User's Guide
SLUU280B–May 2007–Revised July 2008
UCC28060EVM 300-W Interleaved PFC Pre-Regulator
The UCC28060 is a dual-phase, transition-mode Power Factor Correction (PFC) pre-regulator. The
UCC28060EVM 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 UCC28060EVM.
1
Description
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 list, assembly drawing for a single-sided printed
circuit board application, and test set-up information necessary to evaluate the UCC28060 in a typical
PFC application.
2
3
Thermal Requirements
This evaluation module will operate up to 300 W without external cooling in ambient tempatures of 25°C.
Electrical Characteristics
Table 1. UCC28060EVM Electrical Specifications
UCC28060EVM
PARAMETER
CONDITIONS
UNITS
MIN
TYP
MAX
RMS input voltage (ac line)
Output voltage, VOUT
Line frequency
85
265
63
VRMS
V
390
47
Hz
Power factor (PF) at maximum load
Output power
0.9
300
W
AC line = 115 V
AC line = 230 V
94%
97%
Full load efficiency
Natural Interleaving is a trademark of Texas Instruments.
All other trademarks are the property of their respective owners.
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Schematics
+
Figure 2. Controller Circuitry
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Test Setup and Power-Up/Power-Down Instructions
5
Test Setup and Power-Up/Power-Down Instructions
WARNING
There are high voltages present on the pre-regulator. It should only
be handled by experienced power supply professionals. To
evaluate this board as safely as possible, the following test
configuration should 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 UCC28060 control circuitry. The unit will start up
under no-load conditions. However, for safety, a load should be connected to the output of the device
before it is powered up. The unit should also never be handled while power is applied to it or when the
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.
VM
0 to 300W Load
+
Isolation Transformer
13V Bias Supply
Figure 3. Test Setup
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Typical Performance Data
6
Typical Performance Data
Efficiency
100.0%
99.0%
98.0%
97.0%
96.0%
95.0%
94.0%
93.0%
92.0%
91.0%
90.0%
Efficency at Vin 85V RMS
Efficency at Vin = 265V RMS
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% Output Power
Figure 4. Efficiency at 85VRMS and 265VRMS
The UCC28060 control device has phase management capability to improve light load efficiency. To
demonstrate the light load efficiency, the unit efficiency was measured with phase management enabled
and disabled at 115 VRMS and 230 VRMS input voltages. Phase management improved the light load
efficiency up to 3%. Refer to the UCC28060 data sheet for details on how to use the phase management
function of this device.
Efficiency at Vin = 115V RMS
98.0%
97.0%
96.0%
95.0%
94.0%
93.0%
With Phase Management
92.0%
Without Phase Management
91.0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% Output Power
Figure 5. Efficiency at 115 VRMS, With and Without Phase Management
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Typical Performance Data
Efficiency at Vin = 230V RMS
99.0%
97.0%
95.0%
93.0%
91.0%
89.0%
87.0%
85.0%
With Phase Management
Without Phase Management
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% Output Power
Figure 6. Efficiency at 230 VRMS, With and Without Phase Management
1.40706
VIN = 230VRMS
1.17256
0.93805
0.70354
0.46904
0.23453
0.00002
0
6
12
18
24
30
36
42
48
Harmonic No.
Figure 7. Current Harmonics
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Typical Performance Data
6.1 Output Ripple Voltage at Full Load
Figure 8. VOUT Ripple, POUT = 300 W
6.2 Input Ripple Current Cancellation
Figure 9 through Figure 14 show the input current (M1= IL1 + IL2), Inductor Ripple Current (IL1, IL2) versus
rectified line voltage. From these graphs, it can be observed that interleaving reduces the magnitude of
input ripple current caused by the inductor ripple current.
Figure 9. Inductor and Input Ripple Current at
85 VRMS at Peak of Line Voltage
Figure 10. Inductor and Input Ripple Current
at 85 VRMS Input at Half the Line Voltage
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Typical Performance Data
Figure 11. Inductor and Input Ripple Current
Figure 12. Inductor and Input Ripple Current
at 265 VRMS Input at Half Peak Line Voltage
at 265 VRMS Input at Peak Line Voltage
Figure 13. Inductor and Input Ripple Current
at VIN = 85 VRMS, POUT = 300 W
Figure 14. Inductor and Input Ripple Current
at VIN = 265 VRMS, POUT = 350 W
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Typical Performance Data
6.3 Startup Characteristics
Figure 15. Start-Up at VIN = 85 VRMS, POUT
350 W
=
Figure 16. Start-Up at VIN = 265 VRMS, POUT = 0
W
6.4 Brownout Protection
The UCC28060 has a brownout protection that shuts down both gate drives (GDA and GDB) when the
VINAC pin detects that the RMS input voltage is too low. This EVM was designed to go into a brownout
state when the line drops below 64 VRMS. Once the UCC28060 control device has determined that the
input is in a brownout condition, a 400-ms timer starts to allow the line to recover before shutting down the
gate drivers. After 400 ms of brownout, both gate drivers turn off, as shown in Figure 17 and Figure 18.
Figure 17. Brownout at 85 VRMS
Figure 18. Brownout at 265 VRMS
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Typical Performance Data
6.5 Line Transient
A line transient test was conducted with an ac source on the reference design. The line was varied from
230 VRMS to 115 VRMS to 230 VRMS and the transient response was evaluated in each case. From the
oscilloscope image in Figure 19, it can be observed that the output recovered from line transients within
300ms at full load.
Figure 19. Line Transient, POUT = 300W
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Reference Design Assembly Drawing
7
Reference Design Assembly Drawing
Note: Board layouts are not to scale. These figures are intended to show how the board is laid out;
they are not intended to be used for manufacturing UCC28060EVM PCBs.
Output 390V
Maximum Load 0.77A
C2
C3
13
Figure 20. Top Layer Assembly
Figure 21. Bottom Layer Copper
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List of Materials
Output 390V
Maximum Load 0.77A
JP9
JP8
D2
13
Figure 22. Bottom Layer Assembly
8
List of Materials
Table 2. List of Materials
Qty
RefDes
AC_LINE,
Value
Description
Size
Part Number
3267
MFR
4
3267
Connector, Banana Jack, Uninsulated
0.500 dia. inch
Pomona
AC_NEUTRAL,
VOUT,
RETURN
1
1
2
1
1
1
2
C1
0.047µF
220nF
2.2µF
22µF
Capacitor, Polyester, 630V, 10%
Capacitor, Ceramic, 16V, X7R, 10%
Capacitor, Ceramic, 16V, X7R, 10%
Capacitor, Aluminum, 35V, ±20%
Capacitor, Ceramic, 25V, X7R, 10%
Capacitor, Ceramic, 25V, X7R, 10%
Capacitor, Aluminum, 450VDC, ±20%
0.256in × 0.650in
1206
ECQ-E6473KZ
Panasonic
Std
C11
Std
C12, C13
C14
0805
Std
Std
0.200in × 0.435in
0805
ECA-1VM220
Panasonic
Std
C15
1nF
Std
Std
C16
10nF
0805
Std
C2, C3
100µF
18mm × 40 mm
EKXG451ELL101 Nippon
MM40S
Chemi-con
1
2
2
3
3
1
2
C4
0.1µF
Capacitor, Film, 275VAC, ±20%
Capacitor, Film, 275VAC, ±20%
Capacitor, Ceramic, 25V, X7R, 10%
Capacitor, Ceramic, 25V, X7R, 10%
Diode, 3000mA, 600V
0.689in × 0.236in
0.236 × 0.591
0805
ECQU2A104BC1
ECQ-U2A474MG
Std
Panasonic
Panasonic
Std
C5, C6
C7, C8
C9, C10, C17
D1, D2, D4
D3
0.47µF
22pF
1.2nF
0805
Std
Std
MURS360T3
GBU6J
0100056H
SMC
MURS360T3
GBU6J
On Semi
Vishay
Diode, Bridge, 6A, 600V
BU6
F1
Fuse Clip, 5mm x 20mm
0.205in × 0.220in
x2
0100056H
Wickmann
1
F1
BK/GDA-4A
4A, Fast Acting Fuse
5mm × 20mm
BK/S501-4-R
Cooper/
Bussman
3
1
HS1, HS2, HS3 7-345-2PP
J1 ED1609-ND
Heatsink, Universal-mount TO-220
Terminal Block, 2-pin, 15-A, 5.1mm
1.500in × 2.000in
7-345-2PP
ED1609
IERC-CTS
OST
0.40in × 0.35in
12
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List of Materials
Table 2. List of Materials (continued)
Qty
RefDes
Value
Description
Size
Part Number
MFR
1
3
1
1
1
JP1
923345-20-C
Jumper, 1.600 inch length, PVC Insulation,
AWG 22
0.035in dia.
0.035in dia.
0.035in dia.
0.035in dia.
0.035in dia.
2512
Cut to Dimension
923345-20-C
923345-06-C
923345-05-C
Cut to Dimension
Std
3M
3M
3M
3M
3M
Std
JP2, JP4, JP5
923345-20-C
923345-06-C
923345-05-C
923345-20-C
0
Jumper, 2.000 inch length, PVC Insulation,
AWG 22
JP3
JP6
JP7
Jumper, 0.600 inch length, PVC Insulation,
AWG 22
Jumper, 0.500 inch length, PVC Insulation,
AWG 22
Jumper, 1.200 inch length, PVC Insulation,
AWG 22
2
1
2
JP8, JP9
PCB
Resistor, Chip, 1W, 5%
HPA224 Printed Circuit Board
L1, L2
CTX16-17769R
Inductor, Boost PFC With Aux. 330µH at 5.3 1.555in dia.
A PK
CTX16-17769R
Cooper
2
1
2
1
2
1
1
1
3
1
1
Q1, Q2
R1
IRFB11N50APbF
51.1
MOSFET, N-ch, 500V, 11A, 520mΩ
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/2W, 1%
TO-220V
0805
0805
0805
0805
0805
0805
0805
0805
0805
2010
IRFB11N50APbF
IR
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
R13, R14
R15
47.0k
121.0k
5.11
R16, R24
R17
0.00
R18
6.19k
R19
30.1k
R2, R4, R21
R25
10.0k
100
R3
0.015
WSL2010R0150F Vishay
EA
9
R5–R9, R10,
R12, R20, R22,
R23
1.00M
Resistor, Chip, 1/10W, 1%
0805
Std
Std
2
1
R8, R11
RT1
20.5k
Resistor, Chip, 1/10W, 1%
0805
Std
Std
5Ω
Thermistor, NTC, 5Ω, 6A
0.180in × 0.550in
CL-40
Thermo-
metrics
2
1
1
6
TP1, TP2
U1
K24A/M
Pin, Thru Hole, Tin Plate, for 0.062 PCBs
IC, Interleave PFC Controller
0.039in
K24A/M
Vector
TI
UCC28060D
SO16
UCC28060D
S10K275E2
Std
VAR1
SIOV-S10K275E2 VARISTOR 275V RMS
Nut #4-40 (steel)
0.472in × 0.213in
Epcos
Std
X1 at HS1 and
D3, HS2 and
Q1, HS3 and
Q2
6
X1 at HS1 and
D3, HS2 and
Q1, HS3 and
Q2
Pan Head Screw #4-40X3/8 (steel)
Std
Std
1
6
X1 D3 and HS1
Thermal Grease
Std
Std
Std
Std
X1 at HS1 and
D3, HS2 and
Q1, HS3 and
Q2
Split Lock Washer #4(steel)
6
2
X1 at HS1 and
D3, HS2 and
Q1, HS3 and
Q2
Nylon Shoulder Washer #4
Thermal Pad Silicon TO220
3049
Keystone
Electronics
X1 at HS2 and
Q1, HS3 and
Q2
3223-07FR-51
BERQUIST
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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. As such, the goods being provided are not intended to be complete
in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental
measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does
not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling
(WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives.
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 WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY SELLER TO BUYER
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EVM WARNINGS AND RESTRICTIONS
It is important to operate this EVM within the input voltage range of 85VRMS to 265VRMS and the output voltage range of 375V to 450V.
Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are questions
concerning the input range, please contact a TI field representative prior to connecting the input power.
Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the EVM.
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 +100°C. The EVM is designed to operate
properly with certain components above +100°C as long as the input and output ranges are maintained. These components include but are
not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of devices can be identified
using the EVM schematic located in the EVM User's Guide. When placing measurement probes near these devices during operation,
please be aware that these devices may be very warm to the touch.
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