Texas Instruments UCD3138PFCEVM-026 User manual

Using the UCD3138PFCEVM-026

User's Guide

Literature Number: SLUU885B

March 2012–Revised July 2012

www.ti.com

WARNING

Always follow TI’s set-up and application instructions, including use of all interface components within their

recommended electrical rated voltage and power limits. Always use electrical safety precautions to help

ensure your personal safety and the safety of those working around you. Contact TI’s Product Information

Center http://support/ti./com for further information.

Save all warnings and instructions for future reference.

Failure to follow warnings and instructions may result in personal injury, property damage, or

death due to electrical shock and/or burn hazards.

The term TI HV EVM refers to an electronic device typically provided as an open framed, unenclosed

printed circuit board assembly. It is intended strictly for use in development laboratory environments,

solely for qualified professional users having training, expertise, and knowledge of electrical safety risks in

development and application of high-voltage electrical circuits. Any other use and/or application are strictly

prohibited by Texas Instruments. If you are not suitably qualified, you should immediately stop from further

use of the HV EVM.

1. Work Area Safety:

(a) Keep work area clean and orderly.

(b) Qualified observer(s) must be present anytime circuits are energized.

electronics are energized, indicating operation of accessible high voltages may be present, for the

purpose of protecting inadvertent access.

(d) All interface circuits, power supplies, evaluation modules, instruments, meters, scopes and other

related apparatus used in a development environment exceeding 50 VRMS/75 VDC must be

electrically located within a protected Emergency Power Off (EPO) protected power strip.

(e) Use a stable and non-conductive work surface.

(f) Use adequately insulated clamps and wires to attach measurement probes and instruments. No

freehand testing whenever possible.

2. Electrical Safety:

(a) De-energize the TI HV EVM and all its inputs, outputs, and electrical loads before performing any

electrical or other diagnostic measurements. Revalidate that TI HV EVM power has been safely de-

energized.

(b) With the EVM confirmed de-energized, proceed with required electrical circuit configurations, wiring,

measurement equipment hook-ups and other application needs, while still assuming the EVM circuit

and measuring instruments are electrically live.

WARNING: while the EVM is energized, never touch the EVM or its electrical circuits as they

could be at high voltages capable of causing electrical shock hazard.

3. Personal Safety:

(a) Wear personal protective equipment e.g. latex gloves and/or safety glasses with side shields or

protect EVM in an adequate lucent plastic box with interlocks from accidental touch.

4. Limitation for Safe Use:

(a) EVMs are not to be used as all or part of a production unit.

2SLUU885B–March 2012–Revised July 2012

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User's Guide

SLUU885B–March 2012–Revised July 2012

Digitally Controlled Single-Phase PFC Pre-Regulator

1 Introduction

This EVM is to help evaluate the UCD3138 64-pin digital control device in off-line power converter

application and then to aid its design. The EVM is a standalone Power Factor Correction (PFC) pre-

regulator of single-phase AC input. The EVM UCD3138PFCEVM-026 is used together with its control

card, UCD3138CC64EVM-030, also an EVM on which is placed UCD3138RGC.

The EVM of UCD3138PFCEVM-026 together with UCD3138CC64EVM-030 can be used as they are

delivered without additional work, from either hardware or firmware, to evaluate PFC. The

UCD3138PFCEVM-026 together with the UCD3138CC64EVM-030 can also be re-tuned on its design

parameters through the operation of GUI, called Texas Instruments Fusion Digital Power Designer, or re-

loaded up with custom firmware with user’s definition and development.

The EVM system is in topology of single-phase boost converter at its delivery on both hardware and

firmware, but can be re-configured into two other PFC topologies: dual-phase interleaved, and bridgeless,

then corresponding operation can be made by reloading with that associated firmware. All necessity of

hardware and firmware for the two additional topologies are already developed and delivered with the

shipment. Please contact Texas Instruments to obtain the instructions how to make re-configuration.

In the package delivered, three EVMs are included UCD3138PFCEVM-026, UCD3138CC64EVM-030, and

USB-TO-GPIO. In the same package, also included is a hard copy of Evaluation Module Electrical Safety

Guideline.

This user’s guide provides basic evaluation instruction from a viewpoint of system operation in standalone

PFC in its boost configuration.

SLUU885B–March 2012–Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator

Description

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2 Description

UCD3138PFCEVM-026 together with UCD3138CC64EVM-030 is an EVM of PFC pre-regulator with digital

control using UCD3138 device in boost converter topology and in the application of single-phase AC input.

UCD3138 device is located on the board of UCD3138CC64EVM-030. UCD3138CC64EVM-030 is a

daughter card and serves all PFC required control functions with preloaded single-phase boost PFC

firmware. UCD3138PFCEVM-026 accepts universal AC line input from 90 VAC to 264 VAC, and outputs

nominal 390 VDC with full load output power 360 W, or full output current 0.92 A.

2.1 Typical Applications

• Single-Phase Universal AC Line Power Factor Correction Pre-Regulator

• Servers

• Telecommunication Systems

2.2 Features

• Digitally Controlled PFC Pre-Regulator

• Universal AC Line Input from 90 VAC to 264 VAC with AC Line Frequency 47 Hz to 63 Hz

• Regulated Output 390 VDC with Output from No-Load to Full-Load

• Full-Load Power 360 W, or full-Load Current 0.92 A

• High Power Factor Close to 0.999 and Low THD Below 5% in Most Operation Conditions

• High Efficiency

• Protection:

– Over Voltage

– Over Current

– Brownout

– Power-On Inrush Current

• Test Points to Facilitate Device and Topology Evaluation

• Re-Configurable to Dual-Phase Interleaved PFC or Bridgeless PFC (please contact TI for detail)

4Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012

Submit Documentation Feedback

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Electrical Performance Specifications

3 Electrical Performance Specifications

Table 1. UCD3138PFCEVM-026 Electrical Performance Specifications

PARAMETER TEST CONDITIONS MIN TYP MAX UNITS

Input Characteristics

Voltage range 90 264 VAC

Line frequency 47 63 Hz

Input current, peak Input = 90 VAC, 60 Hz, full load = 0.92 A 6.5 7.0 A

Input current, RMS Input = 90 VAC, 60 Hz, full load = 0.92 A 4.5 5.5

Input UVLO On PFC function start (no load) 86 90 VAC

Input UVLO Off PFC function stop (no load) 80 83

Power factor Half load 0.99 -

THD, input current 10% to 30% full load 10%

30% to 100% full load 5%

Output Characteristics

Output voltage, VOUT No load to full load 390 VDC

Output load current, IOUT 90 VAC to 264 VAC 0.92 A

Output voltage ripple Full load and 115 VAC, 60 Hz 13 Vpp

Full load and 230 VAC, 50 Hz 15

Output over current 0.95 A

Systems Characteristics

Switching frequency Normal operation 100 kHz

Peak efficiency 230 VAC, full load 96%

Full load efficiency 115 VAC, full load 94%

Operating temperature Natural convection 25 ºC

SLUU885B–March 2012–Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator

DPWM_3B

FAULT_0

SCI_TX1

PWM-1

SCI_RX0

GND_Ext

FAULT_1

SYNC

SCI_RX1

PWM-0

SCI_TX0

3.3V

Ext Supply

AD_01

AD_02

AD_05

AD_07

AD_08

EADC_P2

EADC_P1

When U11 not installed, connect J14-1 and -3 to external source to get +12V_EXT

Vin = 90 to 264 Vac (47 to 63Hz)

Copper fill for heat-sink

AD_00

AD_03

AD_04

AD_06

EADC_P0

Isolated GND

OPTO Isolated Section

Isolated GND

R31 and R106 are preload resistors

If needed, connect J15-1 and -2 to use U11 to bias secondary side

External sync signal

Bridgeless PFC with CT_1 and CT_2 and Interleaved PFC with ISENSE_SHUNT.

Parts not used

AD_13

AGND

DGND

AC_Line

AC_Neutral

if use VAUX_P but not use VAUX_S

Secondary side

Isolation line

Fuse: T7A/250VAC

(J3-13)

(J3-25)

(J3-26)

(J4-18)

(J4-20)

(J3-11)

(J3-8)

Secondary side

TP8

TP9

TP12

TP13

TP10

R31

1.5k

4.7nF

R19 4.7k

+C1

10uF

TP11

47nF

D18

C37

0.47uF

D21

TP4

R14

3.83k

R13 200k

R27

200k

D20

C20

1nF

R16

3.83k

R29

200k

R15

200k

TP3

R68

C25

R24 R78

1.1k

TP2

TP1

J10

R20 4.7k

C21 10uF

R28

200k

R3 50

C17

0.1uF

C13

0.1uF

C27

0.1uF

R79

100

R36

R34

R72

1.5k

J11

R21 4.7k

MMBT3904TT1

D19

LN1371GTR

D24 MBR0530

C12

1nF

TP7

47nF

C38

0.47uF

MMBT3904TT1

D6 BAT54S

TP14

R30

200k

R22

4.7k

C15

0.1uF

R35 0

R33 0

2mH

3IN

1ADJ/GND 2

OUT

TLV1117-33IDCY

7.80uH

C29

1N4148W

C28

0.1uF

SFH6156-2

C9 0.1uF

C14

0.1uF

1EN

2C1+

3V+

4C1-

5C2+

6C2-

7V-

8R1IN 9

R1OUT

INVALID

T1IN

FORCEON

T1OUT

GND

VCC

FORCEOFF

SN75C3221DBR

1VCC1

2OUTA

3INB

4GND1 5

GND2

OUTB

INA

VCC2

ISO7221CD

MMBT3904TT1

D25

BAT54S

4.7nF

2N7002

1VIN+

2VAUX_P

3-VAUX_-VIN

4-VIN

GND

VIN_MONITOR

VAUX_S

DB-1

PWR050

SH2

R23

3.3k

TP5

C30

330pF

R42 1k

R82

1k R81

R80

R32 0

R49 0

R77 0

R76 0

R75 0

R37 10k

R38 10k

R70

10k

R74

10k

R73

10k

SYNC_IN

LED_3

+12V_EXT

DPWM-1B

SCI_RX0

+3_3V

ISO_SCI_TX

ISO_SCI_RX

VAUX_P

+3_3V

DPWM-2B

+3_3V

+3_3V V33D_ISO

V33D_ISO

VAUX_S_RTN

VAUX_S

+12V_EXT

VAUX_S

VAUX_S_RTN

LED_1

AC_DROP

RLY_CTRL

LED_1

SCI_TX1

SCI_RX1

LED_3

+3_3V

DPWM-0A

DPWM-2A

DPWM-3A

SCI_TX0

IIN_SENSE

VBUS_OV

AC_N

SCI_TX1

SCI_RX1

CT_1

ISENSE_SHUNT

SCI_RX0

VAUX_P_RTN

VAUX_P

VAUX_S

LED_2

SYNC_IN

LED_2

DPWM-1A

RLY_CTRL

AC_L

+12V_EXT

CT_1

AC_L

CT_2

AC_DROP

V33D_ISO

SCI_TX0

AC_NEU_PFC

AC_L_PFC

+12V_EXT

IPM

VBUS_SENSE

CT_2

BUS+

VAUX_P

VAUX_P_RTN

VAUX_S_RTN

AC_N

GND_EARTH

Schematics

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4 Schematics

Figure 1. UCD3138PFCEVM-026 Schematic

6Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012

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Interleaved PFC: Jump across E6 and E4, and E1 and E5.

PGND

Bridgeless PFC: Jump across E2 and E6, and E3 and E1.

Vbus = 390VDC, Iout = 0.92A

DGND

Parts not used

Single-phase PFC: default connection E6 to E4.

(J4-40)

(J3-15)

(J3-7)

Vbus

(J4-10)

(J4-16)

(J4-30)

(J3-3)

(J3-4)

(J3-5)

(J3-6)

(J4-12)

(J4-8)

(J4-6)

TP23

TP22

TP24

TP20

C18

0.1uF TP16

R71 910

SH1

R60

49.9k

TP21

R48

1.8k

C7 4.7nF

C32

150pF

R44 0

R43

R66

TP19

R64 10k

R55

5.23

TP26

BAT54S

D14

C3D10060G

D13

C3D10060G

R50

1.8k

C24

0.1uF

TP17

C40

47nF

C19

0.1uF

100k

TP15

R10

100k

+C34

220uF

5.01k

C23

0.1uF

TP6

R40

C26

1uF

TP25

HS3

C39

47nF

R47

1.8k

R25

100k

BAT54S

R69

1.6k

C36

100pF

R39 2k

C16

0.01uF

R6 0.02

R7 0.02

C22

47nF

TP18

R18

100k

R17

100k

R11

100k

BAT54S

R45 100

MURS160T3

R63

D15

BAT54S

R53

5.23

D22 BAT54S

D11

MBR0530

327uH

C33

47nF

R46

100k

R67

100k

R59 49.9k

OPA350EA

BAT54C

3.3M

R58 2k

D23 BAT54S

R12

100k

D16 6A6-T

1N/C

2INA

3GND

4INB 5

OUTB

VDD

OUTA

N/C

UCC27324D

R65 10k

HS2

IPP60R199CP

PA1005.050

C31

47uF

327uH

IPP60R199CP

PA1005.050

R26

100k

R51

100k

R62

100k

C41

47nF

BAT54S

C35 100pF

D12

MBR0530

OPA350EA

2N7002

D17

GBU8J

0.1uF

VDD

GND

IN+ IN-

OUT

VDD

GND

IN+ IN-

OUT

C10

C11

ZHCS506

D10 ZHCS506

HS1

JMP1

R61

R54

R41 0

R52

R56

10k

R57

10k

AC_L_PFC

+3_3V

IIN_SENSE

IPM

DPWM-3A

SYNC_IN

+3_3V

CT_2

DPWM-1B

DPWM-1A

CT_1

SWITCH_NODE

+3_3V

AC_NEU_PFC

+3_3V

DPWM-2A

DPWM-2B

+3_3V

SWITCH_NODE

+3_3V

VBUS_SENSE

ISENSE_SHUNT

+12V_EXT

VBUS_OV

+12V_EXT

GND_EARTH

BUS+

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Schematics

Figure 2. UCD3138PFCEVM-026 Schematic

SLUU885B–March 2012–Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator

Electronic

Load

VM1

AC Source

J6 J5

TP17 TP22

J1 J2

Test Setup

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5 Test Setup

5.1 Test Equipment

AC Voltage Source:capable of single-phase output AC voltage 85 VAC to 265 VAC, 47 Hz to 63 Hz,

adjustable, with minimum power rating 400 W, the AC voltage source to be used should meet IEC60950

reinforced insulation requirement.

DC Multimeter: capable of 0-V to 500-V input range, four digits display preferred.

Output Load: DC load capable of 400 VDC or greater, 1 A or greater, and 400 W or greater, with display

such as load current and load power.

Oscilloscope: capable of 500-MHz full bandwidth, digital or analog, if digital 5 Gs/s or better.

Current probe: capable of 0 A to 10 A, 100-MHz or greater full bandwidth, AC coupling.

Fan: 200 LFM to 400 LFM forced air cooling is recommended, but not a must.

Recommended Wire Gauge: capable of 4-A RMS, or better than #16 AWG, with the total length of wire

less than 8 feet (4 feet input and 4 feet return).

5.2 Recommended Test Setup

Figure 3. UCD3138PFCEVM-026 Recommended Test Setup

8Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012

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UCD3138CC64EVM-030

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Test Setup

Figure 4. EVM Orientation of UCD3138PFCEVM-030 on the UCD3138PFCEVM-026

SLUU885B–March 2012–Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator

List of Test Points

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6 List of Test Points

Table 2. List of Test Points

TEST POINTS NAME DESCRIPTION

TP1 T1OUT UART0 (J9-2) T1OUT

TP2 R1IN UART0 (J9-3) R1IN

TP3 DGND Digital GND of J3 connection

TP4 +3_3V 3.3-V LDO output on board from 12 V

TP5 RC-PWM-0A DPWM0A RC filter

TP6 CT_2 Second phase current sensing signal

TP7 AC_N Input voltage sensing signal of Neutral wire

TP8 DGND Digital GND and same as TP3

TP9 VAUX_S Secondary side 12 V on board. Not used, but can be used for external circuit.

TP10 VAUX_P 12-V output on board from DB-1, UCC28600EVM400V-12V

TP11 +12V_EXT 12 V on board from VAUX_P

TP12 K1 Relay K1 coil

TP14 AC_L Input sensing signal of Line wire

TP15 VBUS_SENSE PFC output voltage sensing signal

TP16 GND Analog GND

TP17 BUS- PFC output return

TP18 REC-1 Rectifier positive output

TP19 CT-1 Current sensing signal from current transformer T1

TP20 ISENSE Current sensing signal after conditioning

TP21 REC-2 Rectifier return

TP22 BUS+ PFC output positive, nominal 390VDC

TP23 SW2 Q2 Drain pin

TP24 SW1 Q3 Drain pin

TP25 Q2-Gate Gate pin of Q2 MOSFET

TP26 Q3-Gate Gate pin of Q3 MOSFET

7 List of Terminals

Table 3. List of Terminals

TERMINAL NAME DESCRIPTION

J1 Line Board AC input line, single-pin connection – screw type, J1 and J2 are AC input terminals,

rated up to 264 VAC and maximum 7.5 A, 47 Hz to 63 Hz.

J2 Neutral Board AC input neutral, single-pin connection – screw type

J3 DJ Digital signal connection, 40 pins

J4 AJ Analog signal connection, 40 pins

J5 BUS+ PFC output positive connection, single-pin connection – screw type, BUS+ and BUS- are DC

output terminals, rated maximum 400 VDC, and maximum current 1 A.

J6 BUS- PFC output return, single-pin connection – screw type

J7 12V_Sec 12-V auxiliary to supply to external circuit on the secondary side, 2 pins

J8 UART1 Isolated and communication to DC converter, not production tested, 6 pins

J9 UART0 Non-isolated connection, standard RS232, 9 pins,

J10 Sync External 12-V bias and sync signal, 3 pins

J11 Chassis Chassis ground, or earth connection, single-pin connection – screw type

10 Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B–March 2012–Revised July 2012

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