UCC29910APW

UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Buck PFC Controller Check for Samples: UCC29910A FEATURES DESCRIPTION • The UCC29910A Buck Power Factor Correction (PFC) controller provides a relatively flat high-efficiency performance across universal line for designers requiring a high power factor (>0.9) and wishing to meet the requirements of IEC 61000-3-2. Based on a buck topology, inherent inrush current limiting eliminates the need for additional components. With a typical bus voltage of 84 V, the topology is ideally suited for use with low voltage stress downstream regulation/isolation power trains, such as half-bridge stages controlled by the UCC29900, (Texas Instruments Literature Number, SLUS923). This combination offers low common-mode noise generation allowing reduced filtering and exceptionally high conversion efficiency. 1 • • • • • • • Buck Power Factor Correction for High Efficiency Across Line Low Off-Line Startup Current, With SmartStart Algorithm for Fast Startup With Soft-Start Compatible With Resistive or Pass Transistor Fed Startup from the AC Line Low Power SmartBurst Mode for Standby and Light-Load Conditions Current Sense Inputs for PFC control and Overload Protection Line Sense UVLO Sense and Drive Control for External Startup Depletion Mode FET Latching Fault Input Pin The UCC29910A incorporates AC line UVLO and controlled soft start for fast start-up. Enhanced light-load efficiency is achieved through advanced management algorithms for best-in-class no-load and light-load performance. APPLICATIONS • • High Efficiency AC-DC Adapters Low Profile and High Density Adapters SIMPLIFIED APPLICATION DIAGRAM VBULK VAC EMC FILTER HS BULK SENSE DRIVER 4 1 LINESNS VDD 11 10 13 TST PFCDRV CS 3 CS 5 VBULK 2 NC UCC29910APW BIAS SUPPLY 9 BIASSNS 12 BIASCTRL NC REFIN VSS FAULT 7 6 14 8 1 Please be aware that an important notice concerning availability, standard warranty, and use in critical applications of Texas Instruments semiconductor products and disclaimers thereto appears at the end of this data sheet. PRODUCTION DATA information is current as of publication date. Products conform to specifications per the terms of the Texas Instruments standard warranty. Production processing does not necessarily include testing of all parameters. Copyright © 2011, Texas Instruments Incorporated UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com This integrated circuit can be damaged by ESD. Texas Instruments recommends that all integrated circuits be handled with appropriate precautions. Failure to observe proper handling and installation procedures can cause damage. ESD damage can range from subtle performance degradation to complete device failure. Precision integrated circuits may be more susceptible to damage because very small parametric changes could cause the device not to meet its published specifications. ORDERING INFORMATION PART NUMBER PACKAGE PACKING UCC29910APW Plastic, 14-Pin TSSOP (PW) 90-Pc. Tube UCC29910APWR Plastic, 14-Pin TSSOP (PW) 2000-Pc. Tape and Reel ABSOLUTE MAXIMUM RATINGS over operating free-air temperature range (unless otherwise noted) (1) (2) (3) VALUE VDD Supply Voltage -0.3 (4) TA Operating free air temperature, TJ Operational junction temperature, Storage temperature −40 to 105 (4) (4) (2) (3) (4) °C −40 to 105 Lead temperature (10 seconds) (1) V −0.3 to VDD + 0.3 Voltage: All pins TSTG UNIT 4.1 260 These are stress limits. Stress beyond these limits may cause permanent damage to the device. Functional operation of the device at these or any conditions beyond those indicated under RECOMMENDED OPERATING CONDITIONS is not implied. Exposure to absolute maximum rated conditions for extended periods of time may affect device reliability. All voltages are with respect to VSS. All currents are positive into the terminal, negative out of the terminal. Higher temperature may be applied during board soldering process according to the current JEDEC J-STD-020 specification with peak reflow temperatures not higher than classified on the device label on the shipping boxes or reels. THERMAL INFORMATION THERMAL METRIC (1) θJA Junction-to-ambient thermal resistance θJCtop Junction-to-case (top) thermal resistance (3) θJB Junction-to-board thermal resistance (4) ψJT Junction-to-top characterization parameter (5) ψJB Junction-to-board characterization parameter (6) θJCbot Junction-to-case (bottom) thermal resistance (7) (1) (2) (3) (4) (5) (6) (7) 2 PINS UNITS (2) °C/W For more information about traditional and new thermal metrics, see the IC Package Thermal Metrics application report, SPRA953. The junction-to-ambient thermal resistance under natural convection is obtained in a simulation on a JEDEC-standard, high-K board, as specified in JESD51-7, in an environment described in JESD51-2a. The junction-to-case (top) thermal resistance is obtained by simulating a cold plate test on the package top. No specific JEDEC-standard test exists, but a close description can be found in the ANSI SEMI standard G30-88. The junction-to-board thermal resistance is obtained by simulating in an environment with a ring cold plate fixture to control the PCB temperature, as described in JESD51-8. The junction-to-top characterization parameter, ψJT, estimates the junction temperature of a device in a real system and is extracted from the simulation data for obtaining θJA, using a procedure described in JESD51-2a (sections 6 and 7). The junction-to-board characterization parameter, ψJB, estimates the junction temperature of a device in a real system and is extracted from the simulation data for obtaining θJA , using a procedure described in JESD51-2a (sections 6 and 7). The junction-to-case (bottom) thermal resistance is obtained by simulating a cold plate test on the exposed (power) pad. No specific JEDEC standard test exists, but a close description can be found in the ANSI SEMI standard G30-88. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com RECOMMENDED OPERATING CONDITIONS over operating free-air temperature range, all the voltages refer to the VSS pin (unless otherwise noted) MIN TA Operating free air temperature MAX UNIT −40 105 °C 3.0 3.6 0 VDD VDD Input Voltage All Inputs NOM V ELECTRICAL CHARACTERISTICS over operating free-air temperature range (unless otherwise noted) PARAMETER TEST CONDITIONS MIN TYP MAX UNIT Supply Current IVDD Operating current Voltage Monitoring VDD = 3.3 V 5 8 mA (1) VNM VBULK nominal Normal mode (2) PFCDRV = 100 kHz 1.042 1.048 1.054 VBH VLINESNS start-up VB(min) < VBIASSNS < VB(max) 258 264 270 VBL VLINESNS brownout Normal mode (2) 243 249 255 VLM VLINESNS max Normal mode (2) 925 931 937 VB(max VBIASSNS max VLINESNS > VBH 907 913 919 VB(min) VBIASSNS min VLINESNS > VBH 451 457 463 ) V mVRMS mV FAULT Input tf Latch Time (3) Normal mode (2), FAULT pin goes < 0.8 V VIT+ Positive going input threshold voltage 1.45 2.5 VIT- Negative going input threshold voltage 0.8 1.85 VHYS Input voltage hysteresis VIT+ VIT- 0.3 1 µs 100 V PFCDRV section Switching frequency Normal mode (2) DMAX Max duty cycle At PFCDRV pin, normal mode (2), VLINESNS = VBH, VBULK = 1.025 V VOH High level output voltage at PFCDRV pin fSW VOL 94 100 106 89% 90% 91% IO = -1.5 mA VDD0.25V VDD IO = -6 mA VDD0.6V VDD IO = 1.5 mA 0 0.25 IO = 6 mA 0 0.6 Low level output voltage at BIASCTRL pin Start-up mode (4), VBIASSNS increasing and < VB(max), IO = 1.5 mA 0 0.25 High level output voltage at BIASCTRL pin Start-up mode (4), VBIASSNS decreasing and > VB(min), IO = -1.5mA VDD0.25V VDD Low Level Output Voltage at PFCDRV pin kHz V BIASCTRL Output VBC (1) (2) (3) (4) V VBULK, VLINESNS and VBIASSNS voltage thresholds are based on VREFIN = 1.500 V. These will change proportionally as VREFIN changes. Input bias current at these pins is ±50 nA max. Normal mode entered when VDD present, VREFIN = 1.500 V, VLINESNS increased from 0 to VBH < VLINESNS < VLM, VBIASSNS increased from 0 to VB(max) < VBIASSNS < 1.025 V then reduced to VB(min) < VBIASSNS < VB(max), VCS = 150 mV, VBULK increased to VNM then reduced to 1.025 V. There is a 600-ms timeout on this process. FAULT inputs shorter than tf cause a non-latched shutdown. FAULT inputs longer than tf cause a latched shutdown. Start-up mode entered when VDD present, VLINESNS increased from 0 to VBH < VLINESNS < VLM , VBIASSNS increased from 0 to VB(max) < VBIASSNS < 1.025 V then reduced to VB(min) < VBIASSNS < VB(max), VBULK = 0 V. There is a 600 ms timeout on this process. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 3 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com DEVICE INFORMATION UCC29910A 14- Pin TSSOP (PW) VDD 1 14 VSS VBULK 2 13 PFCDRV CS 3 12 BIASCTRL LINESNS 4 11 NC CS 5 10 TST REFIN 6 9 BIASSNS NC 7 8 FAULT TERMINAL FUNCTIONS TERMINAL NAME NO. I/O DESCRIPTION VDD 1 - Provides power to the device; should be decoupled with ceramic capacitor (1 µF), connected directly across pins 1-14. VBULK 2 I Voltage sensing of the bulk capacitor. CS 3 I Current sense input for PFC stage. LINESNS 4 I Rectified AC line sense input. CS 5 I Current sense input for PFC stage. REFIN 6 I Reference input for internal comparators/error amplifier. NC 7 - NC, this pin is not used, and should be left open. FAULT 8 I Fault input for over-voltage or over-load protection. BIASSNS 9 I Sense input for the bias rail for startup control. TST 10 I This pin should be connected directly to VDD. NC 11 - No connection should be made to this pin. BIASCTRL 12 O Control output for the external startup FET for startup control. PFCDRV 13 O Drive for PFC FET. VSS 14 - Ground for internal circuitry. 4 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Detailed Pin Description Pin 1 – VDD: This pin supplies power to the device. A minimum supply voltage level of 3.0 V and maximum of 3.6 V is recommended. Pin 2 – VBULK: The output voltage level, VBULK is sensed on this pin. The HV bulk sensing network should be scaled so that the desired output voltage produces VNM at this pin. The Thevenin impedance at this pin should be below 20 kΩ, with appropriate capacitance provided for noise filtering. NOTE The VBULK scaling and LINESNS scaling must maintain a ratio of close to 4:1 to ensure optimum operation of the SmartStart algorithm. Pin 3 – CS: This pin senses the current in the PFC stage. Both CS pins must be connected to the current sense signal and it is not permissible to leave one floating. The CS pins are intended to sense average low side PFC FET current directly. A 150-mΩ current sense resistor value is optimal for powers of 90 W, with appropriate scaling for higher power levels. The recommended feed impedance level is approximately 100 Ω, and a capacitor of 1 µF is also recommended to act as a filter on the input current and to minimise noise pickup. A smaller value capacitor may result in possible current loop instability. A larger cap value may result in poor Power Factor (PF) due to excessive current signal phase shift. UCC29910A does not provide cycle-by-cycle inductor current limiting. An external circuit is needed if this type of protection is required. Pin 4 – LINESNS: This pin senses the rectified line voltage. The internal reference for this pin is internally scaled to ¼ of the VBULK reference. NOTE The LINESNS scaling and VBULK scaling must maintain a ratio of close to 1:4 to ensure optimum operation of the SmartStart algorithm. A peak of high-line voltage (typically 373-V for 264-VAC input) should be scaled to correspond to 1.158 VDC at this pin. A pin feed impedance of less than 20 kΩ is recommended along with a filter capacitor of at least 2.2 nF for noise filtering. The RMS voltage at this pin must be greater than VBH before PFCDRV can start switching. The PFCDRV will go low if the RMS voltage drops below the brownout level VBL (21 ms timeout). The controller will not start if VLINESNS exceeds VLM, (VBULK = 0 V). Pin 5 – CS: See pin 3 description above. This pin senses the current in the PFC stage, pins 3 and 5 must be connected together. Pin 6 – REFIN: This pin must be connected to an external accurate 1.500 V reference source, e.g. using a suitable shunt regulator with voltage setting resistors such as TLVH431A. The reference voltage must be established within 100 ms after VDD reaches 3.0 V. Pin 7 – NC: This pin is not used, and should be left open. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 5 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Pin 8 – FAULT: This pin when pulled low causes PFCDRV and BIASCTRL to go low, typically within 10 us. After a 100 us delay the FAULT input is sampled again. If the FAULT has cleared high, the UCC29910A goes into SmartStart mode. If the FAULT input is still low the device enters a latched shutdown state. Pin 9 – BIASSNS: This pin is used to sense the PFC stage bias rail (normally in the 8 V to 12 V range to drive the PFC power MOSFET) during start-up to allow control of the external start-up FET. The voltage at this pin must be greater than VB(max) before PFCDRV switching commences. If the voltage drops below VB(min) the BIASCTRL output goes low, which can enable an external start-up FET. Pin 10 – TST: This pin provides no user function. It must be connected to VDD. Pin 11 – NC: This pin is for internal use only, and must be normally left open. Pin 12 – BIASCTRL: This pin allows control of an external start-up FET. Pin 13 – PFCDRV: This pin is used to drive the low-side PFC FET indirectly. This pin should be connected to a level-shifting gate driver to provide the required drive signal amplitude for typical high voltage power FETs. For this drive signal, DMAX is limited to 90% duty cycle. Pin 14 – VSS: This pin is the common ground connection for the device. UCC29910A Functional Block Diagram UCC29910A EN VDD 1 + “Smart-Start” Soft Start Burst Control POR 14 VSS 13 PFCDRV 8 FAULT 9 BIASSNS 12 BIASCTRL 10 TST Start- up Burst 1.92 V Gate Control Logic LINESNS 4 Brown- out Run/ Stop Detection & Filter Latch reset detect BULK OV Clamp PFCDRV Blanking CLK REF Oscillator VBULK 2 Voltage Loop PI Error Amp EN PFC Duty Cycle Disable EN + CS CS PWM Generator 3 Light Load Detect Burst Mode Control Fault Latch 5 EN REFIN 6 NC 7 REF EN Startup Bias Control 11 UDG-11105 NC 6 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com APPLICATION INFORMATION The UCC29910A controls a Buck PFC stage and is particularly suited to AC/DC applications in the power range from 65 W to 130 W. A fully characterised reference design using the UCC29910A PFC controller and the UCC29900 Integral Cycle Controller is available on request. The design is for a 90 W PSU intended for laptop adapter applications. It comprises a Buck PFC front end using the UCC29910A to convert line power to a nominal 84 VDC. A UCC29900 controls the conversion of this bulk voltage to a nominal 19.25 V output using a half bridge output power stage. The paragraphs following give some details on how the UCC29910A has been used in this application. Additional guidelines for both the UCC29910A and UCC29900 are available on request. POR A Power On Reset function operates at turn-on. Start Up Bias Control This block controls the BIASCTRL output which may be used to control an external depletion mode start-up FET during the start-up phase and also while the UCC29910A is operating in SmartBurst Light Load mode (explained below). After POR the BIASCTRL output is held low until the voltage at the BIASSNS pin reaches VB(max) at which point BIASCTRL is driven high which turns the external FET off and the start-up phase is initiated. The UCC29910A continues to monitor the voltage at the BIASSNS pin and if it drops below VB(min) BIASCTRL goes low again, turning the start-up FET on again. At the end of the start-up phase the UCC29910A enters normal mode operation and BIASCTRL pin is held high. In normal mode, auxiliary windings maintain the VCCA rail (see Figure 5). When the UCC29910A is operating in SmartBurst light-load mode there is a possibility that these auxiliary windings can no longer supply enough current to support the bias supply within acceptable limits. The start-up bias control block prevents the bias rail from collapsing by setting the BIASCTRL pin low if VBIASSNS drops below VB(min). This signal may be used to turn on the external start-up FET on, thereby supplying added current to the bias rail. If VBIASSNS increases above VBLO (495 mV approx.) BIASCTRL is set low again. The bias rail is therefore controlled between acceptable limits. Brown_Out Detection and Filter, Latch Reset Detect If the RMS voltage at the LINESNS pin drops below VBL for more than 21 ms (approx) the controller latches off. In this condition, the PFCDRV pin is low. The UCC29910A recovers from this state if the RMS voltage at the LINESNS pin falls below the reset level (VRS = 218-mV RMS) for at least 120 ms and then increases to at least VBH. When this happens the UCC29910A enters its start-up mode after a 10-s timeout. Power cycling is not needed for recovery after a brown_out event. Smart Start, Soft Start, Burst Control This module controls the gate control logic during the start-up phase. Oscillator The internal oscillator runs at a fixed 100 kHz. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 7 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Control system The UCC29910A uses an average current mode control loop to regulate the output voltage, this eliminates the need for slope compensation. The two inputs to this control loop are the voltages at the VBULK and CS (Current Sense) pins. Voltage Loop – PI Error Amp The output of the PI (Proportional Integral) Error Amplifier is proportional to the difference between the voltages at the VBULK pin and the REFIN pins. The integral term in the amplifier drives the steady state error to zero but, in common with virtually all PFC controllers the control loop bandwidth is very low – approximately 10 Hz in this case. Current Sense The CS pins allow the UCC29910A to sense the average current in the power stage. The current sense signal is subtracted from the demand signal from the error amplifier and the result is used to set the PFCDRV duty cycle. PWM Generator The PWM Generator generates a duty cycle signal which is fed into the gate control logic. The duty cycle commanded is proportional to the demand signal from the control loop. Light Load Detect / Burst Mode Control As the load on the power stage decreases the standing losses due to, for example, the drive power needed to effect switching of the main power MOSFET, becomes an increasingly important proportion of the whole. The UCC29910A includes a SmartBurst light-load mode which significantly reduces these standing losses. In Normal Mode operation the UCC29910A continuously switches the power MOSFET, in light load the power MOSFET is switched in a burst mode. Power losses are reduced very significantly between bursts because there is no switching activity in the power train. During the burst, the power train is efficiently operated at close to full power. The average power transferred from input to output is controlled by modulating the interval between bursts. Gate Control Logic The Gate Control Logic block takes the inputs from a number of sources and outputs the PFCDRV signal. The fault latch output disables the gate control logic and sets the PFCDRV to low. The BULK OV clamp forces the PFCDRV output low if the voltage at the VBULK pin exceeds 107% of VNM. The Start-up burst signal determines the PFCDRV on and off times during the start-up phase before the PWM generator becomes active. The PFC duty cycle signal sets the PFCDRV output duty cycle demand in normal mode. A line dependent DMIN and a 90% DMAX limit are applied. The light load detect burst mode control block controls operation during light load mode and entry to and exit from this mode. 8 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com BULK OV Clamp The low bandwidth of the normal control loop prevents it from controlling an increase in VBULK due for example, to a large step reduction in the load on the VBULK output. This clamp activates within 120 µs if the voltage at the VBULK pin exceeds 107% of VNM. When activated, it blanks the gate control logic output and the PFCDRV pin is held low. This clamp is non-latching so it releases once VBULK falls below trip level, i.e., 107% of VNM. For a short duration BULK OV clamp event, recovery will be back to the operating mode in place at the beginning of the event (usually normal mode). If VBULK stays above the clamp level for long enough, the conditions for entry into light load mode may be satisfied and recovery will be into light load mode. Reference All of the measurement functions within the UCC29910A use the REFIN pin for their reference voltage, these include (VNM, VBH, VBL, VLM, VB(max), VB(min) and VCS). The specifications are written on the assumption that the reference voltage is 1.500 V and variations in this will proportionally affect the accuracy of measurements. The REFIN pin should be bypassed to VSS to reduce noise. A 100-nF capacitor connected between pin 6 and pin 14 is recommended, this part should be placed as close as possible to the controller and connected with minimum length tracks. Fault Latch This latch is activated by pulling the FAULT pin to VSS. When activated the current PWM cycle is terminated, PFCDRV is held Low and BIASCTRL is set low. The controller enters SmartStart mode if the FAULT input clears high in less than tf (100 µs). If the FAULT input persists for longer than tf the controller enters a latched shutdown mode The latched state is cleared if the LINESNS pin is held below 215 mVRMS for 120 ms. The controller will re-start after a 10-s delay, providing LINESNS has recovered to at least VBH. Alternatively cycling chip power off then on will also clear the latched state. Connecting a 1-nF capacitor between the FAULT pin and VSS is recommended to reduce the risk of nuisance tripping. PFC Drive A power MOSFET driver, such as an NPN and PNP transistor or a UCC27324 will normally be required to convert the PFCDRV output from the UCC29910A to the current and voltage levels typically needed to ensure correct power MOSFET operation. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 9 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Buck PFC Power Stage The PFC stage converts the incoming rectified line voltage to a DC voltage on the output capacitors, power transfer happening during the times when the line voltage is greater than the output voltage. The resulting conduction angle is a function of both the incoming line and output voltages. In the reference design mentioned above, the output voltage is set to 84 VDC. This is low enough to allow conduction angles sufficient to achieve a PF (Power Factor) of at least 0.9 over an input voltage range from 90 VAC to 264 VAC. Other output voltage levels may be set by altering the voltage sensing network at the VBULK pin. A 4:1 ratio between the VBULK and LINESNS scaling ensures optimum operation of the SmartStart algorithm, so if the VBULK scaling is altered significantly, then the LINESNS scaling should be altered too. A high efficiency second stage, controlled by a UCC29900, can then down-convert to a nominal output of 19.25 V using a transformer with a simple 4:1 turns ratio, or to any other desired output voltage. The basic Buck PFC power stage is shown in Figure 1. This low-side switched buck stage has the same performance as the more usual high-side switched buck converter. It features easy power FET drive, at the expense of requiring output sense through a PNP level shift transistor, Q9. The incoming AC line is fed through a rectifier and filter stages, not shown here. The resulting unipolar voltage (VHV) is then fed into the power stage. The MOSFET is switched at a constant 100 kHz and the freewheeling diode function is provided by D1. The output voltage (VBULK) is developed across the two large capacitors, C2 and C21. HV D1 C2 470 ?F 100 V C21 470 ?F 100 V R21 4.4 M R15 1M 0.5 % R16 1M 0.5 % VBULK L6A EQ25 Q9 R17 330 k? 0.5 % 2 1 Q1 LINESNS VBULK R78 13 k? 1% R3 0R15 VINTER R72 16.875 k? 1% UDG-11106 -VPRI Figure 1. Buck Power Stage (simplified) Vac Iac Vbulk C onduction Angle Figure 2. Illustrative Line Current and Voltage 10 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com The buck converter operates off a rectified sinusoid and there are periodic dead times when the input voltage is lower than the output. During these times no power can be transferred to the output and the input current is nominally zero. Figure 2 shows the line current, IAC, falling to zero when VAC is less than VBULK. The associated conduction angle increases as the RMS line voltage increases and the current waveform changes from low line to high line. The input current is skewed a little towards the beginning of the conduction cycle because VBULK is at its lowest value at this time so conduction starts at a lower voltage than it finishes. This effect may be seen in Figure 3 and Figure 4. These waveforms are taken from a 90-W buck PFC reference design, both meet the harmonics requirements set out in EN61000-3-2 and their PF is greater than 90%. Figure 3. 115 V, 60 Hz, Full Load, 0.5 A/div Figure 4. 230 V, 50 Hz, Full Load, 0.5 A/div Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 11 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Start-Up With External FET Conventional start-up schemes utilising either resistive or enhancement mode MOSFET feeds incur line dependant static power losses. To avoid these power losses and to obtain an optimum turn-on time an external depletion mode FET may be used Figure 5 and Figure 6. The VHV node is connected to the rectified incoming line. Q12 is a depletion mode FET which will start charging C45 as soon as line power is connected. Initially U1 is inactive and BIASCTRL is low. The VDD_3V rail will begin to increase as U10 starts to conduct. The POR (Power On Reset) sequence of U1 will begin once this rail gets to about 1.7 V and will execute while the VDD_3V rail is being established. The BIASCTRL pin will go high when BIASSNS reaches the VB(max) level. If VLINESNS is then > VBH, U1 begins to pulse the PFCDRV pin, which starts the process of charging the bulk capacitors at the output of the buck PFC power stage. The PFCDRV current is drawn from C45, which starts to discharge. If the voltage at the BIASSNS pin falls below VB(min) then PFC switching is disabled and Q12 is turned on to re-charge C45. With the given component values the VB(max) level corresponds to 12 V and a VB(min) level of 6 V at the VCCA rail. The user sets the VB(max) and VB(min) levels depending on the characteristics of any alternative components used by adjusting R84. HV R5 10 kW Q12 BSS126 R77 1M VCCA VDD_3V U10 TPS71533DCKR R80 390 W 4 VIN OUT 5 GND 2 R84 680 kW R76 14.3 kW 9 10 1 TST VDD 11 13 NC PFCDRV VBULK 2 BIASSNS U1 UCC29910APW C45 100 mF 16 V C78 470 nF R76 30 kW 5% R85 56 kW VPRI R75 143 kW 5% CS 5 8 FAULT LINESNS 4 6 REFIN CS 3 NC VSS 7 14 C80 100 nF U13 TLVH431ACDBZR BIAS CTRL 12 TP4 R86 300 kW UDG-11108 Figure 5. Simplified Schematic 12 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Figure 6. Start-Up Sequence Waveforms (Ch1 (Y), PFCDRV, Ch2 (R), VCCA, Ch3 (B), DUT VO) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 13 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com SmartStart, VBULK Ramp-Up Once VCCA has reached 12 V and Q12 has been turned off, and VLINESNS > VBH, the PFCDRV output of U1 becomes active and begins driving the main power MOSFET. The SmartStart algorithm increases VBULK, the voltage across C2 and C21, as rapidly as possible. This is done by transferring the maximum amount of energy possible during each pulse set. The UCC29910A requires that the inductor has a Volt-sec product withstand rating of 600 Vµs. In fact any inductor suitable for application in a buck PFC stage will already meet this requirement in order to carry the full-load currents involved without saturating, therefore the Volt-sec rating will not result in any additional constraints on the inductor design. However it is more convenient to think in terms of applied Volt-sec product rather than the peak-inductor current. The UCC29910A’s SmartStart algorithm generates a series of pulses for the switching MOSFET which apply a constant Volt-sec product to the inductor during the on and off intervals. This ensures that the inductor current is ramped up as high as possible while the MOSFET is on and then decays to zero during the off time. In fact, TOFF is extended to 110% of nominal which provides margin to ensure the inductor current ramps back to zero. The UCC29910A measures the instantaneous line voltage and the output voltage (VHV and VBULK in Figure 1). The voltage applied to the inductor when Q1 is on is then found by subtracting these two values. It then calculates an appropriate TON corresponding to a 600 V x µs product. TOFF is calculated in a similar fashion except that the inductor voltage during the off time is the voltage on the capacitors C2 and C21 (VBULK) plus the forward voltage drop in D1 which is assumed to be 0.6 V. Inductor current is controlled on a cycle-by-cycle basis by constraining the TON and TOFF values so that the inductor Volt-sec product is never exceeded. The initial TOFF intervals are typically 1.1 ms long because the bulk capacitor voltage is still very low. As VBULK increases, the current ramp-down rate increases so that the required TOFF reduces, allowing the pulses to occur more frequently. In addition, as VBULK rises, the voltage across the PFC inductor during TON will drop, so the on-time is adjusted to maintain a constant PFC inductor volt-secs product. During ramp-up the UCC29910A monitors the voltage at the BIASSNS pin and if it falls below VB(MIN) the ramp-up operation is terminated and the BIASCTRL pin goes low. In the reference design the minimum bias voltage will be approximately 6 V. When BIASCTRL goes low, Q12 is turned on again and C45 will begin charging back up towards 12 V. The ramp-up phase is then re-started. A maximum of 10 such restarts is allowed before the UCC29910A goes into a latched shutdown mode. Line power cycling is necessary for recovery from this mode. Typically, the capacitor voltage increases monotonically until the voltage at the VBULK pin reaches 1.024 V. This is slightly lower than VNM and in the circuit of Figure 1 corresponds to a VBULK across C2 and C21 of 82 V. The UCC29910A then switches to Normal Mode operation. This approach allows the fastest possible start-up time. In order to save standby power at no load, once the start-up phase is complete, and VBULK is being regulated (either by the normal mode voltage regulation loop, or the SmartBurst light-load mode), the BIASCTRL pin is driven high. This turns the start-up fet off which eliminates the power loss in the start-up current path. While in SmartBurst mode the voltage at the BIASSNS input is monitored. If the voltage at this pin drops below VB(min) then the start-up fet is turned back on to recharge the capacitors on the VCCA rail. In this way and with the component values shown, the VCCA rail is maintained above 6 V. 14 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Normal Mode Operation In normal mode, the VBULK pin is controlled at VNM. Due to the slow voltage loop, and low gain at 100/120 Hz, the voltage loop PI error amp output will be essentially a fixed demand. If the power stage stays in Discontinuous Conduction Mode (DCM) throughout the half-cycle, then peak current will be proportional to (VHV-VBULK) over the half cycle and IAVG is approximately proportional to IPEAK. If the power stage transitions into Continuous Conduction Mode (CCM) during the line cycle, the current loop, responding to the average current, keeps the peak current flatter, so the line current doesn’t quite follow (VIN-VO) anymore but average line current is approx proportional to (VHV-VBULK) over the half-cycle. The overall effect is shown in the current waveforms in Figure 3 and Figure 4. The line voltage is used by the control loop to set dynamic DMIN and DMAX values. Transient Response and VBULK Regulation When the UCC29910A is regulating in normal mode, the VBULK pin will be at VNM. An AC ripple at twice line frequency will be superimposed on this as the PFC stage drives current into the bulk capacitors. The amplitude of this ripple will be a function of line frequency, capacitance value and load current. Due to the necessary low control loop bandwidth VBULK will reduce in response to a step load increase. If the load step is large enough to cause the VBULK pin to reduce to less than 0.992 V the loop response is temporarily speeded up until this voltage has been increased back up to 1.043 V at which point the original loop response is restored. SmartBurst Mode (light load) As load current reduces the UCC29910A will continue to regulate the voltage at the VBULK pin at VNM. It will do this by reducing the PWMDRV waveform duty cycle, except that any pulses which are commanded to be less than DMIN will be masked and not delivered to the PWMDRV output. The proportion of cycles thus dropped is counted over a 10-ms window and if it exceeds 10% the UCC29910A changes its operating mode to SmartBurst mode. In SmartBurst mode the UCC29910A enters a low power consumption mode to minimize wasted power and improve light-load efficiency. Every 1 ms (approximately) it samples the voltages at the LINESNS and VBULK pins. If the voltage at VBULK is still within a target window of 1.087 V to 1.074 V no action is taken. The applied load will eventually cause the bus voltage to drop below this window and a burst of pulses are then output at the PFCDRV pin. These drive the PFC FET and thereby recharge the PFC bus capacitance. The most efficient transfer of power is achieved by minimizing the number of switching events, thus minimizing switching and gate drive losses. The line voltage sample is used to set the maximum safe duty cycle for the PFCDRV pulses while keeping the inductor current discontinuous, based on an inductor rating of 600 Vµs. The pulse duty cycle is ramped from DMIN to this maximum value. At the end of the burst, the pulse duty cycle is ramped back to DMIN. Ramping the duty cycle in this manner avoids the sudden application of high power pulses to the power train which may cause excessive EMI and unwanted audio noise generation. A full SmartBurst pulse will last for 2 ms – including the ramp-up time but excluding the ramp-down time. The SmartBurst pulse train is terminated if the voltage at the VBULK pin reaches the peak value of the allowed window, 1.087 V or if it exceeds 2 ms in length. There is a 5-ms minimum time between the start of successive SmartBurst pulse trains. The max burst length and minimum burst repetition interval ensure that as load is increased, at some point the burst rate will become insufficient to maintain VBULK. Once the voltage falls below the normal mode setpoint VNM at the VBULK pin the controller reverts to normal regulation mode. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 15 UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com PFC Inductor Value The PFC inductor is designed for an inductance value that ensures DCM operation at high line (i.e. >160 VAC), right up to full-peak load. With an appropriate value of inductance, operation at low line should then result in CCM operation over most of the conduction angle at full load. The inductance required is given by: LPFC æV ö 1 = VIN(pk ) - VBULK )ç BULK ÷ ( çV ÷ 2 ´ fSW ´ IIN(pk ) è IN(pk ) ø 2 (1) where: IIN(pk) = PIN(avg) ´ p 2 ´ VIN(pk) ´ 1 - sin(qSTART ) 1 1 1 ´ p - ´ cos (qSTART )´ sin (qSTART )´ - ´ (qSTART ) 4 2 2 (2) And π is the stage conversion efficiency, θSTART is the phase angle (in radians) at which conduction starts, where the instantaneous line voltage equals the bulk voltage. For a 100-W converter with an 84-VBULK DC output we evaluate the equation at 160 V as follows. 2 LPFC = 1 ( ) 2 ´ 100 ´ 103 Hz ´ 1.033 A ( æ ö 84 V 2 ´ 160 V - 84 V ç ÷ = 94.9 mH ´ 2 160 V è ø ) (3) Compared to the Boost PFC, much smaller values of PFC inductance can typically be used in the buck, because the voltage differential that needs to be supported across the inductor is lower. Practical inductance values that have been used in various designs have ranged from ~150 µH at 50 W, to ~80 µH to 100 µH at 90 W to 130 W. 16 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A UCC29910A SLUSAK8A – MAY 2011 – REVISED JUNE 2011 www.ti.com Bulk Capacitor Choice The value of bulk capacitance required is dictated by requirements on the allowable ripple voltage and hold-up time. In applications where hold-up time is not the main factor, then the capacitors should be sized for approximately 12% peak-to-peak ripple as follows: CBUS = PLOAD ´ qcond _ % 2 VBUS ´ DVBUS(%) ´ 2 ´ fAC (4) For a typical 90-W adapter using buck PFC, the required bus capacitance for ±6% maximum ripple at 90 VAC/50 Hz (12% total ripple) and at 84 VDC bus, assuming 96.5% efficiency of the second stage, would be: CBUS 90 ´ 0.57 0.965 = = 628 mF 84 2 ´ 0.12 ´ 2 ´ 50 (5) where: • PLOAD: load power drawn (usually by the second regulation/isolation stage) • CBUS: bus capacitance • θCOND_%: conduction angle at AC line of interest (as decimal percentage of total cycle, e.g. 50% conduction angle expressed as 0.5) • fAC: AC line frequency The capacitance required to achieve a specific hold up time may be calculated as follows: CBUS = THOLDUP ´ 2 ´ PLOAD (V BUS(min) 2 - VBUS(min_ reg)2 ) (6) For example, in order to achieve 3-ms holdup, with nominal bus voltage of 84 VDC, ±5% maximum bus ripple, and 70-VDC minimum bus regulation level for the second stage, the required bus capacitance would be calculated as follows for a 90-W load, assuming 96.5% second stage efficiency: 90 0.965 = 381mF = 2 (84 ´ 0.95 ) - 702 0.003 ´ 2 ´ CBUS ( ) (7) References 1. 2009/10 Power Supply Design Seminar - SEM1900 Topic 4, Power Factor Correction Using the Buck Topology – Efficiency Benefits and Practical Design Considerations REVISION HISTORY Changes from Original (May 2011) to Revision A Page • Added New DESCRIPTION .................................................................................................................................................. 1 • Added an updated description for the TST pin. .................................................................................................................... 4 • Added an updated description for the TST pin. .................................................................................................................... 6 • Changed UCC29910A Functional Block Diagram ................................................................................................................ 6 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC29910A 17 PACKAGE OPTION ADDENDUM www.ti.com 10-Dec-2020 PACKAGING INFORMATION Orderable Device Status (1) Package Type Package Pins Package Drawing Qty Eco Plan (2) Lead finish/ Ball material MSL Peak Temp Op Temp (°C) Device Marking (3) (4/5) (6) UCC29910APW ACTIVE TSSOP PW 14 90 RoHS & Green NIPDAU Level-1-260C-UNLIM -40 to 85 29910A UCC29910APWR ACTIVE TSSOP PW 14 2000 RoHS & Green NIPDAU Level-1-260C-UNLIM -40 to 85 29910A (1) The marketing status values are defined as follows: ACTIVE: Product device recommended for new designs. LIFEBUY: TI has announced that the device will be discontinued, and a lifetime-buy period is in effect. NRND: Not recommended for new designs. Device is in production to support existing customers, but TI does not recommend using this part in a new design. PREVIEW: Device has been announced but is not in production. Samples may or may not be available. OBSOLETE: TI has discontinued the production of the device. (2) RoHS: TI defines "RoHS" to mean semiconductor products that are compliant with the current EU RoHS requirements for all 10 RoHS substances, including the requirement that RoHS substance do not exceed 0.1% by weight in homogeneous materials. Where designed to be soldered at high temperatures, "RoHS" products are suitable for use in specified lead-free processes. TI may reference these types of products as "Pb-Free". RoHS Exempt: TI defines "RoHS Exempt" to mean products that contain lead but are compliant with EU RoHS pursuant to a specific EU RoHS exemption. Green: TI defines "Green" to mean the content of Chlorine (Cl) and Bromine (Br) based flame retardants meet JS709B low halogen requirements of