Texas Instruments UCC28064EVM-004 User manual

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

User's Guide

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

The UCC28064A is a dual-phase, transition-mode Power Factor Correction (PFC) pre-regulator. The

UCC28064EVM-004 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 UCC28064EVM.

Trademarks

Natural Interleaving is a trademark of Texas Instruments.

All other trademarks are the property of their respective owners.

1 Description

The pre-regulator uses UCC28064A 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 UCC28064A in a typical

PFC application.

2 Thermal Requirements

This evaluation module will operate up to 300 W without external cooling in ambient temperatures of 25°C.

3 Electrical Characteristics

Table 1 summarizes the electrical specifications of the UCC28064EVM-004.

Table 1. UCC28064EVM-004 Electrical Specifications

PARAMETER CONDITIONS UCC28064EVM UNITS

MIN TYP MAX

RMS input voltage (ac line) 85 265 VRMS

Output voltage, VOUT 390 V

Line frequency 47 63 Hz

Power factor (PF) at maximum load 0.9

Output power 300 W

Full load efficiency AC line = 115 V 93%

AC line = 230 V 96%

Schematics

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UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

4 Schematics

Figure 1 shows the schematic for this EVM. See Table 1 for specific values

To evaluate inductor ripple currents, resistors R25 and R26 can be removed and replaced with current loops.

Figure 1. UCC28064EVM-004 Schematic Diagram

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Test Setup and Power-Up/Power-Down Instructions

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

5 Test Setup and Power-Up/Power-Down Instructions

WARNING

There are high voltages present on the pre-regulator. It must only

be handled by experienced power supply professionals. To

evaluate this board as safely as possible, the following test

configuration must 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 UCC28064A control circuitry. The unit will start up

under no-load conditions. However, for safety, a load must be connected to the output of the device before

it is powered up. The unit must also never be handled while power is applied to it or when the output

voltage is above 50-V dc. Refer to Figure 2 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.

Test Setup and Power-Up/Power-Down Instructions

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UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

Figure 2. Test Setup

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Typical Performance Data

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

6 Typical Performance Data

Figure 3 through Figure 14 present characteristic performance data for the UCC28064EVM-004.

Figure 3. Efficiency at 115 VRMS

Figure 4. Efficiency at 230 VRMS

Table 2. Performance Data at 115Vac

Pin (W) Power Factor Vo (V) Io (A) Pout (W) Effic (%) THD (%)

.055 388 0

21.2 0.953 387.8 0.05 19.7 92.92 25.43

41.4 0.985 387.10 0.1 39.1 94.44 4.54

61.83 0.993 386.96 0.15 58.46 94.55 3.19

82.43 0.995 387.15 0.2 77.74 94.31 2.82

103.44 0.997 387.05 0.25 97.07 93.84 7.72

122.9 0.995 386.63 0.3 116.3 94.63 3.31

143.3 0.996 386.54 0.35 135.8 94.77 3.04

163.5 0.997 387.09 0.4 154.89 94.73 2.82

184.1 0.997 386.3 0.45 174.03 94.53 2.49

205 0.998 386.21 0.5 193.85 94.56 2.33

225.4 0.998 386.17 0.55 213.74 94.83 2.28

245.7 0.998 386.4 0.6 232.4 94.59 1.92

266.4 0.998 387.2 0.65 251.2 94.29 2.18

287.4 0.999 386.2 0.7 270.9 94.26 1.98

Table 3. Performance Data at 230Vac

Pin (W) Power Factor Vo (V) Io (A) Pout (W) Effic (%) THD (%)

.075 388 0

20 0.829 388.45 0.05 19.37 96.85 38.4

41.16 0.935 386.7 0.1 39.5 95.97 29.08

60.12 0.958 386.88 0.15 58.4 97.14 18.88

80.4 0.975 386.78 0.2 77.8 96.77 14.03

100.21 0.982 386.52 0.25 97.1 96.90 11.72

120.6 0.977 386.81 0.3 116.3 96.43 18.55

140.51 0.982 386.74 0.35 135.47 96.41 15.97

Typical Performance Data

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Table 3. Performance Data at 230Vac (continued)

Pin (W) Power Factor Vo (V) Io (A) Pout (W) Effic (%) THD (%)

160.1 0.986 386.12 0.4 154.89 96.75 14.45

179.74 0.988 386.28 0.45 174.32 96.98 12.94

199.48 0.99 386.39 0.5 193.79 97.15 11.82

219.15 0.991 386.81 0.55 212.6 97.01 10.84

239.04 0.993 386.89 0.6 232.11 97.10 9.89

258.7 0.993 386.53 0.65 251.75 97.31 9.26

278.44 0.994 387.03 0.7 270.4 97.11 8.64

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Typical Performance Data

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

6.1 Burst Mode Operation

Figure 5 and Figure 6 illustrate burst mode line current at 115Vac and 230Vac

C2: GDA, C3: GDB, C1: ILINE

Figure 5. 115Vac 20W C2: GDA, C3: GDB, C1: ILINE

Figure 6. 230Vac 20W

6.2 Single Phase Operation

Figure 7 and Figure 8 show the input line current, gate drive signals GDA and GDB in the single phase

mode .

C2: GDA, C3: GDB, C1: I LINE

Figure 7. 115Vac 80W C2: GDA, C3: GDB, C1: I LIN

Figure 8. 230Vac 80W

Typical Performance Data

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6.3 Dual Phase (Interleaved) Operation

Figure 9 and Figure 10 show the input line current, gate drive signals GDA and GDB in the dual phase (or

interleaved) mode phase mode

C2: GDA, C3: GDB, C1: I LINE

Figure 9. 115V 200W C2: GDA, C3: GDB, C1: I LINE

Figure 10. 230V 200W

6.4 Startup Characteristics

Figure 11 and Figure 12 show the startup behaviour at 85Vac and 264Vac

C2: V out , C4: V ACin Figure 11. Startup 85Vac 200W C2: V out , C4: V ACin Figure 12. Startup 264Vac 200W

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Typical Performance Data

SNVU587A–November 2017–Revised October 2018

UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

6.5 Load Step

A load transient test was conducted with an ac source on the EVM. The load was varied from 50mA to

500mA to 50mA.

This corresponds to a 20W to 200W to 20W variation.

The results are detailed in Figure 13.

C2: V out , C4: I OUT

Figure 13. Load Step

Line Transient

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UCC28064EVM-004 300-W Interleaved PFC Pre-Regulator

7 Line Transient

A line transient test was conducted with an ac source on the EVM. The load was fixed at 200W and the

line was varied from 115Vac to 230Vac

The results are detailed in to UCC28064A line step data Figure 14

C2: V out , C4: V inAC

Figure 14. Line Step

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