Texas Instruments UCC38500EVM User Manual

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Using the UCC38500EVM

User’s Guide

SLUU068C

Using the UCC38500

User’s Guide

February 2005

Power Management Products

SLUU068C

-2

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.

Mailing Address:

Texas Instruments

Post Office Box 655303

Dallas, Texas 75265

Copyright 2001, Texas Instruments Incorporated

EVM IMPORTANT NOTICE

Texas Instruments (TI) provides the enclosed product(s) under the following conditions:

This evaluation kit being sold by TI is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not considered by TI to be fit for commercial use. As such, the goods being provided may not be complete in terms of requireddesign-,marketing-,and/ormanufacturing-relatedprotective considerations, including product safety measures typically found in the end product incorporating the goods. As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic compatibility and therefore may not meet the technical requirements of the directive.

Should this evaluation kit not meet the specifications indicated in the EVM User’s Guide, the 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. Please be aware that the products received may not be regulatory compliant or agency certified (FCC, UL, CE, 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.

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 EVM User’s Guide and, specifically, the EVM Warnings and Restrictions notice in the EVM User’s Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact the TI application engineer.

Persons handling the product must 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 machine, process, or combination in which such TI products or services might be or are used.

Mailing Address:

Texas Instruments

Post Office Box 655303

Dallas, Texas 75265

Copyright 2001, Texas Instruments Incorporated

EVM WARNINGS AND RESTRICTIONS

It is important to operate this EVM within the input voltage range of 85 V to 265 V and the output voltage of 12 V +/− 5%.

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 2001, Texas Instruments Incorporated

Contents

Contents

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21.3 Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31.3.1 Step 1. Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31.3.2 Step 2. Applying Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.3.3Step 3. Evaluating the Demonstration’s Boards Performance. . . . . . . . . . . . . . 1-3

1.3.4 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 DM38500 EVM Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 DM38500 EVM Part Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.2 DM38500 Board Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

 

 

Figures

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1−1. DM38500 Evaluation Module Application Schematic . . . . . . . . . . . . . . . . .

. . . . . . . . . . . 1-4

 

1−2.

DM38500 EVM Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 1-5

 

1−3.

DM38500 Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 1-5

 

1−4. DM38500 Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 1-6

 

2−1.

DM38500 EVM PC Board: Top Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 2-4

 

Chapter 1

General

Information

This chapter details the Texas Instruments (TI) DM38500 PFC/PWM Combination Controller 100W Power Factor Correction Preregulator Evaluation Module (EVM) SLUU068. It includes a list of EVM features, a brief description of the module illustrated with a pictorial, schematic diagrams, and EVM specifications.

Topic

 

Page

 

 

 

1.1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1−2

1.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1−2

1.3

Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1−3

1.4

DM38500 EVM Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1−5

 

 

 

General Information

1-1

Features

1.1 Features

UCC38500 PFC/PWM Combination Controller 100W Power Factor Correction Preregulator include:

JCombines PFC and 2nd Stage Down Converter Controls

JControls Boost Preregulator to Near-unityPower Factor

JAccurate Power Limiting

JImproved Feedforward Line Regulation

JPeak Current Mode Control in Second Stage

JProgrammable Oscillator

JLeading Edge/Trailing Edge Modulation for Reduced Output Ripple

JLow Startup Supply Current

JSynchronized Second Stage with Programmable Soft-start

JProgrammable Second Stage Shut-down

1.2 Description

The UCC38500 provides all the functions necessary for active power factor correction and a second stage dc-to-dcconverter all in one integrated circuit. The control IC uses leading edge modulation for the boost stage and trailing edge modulation for the step down converter to reduce the RMS current in the boost capacitor. Thedc-to-dccontroller uses peak current mode control for easy loop compensation.

The UCC38500 evaluation board is designed to illustrate the performance of the IC in a complete off-line100Wtwo-stagepower converter using power factor correction. The demonstration board was designed to operate with a universal input voltage range (i.e. 85−265 Vac) with a regulated 12V dc output.

Caution

High-voltagelevels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the EVM. The output capacitor has high levels of energy storage and it must be discharged before the load is removed. Serious injury can occur if proper safety precautions are not followed.

1-2

Description

1.3 Operating Guidelines

The operating guidelines for the evaluation board are provided with reference to the schematic in Figure 1−1 and the component layout in Figure 2−1.

1.3.1Step 1. Load Connections

A resistive or electronic load can be applied to the output terminals labeled OUT− and OUT+.

Note: For safety reasons the load should be connected before power is supplied to the demonstration board.

1.3.2Step 2. Applying Input Power

A 60 Hz AC power source not exceeding 265 VRMS needs be applied across terminals AC−N and AC−L for proper operation.

1.3.3Step 3. Evaluating the Demonstration’s Boards Performance.

With the AC source set between 85−265 V RMS the output voltage should be regulated and the input current should track the input voltage shape with near unity power factor. The operation of the circuit is verified over the line and load range and shows efficiency as high as 85%. At lighter loads, there may be some distortion in the line current due to Discontinuous Conduction Mode (DCM) operation. Please refer to Figures 1−2, 1−3 and 1−4 for typical EVM performance.

1.3.4Additional Information

For more information, pin description and specifications for the UCC38500 PFC/PWM Combination Controller, please refer to the datasheet or contact the Texas Instruments Semiconductor Product Information Center at 1-800-336-5236or1-972-644-5580.Product Information can also be found on the World Wide Web at www.ti.com.

General Information

1-3

R

4-1

Note:

Note:

 

.component Temperature-High

See .component Voltage-High

 

Warnings EVM See

and Warnings EVM

 

at Restrictions and

the at Restrictions

 

back the

of back

 

.document this of

.document this

 

VCC BIAS

 

 

HIGH

 

 

 

 

 

 

D2

 

R2

 

PGND

 

SEE EVM WARNINGS

.1−1Figure

Description

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TEMPERATURE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SEE EVM WARNINGS

 

 

 

C5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AND RESTRICTIONS

 

 

 

C4

R1

 

 

Q1

C3

 

 

HIGH

 

 

 

 

 

 

 

 

 

GT2

 

T2

 

 

 

 

 

 

 

 

 

 

 

 

 

D1

 

 

 

 

 

 

 

 

 

 

 

 

TEMPERATURE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VAC

CIRCUIT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L2

AND RESTRICTIONS

DM38500

 

 

 

 

C2

 

 

SEE EVM WARNINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUT +

 

85−265V RMS

 

L1

 

D3

 

PWR

 

 

 

 

 

 

 

D8

 

 

 

 

 

 

 

GND

 

 

 

 

 

 

T1

 

 

 

+

 

 

AC−L

 

 

 

 

 

 

 

 

 

 

D4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C29

C30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R22

R23

 

 

 

 

 

 

 

 

 

 

 

100 W

 

 

 

 

 

 

 

HIGH VOLTAGE

 

 

 

 

 

 

 

 

 

 

 

 

 

Q3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C26

D11

GT1

 

R33

R34

 

AND RESTRICTIONS

 

 

GT2

Q2

 

 

 

PGND2

OUT −

Evaluation

 

AC−N

R14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R12

R11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R20

 

 

 

 

 

 

 

 

D6

 

 

ISENSE2

 

 

 

 

 

 

R5

 

R21

 

UCC38500

 

 

 

R4

C7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U4

 

 

 

 

 

 

 

R7

 

 

 

 

 

 

 

 

 

 

4

OVP/ENBL

GT1

12

 

 

 

PGND

PGND

GT1

 

 

 

 

 

R19

PGND

C23

 

 

 

 

 

 

 

 

Module

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PKLIMIT

 

 

 

 

 

 

 

 

 

R6

 

 

 

 

 

 

 

R15

C25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

VSENSE

GT2

10

 

 

 

 

 

 

 

GT2

 

 

 

 

 

 

R28

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VCC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HIGH VOLTAGE

R18

R29

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

VAOUT

 

VCC

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D10

 

 

 

 

 

SEE EVM WARNINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C21

 

 

 

 

 

 

 

 

 

AND RESTRICTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Application

 

 

 

 

 

 

18

IAC

PWRGND

11

 

 

VREF

 

 

 

 

 

 

 

 

 

 

 

 

 

16

ISENSE

CT

5

 

 

 

C18

D9

 

 

 

 

 

 

 

 

VREF

 

 

 

 

 

 

 

R25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOUT

 

RT

 

 

 

PGND

 

 

 

 

 

 

 

 

 

 

 

17

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VCCBIAS

R24

D12

 

 

 

15 CAOUT

GND

6

 

 

 

 

PGND

 

 

 

 

 

 

CIRCUIT

 

 

R17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C22

 

 

 

 

 

 

PGND

 

SGND

 

 

 

 

 

Schematic

 

 

 

 

C19

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PKLIMIT

19 VFF

 

SS2

13

C16

R13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R39

 

 

R30

 

14 PKLIMIT

VERR

7

 

 

 

 

 

 

 

R26

 

 

 

 

 

 

 

C28

D16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C24

 

 

 

 

 

 

C17

 

 

 

 

 

 

 

 

 

 

 

 

 

20

VREF

ISENSE2

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q5

 

 

 

 

 

 

 

 

 

ISENSE2

H11AV1

R36

 

D14

 

 

 

 

 

 

SGND

 

 

VREF

 

 

 

 

 

 

 

 

 

D15

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

R31

 

 

 

 

 

 

 

 

 

 

 

 

C13

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PGND2

C8

 

 

 

 

 

 

 

C27

 

 

 

 

 

 

 

 

 

 

D5

R10

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C38

 

 

 

 

 

 

 

 

 

C12

 

VCC

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

L1

 

 

 

SGND

 

 

 

SGND

 

 

 

 

 

 

R32

 

 

 

 

 

 

 

 

 

 

 

 

 

C14

R35

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

3

 

 

 

 

 

 

 

C6

 

 

 

 

 

 

 

 

 

U3

 

 

 

 

 

 

 

 

C20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R27

 

 

−UDG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

00094

 

 

 

 

 

 

 

 

 

 

 

 

SGND

 

PGND2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3