User’s G uide
SLUU068C
User’s G uide
-2
February 2005 Power Management Products
SLUU068C
IMPORTANT NOTICE
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enhancements, improvements, and other changes to its products and services at any time and to discontinue
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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
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TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right,
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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 required design-, marketing-, and/or manufacturing-related protective
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 S TATUTORY, 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 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Description 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Operating Guidelines 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Step 1. Load Connections 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Step 2. Applying Input Power 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Step 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 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 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:
J Combines PFC and 2nd Stage Down Converter Controls
J Controls Boost Preregulator to Near-unity Power Factor
J Accurate Power Limiting
J Improved Feedforward Line Regulation
J Peak Current Mode Control in Second Stage
J Programmable Oscillator
J Leading Edge/Trailing Edge Modulation for Reduced Output Ripple
J Low Startup Supply Current
J Synchronized Second Stage with Programmable Soft-start
J Programmable 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-dc converter 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. The dc-to-dc controller 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-line 100W two-stage power 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-voltage levels 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
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.
1.3.1 Step 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.
1.3.2 Step 2. Applying Input Power
Description
A 60 Hz AC power source not exceeding 265 V
terminals AC−N and AC−L for proper operation.
needs be applied across
RMS
1.3.3 Step 3. Evaluating the Demonstration’s Boards Performance.
With the AC source set between 85−265 V
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.
the output voltage should be
RMS
1.3.4 Additional 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
1-800-336-5236 or 1-972-644-5580. Product Information can also be found
on the World Wide Web at www.ti.com.
General Information
1-3
Description
Figure 1−1.DM38500 Evaluation Module Application Schematic
C8
12 V
OUT −
100 W
OUT +
HIGH
TEMPERATURE −
AND RESTRICTIONS
SEE EVM WARNINGS
L2
PGND
C3
Q1
R2
R1C4
D2
T2
C5
GT2
PWR
HIGH
TEMPERATURE −
AND RESTRICTIONS
SEE EVM WARNINGS
D1
BIAS
CC
CIRCUIT
V
VAC
Note: High-Voltage component. See EVM Warnings and Restrictions at the back of this document.
Note: High-Temperature component. See EVM W arnings and Restrictions at the back of this document.
+
D8
T1
D4
GND
L1 D3
RMS
85−265V
AC−L
−
PGND2
C29 C30
Q2
GT2
HIGH VOLTAGE −
AND RESTRICTIONS
SEE EVM WARNINGS
R23
R34
R22
R33
C2
Q3
GT1
D11
C26
ISENSE2
R12 R11
C7
R4
D6
U4
UCC38500
R21
R20
R5
GT1
R7
PGNDPGND
12
GT1
OVP/ENBL
4
C23
PGND
R14
R19
AC−N
GT2
R6
CC
V
10
GT2
VSENSE
3
R28
C25
R15
PKLIMIT
D10
PGND
D9
C18
C21
R25
9
5
CT
VCC
VAOUT
ISENSE
1
16
R29
REF
V
R18
HIGH VOLTAGE −
AND RESTRICTIONS
SEE EVM WARNINGS
2
RT
MOUT
17
PGND
6
GND
CAOUT
15
D12
R24
BIAS
CC
CIRCUIT
V
SGND
V
PGND
R17
C22
REF
13
11
SS2
PWRGND
IAC
VFF
19
18
C19
R13
C16
7
VERR
PKLIMIT
14
PKLIMIT
R3
R30
R39
R26
D16
C28
C17
8
ISENSE2
VREF
20
C24
D14
R36
H11AV1
ISENSE2
REF
V
SGND
Q5
R31
1
6
D15
PGND2
5
C13
C27
R10
D5
R16
C38
CC
V
2
C12
R32
C14 R35
SGND
SGND
L1
3
4
U3
C6
C20
D7
R27
D13
UDG−00094
PGND2
SGND
1-4
1.4 DM38500 EVM Performance
Figure 1−2 through 1−4 shows the typical evaluation module performance.
Figure 1−2.DM38500 EVM Efficiency
90
85
80
DM38500 EVM Performance
UCC38500 EFFICIENCY
vs
OUTPUT POWER
VIN= 265 V
75
70
Efficiency −%
65
60
55
50
Figure 1−3.DM38500 Power Factor
1.00
VIN= 175 V
VIN= 85 V
2010 4030 6050 8070 90 100
P
− W
OUT
UCC38500 PF
vs
OUTPUT POWER
0.95
Power Factor
0.90
0.85
2010
VIN = 85 V
VIN = 175 V
VIN = 265 V
4030 6050 8070 90 100
P
− W
OUT
General Information
1-5
DM38500 EVM Performance
Figure 1−4.DM38500 Total Harmonic Distortion
UCC38500 TOTAL HARMONIC DISTORTION
vs
35
OUTPUT POWER
30
VIN = 265 V
25
20
VIN = 175 V
15
10
Total Harmonic Distortion
VIN = 85 V
5
0
2010
4030 6050 8070 90 100
P
− W
OUT
1-6
Chapter 2
Reference
This chapter includes a parts list and PCB layout illustrations for the DM38500
EVM.
Topic Page
2.1 DM38500 EVM Part Descriptions 2−2. . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 DM38500 Board Layouts 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference
2-1
DM38500 EVM Part Descriptions
Diodes
Fuses
Heat sinks
Inductors
MOSFETs
2.1 DM38500 EVM Part Descriptions
Table 2−1.DM38500 Part Descriptions
Description Reference Qty Value/Type Number Manufacturer
C12, C20,
C29
C13 1 47 pF, 50 V, ceramic Panasonic ECU−S2A470JCA
C7, C16,
C14
C17, C38 2 100 pF, 50 V, ceramic Panasonic ECU−S1H101JCA
C19 1 2.2 nF, 50 V, ceramic Panasonic ECU−S1H222JCB
C2 1
Capacitors
Diodes
Heat sinks HS4, HS5 2 For D3 and D8 Aavid 579302 B 0 00 00
MOSFETs Q3 1 14 A, 500 V, n−channel IR IRFP450
Not used
C21 1 680 pF, 50 V, ceramic Panasonic ECU−S1H681JCB
C22
C24 1 100 pF, 50 V, ceramic Panasonic ECU−S1H101JCA
C25 1 150 nF, 50 V, ceramic Panasonic ECU−S1H154KBB
C26 1 47 nF, 600 V, polypropylene Panasonic ECQ−E6473KF
C27, C18 2 100 pF, 50 V, ceramic Panasonic ECU−S1H105KBB
C28, C23 2 2.2 µF, 50 V, ceramic Panasonic ECU−S1H225MEB
C3 1 100 µF, 450 V, electrolytic Panasonic ECO−S2WB101BA
C30 1 1800 µF, 25 V, electrolytic Panasonic ECA−IEFQ182
C4, C5, C8 3 0.1 µF, 50 V, ceramic Panasonic ECU−S1H104KBB
C6 1 100 µF, 25 V, electrolytic Panasonic EEU−FCIE101S
D1 1 6 A, 600 V, GI756CT General Inst. GI756CT
D11 1
D12 1 1 A, 40 V, Shottky SR103CT
D13 1 TL431CLP TI TL431C
D14 1 10 V, 1 W, Zener 1N4740
D15, D2
D3 1 6 A, 600 V, ultra fast IR HFA08TB60−ND
D4, D6 2 1 A, 600 V, fast recovery Philips BYV26C
D5,D7,D9,
D10, D16
D8 1
FH1, FH2 2 3AG Fuse clip
F1 1 6 A, 250 V
HS3 1 For Q3 Aavid 513201
HS1, HS2 2 For Q1 and Q2 Avid 593002 B 0 34 00
L1 1 1.7 mH, 2.5 A, coupled Cooper CTX08−14730
L2 1 35 µH, 8.3 A Cooper CTX08−14279
Q1,Q2 2 8 A, 500 V, n−channel IR IRF840
Q5 1 NPN transistor MJE13005
Q4, R8, R9,
C9, C15,
C10
3 1 µF, 50 V, polypropylene Panasonic ECQ−V1H105JL
3 10 nF, 50 V, ceramic Panasonic ECU−S1H103JCB
470 nF, 400 V,
polypropylene
1 390 pF, 50 V, ceramic Panasonic ECU−S1H391JCA
6 A, 600 V, bridge rectifier,
PB66
2 18 V, 1 W, Zener 1N4746
5 1 A, 40 V, Shottky 1N5819
6 A, 600 V, full wave
rectifier
6 Not used
Panasonic ECQ−E4474KZ
Diodes Inc. PB66
IR HBR2045
Part
Number
2-2
DM38500 EVM Part Descriptions
Resistors
Resistors
Transformers
ICs
ICs
Description
Miscellaneous
PCB PCB 1 Bare board UCC38500 PCB
Reference Qty Value/Type Number Manufacturer
R1, R12 2 Short
R10, R36 2 200 Ω, ¼ W
R25, R29,
R27
R13 1 2 kΩ, ¼ W
R14 1 1.5 kΩ, ¼ W
R15, R19 2 3.92 kΩ, ¼ W
R16 1 750 Ω, ¼ W
R17 1 7.5 kΩ, ¼ W
R18, R24 2 392 kΩ, ¼ W
R2, R11 2 1 kΩ, ¼ W
R20 1 22.1 kΩ, ¼ W
R21 1 8.25 kΩ, ¼ W
R22, R33 2 562 kΩ, ¼ W
R23 1 200 kΩ, ¼ W
R26 1 100 Ω, ¼ W
R28 1 100 kΩ, ¼ W
R30 1 30.1 kΩ, ¼ W
R31 1 33.2 kΩ, ¼ W
R32 1 4.75 kΩ, ¼ W
R34 1 221 kΩ, ¼ W
R35 1 16.2 kΩ, ¼ W
R39 1 1 kΩ, 1 W
R4 1 1 Ω, 1 W, ±5%
R5 1 0.33 Ω, 3 W, ±5%
R6, R7 2 20 Ω, ¼ W
R3 1 51 kΩ, 2 W, 400 V
T1 1 8 mH, 10 A, 10.8:1 Cooper CTX08−14226
T2 1 560−990 µH, 1:1 gate drive Cooper CTX08−14225
U4 1
U3 1 Opto-isolator 4N36
X1 3
X2 1
X3
X4 4 Nut #4x40
X5 3
X6 1 Bevel washer #4 (@Q3)
3 10 kΩ, ¼ W
BiCMOS PFC/PWM
combination controller
Thermal pad TO−220
(@ Q1, Q2, D8)
Thermal pad TO−247
(@ Q3)
Screw pan head #4−40 X
4
7/16 (@Q1, Q2, Q3, D8)
Nylon shoulder washer #4
(@Q1, Q2, D8)
Texas
Instruments
Part
Number
UCC38500N
Notes:
1) The values of these components are to be determined by the user in accordance with the application requirements.
2) Unless otherwise specified, all resistors have a tolerance of ±1%.
3) Capacitor C38 is located at reference designator R38 on the PCB.
Reference
2-3
DM38500 Board Layouts
2.2 DM38500 Board Layouts
Board layout examples of the DM38500 EVM PCB are shown in the following
illustrations. They are not to scale and appear here only as a reference.
Figure 2−1.DM38500 EVM PC Board: Top Assembly
2-4
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