UCC28514EVM

User’s Guide UCC28514 User’s Guide User’s Guide EVM IMPORTANT NOTICE (CATEGORY B) IMPORTANT: TI is providing the enclosed HPA013B/HPA020A evaluation module under the following conditions: This evaluation module (EVM) being provided by Texas Instruments (TI) is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not considered by Texas Instruments to be fit for commercial use. As such, this EVM may not be complete in terms of design and/or manufacturing related protective considerations including product safety measures typically found in the end−product incorporating the module. As a prototype, this product does not fall within the scope of the European Union Directive on electromagnetic compatibility and on low voltage and therefore may not meet the technical requirements of the directive. This EVM is not subject to the EU marking requirements. 2 • Should this EVM not meet the specifications indicated in the User’s Guide the EVM may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY TI 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 EVM. The user acknowledge that the use of the EVM could present serious hazards and that it is the user’s responsibility to take all precautions for the handling and use of the EVMs in accordance with good laboratory practices. Please be aware that the products received may not be regulatory compliant or agency certified (FCC, UL, etc.). 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. • NEITHER PARTY WILL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. • TI is currently dealing with various customers for products, and therefore our arrangement with the user will not be 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 section in the User’s Guide pertaining to warnings and restrictions prior to handling the product. This section contains important information regarding high temperature and voltages which TI recommends to be read before handling the EVMs. In case of any doubt regarding safety, please contact the TI application engineer. • Persons handling the product should have electronics training and observe good laboratory practice standards. • No license is granted under any patent right or other intellectual property right of TI covering or relating to any combination, machine, or process in which such TI products or services might be or are used. • This Agreement is subject to the laws of the State of Texas, excluding the body of conflicts of laws and the United Nations Convention on the International Sale of Goods, and will be subject to the exclusive jurisdiction of the courts of the State of Texas. DYNAMIC WARNINGS AND RESTRICTIONS It is important to operate this EVM within the maximum input voltage ranges specified in section 6. 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 50°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  2003, Texas Instruments Incorporated 3 SLUU165A − November 2003 − Revised July 2004 UCC28514 User’s Guide Power Supply Control Products Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 List of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5 Reference Design Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7 Reference Design Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1 Introduction The UCC28514 module is a 100-W offline ac-to-dc voltage converter with power factor correction (PFC). The prototype was designed to show how the UCC28514 could be configured to control a dc-regulated output offline with one control integrated circuit. The module was design to operate over a universal input range of 85 V to 265 V with a regulated 24-V, 100-W output. To correctly operate this EVM a fan is required to keep the ambient temperature at or below 40°C. Not keeping the temperature at or below 40°C could damage the EVM. 2 Caution High-voltage levels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the module. The evaluation module has a large energy storage capacitor and must be completely discharged before the module can be handled. Serious injury can occur if proper safety precautions are not followed. 4 UCC28514 User’s Guide SLUU165A − November 2003 − Revised July 2004 Schematic The schematic is broken up into three sections to make it more legible for the user. + 3 Figure 1. Mother Board HPA013 UCC28514 User’s Guide 5 + SLUU165A − November 2003 − Revised July 2004 Figure 2. Mother Board HPA013 6 UCC28514 User’s Guide + SLUU165A − November 2003 − Revised July 2004 Figure 3. Daughter Board HPA020 UCC28514 User’s Guide 7 SLUU165A − November 2003 − Revised July 2004 4 List of Materials Table 1 lists the components used in this design. With minor component tweaks this design could be modified to meet a wide range of applications. Table 1. Mother Board List of Materials REFERENCE QTY DESCRIPTION MANUFACTURER PART NUMBER AC_L1 0 Connector, binding post, insulated, for standard banana plug, black, 15 A, 141860 Johnson 111−0703−001 AC_N1 0 Connector, binding post, insulated, for standard banana plug, red, 15 A, 141860 Johnson 111−0702−001 C1 1 Capacitor, film, 0.047 µF, 300 VAC, ±20%, 0.236 x 0.591 Panasonic ECQU3A473MG C2 1 Capacitor, polyester, .047 µF, 630 V, 10%, 0.256 x 0.650 Panasonic ECQ−E6473KZ C3 1 Capacitor, electrolytic, 100 µF, 450 V, TS series Panasonic ECO−S2WB101BA C4, C9 2 Capacitor, ceramic, 1 µF, 25 V, X7R, 10%, 1206 Panasonic ECJ−3YB1E105K C5, C6, C15 3 Capacitor, film, 1.0 µF, 50 V, 5%, 7380 Panasonic ECQ−V1H105JL C7, C8 2 Capacitor, ceramic, 0.1 µF, 50 V, X7R, +\−10%, 43200 Panasonic ECU−S1H104KBB C10 1 Capacitor, film, 0.01 µF, 300 VAC, ±20%, 0.197 x 0.591 Panasonic ECQU3A103MG C11 1 Capacitor, ceramic, 0.01 µF, 50 V, X7R, 10%, 1206 Panasonic − ECG ECU−V1H103KBM C12 1 Capacitor, ceramic, 1 nF, 50 V, X7R, 10%, 805 Panasonic ECU−V1H102KBN C13 1 Capacitor, ceramic, 1 µF, 50 V, X7R, 10%, 1206 Panasonic ECJ−3YB1E105K C14 1 Capacitor, electrolytic, 270 µF, 35 V, 0.394 x 0.630 Panasonic EEUFC1V271 C16 1 Capacitor, ceramic, 0.0015 µF, 50 V, X7R, 10%, 805 Panasonic ECJ−2VB2D152K Daughter Card 1 Controller board plugs into J1 Any HPA020 D1 1 Bridge rectifier, 6 A, 600 V, GBJ series General Semiconductor PB66 D2 1 Diode, 600 V, 6 A, 400 A peak surge, 252000 Diodes Inc 6A6−T D3 1 Diode, ultra fast, 8 A, 600 V, 5 mA International Rectifier HFA08TB60 D4, D12 2 Adjustable precision shunt regulator, SOT−89 Texas Instruments TL431CPK D5 1 Diode, rectifier, 2 A, 50 V, SMA Vishay BYG22A D7, D6 2 Diode, schottky, 1.5 A, 25 V, SMA Vishay BYS10−25 D8 1 Diode, zener, 18 V, 83 mA, 1 W, DO−41 On Semi 1N4746 D10, D9 2 Diode, fast recovery, SOD−57 Phillips BYV26 D11 1 Diode, dual schottky, 1.5 A, 100 V, TO220 OnSemi MBR20100CT D13 1 Diode, zener, 10 V, 35 mA, 350 mW, SOT23 Diodes Inc BZX84C10−7 F1 1 Fuseholder, 1/4 fuses, 0.42 Cooper/Bussman BK/1A1907−06 Fuse at F1 1 6 A, 250 V, 3AG Glass Fast Acting *Cartridge Type, 1.25” x 0.25” Littlefuse 312 006 HS1 1 Heatsink, TO−220, vertical mount, 5*C/W, 0.5 x 1.38in. Aavid 513201 HS2 1 Heatsink, TO−220, Vertical mount, 0.98 x 0.44 Aavid 579402B00000 HS3, HS4, HS5 3 Heatsink, TO−220, Vertical mount, 15°C/W, 0.5” x 0.95” Aavid 593002B33402 J1** 1 Receptacle, female 28 pins, 0.197 x 1181 Hirose Electric DF11−28DS−2DSA(xx) L1** 1 Inductor, 50 µH, 5.6 A, 21.5 mΩ, 1,102 X 1,102 Cooper CTX16−16366 OUT+1 0 Connector, binding post, insulated, for standard banana plug, black, 15 A, 141860 Johnson 111−0703−001 PCB 1 Mother board Any HPA013 Q1, Q3, Q4** 3 MOSFET, N-channel, 500 V, 5 A, 1500 mΩ, TO−220 International Rectifier IRF830A Q2** 1 Bipolar, NPN, 400 V, 1 A, 15 W, DPAK On Semi MJD50 8 UCC28514 User’s Guide SLUU165A − November 2003 − Revised July 2004 REFERENCE QTY DESCRIPTION MANUFACTURER PART NUMBER R1 1 Resistor, wirewound, 3 W, axial, 187500 Huntington Electric ALSR−3−.33−1% R2, R4 2 Resistor, chip, 10 kΩ, 1/4 W, 1%, 1210 Panasonic ERJ−14NF1002U R3 1 Resistor, chip, 49.9 kΩ, 1/4 W, 1%, 1210 Panasonic ERJ−14NF4992U R5 1 Resistor, power metal film, 500 V, 3 W, 5±%, 1,000 X 0.200 BCcomponents 5093NW82K00J08AFX R6 1 Resistor, power metal film, 2 kΩ, 3 W, 5±%, 1,000 X 0.200 BCcomponents 5093NW2K00J08AFX R7 1 Resistor, chip, 20 Ω, 1/4 W, 5%, 1210 Panasonic ERJ−14YJ200U R8 1 Resistor, chip, 3 kΩ, 1/10 W, 1%, 805 Std Std R9 1 Resistor, power metal film, 82 kΩ, 3 W, 5±%, 1,000 X 0.200 BCcomponents 5093NW82K00J08AFX R10 1 Resistor, chip, 100 Ω, 1/4 W, 5%, 1210 Panasonic ERJ−14YJ101U R11 1 Resistor, metal oxide, 1.0 Ω, 1 W, 5%, 0.150 x 0.700 Yageo RSF100JB−1R0 R12 1 Resistor, chip, 10 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF1002V R13, R20 2 Resistor, chip, 1 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF1001V R14 1 Resistor, chip, 680 Ω, 1/10 W, 1%, 805 Yageo America 9C08052A6800FKHFT R15 1 Resistor, chip, 100 Ω, 1/10 W, 1%, 805 Std Std R16, R21 2 Resistor, chip, 866 Ω, 1/10 W, 1%, 805 Panasonic ERJ−6ENF8660V R17 1 Resistor, chip, 1.4 kΩ, 1/10 W, 1%, 805 Std Std R18 1 Resistor, chip, 47 Ω, 1/10 W, 1%, 805 Panasonic ERA−S27J470V R19 1 Resistor, chip, 8.66 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF8661V RETURN1 0 Connector, binding post, insulated, for standard banana plug, black, 15 A, 141860 Johnson 111−0703−001 T1** 1 Boost Inductor, 20 primary, 1 secondary, 1.7 mH, 2.5 A, 1,260 x 1,220 Cooper CTX16−16364 T2** 1 XFMR, 100 kHz, 750 µH, toroid, ferrite Coiltronics, Inc CTX08−14225 T3** 1 Transformer, 5.78 primary, 1 secondary, 37 mH, 0.75 A, 1,260 x 1,220 Cooper CTX16−16365 TP1, TP2 0 Jack, test point, clrcle Farnell 240−3xx U1** 1 Optocoupler, 5300 V, 100% center, SMD Fairchild 4N36S X1 at HS1, HS3, HS4, HS5 4 Thermal pad silicon TO220 BERQUIST X1 at HS1, HS3, HS4, HS5 4 Nut #6X32 (steel) X1 at HS1, HS3, HS4, HS5 4 Split lock washer #6(steel) X1 at HS1, HS3, HS4, HS5 4 Flat washer #6 (steel) X1 at HS1, HS3, HS4, HS5 4 Nylon shoulder washer #6 X1 at HS1, HS3, HS4, HS5 4 Pan head screw #6−32X7/16 (steel) NOTES: (1) (2) (3) (4) Keystone Electronics These assemblies are ESD sensitive, ESD precautions shall be observed. These assemblies must be clean and free from flux and all contaminants. Use of no clean flux is not acceptable. These assemblies must comply with workmanship standards IPC−A−610 Class 2. Reference designators marked with an asterisk (’**’) cannot be substituted. All other components can be substituted with equivalent MFG’s components. UCC28514 User’s Guide 9 SLUU165A − November 2003 − Revised July 2004 Table 2. Daughter Board List of Materials REFERENCE QTY DESCRIPTION MANUFACTURER PART NUMBER C1 1 Capacitor, ceramic, 390 pF, 50 V, X7R, 10%, 805 Panasonic ECU−V1H391KBN C2 1 Capacitor, ceramic, 2.2 nF, 50 V, X7R, 10%, 805 Panasonic ECJ−2VB1H222K C3, C6 2 Capacitor, ceramic, 10 nF, 50 V, X7R, 10%, 805 Panasonic ECJ−2VB1H103K C4, C11 2 Capacitor, ceramic, 100 pF, 50 V, X7R, 10%, 805 Panasonic ECJ−2VC1H101J C5 1 Capacitor, ceramic, 2.2 µF, 16 V, X7R, 10%, 1206 muRata ECJ−3YB1C225K C7 1 Capacitor, ceramic, 1 µF, 50 V, X7R, 10%, 1206 Panasonic ECJ−3YB1E105K C8 1 Capacitor, ceramic, 150 nF, 50 V, X7R, 10%, 805 Panasonic ECJ−2YB1E154K C9 1 Capacitor, aluminum, 100 µF, 25 V, 20% (FC Series), 0.2 Panasonic EEU−FC1E101S C10 1 Capacitor, ceramic, 0.1 µF, 50 V, X7R, 10%, 805 Panasonic ECJ−2YB1H104K C12 1 Capacitor, ceramic, 1.5 µF, 16 V, X7R, 10%, 1206 Panasonic ECJ−3YB1C155K C13 1 Capacitor, ceramic, 56 pF, 50 V, X7R, 10%, 805 Panasonic ECJ−2VC1H560J C14 1 Capacitor, ceramic, 330 pF, 50 V, X7R, 10%, 805 Yageo America 08052R331K9B20D D1, D2, D3, D4 4 Diode, schottky, 500 mA, 25 V, SMA Vishay Telefunken BYS10−25 J1 1 Header, right angle 100 mil, 12 pin , 0.495 x 1,200 Hirose Electronic DF11-28DP-2DS(22) Q1 1 Bipolar, NPN, SOT23 Vishay Telefunken MMBT2222A R1, R11 2 Resistor, chip, 1.5 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF1501V R2 1 Resistor, chip, 47 Ω, 1/10 W, 1%, 805 std std R3, R7 2 Resistor, chip, 3.92 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF3921V R4, R5 2 Resistor, chip, 390 kΩ, 1/2 W, 1%, 2010 Std Std R6 1 Resistor, chip, 10 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF1002V R8 1 Resistor, chip, 7.5 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF7501V R9 1 Resistor, chip, 30.1 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF3012V R10, R13 2 Resistor, chip, 10 Ω, 1/4 W, 1%, 1210 Panasonic ERJ−14NF10R0U R12, R18, R21 3 Resistor, chip, 1 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF1001V R14 1 Resistor, chip, 133 kΩ, 1/10 W, 1%, 805 Yageo America 9C08052A1333FKH FT R15 1 Resistor, chip, 48.7 kΩ, 1/10 W, 1%, 805 Panasonic ERJ−6ENF4872V R16 1 Resistor, chip, 22.1 kΩ, 1/4 W, 1%, 1210 Panasonic ERJ−14NF2212U R17, R20 2 Resistor, chip, 562 kΩ, 1/4 W, 1%, 1210 Panasonic ERJ−8ENF5623V R19 1 Resistor, chip, 9.09 kΩ, 1/10 W, 1%, 805 Std Std R22 1 Resistor, chip, 100 Ω, 1/10 W, 1%, 805 std std R23 1 Resistor, chip, 15 kΩ, 1/10 W, 1%, 805 std std TP1, TP2 0 Jack, test point, Clr, Farnell 240−3xx 1 IC, Bi CMOS PFC\PWM Controller, 273600 TI UCC28514DW U1 NOTES: (1) (2) (3) (4) 10 These assemblies are ESD sensitive, ESD precautions shall be observed. These assemblies must be clean and free from flux and all contaminants. Use of no clean flux is not acceptable. These assemblies must comply with workmanship standards IPC−A−610 Class 2. Ref designators marked with an asterisk (’**’) cannot be substituted. All other components can be substituted with equivalent MFG’s components. UCC28514 User’s Guide SLUU165A − November 2003 − Revised July 2004 R9 R6 Reference Design Layout R5 5 Figure 4. Mother Board HPA013 UCC28514 User’s Guide 11 SLUU165A − November 2003 − Revised July 2004 NOTE: R23 can be found on the back of the daughter board. Figure 5. Daughter Board HPA020 6 Electrical Characteristics MIN 12 VIN Output 85 POUT Output Ripple A 10 UCC28514 User’s Guide 23 TYP 24 MAX UNITS 265 VRMS V 25 100 W 500 mV SLUU165A − November 2003 − Revised July 2004 7 Reference Design Performance OUTPUT A EFFICIENCY vs OUTPUT POWER OUTPUT A POWER FACTOR vs OUTPUT POWER 1 90 VIN = 265 V 85 PF − Power Factor 75 VIN = 175 V 70 VIN = 85 V 65 VIN = 175 V VIN = 265 V 50 80 0.95 VIN = 85 V 0.90 60 55 0.85 50 10 20 30 40 50 60 70 80 90 10 100 20 30 40 60 70 90 100 POUT − Output Power − W POUT − Output Power − W Figure 6 Figure 7 OUTPUT A THD vs OUTPUT POWER 35 30 Current THD − % Efficiency − % 80 VIN = 265 V 25 20 VIN = 175 V 15 10 VIN = 85 V 5 0 10 20 30 40 50 60 70 80 90 100 POUT − Output Power − W Figure 8 UCC28514 User’s Guide 13 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 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. 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. Following are URLs where you can obtain information on other Texas Instruments products and application solutions: Products Applications Amplifiers amplifier.ti.com Audio www.ti.com/audio Data Converters dataconverter.ti.com Automotive www.ti.com/automotive DSP dsp.ti.com Broadband www.ti.com/broadband Interface interface.ti.com Digital Control www.ti.com/digitalcontrol Logic logic.ti.com Military www.ti.com/military Power Mgmt power.ti.com Optical Networking www.ti.com/opticalnetwork Microcontrollers microcontroller.ti.com Security www.ti.com/security Telephony www.ti.com/telephony Video & Imaging www.ti.com/video Wireless www.ti.com/wireless Mailing Address: Texas Instruments Post Office Box 655303 Dallas, Texas 75265 Copyright  2004, Texas Instruments Incorporated