Using the UCC28180EVM-573 User's Guide Literature Number: SLUUAT3B October 2013 - Revised December 2013 User's Guide SLUUAT3B - October 2013 - Revised December 2013 UCC28180EVM-573 360-W Power Factor Correction Module 1 Introduction The UCC28180EVM-573 evaluation module (EVM) is a 360-W off-line power factor correction (PFC) boost converter providing a nominal output voltage of 390-V regulated output at 0.923 A of load current. The PFC converter accommodates an input voltage range of 85 VAC to 265 VAC and uses average current mode control at a fixed programmable switching frequency of 120 kHz. The UCC28180 incorporates a wide range of protection features to ensure safe system operation. 2 Description The UCC28180EVM-573 highlights the many benefits of using the UCC28180 Continuous Current Mode Boost PFC Controller (TI Literature Number SLUSBQ5). The controller operates under average current mode control at a fixed programmable switching frequency of 120 kHz. Simple external current and voltage loop compensation, along with advanced protection features, make this controller ideal for server and desktop power supplies, industrial power supplies, and white goods. This user's guide provides the schematic, component list, assembly drawing for a single-sided printed circuit board application, and test set up necessary to evaluate the UCC28180 in a typical PFC application. 2.1 Typical Applications The UCC28180EVM-573 is suited for use in high-power off-line systems that require high-efficiency and advanced fault protection features, applications including, but not limited to: * Server and Desktop Power Supplies * Industrial Power Supplies (DIN Rail) * White Goods - A/C Units - Refrigerators - etc. 2 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Description www.ti.com 2.2 Features The UCC28180EVM-573 features include: * AC Input Range 85 VAC to 265 VAC * 360-W, 390-V Output * Average Current Mode PWM Control * No AC Line Sensing Needed * Fixed 120-kHz Oscillator frequency, Programmable With a Single External Resistor * Soft Over Current and Cycle-by-Cycle Peak Current Limiting * VCC Under Voltage Lockout With Low Start-Up Current * Voltage Regulation Open Loop Detection * Output Over-Voltage Protection With Hysteresis Recovery * Enhanced Dynamic Response * Soft-Start 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 across the output terminals must be completely discharged before the EVM can be handled. Serious injury can occur if proper safety precautions are not followed. SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 3 Electrical Performance Specifications 3 www.ti.com Electrical Performance Specifications Table 1. UCC28180EVM-573 Performance Summary PARAMETER TEST CONDITION MIN TYP MAX UNIT Input Characteristics VIN Input voltage 85 265 VAC fLINE Input frequency 47 63 Hz IIN(no-load) No load input current VIN = VIN(max), fLINE = 50 Hz, IOUT = IOUT(min) IIN(peak) Peak input current VIN = VIN(min), fLINE = 60 Hz, IOUT = IOUT(max) 71 mA 6.8 A Output Characteristics VOUT Output voltage VIN(min) VIN VIN(max), fLINE(min) fLINE fLINE(max), IOUT(min) IOUT IOUT(max) Line Regulation VIN(min) VIN VIN(max), IOUT = IOUT(max) 5% VIN = 115 VAC, fLINE = 60 Hz, IOUT(min) IOUT IOUT(max) 5% VIN = 230 VAC, fLINE = 60 Hz, IOUT(min) IOUT IOUT(max) 5% Load Regulation 390 402 VDC IOUT Output Load Current VIN(min) VIN VIN(max) fLINE(min) fLINE fLINE(max) 0 0.923 A POUT Output Power VIN(min) VIN VIN(max) fLINE(min) fLINE fLINE(max) 0 360 W VRIPPLE(S W) VRIPPLE(f_ LINE) 4 379 High frequency Output voltage ripple Line frequency Output voltage ripple VIN = 115 VAC, fLINE = 60 Hz IOUT = IOUT(max) 3.9 VIN = 230 VAC, fLINE = 50 Hz IOUT = IOUT(max) 3.9 VIN = 115 VAC, fLINE = 60 Hz, IOUT = IOUT(max) 19.5 VIN = 230 VAC, fLINE = 50 Hz, IOUT = IOUT(max) 19.5 VP-P VP-P VOUT(OVP) Output over voltage protection 425 VOUT(UVP) Output under voltage protection 370 V UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Electrical Performance Specifications www.ti.com Table 1. UCC28180EVM-573 Performance Summary (continued) PARAMETER TEST CONDITION MIN TYP MAX UNIT Control Loop Characteristics fSW f(CO) PF THD Switching frequency TJ = 25C Voltage Loop Bandwidth VIN = 162 VDC, IOUT = 0.466 A 8 Hz Voltage Loop Phase Margin VIN = 162 VDC, IOUT = 0.466 A 68 Power Factor VIN = 115 VAC, IOUT = IOUT(max) 0.99 VIN = 115 VAC, fLINE = 60 Hz, IOUT = IOUT(max) 4.1% 10% 4% 10% Total harmonic distortion Full load efficiency 114 VIN = 230 VAC, fLINE = 50 Hz IOUT = IOUT(max) VIN = 115 VAC, fLINE = 60 Hz, IOUT = IOUT(max) 120 126 94.5% Ambient temperature 25 SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback kHz UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated C 5 6 J1 3 2 1 LINE VAR1 S10K275E2 C1 0.47 F UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated Bias 12Vdc + - J2 GND COMPONENTS MAY GET HOT WARNING! HIGH VOLTAGE HS1 COMMON TO Q1, BR1, AND D3 OUTPUT VOLTAGE: 390 VDC nominal MAXIMUM OUTPUT POWER: 360 W MAXIMUM OUTPUT CURRENT: 0.923 A NOTES: LINE INPUT VOLTAGE: 85 VRMS - 265 VRMS, 47 Hz - 63 Hz PEAK INPUT CURRENT: 7 A EARTH LINE NEUTRAL Vin = 85 VAC to 265 VAC, 47 Hz to 63 Hz F1 250 VAC 8A TP1 47 F C3 C2 2200 pF L1 5 mH TP2 GND_EARTH 1 C6 0603 1 R1 0603 C4 2200 pF C5 0.47 F C7 2700pF TP3 ~ 1 Do Not Populate 5 ohm t RT1 + ~ R3 17.8k BR1 GBU8J-BP C8 1000 pF R2 221 JP1 - 1 FREQ ISENSE ICOMP GND UCC28180D C9 4 3 2 1 U1 R4 0.032 C10 0.33 F C11 1 F VCOMP VSENSE VCC GATE 5 6 7 8 TP4 C12 0.1 F TP6 TP5 3.3 R5 C13 4.7F R6 22.6k R7 10.0k D1 MBR140SFT1G L2 327 H D2 TP7 C14 0.47F TP8 TP10 TP9 C16 270 F C15 820 pF Q1 SPP20N60C3 HS1 D3 C3D04060A R13 13.3k R12 0 R11 340k R10 332k R9 332k R8 49.9 GND C17 0.1 F C18 0.1 F TP12 TP11 1 2 3 4 J3 VOUT RTN +VOUT OUTPUT: 390 VDC NOMINAL, 0.923 A MAX 4 1N5406 Schematic www.ti.com Schematic Figure 1. UCC28180EVM-573 Schematic SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Test Setup www.ti.com 5 Test Setup Figure 2 shows the basic test set up recommended in order to evaluate the UCC28180EVM-573 POWER METER AC Source + VHI - + VLO AHI ALO AEXT N Fan L +12V Bias Supply + Electronic Load - - + A1 + V1 + Figure 2. UCC28180EVM-573 Recommended Test Set Up 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. SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 7 Test Setup 5.1 www.ti.com Test Equipment AC Voltage Source: The AC input source shall be capable of supplying between 85 VAC and 265 VAC at no less than 8 A peak. Connect the AC source to the L and N terminals of J1 on the EVM as shown in Figure 2. 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. 12-V Bias Supply: The bias supply to the device shall be capable of supplying up to 12 VDC at no less than 10 mA. Connect the bias supply to the - and + terminals of J2, UCC28180 12-V VCC bias, as shown in Figure 2. Output Load: A programmable electronic load set to constant current mode and capable of sinking 0 to 1 A at 390 VDC shall be used. Connect the load to J3, as shown in Figure 2. Power Meter: For highest accuracy, power analyzer shall be used to measure the input power, THD, and power factor. An example of such an analyzer is the Voltech PM100 Single Phase Power Analyzer. Multimeters: For highest accuracy, the output voltage of the UCC28180EVM-573 shall be monitored by connecting a digital voltmeter, V1, directly across TP11 and TP12 with the positive terminal at TP11 and the negative terminal at TP12. A DC current meter, A1, should be placed in series with the electronic load for accurate output current measurements. Oscilloscope: A digital or analog oscilloscope with 500-MHz scope probes is recommended. Fan: A fan, capable of 200 LFM to 400 LFM, should be used to maintain component temperatures within safe operating ranges at all times during operation of the UCC28180EVM-573. Position the fan so as to blow along the length of the heatsink as shown in Figure 2. Recommended Wire Gauge: The recommended wire size is AWG #16 with the total length of wire less than 8 feet (4 feet input, 4 feet return). The connection between the EVM output terminals (J3) and the electronic load can carry as much as 1 A. The minimum recommended wire size is AWG #20, with the total length of wire less than 8 feet (4 feet output, 4 feet return). 5.2 List of Test Points Table 2. Test Point Functional Description TEST POINT 8 NAME DESCRIPTION TP1 PGND Power ground TP2 ICOMP UCC28180 pin 2 TP3 ISENSE UCC28180 pin 3 TP4 VCC UCC28180 pin 7 TP5 GATE UCC28180 pin 8 TP6 VSENSE UCC28180 pin 6 TP7 SW TP8 VCOMP UCC28180 pin 5 TP9 + LOOP Loop injection point, EVM output TP10 - LOOP Loop injection point TP11 +VOUT Positive output terminal of the EVM to the load TP12 -VOUT Return connection of the EVM output to the load Switch node, MOSFET drain UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Test Setup www.ti.com 5.3 Power-Up/Power-Down Procedure 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. Also, the unit should never be handled while power is applied to it or the output voltage is greater than 50 VDC. WARNING There are very high voltages present on the EVM. Some components reach temperatures above 50C. Precautions must be taken when handling the board. Never operate the UCC28180EVM573 without the fan running. Always make certain the bulk capacitors have completely discharged prior to handling the EVM. 1. Working at an ESD workstation, make sure that the ionizer is on before the EVM is removed from the protective packaging and power is applied. Electrostatic smock and safety glasses should also be worn. Because voltages in excess of 400 V may be present on the EVM, do not connect the ground strap from the smock to the bench. If testing with a load, set the electronic load to constant resistance mode. 2. Power-Up (a) Connect the equipment as shown in Figure 2. (b) Turn on the fan. (c) Set the AC source voltage between 85 VAC and 265 VAC. (d) Turn on the 12-V bias supply and verify that the output of the module is within regulation. (e) Increase the load from 0 A up to 0.923 A. 5.4 Line/Load Regulation and Efficiency Measurement Procedure 1. For load regulation, use the test set up shown in Figure 2. (a) Set the AC source to a constant voltage between 85 VAC and 265 VAC. (b) Vary the load so that the output current varies from 0 A up to 0.923 A, as measured on DMM A1. (c) Observe that the output voltage on DMM V1 remains within 5% of the full load regulation value. 2. For line regulation, use the test set up shown in Figure 2. (a) Set the load to sink the full-load current, 0.923 A. (b) Vary the AC source from 85 VAC to 265 VAC (c) Observe that the output voltage on DMM V1 stays within 5% of the output voltage regulation value. 5.5 Output Voltage Ripple 1. Expose the ground barrel of the scope probe and place the tip of the probe on TP11, +VOUT, and rest the exposed ground barrel of the probe on TP12, -VOUT, for output voltage ripple measurements. 5.6 Equipment Shutdown 1. To quickly discharge the output capacitors, make sure there is a load greater than 0 A on the EVM. 2. Turn off the AC source. 3. Turn off the Bias source. SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 9 Performance Data and Typical Characteristic Curves 6 www.ti.com Performance Data and Typical Characteristic Curves Figure 3 through Figure 21 present typical performance curves for UCC28180EVM-573. Efficiency EFFICIENCY 6.1 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80 85 VAC, 60 Hz 115 VAC, 60 Hz 230 VAC, 50 HZ 265 VAC, 50 Hz 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 LOAD (A) 1.0 C001 Figure 3. UCC28180EVM-573 Efficiency (as a function of line voltage and load current) 6.2 Power Factor Figure 4. UCC28180EVM-573 Power Factor (as a function of line voltage and load current) 10 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Performance Data and Typical Characteristic Curves www.ti.com 6.3 Total Harmonic Distortion Figure 5 shows the measured total harmonic distortion (THD). This design allows the converter to enter into discontinuous current mode (DCM) at the higher line voltages which impacts THD. The converter still meets the design goal of less than 10% THD at full load over the entire input line range despite using a relatively small inductor that allows 40% inductor ripple current. Figure 5. UCC28180EVM-573 Total harmonic Distortion (as a function of line voltage and load current) Figure 6demonstrates improved THD by doubling inductance (20% ripple). Figure 6. Total Harmonic Distortion with 2x Inductance SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 11 Performance Data and Typical Characteristic Curves www.ti.com Using swinging inductors which exhibit higher inductance value at lower magnetization (lowest current) can also help to achieve low THD.Figure 7 shows the total harmonic distortion resulting from using a current of 6.4 A (switching frequency = 18 kHz). The total harmonic distortion measures less than 5% from 50% load to full load under these conditions. Figure 7. Total harmonic distortion (as a function of line voltage and load current) with L = 3.4 mH and fSW = 18 kHz Figure 8 shows the total harmonic distortion resulting from a swinging choke that measured 530 H at a current of 6.4 A (switching frequency = 66 kHz). The total harmonic distortion measures less than 5% from 50% load to full load under these conditions. Figure 8. Total harmonic distortion (as a function of line voltage and load current) with L = 0.4 mH and fSW = 66 kHz 12 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Performance Data and Typical Characteristic Curves www.ti.com 6.4 Current Harmonics 0.14 PWR 573 AMPLITUDE (A) 0.12 EN61000-3-2 Class D max 230 VAC, 50 Hz, Full Load 0.10 0.08 0.06 0.04 0.02 0.00 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 HARMONIC NUMBER C004 Figure 9. UCC28180EVM-573 Current Harmonics, (230-VAC, 50-Hz input, full load, without the fundamental) 0.14 PWR 573 AMPLITUDE (A) 0.12 EN61000-3-2 Class D max 115 VAC, 60 Hz, Full Load 0.10 0.08 0.06 0.04 0.02 0.00 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 HARMONIC NUMBER C005 Figure 10. UCC28180EVM-573 Current Harmonics, (115-VAC, 60-Hz input, full load, without the fundamental) SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 13 Performance Data and Typical Characteristic Curves 6.5 www.ti.com Input Current Figure 11. UCC28180EVM-573 Input Current and Input Voltage at the Output of the Bridge Ruectifier, (115-VAC, 60 Hz, full load. (CH 1 = rectified input voltage on BR1, 100 V/div., CH 3 = IIN 2 A/div.)) Figure 12. UCC28180EVM-573 Input Current and Input Voltage at the Output of the Bridge Rectifier, (230 VAC, 50 Hz, full load. (CH 1 = rectified input voltage on BR1, 100 V/div., CH 3 = IIN 1 A/div.)) 14 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Performance Data and Typical Characteristic Curves www.ti.com 6.6 Output Voltage Ripple Figure 13. UCC28180EVM-573 Line Frequency Output Voltage Ripple (115 VAC, 60 Hz input, full load) Figure 14. UCC28180EVM-573 Line Frequency Output Voltage Ripple ( 230 VAC, 50 Hz input, full load) SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 15 Performance Data and Typical Characteristic Curves www.ti.com Figure 15. UCC28180EVM-573 Switching Frequency Output Voltage Ripple (115 VAC, 60 Hz input, full load) Figure 16. UCC28180EVM-573 Switching Frequency Output Voltage Ripple (230 VAC, 50 Hz input, full load) 16 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Performance Data and Typical Characteristic Curves www.ti.com 6.7 Start Up Figure 17. UCC28180EVM-573 Start-Up Waveform (115-VAC, 60-Hz input, full load, CH 1 = VSENSE at 2 V/div, CH 2 = VOUT at 100 V/div., offset by 150 V, CH 3 = IIN at 5 A/div., CH 4 = VCOMP at 2 V/div.) Figure 18. UCC28180EVM-573 Start-Up Waveform (230-VAC, 50-Hz input, full load, CH 1 = VSENSE at 2 V/div, CH 2 = VOUT at 50 V/div., offset by 300 V, CH 3 = IIN at 5 A/div., CH 4 = VCOMP at 2 V/div.) SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 17 Performance Data and Typical Characteristic Curves 6.8 www.ti.com Load Transient Figure 19. Load Transient (115 -VAC, 60-Hz, load step: 0% to 100%. Ch 2 = VOUT at 20 V/div., offset by 386 V, Ch.4 = VCOMP at 2 V/div) 18 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Performance Data and Typical Characteristic Curves www.ti.com 6.9 Bode Plot The gain, phase bode plots were measured with an AP Instruments Inc. Model 200 analog network analyzer. The loop result was obtained by inserting a 1.77-V AC signal across TP9 and TP10. A DC input equal to the peak of the RMS input was used. GAIN PHASE MARGIN 50 GAIN (dB) 40 120 100 80 30 60 20 40 10 20 0 0 10 20 20 40 30 60 40 80 50 100 162 VIN, 0.923 A Load 60 1 10 PHASE MARGIN () 60 120 1000 100 FREQUENCY (Hz) C006 Figure 20. UCC28180EVM-573 Voltage Loop Response Gain and Phase, (311-VDC, full load, fCO = 10.7-Hz, phase margin = 68 degrees) 50 100 PHASE MARGIN 40 GAIN (dB) 120 GAIN 80 30 60 20 40 10 20 0 0 10 20 20 40 30 60 40 80 50 100 311 VIN, 0.923 A Load 60 1 10 PHASE MARGIN () 60 100 120 1000 FREQUENCY (Hz) C007 Figure 21. UCC28180EVM-573 Voltage Loop Response Gain and Phase, (162-VDC, full load, fCO = 8.6-Hz, phase margin = 63 degrees) SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 19 EVM Assembly Drawing and PCB Layout 7 www.ti.com EVM Assembly Drawing and PCB Layout The following figures (Figure 22 through Figure 25) show the design of the UCC28180EVM-573 printed circuit board. Figure 22. UCC28180EVM-573 Top Layer Assembly Drawing (top view) Figure 23. UCC28180EVM-573 Bottom Layer Assembly Drawing (bottom view) 20 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated EVM Assembly Drawing and PCB Layout www.ti.com Figure 24. UCC28180EVM-573 Top Copper (top view) Figure 25. UCC28180EVM-573 Bottom Copper (bottom view) SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback UCC28180EVM-573 360-W Power Factor Correction Module Copyright (c) 2013, Texas Instruments Incorporated 21 List of Materials 8 www.ti.com List of Materials The EVM components list according to the schematic shown in Figure 1. Table 3. UCC28180EVM-573 List of Materials QTY 22 REFDE S DESCRIPTION MFR PART NUMBER 1 BR1 Diode, Switching-Bridge, 420 V, 8 A, TH Micro Commercial Components GBU8J-BP 2 C1, C5 Capacitor, film, 0.47 F, 275 V, 20%, radial, 25 x 8.5 x 18.5 mm Panasonic ECQ-U2A474ML 2 C2, C4 Capacitor, ceramic, 2200 pF, 250 V, 20%, E, radial disc TDK D10.5 x 7 mm CS11-E2GA222MYNS 1 C3 Capacitor, aluminum, 47 F, 35 V, 20%, radial, 5 x 1mm Panasonic ECA-1VM470 0 C6 Capacitor, ceramic, 0.1 F, 50 V, 10%, X7R, 0603 AVX 06035C104KAT2A 1 C7 Capacitor, ceramic, 2700 pF, 50 V, 10%, X7R, 0603 MuRata GRM188R71H272KA01D 1 C8 Capacitor, ceramic, 1000 pF, 100 V, 10%, X7R, 0603 AVX 06031C102KAT2A 0 C9 Capacitor, ceramic, 0.68 F, 10 V, 10%, X5R, 0603 Kemet C0603C684K8PAC 1 C10 Capacitor, FILM, 0.33 F, 275 V, 20%, radial, 17.5 x 17.5 x 9.5 mm Panasonic ECQ-U2A334ML 1 C11 Capacitor, ceramic, 1 F, 50 V, 10%, X7R, 1210 MuRata GRM32RR71H105KA01L 1 C12 Capacitor, ceramic, 0.1 F, 50 V, 10%, X7R, 1206 AVX 12065C104KAT2A 1 C13 Capacitor, ceramic, 4.7 F, 10 V, 10%, X7R, 0805 MuRata GRM21BR71A475KA73L 1 C14 Capacitor, ceramic, 0.47 F, 16 V, 10%, X7R, 0603 Kemet C0603C474K4RACTU 1 C15 Capacitor, ceramic, 820 pF, 50 V, 10%, X7R, 0603 Kemet C0603C821K5RACTU 1 C16 Capacitor, aluminum, 270 F, 450 V, 20%, 0.737 , radial, 30 x 30 mm Panasonic EETUQ2W271DA 2 C17, C18 Capacitor, ceramic, 0.1 F, 630 V, 10%, X7R, 1812 MuRata GRM43DR72J104KW01L 1 D1 Diode, Schottky, 40 V, 1 A, SOD-123FL ON Semiconductor MBR140SFT1G 1 D2 Diode, Switching, 600 V, 3 A, DO-201AD VishaySemiconductor 1N5406 1 D3 Diode, Schottky, 600 V, 4 A, TO-220-F2 Cree C3D04060A 1 F1 Fuse, 8 A, 250 V, 20 x 5.2 mm Littelfuse 0216008.MXESPP 3 H9, H10, Max clip H11 Aavid Thermalloy MAX01NG 1 HS1 Heatsink vertical max clip, black, 4.25 inches Aavid 782653B04250G 1 J1 Terminal block, 5.08 mm, vertical 3 pos On-Shore Technology ED120/3DS 1 J2 Terminal block, 5.08 mm, vertical, 2 pos On-Shore Technology ED120/2DS 1 J3 Terminal block, 5.08 mm, vertical, 4 pos, TH On-Shore Technology ED120/4DS 1 JP1 Jumper wire, 200 mil spacing, red 3M 923345-02-C 1 L1 Coupled inductor, 5 mH, 0.022 A, 0.022 , 1450 x 1500 x 800 mil Bourns 8113-RC 1 L2 Inductor, toroid, ferrite, 327 H, 0.065 , 1380 x 1310 x 880 mil Nova Magnetics 7840-09-0014 1 Q1 MOSFET, N-channel, 650 V, 20.7 A, TO-220AB Infineon Technologies SPP20N60C3 UCC28180EVM-573 360-W Power Factor Correction Module SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Revision History www.ti.com Table 3. UCC28180EVM-573 List of Materials (continued) QTY REFDE S DESCRIPTION MFR PART NUMBER 0 R1 Resistor, 100 , 1%, 0.1 W, 0603 Vishay-Dale CRCW0603100RFKEA 1 R2 Resistor, 221 , 1%, 0.1 W, 0603 Vishay-Dale CRCW0603221RFKEA 1 R3 Resistor, 17.8 k, 1%, 0.1 W, 0603 Vishay-Dale CRCW060317K8FKEA 1 R4 Resistor, 0.032 , 1%, 2 W, 2512 Vishay-Dale WSL2512R0320FEA18 1 R5 Resistor, 3.3 , 5%, 0.5 W, 1210 Panasonic ERJ-P14J3R3U 1 R6 Resistor, 22.6 k, 1%, 0.1 W, 0603 Vishay-Dale CRCW060322K6FKEA 1 R7 Resistor, 10.0 k, 1%, 0.1 W, 0603 Vishay-Dale CRCW060310K0FKEA 1 R8 Resistor, 49.9 , 1%, 0.25 W, 1206 Vishay-Dale CRCW120649R9FKEA 2 R9, R10 Resistor, 332 k, 1%, 0.125 W, 0805 Vishay-Dale CRCW0805332KFKEA 1 R11 Resistor, 340 k, 1%, 0.125 W, 0805 Vishay-Dale CRCW0805340KFKEA 1 R12 Resistor, 0 , 5%, 0.25 W, 1206 Vishay-Dale CRCW12060000Z0EA 1 R13 Resistor, 13.0 k, 1%, 0.1 W, 0603 Vishay-Dale CRCW060313K3FKEA 1 RT1 Thermistor NTC, 5 , 25%, Disc, 220 x 770 mil GE Sensing CL-40 2 SIL1, SIL2 Silcon thermal pad Bergquist Company Q3-0.005-00-58 1 SIL3 Silcon thermal pad Bergquist Company SP900S-0.009-00-114 2 TP1, TP12 Test point, multipurpose, black, TH Keystone 5011 8 TP2, TP3, TP5, TP6, TP7, TP8, TP9, TP10 Test point, multipurpose, white, TH Keystone 5012 2 TP4, TP11 Test point, multipurpose, red, TH Keystone 5010 1 U1 8-Pin Continuous Conduction Mode (CCM) PFC Controller, SOIC-8 Texas Instruments UCC28180D 1 VAR1 Varistor, 275 VRMS, 10 mm, radial, 10 mm EPCOS Inc S10K275E2 Revision History Changes from Original (October 2013) to A Revision .................................................................................................... Page * * * * * * Changed 39-V regulated output to 390-V regulated output. ........................................................................ 2 Added Figure 7. ......................................................................................................................... 12 Added Figure 8. ......................................................................................................................... 12 Changed CH2 to Ch3. .................................................................................................................. 14 Changed Ch2 to CH3. .................................................................................................................. 14 Changed R13 resistor value from 13.3 k to 13.0 k. ............................................................................ 23 NOTE: Page numbers for previous revisions may differ from page numbers in the current version. Changes from A Revision (November 2013) to B Revision ........................................................................................... Page * Changed Performance data and typical characteristic curve images. ........................................................... 10 NOTE: Page numbers for previous revisions may differ from page numbers in the current version. SLUUAT3B - October 2013 - Revised December 2013 Submit Documentation Feedback Copyright (c) 2013, Texas Instruments Incorporated Revision History 23 EVALUATION BOARD/KIT/MODULE (EVM) ADDITIONAL TERMS Texas Instruments (TI) provides the enclosed Evaluation Board/Kit/Module (EVM) under the following conditions: 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. 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 LIMITED 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. 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. 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 visit www.ti.com/esh or contact TI. 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. 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. REGULATORY COMPLIANCE INFORMATION As noted in the EVM User's Guide and/or EVM itself, this EVM and/or accompanying hardware may or may not be subject to the Federal Communications Commission (FCC) and Industry Canada (IC) rules. For EVMs not subject to the above rules, this evaluation board/kit/module 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 or ICES-003 rules, which are designed to provide reasonable protection against radio frequency interference. Operation of the equipment 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. General Statement for EVMs including a radio User Power/Frequency Use Obligations: This radio is intended for development/professional use only in legally allocated frequency and power limits. Any use of radio frequencies and/or power availability of this EVM and its development application(s) must comply with local laws governing radio spectrum allocation and power limits for this evaluation module. It is the user's sole responsibility to only operate this radio in legally acceptable frequency space and within legally mandated power limitations. Any exceptions to this are strictly prohibited and unauthorized by Texas Instruments unless user has obtained appropriate experimental/development licenses from local regulatory authorities, which is responsibility of user including its acceptable authorization. For EVMs annotated as FCC - FEDERAL COMMUNICATIONS COMMISSION Part 15 Compliant Caution This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. FCC Interference Statement for Class A EVM devices This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. FCC Interference Statement for Class B EVM devices This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: * Reorient or relocate the receiving antenna. * Increase the separation between the equipment and receiver. * Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. * Consult the dealer or an experienced radio/TV technician for help. For EVMs annotated as IC - INDUSTRY CANADA Compliant This Class A or B digital apparatus complies with Canadian ICES-003. Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. Concerning EVMs including radio transmitters This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. Concerning EVMs including detachable antennas Under Industry Canada regulations, this radio transmitter may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that necessary for successful communication. This radio transmitter has been approved by Industry Canada to operate with the antenna types listed in the user guide with the maximum permissible gain and required antenna impedance for each antenna type indicated. Antenna types not included in this list, having a gain greater than the maximum gain indicated for that type, are strictly prohibited for use with this device. Cet appareil numerique de la classe A ou B est conforme a la norme NMB-003 du Canada. Les changements ou les modifications pas expressement approuves par la partie responsable de la conformite ont pu vider l'autorite de l'utilisateur pour actionner l'equipement. Concernant les EVMs avec appareils radio Le present appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisee aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioelectrique subi, meme si le brouillage est susceptible d'en compromettre le fonctionnement. Concernant les EVMs avec antennes detachables Conformement a la reglementation d'Industrie Canada, le present emetteur radio peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inferieur) approuve pour l'emetteur par Industrie Canada. Dans le but de reduire les risques de brouillage radioelectrique a l'intention des autres utilisateurs, il faut choisir le type d'antenne et son gain de sorte que la puissance isotrope rayonnee equivalente (p.i.r.e.) ne depasse pas l'intensite necessaire a l'etablissement d'une communication satisfaisante. Le present emetteur radio a ete approuve par Industrie Canada pour fonctionner avec les types d'antenne enumeres dans le manuel d'usage et ayant un gain admissible maximal et l'impedance requise pour chaque type d'antenne. Les types d'antenne non inclus dans cette liste, ou dont le gain est superieur au gain maximal indique, sont strictement interdits pour l'exploitation de l'emetteur. SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER Important Notice for Users of EVMs for RF Products in Japan This development kit is NOT certified as Confirming to Technical Regulations of Radio Law of Japan If you use this product in Japan, you are required by Radio Law of Japan to follow the instructions below with respect to this product: 1. 2. 3. Use this product in a shielded room or any other test facility as defined in the notification #173 issued by Ministry of Internal Affairs and Communications on March 28, 2006, based on Sub-section 1.1 of Article 6 of the Ministry's Rule for Enforcement of Radio Law of Japan, Use this product only after you obtained the license of Test Radio Station as provided in Radio Law of Japan with respect to this product, or Use of this product only after you obtained the Technical Regulations Conformity Certification as provided in Radio Law of Japan with respect to this product. Also, please do not transfer this product, unless you give the same notice above to the transferee. Please note that if you could not follow the instructions above, you will be subject to penalties of Radio Law of Japan. Texas Instruments Japan Limited (address) 24-1, Nishi-Shinjuku 6 chome, Shinjuku-ku, Tokyo, Japan http://www.tij.co.jp 1. 2. 3. 61118328173 http://www.tij.co.jp SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER SPACER EVALUATION BOARD/KIT/MODULE (EVM) WARNINGS, RESTRICTIONS AND DISCLAIMERS For Feasibility Evaluation Only, in Laboratory/Development Environments. Unless otherwise indicated, this EVM is not a finished electrical equipment and not intended for consumer use. It is intended solely for use for preliminary feasibility evaluation in laboratory/development environments by technically qualified electronics experts who are familiar with the dangers and application risks associated with handling electrical mechanical components, systems and subsystems. It should not be used as all or part of a finished end product. Your Sole Responsibility and Risk. You acknowledge, represent and agree that: 1. 2. 3. 4. You have unique knowledge concerning Federal, State and local regulatory requirements (including but not limited to Food and Drug Administration regulations, if applicable) which relate to your products and which relate to your use (and/or that of your employees, affiliates, contractors or designees) of the EVM for evaluation, testing and other purposes. You have full and exclusive responsibility to assure the safety and compliance of your products with all such laws and other applicable regulatory requirements, and also to assure the safety of any activities to be conducted by you and/or your employees, affiliates, contractors or designees, using the EVM. Further, you are responsible to assure that any interfaces (electronic and/or mechanical) between the EVM and any human body are designed with suitable isolation and means to safely limit accessible leakage currents to minimize the risk of electrical shock hazard. Since the EVM is not a completed product, it may not meet all applicable regulatory and safety compliance standards (such as UL, CSA, VDE, CE, RoHS and WEEE) which may normally be associated with similar items. You assume full responsibility to determine and/or assure compliance with any such standards and related certifications as may be applicable. You will employ reasonable safeguards to ensure that your use of the EVM will not result in any property damage, injury or death, even if the EVM should fail to perform as described or expected. You will take care of proper disposal and recycling of the EVM's electronic components and packing materials. Certain Instructions. It is important to operate this EVM within TI's recommended specifications and environmental considerations per the user guidelines. Exceeding the specified EVM ratings (including but not limited to input and output voltage, current, power, and environmental ranges) may cause property damage, personal injury or death. If there are questions concerning these ratings please contact a TI field representative prior to connecting interface electronics including input power and intended loads. Any loads applied outside of the specified output range may result in unintended and/or inaccurate operation and/or possible permanent damage to the EVM and/or interface electronics. 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 60C as long as the input and output are maintained at a normal ambient operating temperature. These components include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors which can be identified using the EVM schematic located in the EVM User's Guide. When placing measurement probes near these devices during normal operation, please be aware that these devices may be very warm to the touch. As with all electronic evaluation tools, only qualified personnel knowledgeable in electronic measurement and diagnostics normally found in development environments should use these EVMs. Agreement to Defend, Indemnify and Hold Harmless. You agree to defend, indemnify and hold TI, its licensors and their representatives harmless from and against any and all claims, damages, losses, expenses, costs and liabilities (collectively, "Claims") arising out of or in connection with any use of the EVM that is not in accordance with the terms of the agreement. This obligation shall apply whether Claims arise under law of tort or contract or any other legal theory, and even if the EVM fails to perform as described or expected. Safety-Critical or Life-Critical Applications. If you intend to evaluate the components for possible 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, such as devices which are classified as FDA Class III or similar classification, then you must specifically notify TI of such intent and enter into a separate Assurance and Indemnity Agreement. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright (c) 2013, Texas Instruments Incorporated IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. Buyers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. 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