Texas Instruments UCC28610EVM-474 User Manual

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Using the UCC28610EVM-474

User's Guide

Literature Number: SLUU383B

November 2009–Revised May 2011

UCC28610EVM-474 25-W Universal Off-Line Flyback

1 Introduction

The UCC28610EVM-474 evaluation module is a 25-W off-line Discontinuous Mode (DCM) flyback converter providing 12 V at 2.1-A maximum load current, operating from a universal AC input. The module is controlled with the UCC28610 Green-Mode Flyback Controller which uses a cascoded architecture that allows fully integrated current control without an external sense resistor. The converter maintains discontinuous mode operation over the entire operating range. This innovative approach results in efficiency, reliability, and system cost improvements over a conventional flyback.

2 Description

This evaluation module uses the UCC28610 Green-Mode Flyback Controller (TI Literature Number

SLUS888) in a 25-W DCM flyback converter that exceeds Energy Star™ EPS version 2.0 for efficiency

during active load and no-load power consumption. The input accepts a voltage range of 85 VACto 265 VAC. The output provides a regulated output voltage of 12 VDCat a load current of up to 2.1 A. The converter will transition through three operating modes: green mode (GM), amplitude modulation (AM), and frequency modulation (FM), depending upon the power level and FB current. In FM mode, the on-time is fixed, resulting in a fixed peak primary current at each cycle, and the switching frequency is increased with increasing load. In AM mode, the switching frequency is fixed at 30 kHz and the peak primary current is modulated with the on-time as with any typical PWM controller. Green mode operation at light load consists of burst packets of 30-kHz pulses with a fixed on-time and peak primary currents of 33% of the maximum programmed level. Low system parts count and built in advanced protection features result in a cost-effective solution that meets stringent world-wide energy efficiency requirements.

This user’s guide provides the schematic, component list, assembly drawing, art work, and test set up necessary to evaluate the UCC28610 in a typical off-line converter application.

User's Guide

SLUU383B–November 2009–Revised May 2011

Converter

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2.1 Applications

The UCC28610 is suited for use in isolated off-line systems requiring high efficiency and advanced fault protection features including:

• AC/DC Adaptors that have a Peak Power Output of 12 W to 65 W

• Housekeeping and Auxiliary Power Supplies

• Off-line Battery Chargers

• Consumer Electronics (DVD players, set-top boxes, gaming, printers, etc.)

2.2 Features

The UCC28610EVM-474 features include:

• Isolated 25 W, 12-V output

• Universal Off-Line Input Voltage Range

• Exceeds Energy Star™ EPS Version 2.0 Requirements for Active Load Efficiency and No-Load Power

Consumption

• Cascoded Configuration Allows Fully Integrated Current Control Without an External Sense Resistor

• Multiple Operating Modes for Optimum Efficiency Over entire Operating Range

• Over Current Protection to Limit RMS Input and Output Current

• Timed overload with Shutdown/Retry Response

• Opto-Less Output Overload Protection

Description

CAUTION

High voltage levels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the EVM. The large bulk capacitor, C9, and the output capacitors, C15 and C16, must be completely discharged before the EVM can be handled. Serious injury can occur if proper safety precautions are not followed.

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Electrical Performance Specifications

3 Electrical Performance Specifications

Table 1. UCC28610EVM-474 Electrical Performance Specifications

PARAMETER CONDITIONS MIN NOM MAX UNITS

INPUT CHARACTERISTICS

UVLO

OUTPUT CHARACTERISTICS

OUT

ripple

OUT

OCP

OVP

SYSTEM CHARACTERISTICS

PEAK

MECHANICAL CHARACTERISTICS

Width Dimensions 2.3 Length 3.5 inches Height Component height 1

Input voltage 85 265 VRMS Input current VIN= 115 V

VIN= 115 V

Brown out I

OUT

RMS

= max 72 V

Output voltage VIN= min to max, I Output voltage ripple VIN= 115 V

RMS

Output current VIN= min to max 0 2.1 A Output over current VIN= max

inception point Output OVP I Transient response voltage I

over shoot

= min to max 16 V

OUT

= min to max

OUT

Switching frequency 26.3 140.4 kHz Peak efficiency VIN= 115 V No load power consumption VIN= 115 V

VIN= 230 V

RMS

Operating temperature VIN= min to max, I range

, I

= max 0.3 A

OUT

, I

= 0 A 0.03 A

OUT

= min to max 10.8 12 13.2 V

OUT

, I

= max 80 120 mVpp

OUT

3 A

500 mV

, I

= 1.05 A 85.7 %

OUT

107

= min to max

OUT

25 °C

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INSTRUMENTS

EXAS

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4 Schematic/Revision Code Placement

NOTE: For revision A versions of the evaluation module, please refer to Appendix A of this user's

guide for the schematic, list of materials and board layout. The EVM revision code can be found on the lower right corner of the top side of the board, as shown in Figure 1.

Schematic/Revision Code Placement

Figure 1. Placement of Revision Code for the Evaluation Module.

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Schematic/Revision Code Placement

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Figure 2. UCC28610EVM-474 Schematic

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4.1 Circuit Description

A brief description of the circuit elements follows:

• Diode bridge D1, input capacitor C9, transformer (a.k.a. flyback inductor) T1, HV MOSFET Q1, UCC28610 controller U1, Schottky rectifier D6, Output capacitors C15 and C16 form the power stage of the converter. Note that the UCC28610 U1 is part of the power stage. This is because the DRV and GND pins carry the full peak primary side current of the converter.

• Capacitors C12, C14, and C17 filter the high frequency noise directly across the electrolytic input and output capacitors.

• The input EMI filter is made up of X2 capacitors, C1 and C6, and common mode inductor L1 and Y2 capacitors, C4 and C5. Excessive surge current protection is provided by a slow blow fuse, F1.

• Resistor R11, capacitor C11, and diode D5 make up the primary side voltage clamp for the HV MOSFET. The clamp prevents the drain voltage on Q1 from exceeding its maximum rating. The integrated snubber, composed of R12 and C11, reduces the ringing on the primary side windings that might inadvertently trigger the zero current detection circuit in the device.

• Resistors R7, R8, and R9 supply start up bias current to the VGG shunt regulator. Schottky diode D3 is required to provide initial start up to VDD from VGG at start up.

• Operating bias to the controller is provided by the auxiliary winding on T1, diode D2, and bulk capacitor C7. The zener diode, D4, maintains the bias voltage on VDD below the absolute maximum rating at full load.

• Gate drive circuitry is composed of gate drive resistor R10, used for damping oscillations during turn on. Resistor R16 and diode D8 are required to provide a current path at turn off because the gate is shorted to the source of the HV MOSFET during each switching cycle. For circuits that experience high ringing on VGG at turn off, R16 can be replaced with a ferrite bead.

• Capacitors C8 and C10 are decoupling capacitors which should always be good quality low ESR/ESL type capacitors placed as close to the device pins as possible and returned directly to the device ground reference.

• C13 filters the common mode noise between the primary and secondary sides.

• Inductor L2, with capacitor C16, reduces the output voltage ripple.

• Resistors R5 and R3 program the over voltage threshold. Capacitor C3 can be used to add a small

delay to ZCD, to align the turn on time of the primary switch with the resonant valley of the primary winding.

• Resistor R6 programs the maximum on time of the HV MOSFET.

• Resistor R4 sets the maximum value for the peak primary current.

• Resistor R2 and capacitor C2 provide a filter for the FB signal while resistor R1 ensures that the

optocoupler emitter current can go to 0A. Resistor R19 provides a non-intrusive point to monitor the FB by measuring the voltage drop across R19.

• The simple output voltage feedback loop is composed of zener diode D7, resistors R14 and R15, and the optocoupler U2. Using an opto with a low CTR provides better noise immunity. Resistor R13 is used as an injection point for small signal frequency response testing.

Schematic/Revision Code Placement

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EVM Test Set Up

5 EVM Test Set Up

Figure 2 shows the equipment set up when measuring the input power consumption during no load. Note the addition of the 10-Ω shunt resistor in Figure 3. During the no-load test, the power analyzer should be set for long averaging in order to include several cycles of operation and an appropriate current scale factor for using the external shunt must be used. Figure 3 shows the basic test set up recommended to evaluate the UCC28610EVM-474 with a load.

High voltages that may cause injury exist on this evaluation module (EVM). Please ensure all safety procedures are followed when working on this EVM. Never leave a powered EVM unattended.

5.1 Test Equipment

See Figure 3 and Figure 4 for recommended test set ups.

• AC Input Source: The input source shall be an isolated variable AC source capable of supplying between 85 V

Figure 4. For accurate efficiency calculations, a power meter should be inserted between the neutral

line of the AC source and the Neutral terminal of the EVM. For highest accuracy, connect the voltage terminals of the power meter directly across the Line and Neutral terminals of the EVM.

• Load: For the output load, a programmable electronic load set to constant current mode and capable of sinking 0 to 3 ADCat 12 VDCshall be used. For highest accuracy, V connecting a DC voltmeter, DMM V1, directly across the +Vout and –Vout terminals as shown in

Figure 3 and Figure 4. A DC current meter, DMM A1, should be placed in series with the electronic

load for accurate output current measurements.

• Power Meter: The power analyzer shall be capable of measuring low input current, typically less than 10 mA, and a long averaging mode if low power standby mode input power measurements are to be taken. An example of such an analyzer is the Voltech PM100 Single Phase Power Analyzer. To measure the intermittent bursts of current and power drawn from the line during no-load operation, an external 10-Ω shunt, with a current scale factor of 10 A/V, was used at a high sample rate over an extended period of time in order to display the averaged results (refer to Figure 3).

• Multimeters: Two digital multimeters are used to measure the regulated output voltage (DMM V1) and load current (DMM A1).

• Oscilloscope: A digital or analog oscilloscope with a 500-MHz scope probe is recommended.

• Fan: Forced air cooling is not required.

• Recommended Wire Gauge: a minimum of AWG18 wire is recommended. The wire connections

between the AC source and the EVM , and the wire connections between the EVM and the load should be less than two feet long.

RMS

and 265 V

WARNING

at no less than 30 W and connected as shown in Figure 3 and

RMS

can be monitored by

OUT

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NSTRUMENTS

EXAS

AC SOURCE

Line

Neutral

DMM V

+ -

Oscilloscope

POWER METER

VLOA

EXT

+ +

AC SOURCE

LineNeutral

DMM A

+ -

DMM V

+ -

Oscilloscope

ELECTRONIC

LOAD

POWER METER

VLOA

EXT

+ +

NSTRUMENTS

EXAS

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5.2 Recommended Test Set Up for Operation Without a Load

EVM Test Set Up

Figure 3. UCC28610EVM-474 Recommended Test Set Up Without a Load

5.3 Recommended Test Set Up for Operation With a Load

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Figure 4. UCC28610EVM-474 Recommended Test Set Up With a Load

EVM Test Set Up

5.4 List of Test Points

TEST POINT NAME DESCRIPTION

TP1 +Vout TP2 -Vout Return of the output of the EVM, secondary side GND reference.

TP3 Pwr RTN Primary side power ground TP4 QGND Primary side signal ground TP5 +LOOP Loop injection point, EVM output

TP6 -LOOP Loop injection point J1-1 Neutral Neutral input from the AC source J1-2 Earth Earth reference from the AC source J1-3 AC Line Line input from AC source J2-1 +Vout Positive output terminal of the EVM to the load J2-2 -Vout Return connection of the EVM output to the load

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Table 2. Test Point Functional Description

Output voltage of EVM; this designator is not populated with a pin in order to facilitate tip and barrel output ripple voltage measurements.

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6 Test Procedure

All tests should use the set up as described in Section 5 of this user’s guide. The following test procedure is recommended primarily for power up and shutting down the evaluation module. Never leave a powered EVM unattended for any length of time.

6.1 Applying Power to the EVM

1. Set up the EVM as shown in Section 5 of this user’s guide (a) If no-load input power measurements are to be made, set the power analyzer to long averaging

and external shunt mode. Insert a shunt, such as a 10-Ω resistor as shown in Figure 3, in series with the Neutral terminal of the EVM. Set the appropriate current scale on the power analyzer.

(b) For operation with a load, as shown in Figure 4, set the electronic load to constant current mode to

sink 0 A.

2. Prior to turning on the AC source, set the voltage to between 85 VACand 265 VAC.

3. Turn on the AC source.

4. Monitor the output voltage on DMM V1.

5. Monitor the output current on DMM A1.

6. The EVM is now ready for testing.

6.2 No-Load Power Consumption

1. Use the test set up shown in Figure 3. (a) Set the power analyzer to external shunt mode.

(b) Set the appropriate current scale factor for using an external shunt on the power analyzer. A 10-Ω

shunt scales at 10,000 mV/A for the PM100 Voltech.

Voltech should be set to a long averaging time of 10 or more for accurate burst mode measurements.

2. Apply power to the EVM per Section 6.1.

3. Monitor the input power on the power analyzer while varying the input voltage.

4. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM.

Test Procedure

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Test Procedure

6.3 Output Voltage Regulation and Efficiency

1. For load regulation: (a) Use the test set up shown in Figure 4.

(i) Be sure to remove the external shunt from the power analyzer and set the analyzer to normal

mode (not long averaging). (b) Set the AC source to a constant voltage between 85 VACand 265 VAC. (c) Apply power to the EVM per Section 6.1. (d) Vary the load current from 0 A up to 2.1 A, as measured on DMM A1. (e) Observe that the output voltage on DMM V1remains within 10% of 12 VDC.

2. For line regulation: (a) Set the load to sink 2.1 A.

(b) Vary the AC source from 85 VACto 265 VAC. (c) Observe that the output voltage on DMM V1remains within 10% of 12 VDC.

3. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM.

6.4 Output Voltage Ripple

1. Expose the ground barrel of the scope probe. Insert the tip of the probe into the plated via located on the +Vout pad of the EVM (TP1) and lean the probe so that the exposed ground barrel is resting on the test point on the –Vout pad of the EVM (TP2) for a tip and barrel measurement as shown in the example depicted in Figure 5.

2. Apply power to the EVM per Section 6.1.

3. Monitor the output voltage ripple on the oscilloscope.

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Figure 5. Typical Example of Tip and Barrel Measurement Technique

NOTE: This photo was not taken on the UCC28610EVM specifically but serves as a visual aid to

perform the test measurement.

6.5 Equipment Shutdown

1. Ensure the load is at maximum; this will quickly discharge the output capacitors.

2. Turn off the AC source.

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EFFICIENCY vs. LOAD CURRENT

0.800

0.810

0.820

0.830

0.840

0.850

0.860

0.870

0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3

LOA D(A)

E F FI C IE N C Y

85VAC

115VAC

230VAC

264VAC

No-Load Power Consumption vs. Line Voltage

265Vac

230Vac

85Vac

115Vac

100

120

140

80 100 120 140 160 180 200 220 240 260 280

Line Voltage (Vac)

In p u t P o w e r ( m W )

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Performance Data and Typical Characteristic Curves

7 Performance Data and Typical Characteristic Curves

Figure 6 through Figure 23 present typical performance curves for the UCC28610EVM-474.

Figure 6. Efficiency as a Function of Load Current and Input Voltage

Figure 7. No-Load Input Power as a Function of Input Voltage

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FB CURRENTvs. DRV CURRENT

200

400

600

800

1000

1200

1400

1600

1800

0 50 100 150 200 250 300 350

IFB (uA)

ID R V ( m A )

85Vac

115Vac

230Vac

265Vac

FB CURRENT vs. SWITCHING FREQUENCY

100

120

140

0 50 100 150 200 250 300 350

IFB(uA)

F sw ( k H z)

85Vac

115Vac

230Vac

265Vac

Performance Data and Typical Characteristic Curves

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Figure 8. DRV Current as a Function of FB Current

Figure 9. Switching Frequency as a Function of FB Current

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OUTPUT VOLTAGEvs LOADCURRENT

10.8

11.3

11.8

12.3

12.8

0 0.5 1 1.5 2 2.5 3

LOAD CURRENT (A)

O U T P U T V O L T A G E ( V)

85Vac

115Vac

230Vac

265Vac

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Performance Data and Typical Characteristic Curves

Figure 10. Output Voltage as a Function of Load Current and Line Voltage

(Note the shutdown/retry threshold for each line voltage.)

Figure 11. Start-Up Waveform

(Input voltage = 115 VAC, full load. Ch.1 = bulk input voltage, 100 V/div., Ch.2 = VGG, 10 V/div., Ch.3 =

VDD, 10V/div., Ch.4 = DRV, 10V/div.)

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Performance Data and Typical Characteristic Curves

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Figure 12. FM Mode Switching Cycle Waveform

(Input voltage = 115 VAC, full load, fSW= 112 kHz. Ch.1 = I

MOSFET, 100 V/div., Ch.3 = ZCD, 5 V/div.)

, 500 mA/div., I

DRV

= 1.53 A, Ch.2 = Drain of HV

DRV

Figure 13. AM Mode Switching Cycle Waveform

(Input voltage = 85 VAC, 0.3-A load, fSW= 28.2 kHz, Ch.1 = I

MOSFET, 100 V/div., Ch.3 = ZCD, 5 V/div., Ch. 4 = VDD, 10 V/div.)

UCC28610EVM-474 25-W Universal Off-Line Flyback Converter SLUU383B–November 2009– Revised May 2011

, 500 mA/div., I

DRV

= 1.1 A, Ch.2 = Drain of HV

DRV

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Performance Data and Typical Characteristic Curves

Figure 14. GM Mode Switching Cycle Waveform

(Input voltage = 85 VAC, 0-A load, fSW= 28 kHz, Ch.1 = I

MOSFET, 100 V/div., Ch.3 = ZCD, 5 V/div., Ch. 4 = VDD, 10 V/div.)

, 500 mA/div., I

DRV

= 440 mA, Ch.2 = Drain of HV

DRV

Figure 15. Ripple on VGG and VDD During Green Mode Operation

(Ch.3 = VGG, AC coupled, 2 V/div., Ch.4 = VDD, AC coupled, 200 mV/div.)

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Performance Data and Typical Characteristic Curves

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Figure 16. Output Voltage Ripple During Green Mode Operation

(Input voltage = 85 VAC, no load. Ch.2 = V

, AC coupled, 20 mV/div.)

OUT

Figure 17. Output Voltage Ripple During Frequency Modulation Mode (Input voltage = 85 VAC, full load. Ch.2 = V

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, AC coupled, 20 mV/div.)

OUT

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Performance Data and Typical Characteristic Curves

Figure 18. Load Transient, 0% to 100% Load Step

(Ch.1 = I

, 2 A/div., Ch.2 = V

OUT

, AC coupled, 200 mV/div.)

OUT

Figure 19. Brown-Out Protection

(MOT shutdown/retry response triggered at full load when input voltage dropped to 72.4 VAC. Note the

750-ms t

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RETRY

. Ch.1 = I

, Ch.3 = VDD, 10 V/div., Ch.4 = VGG, 10 V/div.)

DRV

Performance Data and Typical Characteristic Curves

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Figure 20. Output Short Circuit Protection

(Short circuit maintained on output; note the output current goes to 4.62 A, refer to equation 13 in the

data sheet, during the 250-ms delay to overload fault, tOL, and retries after t

85 VAC. Ch.1 = I

, 1 A/div., Ch. 3 = V

OUT

, 1 V/div.)

OUT

= 750 ms. Input voltage =

RETRY

Figure 21. Output Over Voltage Protection

(The EVM was tested with an open FB loop, no load. OVP threshold is equal to 15.44 V. Ch. 3 = V

V/div., offset by 4 V.)

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OUT

, 2

115Vac Bode Plot

-60

-40

-20

100 1000 10000

Frequen cy (Hz)

G a in (d B )

-180

-120

-60

120

180

P h a s e ( d e g r e es )

Gain Phase

230Vac Bode Plot

-60

-40

-20

100 1000 10000

Frequency (Hz)

G a i n (d B )

-180

-120

-60

120

180

P h a s e ( d e g r e e s)

Gain Phase

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Performance Data and Typical Characteristic Curves

Figure 22. Bode Plot (Input voltage = 115 VAC, full load.)

Figure 23. Bode Plot (Input voltage = 230 VAC, full load.)

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INSTRUMENTS

EXAS

EVM Assembly Drawing and Layout

8 EVM Assembly Drawing and Layout

Figure 24 through Figure 26 show the design of the UCC28610EVM-474 printed circuit board.

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Figure 24. Top Layer Component Placement

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Figure 28. Bottom Layer Component Placement.

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EVM Assembly Drawing and Layout

Figure 25. Bottom Layer Routing

Figure 26. Bottom Layer Component Placement

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List of Materials

9 List of Materials

COUNT REF DES DESCRIPTION PART NUMBER MFR

2 C1, C6 ECQ-U2A334ML Panasonic 1 C2 Capacitor, ceramic, 100 pF, 50 V, NP0, ±5%, 0603 Std Std

C3 Capacitor, ceramic, not populated, 50 V, NP0, ±5%,

0 Std Std

C4, C5 Capacitor, ceramic, 2200 pF, 250 VAC, X1/Y2, ±20%,

2 DE2E3KY222MA2BM01 muRata

(optional) 0.315 x 0.200 inch 1 C7 EEU-FC1V680 Panasonic 1 C8 Capacitor, ceramic, 0.1 µF, 50 V, X7R, ±10%, 0805 CC0805KRX7R9BB104 Yageo Corporation 1 C9 EET-HC2G101BA Panasonic 1 C10 Capacitor, ceramic, 0.1 µF, 100 V, X7R, ±10%, 1206 Std Std 1 C11 Std Std 1 C12 Capacitor, ceramic, 0.1 µF, 630 V, X7R, ±10%, 1812 C4532X7R2J104K TDK Corporation 1 C13 ECK-ANA102MB Panasonic 2 C14, C17 Capacitor, ceramic, 1 µF, 25 V, X5R, ±10%, 0805 Std Std 2 C15, C16 EEU-FM1E681 Panasonic 1 D1 Diode, bridge, 1 A, 600 V DF06M Diodes Inc.

1 D2 Diode, ultra fast, 1 A, 200 V, SMA MURA120T3G On Semiconductor 1 D3 Diode, schottky, 100 mA, 40 V, SOD-323 RB501V-40TE-17 1 D4 Diode, Zener, 25 V, 500 mW, SOD-123 MMSZ5253BT1G On Semiconductor 1 D5 UF4007-TP 1 D6 Diode, dual Schottky, 20 A, 100 V, TO-220 STPS20H100CT STMicroelectronics 1 D7 Diode, Zener, 10 V, 500 mW, SOD-123 MMSZ5240B 1 D8 Diode, Schottky barrier, 1 A, 30 V, SMini2-F2 MA21D3400L Panasonic - SSG 1 F1 Fuse, slow blow, 1 A, 250 V, 0.335 inch 38211000410 1 HS1 Heatsink, TO-220, vertical-mount, 0.5 x 0.750 inch 507302B00000 Aavid Thermalloy

1 HS2 Heatsink, alloy 1110 copper, 0.530 x 1.200 inch HS001 NH Stamp 1 L1 54P512-276

1 L2 HCP0703-3R3-R Coiltronics/Cooper 1 Q1 MOSFET, Nch, 600 V, 6 A, SC-67 2SK3562 Toshiba

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Table 3. List of Materials for UCC28610EVM-474

Capacitor, film, 0.33 µF, 275 VAC, X2, ±20%, 0.690 x

0.374 inch

0603

Capacitor, aluminum electrolytic, 68 µF, 35 V, ±20%,

0.200 inch

Capacitor, aluminum electrolytic, 100 µF, 400 VDC, ±20%, 25 x 20 mm

Capacitor, ceramic, 330 pF, 630 V, C0G, NP0, ±5%, 1206

Capacitor, ceramic disk, 1000 pF, 250 V, Y1/X1, ±20%,

0.394 x 0.315 inch

Capacitor, aluminum electrolytic, 680 µF, 25 V, ±20%, 10 x 25 mm

Rohm Semiconductor

Diode, fast recovery glass passivated, 1 A, 1 kV, Micro Commercial DO-41 Co.

Fairchild Semiconductor

Littelfuse / Wickmann

Inductor, AC line, common choke, 2 7 mH, 1 A, 0.660 x Vitec Electronics

0.670 inch Corp. Inductor, high current choke, 3.3 µH, 0.276 x 0.288

inch

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References

Table 3. List of Materials for UCC28610EVM-474 (continued)

COUNT REF DES DESCRIPTION PART NUMBER MFR

1 R1 Resistor, chip, 100 kΩ, 1/10 W, ±1%, 0603 Std Std 1 R2 Resistor, chip, 20.5 kΩ, 1/10 W, ±1%, 0603 Std Std 1 R3 Resistor, chip, 51.1 kΩ, 1/10 W, ±1%, 0603 Std Std 1 R4 Resistor, chip, 64.9 kΩ, 1/10 W, ±1%, 0603 Std Std

1 R5 SFR16S0001693FR500 1 R6 Resistor, chip, 68.1 kΩ, 1/10 W, ±1%, 0603 Std Std

R7, R8,

3 Resistor, chip, 2.05MΩ, 1/8 W, 150V, ±1%, 0805 CRCW08052M05FKEA Vishay/Dale

R9 1 R10 Resistor, chip, 15.4 Ω, 1/8 W, ±1%, 0805 Std Std 1 R11 Resistor, chip, 64.9 kΩ, 1/2 W, ±1%, 2010 Std Std 1 R12 Resistor, chip, 33.2 Ω, 1 W, ±5%, 2512 Std Std 1 R13 Resistor, chip, 20.5 Ω, 1/10 W, ±1%, 0603 Std Std 1 R14 Resistor, chip, 1.00 kΩ, 1/10 W, ±1%, 0603 Std Std 1 R15 Resistor, chip, 681 Ω, 1/10 W, ±1%, 0603 Std Std 1 R16 Resistor, chip, 0 Ω, 1/10 W, ±1%, 0603 Std Std 1 R19 Resistor, metal film, 1.00 kΩ, 1/4 W, ±1%, TH-400 Std Std 1 T1 Transformer, flyback, 220 µH, PQ20/20 58P6936 Vitec Electronics 1 U1 Green-mode flyback controller, SO-8 UCC28610D Texas Instruments

1 U2 CNY17F1M

Resistor, metal film, 169 kΩ, 1/2 W, ±1%, 0.300 x Vishay/BC

0.100 inch Components

Optocoupler, CTR 40% - 80%, 70 Vceo, 5000 V DIP6 Optoelectronics

, Fairchild

RMS

10 References

1. UCC28610 Green-Mode Flyback Controller, Datasheet, (TI Literature Number SLUS888)

2. Standby and Low Power Measurements, VOLTECHNOTES, VPN 104-054/1,

http://www.voltech.com/Downloads/PMAppNotes/Low%20Power%20Standby.pdf

SLUU383B–November 2009– Revised May 2011 UCC28610EVM-474 25-W Universal Off-Line Flyback Converter

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Appendix A

A.1 UCC28610EVM-474 Rev. A

The following schematic, board layout, and list of materials apply to the UCC28610EVM-474 Rev. A version of the evaluation module. The Rev. A version of the EVM includes differential mode inductors L2 and L3. Subsequent revisions of the EVM replaced these inductors with a short circuit.

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Figure 27. UCC28610EVM-474 Rev. A Schematic

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NSTRUMENTS

EXAS

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UCC28610EVM-474 Rev. A

Figure 28. Top Side View of UCC28610EVM-474 Rev. A

Figure 29. Top Layer Component Placement for UCC28610EVM-474 Rev. A

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UCC28610EVM-474 Rev. A

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Figure 30. Bottom Layer Routing of UCC28610EVM-474 Rev. A

Figure 31. Bottom Layer Component Placement of UCC28610EVM-474 Rev. A

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UCC28610EVM-474 Rev. A

Table 4. Table 4. List of Materials for UCC28610EVM-474 Rev. A

COUNT REF DES DESCRIPTION PART NUMBER MFR

2 C1, C6 ECQ-U2A334ML Panasonic 1 C2 Capacitor, ceramic, 100 pF, 50 V, NP0, ±5%, 0603 Std Std

0 C3 Capacitor, ceramic, not populated, 50 V, NP0, ±5%, 0603 Std Std

C4, C5 Capacitor, ceramic, 2200 pF, 250 VAC, X1/Y2, ±20%, DE2E3KY222MA2BM

2 muRata

(optional) 0.315 x 0.200 inch 01

1 C7 EEU-FC1V680 Panasonic

1 C8 Capacitor, ceramic, 0.1 µF, 50 V, X7R, ±10%, 0805 Yageo Corporation

1 C9 EET-HC2G101BA Panasonic 1 C10 Capacitor, ceramic, 0.1 µF, 100 V, X7R, ±10%, 1206 Std Std

1 C11 Capacitor, ceramic, 330 pF, 630 V, C0G, NP0, ±5%, 1206 Std Std 1 C12 Capacitor, ceramic, 0.1 µF, 630 V, X7R, ±10%, 1812 C4532X7R2J104K TDK Corporation

1 C13 ECK-ANA102MB Panasonic 2 C14, C17 Capacitor, ceramic, 1 µF, 25 V, X5R, ±10%, 0805 Std Std 2 C15, C16 EEU-FM1E681 Panasonic 1 D1 Diode, bridge, 1 A, 600 V DF06M Diodes Inc.

1 D2 Diode, ultra fast, 1 A, 200 V, SMA MURA120T3G On Semiconductor 1 D3 Diode, Schottky, 100 mA, 40 V, SOD-323 RB501V-40TE-17 Rohm Semiconductor 1 D4 Diode, Zener, 500 mW, 25 V, SOD-123 MMSZ5253BT1G On Semiconductor 1 D5 Diode, fast recovery glass passivated, 1 A, 1 kV, DO-41 UF4007-TP Micro Commercial Co. 1 D6 Diode, dual Schottky, 20 A, 100 V, TO-220 STPS20H100CT STMicroelectronics

1 D7 Diode, Zener, 10 V, 500 mW, SOD-123 MMSZ5240B 1 D8 Diode, Schottky barrier, 1 A, 30 V, SMini2-F2 MA21D3400L Panasonic - SSG

1 F1 Fuse, slow blow, 1 A, 250 V, 0.335 inch 38211000410 Littelfuse / Wickmann 1 HS1 Heatsink, TO-220, vertical mount, 0.5 x 0.750 inch 507302B00000 Aavid Thermalloy 1 HS2 Heatsink, alloy 1110 copper, 0.530 x 1.200 inch HS001 NH Stamp

1 L1 54P512-276

2 L2, L3 Inductor, EMI, 723 µH, 0.620 Ω, ±15%, 11.94 x 15.49 mm 54P2986 1 L4 Inductor, high current choke, 3.3 µH, 0.276 x 0.288 inch HCP0703-3R3-R Coiltronics/Cooper

1 Q1 MOSFET, N-channel, 600 V, 6A, SC-67 2SK3562 Toshiba

Capacitor, film, 0.33 µF, 275VAC, X2, ±20%, 0.690 x

0.374 inch

Capacitor, aluminum electrolytic, 68 µF, 35 V, ±20%,

0.200 inch CC0805KRX7R9BB10

Capacitor, aluminum electrolytic, 100 µF, 400 VDC, ±20%, 25 x 20 mm

Capacitor, ceramic disk, 1000 pF, 250 V, Y1/X1, ±20%,

0.394 x 0.315 inch

Capacitor, aluminum electrolytic, 680 µF, 25 V, ±20%, 10 x 25 mm

Fairchild Semiconductor

Inductor, AC line, common choke, 27 mH, 1 A, 0.660 x Vitec Electronics

0.670 inch Corp.

Vitec Electronics Corp.

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UCC28610EVM-474 Rev. A

Table 4. Table 4. List of Materials for UCC28610EVM-474 Rev. A (continued)

COUNT REF DES DESCRIPTION PART NUMBER MFR

1 R5 1 R6 Resistor, chip, 68.1 kΩ, 1/10 W, ±1%, 0603 Std Std

R7, R8, CRCW08052M05FKE

3 Resistor, chip, 2.05 MΩ, 1/8 W, 150 V, ±1%, 0805 Vishay/Dale

R9 A 1 R10 Resistor, chip, 15.4 W, 1/8 W, ±1%, 0805 Std Std 1 R11 Resistor, chip, 64.9 kΩ, 1/2 W, ±1%, 2010 Std Std 1 R12 Resistor, chip, 33.2 Ω, 1 W, ±5%, 2512 Std Std 1 R13 Resistor, chip, 20.5 Ω, 1/10 W, ±1%, 0603 Std Std 1 R14 Resistor, chip, 1.00 kΩ, 1/10 W, ±1%, 0603 Std Std 1 R15 Resistor, chip, 681 Ω, 1/10 W, ±1%, 0603 Std Std 1 R16 Resistor, chip, 0 Ω, 1/10 W, ±1%, 0603 Std Std 1 R19 Resistor, metal film, 1.00 kΩ, 1/4 W, ±1%, TH-400 Std Std 1 T1 Transformer, flyback, 220 µH, PQ20/20 58P6936 Vitec Electronics 1 U1 Green-Mode Flyback Controller, SO-8 UCC28610D Texas Instruments

1 U2 Optocoupler, CTR 40% - 80%, 70 Vceo, 5000Vrms, DIP6 CNY17F1M

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Resistor, metal film, 169 kΩ, 1/2 W, ±1%, 0.300 x 0.100 SFR16S0001693FR5 Vishay/BC inch 00 Components

Fairchild Optoelectronics

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UCC28610EVM-474 Rev. A

EVALUATION BOARD/KIT IMPORTANT NOTICE

Texas Instruments (TI) provides the enclosed product(s) under the following conditions: This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION

PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives.

Should this evaluation board/kit not meet the specifications indicated in the User’s Guide, the board/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.

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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 User’s Guide and, specifically, the Warnings and Restrictions notice in the User’s Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For additional information on TI’s environmental and/or safety programs, please contact the TI application engineer or visit www.ti.com/esh.

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.

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This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. It generates, uses, and

can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference.

EVM WARNINGS AND RESTRICTIONS

It is important to operate this EVM within the input voltage range of 85 VACto 265 VACand the output voltage of 12 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 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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IMPORTANT NOTICE

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Texas Instruments UCC28610EVM-474 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

2 Description

2.1 Applications

2.2 Features

3 Electrical Performance Specifications

4 Schematic/Revision Code Placement

4.1 Circuit Description

5 EVM Test Set Up

5.1 Test Equipment

5.2 Recommended Test Set Up for Operation Without a Load

5.3 Recommended Test Set Up for Operation With a Load

5.4 List of Test Points

6 Test Procedure

6.1 Applying Power to the EVM

6.2 No-Load Power Consumption

6.3 Output Voltage Regulation and Efficiency

6.4 Output Voltage Ripple

6.5 Equipment Shutdown

7 Performance Data and Typical Characteristic Curves

8 EVM Assembly Drawing and Layout

9 List of Materials

10 References

Appendix A

A.1 UCC28610EVM-474 Rev. A