Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based, Active-ClampFlyback Converter/Evaluation Module
User's Guide
Literature Number: SLUUBV6
August 2018
Page 1: ...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 ...
Page 2: ...ce 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 ...
Page 3: ... 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...
Page 4: ...gust 2018 Submit Documentation Feedback Copyright 2018 Texas Instruments Incorporated Using the UCC28780EVM 021 45 W 20 V High Density Silicon Si Based Active Clamp Flyback Converter Evaluation Module Figure 2 UCC28780EVM 021 Bottom View ...
Page 5: ... 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 1...
Page 6: ...Submit Documentation Feedback Copyright 2018 Texas Instruments Incorporated Using the UCC28780EVM 021 45 W 20 V High Density Silicon Si Based Active Clamp Flyback Converter Evaluation Module 3 Schematic Diagram Figure 3 UCC28780EVM 021 Schematic Diagram ...
Page 7: ...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 handl...
Page 8: ...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 vo...
Page 9: ... 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 1...
Page 10: ...equency 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 Ampli...
Page 11: ...r Primary Winding Current CH2 Switch Node Voltage Figure 13 ABM Mode and SR CH1 PWML CH4 Transformer Primary Winding Current CH2 Switch Node Voltage CH3 SR Vgs Figure 14 Recovery after OPP with 3 Stages of Peak Current CH1 PWML CH4 Transformer Primary Winding Current CH2 Switch Node Voltage Figure 15 LPM Mode Operation when a burst packet contains 2 pulses and the interval between 2 packets is aro...
Page 12: ...Si Based Active Clamp Flyback Converter Evaluation Module 5 6 Start Up CH1 PWML CH2 Switch Node Voltage CH3 Output Voltage CH4 Transformer Primary Current Figure 17 115 VAC and Full Load Startup Figure 18 230 VAC and Full Load Startup 5 7 Line Transient Response CH1 Vout CH2 Line voltage Figure 19 Output Voltage Response to Line Transient with Full Load Figure 20 Output Voltage Response to Line Tr...
Page 13: ...y Silicon Si Based Active Clamp Flyback Converter Evaluation Module 5 8 Output Ripple Voltage CH3 Output Voltage Ripple Figure 21 VOUT_pp 40 0mV VIN 115 VRMS IOUT 2 25 A Figure 22 VOUT_pp 38 6mV VIN 230 VRMS IOUT 2 25 A Figure 23 VOUT_pp 80 mV VIN 115VRMS IOUT 1 125 A Figure 24 VOUT_pp 80mV VIN 230VRMS IOUT 1 125 A Figure 25 VOUT_pp 24 3 mV VIN 115VRMS IOUT 0 A Figure 26 VOUT_pp 24 3mV VIN 230VRMS...
Page 14: ...V High Density Silicon Si Based Active Clamp Flyback Converter Evaluation Module 5 9 Over Power Protection Figure 27 shows the converter Over Power Protection OPP with respect to input voltage Figure 28 shows the converter auto retry to resume operation after OPP Figure 27 OPP with Respect to Input Voltage Figure 28 OPP Auto Retry CH1 PWML CH2 Switch Node Voltage CH3 Transformer Primary Current ...
Page 15: ...Load Transient Response Figure 29 and Figure 30 show output voltage Vout deviation 5 for 0 and 2 25A load step change CH3 Vout CH4 Load Current Figure 29 Vout Load Transient Response at VIN 115 VRMS Figure 30 Vout Load Transient Response at VIN 230 VRMS Figure 31 and Figure 32 show the switching node voltage response for 0 and 2 25A load step change CH2 PWML CH3 Switch Node Voltage CH4 Load Curren...
Page 16: ...V High Density Silicon Si Based Active Clamp Flyback Converter Evaluation Module 5 11 Conducted EMI Output Not Grounded to LISN ground Figure 33 Peak EMI VIN 115 VRMS Load 9 3 Ω Figure 34 Peak VIN 230 VRMS Load 9 3 Ω NOTE Please note this was evaluated on an EMI station for pre qualification purpose only It is recommended that all final designs be verified by an agency qualified EMI test house ...
Page 17: ...ensity Silicon Si Based Active Clamp Flyback Converter Evaluation Module 5 12 Thermal Images at Full Load 2 25 A Figure 35 VIN 90 VAC Top Side Transformer 60 C Figure 36 VIN 90 VAC Bottom Side Q1 64 C U7 63 C DB1 64 C Figure 37 VIN 115 VAC Top Side Transformer 59 C Figure 38 VIN 115 VAC Bottom Side Q1 59 C U7 56 C Figure 39 VIN 230 VAC Top Side Transformer 66 C Figure 40 VIN 230 VAC Bottom Side Q1...
Page 18: ...18 Submit Documentation Feedback Copyright 2018 Texas Instruments Incorporated Using the UCC28780EVM 021 45 W 20 V High Density Silicon Si Based Active Clamp Flyback Converter Evaluation Module Figure 41 VIN 265 VAC Top Side Transformer 69 C Figure 42 VIN 265 VAC Bottom Side Q1 79 C ...
Page 19: ...matic Diagram Sh1 and Sh2 are the terminals for EMI shields Their optimal connections are to be determined and their current connections are to pin P1 Table 5 Transformer Specifications at 25 C PARAMETER VALUE PINS LEADS TEST CONDITIONS Inductance µH 104 to 127 P1 P2 Open all other pins Leakage Inductance µH 2 5 Max P1 P2 Tie S1 S2 0 1 V 200 kHz D C resistance Ω 0 147 Max P1 P2 D C resistance Ω 0 ...
Page 20: ...50 VAC Y2 250 VAC 5 SL 8x5mm DE21XKY330JN3AM0 2F MuRata 2 C15 C25 Capacitor ceramic 22 uF 35 V 20 X5R 0805 C2012X5R1V226M12 5AC TDK 1 C16 Capacitor aluminum polymer 680 µF 25 V 20 0 29256 ohm TH 687AVG025MGBJ Illinois Capacitor 1 C18 Capacitor ceramic 2200 pF 50 V 10 X7R AEC Q200 Grade 1 0402 CGA2B2X7R1H222K 050BA TDK 1 C19 Capacitor ceramic 2 2 uF 50 V 10 X7R 0805 C2012X7R1H225K12 5AC TDK 1 C20 C...
Page 21: ... 0 021 A AEC Q101 SOT 23 BSS126H6327XTSA2 Infineon Technologies 2 Q3 Q4 MOSFET N channel 600 V 10 6 A DPAK IPD60R380P6ATMA1 Infineon Technologies 1 Q5 MOSFET N channel 60 V 0 17 A SOT 23 2N7002 7 F Diodes Inc 1 R1 Resistor 1 00 kΩ 1 0 1 W 0603 ERJ 3EKF1001V Panasonic 1 R2 Resistor 2 21 MΩ 1 0 25 W 1206 RC1206FR 072M21L Yageo America 1 R3 Resistor 0 Ω 5 0 1 W AEC Q200 Grade 0 0603 ERJ 3GEY0R00V Pan...
Page 22: ...1 0 1 W 0603 RC0603FR 0736K5L Yageo 2 R30 R31 Resistor 10 Ω 5 0 063 W AEC Q200 Grade 0 0402 CRCW040210R0JNE D Vishay Dale 2 R32 R34 Resistor 15 Ω 5 0 063 W AEC Q200 Grade 0 0402 CRCW040215R0JNE D Vishay Dale 2 R33 R35 Resistor 10 kΩ 5 0 063 W AEC Q200 Grade 0 0402 CRCW040210K0JNE D Vishay Dale 1 R36 Resistor 0 Ω 5 0 063 W AEC Q200 Grade 0 0402 CRCW04020000Z0E D Vishay Dale 1 R38 Resistor 604 kΩ 1 ...
Page 23: ...y set forth above or credit User s account for such EVM TI s liability under this warranty shall be limited to EVMs that are returned during the warranty period to the address designated by TI and that are determined by TI not to conform to such warranty If TI elects to repair or replace such EVM TI shall have a reasonable time to repair such EVM or provide replacements Repaired EVMs shall be warr...
Page 24: ...the user guide with the maximum permissible gain and required antenna impedance for each antenna type indicated Antenna types not included in this list having a gain greater than the maximum gain indicated for that type are strictly prohibited for use with this device Concernant les EVMs avec antennes détachables Conformément à la réglementation d Industrie Canada le présent émetteur radio peut fo...
Page 25: ...ed loads Any loads applied outside of the specified output range may also result in unintended and or inaccurate operation and or possible permanent damage to the EVM and or interface electronics Please consult the EVM user 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 even ...
Page 26: ...COST OF REMOVAL OR REINSTALLATION ANCILLARY COSTS TO THE PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES RETESTING OUTSIDE COMPUTER TIME LABOR COSTS LOSS OF GOODWILL LOSS OF PROFITS LOSS OF SAVINGS LOSS OF USE LOSS OF DATA OR BUSINESS INTERRUPTION NO CLAIM SUIT OR ACTION SHALL BE BROUGHT AGAINST TI MORE THAN TWELVE 12 MONTHS AFTER THE EVENT THAT GAVE RISE TO THE CAUSE OF ACTION HAS OCCURRED 8 2 Specif...
Page 27: ... TI Resource NO OTHER LICENSE EXPRESS OR IMPLIED BY ESTOPPEL OR OTHERWISE TO ANY OTHER TI INTELLECTUAL PROPERTY RIGHT AND NO LICENSE TO ANY TECHNOLOGY OR INTELLECTUAL PROPERTY RIGHT OF TI OR ANY THIRD PARTY IS GRANTED HEREIN including but not limited to any patent right copyright mask work right or other intellectual property right relating to any combination machine or process in which TI product...
Page 28: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information Texas Instruments UCC28780EVM 021 ...
