350-W Interleaved PFC Pre-Regulator User's Guide September 2005 System Power SLUU228

350-W Interleaved PFC Pre-Regulator User's Guide LiteratureNumber:SLUU228 September2005

Contents 1 Introduction................................................................................................................ 6 2 Description................................................................................................................. 6 3 ThermalRequirements................................................................................................. 6 4 ElectricalSpecifications............................................................................................... 6 5 Schematic.................................................................................................................. 7 6 TestSetup.................................................................................................................. 8 7 PowerUp/PowerDown................................................................................................ 9 8 PerformanceData....................................................................................................... 9 8.1 InputRippleCurrent............................................................................................... 11 8.2 StartupCharacteristics........................................................................................... 12 8.3 LineDropout....................................................................................................... 13 8.4 LineTransient...................................................................................................... 13 8.5 2-WAuxiliarySupply(V )...................................................................................... 14 bias 9 ReferenceDesignAssemblyDrawing.......................................................................... 15 10 BillofMaterials......................................................................................................... 16 ImportantNotices............................................................................................................... 20 SLUU228–September2005 TableofContents 3

List of Figures 1 AuxiliarySupplyandPFCControlCircuitry.............................................................................. 7 2 PFCPre-RegulatorPowerStage.......................................................................................... 8 3 TestSetup.................................................................................................................... 9 4 Efficiencyvs.OutputPower............................................................................................... 10 5 PFvs.OutputPower....................................................................................................... 10 6 CurrentTHDvs.OutputPower........................................................................................... 10 7 CurrentHarmonics......................................................................................................... 10 8 CurrentHarmonics......................................................................................................... 10 9 OutputRippleVoltageatFullLoad...................................................................................... 11 10 InputCurrentandInductorCurrents..................................................................................... 11 11 V =85VRMS,P =350W.......................................................................................... 12 IN OUT 12 V =265VRMS,P =350W......................................................................................... 12 IN OUT 13 Start-UpatV =120V,P =350W.................................................................................. 12 IN OUT 14 Start-UpatV =120V,P =0W..................................................................................... 12 IN OUT 15 V =120V,P =350W................................................................................................ 13 IN OUT 16 LineTransient,P =350W............................................................................................ 13 OUT 17 AuxiliaryGateDriveandCurrentSenseBehavioratNoLoad....................................................... 14 18 AuxiliaryOutputwith2-WLoad,GateDriveandCurrentSense,VOUT1=120V................................ 14 19 AuxiliaryOutputwith2-WLoad,GateDriveandCurrentSense,VOUT1=380V................................ 15 20 TopAssemblyLayer....................................................................................................... 15 21 BottomAssemblyLayer................................................................................................... 16 4 ListofFigures SLUU228–September2005

List of Tables 1 EVMSpecifications.......................................................................................................... 6 2 PartsList .................................................................................................................... 16 SLUU228–September2005 ListofTables 5

User's Guide SLUU228–September2005 350-W Interleaved PFC Pre-Regulator 1 Introduction Theevaluationmoduleisa350-W,twophaseinterleavedpowerfactorcorrectedpre-regulator.This evaluationmodulehasa380-V,350-W,dcoutputthatoperatesoffauniversalinputof(85Vto265V RMS)andprovidespowerfactorcorrection.TheunitmeetsEN61000-3-2classBinputcurrentharmonic specifications. 2 Description Thepre-regulatorusestheUCC28528PFC/PWMcombinationcontrollertoshapetheinputcurrentwave toprovidepowerfactorcorrection.Thisdevicealsocontrolsa2-Wauxiliarybiassupplythatcanbeused tocontrolexternalcircuitry.TheUCC28220interleavedPWMprovidesOVPprotectionandprovidesload sharingbetweenthetwointerleavedboostconverters. 3 Thermal Requirements 1. Theevaluationmoduleworksupto200Wwithoutexternalcooling. 2. Iftheunitistoberunover200W,itrequiresafanpointeddirectlyattheconverterheatsinks. 3. Itisimportanttokeeptheambienttemperaturearoundthecomponentsbelow40(cid:176) C. 4 Electrical Specifications Table1.EVMSpecifications Parameter TestConditions Min Typ Max Unit V Lineinputvoltage 85 265 V IN RMS P Outputpower 25 350 W OUT Efficiency 350W 90% V Outputvoltage 375 380 400 V OUT THD Totalharmonicdistortion 350W 10% 6 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com Schematic 5 Schematic + Figure1.AuxiliarySupplyandPFCControlCircuitry SLUU228–September2005 350-WInterleavedPFCPre-Regulator 7

www.ti.com TestSetup U4 1N/CUCC27324ND/C 8 2INA OUTA 7 3GND VDD 6 4INB OUTB 5 + + + Figure2.PFCPre-RegulatorPowerStage 6 Test Setup Therearehighvoltagespresentonthepre-regulatoranditshouldonlybehandledbyexperiencedpower supplyprofessionals.Toevaluatethisboardassafelyaspossiblethefollowingtestsetupshouldbe used.Anisolationtransformershouldbeconnectedbetweenthesourceandunit.Beforepoweris supplied,avoltmeterandaresistiveorelectronicloadshouldbeattachedtotheunit’soutput. 8 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com PowerUp/PowerDown FANNeededforGreater than200W FAN VM 50to350WLoad - IsolationTransformer Figure3.TestSetup 7 Power Up/Power Down Theunitwillstartupundernoloadconditions.However,forsafetyaloadshouldbeconnectedtothe outputofthedevicebeforeitispoweredup.Theunitshouldalsoneverbehandledwhenpowerisapplied toitortheoutputvoltageisabove50VDC. WARNING There are very high voltages on the board and components can and do reach temperatures above 50(cid:176) C so precautions must be taken in handling theboard. 8 Performance Data Theefficiencyoftheboostpre-regulatorisgreaterthan91%at20%load.Thisconverterinanormal systemwouldbefollowedbyastepdownconverter.Thenew+80initiativerequiresthecascadedpower supplybe80%efficientat20%load.Thiscanbeaccomplishedbyhavingthedownstreamconverter being90%efficientorgreater.Inhighpowerapplications,thiscanbeaccomplishedwithzerovoltage switching(ZVS).AnactiveclampforwardusingaUCC2894PWMoraphaseshiftedfullbridgeusingthe UCC2895PWMcouldbeusedtodesignastep-downconverterwithgreaterthan90%efficiencyforhigh powerapplications. SLUU228–September2005 350-WInterleavedPFCPre-Regulator 9

www.ti.com PerformanceData Efficiencyvs.OutputPower 97 96 95 % 94 a as Efficiency 9923 91 EfficiencyatVin=85V 90 EfficiencyatVin=265V 89 20 30 40 50 60 70 80 90 100 %ofOutputPower Figure4.Efficiencyvs.OutputPower PFvs.OutputPower 1 CurrentTHDvs.OutputPower 20 0.98 18 16 CurrentTHDatVin=85V 0.96 14 CurrentTHDatVin=265V PF 0.94 % 12 D 10 H T 0.92 8 PFatVin=85V 6 0.9 4 PFatVin=265V 2 0.88 20 30 40 50 60 70 80 90 100 0 15 25 35 45 55 65 75 85 95 %ofOutputPower %ofOutputPower Figure5.PFvs.OutputPower Figure6.CurrentTHDvs.OutputPower CurrentHarmonics Vin=85V,Pout=350W CurrentHarmonics Vin=265V,Pout=350W 4.63847 1.41845 3.86540 1.18204 A) 3.09234 Amplitude( 12..5341692207 plitude(A)00..7904952634 m 0.77313 A0.47283 0.00007 0.23643 0 2 4 6 8101214161820222426283032343638404244454850 0.00002 Harmonic 0 2 4 6 8101214161820222426283032343638404244464850 Harmonic Figure7.CurrentHarmonics Figure8.CurrentHarmonics 10 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com PerformanceData Figure9.OutputRippleVoltageatFullLoad 8.1 Input Ripple Current Figure10showsthattheinductorcurrentscanceleachotheroutleavingtheinputcurrentwaveform clean.CH1istherectifiedlinevoltage,Ch2istheinductorcurrentfromL1,CH3istheinductorcurrentof L2,Ch4istheconverterinputcurrent;CH1istherectifiedlinevoltage.Notetheconversionratioforthe currentwaveformis200mA/mV. CH1, Rectified Line Voltage CH4, Input Current CH3, L2 Current CH2, L1 Current Figure10.InputCurrentandInductorCurrents Figure11andFigure12showtherectifiedlinevoltage(CH1),inputcurrent(CH4),andL1andL2inductor currentsCH2andCH3respectively,atmaximumloadwithdifferentlineconditions.Fromthese waveforms,itcanbeobservedthattheinductorripplecurrentsarecancelingeachotheroutduetothe interleaving. SLUU228–September2005 350-WInterleavedPFCPre-Regulator 11

www.ti.com PerformanceData Rectified Line Input Current L2 Current L1 Current Figure11.V =85VRMS,P =350W IN OUT Figure12.V =265VRMS,P =350W IN OUT 8.2 Startup Characteristics PFCpre-regulatorshaveatendencytoovershootduringpowerup.Thisisduetothevoltageloop crossingoverat10Hz.However,theUCC28528usesaslewratecomparatorthatspeedsuptransient responseandreducesovershoot.Figure13andFigure14showthestartupbehavioroftheEVMat120-V RMSinputatmaximumandnoloadconditions.CH4istheoutputvoltageandCH3istheinputcurrent. Fromthesefigures,itcanbeobservedthatthereisverylittleovershootduringstartup. Output Voltage Input Current Figure13.Start-UpatV =120V,P =350W IN OUT Figure14.Start-UpatV =120V,P =0W IN OUT 12 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com PerformanceData 8.3 Line Dropout Theunitwastestedunderalinedropoutconditionandtheunitcamebackintoregulationwithin100ms. RefertoFigure15fordetails.CH1istherectifiedinputvoltageandCH2istheoutputvoltage. Output Voltage Rectified Line Voltage Figure15.V =120V,P =350W IN OUT 8.4 Line Transient Alinetransienttestwasconductedwithanacsourceonthereferencedesign.Thelinewasvariedfrom 120to240-VRMSandthetransientresponsewasevaluated.Fromtheoscilloscopeoutputshownin Figure16itcanbeobservedthattheoutputrecoveredwithin200ms. Output Voltage Rectified Line Voltage Figure16.LineTransient,P =350W OUT SLUU228–September2005 350-WInterleavedPFCPre-Regulator 13

www.ti.com PerformanceData 8.5 2-W Auxiliary Supply (V ) bias Theunithasa2-Wauxiliarybiassupplythatwasdesignedtooperatewithaboostvoltage(VOUT1)of 120Vto400V.ThisbiassupplyisbasedonaflybackconverterandalsoregulatesthePWM/PFCand gatedrivecircuitryoftheevaluationmodule.NotewhenV isnotloaded,thegatedriveoftheflybackis BIAS pulseskipping.OnceV hasbeenloaded,thegatedrivehasafixeddutycycle.RefertoFigure17, AUX Figure18,andFigure19fordetails. VOUT1 = 380 V P = 0 W vbias CH1 = V gateQ2 CH2 = V R5 CH3 = V bias Figure17.AuxiliaryGateDriveandCurrentSenseBehavioratNoLoad VOUT1 = 120 V P = 2 W Vbias CH1 = V gateQ2 CH2 = V R5 CH3 = V bias Figure18.AuxiliaryOutputwith2-WLoad,GateDriveandCurrentSense,VOUT1=120V 14 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com ReferenceDesignAssemblyDrawing VOUT1 = 380 V P = 0 W Vbias CH1 = V gateQ2 CH2 = V R5 CH3 = V bias Figure19.AuxiliaryOutputwith2-WLoad,GateDriveandCurrentSense,VOUT1=380V 9 Reference Design Assembly Drawing R2 R58 Figure20.TopAssemblyLayer SLUU228–September2005 350-WInterleavedPFCPre-Regulator 15

www.ti.com BillofMaterials Figure21.BottomAssemblyLayer 10 Bill of Materials Table2.PartsList RefDes Count Description MFR PartNumber AC_L1, 0 Connector,bindingpost,insulated,forstandardbananaplug, Johnson 111-0702-001 VOUT1 red,15A,0.425diaIn AC_N1, 0 Connector,bindingpost,insulated,forstandardbananaplug, Johnson 111-0703-001 RETURN1 black,15A,0.425diaIn C1,C33 2 Capacitor,polyester,.047m F,630V,10%,0.256x0.650 Panasonic ECQ-E6473KZ C10,C17, 3 Capacitor,ceramic,0.1m F,50V,X7R,10%,0805 Panasonic ECJ-2YB1H104K C18 C12 1 Capacitor,ceramic,0.68m F,16V,X7R,10%,0805 std std C13 1 Capacitor,ceramic,270pF,50V,X7R,10%,0805 std std C14 1 Capacitor,ceramic,0.47m F,16V,X7R,10%,0805 Panasonic ECJ-2YB1H104K C15 1 Capacitor,ceramic,0.027m F,50V,X7R,10%,0805 std std C16,C27 2 Capacitor,ceramic,180pF,50V,X7R,10%,0805 std std C19,C23, 4 Capacitor,ceramic,1.0m F,25V,X7R,10%,0805 std std C28,C35 C2 1 Capacitor,ceramic,3.9nF,50V,X7R,10%,0805 std std C20,C21 2 Capacitor,film,0.47m F,275V ,0.236· 0.591 Panasonic ECQ-U2A474MG AC C22 1 Capacitor,film,0.047m F,300V ,20– %,0.236· 0.591 Panasonic ECQ-U3A473MG AC C24,C26 2 Capacitor,ceramic,56pF,50V,NPO,5%,0603 std std C25 1 Capacitor,ceramic,0.47m F,16V,X7R,10%,0603 std std C29,C30 2 Capacitor,ceramic,47pF,50V,X7R,5%,0603 std std C3 1 Capacitor,ceramic,68pF,50V,X7R,10%,0805 std std C31,C32 2 CAP,tantalumchip,47m F,16V,0.281x0.126 Vishay 595D476X9016C2T 16 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com BillofMaterials Table2.PartsList (continued) RefDes Count Description MFR PartNumber C34 1 Capacitor,220m F,aluminumelectrolytic,450V ,-40/+85°C, Panasonic ECOS2WP221CX DC – 20%,0.984India. C4 1 Capacitor,330m F,aluminumelectrolytic,25V,Temp-55(cid:176) Cto Rubycon UPW1E331MPD6 105(cid:176) C°,– 20%,8x11.5mm C5 1 Capacitor,ceramic,10nF,50V,X7R,10%,0805 std std C6,C11 2 Capacitor,ceramic,100pF,50V,X7R,10%,0805 std std C7 1 Capacitor,ceramic,2.2m F,16V,X7R,10%,1206 std std C8 1 Capacitor,ceramic,1m F,25V,X7R,10%,1206 std std C9 1 Capacitor,ceramic,0.22m F,50V,X7R,10%,0805 std std D1 1 IC,adjustableprecisionshuntregulator,SOT-89 Texas TL431CPK Instruments D13,D14 2 Diode,schottkyrectifier,10A,600V,TO-263-2 CREE CSD10060G D15 1 Diode,zener,15V,350mW,SOT-23 Diodes,Inc. BZX84C15 D16 1 Diode,600V,6A,400Apeaksurge,P600 Diodes,Inc. 6A6-T D2 1 Diode,rectifier,1000mA,50V,SMA Diodes,Inc. RS1A D3,D4,D5 3 Diode,schottky,500mA,25V,SMA Vishay BYS10-25 Telefunken D6,D7 2 Diode,signal,600V,1A,DO-41 On 1N4005RL Semiconductor D8 1 6A,600Vbridgerectifier,GBJseries General PB66 Semiconductor D9,D10, 4 Diode,schottky,500mA,30V,SOD123 ON MBR0530 D11,D12 Semiconductor F1 1 Fuseholder,1/4fuses,0.42 Cooper/Bussman BK/1A1907-06 Fuse 1 4A,250V,3AGglassfastactingcartridgetype,1.25Inx.25In Littlefuse 312004 HS1,HS2 2 Heatsink,TO-220,verticalmount,15(cid:176) C/W,0.5x0.95 Aavid 593002B03400 HS3,HS4 2 Heatsink,TO-220,verticalmount,5(cid:176) C/W,0.5x1.38In Aavid 513201 J1 1 Terminalblock,2pin,15A,5.1mm,0.40x0.35 OST ED1609 **L1,L2 2 200m Hinductor,toroidverticalTHT,100kHz@2A,0.866x Cooper CTX16-17309 1.358In Q1 1 Transistor,switchingpowerNPN,1000V,5A,TO-220 OnSemi MJE18004 Q2,Q3,Q4 3 MOSFET,N-channel,500V,8A,750mW ,TO-220 International IRF840 Rectifier R1 1 Resistor,powermetalfilm,82kW ,3W,5– %,1,000X0.200 Panasonic ERG-3SJ823 R12,R17, 7 Resistor,chip,10kW ,1/10W,1%,0805 std std R21,R22, R39,R56, R57 R13 1 Resistor,chip,5.11kW ,1/10W,1%,0805 std std R14 1 Resistor,chip,30.1kW ,1/10W,1%,0805 std std R15 1 Resistor,chip,3.74kW ,1/10W,1%,0805 std std R16 1 Resistor,chip,2kW ,1/10W,1%,0805 std std R18 1 Resistor,chip,12.1kW ,1/10W,1%,0805 std std R19 1 Resistor,chip,20kW ,1/10W,1%,0805 std std R2 1 Resistor,chip,110kW ,1/10W,1%,0805 std std R20 1 Resistor,chip,316kW ,1/10W,1%,0805 std std R23 1 Resistor,chip,34kW ,1/10W,1%,0805 std std R24 1 Resistor,chip,22.1kW ,1/10W,1%,0805 std std R25,R28 2 Resistor,chip,562kW ,1/8W,1%,0805 std std R26 1 Resistor,chip,15kW ,1/10W,01%,0805 std std SLUU228–September2005 350-WInterleavedPFCPre-Regulator 17

www.ti.com BillofMaterials Table2.PartsList (continued) RefDes Count Description MFR PartNumber R27 1 Resistor,chip,100W ,1/8W,0.1%,1206 std std R29,R40, 3 Resistor,chip,1kW ,1/10W,1%,0805 std std R41 R3 1 Resistor,chip,28.0kW ,1/10W,1%,0805 std std R30 1 Resistor,chip,9.09kW ,1/10W,1%,0805 Panasonic ERJ-6ENF9091V R32,R33 2 Resistorcurrentsense0.20W 3W,0.600· 0.250In Ohmite 13FR200 R34 1 Resistor,chip,59kW ,1/10W,5%,0805 std std R35 1 Resistor,chip,13.3kW ,1/10W,1%,0805 std std R36 1 Resistor,chip,38.3kW ,1/10W,1%,0805 std std R37 1 Resistor,chip,20.0W ,1/4W,1%,1206 std std R38 1 Resistor,chip,6.81kW ,1/10W,1%,0805 std std R4 1 Resistor,powermetalfilm,500V10kW ,3W,5– %,1,000X Panasonic ERG-3SJ103 0.200 R42 1 Resistor,chip,2.94kW ,1/8W,1%,805 std std R43,R44 2 Resistor,chip,6.04kW ,1/10W,1%,1206 std std R45 1 Resistor,chip,20.5kW ,1/10W,1%,0805 std std R46 1 Resistor,chip,80.6kW ,1/10W,1%,0805 std std R47,R50, 3 Resistor,chip,324kW ,1/10W,1%,0805 std std R51 R48,R49 2 Resistor,chip,100W ,1/10W,1%,0805 std std R5 1 Resistor,cabonfilm,4.3W 1/4W,5%,Axial,RN55 YAGEO CFR-25JB-4R3 R52,R54 2 Resistor,chip,0W ,1/10W,5%,0805 std std R53,R55 2 Resistor,chip,5.23W ,1/10W,1%,0805 std std R6,R31 2 Resistor,chip,47W ,1/10W,1%,0805 std std R7,R10 2 Resistor,chip,2.32kW ,1/10W,1%,0805 std std R8,R11 2 Resistor,chip,390kW ,1/8W,1%,1206 std std R9 1 Resistor,chip,1.5kW ,1/10W,1%,0805 std std **T1 1 Inductor,dual-coupled,9:1,0.559x0.508In Cooper CTX16-17169 **T2,T3 2 Transformer,currentsense,10A,500kHz,1:50,0.330x0.360 Pulse PA1005.050 TP1,TP2, 4 Jack,testpoint,clrcle Farnell 240-3xx TP3,TP4 **U1 1 IC,BiCMOSPFC\PWMController,SOP20(DW) TI UCC28528DW **U2 1 IC,Precisionop-amp,SO8 TI OP07DD **U3 1 IC,DualinterleavedPWMcontrollerwithprogrammablemax TI UCC28220D dutycycle,SO16 **U4 1 IC,HighspeedlowsidepowerMOSFETdriver,SO8 TI UCC27324D X1@HS1, 4 Thermalpadsilicon,TO-220size BERQUIST 3223-07FR-51 HS2,HS3, HS4 X1@HS1, 4 Nut#4-40(steel) HS2,HS3, HS4 X1@HS1, 4 Splitlockwasher#4(steel) HS2,HS3, HS4 X1@HS1, 4 Flatwasher#4(steel) HS2,HS3, HS4 X1@HS1, 4 Nylonshoulderwasher#4 Keystone 3049 HS2,HS3, Electronics HS4 18 350-WInterleavedPFCPre-Regulator SLUU228–September2005

www.ti.com BillofMaterials Table2.PartsList (continued) RefDes Count Description MFR PartNumber X1@HS1, 4 Panheadscrew#4-40X3/8(steel) HS2,HS3, HS4 Standoff 4 Panheadscrew#6X321/4nylon,usedwithstandoffs Standoff 4 Standoff6/32thrd3/8· 3/8In Daburn 10-42 Electronics -- 1 PCB,0Inx0Inx0In Any HPA117A SLUU228–September2005 350-WInterleavedPFCPre-Regulator 19

FCCWarnings Thisequipmentisintendedforuseinalaboratorytestenvironmentonly.Itgenerates,uses,and canradiateradiofrequencyenergyandhasnotbeentestedforcompliancewiththelimitsof computingdevicespursuanttosubpartJofpart15ofFCCrules,whicharedesignedtoprovide reasonableprotectionagainstradiofrequencyinterference.Operationofthisequipmentinother environmentsmaycauseinterferencewithradiocommunications,inwhichcasetheuserathis ownexpensewillberequiredtotakewhatevermeasuresmayberequiredtocorrectthis interference. EVMWARNINGSANDRESTRICTIONS ItisimportanttooperatethisEVMwithintheinputvoltagerangeof85Vto125VRMSandthe outputvoltagerangeof374Vto425V. Exceedingthespecifiedinputrangemaycauseunexpectedoperationand/orirreversibledamage totheEVM.Iftherearequestionsconcerningtheinputrange,pleasecontactaTIfield representativepriortoconnectingtheinputpower. Applyingloadsoutsideofthespecifiedoutputrangemayresultinunintendedoperationand/or possiblepermanentdamagetotheEVM.PleaseconsulttheEVMUser'sGuidepriorto connectinganyloadtotheEVMoutput.Ifthereisuncertaintyastotheloadspecification,please contactaTIfieldrepresentative. Duringnormaloperation,somecircuitcomponentsmayhavecasetemperaturesgreaterthan 50(cid:176) C.TheEVMisdesignedtooperateproperlywithcertaincomponentsabove50(cid:176) Caslongas theinputandoutputrangesaremaintained.Thesecomponentsincludebutarenotlimitedto linearregulators,switchingtransistors,passtransistors,andcurrentsenseresistors.Thesetypes ofdevicescanbeidentifiedusingtheEVMschematiclocatedintheEVMUser'sGuide.When placingmeasurementprobesnearthesedevicesduringoperation,pleasebeawarethatthese devicesmaybeverywarmtothetouch. MailingAddress:TexasInstruments,PostOfficeBox655303,Dallas,Texas75265 Copyright©2005,TexasInstrumentsIncorporated

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