Texas Instruments UCC28780EVM-021 Manual de usuario

Using the UCC28780EVM-021, 45-W, 20-V High-

Density Silicon (Si) Based, Active-Clamp

Flyback Converter/Evaluation Module

User's Guide

Literature Number: SLUUBV6

August 2018

WARNING

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

Always follow TI’s setup and application instructions, including use of all interface components within their

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://support/ti./com for further information.

Save all warnings and instructions for future reference.

Failure to follow warnings and instructions may 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 suitable qualified, you should

immediately stop from further use of the HV EVM.

1. Work Area Safety

1. Keep work area clean and orderly.

2. Qualified observer(s) must be present anytime circuits are energized.

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

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

purpose of protecting inadvertent access.

4. 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.

5. Use stable and nonconductive work surface.

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

freehand testing whenever possible.

2. Electrical Safety

As a precautionary measure, it is always a good engineering practice to assume that the entire EVM

may have fully accessible and active high voltages.

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

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

de-energized.

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

wiring, measurement equipment connection, and other application needs, while still assuming the

EVM circuit and measuring instruments are electrically live.

3. After EVM readiness is complete, energize the EVM as intended.

WARNING: WHILE THE EVM IS ENERGIZED, NEVER TOUCH THE EVM OR ITS ELECTRICAL

CIRCUITS AS THEY COULD BE AT HIGH VOLTAGES CAPABLE OF CAUSING ELECTRICAL

SHOCK HAZARD.

3. Personal Safety

1. Wear personal protective equipment (for example, latex gloves or safety glasses with side shields)

or protect EVM in an adequate lucent plastic box with interlocks to protect from accidental touch.

Limitation for safe use:

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

SLUUBV6–August 2018

Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,

Active-Clamp Flyback Converter/Evaluation Module

User's Guide

SLUUBV6–August 2018

Using the UCC28780EVM-021, 45-W, 20-V High-Density

Silicon (Si) Based, Active-Clamp Flyback

Converter/Evaluation Module

1 Description

The UCC28780EVM-021 is a 45-W evaluation module (EVM) for evaluating an off-line active-clamp

flyback adapter for notebook charging and other applications. The EVM meets CoC Tier 2 and DoE Level

6 efficiency requirements. It is intended for evaluation purposes and is not intended to be an end product.

The UCC28780EVM-021 converts input voltage of 90-VRMS to 264-VRMS down to 20-VDC, with a 2.25-A

nominal output current rating and a 160-ms limit for over-power capability. The main devices used in this

design are active clamp flyback controller UCC28780, SR controller UCC24612, and Si MOSFETs.

Figure 1. UCC28780EVM-021 Top View

Description

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Figure 2. UCC28780EVM-021 Bottom View

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Electrical Performance Specifications

SLUUBV6–August 2018

Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,

Active-Clamp Flyback Converter/Evaluation Module

2 Electrical Performance Specifications

(1) The performance listed in this table is achieved using secondary resonance and based on the test results from a single board.

(2) Average efficiency of four load points, IOUT = 25%, 50%, 75% and 100% nom.

Table 1. UCC28780EVM-021 Electrical Performance Specifications(1)

PARAMETER TEST CONDITIONS MIN NOM MAX UNIT

INPUT CHARACTERISTICS

VIN Input line voltage (RMS) 90 115 / 230 264 V

fLINE Input line frequency 47 50 / 60 63 Hz

PSTBY Input power at no-load VIN = 115 VRMS, IOUT = 0 A 37.2 mW

PSTBY Input power at no-load VIN = 230 VRMS, IOUT = 0 A 40.1 mW

P0.25W Input power at 0.25W load VIN = 115 VRMS, POUT = 237mW 330 mW

P0.25W Input power at 0.25W load VIN = 230 VRMS, POUT = 237 mW 392 mW

OUTPUT CHARACTERISTICS

VOUT Output voltage VIN = 115 VRMS, IOUT = 2.249 A 19.928 V

VIN = 230VRMS, IOUT = 2.249 A 19.924 V

VOUT Output voltage VIN = 115 VRMS, IOUT = 0 A 19.937 V

VIN = 230VRMS, IOUT = 0 A 19.936 V

IOUT Full load rated output current VIN = 90 to 264 VRMS 2.25 A

VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 to 2.25 652/600 mVpp

VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 2.25 A 20/28 mVpp

VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 A 20/21 mVpp

POUT_opp Over-power protection power

limit VIN = 90 to 264 VRMS 55 W

tOPP Over-power protection duration VIN = 90 to 264 VRMS, POUT = POUT_opp 160 ms

VOUT_ΔOutput voltage deviation due to

load step up IOUT step between 0 A and 2.25A < 5%

SYSTEMS CHARACTERISTICS

ηFull-load efficiency VIN = 115 VRMS, IOUT = 2.25A 94.06%

VIN = 230 VRMS, IOUT = 2.25A 93.82%

VIN = 90V RMS, IOUT = 2.25A 93.08%

η4-point average efficiency(2) VIN = 115 VRMS 92.82%

VIN = 230 VRMS 91.71%

ηEfficiency at 10% Load VIN = 115 VRMS, IOUT = 10% rated current 88.09%

VIN = 230 VRMS, IOUT = 10% rated current 85.08%

TAMB Ambient operating temperature

range VIN = 90 to 264 VRMS, IOUT = 0 to 2.25A 25 °C

Schematic Diagram

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3 Schematic Diagram

Figure 3. UCC28780EVM-021 Schematic Diagram

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Test Setup

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4 Test Setup

4.1 Test Setup Requirements

Safety: This evaluation module is not encapsulated and there are accessible voltages that are greater

than 50 VDC.

Isolation Input Transformer: A suitably rated 1:1 isolation transformer shall be used on the input(s) to

this EVM and be constructed in a manner in which the primary winding(s) are separated from the

secondary winding(s) by reinforced insulation, double insulation, or a screen connected to the protective

conductor terminal.

WARNING

If you are not trained in the proper safety of handling and testing

power electronics please do not test this evaluation module.

Read this user's guide thoroughly before making test.

Voltage Source: Isolated AC source or variable AC transformer capable of 264 VRMS cable of handling

100 W

Voltmeter: Digital voltage meter

Power Analyzer: Capable of measuring 1 mW to 100 W of input power and capable of handling 264-VRMS

input voltage. Some power analyzers may require a precision shunt resistor for measuring input current to

measure input power of 5 W or less. Please read the power analyzer’s user manual for proper

measurement setups for full power and for stand-by power.

Oscilloscope:

• 4-Channel, 500 MHz bandwidth.

• Probes capable of handling 600 V.

Output Load: Resistive or electronic load capable of handling 100 W at 20 V.

Recommended Wire Gauge: Insulated 22 AWG to 18 AWG.

WARNING

Caution: Do not leave EVM powered when unattended

UCC28780EVM-021

Test Setup

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4.2 Test Setup Diagram

Figure 4. UCC28780EVM-021 Test Setup Diagram

4.3 Design Notes

In Table 6, a component list shows critical components to achieve stable ABM operation with secondary

resonance which provides better efficiency and output voltage ripple performance. Details on secondary

resonance can be found in the UCC28780 datasheet.

4.4 Test Points

Table 2. Test Point Functions

TEST POINTS NAME DESCRIPTION

J1-L Location J1 Terminal L AC line voltage input

J1-N N AC neutral input

J2+ Location J2 Terminal VOUT + Output supply

J2- VOUT – Output return

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Performance Data and Typical Characteristic Curves

SLUUBV6–August 2018

Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,

Active-Clamp Flyback Converter/Evaluation Module

5 Performance Data and Typical Characteristic Curves

5.1 Efficiency Typical Result of 4-Point Average

Table 3. Efficiency Test Data

VIN RMS PIN VOUT IOUT POUT(%) EFFICIENCY EFFICIENCY

4pt-

AVERAGE

Switching

Frequency @

Full Load

90 48.210 19.927 2.252 100% 93.08% 92.57% 179kHz

90 35.875 19.930 1.680 75% 93.33%

90 24.240 19.932 1.123 50% 92.34%

90 12.720 19.935 0.584 25% 91.53%

115 47.670 19.928 2.250 100% 94.06% 92.82% 224kHz

115 35.760 19.930 1.680 75% 93.63%

115 24.290 19.931 1.123 50% 92.15%

115 12.710 19.935 0.583 25% 91.44%

230 47.780 19.924 2.250 100% 93.82% 91.71% 288kHz

230 36.130 19.925 1.681 75% 92.70%

230 24.970 19.926 1.131 50% 90.25%

230 12.950 19.933 0.585 25% 90.04%

264 47.930 19.923 2.249 100% 93.48% 91.47% 291kHz

264 36.310 19.924 1.683 75% 92.35%

264 24.870 19.93 1.131 50% 90.63%

264 13.060 19.93 0.586 25% 89.44%

5.2 Efficiency Typical Results

Figure 5. Efficiency Over Load Figure 6. Efficiency Over Input Voltage

19.4

19.58

19.76

19.94

20.12

20.3

20.48

75 105 135 165 195 225 255

Vout, V

AC Input Voltage, Vac

Full Load

Performance Data and Typical Characteristic Curves

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5.3 VI Characteristics

Figure 7. VOUT Line Regulation Figure 8. VOUT Load Regulation

5.4 Switching Frequency

Figure 9. Switching Frequency Over Input at Full Load

Figure 10. Maximum switching frequency about 500kHz at

high line and entering ABM

CH1 = PWML, CH4 = Transformer Primary Winding Current, CH3 = Switch Node Voltage

5.5 Key Switching Waveforms and Operation Mode Load Current

This section shows typical operation modes in Table 4 along with typical load currents in this design and

with Vin = 115Vac as an example.

• AAM: Adaptive Amplitude Modulation

• ABM: Adaptive Burst Mode

• LPM: Lower Power Mode

• SBP: Standby Power Mode

Table 4. Operation Mode and Load Current

Mode AAM AAM to ABM ABM End LPM SBP

Typical Load Current 1.50 A to 2.25 A 1.30 A to 1.60 A 0.15 A to 0.18 A 0.05 A to 0.15 A < 0.08 A

Typical Load % 67% to 100% 58% to 71% 6.7% to 8% 2.2% to 6.7% < 3.5%

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