Test Report - PMP7668_RevB
Test Report of 2W Wide Input Buck Bias Supply
PMP7668
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Test Report - PMP7668_RevB
CONTENTS
Contents
I.
INTRODUCTION.................................................................................................................................................................... 3
II.
DESCRIPTION ........................................................................................................................................................................ 3
III.
BLOCK DIAGRAM ............................................................................................................................................................ 3
IV.
SPECIFICATIONS .............................................................................................................................................................. 3
V.
TEST SETUP ........................................................................................................................................................................... 3
VI.
BOARD ASSEMBLY DRAWINGS ................................................................................................................................... 4
VII.
LAYOUT ............................................................................................................................................................................. 5
VIII.
EFFICIENCY AND REGULATION .................................................................................................................................. 5
a.
Performance Data ..................................................................................................................................................................... 5
b.
Plots.......................................................................................................................................................................................... 6
IX.
WAVEFORMS .................................................................................................................................................................... 8
a.
Switching Node Waveforms ................................................................................................................................................ 8
b.
Output Ripple....................................................................................................................................................................... 9
c.
Turn On Characteristics ..................................................................................................................................................... 10
d.
Transient response ............................................................................................................................................................. 11
X.
CONDUCTED EMISSIONS ................................................................................................................................................. 12
XI.
SCHEMATIC .................................................................................................................................................................... 13
XII.
BILL OF MATERIALS ..................................................................................................................................................... 14
XIII.
CONCLUSION .................................................................................................................................................................. 15
XIV.
APPENDIX........................................................................................................................................................................ 16
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I.
INTRODUCTION
The following document is a compilation of test results of the PMP7668 reference design, a 2W bias
supply using UCC28722 in buck configuration. The test results are taken over an input voltage
range of 80V – 275V AC and 400V – 705V DC, driving a load up to 200mA.
II.
DESCRIPTION
The PMP7668 is developed with the UCC28722 controller IC. The design is targeted for small form
factor (69mm x 26mm) bias power solutions, especially for applications like e-metering. The
differentiating feature of this design is its ability to operate over a wide input range (110 – 500VAC).
It can work down to 80VAC with reduced output current. The design has an operating efficiency of
around 70% at full load, with a voltage regulation of +/- 1%. Regulation, efficiency, output ripple,
startup and switching stress of the design were tested under various conditions and are
documented in this report. The circuit has an optional 3.3V output also.
BLOCK DIAGRAM
III.
110VAC- 500VAC
UCC28722
IV.
10V @200mA
BUCK
Feedback
TLV
70433
3.3V @20mA
SPECIFICATIONS
Input Voltage Range: 110VAC - 500VAC
Output Voltage: 10V +/- 1V
Output Current: 200mA
Board Form Factor: 69mm x 26mm
Expected efficiency: >65%
V.
TEST SETUP
Input conditions:
Vin: 80 – 275 VAC, 400 – 705 VDC
Set Input current limit to 0.2A
Output:
Variable resistive load to 200mA
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Test Report - PMP7668_RevB
Equipment Used:
1.
2.
3.
4.
5.
Isolated AC Source
High voltage DC source
Digital Oscilloscope
Multimeters
Electronic load
Procedure:
1.
2.
3.
4.
5.
VI.
Connect input terminals of the PMP7668 reference board to the AC/DC Power Source.
Connect output terminals to electronic load, maintaining correct polarity.
Maintain minimum load of about 2mA.
Gradually increase the input voltage from 0V to turn on voltage of 80VAC.
Observe the startup conditions for smooth switching waveforms.
BOARD ASSEMBLY DRAWINGS
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VII.
LAYOUT
VIII. EFFICIENCY AND REGULATION
a. Performance Data
AC Efficiency
Vin (VAC)
Pin (W)
VA
Vo (V)
Io (mA)
Po (W)
Efficiency
(%)
80
100
110
130
150
170
190
210
230
250
275
1.29
2.01
2.84
2.77
2.73
2.70
2.69
2.68
2.68
2.68
2.69
2.77
4.29
6.04
6.03
6.24
6.51
6.80
7.09
7.37
7.64
7.95
9.51
9.52
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
100
150
200
200
200
200
200
200
200
200
200
0.95
1.43
1.91
1.91
1.91
1.91
1.91
1.91
1.91
1.91
1.91
73.5
71.0
67.2
68.7
69.9
70.5
70.9
71.0
71.0
71.0
70.8
Vin (VDC)
Iin (mA)
Pin (W)
Vo (V)
Io (mA)
Po (W)
Efficiency
(%)
400
6.49
2.60
9.53
200
1.91
73.42
500
5.28
2.64
9.53
200
1.91
72.20
600
4.50
2.70
9.53
200
1.91
70.59
705
3.93
2.77
9.53
200
1.91
68.79
DC Efficiency
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Regulation and Efficiency with output load
Vin (VDC)
Iin (mA)
Pin (W)
Vo (V)
Io (mA)
Po (W)
Efficiency
(%)
325
0.20
0.07
9.55
2
0.02
29.38
325
0.51
0.17
9.52
10
0.10
57.44
325
1.09
0.35
9.52
25
0.24
67.18
325
2.04
0.66
9.51
50
0.48
71.72
325
2.96
0.96
9.51
75
0.71
74.14
325
3.86
1.25
9.51
100
0.95
75.81
325
4.82
1.57
9.52
125
1.19
75.97
325
5.81
1.89
9.52
150
1.43
75.63
325
6.85
2.23
9.53
175
1.67
74.91
325
7.96
2.59
9.53
200
1.91
73.68
325
8.42
2.74
9.52
210
2.00
73.06
325
8.48
2.76
8.99
220
1.98
71.76
325
7.81
2.54
7.67
230
1.76
69.50
b. Plots
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Test Report - PMP7668_RevB
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Test Report - PMP7668_RevB
IX.
WAVEFORMS
a. Switching Node Waveforms
Vin = 110VAC, Full Load
Red trace: Drain voltage, 50V/div; Blue trace: Drain current, 500mA/div
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Vin = 275VAC, Full Load
Red trace: Drain voltage, 100V/div; Blue trace: Drain current, 500mA/div
b. Output Ripple
Vin = 110VAC, Full Load
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Test Report - PMP7668_RevB
Vin = 275VAC, Full Load
c. Turn On Characteristics
Vin = 110VAC, Full Load
Red trace: Input DC bus, 50V/div; Yellow trace: Output voltage, 5V/div
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Vin = 275VAC, Full Load
Red trace: Input DC bus, 100V/div; Yellow trace: Output voltage, 2V/div
d. Transient response
Vin = 230VAC, Load transient from 2mA to 200mA
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X.
CONDUCTED EMISSIONS
230VAC Input, 200mA resistive load connected to PSU with short leads.
The conducted emissions in a pre-compliance test set-up were compared against EN55022 class
B limits and found to be meeting them comfortably.
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XI.
SCHEMATIC
Schematic for PMP7668 Reference Design
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XII.
BILL OF MATERIALS
Ite
m
Qt
y
Referenc
e
PMP7668 BOM Revision B
Value
Description
Part Number
Manufactur
er
PHE840MA6100KA04R
17
Kemet
UCA2G100MPD1TD
Nichicon
Std
Std
25YXG220MEFC8X11.5
Rubycon
Size
0.157 x
0.512
inch
10.00
mm Dia
5 x 11
mm
8 x 11.5
mm
Std
Std
805
1N4007
1N4937
Diodes
Fairchild
DO-41
DO-41
2.5 x
7.5 mm
8.5 x
5.5mm
7.8 x
9.5mm
1
1 C1
0.1uF
2
2 C2, C3
10uF
3
1 C4
10uF
4
1 C5
220 uF
5
2 C6, C7
0.1uF
6
7
1 D1
2 D2, D3
1N4007
1N4937
Capacitor, Leaded, 760
VDC, ±10%
Capacitor, Alum
Electrolytic 400V, ±20%
Capacitor, Alum Elect,
25V, ±20%
Capacitor, Alum
Electrolytic, 25V, ±20%
Capacitor, Ceramic Chip,
X7R, 50V, ±10%
Diode, Rectifier, 1000V,
1A
Diode, Fast, 600V, 1A
8
1 FR1
10
Fusible resistor, 0.5W
NFR25H0001009J
9
1 L1
4.7mH
Inductor, 150mA, 25ohm
744741472
10
1 L2
1
1
1
1
Inductor, 0.7A, 1.56ohm
Trans, NPN Medium
Power, 800V, 1.5A
Resistor, Chip, 1/4W, 1%
Resistor, Chip, 1/8W, 1%
Resistor, Chip, 1/2W, 5%
7447728215
11
12
13
14
820uH
KSC5026
M
150K
100K
0.75
Vishay
Wurth
Elektronik
Wurth
Elektronik
KSC5026MOS
Std
Std
CRL1206-FW-R750ELF
Fairchild
Std
Std
Bourns
TO-126
1206
805
1206
1M
68.1K
Resistor, Chip, 1/4W, 5%
Resistor, Chip, 1/8W, 1%
Std
Std
Std
Std
MOV, 510VAC
IC, CV/CC PWM With
Primary Side Regulation
IC, 24-V Input, 150 mA,
Utralow IQ LDO
Regulator
MOV-10D821KTR
Bourns
1206
805
10mm
dia
UCC28722DBV
TI
SOT-23
TLV70433DBV
TI
SOT-23
15
16
Q1
R1
R2
R3
R4, R5,
4 R6, R7
1 R8
17
1 RT1
18
1 U1
510V
UCC2872
2
19
1 U2
TLV70433
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XIII. CONCLUSION
The board is tested against the specifications given in section IV and found to meet them
including an overall efficiency of >65% and a board form factor of <1800mm2. Also, the emission
test performed in section X shows that this reference design is in compliance with EN55022 class
B limits.
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XIV. APPENDIX
EVALUATION BOARD/KIT/MODULE (EVM) WARNINGS, RESTRICTIONS AND DISCLAIMER
For Feasibility Evaluation Only, in Laboratory/Development Environments. The EVM is not a complete product. It
is intended solely for use for preliminary feasibility evaluation in laboratory / development environments by technically
qualified electronics experts who are familiar with the dangers and application risks associated with handling electrical /
mechanical components, systems and subsystems. It should not be used as all or part of a production unit.
Your Sole Responsibility and Risk. You acknowledge, represent and agree that:
1. You have unique knowledge concerning Federal, State and local regulatory requirements (including but not
limited to Food and Drug Administration regulations, if applicable) which relate to your products and which
relate to your use (and/or that of your employees, affiliates, contractors or designees) of the EVM for
evaluation, testing and other purposes.
2. You have full and exclusive responsibility to assure the safety and compliance of your products with all
such laws and other applicable regulatory requirements, and also to assure the safety of any activities to be
conducted by you and/or your employees, affiliates, contractors or designees, using the EVM. Further, you
are responsible to assure that any interfaces (electronic and/or mechanical) between the EVM and any
human body are designed with suitable isolation and means to safely limit accessible leakage currents to
minimize the risk of electrical shock hazard.
3. Since the EVM is not a completed product, it may not meet all applicable regulatory and safety compliance
standards (such as UL, CSA, VDE, CE, RoHS and WEEE) which may normally be associated with similar
items. You assume full responsibility to determine and/or assure compliance with any such standards and
related certifications as may be applicable. You will employ reasonable safeguards to ensure that your use of
the EVM will not result in any property damage, injury or death, even if the EVM should fail to perform as
described or expected.
Certain Instructions. Exceeding the specified EVM ratings (including but not limited to input and output voltage,
current, power, and 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 loads applied outside of the specified output range may result in
unintended and/or inaccurate operation and/or possible permanent damage to the EVM and/or interface electronics.
Please consult the EVM User’s 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, some circuit components may
have case temperatures greater than 60°C as long as the input and output ranges are maintained at nominal
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These components include but are not limited to linear regulators, switching
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you must specifically notify TI of such intent and enter into a separate Assurance and Indemnity Agreement.
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