Using the UCC28810EVM-002 User's Guide Literature Number: SLUU355A March 2009 – Revised June 2009 User's Guide SLUU355A – March 2009 – Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 1 Introduction The UCC28810EVM-002 is a constant current non-isolated power supply for LED lighting applications. It will convert universal mains (90 VRMS to 264 VRMS) to a 0.9-A constant current into a 100-W load. This evaluation module will allow the customer evaluate the UCC28810/11 in a typical LED lighting application. 2 Description The evaluation module uses a two stage approach to controlling the output current. The first stage is a transition mode PFC circuit. This ensures the design meets the harmonic current or power factor requirements set out by various standards, such as EN61000-3-2. The PFC circuit converts the AC input to a regulated DC voltage. This DC voltage can be configured in one of two ways. The default configuration of the module is that of a boost follower type PFC. The boost follower PFC is where the PFC regulated output DC voltage tracks the AC input peak voltage. The second configuration requires removing some components and changing a resistor value see below for more details. This second configuration removes the tracking element of the PFC circuit. The PFC DC output voltage will then be regulated to a fixed value in the region of 396 VDC. The second stage also uses transition mode but is configured as a buck converter. It converts the PFC output voltage to a fixed constant current. This circuit is capable of supplying 0.9 A into a 100-W load. It also accepts PWM dimming inputs. Alternatively the user can use the PWM circuit on the module to see the dimming function. This module will work with most high brightness LED’s (HB-LED) that operate with 0.9 A and a total string voltage drop of between 55 V and 110 V. 2.1 Typical Applications • • • 2.2 Features • • • • • 2 AC Input General Lighting Applications Using HB-LED’s Industrial, Commercial and Residential Lighting Fixtures Outdoor Lighting: Street, Roadway, Parking, Construction and Ornamental LED Lighting Fixtures 90 VRMS to 264 VRMS operation Boost Follower or Fixed Output PFC Stage PFC Disable Output Current Disable External or Internal PWM Dimming A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Electrical Performance Specifications www.ti.com 3 Electrical Performance Specifications Table 1. UCC28810EVM-002 Electrical Performance Specifications SYMBOL PARAMETER CONDITIONS MIN NOM MAX UNITS INPUT CHARACTERSTICS VIN Input voltage IIN Input current PF Power factor 90 0.175 POUT = 80 W to 100 W 0.95 264 VRMS 1.1 ARMS 415 VDC W 0.97 OUTPUT CHARACTERSTICS PFC Stage VOUT PFC output voltage 235 LED Driver Stage POUT Output power IOUT Output current 45 80 100 0.84 0.9 0.96 Line regulation 0.03 Frequency 60 128 A kHz SYSTEMS CHARACTERSTICS η Full load efficiency 90% 93% PWM Dimming (1) (1) Threshold 0.72 1.3 V Frequency range 200 1000 Hz Duty cycle 0% 90% The PWM dimming signal is inverted, 0% duty cycle is 100% LED current. SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 3 Schematic Schematic + + + 4 www.ti.com Figure 1. UCC28810EVM-002 PFC Stage Schematic 4 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Schematic GND TZE ISENSE EAOUTGDRV VINS VSENSE VDD www.ti.com Figure 2. UCC28810EVM-002 Buck Stage Schematic SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 5 Test Setup 5 www.ti.com Test Setup WARNING High voltages, that may cause injury, exist on this evaluation module (EVM). Please ensure all safety procedures are followed when working on this EVM. Never leave a powered EVM unattended. The use of isolated test equipment is highly recommended. 5.1 Test Equipment See Figure 3 for recommended test set up. 5.1.1 • • 5.1.2 Voltage Source: Source 1: Isolated AC voltage source or VARIAC, capable of 90 VRMS to 264 VRMS at 150 W. Source 2: A 3.3-V DC source capable of 100 mA. Multimeters Three digital multimeters are recommend, one for current measurement, A1, and two for voltage measurements, V1 and V2. 5.1.3 Output Load It is recommended that actual high brightness LED’s (HB-LED’s) are used for the load. They should be rated at 0.9 A. The HB-LED’s should be connected in series. Their voltage drop should be between 55 VDC and 110 VDC. Alternatively a constant voltage electronic load could be used. If using a constant voltage electronic load a 1000-µF/250 VDC capacitor is required at the input to the electronic load. The 1000 µF capacitor should not be used if using HB-LED’s as the load. 5.1.4 Oscilloscope A digital or analog oscilloscope with current probe is required to view the AC current in the PFC inductor or buck inductor. 5.1.5 Signal Generator A signal generator that can produce a square wave pulse train at between 200 Hz and 1 kHz is required to do external PWM dimming. 5.1.6 Fan Forced air cooling is not required 5.1.7 Recommended Wire Gauge A minimum of 18 AWG wire is recommended. Also the wire connections between the AC source and the EVM, and the EVM and load should be less than two feet long. The AC input connector accepts a standard IEC320-C13 connector with ground pin. 6 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Test Setup www.ti.com 5.2 Recommended Test Setup 90 - 265 VRMS AC Source L CL1 Current Probe: PFC inductor ripple current monitor N TP1 & TP2 Loop injection point TP4 & TP5 PFC output voltage Constant Voltage Load + - CL2 Current Probe: Buck inductor ripple current monitor 1000uF 250V + V2 A1 V1 IEC320 -C13 Plug J2 Pin 1: PFC Shutdown Pin 2: GND TP3 Buck bias voltage monitor J4 Pin 1: Buck Shutdown Pin 2: GND Pin 3 External PWM dimming input J3 Short pins to Enable On Board Dimming Figure 3. UCC28810EVM-002 Recommended Test Set Up Note: 5.3 The 1000-µF/250-V capacitor on the output is not required if the load is a string of HB-LED’s. List of Test Points Table 2. Test Point Functions TEST POINTS NAME TP1 DESCRIPTION Loop injection point TP2 Loop injection point, PFC output TP3 VCC_BK TP4 PFC+ PFC output voltage TP5 PFC- PFC output voltage ground TP6 VCC_BK TP7 GND Buck bias voltage ground TP8 GND Ground connection TP9 EN TP10 GND TP11 BK_IN J2-1 PFC shutdown J2-2 GND J4-1 BK_Shutdown J4-2 GND J4-3 PWM Dim J3 On board dim SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Buck bias voltage output Buck bias voltage input Buck enable Buck input voltage ground Buck input voltage Apply 3.3 V to this pin to shutdown PFC stage Apply 3.3 V to this pin to shutdown buck stage Input for external PWM dimming Short the two pins on J3 to enable on board PWM diming. R26 varies dimming duty cycle A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 7 Test Procedure 6 www.ti.com Test Procedure All tests will use the set up described in Section 5 of this user guide. Ensure potentiometer R26 is rotated completely clockwise. WARNING HIGH VOLTAGE levels are present on this evaluation module whenever it is energized. Proper precautions must be observed whenever working with this module. There is an energy storage capacitor (C17) on this module which must be discharged before the board can be handled. Serious injury can occur if proper safety procedures are not followed. 6.1 Applying Power to the EVM 1. 2. 3. 4. Set up the EVM as described in Section 5 of this user guide. Ensure the AC source is off. Ensure potentiometer R26 is rotated completely clockwise. Set constant voltage load to between 55 V and 110 V. If using a HB-LED string ensure the voltage drop, when operating, is between 55 V to 110 V nominal. Note the 1000-µF/250 V capacitor is not required on the output if using a HB-LED string. 5. Set AC source to 90 VRMS. 6. Turn on AC source. 7. Monitor PFC output voltage at TP4 and TP5, V2. 8. Monitor output current at A1. 9. Monitor output voltage at V1. 10. The EVM is now ready for testing. 6.2 Line/Load Regulation and Efficiency Measurement Procedure 1. 2. 3. 4. 5. 6. 7. 8. 6.3 PFC Disable 1. 2. 3. 4. 5. 6. 7. 8 Apply power to the EVM per Section 6.1. Vary the constant voltage load from 110 V to 55 V. Observe output current on A1 stays constant. Vary AC source from 90 VRMS to 264 VRMS. Observe output current on A1 stays constant. PFC inductor ripple current can be measured at CL1 using an oscilloscope and current probe. The buck output inductor current can be measured at CL2 using an oscilloscope and current probe. See Section 7 for some typical test results. Ensure the AC source is off. Connect a DC source to J2. Set DC source to 0 V. Apply power to the EVM per Section 6.1. Increase DC source to 3.3 V. This input can accept up to 12 V. Observe PFC output voltage reduces, V2. PFC inductor ripple current looses high frequency component. A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Test Procedure www.ti.com 6.4 Buck Disable 1. 2. 3. 4. 5. 6. 7. 6.5 Internal Dimming Function 1. 2. 3. 4. 5. 6.6 Ensure the AC source is off. Connect a DC source to J4, pins 1 and 2. Set DC source to 0 V. Apply power to the EVM per Section 6.1. Increase DC source to 3.3 V. This input can accept up to 12 V. Observe output current, A1, drops to zero. PFC voltage, V2, does not change. Ensure the AC source is off. Ensure jumper is present on J3. Apply power to the EVM per Section 6.1. Rotate R26 potentiometer slowly anti clockwise. Observe output current on A1 reduce from nominal 0.9 A to 0.1 A. If LED string is attached observe LED’s dim. External Dimming Function 1. 2. 3. 4. Ensure the AC source is off. Ensure jumper is removed from J3. Connect signal generator to J4, pins 3 and 2. Set signal generator to generator a pulse from 0 V to 3.3 V at 200 Hz with variable duty cycle. Note when the PWM signal is high the LED light is reduced. 100% duty cycle will turn LED off. 5. Apply power to the EVM per Section 6.1. 6. Vary the duty cycle of the signal generator output. 7. Observe output current, A1, changes. If an LED string is attached observe LED’s dim. 6.7 Configuring the PFC Stage for Fixed Output The EVM ships configured as a boost follower PFC. Using a soldering iron some simple component modifications can change the PFC configuration from boost follower to fixed output voltage. 1. Remove R1, R3, R4, R6, C1 and Q1. 2. Change R11 to 6.49 kΩ. 3. The EVM now uses a fixed output voltage PFC stage. Repeat tests to see functionality. 6.8 Equipment Shutdown 1. 2. 3. 4. If DC sources are connected to shutdown pins, J2 and J4, ensure they are set to 0 V. Ensure load is at maximum, this will help discharge C17. Turn off AC source. Monitor PFC output voltage V2. Do not handle EVM until V2 reads less than 50 VDC. SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 9 Performance Data and Typical Characteristic Curves 7 www.ti.com Performance Data and Typical Characteristic Curves Figure 4 through Figure 8 present some typical performance curves for the UCC28810EVM-002 with 30 Cree XRE LED’s at 900 mA. EFFICIENCY/POWER FACTOR vs LINE VOLTAGE TOTAL HARMONIC DISTORTION vs LINE VOLTAGE 12 0.98 Power Factor 0.96 0.94 0.92 Efficiency 0.90 0.88 THD - Total Harmonic Distortion - % PF - Power Factor and Efficiency - % 1.00 10 8 6 4 2 0 80 100 120 140 160 180 200 220 240 260 80 100 120 140 160 180 VRMS - Line Voltage - V Figure 4. 7.1 200 220 240 260 VRMS - Line Voltage - V Figure 5. Transient TRANSITION MODE BUCK PWM RESPONSE (Ch1 and Ch 4 share GND reference) TRANSITION MODE BUCK PWM RESPONSE EXPANDED (Ch1 and Ch4 share GND reference) Ch1: Buck VIN Ch3: LED Current Ch1: Buck VIN Ch4: LED Voltage 0.5 A/div. Ch4: LED Voltage 0.5 A/div. Ch2: Buck VDS Ch2: Buck VDS Ch3: LED Current Figure 6. 10 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications Figure 7. SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback Performance Data and Typical Characteristic Curves www.ti.com 7.2 Input Current TRANSITION MODE BUCK PWM AND LINE INPUT CURRENT (Ch1 and Ch4 share GND reference) Ch1: Buck VIN Ch3: AC Input Current Ch4: LED VOUT Ch2: Buck VDS Figure 8. SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 11 EVM Assembly Drawing and PCB layout 8 www.ti.com EVM Assembly Drawing and PCB layout Figure 9 through Figure 11 show the design of the UCC28810EVM-002 printed circuit board. Figure 9. UCC28810EVM-002 Top Layer Assembly Drawing (top view) Figure 10. UCC28810EVM-002 Top Copper (top view) Figure 11. UCC28810EVM-002 Bottom Layer (viewed through top layer) 12 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback List of Materials www.ti.com 9 List of Materials The EVM components list according to the schematic shown in Figure 1 and Figure 2. Table 3. List of Materials QTY REF DES DESCRIPTION MFR PART NUMBER C1 Capacitor, ceramic, 10 µF, 25 V, X5R, 20%, 1206 Std Std C2, C5 Capacitor, metallized polyester film, 0.1 µF, 275 VAC, 10%, X2, 17.5 mm x 5.5 mm Std Std 2 C3, C4 Capacitor, ceramic disc, 1 nF, 250 V, Y1/X1 Panasonic ECK-ANA102MB 1 C6 Capacitor, ceramic, 2.2 µF, 25 V, X7R, 10%, 0805 Std Std 6 C7, C9, Capacitor, ceramic, 1 nF, 50 V, NPO, 5%, 0805 C10, C21, C23, C25 Std Std 1 C8 Capacitor, ceramic, 330 nF, 16 V, X7R, 10%, 0805 Std Std 1 C11 Capacitor, ceramic, 18 pF, 50 V, NPO, 5%, 1206 Std Std 3 C12, C28, Capacitor, ceramic, 1 µF, 25 V, X5R, 10%, 0805 C34 Std Std 3 C13, C20, Capacitor, ceramic, 0.1 µF, 25 V, X7R, 10%, 0805 C29 Std Std 1 C14 Capacitor, polypropylene film, 0.56 µF, 400 V, 5% Panasonic ECW-F4564JL C15, C16 Capacitor, aluminum electrolytic, 100 µF, 35 V, 20%, 6.3 mm x 11.5 mm Std Std 1 C17 Capacitor, aluminum electrolytic, 82 µF, 450 V, TS-HB Panasonic ECO-S2WB820BA 1 C18 Capacitor, ceramic, 10 µF, 25 V, X7R, 10%, 1210 Std Std 2 C19, C22 Capacitor, ceramic, 10 nF, 50 V, X7R, 10%, 0805 Std Std 1 C24 Capacitor, ceramic, 100 pF, 200 V, NPO, 5%, 0805 Std Std 1 C26 Capacitor, ceramic, 47 pF, 50 V, NPO, 5%, 0805 Std Std 1 C27 Capacitor, ceramic, 33 pF, 50 V, NPO, 5%, 1206 Std Std 1 C30 Capacitor, polypropylene film, 0.56 µF, 630 V, 5% Panasonic ECW-F6564JL 2 C31, C32 Capacitor, metallized polyester film, 1.0 µF, 250 V, 10% Panasonic ECQ-E2105KF 1 C33 Capacitor, ceramic, 470 pF, 50 V, NPO, 5%, 0805 Std Std 2 CL1, CL2 Current loop, wire, 20 AWG., stranded, 3.0 in. Std NA 2 D1, D2 Diode, 1.5 A, 600 V Std BYG10J 1 D3 Diode, bridge rectifier, 6 A, 600 V Std GBJ606 2 D4, D16 Diode, Schottky, 1.5 A, 30 V Std SL13-E3/61T 2 D5, D7 Diode, Schottky, 1 A, 90 V Std BYS11-90-E3/TR 2 D6, D17 Diode, switching, 90 V, 225 mA Ifm, high speed Rohm 1SS355 2 D8, D18 Diode, ultra fast, 8 A, 600 V IR HFA08TB60S 2 D9, D10 Diode, Zener, 18 V, 1 W Std SMAZ18-13 3 D11, D13, Diode, signal, 300 mA, 75 V, 35 mW D15 Std 1N4148W 2 D12, D21 Diode, dual Schottky, 200 mA, 30 V Std BAT54C 1 D14 Diode, Zener, 5.1 V, 1 W Std SMAZ5V1-13-F 4 D19, D20, Diode, Zener, 500 mW, 75 V D22, D23 Std MMSZ5267BT1 1 2 2 SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 13 List of Materials www.ti.com Table 3. List of Materials (continued) QTY 14 REF DES DESCRIPTION MFR PART NUMBER 1 F1 Fuse, SMP, 1.25 A Bel SMP 1.25 1 F1 Fuse 250 V UL fast 5 X 20 MM Std Std 2 FH1 Fuse clip, 5 x 20 mm, PC mount Wickmann 01000056H 2 HS1, HS2 Heatsink, TO-220, vertical mount, 15°C/W Aavid 593002 1 J1 Connector, AC receptacle, board mount, R/A, 9 mm Qualtek Electronics 703W-00/54 2 J2, J3 Header, male 2 pin, 100-mil spacing, (36-pin strip) Sullins PTC36SAAN 1 J4 Header, male 3 pin, 100-mil spacing, (36-pin strip) Sullins PTC36SAAN 1 J5 Terminal block, 2 pin 9.52-mm spacing OST OSTT7022150 1 L1 Inductor, thru hole, 1.3 A, 126 mΩ muRata 33331C 1 L2 Transformer, 1 prim, 1 sec, 1 mH, 3.1 A Coiltronics CTX16-18484 1 L3 Transformer, 1 prim, 1 sec, 400 µH, 2 A Coiltronics CTX33-18428 4 Q1, Q2, Q4, Q7 Transistor, NPN, 75 V, 500 mA Std MMBT2222A 1 Q3 MOSFET, N-channel , 400 V, 10 A IR IRF840 1 Q5 MOSFET, N-channel, 500 V, 6 A ST STP6NK50Z 1 Q6 Bipolar, PNP, -500 V, -500 mA Zetex FMMT560 2 R1, R3 Resistor, chip, 301 kΩ, 1/4 W, 1%, 1206 Std Std 2 R2, R5 Resistor, chip, 1.00 MΩ, 1/4 W, 1%, 1206 Std Std 1 R4 Resistor, chip, 4.02 kΩ, 1/8 W, 1%, 0805 Std Std 1 R6 Resistor, chip, 6.19 kΩ, 1/8 W, 1%, 0805 Std Std 2 R7, R28 Resistor, chip, 4.75 kΩ, 1/8 W, 1%, 0805 Std Std 6 R8, R11, Resistor, chip, 10.7 kΩ, 1/8 W, 1%, 0805 R29, R30, R33, R44 Std Std 1 R9 Resistor, chip, 24.3 kΩ, 1/8 W, 1%, 0805 Std Std 1 R10 Resistor, chip, 6.81 kΩ, 1/8 W, 1%, 0805 Std Std 1 R12 Resistor, chip, 332 Ω, 1/8 W, 1%, 0805 Std Std 4 R13, R15, Resistor, chip, 511 kΩ, 1/4 W, 1%, 1206 R39, R40 Std Std 2 R14, R16 Resistor, chip, 100 kΩ, 1/4 W, 1%, 1206 Std Std 1 R17 Resistor, chip, 47.5 Ω, 1/8 W, 1%, 0805 Std Std 2 R18, R37 Resistor, chip, 21.5 kΩ, 1/8 W, 1%, 0805 Std Std 2 R19, R36 Resistor, chip, 10.0 Ω, 1/8 W, 1%, 0805 Std Std 2 R20, R35 Resistor, chip, 0.40 Ω, 1 W, 1%, 2512 Std Std 2 R22, R23 Resistor, chip, 200Ω, 1/2 W, 1%, 1812 Std Std 2 R24, R42 Resistor, chip, 10.0 kΩ, 1/8 W, 1%, 0805 Std Std 2 R25, R46 Resistor, chip, 100 kΩ, 1/8 W, 1%, 0805 Std Std 1 R26 Potentiometer, 3/8 cermet, single turn, flat Bourns 3362P-504 1 R27 Resistor, chip, 665 Ω, 1/4 W, 1%, 1206 Std Std A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback List of Materials www.ti.com Table 3. List of Materials (continued) QTY REF DES DESCRIPTION 3 R31, R32, Resistor, chip, 15.0 kΩ, 1/8 W, 1%, 0805 R45 1 R34 1 R38 1 1 MFR PART NUMBER Std Std Resistor, chip, 560 Ω, 1/8 W, 1%, 0805 Std Std Resistor, chip, 0.47 Ω, 1 W, 1%, 2512 Std Std R41 Resistor, chip, 4.75 kΩ, 1/4 W, 1%, 1206 Std Std R43 Resistor, chip, 221 kΩ, 1/8 W, 1%, 0805 Std Std 2 R47, R48 Resistor, chip, 221 kΩ, 1/4 W, 1%, 1206 Std Std 1 U1 LED Lighting Power Controller TI UCC28810D 1 U2 Timer, Low-Power CMOS TI TLC555D 1 U3 LED Lighting Power Controller TI UCC28811D 1 -- PCB, 10.4 in x 2 in x 0.062 in Any HPA439 REVA 2 Washer, #4, shoulder, nylon Keystone 2 Heatpad TO-220 0.009" SP900 Bergquist SP900S-90 2 Washer, #4 split, ss Std Std 2 Nut, #4-40, ss Std Std 2 Screw, #4 - 40, SS, 0.5 in. Std Std Connector, jumper, shorting, gold, 0.100" Sullens 1 JP1 SLUU355A – March 2009 – Revised June 2009 Submit Documentation Feedback A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications 15 EVALUATION BOARD/KIT IMPORTANT NOTICE Texas Instruments (TI) provides the enclosed product(s) under the following conditions: This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental measures typically found in end products that incorporate such semiconductor components or circuit boards. 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