Texas Instruments UCC28740EVM-525 User Manual Download

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User Guide

SLUUAL8 – July 2013

Using the UCC28740EVM-525 10 W Constant-
Voltage, Constant-Current Charger Adaptor
Module

User’s Guide

Literature Number: SLUUAL8

July, 2013

Summary of Contents for UCC28740EVM-525

Page 1: ...User Guide SLUUAL8 July 2013 Using the UCC28740EVM 525 10 W Constant Voltage Constant Current Charger Adaptor Module User s Guide Literature Number SLUUAL8 July 2013 ...

Page 2: ... Consumption 15 6 5 Output Voltage vs Output Current 16 6 6 Control Law 17 6 7 Bode Plot 18 6 8 Transient Response 19 6 9 Output Ripple 20 6 10 Turn On Waveform 21 6 11 Switching Waveform 22 6 12 EMI Dithering Waveform 23 7 EVM Assembly Drawing and PCB layout 23 8 Bill of Materials 28 Figures Figure 1 UCC28740EVM 525 Schematic 7 Figure 2 UCC28740EVM 525 Recommended Test Set Up For No Load Operatio...

Page 3: ... Top Layer Assembly Drawing Top view 24 Figure 17 UCC28740EVM 525 Bottom Layer Assembly Drawing Bottom view 25 Figure 18 UCC28740EVM 525 Top Copper Top View 26 Figure 19 UCC28740EVM 525 Bottom Copper Bottom View 27 Tables Table 1 UCC28740EVM 525 EVM 001 Electrical Performance Specifications 6 Table 2 Test Point Functional Description 10 Table 3 The EVM components list according to the schematic sh...

Page 4: ...primary current is held constant at one quarter of its full load peak value as the switching frequency increases from a minimum value to maintain energy transfer up to 32 kHz When the load is increased to the level at which the switching frequency reaches 32 kHz the controller will keep the switching frequency fixed and modulate the peak primary current increasing it from one quarter its peak valu...

Page 5: ... and Short Circuit Protection Output Over Voltage Protection Input Brown Out Protection Auto Re Start on Fault Quasi Resonant Valley Switching Frequency Dither Internal 700V Start Up Switch to Start up the Supply Directly From the Bulk Rail 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 ...

Page 6: ... mode IOUTmax VINmin VIN VINmax 1 995 2 1 2 205 A Output voltage regulation Line Regulation VINmin VIN VINmax IOUT IOUTmax 0 1 Load Regulation 0A IOUT IOUTmax 0 1 Output voltage ripple VINmin VIN VINmax 0A IOUT IOUTmax 150 mVpp Output over current IOCC VINmin VIN VINmax 2 5 A Minimum output voltage CC mode VINmin VIN VINmax IOUT IOCC 1 78 2 V Brown out protection IOUT IOUTmax 68 VRMS Transient res...

Page 7: ...0k R16 196k R7 SGND 1 2 4 3 U2 LTV 817A 1 2 3 4 5 6 J2 C12 2700pF C13 R18 D7 BAS16 7 F PGND SGND 1 FLa 5 FLb 3 2 PRI BIAS OUT 4 560 µH T1 0 047 µF C5 100 pF C6 1 1 1 U3 TL431AIDBZ 42 2k R19 TP4 TP2 49 9 R21 TP3 TP1 DANGER HIGH VOLTAGE VOUT NC NC VOUT OUTPUT 5V 2 1A MAX 24 3 R1 1 27k R9 JMP1 27 4k R3 BAS21 D1 105k R2 22 0k R4 1 50k R15 JMP2 10 ohm t RT1 0 R5 220 µH L1 R13 R14 SGND 1 1 µF C7 0 R8 0 ...

Page 8: ...oss the Line and Neutral terminals of the EVM Output Load A programmable electronic load capable of sinking 0 A to 3 A shall be used For constant current mode testing of the EVM the electronic load should be set to constant resistance mode Power Meter A power analyzer shall be capable of measuring low input current typically less than 10mA and a long averaging mode if low power standby mode input ...

Page 9: ...SLUUAL8 5 2 Recommended Test Setup Figure 2 UCC28740EVM 525 Recommended Test Set Up For No Load Operation ...

Page 10: ... Recommended Test Set Up With Load 5 3 List of Test Points Table 2 Test Point Functional Description TEST POINT NAME DESCRIPTION TP1 PGND Primary side power ground TP2 LOOP Loop injection point EVM output TP3 LOOP Loop injection point ...

Page 11: ... Voltech c Set the power analyzer for long averaging time to include several cycles of operation The PM100 Voltech used for this test data was set to a long averaging time of 30 for accurate power consumption measurement 2 Apply power to the EVM per section 5 4 3 Monitor the input power on the power analyzer while varying thinput voltage 4 Make sure the EVM is off and the bulk capacitors and outpu...

Page 12: ...et the constant resistance load to sink the full load current approximately 2 38 Ω b Vary the AC source from 85 VAC to 265 VAC c Observe that the output voltage on DMM V1 stays within 3 of the 5 V constant voltage regulation value 5 7 Output Voltage Ripple 1 Expose the ground barrel of the scope probe and place the tip of the probe on TP5 VOUT and rest the exposed ground barrel of the probe on TP6...

Page 13: ...z nominal input and 230 VAC 50 Hz nominal input exceeds the 0 80 design goal Further increases in efficiency could be achieved with a transformer made with a custom core and designed to operate at lower switching frequency over the entire operating range 85 115 230 265 0 750 0 755 0 760 0 765 0 770 0 775 0 780 0 785 0 790 0 795 0 800 0 805 0 810 0 815 0 820 85 115 145 175 205 235 265 EFFICIENCY IN...

Page 14: ...CC28740EVM 525 Load Regulation Figure 5 shows the actual measured load regulation exceeded the 3 design goal 85 115 230 265 0 5 0 4 0 3 0 2 0 1 0 0 1 0 2 0 3 0 4 0 5 85 135 185 235 OUTPUT VOLTAGE REGULATION INPUT VOLTAGE VAC LOAD REGULATION ...

Page 15: ...gn goal 6 4 No Load Power Consumption Figure 7 UCC28740EVM 525 No Load Power Consumption 0 5 0 4 0 3 0 2 0 1 0 0 1 0 2 0 3 0 4 0 5 0 10 20 30 40 50 60 70 80 90 100 OUTPUT VOLTAGE REGULATION PERCENT OF FULL LOAD LINE REGULATION 0 2 4 6 8 10 12 14 16 18 20 85 115 145 175 205 235 265 INPUT POWER mW INPUT VOLTAGE VAC NO LOAD POWER CONSUMPTION ...

Page 16: ...ing this output over current threshold the converter transitions into constant current mode where the load current remains constant until the output voltge falls below 2 V at which point the converter shuts down If the load demand is decreased to the constant current operating region the converter will automatically re start 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 0 0 5 1 1 5 2 2 5 OUTPUT VOLTAGE V ...

Page 17: ...eak primary side current is fixed at its peak programmed value and the frequency will increase from 32 kHz up to the maimum frequency required for energy transfer The maximum designed switching frequency for this module is 71 kHz For ease in measuring the switching frequency the data was taken with a DC input voltage This reduced the frequency dithering to only the controller s EMI dithering schem...

Page 18: ...el 200 analog network analyzer The loop result was obtained by inserting a 200mV AC signal across TP2 and TP3 The crossover frequency with a 115 VAC 60 Hz input and load current of 2 A measured 1 38 kHz with a phase margin of 71 degrees 180 90 0 90 180 60 30 0 30 60 10 100 1000 10000 PHASE degrees GAIN dB FREQUENCY Hz GAIN dB PHASE degrees ...

Page 19: ...l 1 is the load current on a scale of 1 A per division channel 4 is the otutput voltage on a scale of 1 V per division The cursor shows the minimum acceptable voltage limit 4 30 V under transient conditions Also note that the output waveform was taken with the probe on TP5 with the ground referenced to TP4 but not using the tip and barrel technique accounting for the high frequency noise seen on t...

Page 20: ... the output voltage ripple measured using tip and barrel across TP5 and TP6 on the EVM The measurement was taken at full load with an input voltage of 85 VAC 60 Hz and the waveform is AC coupled The cursor shows the maximum peak to peak limit permitted for the design ...

Page 21: ...aveform Figure 13 Output voltage Turn On Waveform Figure 13 shows the output voltage at turn on under full load conditions with an input voltage of 115 VAC 60 Hz The maximum voltage at the output was measured to be 5 12 VDC ...

Page 22: ...Figure 14 Channel 1 shows the VS pin at 2 V per division and channel 2 shows the MOSFET drain to source voltage at 100 V per division The scan was taken at 1 8 A load 115 VAC 60 Hz input voltage At this operating point the switching frequency is dithering between 58 8 kHz and 52 6 kHz due to valley skipping ...

Page 23: ... the result of these varying pulse widths on the CS signal shown on channel 4 The longer pulses result in a peak current threshold of 808 mV the medium length pulses are shown measured at 780 mV and the shorter pulses measure a threshold voltage of 752 mV This dithering adds to the frequency jitter caused by valley skipping and results in a spread spectrum for better EMI compliance 7 EVM Assembly ...

Page 24: ...SLUUAL8 Figure 16 UCC28740EVM 525 Top Layer Assembly Drawing Top view ...

Page 25: ...SLUUAL8 Figure 17 UCC28740EVM 525 Bottom Layer Assembly Drawing Bottom view ...

Page 26: ...SLUUAL8 Figure 18 UCC28740EVM 525 Top Copper Top View ...

Page 27: ...SLUUAL8 Figure 19 UCC28740EVM 525 Bottom Copper Bottom View ...

Page 28: ...13 F 1 D4 Diode Ultra Fast 1000 V 1 A SMA Vishay Semiconductor Diodes Division US1M E3 61T 2 D5 D6 Diode Super Barrier Rectifier 45 V 10 A PowerDI5 Diodes Inc SBR10U45SP5 13 0 D7 Diode Ultrafast 75 V 0 3 A SOT 23 Diodes Inc BAS16 7 F 1 F1 Fuse 2 A 250 V TH 8 35 x 7 7 x 4 mm Bel Fuse Inc RST 2 1 J1 Conn Term Block 2POS 5 08 mm TH Phoenix Contact 1715721 1 J2 Connector Receptable USB Type A Vertical...

Page 29: ...geo America RC0603FR 071KL 0 R18 RES 140 kΩ 1 0 1 W 0603 Vishay Dale CRCW0603140KFKEA 2 R19 R20 RES 42 2 kΩ 1 0 1 W 0603 Vishay Dale CRCW060342K2FKEA 1 R21 RES 49 9 Ω 1 0 1 W 0603 Yageo America RC0603FR 0749R9L 1 RT1 Thermistor NTC 10 Ω 20 Leaded Ametherm SL03 10001 1 T1 Transformer 560 µH TH 580 mil x 600 mil x 580 mil Wurth Elektronik eiSos 7508111111 Rev 001 6 TP1 TP2 TP3 TP4 TP5 TP6 Pin Thru H...

Page 30: ... Exceeding the specified EVM ratings including but not limited to 85 VAC to 265 VAC input and 5 V output voltage 2 5 A current 10 5 W power and 25 C environmental ranges may cause property damage personal injury or death If there are questions concerning these ratings please contact a TI field representative prior to connecting interface electronics including input power and intended loads Any loa...

Page 31: ...usiness practice TI is not responsible or liable for any such statements TI products are not authorized for use in safety critical applications such as life support where a failure of the TI product would reasonably be expected to cause severe personal injury or death unless officers of the parties have executed an agreement specifically governing such use Buyers represent that they have all neces...

Page 32: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information Texas Instruments UCC28740EVM 525 ...

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