Texas Instruments UCC25660 Series Manual de usuario

EVM User's Guide: UCC25660EVM-064 UCC256601 UCC256602

UCC256603 UCC256604

UCC25660x Half Bridge LLC Evaluation Module

Description

The UCC25660EVM-064 assists designers to

evaluate the operation and performance of the

UCC25660x LLC Resonant controller (16-pin SOIC

package with removed pins for high voltage

clearance). This evaluation module demonstrates how

UCC25660x controls the LLC resonant half bridge

DC-DC converter to achieve high effciency through

out the load and input voltage range.

Features

• IPPC controlled (Input power proportional

control) LLC resonant half-bridge DC-DC power

conversion

• DC line input from 365 VDC to 410 VDC

• AC input voltage from 85 VDC to 265 VAC

• Regulated 12-VDC typical output

• Full-load power of 180 W, or full-load current of 15

• High efficiency

• Enhanced light load management:

– High frequency pulse skip for improved light

load efficiency

– Low frequency burst for reduced standby power

– Audible frequency range skip for reduced

audible noise

– User option to disable

– Integrated PFC on/off control signal

• Combined resonant current and resonant capacitor

voltage sensing through one pin

• Adaptive dead-time

• X-capacitor discharge

• Automatic capacitive region avoidance

• Adaptive soft start with minimized inrush current

• Complete sets of protections:

– Cycle-by-cycle current limit, OCP1 protection

– Configurable over power protection

– OVP, internal & external OTP

– Vin & VCC UVLO

– Inbuilt 19.5 V VCC Clamp

• Test points to facilitate device and topology

evaluation

Applications

•SMPS power supply for TV

•Industrial AC-DC adapters

•Power tools

•Medical power supply

•Multifunctional printer

•Enterprise and cinema projector

•PC power supply

•Gaming console power supply

•Lighting

UCC25660EVM-064 180W LLC Resonant DC-DC Converter (Top View)

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UCC25660x Half Bridge LLC Evaluation Module 1

General Texas Instruments High Voltage Evaluation (TI HV EVM) User Safety Guidelines

WARNING

Always follow TI's set-up and application instructions, including use of all interface components within the

recommended electrical rated voltage and power limits. Always use electrical safety precautions to help ensure

your personal safety and those working around you. Contact TI's Product Information Center http://ti.com/

customer support for further information.

Save all warnings and instructions for future reference.

WARNING

Failure to follow warnings and instructions can result in personal injury, property damage or death

due to electrical shock and burn hazards.

The term TI HV EVM refers to an electronic device typically provided as an open framed, unenclosed printed

circuit board assembly. It is intended strictly for use in development laboratory environments, solely for qualified

professional users having training, expertise and knowledge of electrical safety risks in development and

application of high voltage electrical circuits. Any other use and/or application are strictly prohibited by Texas

Instruments. If you are not suitably qualified, you should immediately stop from further use of the HV EVM.

1. Work Area Safety:

a. Keep work area clean and orderly.

b. Qualified observers must be present anytime circuits are energized.

c. Effective barriers and signage must be present in the area where the TI HV EVM and the interface

electronics are energized, indicating operation of accessible high voltages can be present, for the

purpose of protecting inadvertent access.

d. All interface circuits, power supplies, evaluation modules, instruments, meters, scopes, and other related

apparatus used in a development environment exceeding 50Vrms/75VDC must be electrically located

within a protected Emergency Power Off EPO protected power strip.

e. Use stable and non-conductive work surface.

f. Use adequately insulated clamps and wires to attach measurement probes and instruments. No

freehand testing whenever possible.

2. Electrical Safety:

a. As a precautionary measure, a good engineering practice is to assume that the entire EVM can have

fully accessible and active high voltages.

b. De-energize the TI HV EVM and all the inputs, outputs and electrical loads before performing any

electrical or other diagnostic measurements. Revalidate that TI HV EVM power has been safely de-

energized.

c. With the EVM confirmed de-energized, proceed with required electrical circuit configurations, wiring,

measurement equipment hook-ups and other application needs, while still assuming the EVM circuit and

measuring instruments are electrically live.

d. Once EVM readiness is complete, energize the EVM as intended.

WARNING

While the EVM is energized, never touch the EVM or the electrical circuits, as the EVM or

the electrical circuits can be at high voltages capable of causing electrical shock hazard.

3. Personal Safety

a. Wear personal protective equipment e.g. latex gloves or safety glasses with side shields or protect EVM

in an adequate lucent plastic box with interlocks from accidental touch.

Limitation for safe use:

EVMs are not to be used as all or part of a production unit.

General Texas Instruments High Voltage Evaluation (TI HV EVM) User Safety Guidelines www.ti.com

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1 Evaluation Module Overview

1.1 Introduction

The purpose of the EVM is to aid in evaluation of the UCC25660x LLC resonant controller. The EVM is a

stand-alone LLC resonant half-bridge DC-DC power converter designed to operate with DC input from 365 VDC

to 410 VDC, AC input from 85 to 265 VRMS, 47 to 63 Hz, and a nominal output of 12 VDC up to 180-W. The

EVM is delivered using a diode rectifier at the output. The user has the option to evaluate this converter with a

synchronous rectifier (SR) by populating the UCC24624 and SR FETs.

This user’s guide describes the UCC25660EVM-064 evaluation module (EVM). The user’s guide provides basic

evaluation instructions from a viewpoint of system operation of the stand-alone LLC resonant power converter.

Please read this user's guide thoroughly before applying power to this board.

1.2 Kit Contents

Table 1-1. UCC25660EVM-064 Kit Contents

Item Description Quantity

UCC25660EVM-064 PCB 1

1.3 Specifications

Table 1-2. UCC25660EVM-064 Specifications

PARAMETER TEST CONDITIONS MIN TYP MAX UNITS

INPUT CHARACTERISTICS

DC voltage range 365 390 410 VDC

AC voltage range 85 265 VAC

AC voltage frequency 47 63 Hz

Input DC UVLO On 365 VDC

OUTPUT CHARACTERISTICS

VOUT Output voltage - Normal mode Burst mode threshold to full load =

15 A

12 VDC

IOUT Output load current 365 to 410 VDC 15 A

Output voltage ripple 390 VDC and full load = 15 A 120 mVpp

SYSTEM CHARACTERISTICS

Resonant frequency 100 kHz

Peak efficiency 390 VDC, load = 8 A 93%

Operating temperature Natural convection 25 °C

1.4 Device Information

The UCC25660x is a fully featured LLC controller with integrated high-voltage gate driver. The UCC25660x has

been designed to cover a wide range of applications with specific features added to make the device easy to

design for wide input and output voltage operation needs. The device can be paired with a PFC controller to

provide a complete power system using a minimum of external components. The resulting power system is

designed to meet the most stringent requirements for standby power without the need for a separate standby

power converter.

UCC25660x implements a new control algorithm which provides a highly efficient and consistent low power and

burst mode. Both the low power and burst mode operation are designed to minimize audible noise while meeting

DoE level VI, EuP regulations. The burst power level and hysteresis are programmable and directly relate to

input power, simplifying the design and enabling wide input and output voltage operation.

The UCC25660x provides several protection features ranging from cycle-by-cycle protection, capacitive region

operation avoidance, external OVP and OTP to enhance the reliability of the LLC power stage.

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UCC25660x Half Bridge LLC Evaluation Module 3

2 Hardware

2.1 Test Setup

2.1.1 Test Equipment

High Voltage DC Voltage Source: Capable of 365 VDC to 410 VDC, adjustable, with minimum power rating

500 W, or current rating not less than 1 A, with current limit function. The DC voltage source to be used must

meet IEC 60950 reinforced insulation requirement.

AC Voltage Source: Capable of single-phase output AC voltage 85 to 265 VAC, 47 to 63 Hz, adjustable, with

minimum power rating 100 W and current limit function. The AC voltage source to be used must meet IEC 60950

reinforced insulation requirement.

DC Digital Multimeter: One unit capable of 0-VDC to 450-VDC input range, four digit display preferred; and one

unit capable of 0-VDC to 20-VDC input range, four digit display preferred.

Output Load: DC load capable of receiving 0 VDC to 20 VDC, 0 A to 15 A, and 0 W to 300 W or greater, with

the capability to display information such as load current and load power.

Oscilloscope: Capable of 500-MHz full bandwidth, digital or analog: if digital, 5 Gsps, or better.

Fan: 200 to 400 LFM forced air cooling is recommended, but not required.

Recommended Wire Gauge: Capable of 25 A, or better than #14 AWG, with the total length of wire less than 8

feet (4 feet input and 4 feet return).

2.1.2 Recommended Test Setup

390V 1.00 A

12.00 V

High Voltage DC Source

Electronic Load

AC Source

Figure 2-1. UCC25660EVM-064 Test Setup Diagram

WARNING

High voltages that can cause injury exist on this evaluation module (EVM). Please make sure all

safety procedures are followed when working on this EVM. Never leave a powered EVM unattended.

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2.2 Test Points

Table 2-1 lists the EVM test points.

Table 2-1. Test Points

Test Points Description

Vin Input voltage positive terminal

HG Primary-side high side MOSFET gate, Q1

SGND1 Secondary-side ground

SGND2 Secondary-side ground

SW Primary-side switch node, or the intersection of Q1 and Q3

VCC Controller Supply input

LG Primary-side low side MOSFET gate, Q3

TP8 Primary-side ground

TP9 Primary-side ground

Vout Output voltage positive terminal

Inj Small signal injection terminal

I_opt Feedback current measurement

HV High-voltage start pin

HV_diode High-voltage start pin

5VP Regulated 5-V bias

BLK Input voltage sensing

L AC line

N AC neutral

LL Light-load burst mode thresholds

ISNS Resonant current sense

BW_OTP Bias winding voltage sense/External over temperature protection

TSET On time min and max programming/ PFC on/off logic

2.3 Terminals

Table 2-2 lists the EVM terminals.

Table 2-2. List of Terminals

Terminal Name Description

J1 VIN Input voltage positive terminal

J2 PGND Input voltage return terminal

J3 AC Input 3-pin, AC power input, 85–265 VRMS

T2 VOUT Output voltage positive terminal

T3 SGND Output voltage ground terminal

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2.4 Test Procedure

Use the following steps for the test procedure:

1. Refer to Section 2.1.2 for basic setup. The required equipment for this measurement is listed in Section

2.1.1.

2. Before making electrical connections, visually check the board to make sure there are no suspected spots of

damage.

3. Keep the High Voltage DC voltage source output off. Connect this DC source to J1 (+) and J2 (-). This DC

voltage source must be isolated and meet the IEC 60950 requirement. Set the DC output voltage within the

range specified in Table 1-2, between 365 VDC and 410 VDC; set the DC source current limit to 1 A.

CAUTION

The board has no fuse installed and relies on the external voltage source current limit to verify

circuit protection.

4. Keep the AC voltage source output off. Connect the source with AC_neutral to J3-1, AC_earth to J3-2, and

AC_line to J3-3. Isolate the AC voltage source and meet the IEC 60950 requirement. Set the AC output

voltage and frequency within the range specified in Table 1-2, between 85 and 265 VAC and 47 to 63 Hz.

Set the AC source current limit to 200 mA.

5. Connect an electronic load set to either constant-current mode or constant-resistance mode. The load range

is from 0 to 15 A.

6. If the load does not have a current or a power display, TI recommends inserting a current meter between the

output voltage and the electronic load.

7. Connect a voltage meter to Vout and SGND1/SGND2 to monitor the output voltage.

8. Turn on the AC source output.

9. Turn on the DC source output.

2.4.1 Equipment Shutdown

Shut down the equipment using the following steps:

1. Shut down the AC voltage source.

2. Shut down the DC voltage source.

3. Shut down the electronic load.

WARNING

High voltage can still be present on the resonant capacitors after turning off the DC source.

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3 Implementation Results

3.1 Performance Data and Typical Characteristic Curves

3.1.1 UCC25660EVM-064 Standalone Standby and Light Load Power

Table 3-1 lists the total standby and light load power measurement for the standalone EVM. The average input

power is measured over a 6min interval.

Table 3-1. Standalone Standby Power

IOUT (mA) VOUT (V) POUT (mW) VIN (V) PIN (mW)

0 12 0 390 51

10 12 120 390 227.6

20 12 240 390 305.88

50 12 600 390 753.71

100 12 1200 390 1516.4

3.1.2 Efficiency, Load Regulation, Switching Frequency vs Output Current

Table 3-2 gives the efficiency, load regulation, switching frequency data at various input voltage and at different

load currents.

Table 3-2. Performance Data

VIN (V) IIN (mA) PIN (W) VOUT(V) IOUT(A)

Operating

Frequency

(kHz)

Operating

Frequency Efficiency (%)

390 501.7 195.663 11.997 15 100.5 Normal 91.97191

390 433.2 168.948 11.998 13 101.4 Normal 92.32071

390 374.4 146.016 11.998 11.25 102.2 Normal 92.44021

390 366.2 142.818 11.998 11 102.36 Normal 92.40992

390 299.5 116.805 11.998 9 103.45 Normal 92.44639

390 249.9 97.461 11.998 7.5 103.9 Normal 92.32924

390 233.2 90.948 11.998 7 104.5 Normal 92.34508

390 167.61 65.3679 11.997 5 105.9 Normal 91.76522

390 126.72 49.4208 11.997 3.75 106.9 Normal 91.03201

365 537 196.005 11.995 15 88.4 Normal 91.79613

365 464.2 169.433 11.997 13 89.07 Normal 92.04877

365 401.2 146.438 11.998 11.25 89.67 Normal 92.17382

365 392 143.08 11.998 11 89.78 Normal 92.2407

365 321 117.165 11.998 9 90.48 Normal 92.16234

365 267.9 97.7835 11.998 7.5 90.99 Normal 92.02473

365 250.2 91.323 11.998 7 91.21 Normal 91.96588

365 179.6 65.554 11.998 5 92.02 Normal 91.51234

365 136.23 49.72395 11.997 3.75 92.67 Normal 90.47702

410 476.6 195.406 11.995 15 110.65 Normal 92.07752

410 412.2 169.002 11.997 13 112.27 Normal 92.28352

410 356.3 146.083 11.997 11.25 113.8 Normal 92.39011

410 348.2 142.762 11.998 11 114.14 Normal 92.44617

410 284.9 116.809 11.998 9 116.2 Normal 92.44322

410 237.7 97.457 11.997 7.5 118.14 Normal 92.32533

410 221.9 90.979 11.997 7 118.89 Normal 92.30592

410 159.05 65.2105 11.997 5 122.4 Normal 91.98672

410 120.38 49.3558 11.997 3.75 125.4 Normal 91.1519

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3.1.3 Startup

The following waveforms show the output voltage, resonant current sense resistor voltage, and low side gate

behavior during startup. 115 VAC, 60 Hz is applied initially to the AC input, then the 390 VDC input is applied to

the DC input.

Figure 3-1. No Load (0 A) Startup (Ch1 = ISNS; Ch2 = LO; Ch4 = VOUT)

Figure 3-2. Full Load (15 A) Startup (Ch1 = ISNS; Ch2 = LO; Ch4 = VOUT)

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3.1.4 Enhanced ZCS Avoidance During Softstart

The following waveforms show the resonant current sense resistor voltage, Switch node voltage during startup.

115 VAC, 60 Hz is applied initially to the AC input, then the 390 VDC input is applied to the DC input.

Figure 3-3. Full Load (15 A) Startup (Ch1 = ISNS; Ch3 = SW)

3.1.5 Thermal Image

The following images show the EVM temperature after 20min soak at full load, no forced air and 390Vdc input

applied to the DC input.

Figure 3-4. Thermal Image Top Figure 3-5. Thermal Image Top

Table 3-3. Component Temperature

Component Temperature (°C)

T1 77.3

D2 86

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3.1.6 Output Voltage Ripple

The following waveforms show the output voltage ripple with 115 VAC, 60 Hz applied to the AC input and 390

VDC applied to the DC input. The oscilloscope probe is AC coupled.

Figure 3-6. No Load (0 A) Output Ripple (Ch4 = VOUT)

Figure 3-7. Full Load (15 A) Output Ripple (Ch4 = VOUT)

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