Using the UCC24610EVM-563 User's Guide Literature Number: SLUU434 August 2010 User's Guide SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification 1 Introduction The UCC24610EVM-563 evaluation module is a 25-W off-line Discontinuous Mode (DCM) flyback converter providing an output voltage of 5 V at 5-A maximum load current, operating from a universal AC input. The module is controlled by the UCC28610 Green-Mode Flyback Controller on the primary side which uses a cascoded architecture that allows fully integrated current control without an external sense resistor. Secondary-side synchronous rectification is controlled by the UCC24610 GREEN RectifierTM Controller. The UCC24610 senses the drain-to-source voltage of the synchronous rectifier MOSFET in order to drive the GATE signal. The GATE output duty cycle is dependent upon the system line and load conditions, as well as the programmed minimum on-time and off-time. The converter maintains discontinuous mode operation over the entire operating range. This innovative approach results in efficiency, reliability, and system cost improvements over a conventional flyback. 2 Description This evaluation module uses the UCC24610 GREEN RectifierTM Controller (TI Literature Number SLUSA87) in a 25-W DCM flyback converter that exceeds Energy StarTM EPS version 2.0 for efficiency during active load and no-load power consumption for low voltage AC-to-DC external power supplies. The input accepts a voltage range of 85 VAC to 265 VAC. The output provides a regulated output voltage of 5 VDC at a load current of up to 5 A. The converter will transition through three operating modes: Green Mode (GM), Amplitude Modulation (AM), and Frequency Modulation (FM), depending upon the power level and FB current of the primary-side controller. In FM Mode, which occurs between approximately 25% and 100% rated load, the on time is fixed, resulting in a fixed peak primary current at each cycle, and the switching frequency is increased with increasing load. In AM Mode, which occurs from approximately 2% rated load up to 25% rated load, the switching frequency is fixed at 30 kHz and the peak primary current is modulated with the on time as with any typical PWM controller. Green Mode operation, at loads less than 2%, consist of burst packets of 30-kHz pulses with a fixed on time and peak primary currents of 33% the maximum programmed level. The conduction time of the synchronous rectifier MOSFET (SR-MOSFET) is determined by comparing the SR-MOSFET's drain-to-source voltage against internal turn-on and turn-off thresholds. Secondary-side control features automatic light-load management based upon internal timing conditions and the RDS(on) of the SR-MOSFET. The UCC24610 requires a minimal amount of simple, low-power external components to provide a cost effective, efficient solution for low-voltage power supplies. This user's guide provides the schematic, component list, assembly drawing, art work, and test set up necessary to evaluate the UCC24610 in a typical off-line DCM Flyback converter application. 2 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 Description www.ti.com 2.1 Applications The UCC24610 is suited for use in isolated off-line systems requiring high efficiency and advanced fault protection features including: * 5-V AC-to-DC Adaptors * Housekeeping and Auxiliary 5-V Bias Supplies * Low-Voltage Rectification Circuits 2.2 Features The UCC24610EVM-563 features include: * Isolated 5-V, 25-W Output * Universal Off-Line Input Voltage Range * Exceeds Energy StarTM EPS Version 2.0 Requirements (for active load efficiency and no-load power consumption for low voltage external power supplies) * Cascoded Configuration on Primary Side (allows fully integrated current control without an external sense resistor) * Multiple Operating Modes (for optimum efficiency over entire operating range) * Automatic Light-Load Management * Output Short-Circuit Protection * Improved Efficiency Over Traditional Output Diode Applications CAUTION High voltage levels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the EVM. The large bulk capacitor, C5, must be completely discharged before the EVM can be handled. Serious injury can occur if proper safety precautions are not followed. SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 3 Electrical Performance Specifications 3 www.ti.com Electrical Performance Specifications Table 1. UCC24610EVM-563 Electrical Performance Specifications PARAMETER NOTES AND CONDITIONS MIN NOM MAX UNITS Input Characteristics VIN Input voltage IIN Input current VUVLO Brown out 85 265 VIN = 115 VRMS, IOUT = 5 A 0.6 VIN = 115 VRMS, IOUT = 0 A 0.03 IOUT = 5 A VRMS A 69 V Output Characteristics VOUT Output voltage VIN = 85 VRMS to 265 VRMS, IOUT = 0 A to 5 A 4.5 5 5.6 VRIPPLE Output voltage ripple VIN = 115 VRMS, IOUT = 5 A IOUT Output current VIN = 85 VRMS to 265 VRMS IOCP Output over current inception point VIN = 115 VRMS VOVP Output OVP IOUT = 0 A to 5 A 6.5 V Transient response voltage over shoot VIN = 115 VRMS, IOUT = 0 A to 5 A 600 mV 200 0 V mVpp 5 A 7 System Characteristics fSW Switching frequency hPEAK Peak efficiency hAVG Average efficiency No-load power consumption Operating temperature range 26.3 140.4 VIN = 115 VRMS, IOUT = 1.75 A 82.7% VIN = 115 VRMS, IOUT = 25%, 50%, 75%, 100% rated load 82.3% VIN = 230 VRMS, IOUT = 25%, 50%, 75%, 100% rated load 82.3% VIN = 115 VRMS 181 VIN = 230 VRMS 368 VIN = 85 VRMS to 265 VRMS, IOUT = 0 A to 5 A 25 kHz mW C Mechanical Characteristics Width Length Height 4 2.3 Dimensions 3.5 Component height 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated inches 1 SLUU434 - August 2010 Schematic www.ti.com Schematic + + + + + + 4 Figure 1. UCC24610EVM-563 Schematic SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 5 Schematic 4.1 www.ti.com Circuit Description Diode bridge D1, input capacitor C5, transformer (a.k.a. flyback inductor) T1, HV MOSFET Q2, UCC28610 controller U3, synchronous rectification MOSFET Q1, output capacitors C8, C9, and C10 form the power stage of the converter. Note that the UCC28610 U3 is part of the power stage. This is because the DRV and GND pins carry the full-peak primary-side current of the converter. UCC24610 controller U1 drives the synchronous rectification MOSFET Q1, R11 sets the minimum time that Q1 will remain off, ignoring any resonant ringing that may inadvertently trigger the turn-on detection circuit. Resistor R12 performs a similar function in regards to the on-time of Q1 by programming the minimum time that Q1 will remain on despite any ringing due to noise that may inadvertently trigger a turn-off response. Resistor R9 dampens any resonant tank ringing on the gate of Q1. To reduce the current drawn out of VD, resistor R5 is added between VD and the drain of Q1. Because VD and VS are inputs to a differential comparator, a resistor, R8, is also needed between VS and the source of Q1. Bench testing concluded that using a slightly larger value for R8 on VS extended the on-time of Q1, and reduced the body diode conduction time. Capacitors C6, C7, and C12 filter the high-frequency noise directly across the electrolytic input and output capacitors. The input EMI filter is made up of X2 capacitors, C3 and C4, and common mode inductor L1. Excessive surge current protection is provided by a slow blow fuse, F1. Resistor R1, capacitor C1, and diode D2 make up the primary side voltage clamp for the HV MOSFET. The clamp prevents the drain voltage on Q2 from exceeding its maximum rating. The integrated snubber, composed of R2 and C1, reduces the ringing on the primary-side windings that might inadvertently trigger the light-load shutdown point of the UCC24610 gate drive. Resistors R4, R6, and R7 supply start-up bias current to the VGG shunt regulator of U3. Schottky diode D5 is required to provide initial start up to VDD from VGG at start up. Operating bias to the UCC28610 controller is provided by the auxiliary winding on T1, diode D3, and bulk capacitor C16. The zener diode, D7, maintains the bias voltage on U3 VDD below the absolute maximum rating at full load. Primary switch gate drive circuitry is composed of gate drive resistor R13, used for damping oscillations during turn on. Resistor R14 and diode D4 are required to provide a current path at turn off because the gate is shorted to the source of the HV MOSFET during each switching cycle. Ferrite bead FB1 reduces the high ringing on VGG at turn off. Capacitors C17, C18, and C13 are decoupling capacitors which should always be good quality low ESR/ESL type capacitors placed as close to the controller device pins as possible and returned directly to the device ground reference. C2 filters the common mode noise between the primary and secondary sides. Inductor L2, with capacitor C11, reduces the output voltage ripple. Resistors R19 and R21 program the over voltage threshold. Capacitor C15 can be used to add a small delay to U3 ZCD, to align the turn-on time of the primary switch with the resonant valley of the primary winding. Resistor R23 programs the maximum on time of the primary side HV MOSFET. Resistor R22 sets the maximum value for the peak-primary current. Resistor R18 and capacitor C14 provide a filter for the U3 FB signal while resistor R20 ensures that the optocoupler emitter current can go to 0 A. Output voltage regulation is provided by diode D6, resistors R15 and R17, and the optocoupler U2. Using an opto with a low current transfer ratio provides better noise immunity. Resistor R10 is used as an injection point for small signal frequency response testing. 6 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 EVM Test Set Up www.ti.com 5 EVM Test Set Up Figure 2 shows the equipment set up when measuring the input power consumption during no load. Notice the addition of the 10- shunt resistor in Figure 2. During the no-load test, the power analyzer should be set for long averaging in order to include several cycles of operation and an appropriate current scale factor for using the external shunt must be used. Figure 3 shows the basic test set up recommended to evaluate the UCC24610EVM-563 with a load. WARNING High voltages that may cause injury exist on this evaluation module (EVM). Please ensure all safety procedures are followed when working on this EVM. Never leave a powered EVM unattended. 5.1 Test Equipment See Figure 2 and Figure 3 for recommended test set ups. * AC Input Source: The input source shall be an isolated variable AC source capable of supplying between 85 VRMS and 265 VRMS at no less than 30 W and connected as shown in Figure 2 and Figure 3. For accurate efficiency calculations, a power meter should be inserted between the neutral line of the AC source and the Neutral terminal of the EVM. For highest accuracy, connect the voltage terminals of the power meter directly across the Line and Neutral terminals of the EVM. * Load: For the output load, a programmable electronic load set to constant current mode and capable of sinking 0 to 5 ADC at 5 VDC shall be used. For highest accuracy, VOUT can be monitored by connecting a DC voltmeter, DMM V1, directly across the VOUT+ and VOUT- terminals as shown in Figure 3. A DC current meter, DMM A1, should be placed in series with the electronic load for accurate output current measurements. * Power Meter: The power analyzer shall be capable of measuring low input current, typically less than 50 mA, and a long averaging mode if low power standby mode input power measurements are to be taken. An example of such an analyzer is the Voltech PM100 Single Phase Power Analyzer. To measure the intermittent bursts of current and power drawn from the line during no-load operation, an external 10- shunt, with a current scale factor of 10A/V, was used at a high sample rate over an extended period of time in order to display the averaged results (refer to Figure 2). * Multimeters: Two digital multimeters are used to measure the regulated output voltage (DMM V1) and load current (DMM A1). * Oscilloscope: A digital or analog oscilloscope with a 500-MHz scope probe is recommended. * Fan: Forced air cooling is not required. * Recommended Wire Gauge: a minimum of AWG18 wire is recommended. The wire connections between the AC source and the EVM, and the wire connections between the EVM and the load should be less than two feet long. SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 7 EVM Test Set Up 5.2 www.ti.com Recommended Test Set Up for Operation Without a Load AC SOURCE LINE NEUTRAL POWER METER + - + VHI VLO AHI ALO AEXT 10 TEXAS INSTRUMENTS Figure 2. Recommended Test Set Up Without a Load. 8 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 EVM Test Set Up www.ti.com 5.3 Recommended Test Set Up for Operation With a Load AC SOURCE LINE NEUTRAL POWER METER + - + VHI VLO AHI ALO AEXT DMM V 1 + - TEXAS I NSTRUMENTS ELECTRONIC LOAD + + - - DMM A 1 Figure 3. Recommended Test Set Up With a Load. SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 9 EVM Test Set Up 5.4 www.ti.com List of Test Points Table 2. Test Point and Connector Functional Descriptions TEST POINT 10 NAME DESCRIPTION TP1 Vout+ Output voltage of EVM; this designator is not populated with a pin in order to facilitate tip and barrel output ripple voltage measurements in conjunction with TP3, Vout-. TP2 PGND Primary side power ground. Use this pin as a reference for TP15, VGG. TP3 Vout- Output return of EVM; use this pin to facilitate tip and barrel output ripple voltage measurements in conjunction with TP1, Vout+. TP4 SW Secondary side switch node, reference the probe to U1_GND, TP11 or TP12. TP5 VD VD pin, U1. Reference the probe to U1_GND, TP11 or TP12. TP6 - Located on the drain trace of the primary side HV MOSFET, the user can cut the trace between this test point and TP8 to insert their own current loop to monitor primary side drain current. TP7 EN EN/TOFF pin, U1, shorting this pin to U1_GND (TP11 or TP12) will disable the GATE of U1 resulting in body diode conduction. TP8 - Located on the drain trace of the primary side HV MOSFET, the user can cut the trace between this test point and TP6 to insert their own current loop to monitor primary side drain current. TP9 GATE Gate pin, U1. Reference the probe to U1_GND, TP11 or TP12. TP10 +LOOP TP11 U1_GND Loop injection point, EVM output. GND pin of U1, use as a return for TP4, TP5, TP7, and TP9. TP12 U1_GND GND pin of U1, use as a return for TP4, TP5, TP7, and TP9. TP13 -LOOP TP14 AUX Auxiliary winding of T1. Reference the probe to TP17, PGND. TP15 VGG VGG pin, U3. Reference the probe to TP2, PGND. TP16 ZCD ZCD pin, U3. Reference the probe to TP17, PGND. TP17 PGND TP18 - J1 Line Loop injection point Primary side power ground. Use this pin as a reference for TP14, AUX, and TP16, ZCD. PGND, can be used as a reference when probing the drain pin of Q2 Line input from AC source J2 Vout+ Positive output terminal of the EVM to the load J3 Neutral Neutral input from the AC Source J4 Vout- Return connection of the EVM output to the load 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 Test Procedure www.ti.com 6 Test Procedure All tests should use the set up as described in Section 5 of this user's guide. The following test procedure is recommended primarily for power up and shutting down the evaluation module. Never leave a powered EVM unattended for any length of time. 6.1 Applying Power to the EVM 1. Set up the EVM as shown in Section 5 of this user's guide. (a) If no-load input power measurements are to be made, set the power analyzer to long averaging and external shunt mode. Insert a shunt, such as a 10- resistor as shown in Figure 2, in series with the Neutral terminal of the EVM. Set the appropriate current scale on the power analyzer. (b) For operation with a load, as shown in Figure 3, set the electronic load to constant current mode to sink 0 A. 2. Prior to turning on the AC source, set the voltage to between 85 VAC and 265 VAC. 3. Turn on the AC source. 4. Monitor the output voltage on DMM V1. 5. Monitor the output current on DMM A1. 6. The EVM is now ready for testing. 6.2 No-Load Power Consumption 1. Use the test set up shown in Section 5 (a) Set the power analyzer to external shunt mode. (b) Set the appropriate current scale factor for using an external shunt on the power analyzer. A 10- shunt scales at 10,000 mV/A for the PM100 Voltech. (c) Set the power analyzer long averaging time to include several cycles of operation. The PM100 Voltech should be set to a long averaging time of 10 or more for accurate Burst Mode measurements. 2. Apply power to the EVM per Section 6.1. 3. Monitor the input power on the power analyzer while varying the input voltage. 4. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM. 6.3 Output Voltage Regulation and Efficiency 1. For load regulation: (a) Use the test set up shown in Figure 3. (i) Be sure to remove the external shunt from the power analyzer and set the analyzer to normal mode (not long averaging). (b) Set the AC source to a constant voltage between 85 VAC and 265 VAC. (c) Apply power to the EVM per Section 6.1. (d) Vary the load current from 0 A up to 5 A, as measured on DMM A1. (e) Observe that the output voltage on DMM V1 remains within 15% of 5 VDC. 2. For line regulation: (a) Set the load to sink 5 A. (b) Vary the AC source from 85 VAC to 265 VAC. (c) Observe that the output voltage on DMM V1 remains within 15% of 5 VDC. 3. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM. SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 11 Test Procedure 6.4 www.ti.com Output Voltage Ripple 1. Expose the ground barrel of the scope probe. Insert the tip of the probe into the plated via located on the VOUT+ pad of the EVM (TP1) and lean the probe so that the exposed ground barrel is resting on the test point on the Vout- pad of the EVM (TP3) for a tip and barrel measurement as shown in the example depicted in Figure 4. 2. Apply power to the EVM per Section 6.1. 3. Monitor the output voltage ripple on the oscilloscope. Figure 4. Typical Example of Tip and Barrel Measurement Technique NOTE: This photo was not taken on the UCC24610EVM specifically but serves as a visual aid to perform the test measurement. 6.5 Equipment Shutdown 1. Ensure the load is at maximum of 5 A; this will quickly discharge the output capacitors. 2. Turn off the AC source. 12 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 Typical Characteristic Curves www.ti.com 7 Typical Characteristic Curves Figure 5 through Figure 10 present typical performance curves for the UCC24610EVM-563. NO-LOAD POWER CONSUMPTION vs LINE VOLTAGE EFFICIENCY vs LOAD 0.85 500 0.80 450 400 0.75 85 VAC Input Power - mW 115 VAC h - Efficiency - % 265 VAC 0.70 0.65 230 VAC 0.60 350 300 150 0.50 100 265 VAC 85 VAC 50 0 0.40 0 1 2 3 4 80 5 100 120 140 160 180 200 220 240 260 280 VAC - Line Voltage - V Load - A Figure 5. Efficiency (as a function of load current and input voltage) Figure 6. No-Load Input Power (as a function of input voltage) OUTPUT VOLTAGE vs LOAD CURRENT AVERAGE SWITCHING FREQUENCY vs LOAD CURRENT 6.0 120 115 VAC 80 60 265 VAC 40 230 VAC VOUT - Output Voltage - V 85 VAC 100 fSW - Switching Frequency - kHz 230 VAC 200 0.55 0.45 115 VAC 250 265 VAC 5.5 230 VAC 5.0 115 VAC 4.5 85 VAC 20 4.0 0 0 1 2 3 4 5 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 Load Current - A Load Current - A Figure 7. Average Switching Frequency (as a function of load current) SLUU434 - August 2010 Figure 8. Output Voltage (as a function of load current and line voltage) 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 13 Typical Characteristic Curves www.ti.com GAIN/PHASE vs FREQUENCY GAIN/PHASE vs FREQUENCY 135 30 20 90 20 90 10 45 10 45 0 0 0 0 Phase -10 -45 Gain 180 135 Phase -10 -45 Gain -20 -90 -20 -90 -30 -135 -30 -135 -180 -40 -40 100 10000 1000 100000 Phase Margin - degrees Gain -dB 30 Gain -dB 40 Phase Margin - degrees 180 40 -180 100 1000 10000 100000 f - Frequency - Hz f - Frequency - Hz Figure 9. Gain Phase Bode Plot (Input voltage = 115-VAC, 5-A load.) Figure 10. Gain Phase Bode Plot (Input voltage = 230-VAC, 5-A load.) LOAD OVER CURRENT vs INPUT VOLTAGE 8.5 265 VAC 8.0 115 VAC Load Current - A 7.5 7.0 230 VAC 6.5 85 VAC 6.0 5.5 5.0 80 100 120 140 160 180 200 220 240 260 280 VAC - Input Voltage - V Figure 11. Overcurrent Threshold as a Function of Line Voltage 14 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 Performance Data www.ti.com 8 Performance Data Figure 12. Primary-Side Waveforms (Input voltage = 115-VAC, no load, Green Mode operation.) Figure 13. Primary-Side Waveforms (Input voltage = 115-VAC, 1-A load, Amplitude Modulation Mode.) Figure 14. Primary-Side Waveforms (Input voltage = 115-VAC, 5-A load, Frequency Modulation Mode.) Figure 15. Primary and Secondary Currents (Current loops were added to EVM in the HV MOSFET drain and the trace from the transformer to the SR FET drain. Input voltage = 115-VAC, 5-A load.) Figure 16. Secondary-Side Current (Current loop Figure 17. Secondary-Side Waveforms (Input voltage = added between transformer and drain of SR FET and 115-VAC, 5-A load.) SR GATE signal, Input voltage = 115-VAC, 5-A load.) SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 15 Performance Data 16 www.ti.com Figure 18. Close-Up View of VD and SR GATE (Input voltage = 115-VAC, 5-A load.) Figure 19. Secondary-Side Waveforms (Current loop added from transformer to SR FET gate. Input voltage = 115-VAC, 0-A load, Green Mode.) Figure 20. Secondary-Side Waveforms (Current loop added between transformer and SR FET gate. Low power mode. Input voltage = 115-VAC, 0.311-A load.) Figure 21. Secondary-Side Waveforms (Current loop added between transformer and SR FET gate. Normal operating mode. Input voltage = 115-VAC, 5-A load.) Figure 22. Output Voltage During Transient Load (0% to 100% load transient, input voltage = 115-VAC.) Figure 23. Output Voltage Ripple (Input voltage = 115-VAC, 0-A load.) 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 Performance Data www.ti.com Figure 24. Output Voltage Ripple (Input voltage = 115-VAC, 5-A load.) SLUU434 - August 2010 Figure 25. Low Frequency Output Voltage Ripple (Input voltage = 115-VAC, 5-A load.) 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 17 EVM Assembly Drawing and PCB Layout 9 www.ti.com EVM Assembly Drawing and PCB Layout Figure 26 through Figure 34 present EVM Assembly Drawing and PCB Layout drawings for the UCC24610EVM-563. Figure 26. Top Assembly Figure 27. Bottom Assembly 18 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 EVM Assembly Drawing and PCB Layout www.ti.com Figure 28. Top Paste Figure 29. Bottom Silk SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 19 EVM Assembly Drawing and PCB Layout www.ti.com TEXAS I NSTRUMENTS Figure 30. Top Silk Figure 31. Layer 3 Copper 20 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 EVM Assembly Drawing and PCB Layout www.ti.com Figure 32. Layer 2 Copper Figure 33. Bottom Layer Copper SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 21 EVM Assembly Drawing and PCB Layout www.ti.com Figure 34. Top Layer Copper 22 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 List of Materials www.ti.com 10 List of Materials Table 3. List of Materials for UCC24610EVM-563 COUNT 1 REF DES DESCRIPTION PART NUMBER MFR C1 Capacitor, ceramic, 330 pF, 630 V, C0G, NP0, 5%, 1206 Std Std C2 Capacitor, ceramic disk, 1000 pF, 250 V, X1/Y1, 20%, 0.394 inch x 0.315 inch ECK-ANA102MB Panasonic C3, C4 Capacitor, film, 0.33 F, 275 VAC, X2, 20%, 15 mm pitch, 0.690 inch x 0.374 inch ECQ-U2A334ML Panasonic C5 Capacitor, aluminum electrolytic, 100 F, 400 VDC, 20%, EET-HC2G101BA 105C, 25 mm x 20 mm Panasonic 1 C6 Capacitor, ceramic, 0.1 F, 630 V, X7R, 10%, 1812 C4532X7R2J104K TDK Corporation 2 C7, C12 Capacitor, ceramic, 1 F, 25 V, X5R, 10%, 0805 Std Std 3 C8, C9, C10 Capacitor, aluminum electrolytic, 1500 F, 6.3 V, 20%, 105C, 10 mm x 25 mm EEU-FM0J152 Panasonic C11 Capacitor, aluminum electrolytic, 100 F, 6.3 V, 20%, 5.0 UPW0J101MDD mm x 11.0 mm Nichicon 1 C13 Capacitor, ceramic, 0.68 F, 25 V, X5R, 10%, 0805 Std Std 1 C14 Capacitor, ceramic, 100 pF, 50 V, NP0, 5%, 0603 Std Std 0 C15 Capacitor, ceramic, no pop., 50 V, NP0, 5%, 0603 Std Std C16 Capacitor, aluminum electrolytic, 68 F, 35 V, 20%, 105C, 6.3 mm x 11.2mm EEU-FM1V680 Panasonic 1 C17 Capacitor, ceramic, 0.1 F, 50 V, X7R, 10%, 0805 Std Std 1 C18 Capacitor, ceramic, 0.1 F, 100 V, X7R, 10%, 1206 Std Std 1 D1 Diode, bridge, 1 A, 600 V, DF-M DF06M Diodes Inc. 1 D2 Diode, fast recovery glass passivated, 1 A, 1 kV, DO-41 UF4007-TP Micro Commercial Co. D3 Diode, super fast rectifier, 1 A, 200 V, 0.220 inch x 0.115 inch ES1D-13-F Diodes Inc. 1 D4 Diode, Schottky, 1 A, 30 V, SOD-323 SDM100K30L-7 Diodes Inc. 1 D5 Diode, Schottky, 100 mA, 40 V, SOD-323 RB501V-40TE-17 Rohm Semiconductor 1 D6 Diode, Zener, 3.9 V, 500 mW, SOD-123 BZT52C3V9-7-F Diodes Inc. 1 D7 Diode, Zener, 25 V, 500 mW, SOD-123 MMSZ5253BT1G On Semiconductor 1 F1 Fuse, slow blow, 1 A, 250 V, 0.335 inch diameter 38211000410 Littelfuse / Wickmann 1 FB1 Bead, SMD ferrite, 70 at 100 MHz, 4 A, 25%, 0603 BLM18SG700TN1D Murata Electronics 1 HS1 Heatsink, TO-220, vertical mount, 0.5 inch x 0.750 inch 577102B00000G Aavid 1 HS2 Heatsink, alloy 1110 copper, 0.530 inch x 1.200 inch HS001 NH Stamp J1, J3 Connector, 4-mm safety jack, white, 1000 V, 25 A, 0.530 inch x 0.950 inch CT3151-9 Cal Test Electronics J2 Connector, 4-mm safety jack, red, 1000 V, 25 A, 0.530 inch x 0.950 inch CT3151-2 Cal Test Electronics J4 Connector, 4-mm safety jack, black, 1000 V, 25 A, 0.530 inch x 0.950 inch CT3151-0 Cal Test Electronics JP1 Jumper, 0.500 inch length, PVC insulation, AWG 22 923345-05-C 3M L1 Inductor, AC line, common choke, 27 mH, 1 A, 0.660 inch x 0.670 inch 54PR512-276 Vitec Electronics Corp. L2 Inductor, ferrite core, 1.0 H, 7.5 A, 10%, 0.521 inch x 0.502 inch 744772010 Wuerth Elektronik Q1 MOSFET, N-channel, logic level gate, 55 V, 75 A, 8 m, TO-220AB IRL3705ZPBF International Rectifier Q2 MOSFET, N-channel, 800 V, 6.5 A, 0.95 , TO-220V STP7NM80 STMicroelectronics 1 2 1 1 1 1 2 1 1 1 1 1 1 1 SLUU434 - August 2010 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated 23 References www.ti.com Table 3. List of Materials for UCC24610EVM-563 (continued) COUNT DESCRIPTION PART NUMBER MFR R1 Resistor, chip, 64.9 k, 1 W, 1%, 2512 Std Std 1 R2 Resistor, chip, 33 , 1 W, 5%, 2512 Std Std 1 R3 Resistor, chip, 20 , 1/4 W, 1%, 1206 Std Std 3 R4, R6, R7 Resistor, chip, 2.05 M, 1/8 W, 1%, 0805 Std Std 1 R5 Resistor, chip, 10 , 1/10 W, 1%, 0603 Std Std 1 R8 Resistor, chip, 100 , 1/10 W, 1%, 0603 Std Std 1 R9 Resistor, chip, 6.19 , 1/10 W, 1%, 0603 Std Std 1 R10 Resistor, chip, 20.5 , 1/10 W, 1%, 0603 Std Std 1 R11 Resistor, chip, 196 k, 1/10 W, 1%, 0603 Std Std 1 R12 Resistor, chip, 133 k, 1/10 W, 1%, 0603 Std Std 1 R13 Resistor, chip, 205 , 1/8 W, 1%, 0805 Std Std 1 R14 Resistor, chip, 2.26 , 1/10 W, 1%, 0603 Std Std 1 R15 Resistor, chip, 442 , 1/10 W, 1%, 0603 Std Std 1 R16 Resistor, metal film, 1.00 k, 1/4 W, 1%, TH-400 Std Std 1 R17 Resistor, chip, 1.00 k, 1/10 W, 1%, 0603 Std Std 1 R18 Resistor, chip, 20.5 k, 1/10 W, 1%, 0603 Std Std R19 Resistor, metal film, 130 k, 1/4 W, 1%, 0.300 inch x 0.100 inch Std Std 1 R20 Resistor, chip, 100 k, 1/10 W, 1%, 0603 Std Std 2 R21, R22 Resistor, chip, 59.0 k, 1/10 W, 1%, 0603 Std Std 1 R23 Resistor, chip, 68.1 k, 1/10 W, 1%, 0603 Std Std 1 T1 Transformer, flyback, 200 H, 10%, 24.5 mm x 24.5 mm G104070LF GCi 1 U1 Secondary-Side Synchronous Rectifier Controller, SO-8 UCC24610D Texas Instruments U2 Optocoupler, CTR 40% - 80%, 70 VCEO, 5000 VRMS, DIP6 CNY17F1M Fairchild Optoelectronics U3 Green-Mode Flyback Controller, SO-8 UCC28610D Texas Instruments 1 1 1 11 REF DES 1 References 1. UCC24610 GREEN RectifierTM Controller Device, Datasheet, SLUSA87 2. UCC28610 Green-Mode Flyback Controller, Datasheet, SLUS888 3. Standby and Low Power Measurements, VOLTECHNOTES, VPN 104-054/1, http://www.voltech.com/Downloads/PMAppNotes/Low%20Power%20Standby.pdf 24 5-V, 25-W Flyback Converter With Secondary-Side Synchronous Rectification Copyright (c) 2010, Texas Instruments Incorporated SLUU434 - August 2010 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. 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