UCC28720 www.ti.com SLUSBE8 – MAY 2013 Constant-Voltage, Constant-Current Controller With Primary-Side Regulation Check for Samples: UCC28720 FEATURES APPLICATIONS • • • 1 < 10-mW No-Load Power Primary-Side Regulation (PSR) Eliminates Opto-Coupler ±5% Voltage and Current Regulation Across Line and Load 700-V Start-Up Switch 80-kHz Maximum Switching Frequency Enables High-Power Density Charger Designs Quasi-Resonant Valley-Switching Operation for Highest Overall Efficiency Wide VDD Range Allows Small Bias Capacitor Dynamic BJT Drive Overvoltage, Low-Line, and Overcurrent Protection Functions Programmable Cable Compensation SOIC-7 Package • • • • • • • • • + SIMPLIFIED APPLICATION – VAC VOUT UCC28720 VAUX VDD HV DRV VS CBC CS GND UDG-13090 • • USB-Compliant Adapters and Chargers for Consumer Electronics – Smart phones – Tablet computers – Cameras Standby Supply for TV and Desktop White Goods DESCRIPTION The UCC28720 flyback power supply controller provides isolated-output Constant-Voltage (CV) and Constant-Current (CC) output regulation without the use of an optical coupler. The devices process information from the primary power switch and an auxiliary flyback winding for precise control of output voltage and current. An internal 700-V start-up switch, dynamicallycontrolled operating states and a tailored modulation profile support ultra-low standby power without sacrificing start-up time or output transient response. Control algorithms in the UCC28720 allow operating efficiencies to meet or exceed applicable standards. The output drive interfaces to a bipolar transistor power switch. Discontinuous conduction mode (DCM) with valley switching reduces switching losses. Modulation of switching frequency and primary current peak amplitude (FM and AM) keeps the conversion efficiency high across the entire load and line ranges. The controller has a maximum switching frequency of 80 kHz and always maintains control of the peakprimary current in the transformer. Protection features help keep primary and secondary component stresses in check. The UCC28720 allows compensation for voltage drop in the cable to be programmed with an external resistor. 1 Please be aware that an important notice concerning availability, standard warranty, and use in critical applications of Texas Instruments semiconductor products and disclaimers thereto appears at the end of this data sheet. PRODUCTION DATA information is current as of publication date. Products conform to specifications per the terms of the Texas Instruments standard warranty. Production processing does not necessarily include testing of all parameters. Copyright © 2013, Texas Instruments Incorporated UCC28720 SLUSBE8 – MAY 2013 www.ti.com This integrated circuit can be damaged by ESD. Texas Instruments recommends that all integrated circuits be handled with appropriate precautions. Failure to observe proper handling and installation procedures can cause damage. ESD damage can range from subtle performance degradation to complete device failure. Precision integrated circuits may be more susceptible to damage because very small parametric changes could cause the device not to meet its published specifications. Table 1. PRODUCT INFORMATION (1) (1) (2) (2) PACKAGE PINS ORDERABLE DEVICES SOIC (D) 7 UCC28720D See Orderable Addendum for specific device ordering information. For other fixed cable compensation options, please consult the factory. ABSOLUTE MAXIMUM RATINGS (1) MIN MAX Start-up pin voltage, HV VHV 700 Bias supply voltage, VDD VVDD 38 Continuous base current sink IDRV 50 Continuous base current source IDRV Self- limiting Peak current, VS IVS Base drive voltage at DRV VDRV Self- limiting −0.75 7 −0.5 5 Operating junction temperature range TJ −55 150 Storage temperature TSTG −65 150 VS Lead temperature 0.6 mm from case for 10 seconds ESD rating (1) 2 V mA −1.2 −0.5 CS, CBC Voltage range UNIT V °C 260 Human-body model (HBM) Charged-device model (CDM) 2000 500 V Stresses beyond those listed under “Absolute Maximum Ratings” may cause permanent damage to the device. Exposure to absolutemaximum-rated conditions for extended periods may affect device reliability. These are stress ratings only and functional operation of the device at these or any other conditions beyond those indicated under “Recommended Operating Conditions” is not implied. Extended exposure to stresses above the Recommended Operating Conditions may affect device reliability. All voltages are with respect to GND. Currents are positive into, negative out of the specified terminal. These ratings apply over the operating ambient temperature ranges unless otherwise noted. Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 RECOMMENDED OPERATING CONDITIONS over operating free-air temperature range (unless otherwise noted) MIN TYP MAX UNIT VDD Bias supply operating voltage CVDD VDD bypass capacitor 9 35 V 1.0 10 µF RCBC Cable-compensation resistance 10 kΩ IVS VS pin current −1 mA TJ Operating junction temperature −40 125 °C THERMAL INFORMATION UCC28720 THERMAL METRIC (1) D UNITS 7 PINS θJA Junction-to-ambient thermal resistance (2) 141.5 θJCtop Junction-to-case (top) thermal resistance (3) 73.8 θJB Junction-to-board thermal resistance (4) 89.0 ψJT Junction-to-top characterization parameter (5) 23.5 ψJB Junction-to-board characterization parameter (6) 88.2 (1) (2) (3) (4) (5) (6) °C/W For more information about traditional and new thermal metrics, see the IC Package Thermal Metrics application report, SPRA953. The junction-to-ambient thermal resistance under natural convection is obtained in a simulation on a JEDEC-standard, high-K board, as specified in JESD51-7, in an environment described in JESD51-2a. The junction-to-case (top) thermal resistance is obtained by simulating a cold plate test on the package top. No specific JEDECstandard test exists, but a close description can be found in the ANSI SEMI standard G30-88. The junction-to-board thermal resistance is obtained by simulating in an environment with a ring cold plate fixture to control the PCB temperature, as described in JESD51-8. The junction-to-top characterization parameter, ψJT, estimates the junction temperature of a device in a real system and is extracted from the simulation data for obtaining θJA, using a procedure described in JESD51-2a (sections 6 and 7). The junction-to-board characterization parameter, ψJB, estimates the junction temperature of a device in a real system and is extracted from the simulation data for obtaining θJA , using a procedure described in JESD51-2a (sections 6 and 7). Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 3 UCC28720 SLUSBE8 – MAY 2013 www.ti.com ELECTRICAL CHARACTERISTICS over operating free-air temperature range, VVDD = 25 V, HV = open, RCBC = open, TA = -40°C to 125°C, TA = TJ (unless otherwise noted) PARAMETER TEST CONDITIONS MIN TYP MAX UNITS HIGH-VOLTAGE START UP IHV Start-up current out of VDD VHV = 100 V, VVDD = 0 V, start state 225 500 IHVLKG Leakage current at HV VHV = 400 V, run state, TJ = 25 ºC 100 0.01 0.25 2.00 2.65 150 µA BIAS SUPPLY INPUT IRUN Supply current, run IDRV = 0, run state IWAIT Supply current, wait IDRV = 0, wait state 95 ISTART Supply current, start IDRV = 0, VVDD = 18 V, start state, IHV = 0 18 30 IFAULT Supply current, fault IDRV = 0, fault state 95 150 mA µA UNDERVOLTAGE LOCKOUT VVDD(on) VDD turn-on threshold VVDD low to high 19 21 23 VVDD(off) VDD turn-off threshold VVDD high to low 7.35 7.7 8.15 VVSR Regulating level Measured at no-load condition, TJ = 25°C (1) 4.01 4.05 4.09 V VVSNC Negative clamp level IVS = -300 µA, volts below ground 190 250 325 mV IVSB Input bias current VVS = 4 V -0.25 0 0.25 µA V VS INPUT CS INPUT VCST(max) Max CS threshold voltage VVS = 3.7 V 735 780 815 VCST(min) Min CS threshold voltage VVS = 4.35 V 175 190 215 KAM AM control ratio VCST(max) / VCST(min) 3.6 4.0 4.4 VCCR Constant current regulating level CC regulation constant 317 330 344 mV KLC Line compensation current ratio IVSLS = -300 µA, IVSLS / current out of CS pin 24.0 25.0 28.6 A/A TCSLEB Leading-edge blanking time DRV output duration, V CS = 1 V 230 290 355 ns IDRS(max) Maximum DRV source current VDRV = 2 V, VVDD = 9 V, VVS = 3.85 V 32 37 41 IDRS(min) Minimum DRV source current VDRV = 2 V, VVDD = 9 V, VVS = 4.30 V 16 19 22 RDRVLS DRV low-side drive resistance IDRV = 10 mA VDRCL DRV clamp voltage VVDD = 35 V RDRVSS DRV pull-down in start state mV V/V DRIVER mA Ω 1 2.4 5.9 7 V 20 25 kΩ TIMING fSW(max) Maximum switching frequency VVS = 3.7 V 74 80 87 kHz fSW(min) Minimum switching frequency VVS = 4.35 V 580 650 740 Hz tZTO Zero-crossing timeout delay 2.5 3.1 3.6 µs (1) 4 The regulating level and over voltage at VS decreases with temperature by 0.8 mV/˚C. This compensation is included to reduce the power supply output voltage variance over temperature. Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 ELECTRICAL CHARACTERISTICS (continued) over operating free-air temperature range, VVDD = 25 V, HV = open, RCBC = open, TA = -40°C to 125°C, TA = TJ (unless otherwise noted) PARAMETER TEST CONDITIONS MIN TYP MAX UNITS PROTECTION VOVP Over-voltage threshold At VS input, TJ = 25°C (2) 4.51 4.60 4.73 VOCP Over-current threshold At CS input 1.4 1.5 1.6 IVSL(run) VS line-sense run current Current out of VS pin increasing 190 225 275 IVSL(stop) VS line-sense stop current Current out of VS pin decreasing 70 80 100 KVSL VS line sense ratio IVSL(run) / IVSL(stop) 2.45 2.80 3.05 TJ(stop) Thermal shut-down temperature Internal junction temperature 165 V µA A/A °C CABLE COMPENSATION VCBC(max) Cable compensation maximum voltage Voltage at CBC at full load 2.9 3.1 3.5 VCVS(min) Minimum compensation at VS VCBC = open, change in VS regulating level at full load -55 -15 25 VCBC = 0 V, change in VS regulating level at full load 275 320 380 VCVS(max) Maximum compensation at VS (2) V mV The regulating level and over voltage at VS decreases with temperature by 0.8 mV/˚C. This compensation is included to reduce the power supply output voltage variance over temperature. Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 5 UCC28720 SLUSBE8 – MAY 2013 www.ti.com DEVICE INFORMATION Functional Block Diagram IHV HV OC FAULT OV FAULT TSD/SD FAULT LINE FAULT POWER & FAULT MANAGEMENT UVLO 21 V / 8 V VDD VDD 5V GND 4.05 V + VCVS + VS SAMPLER 35 mA CONTROL LAW E/A DRV VCST + 20 kΩ OV FAULT VOVP VALLEY SWITCHING 14 V 1 / fSW S Q R Q + SECONDARY TIMING DETECT CURRENT REGULATION CS VCST LEB IVSLS LINE SENSE IVSLS 10 kΩ IVSLS / KLC + LINE FAULT 2.2 V / 0.80 V OC FAULT + 1.5 V VCVS = ICBC x 3 kΩ CABLE COMPENSATION 0 V-VCVS(max) + ICBC 28 kΩ CBC UDG-13094 6 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 SOIC (D) PACKAGE 7 PINS (TOP VIEW) UCC28720 SOIC-7 (D) VDD 1 7 HV CBC 3 6 DRV GND 4 5 CS VS 2 (TOP VIEW) PIN FUNCTIONS NAME NUMBER I/O DESCRIPTION CBC 3 I Cable compensation is a programming pin for compensation of cable voltage drop. Cable compensation is programmed with a resistor to GND. CS 5 I Current sense input connects to a ground-referenced current-sense resistor in series with the power switch. The resulting voltage is used to monitor and control the peak primary current. A series resistor can be added to this pin to compensate the peak switch current levels as the AC-mains input varies. DRV 6 O Drive is an output used to drive the base of an external high voltage NPN transistor. GND 4 — The ground pin is both the reference pin for the controller and the low-side return for the drive output. Special care should be taken to return all AC decoupling capacitors as close as possible to this pin and avoid any common trace length with analog signal return paths. HV 7 I The high-voltage pin connects directly to the rectified bulk voltage and provides charge to the VDD capacitor for start-up of the power supply. NTC — I NTC an interface to an external negative temperature coefficient resistor for remote temperature sensing. Pulling this pin low shuts down PWM action. VDD 1 I VDD is the bias supply input pin to the controller. A carefully-placed bypass capacitor to GND is required on this pin. I Voltage sense is an input used to provide voltage and timing feedback to the controller. This pin is connected to a voltage divider between an auxiliary winding and GND. The value of the upper resistor of this divider is used to program the AC-mains run and stop thresholds and line compensation at the CS pin. VS 2 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 7 UCC28720 SLUSBE8 – MAY 2013 www.ti.com Detailed Pin Description VDD (Device Bias Voltage Supply): The VDD pin is connected to a bypass capacitor to ground. The VDD turnon UVLO threshold is 21 V and turn-off UVLO threshold is 8.1 V, with an available operating range up to 35 V on VDD. The USB charging specification requires the output current to operate in constant-current mode from 5 V to a minimum of 2 V; this is easily achieved with a nominal VDD of approximately 25 V. The additional VDD headroom up to 35 V allows for VDD to rise due to the leakage energy delivered to the VDD capacitor in highload conditions. GND (Ground): There is a single ground reference external to the device for the base drive current and analog signal reference. Place the VDD bypass capacitor close to GND and VDD with short traces to minimize noise on the VS and CS signal pins. HV (High Voltage Startup): The HV pin is connected directly to the bulk capacitor to provide startup current to the VDD capacitor. The typical startup current is ~300 µA which provides fast charging of the VDD capacitor. The internal HV start-up device is active until VDD exceeds the turn-on UVLO threshold at which time the HV start-up device is turned off. In the off state the leakage current is very low to minimize standby losses of the controller. When VDD falls below the UVLO turn-off threshold the HV start-up device is turned on. VS (Voltage-Sense): The VS pin is connected to a resistor divider from the auxiliary winding to ground. The output-voltage feedback information is sampled at the end of the transformer secondary current demagnetization time to provide an accurate representation of the output voltage. Timing information to achieve valley-switching and to control the duty cycle of the secondary transformer current is determined by the waveform on the VS pin. Avoid placing a filter capacitor on this input which would interfere with accurate sensing of this waveform. The VS pin also senses the bulk capacitor voltage to provide for AC-input run and stop thresholds, and to compensate the current-sense threshold across the AC-input range. During the transistor on-time the VS pin is clamped to approximately 250 mV below GND and the current out of the VS pin is sensed. For the AC-input run/stop function, the run threshold on VS is 225 µA and the stop threshold is 80 µA. The values for the auxilliary voltage divider upper-resistor RS1 and lower-resistor RS2 can be determined by the equations below. where • • • RS2 = NPA is the transformer primary-to-auxiliary turns ratio, VIN(run) is the AC RMS voltage to enable turn-on of the controller (run), IVSL(run) is the run-threshold for the current pulled out of the VS pin during the switch on-time. (see ELECTRICAL CHARACTERISTICS) (1) RS1 ´ VVSR NAS ´ (VOCV + VF ) - VVSR where • • • • • VOCV is the converter regulated output voltage, VF is the output rectifier forward drop at near-zero current, NAS is the transformer auxiliary to secondary turns ratio, RS1 is the VS divider high-side resistance, VVSR is the CV regulating level at the VS input (see ELECTRICAL CHARACTERISTICS). (2) DRV (Base Drive): The DRV pin is connected to the NPN transistor base pin. The driver provides a base drive signal limited to 7 V. The turn-on characteristic of the driver is a 15 mA to 35-mA current source that is scaled with the current sense threshold dictated by the operating point in the control scheme. When the minimum current sense threshold is being used, the base drive current is also at its minimum value. As the current sense threshold is increased to the maximum, the base drive current scales linearly with it to its maximum of 35 mA typical. The turn-off current is determined by the low-side driver RDS(on) 8 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 CS (Current Sense): The current-sense pin is connected through a series resistor (RLC) to the current-sense resistor (RCS). The current-sense threshold is 0.78 V for IPP(max) and 0.195 V for IPP(min). The series resistor RLC provides the function of feed-forward line compensation to eliminate change in IPP due to change in di/dt and the propagation delay of the internal comparator and NPN transistor turn-off time. There is an internal leading-edge blanking time of approximately 300 ns to eliminate sensitivity to the turn-on current spike. It should not be necessary to place a bypass capacitor on the CS pin. The value of RCS is determined by the target output current in Constant Current (CC) regulation. The values of RCS and RLC can be determined by the equations below. The term ηXFMR is intended to account for the energy stored in the transformer but not delivered to the secondary. This includes transformer resistance and core loss, bias power, and primary-to-secondary leakage ratio. Example: With a transformer core and winding loss of 5%, primary-to-secondary leakage inductance of 3.5%, and bias power to output power ratio of 1.5%. The ηXFMR value is approximately: 1 - 0.05 - 0.035 - 0.015 = 0.9. V ´ NPS RCS = CCR ´ hXFMR 2IOCC where • • • • RLC = VCCR is a current regulation constant (see ELECTRICAL CHARACTERISTICS), NPS is the transformer primary-to-secondary turns ratio (a ratio of 13 to 15 is recommended for 5-V output), IOCC is the target output current in constant-current regulation, ηXFMR is the transformer efficiency. (3) KLC ´ RS1 ´ RCS ´ tD ´ NPA LP where • • • • • • RS1 is the VS pin high-side resistor value, RCS is the current-sense resistor value, t D is the current-sense delay including NPN transistor turn-off delay, add ~50 ns to transistor delay, NPA is the transformer primary-to-auxiliary turns ratio, LP is the transformer primary inductance, KLC is a current-scaling constant (see ELECTRICAL CHARACTERISTICS). (4) CBC (Cable Compensation): The cable compensation pin is connected to a resistor to ground to program the amount of output voltage compensation to offset cable resistance. The cable compensation block provides a 0-V to 3-V voltage level on the CBC pin corresponding to IOCC(max) output current. Connecting a resistance from CBC to GND programs a current that is summed into the VS feedback divider, increasing the regulation voltage as IOUT increases. There is an internal series resistance of 28 kΩ to the CBC pin which sets a maximum cable compensation of a 5-V output to 400 mV when CBC is shorted to ground. The CBC resistance value can be determined by the equation below. where • • • • • VOCV is the regulated output voltage, VF is the diode forward voltage in V, VOCBC is the target cable compensation voltage at the output terminals, VCBC(max) is the maximum voltage at the cable compensation pin at the maximum converter output current (see ELECTRICAL CHARACTERISTICS), VVSR is the CV regulating level at the VS input (see ELECTRICAL CHARACTERISTICS). (5) Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 9 UCC28720 SLUSBE8 – MAY 2013 www.ti.com TYPICAL CHARACTERISTICS VDD = 25 V, unless otherwise noted. 10 10.000 IRUN, VDD = 25V 1 IVDD - Operating current - mA IVDD- Bias supply current - mA VDD off Run state 0.1 0.01 VDD on 0.001 Startup state 0.0001 1.000 IWAIT, VDD = 25V 0.100 ISTART, VDD = 18V 0.010 0.00001 0 10 20 30 40 VVDD - Input voltage - V 0.001 C001 -50 -25 0 25 50 75 100 TJ - Temperature - ƒC Figure 1. Bias Supply Current vs. VDD Voltage 250 IVS - VS pin current threshold - µA VVSR - VS Regulating Voltage - V 4.15 4.1 4.05 4 3.95 Start 200 150 100 50 Stop 0 3.9 ±50 ±25 0 25 50 75 100 -50 125 TJ - Junction Temperature - °C VVS = 3.7V 600.0 500.0 400.0 VVS = 4.35V 200.0 100.0 0.0 -50 -25 0 25 50 75 TJ - Junction temperature - ƒC 100 125 VCCR - Constant current regulating level - mV 800.0 300.0 0 25 50 75 100 TJ - Junction temperature - ƒC 125 C004 Figure 4. VS Pin Start and Stop Thresholds vs. Junction Temperature 900.0 700.0 -25 C003 Figure 3. VS Pin Regulation Voltage vs. Junction Temperature VCST(min) - Min current sense threshold- mV C002 Figure 2. Operating Current vs. Junction Temperature 4.2 340.0 335.0 330.0 325.0 320.0 -50 -25 0 25 50 75 TJ- Junction temperature - ƒC C005 Figure 5. Current Sense Threshold vs. Temperature 10 125 100 125 C006 Figure 6. Constant Current Regulation Level vs. Junction Temperature Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 TYPICAL CHARACTERISTICS (continued) VDD = 25 V, unless otherwise noted. fSW(max) - Maximum switching freq. - kHz fSW(min) - Min. switching freq. - Hz 700 690 680 670 660 650 640 630 620 610 600 -50 -25 0 25 50 75 100 TJ - Junction temperature - ƒC 85.00 84.00 83.00 82.00 81.00 80.00 79.00 78.00 77.00 76.00 75.00 -50 125 25 50 75 100 125 C012 Figure 8. Maximum Switching Frequency vs. Junction Temperature 1.60 35.00 RDRVLS - Driver low side resistance - 40.00 IDRS - Driver source current - mA 0 TJ - Junction temperature - ƒC Figure 7. Minimum Switching Frequency vs. Junction Temperature VVS = 3.7V 30.00 25.00 20.00 VVS = 4.35V 15.00 VDRV=2V, VVDD = 9V 10.00 1.50 1.40 1.30 1.20 1.10 1.00 0.90 0.80 0.70 0.60 -50 -25 0 25 50 75 100 TJ - Junction temperature - ƒC 125 -50 4.66 4.64 4.62 4.6 4.58 4.56 4.54 -25 0 25 50 75 TJ - Junction temperature - ƒC 100 125 25 50 75 100 125 C009 Figure 10. Driver Pull Down Resistance vs. Junction Temperature 227.00 226.00 225.00 224.00 223.00 222.00 221.00 220.00 219.00 -50 -25 0 25 50 75 100 TJ - Junction temperature - ƒC C010 Figure 11. Over Voltage Protection Threshold vs. Junction Temperature 0 TJ - Junction temperature - ƒC IHV - High voltage charging current - µA 4.68 -50 -25 C008 Figure 9. Driver Output Source Current vs. Junction Temperature VOVP - Over voltage protection threshold - V -25 C007 125 C011 Figure 12. HV Charging Current vs. Junction Temperature Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 11 UCC28720 SLUSBE8 – MAY 2013 www.ti.com FUNCTIONAL DESCRIPTION The UCC28720 is a flyback power supply controller which provides accurate voltage and constant current regulation with primary-side feedback, eliminating the need for opto-coupler feedback circuits. The controller operates in discontinuous conduction mode with valley-switching to minimize switching losses. The modulation scheme is a combination of frequency and primary peak current modulation to provide high conversion efficiency across the load range. The control law provides a wide-dynamic operating range of output power which allows the power designer to achieve the <10-mW stand-by power requirement. During low-power operating ranges the device has power management features to reduce the device operating current at operating frequencies below 28 kHz. Accurate voltage and constant current regulation, fast dynamic response, and fault protection are achieved with primary-side control. A complete charger solution can be realized with a straightforward design process, low cost and low component count. Primary-Side Voltage Regulation Figure 13 illustrates a simplified flyback convertor with the main voltage regulation blocks of the device shown. The power train operation is the same as any DCM flyback circuit but accurate output voltage and current sensing is the key to primary-side control. Bulk Voltage Secondary Winding Primary Winding VOUT Cout Rload Timing Aux Winding RS1 VS Discriminator and Sampler VCL RS2 Zero Crossings Control Law GD DRV - Minimum Period And Peak Primary Current CS RCS UDG -13093 Figure 13. Simplified Flyback Convertor (with the main voltage regulation blocks) 12 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 In primary-side control, the output voltage is sensed on the auxiliary winding during the transfer of transformer energy to the secondary. As shown in Figure 14 it is clear there is a down slope representing a decreasing total rectifier VF and resistance voltage drop (ISRS) as the secondary current decreases to zero. To achieve an accurate representation of the secondary output voltage on the auxiliary winding, the discriminator reliably recognizes the leakage inductance reset and ringing and ingores it, continuously samples the auxiliary voltage during the down slope after the ringing is diminished, and captures the error signal at the time the secondary winding reaches zero current. The internal reference on VS is 4.05 V. Temperature compensation on the VS reference voltage of -0.8-mV/°C offsets the change in the output rectifier forward voltage with temperature. The resistor divider is selected as outlined in the VS pin description. Figure 14. Auxiliary Winding Voltage The UCC28720 includes a VS signal sampler that uses discrimination methods to ensure an accurate sample of the output voltage from the auxiliary winding. There are some conditions that must be met on the auxiliary winding signal to ensure reliable operation. These conditions are the reset time of the leakage inductance and the duration of any subsequent leakage inductance ring. Refer to Figure 15 below for a detailed illustration of waveform criteria to ensure a reliable sample on the VS pin. The first detail to examine is the duration of the leakage inductance reset pedestal, tLK_RESET in Figure 15. Because this can mimic the waveform of the secondary current decay, followed by a sharp downslope, it is important to keep the leakage reset time less than 600 ns for IPRI minimum, and less than 2.2 µs for IPRI maximum. The second detail is the amplitude of ringing on the VAUX waveform following tLK_RESET. The peak-to-peak voltage at the VS pin should be less than approximately 100 mVp-p at least 200 ns before the end of the demagnetization time, tDM. If there is a concern with excessive ringing, it usually occurs during light or no-load conditions, when tDM is at the minimum. The tolerable ripple on VS scales up when measured at the auxiliary winding by RS1 and RS2, and is equal to 100 mV x (RS1 + RS2) / RS2 when measured directly at the auxilliary winding. tLK_RESET tSMPL VS ring(p-p) tDM UDG-12202 Figure 15. Auxiliary Waveform Details Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 13 UCC28720 SLUSBE8 – MAY 2013 www.ti.com During voltage regulation, the controller operates in frequency modulation mode and amplitude modulation mode as illustrated in Figure 16 below. The internal operating frequency limits of the device are 80 kHz, fSW(max) and 65 Hz, fSW(min). The transformer primary inductance and primary peak current chosen sets the maximum operating frequency of the converter. The output preload resistor and efficiency at low power determines the converter minimum operating frequency. There is no stability compensation required for the UCC28720. Control Law Profile in Constant Voltage(CV) Mode 80 kHz fSW(max) I PP (peak primary current) fSW (1 / MINP) I PP(max ) I PP fSW 28 kHz FM AM I PP(max ) / 4.0 FM f SW(min) 3.3 kHz 0.75 V 1.3 V 2.2 V 3.55 V Control Voltage , E/A Output - VCL 5V UDG-13095 Figure 16. Frequency and Amplitude Modulation Modes (during voltage regulation) 14 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 Primary-Side Current Regulation Timing information at the VS pin and current information at the CS pin allow accurate regulation of the secondary average current. The control law dictates that as power is increased in CV regulation and approaching CC regulation the primary-peak current is at IPP(max). Referring to Figure 17 below, the primary-peak current, turns ratio, secondary demagnetization time (tDM), and switching period (tSW) determine the secondary average output current. Ignoring leakage inductance effects, the average output current is given by Equation 6. When the average output current reaches the regulation reference in the current control block, the controller operates in frequency modulation mode to control the output current at any output voltage at or below the voltage regulation target as long as the auxiliary winding can keep VDD above the UVLO turn-off threshold. IPP IS × NS/NP tON tDM tSW UDG-12203 Figure 17. Transformer Currents I N t IOUT = PP ´ P ´ DM 2 NS tSW (6) VOCV 5.25 5 Output Voltage (V) 4.75 4 ±5% 3 2 1 Output Current IOCC UDG-12201 Figure 18. Typical Target Output V-I Characteristic Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 15 UCC28720 SLUSBE8 – MAY 2013 www.ti.com Valley Switching The UCC28720 utilizes valley switching to reduce switching losses in the transistor, to reduce induced-EMI, and to minimize the turn-on current spike at the sense resistor. The controller operates in valley-switching in all load conditions unless the collector voltage (VC) ringing has subsided. Referring to Figure 19 below, the UCC28720 operates in a valley-skipping mode in most load conditions to maintain an accurate voltage or current regulation point and still switch on the lowest available VC. VC VDRV UDG-13091 Figure 19. Valley-Skipping Mode Start-Up Operation The internal high-voltage start-up switch connected to the bulk capacitor voltage (VBLK) through the HV pin charges the VDD capacitor. During start up there is typically 300 µA available to charge the VDD capacitor. When VDD reaches the 21-V UVLO turn-on threshold, the controller is enabled, the converter starts switching and the start-up switch is turned off. The initial three cycles are limited to IPP(min). After the initial three cycles at minimum IPP(min), the controller responds to the condition dictated by the control law. The converter will remain in discontinuous mode during charging of the output capacitor(s), maintaining a constant output current until the output voltage is in regulation. 16 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 Fault Protection The UCC28720 provides comprehensive fault protection. Protection functions include: • Output over-voltage fault • Input under-voltage fault • Internal over-temperature fault • Primary over-current fault • CS pin fault • VS pin fault A UVLO reset and restart sequence applies for all fault protection events. The output over-voltage function is determined by the voltage feedback on the VS pin. If the voltage sample on VS exceeds 115% of the nominal VOUT, the device stops switching and the internal current consumption is IFAULT which discharges the VDD capacitor to the UVLO turn-off threshold. After that, the device returns to the start state and a start-up sequence ensues. The UCC28720 always operates with cycle-by-cycle primary peak current control. The normal operating range of the CS pin is 0.78 V to 0.195 V. There is additional protection if the CS pin reaches 1.5 V. This results in a UVLO reset and restart sequence. The line input run and stop thresholds are determined by current information at the VS pin during the transistor on-time. While the VS pin is clamped close to GND during the transistor on-time, the current through RS1 is monitored to determine a sample of the bulk capacitor voltage. A wide separation of run and stop thresholds allows clean start-up and shut-down of the power supply with the line voltage. The run current threshold is 225 µA and the stop current threshold is 80 µA. The internal over-temperature protection threshold is 165°C. If the junction temperature reaches this threshold the device initiates a UVLO reset cycle. If the temperature is still high at the end of the UVLO cycle, the protection cycle repeats. Protection is included in the event of component failures on the VS pin. If complete loss of feedback information on the VS pin occurs, the controller stops switching and restarts. Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 17 UCC28720 SLUSBE8 – MAY 2013 www.ti.com DESIGN PROCEDURE This procedure outlines the steps to design a constant-voltage, constant-current flyback converter using the UCC28720 controller. Refer to the Figure 20 for component names and network locations. The design procedure equations use terms that are defined below. VBLK + CB1 + VF - CB2 RPL Ns Np COUT VOUT – VAC UCC28720 SOIC-7 VAUX + VFA HV VDD Na CDD RS1 DRV VS CS RLC CBC RS2 RCS R CBC GND UDG-13091 Figure 20. Design Procedure Application Example Definition of Terms Capacitance Terms in Farads • CBULK: total input capacitance of CB1 and CB2. • CDD: minimum required capacitance on the VDD pin. • COUT: minimum output capacitance required. Duty Cycle Terms • DMAGCC: secondary diode conduction duty cycle in CC, 0.425. • DMAX: transistor on-time duty cycle. Frequency Terms in Hertz • fLINE: minimum line frequency. • fMAX: target full-load maximum switching frequency of the converter. • fMIN: minimum switching frequency of the converter, add 15% margin over the fSW(min) limit of the device. • fSW(min): minimum switching frequency (see ELECTRICAL CHARACTERISTICS). Current Terms in Amperes • IOCC: converter output constant-current target. • IPP(max): maximum transformer primary current. • ISTART: start-up bias supply current (see ELECTRICAL CHARACTERISTICS). • ITRAN : required positive load-step current. • IVSL(run): VS pin run current (see ELECTRICAL CHARACTERISTICS). • IDRS: Driver source current (see ELECTRICAL CHARACTERISTICS). 18 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 Current and Voltage Scaling Terms • KAM: maximum-to-minimum peak primary current ratio (see ELECTRICAL CHARACTERISTICS). • KLC: current-scaling constant (see ELECTRICAL CHARACTERISTICS). Transformer Terms • LP: transformer primary inductance. • NAS: transformer auxiliary-to-secondary turns ratio. • NPA: transformer primary-to-auxiliary turns ratio. • NPS: transformer primary-to-secondary turns ratio. Power Terms in Watts • PIN: converter maximum input power. • POUT: full-load output power of the converter. • PRSTR: VDD start-up resistor power dissipation. • PSB: total stand-by power. • PSB_CONV: PSB minus start-up resistor and snubber losses. Resistance Terms in Ω • RCS: primary current programming resistance. • RESR: total ESR of the output capacitor(s). • RPL: preload resistance on the output of the converter. • RS1: high-side VS pin resistance. • RS2: low-side VS pin resistance. Timing Terms in Seconds • tD: current-sense delay including transistor turn-off delay; add 50 ns to transistor delay. • tDMAG(min): minimum secondary rectifier conduction time. • tON(min): minimum transistor on time. • tR: resonant frequency during the DCM (discontinuous conduction mode) time. Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 19 UCC28720 SLUSBE8 – MAY 2013 www.ti.com Voltage Terms in Volts • VBLK: highest bulk capacitor voltage for stand-by power measurement. • VBULK(min): minimum voltage on CB1 and CB2 at full power. • VOCBC: target cable compensation voltage at the output terminals. • VCBC(max): maximum voltage at the CBC pin at the maximum converter output current (see ELECTRICAL CHARACTERISTICS). • VCCR: constant-current regulating voltage (see ELECTRICAL CHARACTERISTICS). • VCST(max): CS pin maximum current-sense threshold (see ELECTRICAL CHARACTERISTICS). • VCST(min): CS pin minimum current-sense threshold (see ELECTRICAL CHARACTERISTICS). • VDD(off): UVLO turn-off voltage (see ELECTRICAL CHARACTERISTICS). • VDD(on): UVLO turn-on voltage (see ELECTRICAL CHARACTERISTICS). • VOΔ: output voltage drop allowed during the load-step transient. • VCPK: peak transistor collector to emitter voltage at high line. • VF: secondary rectifier forward voltage drop at near-zero current. • VFA: auxiliary rectifier forward voltage drop. • VLK: estimated leakage inductance energy reset voltage. • VOCV: regulated output voltage of the converter. • VOCC: target lowest converter output voltage in constant-current regulation. • VREV: peak reverse voltage on the secondary rectifier. • VRIPPLE: output peak-to-peak ripple voltage at full-load. • VVSR: CV regulating level at the VS input (see ELECTRICAL CHARACTERISTICS). AC Voltage Terms in VRMS • VIN(max): maximum input voltage to the converter. • VIN(min): minimum input voltage to the converter. • VIN(run): converter input start-up (run) voltage. Efficiency Terms • ηSB: estimated efficiency of the converter at no-load condition, not including start-up resistance or bias losses. For a 5-V USB charger application, 60% to 65% is a good initial estimate. • η: converter overall efficiency. • ηXFMR: transformer primary-to-secondary power transfer efficiency. 20 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 Stand-by Power Estimate Assuming no-load stand-by power is a critical design parameter, determine estimated no-load power based on target converter maximum switching frequency and output power rating. The following equation estimates the stand-by power of the converter. (7) For a typical USB charger application, the bias power during no-load is approximately 2.5 mW. This is based on 25-V VDD and 100-µA bias current. The output preload resistor can be estimated by VOCV and the difference in the converter stand-by power and the bias power. The equation for output preload resistance accounts for bias power estimated at 2.5 mW. (8) The capacitor bulk voltage for the loss estimation is the highest voltage for the stand-by power measurement, typically 325 VDC. For the total stand-by power estimation add an estimated 2.5 mW for snubber loss to the converter stand-by power loss. PSB = PSB _ CONV + 2.5 mW (9) Input Bulk Capacitance and Minimum Bulk Voltage Determine the minimum voltage on the input capacitance, CB1 and CB2 total, in order to determine the maximum Np to Ns turns ratio of the transformer. The input power of the converter based on target full-load efficiency, minimum input RMS voltage, and minimum AC input frequency are used to determine the input capacitance requirement. Maximum input power is determined based on VOCV, IOCC, and the full-load efficiency target. (10) The below equation provides an accurate solution for input capacitance based on a target minimum bulk capacitor voltage. To target a given input capacitance value, iterate the minimum capacitor voltage to achieve the target capacitance. (11) Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 21 UCC28720 SLUSBE8 – MAY 2013 www.ti.com Transformer Turns Ratio, Inductance, Primary-Peak Current The maximum primary-to-secondary turns ratio can be determined by the target maximum switching frequency at full load, the minimum input capacitor bulk voltage, and the estimated DCM quasi-resonant time. Initially determine the maximum available total duty cycle of the on time and secondary conduction time based on target switching frequency and DCM resonant time. For DCM resonant time, assume 500 kHz if you do not have an estimate from previous designs. For the transition mode operation limit, the period required from the end of secondary current conduction to the first valley of the VCE voltage is ½ of the DCM resonant period, or 1 µs assuming 500-kHz resonant frequency. DMAX can be determined using the equation below. æt ö DMAX = 1 - ç R ´ fMAX ÷ - DMAGCC è 2 ø (12) Once DMAX is known, the maximum turns ratio of the primary to secondary can be determined with the equation below. DMAGCC is defined as the secondary diode conduction duty cycle during constant-current, CC, operation. It is set internally by the UCC28720 at 0.425. The total voltage on the secondary winding needs to be determined; which is the sum of VOCV, the secondary rectifier VF, and the cable compensation voltage (VOCBC). For the 5-V USB charger applications, a turns ratio range of 13 to 15 is typically used. (13) Once an optimum turns ratio is determined from a detailed transformer design, use this ratio for the following parameters. The UCC28720 constant-current regulation is achieved by maintaining a maximum DMAG duty cycle of 0.425 at the maximum primary current setting. The transformer turns ratio and constant-current regulating voltage determine the current sense resistor for a target constant current. Since not all of the energy stored in the transformer is transferred to the secondary, a transformer efficiency term is included. This efficiency number includes the core and winding losses, leakage inductance ratio, and bias power ratio to rated output power. For a 5-V, 1-A charger example, bias power of 1.5% is a good estimate. An overall transformer efficiency of 0.9 is a good estimate to include 3.5% leakage inductance, 5% core and winding loss, and 1.5% bias power. V ´ NPS RCS = CCR ´ hXFMR 2IOCC (14) The primary transformer inductance can be calculated using the standard energy storage equation for flyback transformers. Primary current, maximum switching frequency and output and transformer power losses are included in the equation below. Initially determine transformer primary current. Primary current is simply the maximum current sense threshold divided by the current sense resistance. (15) (16) The secondary winding to auxiliary winding transformer turns ratio (NAS) is determined by the lowest target operating output voltage in constant-current regulation and the VDD UVLO of the UCC28720. There is additional energy supplied to VDD from the transformer leakage inductance energy which allows a lower turns ratio to be used in many designs. (17) 22 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 UCC28720 www.ti.com SLUSBE8 – MAY 2013 Transformer Parameter Verification The transformer turns ratio selected affects the transistor VC and secondary rectifier reverse voltage so these should be reviewed. The UCC28720 does require a minimum on time of the transistor (tON) and minimum DMAG time (tDMAG) of the secondary rectifier in the high line, minimum load condition. The selection of fMAX, LP and RCS affects the minimum tON and tDMAG. The secondary rectifier and transistor voltage stress can be determined by the equations below. (18) For the transistor VC voltage stress, an estimated leakage inductance voltage spike (VLK) needs to be included. ( ) VCPK = VIN (max) ´ 2 + (VOCV + VF + VOCBC )´ NPS + VLK (19) Equation 20 and Equation 21 are used to determine if the minimum tON target of 300 ns and minimum tDMAG target of 1.2 µs is achieved. IPP(max ) ´ VCST(min ) LP tON(min ) = ´ VCST(max ) VIN max ´ 2 ( tDMAG(min ) = ) (20) tON ´ VIN(max ) ´ 2 NPS ´ (VOCV + VF ) (21) Output Capacitance The output capacitance value is typically determined by the transient response requirement from no-load. For example, in some USB charger applications there is a requirement to maintain a minimum VO of 4.1 V with a load-step transient of 0 mA to 500 mA . The equation below assumes that the switching frequency can be at the UCC28720 minimum of fSW(min). (22) Another consideration of the output capacitor(s) is the ripple voltage requirement which is reviewed based on secondary peak current and ESR. A margin of 20% is added to the capacitor ESR requirement in the equation below. (23) Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 23 UCC28720 SLUSBE8 – MAY 2013 www.ti.com VDD Capacitance, CDD The capacitance on VDD needs to supply the device operating current until the output of the converter reaches the target minimum operating voltage in constant-current regulation. At this time the auxiliary winding can sustain the voltage to the UCC28720. The total output current available to the load and to charge the output capacitors is the constant-current regulation target. The equation below assumes the output current of the flyback is available to charge the output capacitance until the minimum output voltage is achieved. There is 1 V of margin added to VDD in the calculation. (I RUN CDD = COUT ´ VOCC IO (VDD(on ) - VDD(off ) )- 1 V + L DRS(max) ´ (1 - D magcc ) ))´ (24) VS Resistor Divider, Line Compensation, and Cable Compensation The VS divider resistors determine the output voltage regulation point of the flyback converter, also the high-side divider resistor (RS1) determines the line voltage at which the controller enables continuous DRV operation. RS1 is initially determined based on transformer auxiliary to primary turns ratio and desired input voltage operating threshold. (25) The low-side VS pin resistor is selected based on desired VO regulation voltage. (26) The UCC28720 can maintain tight constant-current regulation over input line by utilizing the line compensation feature. The line compensation resistor (RLC) value is determined by current flowing in RS1 and expected base drive and transistor turn-off delay. Assume a 50-ns internal delay in the UCC28720. K ´ RS1 ´ RCS ´ tD ´ NPA RLC = LC LP (27) The UCC28720 has adjustable cable drop compensation. The resistance for the desired compensation level at the output terminals can be determined using Equation 28. (28) 24 Submit Documentation Feedback Copyright © 2013, Texas Instruments Incorporated Product Folder Links: UCC28720 PACKAGE OPTION ADDENDUM www.ti.com 27-Jul-2013 PACKAGING INFORMATION Orderable Device Status (1) Package Type Package Pins Package Drawing Qty Eco Plan Lead/Ball Finish (2) MSL Peak Temp Op Temp (°C) Device Marking (3) (4/5) UCC28720D ACTIVE SOIC D 7 75 Green (RoHS & no Sb/Br) CU NIPDAU Level-1-260C-UNLIM -40 to 125 U28720 UCC28720DR ACTIVE SOIC D 7 2500 Green (RoHS & no Sb/Br) CU NIPDAU Level-1-260C-UNLIM -40 to 125 U28720 (1) The marketing status values are defined as follows: ACTIVE: Product device recommended for new designs. LIFEBUY: TI has announced that the device will be discontinued, and a lifetime-buy period is in effect. NRND: Not recommended for new designs. Device is in production to support existing customers, but TI does not recommend using this part in a new design. PREVIEW: Device has been announced but is not in production. Samples may or may not be available. OBSOLETE: TI has discontinued the production of the device. (2) Eco Plan - The planned eco-friendly classification: Pb-Free (RoHS), Pb-Free (RoHS Exempt), or Green (RoHS & no Sb/Br) - please check http://www.ti.com/productcontent for the latest availability information and additional product content details. TBD: The Pb-Free/Green conversion plan has not been defined. Pb-Free (RoHS): TI's terms "Lead-Free" or "Pb-Free" mean semiconductor products that are compatible with the current RoHS requirements for all 6 substances, including the requirement that lead not exceed 0.1% by weight in homogeneous materials. Where designed to be soldered at high temperatures, TI Pb-Free products are suitable for use in specified lead-free processes. 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Addendum-Page 1 Samples PACKAGE MATERIALS INFORMATION www.ti.com 24-Jul-2013 TAPE AND REEL INFORMATION *All dimensions are nominal Device UCC28720DR Package Package Pins Type Drawing SOIC D 7 SPQ Reel Reel A0 Diameter Width (mm) (mm) W1 (mm) 2500 330.0 12.4 Pack Materials-Page 1 6.4 B0 (mm) K0 (mm) P1 (mm) 5.2 2.1 8.0 W Pin1 (mm) Quadrant 12.0 Q1 PACKAGE MATERIALS INFORMATION www.ti.com 24-Jul-2013 *All dimensions are nominal Device Package Type Package Drawing Pins SPQ Length (mm) Width (mm) Height (mm) UCC28720DR SOIC D 7 2500 367.0 367.0 35.0 Pack Materials-Page 2 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. 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