0185
Pulse
9
TP1, TP2,
TP3, TP4,
TP5, TP7, Pin, Thru Hole, Tin Plate, for 0.062 PCB's, 0.039 inch
TP8, TP9,
TP10
3103-1-00-15-00-0008-0
Mill-Max
1
TP11
Adaptor, 3.5-mm probe clip ( or 131-5031-00), 0.200 inch
131-4244-00
Tektronix
TI
1
U1
DUAL INVERTER GATE, 32mA, 3.3V, SOT23-6
SN74LVC2GU04DBV
R
1
U2
120 V Boot, 2.5A Peak, High-Freq. High-Side Low-Side
Driver, QFN-8
UCC27201DRM
TI
1
U3
Advanced PWM Controller with Pre-Bias Operation,
TSSOP-20
UCC28250PW
TI
1
U4
Dual 4-A High Speed Low-Side Power MOSFET Drivers ,
MSOP-8
UCC37324DGN
TI
1
U5
Photocoupler, SOP-4
PS2701-1
NEC
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This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION
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EVM Warnings and Restrictions
It is important to operate this EVM within the input voltage range of 36 V to 75 V and the output voltage range of 3.3 V .
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 60° C. The EVM is designed to
operate properly with certain components above 60° 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.
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www.ti.com/audio
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amplifier.ti.com
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dataconverter.ti.com
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DLP® Products
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logic.ti.com
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power.ti.com
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Microcontrollers
microcontroller.ti.com
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