UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Natural Interleaving™ Transition-Mode PFC Controller with Improved Audible Noise Immunity Check for Samples: UCC28063 NATURAL INTERLEAVING FEATURES SYSTEM FEATURES • • • • • • • 1 • • • Input Filter and Output Capacitor Ripple-Current Cancellation – Reduced current ripple for higher system reliability and smaller bulk capacitor – Reduced EMI filter size Phase Management Capability FailSafe OVP with Dual Paths Prevents Output Over-Voltage Conditions by Voltage-Sensing Failures Sensorless Current-Shaping Simplifies Board Layout and Improves Efficiency • APPLICATIONS • • • • • • 100-W to 800-W Power Supplies Gaming D-to-A Set-Top Boxes Adapters LCD, Plasma and DLP™ TVs Home Audio Systems • • • • • • Advanced Audible Noise Performance Non-linear Error-Amplifier Gain Soft Recovery on Overvoltage Integrated Brownout and Dropout Handling Reduced Bias Currents Improved Efficiency and Design Flexibility over Traditional Single-Phase Continuous Conduction Mode (CCM) Inrush-Safe Current Limiting: – Prevents MOSFET conduction during inrush – Eliminates reverse recovery events in output rectifiers Enables Use of Low-Cost Diodes without Extensive Snubber Circuitry Improved Light-Load Efficiency Fast, Smooth Transient Response Expanded System-Level Protections 1-A Source/1.8-A Sink Gate Drivers -40°C to 125°C Operating Temperature Range in a 16-lead SOIC package Typical Application Diagram Ripple Current Reduction 400 VDC EMI Filter – + 5 UCC28063 12 VCC 10 CS 7 3 ZCDA 16 GDA 14 VINAC TSET ZCDB 1 GDB 11 PWMCNTL 9 VSENSE 2 PHB 4 COMP 5 Power Good to Down Stream Converter Phase Management 15 VREF HVSEN AGND PGND 6 13 8 Capacitor ripple current (A) 85 VAC to 265 VAC POUT = 600 W VOUT = 400 V 4 1-phase TM 3 1-phase CCM 2 2-phase TM Interleave 1 70 120 170 220 Input Voltage (V) 270 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 © 2011, Texas Instruments Incorporated UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com CONTENTS • • • • • • • Electrical Characteristics 5 Device Information 9 Functional Block Diagram 12 Typical Characteristics 13 Application Information 19 Design Example 33 Additional References 41 DESCRIPTION Optimized for consumer applications concerned with audible noise elimination, this solution extends the advantages of transition mode – high efficiency with low-cost components – to higher power ratings than previously possible. By utilizing a Natural Interleaving™ technique, both channels operate as masters (that is, there is no slave channel) synchronized to the same frequency. This approach delivers inherently strong matching, faster responses, and ensures that each channel operates in transition mode. Expanded system level protections feature input brownout and dropout recovery, output over-voltage, open-loop, overload, soft-start, phase-fail detection, and thermal shutdown. The additional FailSafe over-voltage protection (OVP) feature protects against shorts to an intermediate voltage that, if undetected, could lead to catastrophic device failure. Advanced non-linear gain results in rapid, yet smoother response to line and load transient events. Reduced bias currents improve stand-by power efficiency. Special line-dropout handling avoids significant current disruption and minimizes audible-noise generation. 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. ORDERING INFORMATION (1) (1) (2) 2 PART NUMBER PACKAGE (2) OPERATING TEMPERATURE RANGE, TA UCC28063D SOIC 16-Pin (D) -40°C to +125°C For the most current package and ordering information see the Package Option Addendum at the end of this document, or see the TI web site at www.ti.com. SOIC (D) package is available taped and reeled by adding R to the above part number. Reeled quantities for UCC28063DR are 2,500 devices per reel. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ABSOLUTE MAXIMUM RATINGS (1) All voltages are with respect to GND, −40°C < TJ = TA < 125°C, currents are positive into and negative out of the specified terminal, unless otherwise noted. MIN Continuous input voltage range Continuous input current Peak input current Output current Continuous gate current Junction Temperature, TJ Lead Temperature, TSOL 21 PWMCNTL −0.5 20 COMP (3), PHB, HVSEN (4), VINAC (4), VSENSE (4) −0.5 7 ZCDA, ZCDB −0.5 4 CS (5) −0.5 3 VCC 20 PWMCNTL 10 ZCDA, ZCDB ±5 CS −30 VREF −10 GDA, GDB (6) ±25 Operating −40 125 Storage −65 150 Soldering, 10s (3) (4) (5) (6) V mA °C 260 2,000 Charged Device Model (CDM) (2) UNIT −0.5 Human Body Model (HBM) (1) MAX VCC (2) 500 V Stresses beyond those listed under Absolute Maximum Ratings may cause permanent damage to the device. These are stress ratings only and functional operation of the device at these or any other condition beyond those included under Recommended Operating Conditions is not implied. Exposure to absolute-maximum-rated conditions for extended periods of time may affect device reliability. Voltage on VCC is internally clamped. VCC may exceed the continuous absolute maximum input voltage rating if the source is current limited below the absolute maximum continuous VCC input current level. In normal use, COMP is connected to capacitors and resistors and is internally limited in voltage swing. In normal use, VINAC, VSENSE, and HVSEN are connected to high-value resistors and are internally limited in negative-voltage swing. Although not recommended for extended use, VINAC, VSENSE, and HVSEN can survive input currents as high as -10mA from negative voltage sources, and input currents as high as +0.5mA from positive voltage sources. In normal use, CS is connected to a series resistor to limit peak input current during brief system line-inrush conditions. In these situations, negative voltage on CS may exceed the continuous absolute maximum rating. No GDA or GDB current limiting is required when driving a power MOSFET gate. However, a small series resistor may be required to damp resonant ringing due to stray inductance. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 3 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com RECOMMENDED OPERATING CONDITIONS All voltages are with respect to GND, −40°C < TJ = TA < 125°C, currents are positive into and negative out of the specified terminal, unless otherwise noted. MIN MAX VCC input voltage from a low-impedance source PARAMETER 14 21 VCC input current from a high-impedance source 8 18 VREF load current 0 −2 VINAC input voltage ZCDA, ZCDB series resistor TSET resistor to program PWM on-time HVSEN input voltage 0 6 20 80 66.5 400 0.8 4.5 UNIT V mA V kΩ V THERMAL INFORMATION UCC28063 THERMAL METRIC (1) SOIC (D) UNITS 16 PINS θJA Junction-to-ambient thermal resistance (2) 91.6 θJCtop Junction-to-case (top) thermal resistance (3) 52.1 (4) θJB Junction-to-board thermal resistance ψJT Junction-to-top characterization parameter (5) 14.9 ψJB Junction-to-board characterization parameter (6) 48.3 (1) (2) (3) (4) (5) (6) 4 48.6 °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 JEDEC-standard 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 © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ELECTRICAL CHARACTERISTICS At VCC = 16 V, AGND = PGND = 0 V, VINAC = 3 V, VSENSE = 6 V, HVSEN = 3 V, PHB = 5 V, RTSET = 133 kΩ, all voltages are with respect to GND, all outputs unloaded, −40°C < TJ = TA < 125°C, and currents are positive into and negative out of the specified terminal, unless otherwise noted. PARAMETER TEST CONDITION MIN TYP MAX UNIT VCC Bias Supply VCCSHUNT VCC shunt voltage (1) IVCC = 10 mA IVCC(ULVO) VCC current, UVLO VCC = 11.4 V prior to turn-on IVCC(stby) VCC current, disabled VSENSE = 0 V IVCC(on) VCC current, enabled VSENSE = 2 V 5 8 22 24 26 95 200 100 200 V µA mA Undervoltage Lockout (UVLO) VCCON VCC turn-on threshold VCC rising 11.5 12.6 13.5 VCCOFF VCC turn-off threshold VCC falling 9.5 10.35 11.5 1.85 2.15 2.45 UVLO Hysteresis V Reference VREF VREF output voltage, no load IVREF = 0 mA 5.82 6.00 6.18 VREF change with load 0 mA ≤ IVREF ≤ −2 mA - −1 −6 VREF change with VCC 12 V ≤ VCC ≤ 20 V - +2 +10 5.85 6.00 6.15 5.82 6.00 6.18 50 100 150 1.15 1.25 1.35 0.02 0.07 0.15 4.70 4.95 5.10 0.03 0.125 40 55 70 3.25% 5% 6.75% −3.25% −5% −6.75% V mV Error Amplifier VSENSEreg25 VSENSE input regulation voltage VSENSEreg VSENSE input regulation voltage IVSENSE VSENSE input bias current VENAB VSENSE enable threshold, rising TA = 25°C V In regulation VSENSE enable hysteresis VCOMPCLMP gM COMP high voltage, clamped VSENSE = VSENSEreg – 0.3 V COMP low voltage, saturated VSENSE = VSENSEreg + 0.3 V VSENSE to COMP transconductance, small signal 0.99(VSENSEreg) < VSENSE < 1.01(VSENSEreg), COMP = 3 V VSENSE high-going threshold to enable COMP large signal gain, percent Relative to VSENSEreg, COMP = 3 V VSENSE low-going threshold to Relative to VSENSEreg, COMP = 3 V enable COMP large signal gain, percent nA V µS VSENSE to COMP transconductance, large signal VSENSE = VSENSEreg – 0.4 V , COMP = 3 V 210 290 370 VSENSE to COMP transconductance, large signal VSENSE = VSENSEreg + 0.4 V, COMP = 3 V 210 290 370 −80 −125 −170 µA COMP maximum source current VSENSE = 5.0 V, COMP = 3 V RCOMPDCHG COMP discharge resistance 1.6 2.0 2.4 kΩ IDODCHG COMP discharge current during VSENSE = 5.0 V, VINAC = 0.3 V Dropout 3.2 4 4.8 µA VLOW_OV VSENSE over-voltage threshold, rising Relative to VSENSEreg 7% +8% 10% VSENSE over-voltage hysteresis Relative to VLOW_OV −1.5% −2% −3% VSENSE 2nd over-voltage threshold, rising Relative to VSENSEreg 10.5% 11.3% 14% VHIGH_OV (1) HVSEN = 5.2 V, COMP = 3 V µS Excessive VCC input voltage and current will damage the device. This clamp will not protect the device from an unregulated bias supply. If an unregulated bias supply is used, a series-connected Fixed Positive-Voltage Regulator such as the UA78L15A is recommended. See the Absolute Maximum Ratings table for the limits on VCC voltage, current, and junction temperature. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 5 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ELECTRICAL CHARACTERISTICS (continued) At VCC = 16 V, AGND = PGND = 0 V, VINAC = 3 V, VSENSE = 6 V, HVSEN = 3 V, PHB = 5 V, RTSET = 133 kΩ, all voltages are with respect to GND, all outputs unloaded, −40°C < TJ = TA < 125°C, and currents are positive into and negative out of the specified terminal, unless otherwise noted. PARAMETER TEST CONDITION MIN TYP MAX UNIT Soft Start VSSTHR COMP Soft-Start threshold, falling VSENSE = 1.5 V ISS,FAST COMP Soft-Start current, fast SS-state, VENAB < VSENSE < VREF/2 ISS,SLOW COMP Soft-Start current, slow SS-state, VREF/2 < VSENSE < 0.88VREF KEOSS VSENSE End-of-Soft-Start threshold factor Percent of VSENSEreg 15 23 30 −80 −125 −170 −11.5 −16 −20 96.5% 98.3% 99.8% 2.35 2.50 2.65 ±0.03 ±0.5 9.2 11.4 14.0 4.64 4.87 5.10 4.45 4.67 4.80 0.21 0.225 0.25 mV µA Output Monitoring VPWMCNTL HVSEN threshold to PWMCNTL HVSEN rising IHVSEN HVSEN input bias current, high HVSEN = 3 V IHV_HYS HVSEN hysteresis bias current, low HVSEN = 2 V VHV_OV_FLT HVSEN threshold to over-voltage fault HVSEN rising VHV_OV_CLR HVSEN threshold to over-voltage clear HVSEN falling VCOMP_PHFOFF Phase Fail monitoring-disable threshold COMP falling VCOMP_PHFHYS Phase Fail monitoring hysteresis COMP rising PWMCNTL output voltage low HVSEN = 3 V, IPWMCNTL = 5 mA, COMP = 0 V tPHFDLY Phase Fail filter time to PWMCNTL high PHB = 5 V, ZCDA switching, ZCDB = 0.5 V, COMP = 3 V IPWMCNTL_LEAK PWMCNTL leakage current, high HVSEN = 2 V, PWMCNTL = 15 V 6 Submit Documentation Feedback V µA V 0.051 7.9 0.2 0.5 12 17 ms ±0.03 ±0.5 µA Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ELECTRICAL CHARACTERISTICS (continued) At VCC = 16 V, AGND = PGND = 0 V, VINAC = 3 V, VSENSE = 6 V, HVSEN = 3 V, PHB = 5 V, RTSET = 133 kΩ, all voltages are with respect to GND, all outputs unloaded, −40°C < TJ = TA < 125°C, and currents are positive into and negative out of the specified terminal, unless otherwise noted. PARAMETER TEST CONDITION MIN TYP MAX UNIT Gate Drive (2) GDA, GDB output voltage, high IGDA, IGDB = −100 mA GDA, GDB on-resistance, high IGDA, IGDB = −100 mA GDA, GDB output voltage, low IGDA, IGDB = 100 mA GDA, GDB on-resistance, low IGDA, IGDB = 100 mA GDA, GDB output voltage high, clamped VCC = 20 V, IGDA, IGDB = −5 mA GDA, GDB output voltage high, low VCC VCC = 12 V, IGDA, IGDB = −5 mA Rise time Fall time GDA, GDB output voltage, UVLO VCC = 3.0 V, IGDA, IGDB = 2.5 mA 11.5 12.4 15 V 8.8 14 Ω 0.18 0.32 V 2 3.2 Ω 12 13.5 15 10 10.5 11.5 1 V to 9 V, CLOAD = 1 nF 18 30 9 V to 1 V, CLOAD = 1 nF 12 25 100 200 V ns mV Zero Current Detector ZCDA, ZCDB voltage threshold, falling 0.8 1.0 1.2 ZCDA, ZCDB voltage threshold, rising 1.5 1.7 1.9 ZCDA, ZCDB clamp, high IZCDA = +2 mA, IZCDB = +2 mA 2.6 3.0 3.4 ZCDA, ZCDB clamp, low IZCDA = −2 mA, IZCDB = −2 mA 0 −0.2 −0.4 ZCDA, ZCDB input bias current ZCDA = 1.4 V, ZCDB = 1.4 V ±0.03 ±0.5 ZCDA, ZCDB delay to GDA, GDB outputs (2) From ZCDx input falling to 1 V to respective gate drive output rising 10% 50 100 ZCDA blanking time (3) From GDA rising and GDA falling 100 ZCDB blanking time (3) From GDB rising and GDB falling 100 CS input bias current, dual-phase At rising threshold V µA ns Current Sense (2) (3) −120 −166 −200 CS current-limit rising threshold, PHB = 5 V dual-phase −0.180 −0.200 −0.220 CS current-limit rising threshold, PHB = 0 V single-phase −0.149 −0.166 −0.183 CS current-limit reset falling threshold −0.003 −0.015 −0.025 60 100 CS current-limit response time (2) From CS exceeding threshold−0.05 V to GDx dropping 10% CS blanking time From GDx rising and falling edges µA V ns 100 Refer to Figure 13, Figure 14, Figure 15, and Figure 16 of the Typical Characteristics for typical gate drive waveforms. ZCD blanking times are ensured by design. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 7 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ELECTRICAL CHARACTERISTICS (continued) At VCC = 16 V, AGND = PGND = 0 V, VINAC = 3 V, VSENSE = 6 V, HVSEN = 3 V, PHB = 5 V, RTSET = 133 kΩ, all voltages are with respect to GND, all outputs unloaded, −40°C < TJ = TA < 125°C, and currents are positive into and negative out of the specified terminal, unless otherwise noted. PARAMETER TEST CONDITION MIN TYP MAX UNIT VINAC Input IVINAC VINAC input bias current, above brownout VINAC = 2 V VBODET VINAC brownout detection threshold VINAC falling tBODLY VINAC brownout filter time VINAC below the brownout detection threshold for the brownout filter time VBOHYS VINAC brownout threshold hysteresis VINAC rising IBOHYS VINAC brownout hysteresis current VINAC = 1 V for > tBODLY VDODET VINAC dropout detection threshold VINAC falling tDODLY VINAC dropout filter time VINAC below the dropout detection threshold for the dropout filter time VDOCLR VINAC dropout clear threshold VINAC rising ±0.03 ±0.5 µA 1.33 1.39 1.44 V 340 440 540 ms 30 62 75 mV 1.6 2 2.5 µA 0.315 0.35 0.38 V 3.5 5 7.0 ms 0.67 0.71 0.75 V Pulse-Width Modulator KT On-time factor, phases A and B VSENSE = 5.8 V (4) 3.6 4.0 4.4 KTS On-time factor, single-phase, A VSENSE = 5.8 V, PHB = 0 V (4) 7.2 8.0 8.9 Phase B to phase A on-time matching error VSENSE = 5.8 V ±2% ±6% Zero-crossing distortion correction additional on time COMP = 0.25 V, VINAC = 1 V VPHBF PHB threshold falling, to single-phase operation To GDB output shutdown, VINAC = 1.5 V VPHBR PHB threshold rising, to two-phase operation To GDB output running, VINAC = 1.5 V TMIN Minimum switching period RTSET = 133 kΩ (4) 1.7 2.2 3.0 TSTART PWM restart time ZCDA = ZCDB = 2 V (5) 165 210 265 COMP = 0.25 V, VINAC = 0.1 V 1.2 2 2.8 12.6 20 29 0.7 0.8 0.9 0.9 1.0 1.1 µs/V µs V µs Thermal Shutdown TJ Thermal shutdown temperature Temperature rising (6) 160 TJ Thermal restart temperature Temperature falling (6) 140 (4) (5) (6) 8 °C Gate drive on-time is proportional to (VCOMP – 0.125 V). The on-time proportionality factor, KT, scales linearly with the value of RTSET and is different in two-phase and single-phase modes. The minimum switching period is proportional to RTSET. An output on-time is generated at both GDA and GDB if both ZCDA and ZCDB negative-going edges are not detected for the restart time. In single-phase mode, the restart time applies for the ZCDA input and the GDA output. Thermal shutdown occurs at temperatures higher than the normal operating range. Device performance above the normal operating temperature is not specified or assured. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com DEVICE INFORMATION UCC28063D SOIC 16-Pin (D) ZCDB 1 16 ZCDA VSENSE 2 15 VREF TSET 3 14 GDA PHB 4 13 PGND COMP 5 12 VCC AGND 6 11 GDB VINAC 7 10 CS HVSEN 8 9 PWMCNTL TERMINAL FUNCTIONS TERMINAL I/O DESCRIPTION NAME NO. AGND 6 - Analog Ground COMP 5 O Error Amplifier Output CS 10 I Current Sense Input GDA 14 O GDB 11 O HVSEN 8 I High Voltage Output Sense PHB 4 I Phase-B Enable/Disable PWMCNTL 9 O PWM-Control Output Channel A and Channel B Gate Drive Output TSET 3 I Timing Set VCC 12 - Bias Supply Input VINAC 7 I Input AC Voltage Sense VREF 15 O Voltage Reference Output VSENSE 2 I Output DC Voltage Sense ZCDA 16 I ZCDB 1 I Zero Current Detection Inputs Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 9 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Detailed Pin Description Analog Ground: Connect analog signal bypass capacitors, compensation components, and analog signal returns to this pin. Connect the analog and power grounds at a single point to isolate high-current noise signals of the power components from interference with the low-current analog circuits. Error Amplifier Output: The error amplifier is a transconductance amplifier, so this output is a high-impedance current source. Connect voltage-regulation loop-compensation components from this pin to AGND. The on-time seen at the gate-drive outputs is proportional to the voltage at this pin minus an offset of approximately 125 mV. During normal operation, the error amplifier maintains a transconductance of 55 μS for small-signal disturbances on VSENSE, and shifts to ~290 μS when VSENSE deviates more than +/-5% from VSENSEreg. During an AC-line Dropout condition, the error amplifier output is disabled and an internal 4-μA source discharges COMP for the duration of the Dropout condition. During a VSENSE-based OV event, an internal 2-kΩ resistor is applied from COMP to GND until the OV condition clears. During soft-start triggering events (UVLO, Disable, Brownout, HVSEN over-voltage, TSET-Fault, CS open-circuit, or Thermal Shutdown), the error-amp output is disabled and COMP is pulled low by an internal 2-kΩ resistor. The soft-start condition begins only after the triggering event clears and COMP has been discharged below 20 mV, ensuring that the circuit restarts with a low COMP voltage and a short on-time. (Do not connect COMP to a low-impedance source that would interfere with COMP falling below 20 mV.) During Soft-Start, the error amplifier high transconductance is enabled and COMP current is -125 μA as long as VSENSE < VREF/2. Once VSENSE exceeds VREF/2, the high gain is disabled and only the small-signal gain capability is available with a maximum COMP current of approximately -16 μA. Normal operation resumes once VSENSE > 0.983VREF (~5.9 V). Current Sense Input: Connect the current-sense resistor and the negative terminal of the diode bridge to this pin. Connect the return of the current sense resistor to the AGND pin with a separate trace. As input current increases, the voltage on CS will go more negative. This cycle-by-cycle over-current protection limits input current by turning off both gate driver outputs (GDx) when CS is more negative than the CS rising threshold (approximately -200 mV in two-phase operation and approximately -167 mV in single-phase and phase-fail condition). The gate drive outputs will remain low until CS falls to the CS falling threshold (approx. -15 mV). Current sense is blanked for approximately 100 ns following the rising and falling edge of either GDx output. This filters noise that may occur from gate-drive current or when inductor current switches from a power FET to a boost diode. In most cases, no additional current sense filtering is required. If external filtering is deemed necessary, or to prevent excessive negative voltage on the CS pin during AC-inrush conditions, a series resistor is recommended to connect the current sensing resistor to the CS pin. Due to the CS bias current, this external resistor should be less than 100 Ω to maintain accuracy. If the CS pin becomes open-circuited, the voltage on CS floats up to about +1.5 V. This condition is detected and treated as a soft-start-triggering fault condition (CS open-circuit). Channel A and Channel B Gate Drive Output: Connect these pins to the gate of the power FET for each phase through the shortest connection practicable. If it is necessary to use a trace longer than 0.5 inch (12.6 mm) for this connection, some ringing may occur due to trace series inductance. This ringing can be damped by adding a low-value resistor in series with GDA and GDB. High Voltage Output Sense: The UCC28063 incorporates FailSafe OVP so that any single failure does not allow the output to boost above safe levels. Output over-voltage is monitored by both VSENSE and HVSEN but their actions are different if either pin exceeds their respective over-voltage thresholds. Using two pins to monitor for over-voltage provides redundant protection and fault tolerance. When HVSEN exceeds its over-voltage threshold, it triggers a full soft-start of the controller. HVSEN can also be used to enable a downstream power converter when the voltage on HVSEN is within the operating region. When HVSEN is greater than 2.5 V, the PWMCNTL output may be driven Low (provided no other fault exists). When HVSEN falls below 2.5 V, the PWMCNTL output becomes high-impedance. Select the HVSEN divider ratio for the desired over-voltage and power-good thresholds. Select the HVSEN divider impedance for the desired power-good hysteresis based on the hysteresis current. During operation, HVSEN must never fall below 0.8 V. Dropping HVSEN below 0.8 V puts the UCC28063 into a special test mode, used only for factory testing. A bypass capacitor from HVSEN to AGND is recommended to filter noise and avoid false over-voltage shutdown. Phase-B Enable/Disable: When the voltage applied to this pin is below the Phase-B enable threshold, Phase B of the boost converter and the Phase Fail detector are disabled. The commanded on-time for Phase A is immediately doubled when Phase B is disabled, which helps keep COMP voltage constant during the phase-management transient. The PHB pin allows the user to add external phase-management control circuitry, if desired. To disable phase-management, connect the PHB pin to the VREF pin. 10 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com PWM-Control Output: This open-drain output goes low when HVSEN is within the HVSEN-good region (HVSEN > 2.5 V), there is no FailSafe OV, and there is no Phase-Fail condition when operating in two-phase mode (see PHB pin). Otherwise, PWMCNTL is high-impedance. Timing Set: PWM on-time programming input. Connect a resistor from TSET to AGND to set the on-time versus COMP voltage and the minimum switching period at the gate-drive outputs. Protection circuits prevent the controller from operating if the TSET input is in an open-circuit or short-circuit condition. As long as this pin is open-circuited, it triggers a full soft-start condition. If this pin becomes shorted to GND, its current is limited and also triggers a soft-start condition. Bias Supply Input: Connect this pin to a controlled bias supply of between 14 V and 21 V. Also connect a 0.1-μF or larger ceramic bypass capacitor from this pin to PGND with the shortest possible board trace. This bias supply powers all circuits within the device and must be capable of delivering the steady-state dc current plus the transient power-MOSFET gate-charging current. Input bias current is very low during undervoltage-lockout (UVLO) or stand-by conditions (VSENSE < 1.25 V). Input AC Voltage Sense: For normal operation, connect this pin to a voltage divider across the rectified input power mains. When the voltage on VINAC remains below the brownout threshold for longer than the brownout filter time, the device enters a brownout mode, both output drivers are disabled and a full soft-start is triggered. Select the input voltage divider ratio for the desired brownout threshold. Select the divider impedance for the desired brownout hysteresis based on the hysteresis current. A dropout condition is triggered when VINAC remains below the dropout threshold for longer than the dropout filter time. The error amplifier is disabled and an internal 4-μA current source discharges COMP for the duration of the dropout condition. The dropout condition is immediately cleared and normal operation resumes when VINAC exceeds the dropout-clear threshold. Voltage Reference Output: Connect a 0.1-μF or larger ceramic bypass capacitor from this pin to AGND. VREF turns off during UVLO and VSENSE-disable to save bias current and increase stand-by efficiency. This reference output can be used to bias other circuits requiring less than a few milliamperes of non-pulsing total supply current. Output DC Voltage Sense: Connect this pin to a voltage divider across the output of the power converter. In a closed-loop system, the voltage at VSENSE is regulated to the error amplifier reference voltage. Select the output voltage divider ratio for the desired output voltage. Connect the ground side of this divider to analog ground (AGND) through a separate short trace for best output regulation accuracy and noise immunity. Controller operation may be enabled when VSENSE voltage exceeds the 1.25-V enable threshold. VSENSE can be pulled low by an open-drain logic output, or >6-V logic output in series with a low-leakage diode, to disable the outputs and reduce VCC current. Two levels of output overvoltage are detected at this input. If VSENSE exceeds the first-level overvoltage protection threshold VLOW_OV, an internal 2-kΩ resistor is applied to COMP to quickly reduce gate-drive on-time. If VSENSE continues to rise past the second-level threshold VHIGH_OV, GDA and GDB are immediately latched off. This latch is cleared when VSENSE falls below the OV-clear threshold. If VSENSE becomes disconnected, open-loop protection provides an internal current source to pull VSENSE low, which disables the controller and triggers a soft-start condition. Zero Current Detection Inputs: These inputs are used to detect a negative-going edge when the boost inductor current in each respective phase goes to zero. The inputs are clamped between 0 V and 3 V. Connect each pin through a current limiting resistor to the zero-crossing detection (ZCD) winding of the corresponding boost inductor. The resistor value should be chosen to limit the clamping currents to less than ±3 mA. The inductor winding polarity must be arranged so that this ZCD voltage falls when the inductor current decays to zero. When the inductor current falls to zero, the ZCD input must drop below the falling threshold (approximately 1 V) to cause the gate drive output to rise. Subsequently, when the power-MOSFET turns off, the ZCD input must rise above the rising threshold (approximately 1.7 V) to arm the logic for another falling ZCD edge. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 11 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Functional Block Diagram Overcurrent + 100ns Blanking Open Detection CS_OPEN VINAC BROWNOUT HVSEN_OV UVLO EN OC TSET_FLT CS_OPEN TSD Brownout Detection 7 440ms Delay 50mV R Q STOP_GDA S Q STOP_GDB OC HIGH _OV PHASE_B_OFF 12 VCC UVLO 12.6V / 10.35V + BROWNOUT + 1.4V COMP_DSCHG 6.00V Reg. -0.200 V / -0.015V CS 10 DSCHG _RST 1-PHASE VGD Reg. -0.167 V / -0.015V 24V Thermal ShutDown 5ms Delay PHASE_B_OFF TSET_FLT Trigger + 100ns Blanking Crossover Notch Reduction Trigger DROPOUT DSCHG_RST + 20mV VCC + EA Gain Control for Soft-Start and Dropout EN 50mV + 1.25V ZCA LOW_OV 120mV 6.48V TON Modulation Phase B On-Time Control HIGH_OV 6.67V DIS_EA DIS_High_Gain ZCB PhaseFail VSENSE 2 VREF 272mV / 222 mV +g M 50μS / 250μS 100nA 1.0V / 0.8V 13.5V 11 GDB STOP_GDB 13 PGND HVSEN_OV + 8 HVSEN 9 PWMCNTL 4.87V / 4.67V + 2.5V 12μA + + PHASE_B_OFF 4.95V 12 PGND Interleave Control LOW_OV COMP_DSCHG 2k 4μA + 14 GDA ZCB 100ns Blanking TON Basis 1 Clamping ZCDB + TON Modulation STOP_GDA ZCA VINAC 1.7V / 1.0V VREF PWMB 1.7V / 1.0V 15 VREF UVLO EN 13.5V Phase Fail Detector and 12ms Filter ZCDA 16 Open/Short Detection 13.5V Phase A On-Time Control 1-PHASE 3 Clamping TSET TJ 160°C / 140 °C DROPOUT + TON Basis 0.70V / 0.35V + TSD PWMA Dropout Detection 2μA 6 5 4 AGND COMP PHB Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS At VCC = 16 V, AGND = PGND = 0 V, VINAC = 3 V, VSENSE = 6 V, HVSEN = 3 V, PHB = 5 V, RTSET = 133 kΩ; all voltages are with respect to GND, all outputs unloaded, TJ = TA = +25°C, and currents are positive into and negative out of the specified terminal, unless otherwise noted. BIAS SUPPLY CURRENT vs BIAS SUPPLY VOLTAGE BIAS SUPPLY CURRENT vs TEMPERATURE 10 10 Enabled IVCC − Bias Supply Current (mA) IVCC − Bias Supply Current (mA) Enabled 1 VCC Turn OFF VCC Turn ON 0.1 Disabled 0.01 0 2 4 6 8 10 12 14 16 VCC − Bias Supply Voltage (V) 18 1 0.1 Disabled 0.01 −40 20 −20 0 20 40 60 80 TJ − Temperature (°C) 100 G000 G001 Figure 1. Figure 2. REFERENCE VOLTAGE vs TEMPERATURE VSENSE INPUT BIAS CURRENT vs INPUT VOLTAGE 150 6.10 6.08 IVREF = 0 to −2 mA 125 IVSENSE − Input Bias Current (nA) 6.06 VREF Reference Voltage (V) 120 6.04 6.02 6.00 5.98 5.96 5.94 100 75 50 25 5.92 5.90 −40 −20 0 20 40 60 80 TJ − Temperature (°C) 100 120 0 0 1 2 3 4 VVSENSE − Input Voltage (V) 5 G002 Figure 3. 6 G003 Figure 4. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 13 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS (continued) ERROR AMPLIFIER OUTPUT CURRENT vs INPUT VOLTAGE ERROR AMPLIFIER TRANSCONDUCTANCE vs VSENSE 150 300 Soft−start Completed 250 LOW_OV Trigger Transconduction 54 µS 50 gM − Transconductance (µS) ICOMP − Output Current (µA) 100 LOW_OV Clear 0 −50 −100 200 150 100 50 −150 5.0 5.2 5.4 5.6 5.8 6.0 6.2 6.4 VVSENSE − Input Voltage (V) 6.6 6.8 0 5.0 7.0 5.2 5.4 5.6 5.8 6.0 6.2 6.4 VVSENSE − Input Voltage (V) 6.6 6.8 G004 7.0 G005 Figure 5. Figure 6. ERROR AMPLIFIER TRANSCONDUCTANCE vs TEMPERATURE ERROR AMPLIFIER OUTPUT CURRENT vs OUTPUT VOLTAGE 20 60 5.9 V < VVSENSE < 6.1 V 58 15 VVSENSE = 6.2 V 10 ICOMP − Output Current (µA) gM − Transconductance (µS) 56 54 52 50 48 46 VVSENSE = 6.1 V 5 0 VVSENSE = 5.9 V −5 VVSENSE = 5.8 V −10 44 −15 42 40 −40 −20 0 20 40 60 80 TJ − Temperature (°C) 100 120 −20 0 1 2 3 VCOMP − Output Voltage (V) G006 Figure 7. 14 4 5 G007 Figure 8. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS (continued) ON-TIME FACTOR vs TIME SETTING RESISTOR 10 9 9 8 RTSET = 266 kW 8 KTL KTL - On-Time Factor - ms/V KT - On-Time Factor - ms/V ON-TIME FACTOR PHASE A AND B vs TEMPERATURE 7 6 5 4 3 2 7 6 5 RTSET = 133 kW 4 3 2 RTSET = 66 kW 1 1 0 0 60 80 100 120 140 160 180 200 220 240 260 280 -40 0 -20 RTSET - Time Setting Resistor - kW ADDITIONAL ON TIME vs VINAC RTSET = 266 kW 102 100 98 96 KT0 = 92 120 RTSET = 133 kW RTSET = 66 kW 94 100 RTSET = 266 kW GDB Additional On-Time - ms 104 KT/KT0 - % 80 ON-TIME FACTOR vs PHASE ERROR RTSET = 133 kW 106 60 Figure 10. 100 108 40 Figure 9. 110 GDA 20 TJ - Temperature - °C RTSET = 66 kW 10 1 2(KTA ´ KTB) KTA + KTB 0.1 90 150 160 170 180 190 200 210 0 Phase Shift of GDA Relative to GDB - Degrees Figure 11. 0.5 1.0 1.5 2.0 2.5 3.0 VVINAC - Input AC Voltage Sense - V Figure 12. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 15 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS (continued) GATE DRIVE RISING vs TIME GATE DRIVE FALLING vs TIME 2.0 GD Source Current: VCC = 20 V VCC = 12 V 6 1.5 1.0 4 0.5 2 0 0 -2 0 50 100 150 200 250 300 10 2.0 GD Sink Current: VCC = 20 V VCC = 12 V 8 6 1.0 4 0.5 -0.5 0 -1.0 -2 0 GD Voltage: VCC = 20 V VCC = 12 V -0.5 -1.0 0 20 40 Time - ns 60 80 100 120 140 Time - ns Figure 13. Figure 14. GATE DRIVE RISING AND DELAY FROM ZCD INPUT vs TIME GATE DRIVE FALLING AND DELAY FROM CS INPUT vs TIME 7 500 14 14 CLOAD = 4.7 nF CLOAD = 4.7 nF GD Output: TJ = -40°C TJ = +25°C TJ = +125°C 4 3 400 12 10 300 10 200 8 8 6 2 4 1 2 0 0 Current Sense Input - mV 5 12 Gate Drive Output - V 6 ZCD Input - V 1.5 2 350 2.5 100 CS Input Voltage 6 GD Output: TJ = -40°C TJ = +25°C TJ = +125°C 0 -100 4 Gate Drive Output - V 8 GD Voltage: VCC = 20 V VCC = 12 V Gate Drive Output - V 10 3.0 VCC = 20 V and 12 V CLOAD = 4.7 nF 12 2.5 Gate Drive Source Current - A 12 Gate Drive Output - V 14 3.0 VCC = 20 V and 12 V CLOAD = 4.7 nF Gate Drive Source Current - A 14 2 0 -200 ZCD Input Voltage -1 -2 -25 0 50 100 150 200 250 300 -300 -2 -25 0 Time - ns Figure 15. 16 50 100 150 200 250 300 Time - ns Figure 16. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS (continued) GATE DRIVE OUTPUT HIGH vs VCC GATE DRIVE HIGH VOLTAGE vs TEMPERATURE 15 15 RLOAD = 2.7 kW 14 TJ = -40°C 13 13 TJ = +125°C 12 Gate Drive Voltage - V Gate Drive Voltage - V 14 TJ = +25°C 11 10 Clamped VCC ³ 15 V 12 11 Unclamped VCC = 12 V 10 9 8 7 9 6 RLOAD = 2 kW 8 5 10 11 12 13 14 15 16 17 18 19 20 -40 VVCC - Bias Supply Voltage - V -20 0 20 40 60 60 100 120 TJ - Temperature - °C Figure 17. Figure 18. GATE DRIVE LOW VOLTAGE vs TEMPERATURE GATE DRIVE LOW VOLTAGE IN UVLO vs BIAS SUPPLY VOLTAGE 2.5 320 Load = 100 mA Load = 10 mA 280 Load = 5 mA 240 VOL − Gate Drive Voltage (V) VOL − Gate Drive Voltage (mV) 2.0 200 160 120 1.5 1.0 Load = 2.5 mA Load = 1.0 mA 80 0.5 40 0 −40 −20 0 20 40 60 80 TJ − Temperature (°C) 100 120 0.0 0 1 2 3 VCC − Bias Supply Voltage (V) G008 Figure 19. 4 G009 Figure 20. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 17 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com TYPICAL CHARACTERISTICS (continued) VARIOUS DELAY TIMES vs TEMPERATURE ZERO CURRENT DETECT CLAMP VOLTAGE vs INPUT CURRENT 1000 3.5 3.0 Brownout Filter Delay 2.5 VZCD − Clamp Voltage (V) Delay Time (ms) 100 Phase−Fail Filter Delay 10 Dropout Filter Delay 1 1.5 1.0 0.5 Restart Time Delay 0.1 −40 2.0 −20 0 20 40 60 80 TJ − Temperature (°C) 0.0 100 −0.5 120 −5 −4 −3 −2 −1 0 1 2 IZCD − Input Current (mA) 3 4 G010 5 G011 Figure 21. Figure 22. CURRENT SENSE INPUT BIAS CURRENT vs TEMPERATURE CURRENT SENSE INPUT BIAS CURRENT vs INPUT VOLTAGE 0 −150 VCS = −195 mV −155 ICS − Input Current (µA) ICS − Input Bias Current (µA) −50 −160 −165 −170 −175 −100 −150 Single−Phase Mode Dual−Phase Mode −180 −200 −185 −190 −40 −20 0 20 40 60 80 TJ − Temperature (°C) 100 120 −250 −300 −250 −200 −150 −100 VCS − Input Voltage (mV) G012 Figure 23. 18 −50 0 G013 Figure 24. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com APPLICATION INFORMATION Principles of Operation The UCC28063 contains the control circuits for two parallel-connected boost pulse-width modulated (PWM) power converters. The boost PWM power converters ramp current in the boost inductors for a time period proportional to the voltage on the error amplifier output. Each power converter then turns off the power MOSFET until current in the boost inductor decays to zero, as sensed on the zero current detection inputs (ZCDA and ZCDB). Once the inductor is demagnetized, the power converter starts another cycle. This on/off cycling produces a triangle wave of current, with peak current set by the on-time and instantaneous power mains input voltage, VIN(t), as shown in Equation 1. V (t) ´ TON IPEAK (t) = IN L (1) The average line current is exactly equal to half of the peak line current, as shown in Equation 2. V (t) ´ TON IAVG (t) = IN 2´L (2) With TON and L being essentially constant during an AC-line period, the resulting triangular current waveform during each switching cycle will have an average value proportional to the instantaneous value of the rectified AC-line voltage. This architecture results in a resistive input impedance characteristic at the line frequency and a near-unity power factor. Natural Interleaving Under normal operating conditions, the UCC28063 regulates the relative phasing of the channel A and channel B inductor currents to be very close to 180°. This greatly reduces the switching-frequency ripple currents seen at the line-filter and output capacitors, compared to the ripple current of each individual converter. This design allows a reduction in the size and cost of input and output filtering. The phase-control function differentially modulates the on-times of the A and B channels based on their phase and frequency relationship. The Natural Interleaving method allows the converter to achieve 180° phase-shift and transition-mode operation for both phases without tight requirements on boost inductor tolerance. Ideally, the best current-sharing is achieved when both inductors are exactly the same value. Typically the inductances are not the same, so the current-sharing of the A and B channels is proportional to the inductor tolerance. Also, switching delays and resonances of each channel typically differ slightly, and the controller allows some necessary phase-error deviation from 180° to maintain equal switching frequencies. Optimal phase balance occurs if the individual power stages and the on-times are well matched. Mismatches in inductor values do not affect the phase relationship. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 19 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com On-Time Control, Maximum Frequency Limiting, and Restart Timer Gate-drive on-time varies proportionately with the error-amplifier output voltage by a factor called KT (in units of μs/V), as shown in Equation 3. TON = K T (VCOMP - 125mV ) (3) Where: • VCOMP is the output voltage of the error amplifier and 125 mV is a modulator offset voltage. The maximum output of the error amplifier is limited to 4.95 V. This value, minus the 125-mV modulator offset, limits maximum on-time as determined by Equation 4. TON(max) = K T ´ 4.825 V (4) This on-time limit sets the maximum power that can be delivered by the converter at a given input voltage. At lower power, one boost channel (phase) may be turned off to achieve efficiency benefits (see Phase Management section, below). To provide a smooth transition between two-phase and single-phase operation, KT increases by a factor of two in single-phase mode: K TS = 2 ´ K T ; active during single-phase operation (5) The maximum switching frequency of each phase is limited by minimum-period timers. If inductor current decays to zero before the minimum-period timer elapses, the next turn-on will be delayed, resulting in discontinuous phase current. A restart timer ensures starting under all circumstances by restarting both phases if the ZCD input of either phase has not transitioned from high-to-low within approximately 200 µs. To prevent the circuit from operating in continuous conduction mode (CCM), the restart timer does not trigger turn-on until both phase-currents return to zero. The on-time factors (KT, KTS) and the minimum switching period, T(MIN), are proportional to the time-setting resistor RTSET (the resistor from the TSET pin to ground), and these factors can be calculated by Equation 5, Equation 6 and Equation 7: R ms K T = TSET ´ 4.0 133kW volt (6) RTSET T(MIN) = ´ 2.2 ms ; Minimum Switching Period 133kW (7) The proper value of RTSET will result in the clamped maximum on-time, TON(max), required by the converter operating at the minimum input line voltage and maximum load. 20 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Distortion Reduction Due to the parasitic resonance between the drain-source capacitance of the switching MOSFET and the boost inductor, conventional transition-mode PFC circuits may not be able to absorb power from the input line when the input voltage is near zero. This limitation increases total harmonic distortion as a result of ac-line current waveform distortion in the form of flat spots. To help reduce line-current distortion, the UCC28063 increases switching MOSFET on-time when the input voltage is near 0 V to improve the power absorption capability and compensate for this effect. Figure 12 in the Typical Characteristics section shows the increase in on-time with respect to VINAC voltage. Excessive filtering of the VINAC signal will nullify this function. Zero-Current Detection and Valley Switching In transition-mode PFC circuits, the MOSFET turns on when the boost inductor current reaches zero. Because of the resonance between the boost inductor and the parasitic capacitance at the MOSFET drain node, part of the energy stored in the MOSFET junction capacitor can be recovered, reducing switching losses. Furthermore, when the rectified input voltage is less than half of the output voltage, all the energy stored in the MOSFET junction capacitor can be recovered and zero-voltage switching (ZVS) can be realized. By adding an appropriate delay, the MOSFET can be turned on at the valley of its resonating drain voltage (valley-switching). In this way, the energy recovery can be maximized and switching loss is minimized. The optimal time delay is generally derived empirically, but a good starting point is a value equal to 25% of the resonant period of the drain circuit. The delay can be realized by a simple RC filter, as shown in Figure 25, but the delay time increases slightly as the input voltage nears the output voltage. Because the ZCD pin is internally clamped, a more accurate delay can also be realized by using the circuit shown in Figure 26. ZCD R CT C Figure 25. Simple RC Delay Circuit ZCD R1 CT C R2 Figure 26. More Accurate Time Delay Circuit Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 21 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Phase Management and Light-Load Operation Under light-load conditions, switching losses may dominate over conduction losses and efficiency may be improved if one phase (channel) is turned off. At a certain power level, the reduction of switching losses is greater than the increase in conduction losses. Turning off one phase at light load is especially valuable for meeting light-load efficiency standards. This is one of the major benefits of interleaved PFC and it is especially valuable for meeting 80+ design requirements. The PHB input can be used to force the UCC28063 to operate in single-phase mode. When PHB is driven below 0.8 V, channel B will stop switching and channel A on-time will automatically double to compensate. The device will resume dual-phase mode when PHB is raised above 1.0 V. For customized phase management, an external circuit can detect the conditions for switching to single-phase operation and drive PHB accordingly. To operate continuously in two-phase mode (normal mode) when phase management is not desired, simply connect PHB to VREF. As load current decreases, the error amplifier commands less ac-line input current by lowering COMP voltage. In applications where the ac-line is limited to the low-voltage range only, it may be advantageous to connect PHB directly to COMP to allow automatic selection of single-phase operation without additional external circuitry. External Disable The UCC28063 can be externally disabled by purposefully grounding the VSENSE pin with an open-drain or open-collector driver. When disabled, the device supply current drops significantly and COMP is actively pulled low. This disable method forces the device into standby mode and minimizes its power consumption. This is particularly useful when standby power is a key design aspect. When VSENSE is released, the device enters soft-start mode. 22 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Improved Error Amplifier The voltage-error amplifier is a transconductance amplifier. Voltage-loop compensation is connected from the error amplifier output, COMP, to analog ground, AGND. The recommended Type-II compensation network is shown in Figure 27. For loop-stability purposes, the compensation network values are calculated based on small-signal perturbations of the output voltage using the nominal transconductance (gain) of 55 μS. VREF + COMP gM VSENSE CZ CP 4.95V RZ Figure 27. Transconductance Error Amplifier with Typical Compensation Network To improve the transient response to large perturbations, the error amplifier gain increases by a factor of ~5X when the error amp input deviates more than ±5% from the nominal regulation voltage, VSENSEreg. This increase allows faster charging and discharging of the compensation components following sudden load-current increases or decreases (also refer to Figure 5 in the Typical Characteristics). IEA VSENSE VREF Figure 28. Basic Voltage-Error Amplifier Transconductance Curve NOTE Basic voltage-error amplifier transconductance curve showing large-signal gain sections, with maximum current limitations. small-signal and Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 23 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Soft Start Soft-start is a process for boosting the output voltage of the PFC converter from the peak of the ac-line input voltage to the desired regulation voltage under controlled conditions. Instead of a dedicated soft-start pin, the UCC28063 uses the voltage error amplifier as a controlled current source to increase the PWM duty-cycle by way of increasing the COMP voltage. To avoid excessive start-up time-delay when the ac-line voltage is low, a higher current is applied until VSENSE exceeds 3 V at which point the current is reduced to minimize the tendency for excess COMP voltage at no-load start-up. The PWM gradually ramps from zero on-time to normal on-time as the compensation capacitor from COMP to AGND charges from zero to near its final value. This process implements a soft-start, with timing set by the output current of the error amplifier and the value of the compensation capacitors. In the event of a HVSEN FailSafe OVP, brownout, external-disable, UVLO fault, or other protection faults, COMP is actively discharged and the UCC28063 will soft-start after the triggering event is cleared. Even if a fault event happens very briefly, the fault is latched into the soft-start state and soft-start is delayed until COMP is fully discharged to 20 mV and the fault is cleared. See Figure 29 for details on the COMP current. See Figure 30 which illustrates an example of typical system behavior during soft-start. ICOMP OVP1 trigger. 2k pull -down applied to COMP . +63μA +15μA OVP1 reset. 2k pull -down removed from COMP . 1.0 2.0 3.0 4.0 5.0 -15μA 6.0 7.0 VSENSE COMP current limit during Soft -Start only (high-gain disabled ) -111 μA Figure 29. Expanded COMP Output Current Curve NOTE Expanded COMP output current curve including voltage-error amplifier transconductance and modifications applicable to soft-start and over-voltage conditions. 24 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com OVERSHOOT V VSENSEREG VENDofSS VSENSE VCOMPCLMP COMP VSSTHR t I AC-LINE ICOMP ISS,SLOW ISS,FAST HIGH GAIN ENABLED SOFTSTART Figure 30. Soft-Start Timing with Illustrative System Behavior Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 25 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Brownout Protection As the power line RMS voltage decreases, RMS input current must increase to maintain a constant output voltage for a specific load. Brownout protection helps prevent excess system thermal stress (due to the higher RMS input current) from exceeding a safe operating level. Power-line voltage is sensed at VINAC. When the VINAC fails to exceed the brownout threshold for the brownout filter time, a brownout condition is detected and both gate drive outputs are turned off. During brownout, COMP is actively pulled low and a soft-start condition is initiated. Hysteresis is built into the brownout detection circuit to avoid chatter around the threshold. When VINAC rises above the brownout threshold, the power stage soft-starts as COMP rises with controlled current. The brownout detection threshold and its hysteresis are set by the voltage-divider ratio and resistor values. Brownout protection is based on VINAC peak voltage; the threshold and hysteresis are also based on the line peak voltage. Major hysteresis is provided by a 2-μA current-sink (IBOHYS) enabled whenever VINAC falls below the brownout detection threshold. Minor hysteresis is also present in the form of a 50-mV offset (VBOHYS) between the VINAC detection and clear thresholds. The peak VINAC voltage can be easily translated into an RMS value. Example resistor values for the voltage divider are 8.61 MΩ ±1% from the rectified input voltage to VINAC and 133 kΩ ±1% from VINAC to ground. These resistors set the typical thresholds for RMS line voltages, as shown in Table 1. Table 1. Brownout Thresholds (for conditions stated in the text) THRESHOLD AC-LINE VOLTAGE (RMS) Falling 66 V Rising 78 V Equation 8 and Equation 9 can be used to calculate the VINAC divider-resistor values based on desired brownout detection and brownout clear voltage levels. VAC_OK is the desired RMS turn-on voltage, VAC_BO is the desired RMS turn-off brownout voltage, and VLOSS is total series voltage drop due to wiring, EMI-filter, and bridge-rectifier impedances at VAC_BO. VBODET, VBOHYS and IBOHYS are found in the data-tables of this datasheet. 2(VAC _ OK - VAC _ BO ) - VBOHYS ö÷ æ VBOHYS ö ç 1+ ÷ ç ÷è IBOHYS VBODET ø æ RA = ç è RB = ø (8) RA æ 2VAC _ BO - VLOSS ö ç - 1÷ ç ÷ VBODET è ø (9) Once standard values for the VINAC divider-resistors RA and RB are selected, the actual turn-on and brownout threshold RMS voltages for the ac-line can be back-calculated with Equation 10 and Equation 11: æ R öV V VAC _ BO = ç 1 + A ÷ BODET + LOSS R 2 2 B ø è (10) VAC _ OK = VAC _ BO + R AIBOHYS æ 2 ç 1+ ç è VBOHYS ö ÷ VBODET ÷ø + VBOHYS 2 (11) An example of the timing for the brownout function is illustrated in Figure 31. For a quick estimation of the turn-on and brownout voltages, simplify the foregoing equations by setting the VLOSS and VBOHYS terms to zero. 26 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Dropout Detection It is often the case that the ac-line voltage momentarily drops to zero or nearly zero, due to transient abnormal events affecting the local ac power distribution network. Referred to as ac-line dropouts (or sometimes as line-dips) the duration of such events usually extends to only 1 or 2 line cycles. During a dropout, the down-stream power conversion stages depend on sufficient energy storage in the PFC output capacitance, which is sized to provide the ride-through energy for a specified hold-up time. Typically while the PFC output voltage is falling, the voltage-loop error amplifier output rises in an attempt to maintain regulation. As a consequence, excess duty-cycle is commanded when the ac-line voltage returns and high peak current surges may saturate the boost inductors with possible overstress and audible noise. The UCC28063 incorporates a dropout detection feature which suspends the action of the error amplifier for the duration of the dropout. If the VINAC voltage falls below 0.35 V for longer than 5 ms, a dropout condition is detected and the error amplifier output is turned off. In addition, a 4-μA pull-down current is applied to COMP to gently discharge the compensation network capacitors. In this way, when the ac-line voltage returns, the COMP voltage (and corresponding duty-cycle setting) remains very near or even slightly below the level it was before the dropout occurred. Current surges due to excess duty-cycle, and their undesired attendant effects, are avoided. The dropout condition is cancelled and the error amplifier resumes normal operation when VINAC rises above 0.71 V. Based on the VINAC divider-resistor values calculated for brownout in the previous section, the input RMS voltage thresholds for dropout detection VAC_DO and dropout clearing VDO_CLR can be determined using Equation 12 and Equation 13, below. æR ö VDODET ç A + 1÷ + VLOSS R è B ø VAC _ DO = 2 (12) æR ö VDOCLR ç A + 1÷ + VLOSS è RB ø VDO _ CLR = 2 (13) Avoid excessive filtering of the VINAC signal, or dropout detection may be delayed or defeated. An RC time-constant of ≤ 100-μs should provide good performance. An example of the timing for the dropout function is illustrated in Figure 32. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 27 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com VSENSE COMP IBOHYS ON VINAC VBOCLR VBODET 0V t BROWNOUT DETECT BROWNOUT t BODLY Figure 31. AC-Line Brownout Timing with Illustrative System Behavior VSENSE VINAC COMP VDOCLR VDODET 0V t DROPOUT tDODLY Figure 32. AC-Line Dropout Timing with Illustrative System Behavior 28 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com VREF VREF is an output which supplies a well-regulated reference voltage to circuits within the device as well as serving as a limited source for external circuits. This output must be bypassed to GND with a low-impedance 0.1-μF or larger capacitor placed as close to the VREF and GND pins as possible. Current draw by external circuits should not exceed a few milli-amperes and should not be pulsing. The VREF output is disabled under the following conditions: when VCC is in UVLO, or when VSENSE is below the Enable threshold. This output can only source current and is unable to accept current into the pin. VCC VCC is usually connected to a bias supply of between 13 V and 21 V. To minimize switching ripple voltage on VCC, it should be by-passed with a low-impedance capacitor as close to the VCC and GND pins as possible. The capacitance should be sized to adequately decouple the peak currents due to gate-drive switching at the highest operating frequency. When powered from a poorly-regulated low-impedance supply, an external zener diode is recommended to prevent excessive current into VCC. The undervoltage-lockout (UVLO) condition is when VCC voltage has not yet reached the turn-on threshold or has fallen below the turn-off threshold, having already been turned on. While in UVLO, the VREF output and most circuits within the device are disabled and VCC current falls significantly below the normal operating level. The same situation applies when VSENSE is below its Enable threshold. This helps minimize power loss during pre-powerup and standby conditions. Control of Downstream Converter In the UCC28063, the PWMCNTL pin can be used to coordinate the PFC stage with a downstream converter. Through the HVSEN pin, the PFC output voltage is monitored. A 12-μA current source (IHV_HYS) is enabled as long as the output voltage remains below a programmed threshold. When the output voltage exceeds that threshold, PWMCNTL pin is pulled to ground internally and can be used to enable a downstream converter. At the same time the current source is disabled, providing hysteresis for a lower threshold at which the downstream converter should be turned off. The enable/disable hysteresis is adjusted through the HVSEN voltage-divider ratio and resistor values. The HVSEN pin is also used for the FailSafe over-voltage protection (OVP). When designing the voltage divider, make sure this FailSafe OVP level is set above normal VSENSE OVP levels. Because there are two thresholds associated with the HVSEN input detected through a single resistor divider, the PWMCNTL turn-off voltage, VPWM-OFF, is linked to the FailSafe OVP voltage, VFLSF_OV, as shown by Equation 14: VPWM-OFF VFLSF _ OV = 2.5 V 4.87 V (14) Choosing either one first arbitrarily determines the other, so a trade-off may be necessary. The PWMCNTL turn-on voltage, VPWM-ON, is programmed by choosing the upper divider resistor value in consideration with the HVSEN hysteresis current, as shown in Equation 15 and Equation 16. The lower divider resistor is then calculated as shown in Equation 17. VPWM-ON = VPWM-OFF + IHV _ HYSRHV _ UPPER (15) V - VPWM-OFF RHV _ UPPER = PWM-ON IHV _ HYS RHV _ LOWER = (16) RHV _ UPPER æ VPWM-OFF ö - 1÷ ç è 2.5 V ø (17) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 29 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com SYSTEM LEVEL PROTECTIONS FailSafe OVP - Output Over-Voltage Protection FailSafe OVP prevents any single failure from allowing the output to boost above safe levels. Redundant paths for output voltage sensing provide additional protection against output over-voltage. Over-voltage protection is implemented through two independent paths: VSENSE and HVSEN. The converter shuts down if either input senses a severe over-voltage condition. The output voltage can still remain below a safe limit if either sense path fails. The device is re-enabled when both sense inputs fall back into their normal ranges. At that time, the gate drive outputs will resume switching under PWM control. A low-level over-voltage on VSENSE does not trigger soft-start, but the COMP pin is discharged by an internal 2-kΩ resistance until the output voltage falls below the 2% hysteresis OV-clear threshold. A higher-level over-voltage on VSENSE additionally shuts off the gate-drive outputs until the OV clears, but still does not trigger a soft-start. However, an overvoltage detected on HVSEN does trigger a full soft-start and the COMP pin is fully discharged to 20 mV before the soft-start can begin. Over-Current Protection Under certain conditions (such as inrush, brownout-recovery, and output over-load) the PFC power stage sees large currents. It is critical that the power devices be protected from switching during these conditions. The conventional current-sensing method uses a shunt resistor in series with each MOSFET source leg to sense the converter currents, resulting in multiple ground points and high power dissipation. Furthermore, since no current information is available when the MOSFETs are off, the source-resistor current-sensing method results in repeated turn-on of the MOSFETs during over-current (OC) conditions. Consequently, the converter may temporarily operate in continuous conduction mode (CCM) and may experience failures induced by excessive reverse-recovery currents in the boost diodes or other abnormal stresses. The UCC28063 uses a single resistor to continuously sense the combined total inductor (input) current. This way, turn-on of the MOSFETs is completely avoided when the inductor currents are excessive. The gate drive to the MOSFETs is inhibited until total inductor current drops to near zero, precluding reverse-recovery-induced failures (these failures are most likely to occur when the ac-line recovers from a brownout condition). The nominal OC threshold voltage during two-phase operation is -200 mV, which helps minimize losses. This threshold is automatically reduced to -166 mV during single-phase operation, either by detection of a phase failure or because PHB is driven below 0.8 V. Note that the single-phase threshold is not simply 1/2 of the dual-phase threshold, because the ratio of the single-phase peak current to the interleaved peak current is higher than 1/2. An OC condition immediately turns off both gate-drive outputs, but does not trigger a soft-start and does not modify the error amplifier operation. The over-current condition is cleared when the total inductor current-sense voltage falls below the OC-clear threshold (-15 mV). Following an over-current condition, both MOSFETs are turned on simultaneously once the input current drops to near zero. Because the two phase currents are temporarily operating in-phase, the current-sense resistance should be chosen so that OC protection is not triggered with twice the maximum current peak value of either phase in order to allow quick return to normal operation after an over-current event. Automatic phase-shift control will re-establish interleaving within a few switching cycles. 30 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Open-Loop Protection If the feedback loop is disconnected from the device, a 100-nA current source internal to the UCC28063 pulls the VSENSE pin voltage towards ground. When VSENSE falls below 1.20 V, the device becomes disabled. When disabled, the bias supply current decreases, both gate-drive outputs and COMP are actively pulled low, and a soft-start condition is initiated. The device is re-enabled when VSENSE rises above 1.25 V. At that time, the gate drive outputs will begin switching under soft-start PWM control. If the feedback loop is disconnected from ground, the VSENSE voltage will be pulled high. When VSENSE rises above the 2nd-level over-voltage protection threshold, both gate drive outputs are shut off and COMP is actively pulled low. The device is re-enabled when VSENSE falls below the OV-clear threshold. The VSENSE input can tolerate a limited amount of current into the device under abnormally high input voltage conditions. Refer to the Absolute Maximum Ratings table near the beginning of this datasheet for details. VCC Under-Voltage Lock-Out (UVLO) Protection VCC must rise above the turn-on threshold for the PWM to begin functioning. If VCC drops below the UVLO threshold during operation, both gate-drive outputs are actively pulled low, COMP is actively pulled low, and a soft-start condition is triggered. VCC must again rise above the turn-on threshold for the PWM function to restart in soft-start mode. Phase-Fail Protection The UCC28063 detects failure of either of the phases by monitoring the sequence of ZCD pulses. During normal two-phase operation, if one ZCD input remains idle for longer than approximately 12 ms while the other ZCD input switches normally, the over-current threshold is reduced and PWMCNTL goes to a high-impedance state, indicating that the PFC power stage is not operating correctly. During normal single-phase operation (PHB < 0.8 V), phase failure is not monitored. Also on the UCC28063, phase failure is not monitored when COMP is below approximately 222 mV. CS-Open, TSET-Open & -Short Protection In the event that the CS input becomes open-circuited, the UCC28063 detects this condition and will shutdown the outputs and trigger a full-soft-start condition. In the event that the TSET input becomes either open-circuited or short-circuited to GND, the UCC28063 detects these conditions and will shutdown the outputs and trigger a full-soft-start condition. Normal operation will resume (with a soft-start) when the fault clears. Thermal Shutdown Protection Overloading of the gate-drive outputs and/or VREF can dissipate excess power within the device which may raise the internal temperature of the circuits beyond a safe level. Even normal power dissipation can generate excess heat if the thermal impedance is too high or the ambient temperature is too high. When the UCC28063 detects an internal over-temperature condition it will shutdown the outputs and trigger a full soft-start condition. When the internal device junction temperature has cooled below the thermal hysteresis temperature, operation will resume under soft-start control. AC-Line Brownout and Dropout Protections See specific discussions for each topic in previous sections (above) of this datasheet. Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 31 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Fault Logic Diagram Figure 33 depicts the fault-handling logic involving VSENSE, COMP, and several internal states. PHASE_B_OFF STOP GDB OC STOP GDA HIGH _OV BROWNOUT HVSEN_OV UVLO EN TSET_FLT CS_OPEN TSD HIGH_OV Latch S Q 6.67V COMP Discharge Latch S Q + R R Q Q LOW _OV Latch S Q 6.48V + + 20mV 6.36V R + Q OV-Clear COMP 4μA 2kΩ 1.25V EN + LOW_OV DIS _EA DROPOUT Gain -Disable Latch S Q VCC DIS _High_Gain + R 5.9V VSENSE Q + 3.0V Figure 33. Fault Logic with VSENSE Detections and Error Amplifier Control 32 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com DESIGN EXAMPLE An example of the UCC28063 PFC controller in a two-phase interleaved, transition-mode PFC pre-regulator is shown in Figure 34. Bridge + D3 CIN – RS 12V CA R 100 F1 RZA 2.2uF CF1 1 nF RP 50 k VCC RG1 5 RZB UCC28063 VREF CB 2.2uF Q1 GDA VINAC RB VOUT ZCDA PWMCNTL PWMCNTL CF2 D1 22pF CS RA L1 20 k CF4 RLOAD 20 k CF5 D2 ZCDB PHB COMP COUT L2 RG2 22pF Q2 GDB 5 RC RE RD RF HVSEN RZ TSET VSENSE CP RT CF3 CZ AGND PGND Figure 34. Typical Interleaved Transition-Mode PFC Pre-Regulator Design Goals The specifications for this design were chosen based on the power requirements of a typical 300-W LCD TV. These specifications are shown in Table 2. Table 2. Design Specifications PARAMETER MIN TYP VIN RMS input voltage VOUT Output voltage fLINE AC-line frequency PF Power factor at maximum load 0.90 η Full-load efficiency 92% fMIN Minimum switching frequency MAX 85 (VIN_MIN) UNIT 265 (VIN_MAX) VRMS 390 47 POUT V 63 Hz 300 W 45 kHz Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 33 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Recommended PCB Device Layout CF4 Interleaved transition-mode PFC system architecture dramatically reduces input and output ripple current, allowing the circuit to use smaller and less expensive filters. To maximize the benefits of interleaving, the input and output filter capacitors should be located after the two phase currents are combined together. Similar to other power management devices, when laying out the printed circuit board (PCB) it is important to use star grounding techniques and keep filter capacitors as close to device ground as possible. To minimize the interference caused by capacitive coupling from the boost inductor, the device should be located at least 1 in (25.4 mm) away from the boost inductor. It is also recommended that the device not be placed underneath magnetic elements. Because of the precise timing requirement, timing-setting resistor RT should be placed as close as possible to the TSET pin and returned to the analog ground. See Figure 35 for a recommended component placement and layout. Figure 35. Recommended PCB Layout NOTE PHB and VREF pins are connected by a jumper on the back of the board. 34 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Inductor Selection The boost inductor is selected based on the inductor ripple current requirements at the peak of low line. Selecting the inductor requires calculating the boost converter duty cycle at the peak of low line (DPEAK_LOW_LINE), as shown in Equation 18. DPEAK _ LOW _ LINE = VOUT - VIN_MIN 2 VOUT = 390 V - 85 V 2 » 0.69 390 V (18) The minimum switching frequency of the converter (fMIN) under low line conditions occurs at the peak of low line and is set between 25 kHz and 50 kHz to avoid audible noise. For this design example, fMIN is set to 45 kHz. For a 2-phase interleaved design, L1 and L2 are determined as shown in Equation 19. L1 = L2 = h ´ VIN _ MIN2 ´ DPEAK _ LOW _ LINE POUT ´ fMIN = 0.92(85 V)2 0.69 » 340 mH 300 W ´ 45kHz (19) The inductor for this design would have a peak current (ILPEAK) of 5.4 A, as shown in Equation 20, and an RMS current (ILRMS) of 2.2 A, as shown in Equation 21. ILPEAK = ILRMS = POUT 2 300 W 2 = » 5.4 Apk VIN _ MIN ´ h 85 V ´ 0.92 ILPEAK 6 = 5.4 A 6 (20) » 2.2 Arms (21) This converter uses constant on time (TON) and zero-current detection (ZCD) to set up the converter timing. Auxiliary windings on L1 and L2 detect when the inductor currents are zero. Selecting the turns ratio using Equation 22 ensures that there will be at least 2 V at the peak of high line to reset the ZCD comparator after every switching cycle. The turns-ratio of each auxiliary winding is: NP VOUT - VIN_MAX 2 390 V - 265 V 2 = = »8 Ns 2V 2V (22) ZCD Resistor Selection (RZA, RZB) The minimum value of the ZCD resistors is selected based on the internal clamps maximum current ratings of 3 mA, as shown in Equation 23. V N 390 V R ZA = R ZB ³ OUT S = » 16.3kW NP ´ 3mA 8 ´ 3mA (23) In this design the ZCD resistors are set to 20 kΩ, as shown in Equation 24. R ZA = R ZB = 20kW (24) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 35 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com HVSENSE The HVSENSE pin programs the PWMCNTL output of the UCC28063. The PWMCNTL open-drain output can be used to disable a downstream converter while the PFC output capacitor is charging. PWMCNTL starts high impedance and pulls to ground when HVSEN increases above 2.5 V. Setting the point where PWMCNTL becomes active requires a voltage divider from the boost voltage to the HVSEN pin to ground. Equation 25 to Equation 30 show how to set the PWMCNTL pin to activate when the output voltage is within 90% of its nominal value. VOUT _ OK = VOUT ´ 0.90 » 351 V (25) Resistor RE sets up the high side of the voltage divider and programs the hysteresis of the PWMCNTL signal. For this example, RE was selected to provide 99 V of hysteresis, as shown in Equation 26. Three resistors in series were used to meet voltage requirements. Hysteresis 99 V RE = = = 8.25MW » 3 ´ 2.74MW 12 mA 12 mA (26) Resistor RF is used to program the PWMCNTL active threshold, as shown in Equation 27. 2.5 V 2.5 V RF = = = 82.25kW VOUT _ OK - 2.5 V 351V - 2.5 V - 12 mA - 12 mA 8.22MW RE (27) Select a standard resistor value for RF. RF = 82.5kW (28) This PWMCNTL output will remain active until a minimum output voltage (VOUT_MIN) is reached, as shown in Equation 29. VOUT _ MIN = 2.5 V (RE + RF ) 2.5 V (8.22MW + 82.5kW ) = » 252 V RF 82.5kW (29) According to these resistor values, the FailSafe OVP threshold will be set according to Equation 30 VOV _ FAILSAFE = 36 4.87 V (RE + RF ) 4.87 V (8.22MW + 82.5kW ) = » 490 V RF 82.5kW Submit Documentation Feedback (30) Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Output Capacitor Selection The output capacitor (COUT) is selected based on holdup requirements, as shown in Equation 31. POUT 1 300 W 1 2 h fLINE 0.92 47Hz ³ = » 156 mF 2 2 VOUT - (VOUT _ MIN ) 390 V 2 - (252 V)2 2 COUT (31) Two 100-μF capacitors were used in parallel for the output capacitor. COUT = 200 mF (32) For this size capacitor, the low-frequency peak-to-peak output voltage ripple (VRIPPLE) is approximately 14 V, as shown in Equation 33: 2 ´ POUT 1 2 ´ 300 W VRIPPLE = = » 14 Vppk VOUT ´ 4p ´ fLINE ´ COUT 0.92 ´ 390 V ´ 4p ´ 47Hz ´ 200 mF h (33) In addition to holdup requirements, a capacitor must be selected so that it can withstand the low-frequency RMS current (ICOUT_100Hz) and the high-frequency RMS current (ICOUT_HF); see Equation 34 to Equation 36. High-voltage electrolytic capacitors generally have both a low- and a high-frequency RMS current ratings on the product data sheets. POUT 300 W ICOUT _100Hz = = = 0.591 Arms VOUT ´ h ´ 2 390 V ´ 0.92 ´ 2 (34) ICOUT _ HF æ POUT 2 2 = ç çç 2 ´ h ´ VIN _ MIN è æ 300 W ´ 2 2 ICOUT _ HF = ç ç 2 ´ 0.92 ´ 85 V è 2 4 2VIN _ MIN ö ÷ - I COUT _100Hz 9pVOUT ÷÷ ø ( 2 ) (35) 2 4 2 ´ 85 V ö ÷ - (0.591A )2 » 0.966 Arms 9p ´ 390 V ÷ ø (36) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 37 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Selecting (RS) for Peak Current Limiting The UCC28063 peak limit comparator senses the total input current and is used to protect the MOSFETs during inrush and over-load conditions. For reliability, the peak current limit (IPEAK) threshold in this design is set for 120% of the nominal maximum current that will be observed during power up, as shown in Equation 37. IPEAK = 2POUT 2(1.2) 2 ´ 300 W 2 ´ 1.2 = » 13 A h ´ VIN _ MIN 0.92 ´ 85 V (37) A standard 15-mΩ metal-film current-sense resistor will be used for current sensing, as shown in Equation 38. The estimated power loss of the current-sense resistor (PRS) is less than 0.25 W during normal operation, as shown in Equation 39. RS = 200mV 200mV = » 15mΩ IPEAK 13 A 2 PRS (38) 2 æ POUT ö æ 300 W ö =ç ÷÷ RS = ç ÷ ´ 15mW » 0.22 W çV è 85 V ´ 0.92 ø è IN_MIN ´ h ø (39) The most critical parameter in selecting a current-sense resistor is the surge rating. The resistor needs to withstand a short-circuit current larger than the current required to open the fuse (F1). I2t (ampere-squaredseconds) is a measure of thermal energy resulting from current flow required to melt the fuse, where I2t is equal to RMS current squared times the duration of the current flow in seconds. A 4-A fuse with an I2t of 14 A2s was chosen to protect the design from a short-circuit condition. To ensure the current-sense resistor has high-enough surge protection, a 15-mΩ, 500-mW, metal-strip resistor was chosen for the design. The resistor has a 2.5-W surge rating for 5 seconds. This result translates into 833 A2s and has a high-enough I2t rating to survive a short-circuit before the fuse opens, as described in Equation 40. 2.5 W I2 t = ´ 5s = 833 A 2 s 0.015 W (40) Power Semiconductor Selection (Q1, Q2, D1, D2) The selection of Q1, Q2, D1, and D2 are based on the power requirements of the design. Application note SLUU138, UCC38050 100-W Critical Conduction Power Factor Corrected (PFC) Pre-regulator, explains how to select power semiconductor components for transition-mode PFC pre-regulators. The MOSFET (Q1, Q2) pulsed-drain maximum current is shown in Equation 41: IDM ³ IPEAK = 13 A (41) The MOSFET (Q1, Q2) RMS current calculation is shown in Equation 42: IDS = IPEAK 2 1 4 2 VIN _ MIN 13 A = 6 9p ´ VOUT 2 1 4 2 ´ 85 V » 2.3 A 6 9p ´ 390 V (42) To meet the power requirements of the design, IRFB11N50A 500-V MOSFETs were chosen for Q1 and Q2. The boost diode (D1, D2) RMS current is shown in Equation 43: I ID = PEAK 2 4 2 ´ VIN _ MIN 9p ´ VOUT = 13 A 2 4 2 ´ 85 V » 1.4 A 9p ´ 390 V (43) To meet the power requirements of the design, MURS360T3, 600-V diodes were chosen for D1 and D2. 38 Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Brownout Protection Resistor RA and RB are selected to activate brownout protection at ~75% of the specified minimum-operating input voltage. Resistor RA programs the brownout hysteresis comparator, which is selected to provide 17 V (~12 VRMS) of hysteresis. Calculations for RA and RB are shown in Equation 44 through Equation 47. Hysteresis 17 V RA = = = 8.5MW 2 mA 2 mA (44) To meet voltage requirements, three 2.87-MΩ resistors were used in series for RA. R A = 3 ´ 2.87MW = 8.61MW RB = 1.4 V ´ R A VIN _ MIN ´ 0.75 2 - 1.4 V = 1.4 V ´ 8.61MW 85 V ´ 0.75 2 - 1.4 V (45) = 135.8kW (46) Select a standard value for RB. RB = 133kW (47) In this design example, brownout becomes active (shuts down PFC) when the input drops below 66 VRMS for longer than 440 ms and deactivates (restarts with a full soft start) when the input reaches 78 VRMS. Converter Timing The maximum on-time TON depends on fMIN as determined by Equation 48. To ensure proper operation, the timing must be set based on the highest boost inductance (L1MAX) and output power (POUT). In this design example, the boost inductor could be as high as 390 µH. Calculate the timing resistor RT as shown in Equation 49. VIN _ MIN ´ 2 ö æ ö ÷ 0.92 ´ (85 V )2 ç 1 - 85 V ´ 2 ÷ ÷ ç ÷ VOUT 390 V ø è ø= è = 39.2kHz POUT ´ L1MAX 300 W ´ 390 mH h ´ VIN _ MIN ( fMIN = 2æ ) çç1 - æ VIN _ MIN ´ 2 ö æ ö ÷ 133kW ç 1 - 85 V ´ 2 ÷ 133kW ç 1 ç ÷ ç ÷ Vout 390 V ø è ø= è RT = » 121kW 4 ms 4 ms 4.85 V ´ 4.85 V ´ ´ fMIN ´ 39.2kHz V V (48) (49) This result sets the maximum frequency clamp (fMAX), as shown in Equation 50, which improves efficiency at light load. 133kW 133kW fMAX = = » 550kHz 2 ms ´ RT 2 ms ´ 121kW (50) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 39 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com Programming VOUT Resistor RC is selected to minimize loading on the power line when the PFC is disabled. Construct resistor RC from two or more resistors in series to meet high-voltage requirements. Resistor RD is then calculated based on RC, the reference voltage, VREF, and the required output voltage, VOUT. Based on the values shown in Equation 51 to Equation 54, the primary output over-voltage protection threshold should be as shown in Equation 55: RC = 2.74MW + 2.74MW + 3.01MW = 8.49MW (51) VREF = 6 V (52) VREF ´ RC 6 V ´ 8.49MW RD = = = 132.7kW VOUT - VREF 390 V - 6 V (53) Select a standard value for RD. RD = 133kW (54) R + RD 8.49MW + 133kW VOVP = 6.48 V C = 6.48 V = 420.1V RD 133kW (55) Voltage Loop Compensation Resistor RZ is sized to attenuate low-frequency ripple to less than 2% of the voltage amplifier output range. This value ensures good power factor and low harmonic distortion on the input current. The transconductance amplifier small-signal gain is shown in Equation 56: gm = 50 mS (56) The voltage-divider feedback gain is shown in Equation 57: V 6V H = REF = » 0.015 VOUT 390 V (57) The value of RZ is calculated as shown in Equation 58: 100mV 100mV RZ = = = 9.52 kW VRIPPLE ´ H ´ gm 14 V ´ 0.015 ´ 50 mS (58) CZ is then set to add 45° phase margin at 1/5th of the line frequency, as shown in Equation 59: 1 1 CZ = = = 1.78 mF fLINE 47Hz ´ 9.52kW 2p ´ ´ R Z 2p ´ 5 5 (59) CP is sized to attenuate high-frequency switching noise, as shown in Equation 60: 1 1 Cp = = = 770pF f 45kHz ´ 9.52kW 2p ´ MIN ´ R Z 2p ´ 2 2 (60) Standard values should be chosen for RZ, CZ and CP, as shown in Equation 61 to Equation 63. R Z = 9.53kW (61) 40 CZ = 2.2 mF (62) CP = 820pF (63) Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 UCC28063 SLUSAO7 – SEPTEMBER 2011 www.ti.com ADDITIONAL REFERENCES Related Parts Table 3 lists several TI parts that have characteristics similar to the UCC28063. Table 3. TI Related Parts DEVICE DESCRIPTION UCC28050/51 Transition-mode PFC controller for low to medium power applications UCC28019 8-pin continuous-conduction-mode (ccm) pfc controller (with slew-rate correction current) UCC28019A 8-pin continuous-conduction-mode (ccm) pfc controller (with 2-level voltage-error gain) UCC28060 Two-phase interleaved transition-mode pfc controller (with input voltage range gain change) UCC28061 Two-phase interleaved transition-mode pfc controller (with no input voltage gain change) UCC28070 Two-phase interleaved ccm (average current mode) pfc controller References These references, design tools, and links to additional references, including design software, may be found at www.power.ti.com 1. Evaluation Module, UCC28063EVM 300W Interleaved PFC Pre-regulator, SLUU512 from Texas Instruments 2. Application Note, UCC38050 100-W Critical Conduction Power Factor Corrected (PFC) Pre-regulator, SLUU138 from Texas Instruments Submit Documentation Feedback Copyright © 2011, Texas Instruments Incorporated Product Folder Link(s): UCC28063 41 PACKAGE OPTION ADDENDUM www.ti.com 24-Sep-2011 PACKAGING INFORMATION Orderable Device Status (1) Package Type Package Drawing Pins Package Qty Eco Plan (2) Lead/ Ball Finish MSL Peak Temp UCC28063D ACTIVE SOIC D 16 40 Green (RoHS & no Sb/Br) CU NIPDAU Level-1-260C-UNLIM UCC28063DR ACTIVE SOIC D 16 2500 Green (RoHS & no Sb/Br) CU NIPDAU Level-1-260C-UNLIM (3) Samples (Requires Login) (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. Pb-Free (RoHS Exempt): This component has a RoHS exemption for either 1) lead-based flip-chip solder bumps used between the die and package, or 2) lead-based die adhesive used between the die and leadframe. The component is otherwise considered Pb-Free (RoHS compatible) as defined above. Green (RoHS & no Sb/Br): TI defines "Green" to mean Pb-Free (RoHS compatible), and free of Bromine (Br) and Antimony (Sb) based flame retardants (Br or Sb do not exceed 0.1% by weight in homogeneous material) (3) MSL, Peak Temp. -- The Moisture Sensitivity Level rating according to the JEDEC industry standard classifications, and peak solder temperature. Important Information and Disclaimer:The information provided on this page represents TI's knowledge and belief as of the date that it is provided. TI bases its knowledge and belief on information provided by third parties, and makes no representation or warranty as to the accuracy of such information. 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Addendum-Page 1 PACKAGE MATERIALS INFORMATION www.ti.com 21-Sep-2011 TAPE AND REEL INFORMATION *All dimensions are nominal Device UCC28063DR Package Package Pins Type Drawing SOIC D 16 SPQ Reel Reel A0 Diameter Width (mm) (mm) W1 (mm) 2500 330.0 16.4 Pack Materials-Page 1 6.5 B0 (mm) K0 (mm) P1 (mm) 10.3 2.1 8.0 W Pin1 (mm) Quadrant 16.0 Q1 PACKAGE MATERIALS INFORMATION www.ti.com 21-Sep-2011 *All dimensions are nominal Device Package Type Package Drawing Pins SPQ Length (mm) Width (mm) Height (mm) UCC28063DR SOIC D 16 2500 333.2 345.9 28.6 Pack Materials-Page 2 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI’s standard warranty. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. TI assumes no liability for applications assistance or customer product design. Customers are responsible for their products and applications using TI components. To minimize the risks associated with customer products and applications, customers should provide adequate design and operating safeguards. TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right, copyright, mask work right, or other TI intellectual property right relating to any combination, machine, or process in which TI products or services are used. Information published by TI regarding third-party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof. Use of such information may require a license from a third party under the patents or other intellectual property of the third party, or a license from TI under the patents or other intellectual property of TI. Reproduction of TI information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties, conditions, limitations, and notices. Reproduction of this information with alteration is an unfair and deceptive business practice. TI is not responsible or liable for such altered documentation. Information of third parties may be subject to additional restrictions. Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice. TI is not responsible or liable for any such statements. TI products are not authorized for use in safety-critical applications (such as life support) where a failure of the TI product would reasonably be expected to cause severe personal injury or death, unless officers of the parties have executed an agreement specifically governing such use. Buyers represent that they have all necessary expertise in the safety and regulatory ramifications of their applications, and acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements concerning their products and any use of TI products in such safety-critical applications, notwithstanding any applications-related information or support that may be provided by TI. Further, Buyers must fully indemnify TI and its representatives against any damages arising out of the use of TI products in such safety-critical applications. TI products are neither designed nor intended for use in military/aerospace applications or environments unless the TI products are specifically designated by TI as military-grade or "enhanced plastic." Only products designated by TI as military-grade meet military specifications. Buyers acknowledge and agree that any such use of TI products which TI has not designated as military-grade is solely at the Buyer's risk, and that they are solely responsible for compliance with all legal and regulatory requirements in connection with such use. TI products are neither designed nor intended for use in automotive applications or environments unless the specific TI products are designated by TI as compliant with ISO/TS 16949 requirements. Buyers acknowledge and agree that, if they use any non-designated products in automotive applications, TI will not be responsible for any failure to meet such requirements. Following are URLs where you can obtain information on other Texas Instruments products and application solutions: Products Applications Audio www.ti.com/audio Communications and Telecom www.ti.com/communications Amplifiers amplifier.ti.com Computers and Peripherals www.ti.com/computers Data Converters dataconverter.ti.com Consumer Electronics www.ti.com/consumer-apps DLP® Products www.dlp.com Energy and Lighting www.ti.com/energy DSP dsp.ti.com Industrial www.ti.com/industrial Clocks and Timers www.ti.com/clocks Medical www.ti.com/medical Interface interface.ti.com Security www.ti.com/security Logic logic.ti.com Space, Avionics and Defense www.ti.com/space-avionics-defense Power Mgmt power.ti.com Transportation and Automotive www.ti.com/automotive Microcontrollers microcontroller.ti.com Video and Imaging RFID www.ti-rfid.com OMAP Mobile Processors www.ti.com/omap Wireless Connctivity www.ti.com/wirelessconnectivity TI E2E Community Home Page www.ti.com/video e2e.ti.com Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2011, Texas Instruments Incorporated User's Guide SLUU512 – August 2011 UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator The UCC28063 is a dual-phase, transition-mode Power Factor Correction (PFC) pre-regulator. The UCC28063EVM-723 is an evaluation module (EVM) with a 390-V, 300-W, dc output that operates from a universal input of 85 VRMS to 265 VRMS and provides power-factor correction. Throughout this document, the acronym EVM and the phrases evaluation board and evaluation module are synonymous with the UCC28063EVM. 1 Description The pre-regulator uses the UCC28063 PFC interleaved controller to shape the input current wave to provide power-factor correction. This device uses TI’s Natural Interleaving ™ technology to interleave boost phases. This user’s guide provides the schematic, List of Materials, assembly drawing for a single-sided printed circuit board application, and test set-up information necessary to evaluate the UCC28063 in a typical PFC application. 2 Thermal Requirements This evaluation module will operate up to 300 W without external cooling in ambient tempatures of 25°C. 3 Electrical Characteristics Table 1 summarizes the electrical specifications of the UCC28063EVM-723. Table 1. UCC28063EVM-723 Electrical Specifications PARAMETER CONDITIONS RMS input voltage (ac line) UCC28063EVM MIN TYP 85 Output voltage, VOUT MAX UNITS 265 VRMS 63 Hz 300 W 390 Line frequency 47 Power factor (PF) at maximum load 0.9 Output power Full load efficiency AC line = 115 V 94% AC line = 230 V 97% V Natural Interleaving is a trademark of Texas Instruments. All other trademarks are the property of their respective owners. SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 1 Schematics 4 www.ti.com Schematics Figure 1 and Figure 2 show the schematics for this EVM. See the List of Materials for specific values. + + To evaluate inductor ripple currents, resistors R25 and R26 can be removed and replaced with current loops. Figure 1. Interleaved PFC Power Stage 2 UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Schematics + www.ti.com Figure 2. Controller Circuitry SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 3 Test Setup and Power-Up/Power-Down Instructions 5 www.ti.com Test Setup and Power-Up/Power-Down Instructions WARNING There are high voltages present on the pre-regulator. It should only be handled by experienced power supply professionals. To evaluate this board as safely as possible, the following test configuration should be used: • Connect an isolation transformer between the source and unit • Attach a voltmeter and a resistive or electronic load to the unit output before supplying power to the EVM. A separate 13-V bias supply is required to power the UCC28063 control circuitry. The unit will start up under no-load conditions. However, for safety, a load should be connected to the output of the device before it is powered up. The unit should also never be handled while power is applied to it or when the output voltage is above 50-V dc. Refer to Figure 3 for a recommended test setup diagram. CAUTION There are very high voltages on the board. Components can and will reach temperatures greater than 100°C. Use caution when handling the EVM. 4 UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Test Setup and Power-Up/Power-Down Instructions www.ti.com VM 0 to 300W Load TEXAS I NSTRUMENTS Isolation Transformer + 13V Bias Supply Figure 3. Test Setup SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 5 Typical Performance Data 6 www.ti.com Typical Performance Data Figure 4 through Figure 7 present characteristic performance data for the UCC28063EVM-723. Efficiency Efficiency at Vin = 115Vrms 100.0 100.0 99.0 99.0 98.0 97.0 Efficiency (%) Efficiency (%) 98.0 96.0 95.0 94.0 93.0 97.0 96.0 95.0 94.0 93.0 92.0 92.0 91.0 91.0 90.0 10 20 30 40 50 60 70 80 90 90.0 100 10 Output Power (%) 20 30 40 50 60 70 80 90 100 Output Power (%) Efficiency at Vin 85Vrms Efficiency at Vin 265Vrms Phase Management Disabled Figure 4. Efficiency at 85 VRMS and 265 VRMS Figure 5. Efficiency at 115 VRMS, Without Phase Management Efficiency at Vin = 230Vrms Current Harmonics Vin = 230V RMS, Pout = 300W 100.0 1.40706 99.0 1.17256 97.0 EN61000-3-2 SPEC 96.0 Amplitude Efficiency (%) 98.0 95.0 94.0 93.0 92.0 0.93805 0.70354 0.46904 91.0 0.23453 90.0 10 20 30 40 50 60 70 80 90 Output Power (%) Phase Management Disabled 100 0.00002 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 Harmonic Number Figure 6. Efficiency at 230 VRMS, Without Phase Management 6 Figure 7. Current Harmonics UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Typical Performance Data www.ti.com 6.1 Output Ripple Voltage at Full Load Figure 8 illustrates the output ripple voltage. Figure 8. VOUT Ripple, POUT = 300 W 6.2 Input Ripple Current Cancellation Figure 9 through Figure 14 show the input current (M1= IL1 + IL2), Inductor Ripple Current (IL1, IL2) versus rectified line voltage. From these graphs, it can be observed that interleaving reduces the magnitude of input ripple current caused by the inductor ripple current. Figure 9. Inductor and Input Ripple Current at 85 VRMS Figure 10. Inductor and Input Ripple Current at 85 VRMS at Peak of Line Voltage Input at Half the Line Voltage SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 7 Typical Performance Data 8 www.ti.com Figure 11. Inductor and Input Ripple Current at 265 VRMS Input at Peak Line Voltage Figure 12. Inductor and Input Ripple Current at 265 VRMS Input at Half Peak Line Voltage Figure 13. Inductor and Input Ripple Current at VIN = 85 VRMS, POUT = 300 W Figure 14. Inductor and Input Ripple Current at VIN = 265 VRMS, POUT = 300 W UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Typical Performance Data www.ti.com 6.3 Startup Characteristics Figure 15 and Figure 16 illustrate the UCC28063EVM-723 startup characteristics. Figure 15. Start-Up at VIN = 85 VRMS, POUT = 300 W 6.4 Figure 16. Start-Up at VIN = 265 VRMS, POUT = 0 W Brownout Protection The UCC28063 has a brownout protection that shuts down both gate drives (GDA and GDB) when the VINAC pin detects that the RMS input voltage is too low. This EVM was designed to go into a brownout state when the line drops below 64 VRMS. Once the UCC28063 control device has determined that the input is in a brownout condition, a 400-ms timer starts to allow the line to recover before shutting down the gate drivers. After 400 ms of brownout, both gate drivers turn off, as shown in Figure 17 and Figure 18. VOUT C3 15.2VPP Rectified Line Voltage After the Bridge Rectifier C3 9.67VRMS GDA GDB Figure 17. Brownout at 85 VRMS SLUU512 – August 2011 Submit Documentation Feedback Figure 18. Brownout at 265 VRMS UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 9 Typical Performance Data 6.5 www.ti.com Line Transient A line transient test was conducted with an ac source on the reference design. The line was varied from 230 VRMS to 115 VRMS to 230 VRMS and the transient response was evaluated in each case. From the oscilloscope image in Figure 19, it can be observed that the output recovered from line transients within 300ms at full load. Figure 19. Line Transient, POUT = 300W 10 UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Reference Design Assembly Drawing www.ti.com 7 Reference Design Assembly Drawing Figure 20 and Figure 22 show the top and bottom layers (respectively) of the UCC28063EVM-723. NOTE: Board layouts are not to scale. These figures are intended to show how the board is laid out; they are not intended to be used for manufacturing UCC28063EVM-723 PCBs. TEXAS I NSTRUMENTS Figure 20. Top Layer Assembly SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 11 Reference Design Assembly Drawing www.ti.com Figure 21. Bottom Layer Copper 12 UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback Reference Design Assembly Drawing www.ti.com Figure 22. Bottom Layer Assembly SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 13 List of Materials 8 www.ti.com List of Materials Table 2 lists the EVM components as configured according to the schematics (see Section 4). Table 2. List of Materials COUNT 14 REF DES DESCRIPTION PART NUMBER MFR 4 AC_LINE, AC_NEUTRAL, RETURN, VOUT Terminal block, 2 pin, 15 A, 5.1 mm ED120/2DS OST 1 C1 Capacitor, film, 275VAC, 20±%, 0.1 μF, 0.689 x 0.236 inch ECQU2A104BC1 Panasonic 1 C11 Capacitor, ceramic, 16 V, X7R, 10%, 220 nF, 1206 Std Std 2 C12, C13 Capacitor, ceramic, 16 V, X7R, 10%, 2.2 μF, 0805 Std Std 1 C14 Capacitor, aluminum, 35 V, ±20%, 22 μF, 0.200 * ECA-1VM220 0.435 inch Panasonic 1 C15 Capacitor, ceramic, 25 V, X7R, 10%, 820 pF, 0805 Std Std 1 C17 Capacitor, ceramic, 25 V, X7R, 10%, 10 nF, 0805 Std Std 1 C2 Capacitor, polyester, 630 V, 10%, 0.047 μF, 0.256 x 0.650 inch ECQ-E6473KZ Panasonic 2 C3, C4 Capacitor, aluminum, 450 VDC, ±20% , 100 μF, 18 x 40 mm EKXG451ELL101 MM40S Nippon Chemi-con 2 C5, C6 Capacitor, film, 275 VAC, 20±%, 0.47 μF, 0.236 X 0.591 ECQ-U2A474MG Panasonic 2 C7, C10 Capacitor, ceramic, 25 V, X7R, 10%, 22 pF, 0805 Std Std 3 C8, C9, C16 Capacitor, ceramic, 25 V, X7R, 10%, 1.2 nF, 0805 Std Std 3 D1, D2, D4 Diode, 3000 mA, 600 V, SMC MURS360T3 On Semi 1 D3 Diode, bridge, 6 A, 600 V, BU6 GBU6J Vishay 2 F1 Fuse clip, 5x20 mm 0100056H Wickmann 3 HS1, HS2, HS3 Heatsink, universal-mount TO-220, 7-345-2PP, 1.500 x 2.000 inch 7-345-2PP IERC-CTS 1 J1 Terminal block, 2 pin, 15 A, 5.1 mm, ED1609-ND, 0.40 x 0.35 inch ED1609 OST 3 JP1, JP2, JP3 Jumper, 2.000 inch length, PVC insulation, AWG 22, 0.035 inch dia. 923345-20-C 3M 1 JP4 Jumper, 2.100 inch length, PVC insulation, AWG 22, 0.035 inch dia. 923345-21-C 3M 1 JP5 Jumper, 0.500 inch length, PVC insulation, AWG 22, 0.035 inch dia 923345-05-C 3M 2 JP6, JP8 Jumper, 0.700 inch length, PVC insulation, AWG 22 923345-07-C 3M 1 JP7 Jumper, 0.100 inch length, non-insulated, AWG 22 923345-01-C 3M 1 JP10 Header, 2-pin, 100-mil spacing, 0.100 inch x 2 PEC02SAAN Sullins 1 JP9 Jumper, 1.2 inch length, PVC insulation, AWG 22, 0.035 inch dia. 923345-20-C 3M 2 L1, L2** Inductor, boost PFC with aux. 330 uH @ 5.3 A PK, 1.555 Dia. inch CTX16-17769R Cooper 2 Q1, Q2 MOSFET, N-channel, 500 V, 11 A, 520 mΩ, TO-220V IRFB11N50APbF IR UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated SLUU512 – August 2011 Submit Documentation Feedback List of Materials www.ti.com Table 2. List of Materials (continued) COUNT REF DES DESCRIPTION PART NUMBER MFR 1 R1 Resistor, chip, 1/10 W, 1%, 51.1 Ω, 0805 Std Std 2 R11, R14 Resistor, chip, 1/10 W, 1%, 20.5 kΩ, 0805 Std Std 2 R12, R13 Resistor, chip, 1/10 W, 1%, 133 kΩ, 0805 Std Std 1 R15 Resistor, chip, 1/10 W, 1%, 121 kΩ, 0805 Std Std 2 R16, R19 Resistor, chip, 1/10 W, 1%, 5.11 Ω, 0805 Std Std 1 R18 Resistor, chip, 1/10 W, 1%, 9.53 kΩ, 0805 Std Std 3 R2, R4, R17 Resistor, chip, 1/10 W, 1%, 10.0 kΩ, 0805 Std Std 1 R23 Resistor, chip, 1/10 W, 1%, 82.5 kΩ, 0805 Std Std 1 R24 Resistor, chip, 1/10 W, 1%, 100 Ω, 0805 Std Std 2 R25, R26 Resistor, chip, 1 W, 5%, 0 Ω, 2512 Std Std 1 R3 Resistor, chip, 1/2 W, 1%, 0.015 Ω, 2010 WSL2010R0150F EA Vishay 3 R5, R6, R7 Resistor, Chip, 1/10 W, 1%, 2.87 MΩ Std Std 5 R8, R9, R20, R21, R22 Resistor, chip, 1/10 W, 1%, 2.74 MΩ, 0805 Std Std 1 R10 Resistor, Chip, 1/10 W, 1%, 3.01 MΩ, 0805 Std Std 1 RT1 Thermistor, NTC, 5 Ω, 6 A, 5 Ω, 0.180 X 0.550 inch CL-40 Thermometrics 2 TP1, TP2 Pin, thru hole, tin plate, for 0.062 PCB's, K24A/M, 0.039 inch K24A/M Vector 1 U1 Interleave PFC Controller, SO16 UCC28063D TI 1 VAR1 Varistor 275 V RMS, 0.472 x 0.213 inch S10K275E2 Epcos 1 PCB HPA343 printed circuit board HPA343 1 X1 @ F1 4 A, fast acting fuse, BK/GDA-4A, 5mmX20mm BK/S501-4-R Cooper/Bussman 6 "X1 @ HS1 and D3, HS2 and Q1, HS3 and Q2" Nut #4-40 (steel) Std Std 6 "X1 @ HS1 and D3, HS2 and Q1, HS3 and Q2" Pan head screw #4-40X3/8 (steel) Std Std 1 X1 D3 and HS1 Thermal grease Std Std 6 "X1 @ HS1 and D3, HS2 and Q1, HS3 and Q2" Split lock washer #4(steel) Std Std 6 "X1 @ HS1 and D3, HS2 and Q1, HS3 and Q2" Nylon shoulder washer #4 3049 Keystone Electronics 2 "X1 @ HS2 and Q1, HS3 and Q2" Thermal pad silicon TO220 3223-07FR-51 BERQUIST 4 1903C Standoff hex .500/6-32THR nylon 1903C Keystone Electronics 4 4824 Nut 4824 Keystone Electronics SLUU512 – August 2011 Submit Documentation Feedback UCC28063EVM-723 300-W Interleaved PFC Pre-Regulator Copyright © 2011, Texas Instruments Incorporated 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. This evaluation board/kit does not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives. Should this evaluation board/kit not meet the specifications indicated in the User’s Guide, the board/kit may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies TI from all claims arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all appropriate precautions with regard to electrostatic discharge. EXCEPT TO THE EXTENT OF THE INDEMNITY SET FORTH ABOVE, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. TI currently deals with a variety of customers for products, and therefore our arrangement with the user is not exclusive. TI assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or services described herein. Please read the User’s Guide and, specifically, the Warnings and Restrictions notice in the User’s Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For additional information on TI’s environmental and/or safety programs, please contact the TI application engineer or visit www.ti.com/esh. No license is granted under any patent right or other intellectual property right of TI covering or relating to any machine, process, or combination in which such TI products or services might be or are used. FCC Warning 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. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. EVM Warnings and Restrictions It is important to operate this EVM within the input voltage range of xxx V to xxx V and the output voltage range of xxx V to xxx V . Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are questions concerning the input range, please contact a TI field representative prior to connecting the input power. Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the EVM. 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 xxx° C. The EVM is designed to operate properly with certain components above xxx° C as long as the input and output ranges are maintained. These components include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of devices can be identified using the EVM schematic located in the EVM User's Guide. When placing measurement probes near these devices during operation, please be aware that these devices may be very warm to the touch. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2011, Texas Instruments Incorporated IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI’s standard warranty. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. TI assumes no liability for applications assistance or customer product design. Customers are responsible for their products and applications using TI components. To minimize the risks associated with customer products and applications, customers should provide adequate design and operating safeguards. TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right, copyright, mask work right, or other TI intellectual property right relating to any combination, machine, or process in which TI products or services are used. Information published by TI regarding third-party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof. Use of such information may require a license from a third party under the patents or other intellectual property of the third party, or a license from TI under the patents or other intellectual property of TI. Reproduction of TI information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties, conditions, limitations, and notices. Reproduction of this information with alteration is an unfair and deceptive business practice. TI is not responsible or liable for such altered documentation. Information of third parties may be subject to additional restrictions. Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice. TI is not responsible or liable for any such statements. TI products are not authorized for use in safety-critical applications (such as life support) where a failure of the TI product would reasonably be expected to cause severe personal injury or death, unless officers of the parties have executed an agreement specifically governing such use. Buyers represent that they have all necessary expertise in the safety and regulatory ramifications of their applications, and acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements concerning their products and any use of TI products in such safety-critical applications, notwithstanding any applications-related information or support that may be provided by TI. Further, Buyers must fully indemnify TI and its representatives against any damages arising out of the use of TI products in such safety-critical applications. TI products are neither designed nor intended for use in military/aerospace applications or environments unless the TI products are specifically designated by TI as military-grade or "enhanced plastic." Only products designated by TI as military-grade meet military specifications. Buyers acknowledge and agree that any such use of TI products which TI has not designated as military-grade is solely at the Buyer's risk, and that they are solely responsible for compliance with all legal and regulatory requirements in connection with such use. TI products are neither designed nor intended for use in automotive applications or environments unless the specific TI products are designated by TI as compliant with ISO/TS 16949 requirements. Buyers acknowledge and agree that, if they use any non-designated products in automotive applications, TI will not be responsible for any failure to meet such requirements. Following are URLs where you can obtain information on other Texas Instruments products and application solutions: Products Applications Audio www.ti.com/audio Communications and Telecom www.ti.com/communications Amplifiers amplifier.ti.com Computers and Peripherals www.ti.com/computers Data Converters dataconverter.ti.com Consumer Electronics www.ti.com/consumer-apps DLP® Products www.dlp.com Energy and Lighting www.ti.com/energy DSP dsp.ti.com Industrial www.ti.com/industrial Clocks and Timers www.ti.com/clocks Medical www.ti.com/medical Interface interface.ti.com Security www.ti.com/security Logic logic.ti.com Space, Avionics and Defense www.ti.com/space-avionics-defense Power Mgmt power.ti.com Transportation and Automotive www.ti.com/automotive Microcontrollers microcontroller.ti.com Video and Imaging www.ti.com/video RFID www.ti-rfid.com Wireless www.ti.com/wireless-apps RF/IF and ZigBee® Solutions www.ti.com/lprf TI E2E Community Home Page e2e.ti.com Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2011, Texas Instruments Incorporated