Texas Instruments UCC28060EVM User Manual

Size:
1.16 Mb
Download

User's Guide

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

The UCC28060 is a dual-phase,transition-modePower Factor Correction (PFC)pre-regulator.The UCC28060EVM is an evaluation module (EVM) with a390-V,300-W,dc output that operates from a universal input of 85 VRMS to 265 VRMS and providespower-factorcorrection.

Throughout this document, the acronym EVM and the phrasesevaluation board andevaluation module are synonymous with the UCC28060EVM.

1Description

The pre-regulatoruses theUCC28060 PFC interleaved controller to shape the input current wave to providepower-factorcorrection. This device uses TI’sNatural Interleaving™ technology to interleave boost phases.

This user’s guide provides the schematic, List of Materials list, assembly drawing for a single-sidedprinted circuit board application, and testset-upinformation necessary to evaluate the UCC28060 in a typical PFC application.

2Thermal Requirements

This evaluation module will operate up to 300 W without external cooling in ambient tempatures of 25°C.

3Electrical Characteristics

Table 1 summarizes the electrical specifications of the UCC28060EVM.

Table 1. UCC28060EVM Electrical Specifications

PARAMETER

CONDITIONS

UCC28060EVM

 

UNITS

TYP

MAX

 

MIN

 

RMS input voltage (ac line)

 

85

265

VRMS

Output voltage, VOUT

 

390

 

V

Line frequency

 

47

63

Hz

Power factor (PF) at maximum load

 

0.9

 

 

Output power

 

 

300

W

Full load efficiency

AC line = 115 V

94%

 

 

AC line = 230 V

97%

 

 

 

 

 

Natural Interleaving is a trademark of Texas Instruments.

All other trademarks are the property of their respective owners.

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

1

Submit Documentation Feedback

 

 

Schematics

www.ti.com

4Schematics

Figure 1 andFigure 2 show the schematics for this EVM. See theList of Materials for specific values.

To evaluate inductor ripple currents, Jumpers JP8 and JP9 can be removed and replaced with current loops.

+ +

Figure 1. Interleaved PFC Power Stage

2

UCC28060EVM 300-WInterleaved PFCPre-Regulator

SLUU280B–May2007–RevisedJuly 2008

Submit Documentation Feedback

www.ti.com

Schematics

 

+

Figure 2. Controller Circuitry

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

3

Submit Documentation Feedback

 

 

Test Setup and Power-Up/Power-DownInstructions

www.ti.com

5 Test Setup and Power-Up/Power-DownInstructions

WARNING

There are high voltages present on the pre-regulator.It should only be handled by experienced power supply professionals. To evaluate this board as safely as possible, the following test configuration should be used:

Connect an isolation transformer between the source and unit

Attach a voltmeter and a resistive or electronic load to the unit output before supplying power to the EVM.

A separate 13-Vbias supply is required to power the UCC28060 control circuitry. The unit will start up underno-loadconditions. However, for safety, a load should be connected to the output of the device before it is powered up. The unit should also never be handled while power is applied to it or when the output voltage is above50-Vdc. Refer toFigure 3 for a recommended test setup diagram.

CAUTION

There are very high voltages on the board. Components can and will reach temperatures greater than 100°C. Use caution when handling the EVM.

VM

0 to 300W Load

Isolation Transformer

+

13V Bias Supply

Figure 3. Test Setup

4

UCC28060EVM 300-WInterleaved PFCPre-Regulator

SLUU280B–May2007–RevisedJuly 2008

Submit Documentation Feedback

www.ti.com

Typical Performance Data

6Typical Performance Data

Figure 4 throughFigure 7 present characteristic performance data for the UCC28060EVM.

Efficiency

 

100.0%

 

 

 

 

 

 

 

 

 

 

99.0%

 

 

 

 

 

 

 

 

 

 

98.0%

 

 

 

 

 

 

 

 

 

 

97.0%

 

 

 

 

 

 

 

 

 

(%)

96.0%

 

 

 

 

Effice ncy at Vin 85V RM S

 

Efficiency

 

 

 

 

 

 

95.0%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Effice ncy at Vin = 265V RM S

 

 

 

 

 

 

 

 

 

 

 

 

94.0%

 

 

 

 

 

 

 

 

 

 

93.0%

 

 

 

 

 

 

 

 

 

 

92.0%

 

 

 

 

 

 

 

 

 

 

91.0%

 

 

 

 

 

 

 

 

 

 

90.0%

 

 

 

 

 

 

 

 

 

 

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

 

 

 

 

 

% Output Pow e r

 

 

 

 

Figure 4. Efficiency at 85VRMS and 265VRMS

The UCC28060 control device has phase management capability to improve light load efficiency. To demonstrate the light load efficiency, the unit efficiency was measured with phase management enabled and disabled at 115 VRMS and 230 VRMS input voltages. Phase management improved the light load efficiency up to 3%. Refer to theUCC28060 data sheet for details on how to use the phase management function of this device.

Efficiency at Vin = 115V RMS

 

98.0%

 

97.0%

 

96.0%

(%)

 

Efficiency

95.0%

94.0%

 

 

93.0%

With Phas e Manage m e nt

92.0%

Without Phas e Manage m e nt91.0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

 

 

 

 

% Output Power

 

 

 

 

Figure 5. Efficiency at 115 VRMS, With and Without Phase Management

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

5

Submit Documentation Feedback

Typical Performance Data

www.ti.com

Efficiency at Vin = 230V RMS

 

99.0%

 

 

 

 

 

 

 

 

 

 

97.0%

 

 

 

 

 

 

 

 

 

 

95.0%

 

 

 

 

 

 

 

 

 

(%)

 

 

 

 

 

 

 

 

 

 

Efficiency

93.0%

 

 

 

 

 

 

 

 

 

91.0%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

89.0%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With Phas e Manage m e nt

 

 

87.0%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Without Phas e M anage m e nt

 

 

85.0%

 

 

 

 

 

 

 

 

 

 

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

 

 

 

 

 

% Output Power

 

 

 

 

Figure 6. Efficiency at 230 VRMS, With and Without Phase Management

Amplitude(A)

1.40706 VIN = 230VRMS

1.17256

0.93805

0.70354

0.46904

0.23453

0.00002

0

6

12

18

24

30

36

42

48

Harmonic No.

Figure 7. Current Harmonics

6

UCC28060EVM 300-WInterleaved PFCPre-Regulator

SLUU280B–May2007–RevisedJuly 2008

 

 

Submit Documentation Feedback

www.ti.com

Typical Performance Data

6.1Output Ripple Voltage at Full Load

Figure 8 illustrates the output ripple voltage.

Figure 8. VOUT Ripple, POUT = 300 W

6.2Input Ripple Current Cancellation

Figure 9 throughFigure 14 show the input current (M1= IL1 + IL2), Inductor Ripple Current (IL1, IL2) versus rectified line voltage. From these graphs, it can be observed that interleaving reduces the magnitude of input ripple current caused by the inductor ripple current.

Figure 9. Inductor and Input Ripple Current at

Figure 10. Inductor and Input Ripple Current

85 VRMS at Peak of Line Voltage

at 85 VRMS Input at Half the Line Voltage

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

7

Submit Documentation Feedback

Typical Performance Data

www.ti.com

Figure 11. Inductor and Input Ripple Current

Figure 12. Inductor and Input Ripple Current

at 265 VRMS Input at Peak Line Voltage

at 265 VRMS Input at Half Peak Line Voltage

Figure 13. Inductor and Input Ripple Current

Figure 14. Inductor and Input Ripple Current

at VIN = 85 VRMS, POUT = 300 W

at VIN = 265 VRMS, POUT = 350 W

8

UCC28060EVM 300-WInterleaved PFCPre-Regulator

SLUU280B–May2007–RevisedJuly 2008

Submit Documentation Feedback

www.ti.com

Typical Performance Data

6.3Startup Characteristics

Figure 15 andFigure 16 illustrate the UCC28060EVM startup characteristics.

Figure 15. Start-Upat VIN = 85 VRMS, POUT =

Figure 16. Start-Upat VIN = 265 VRMS, POUT = 0

350 W

W

6.4Brownout Protection

The UCC28060 has a brownout protection that shuts down both gate drives (GDA and GDB) when the VINAC pin detects that the RMS input voltage is too low. This EVM was designed to go into a brownout

state when the line drops below 64 VRMS. Once the UCC28060 control device has determined that the input is in a brownout condition, a400-mstimer starts to allow the line to recover before shutting down the gate drivers. After 400 ms of brownout, both gate drivers turn off, as shown inFigure 17 andFigure 18.

Figure 17. Brownout at 85 VRMS

Figure 18. Brownout at 265 VRMS

SLUU280B–May2007–RevisedJuly 2008

UCC28060EVM 300-WInterleaved PFCPre-Regulator

9

Submit Documentation Feedback

Typical Performance Data

www.ti.com

6.5Line Transient

A line transient test was conducted with an ac source on the reference design. The line was varied from

230 VRMS to 115 VRMS to 230 VRMS and the transient response was evaluated in each case. From the oscilloscope image inFigure 19, it can be observed that the output recovered from line transients within 300ms at full load.

Figure 19. Line Transient, POUT = 300W

10

UCC28060EVM 300-WInterleaved PFCPre-Regulator

SLUU280B–May2007–RevisedJuly 2008

Submit Documentation Feedback