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Texas Instruments PFCLLCSREVM034 User Manual Download Page 7

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SLUUC46 – June 2020

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Copyright © 2020, Texas Instruments Incorporated

PFCLLCSREVM034 User Guide

User's Guide

SLUUC46 – June 2020

PFCLLCSREVM034 User Guide

1

Trademarks

All trademarks are the property of their respective owners.

2

Introduction

The purpose of the PFCLLCSREVM034 is to aid in evaluation of the UCC256404 LLC resonant controller,
UCC28056B transition mode PFC controller and UCC24624 dual channel synchronous rectification
controller. The EVM features a transition mode boost PFC front end and isolated half bridge LLC
converter with synchronous rectification. The EVM meets efficiency requirements of CoC Tier II and is
built on low cost single layer PCB.

3

Description

3.1

Typical Applications

•

Industrial AC-DC adapters

•

Power tools

•

Medical power supply

•

Multi-functional printer

•

Enterprise and cinema projector

•

PC power supply

•

Gaming console power supply

3.2

Features

•

Low cost single layer PCB

•

AC Input voltage from 90 Vrms to 264Vrms

•

Regulated 12-VDC typical output

•

Full-load power of 168 W, or full-load current of 14 A

•

High efficiency

•

Optimized low power features enable extremely low standby power

•

Advanced burst mode with burst soft-on and soft-off for minimized audible noise

•

X-capacitor discharge

•

Test points to facilitate device and topology evaluation

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Summary of Contents for PFCLLCSREVM034

Page 1: ...PFCLLCSREVM034 User Guide User s Guide Literature Number SLUUC46 June 2020 ...

Page 2: ...9 6 Test Points 11 7 Terminals 11 8 Test Setup 12 8 1 Test Equipment 12 8 2 Recommended Test Setup 12 9 Performance Data and Typical Characteristics Curves 13 9 1 Efficiency 13 9 2 Standby Power 14 9 3 Power Factor 14 9 4 Total Harmonic Distortion 15 9 5 Load Regulation 16 9 6 Startup 17 9 7 Output Ripple 21 9 8 Load Transient 22 9 9 LLC Loop Response 23 9 10 Steady State Waveforms 23 9 11 X Capac...

Page 3: ... into No Load CH1 PFC Output CH2 AC Input CH3 LLC Output 19 13 230Vrms Startup into No Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output 19 14 230Vrms Input Startup into Full Load CH1 PFC Output CH2 AC Input CH3 LLC Output 20 15 230Vrms Startup into Full Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output 20 16 No Load Output Ripple CH3 LLC Output AC Coupled 21 17 Full Load Output Ri...

Page 4: ...ck Copyright 2020 Texas Instruments Incorporated List of Tables List of Tables 1 PFCLLCSREVM034 Electrical Performance Specifications 8 2 Test Points 11 3 List of Terminals 11 4 Efficiency Measurements 13 5 Standby Power Measurements 14 6 List of Materials 27 ...

Page 5: ...further use of the HV EVM 1 Work Area Safety a Keep work area clean and orderly b Qualified observer s must be present anytime circuits are energized c 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 d All interf...

Page 6: ... its electrical circuits as they could 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 ...

Page 7: ...dge LLC converter with synchronous rectification The EVM meets efficiency requirements of CoC Tier II and is built on low cost single layer PCB 3 Description 3 1 Typical Applications Industrial AC DC adapters Power tools Medical power supply Multi functional printer Enterprise and cinema projector PC power supply Gaming console power supply 3 2 Features Low cost single layer PCB AC Input voltage f...

Page 8: ...N TYP MAX UNITS Input Characteristics AC Voltage Range 90 264 Vrms AC Voltage Frequency 47 63 Hz Output Characteristics Output Voltage 12 V Output Current 14 A System Characteristics No Load Standby Power 115 Vrms Input 84 90 mW No Load Standby Power 230 Vrms Input 113 59 mW 10 Efficiency 115 Vrms Input 80 96 10 Efficiency 230 Vrms Input 80 60 4pt Average Efficiency 115 Vrms Input 90 05 4pt Averag...

Page 9: ...Schematic Diagram 9 SLUUC46 June 2020 Submit Documentation Feedback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide 5 Schematic Diagram Figure 1 PFCLLCSREVM034 Schematic Diagram PFC Section ...

Page 10: ...hematic Diagram www ti com 10 SLUUC46 June 2020 Submit Documentation Feedback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide Figure 2 PFCLLCSREVM034 Schematic Diagram LLC Section ...

Page 11: ... voltage TP9 RVCC RVCC Voltage TP10 VOUT Output voltage positive terminal TP11 INJECT Small SignalIinjection Terminal TP12 FB_Current Feedback current measurement TP13 LL SS Soft Start and Light Load Burst Mode Threshold TP14 AC_Rect Rectified AC input TP15 AC_L AC Line TP16 AC_N AC Neutral TP17 HV High Voltage Startup and X Capacitor Discharge TP18 PGND Primary Ground TP19 PGND Primary Ground TP2...

Page 12: ...50 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 14 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 Fa...

Page 13: ...ed EVM unattended 9 Performance Data and Typical Characteristics Curves 9 1 Efficiency Figure 4 illustrates the efficiency vs output current Figure 4 Efficiency vs Output Current Table 4 summarizes the 10 and 4pt average efficiency Table 4 Efficiency Measurements Input Voltage Vrms 10 Load Efficiency 25 Load Efficiency 50 Load Efficiency 75 Load Efficiency 100 Load Efficiency 4pt Average Efficienc...

Page 14: ...CSREVM034 User Guide 9 2 Standby Power Table 5 summarizes the input power performance at light load Table 5 Standby Power Measurements Input Voltage Vrms Output Power mW Input Power mW 115 0 84 896 125 324 54 250 558 78 230 0 113 594 125 348 06 250 574 90 9 3 Power Factor Figure 5 illustrates the power factor vs output current Figure 5 Power Factor vs Output Power ...

Page 15: ...Curves 15 SLUUC46 June 2020 Submit Documentation Feedback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide 9 4 Total Harmonic Distortion Figure 6 summarizes the total harmonic distortion vs output current Figure 6 THD vs Output Current ...

Page 16: ...16 SLUUC46 June 2020 Submit Documentation Feedback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide 9 5 Load Regulation Figure 7 illustrates the output voltage regulation performance vs output current Figure 7 Output Voltage vs Output Current ...

Page 17: ...ncorporated PFCLLCSREVM034 User Guide 9 6 Startup 9 6 1 115Vrms Input Figure 8 and Figure 9 illustrates the startup behavior from 115Vrms input into no load condition Figure 8 115Vrms Input Startup into No Load CH1 PFC Output CH2 AC Input CH3 LLC Output Figure 9 115Vrms Input Startup into No Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output ...

Page 18: ...xas Instruments Incorporated PFCLLCSREVM034 User Guide Figure 10 and Figure 11 illustrates the startup behavior from 115Vrms input into full load condition Figure 10 115Vrms Startup into Full Load CH1 PFC Output CH2 AC Input CH3 LLC Output Figure 11 115Vrms Startup into Full Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output ...

Page 19: ...ments Incorporated PFCLLCSREVM034 User Guide 9 6 2 230Vrms Input Figure 12 and Figure 13 illustrates the startup behavior from 230Vrms input into no load condition Figure 12 230Vrms Input Startup into No Load CH1 PFC Output CH2 AC Input CH3 LLC Output Figure 13 230Vrms Startup into No Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output ...

Page 20: ... Instruments Incorporated PFCLLCSREVM034 User Guide Figure 14 and Figure 15 illustrates the startup behavior from 230Vrms input into full load condition Figure 14 230Vrms Input Startup into Full Load CH1 PFC Output CH2 AC Input CH3 LLC Output Figure 15 230Vrms Startup into Full Load Zoomed In CH1 PFC Output CH2 AC Input CH3 LLC Output ...

Page 21: ...2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide 9 7 Output Ripple Figure 16 illustrates the LLC output voltage ripple at no load Figure 16 No Load Output Ripple CH3 LLC Output AC Coupled Figure 17 illustrates the LLC output voltage ripple at full load Figure 17 Full Load Output Ripple CH3 LLC Output AC Coupled ...

Page 22: ...as Instruments Incorporated PFCLLCSREVM034 User Guide 9 8 Load Transient Figure 18 and Figure 19 illustrates the no load to full load transient response Figure 18 No Load to Full Load Transient CH3 LLC Output AC Coupled CH4 Output Current Figure 19 No Load to Full Load Transient Zoomed In CH3 LLC Output AC Coupled CH4 Output Current ...

Page 23: ...ated PFCLLCSREVM034 User Guide 9 9 LLC Loop Response Figure 20 illustrates the LLC converter loop response Figure 20 LLC Loop Response 9 10 Steady State Waveforms 9 10 1 PFC Figure 21 illustrates the PFC switch node and inductor current waveforms at full load with 115Vrms input Figure 21 115Vrms Input Full Load CH1 PFC Switch Node CH4 PFC Inductor Current ...

Page 24: ...CSREVM034 User Guide Figure 22 illustrates the PFC switch node and inductor current waveforms at full load with 230Vrms input Figure 22 230Vrms Input Full Load CH1 PFC Switch Node CH4 PFC Inductor Current 9 10 2 LLC Figure 23 illustrates the LLC switch node and resonant current waveforms at 10mA load Figure 23 10mA Load CH1 LLC Switch Node CH4 LLC Resonant Current ...

Page 25: ...edback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide 9 11 X Capacitor Discharge Figure 24 illustrates the X capacitor discharge performance at 264Vrms input and no load Figure 24 X Capacitor Discharge CH1 Voltage between Line Neutral 10 Assembly Drawings Figure 25 Top Layer Assembly ...

Page 26: ...ly Drawings www ti com 26 SLUUC46 June 2020 Submit Documentation Feedback Copyright 2020 Texas Instruments Incorporated PFCLLCSREVM034 User Guide Figure 26 Bottom Layer Assembly Figure 27 Bottom Layer Copper ...

Page 27: ...ACTU C25 1 Capacitor ceramic 3900 pF 50 V 5 C0G NP0 0603 GRM1885C1H392JA01D C26 1 Capacitor ceramic 100 pF 25 V 10 X7R 0603 06033C101KAT2A C27 1 Capacitor ceramic 4 7 uF 25 V 10 X7R 0805 C2012X7R1E475K125AB C29 1 Capacitor ceramic 0 068 uF 50 V 10 X7R AEC Q200 Grade 1 0603 CGA3E2X7R1H683K080 AA C30 1 Capacitor ceramic 5 6 pF 50 V 5 C0G NP0 0603 06035A5R6CAT2A C31 C32 C36 3 Capacitor ceramic 2200 p...

Page 28: ...hermal pad amber 18 42mm x 13 21mm rectangular 43 77 9G NTC1 1 Thermistor NTC 5 ohm 20 13x6mm B57211P0509M351 Q1 Q3 2 MOSFET N channel 650 V 20 7 A TO 220AB SPP20N65C3XKSA1 Q2 Q4 2 MOSFET N channel 60 V 200 A KTT0002A TO 263 2 CSD18535KTTT Q5 1 MOSFET N channel 600 V 18 A TO 220FP STF24N60DM2 R1 R9 2 Resistor 11 3 Ω 1 0 25 W AEC Q200 grade 0 1206 ERJ 8ENF11R3V R2 R8 2 Resistor 10 0 Ω 1 0 125 W AEC...

Page 29: ...52R20JNEA R51 1 Resistor 27 4 kΩ 1 0 125 W AEC Q200 grade 0 0805 ERJ 6ENF2742V R52 1 Resistor 82 0 kΩ 1 0 1 W 0603 RC0603FR 0782KL R53 1 Resistor 402 kΩ 1 0 1 W AEC Q200 grade 0 0603 CRCW0603402KFKEA R55 1 Resistor 10 Ω 5 0 125 W AEC Q200 grade 0 0805 CRCW080510R0JNEA R56 1 Resistor 47 5 Ω 1 0 1 W 0603 CRCW060347R5FKEA R57 1 Resistor 1 0 Ω 5 0 125 W AEC Q200 grade 0 0805 CRCW08051R00JNEA RV1 1 Var...

Page 30: ...se resources are subject to change without notice TI grants you permission to use these resources only for development of an application that uses the TI products described in the resource Other reproduction and display of these resources is prohibited No license is granted to any other TI intellectual property right or to any third party intellectual property right TI disclaims responsibility for...

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