Texas Instruments Network Card UCC38500EVM User Manual

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User’s Guide  
SLUU068C  
 
IMPORTANT NOTICE  
Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications,  
enhancements, improvements, and other changes to its products and services at any time and to discontinue  
any product or service without notice. Customers should obtain the latest relevant information before placing  
orders and should verify that such information is current and complete. All products are sold subject to TI’s terms  
and conditions of sale supplied at the time of order acknowledgment.  
TI warrants performance of its hardware products to the specifications applicable at the time of sale in  
accordance with TI’s standard warranty. Testing and other quality control techniques are used to the extent TI  
deems necessary to support this warranty. Except where mandated by government requirements, testing of all  
parameters of each product is not necessarily performed.  
TI assumes no liability for applications assistance or customer product design. Customers are responsible for  
their products and applications using TI components. To minimize the risks associated with customer products  
and applications, customers should provide adequate design and operating safeguards.  
TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right,  
copyright, mask work right, or other TI intellectual property right relating to any combination, machine, or process  
in which TI products or services are used. Information published by TI regarding third−party products or services  
does not constitute a license from TI to use such products or services or a warranty or endorsement thereof.  
Use of such information may require a license from a third party under the patents or other intellectual property  
of the third party, or a license from TI under the patents or other intellectual property of TI.  
Reproduction of information in TI data books or data sheets is permissible only if reproduction is without  
alteration and is accompanied by all associated warranties, conditions, limitations, and notices. Reproduction  
of this information with alteration is an unfair and deceptive business practice. TI is not responsible or liable for  
such altered documentation.  
Resale of TI products or services with statements different from or beyond the parameters stated by TI for that  
product or service voids all express and any implied warranties for the associated TI product or service and  
is an unfair and deceptive business practice. TI is not responsible or liable for any such statements.  
Mailing Address:  
Texas Instruments  
Post Office Box 655303  
Dallas, Texas 75265  
Copyright 2001, Texas Instruments Incorporated  
 
EVM IMPORTANT NOTICE  
Texas Instruments (TI) provides the enclosed product(s) under the following conditions:  
This evaluation kit being sold by TI is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION  
PURPOSES ONLY and is not considered by TI to be fit for commercial use. As such, the goods being provided  
may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective  
considerations, including product safety measures typically found in the end product incorporating the goods.  
As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic  
compatibility and therefore may not meet the technical requirements of the directive.  
Should this evaluation kit not meet the specifications indicated in the EVM User’s Guide, the 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 AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED,  
IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY  
PARTICULAR PURPOSE.  
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. Please be aware that the products  
received may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). Due to the open construction  
of the product, it is the user’s responsibility to take any and all appropriate precautions with regard to electrostatic  
discharge.  
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.  
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.  
Please read the EVM User’s Guide and, specifically, the EVM Warnings and Restrictions notice in the EVM  
User’s Guide prior to handling the product. This notice contains important safety information about temperatures  
and voltages. For further safety concerns, please contact the TI application engineer.  
Persons handling the product must have electronics training and observe good laboratory practice standards.  
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.  
Mailing Address:  
Texas Instruments  
Post Office Box 655303  
Dallas, Texas 75265  
Copyright 2001, Texas Instruments Incorporated  
 
EVM WARNINGS AND RESTRICTIONS  
It is important to operate this EVM within the input voltage range of 85 V to 265 V and the output  
voltage of 12 V +/− 5%.  
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  
50°C. The EVM is designed to operate properly with certain components above 50°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.  
Mailing Address:  
Texas Instruments  
Post Office Box 655303  
Dallas, Texas 75265  
Copyright 2001, Texas Instruments Incorporated  
 
Contents  
1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1  
1.1  
1.2  
1.3  
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2  
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2  
Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3  
1.3.1 Step 1. Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3  
1.3.2 Step 2. Applying Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3  
1.3.3 Step 3. Evaluating the Demonstration’s Boards Performance. . . . . . . . . . . . . . 1-3  
1.3.4 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3  
DM38500 EVM Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5  
1.4  
2
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1  
2.1  
2.2  
DM38500 EVM Part Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2  
DM38500 Board Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4  
Figures  
1−1. DM38500 Evaluation Module Application Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4  
1−2. DM38500 EVM Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5  
1−3. DM38500 Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5  
1−4. DM38500 Response, VCC = +15 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6  
2−1. DM38500 EVM PC Board: Top Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4  
 
Chapter 1  
General  
Information  
This chapter details the Texas Instruments (TI) DM38500 PFC/PWM  
Combination Controller 100W Power Factor Correction Preregulator  
Evaluation Module (EVM) SLUU068. It includes a list of EVM features, a brief  
description of the module illustrated with a pictorial, schematic diagrams, and  
EVM specifications.  
Topic  
Page  
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2  
1.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2  
1.3 Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3  
1.4 DM38500 EVM Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−5  
1-1  
 
Features  
1.1 Features  
UCC38500 PFC/PWM Combination Controller 100W Power Factor Correc-  
tion Preregulator include:  
J
J
J
J
J
J
J
J
J
J
Combines PFC and 2nd Stage Down Converter Controls  
Controls Boost Preregulator to Near-unity Power Factor  
Accurate Power Limiting  
Improved Feedforward Line Regulation  
Peak Current Mode Control in Second Stage  
Programmable Oscillator  
Leading Edge/Trailing Edge Modulation for Reduced Output Ripple  
Low Startup Supply Current  
Synchronized Second Stage with Programmable Soft-start  
Programmable Second Stage Shut-down  
1.2 Description  
The UCC38500 provides all the functions necessary for active power factor  
correction and a second stage dc-to-dc converter all in one integrated circuit.  
The control IC uses leading edge modulation for the boost stage and trailing  
edge modulation for the step down converter to reduce the RMS current in the  
boost capacitor. The dc-to-dc controller uses peak current mode control for  
easy loop compensation.  
The UCC38500 evaluation board is designed to illustrate the performance of  
the IC in a complete off-line 100W two-stage power converter using power fac-  
tor correction. The demonstration board was designed to operate with a uni-  
versal input voltage range (i.e. 85−265 Vac) with a regulated 12V dc output.  
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 output capacitor has high levels of energy storage and it must  
be discharged before the load is removed. Serious injury can occur if  
proper safety precautions are not followed.  
1-2  
 
Description  
1.3 Operating Guidelines  
The operating guidelines for the evaluation board are provided with reference  
to the schematic in Figure 1−1 and the component layout in Figure 2−1.  
1.3.1 Step 1. Load Connections  
A resistive or electronic load can be applied to the output terminals labeled  
OUT− and OUT+.  
Note: For safety reasons the load should be connected before power is sup-  
plied to the demonstration board.  
1.3.2 Step 2. Applying Input Power  
A 60 Hz AC power source not exceeding 265 V  
needs be applied across  
RMS  
terminals AC−N and AC−L for proper operation.  
1.3.3 Step 3. Evaluating the Demonstration’s Boards Performance.  
With the AC source set between 85−265 V  
the output voltage should be  
RMS  
regulated and the input current should track the input voltage shape with near  
unity power factor. The operation of the circuit is verified over the line and load  
range and shows efficiency as high as 85%. At lighter loads, there may be  
some distortion in the line current due to Discontinuous Conduction Mode  
(DCM) operation. Please refer to Figures 1−2, 1−3 and 1−4 for typical EVM  
performance.  
1.3.4 Additional Information  
For more information, pin description and specifications for the UCC38500  
PFC/PWM Combination Controller, please refer to the datasheet or contact  
the Texas Instruments Semiconductor Product Information Center at  
1-800-336-5236 or 1-972-644-5580. Product Information can also be found  
General Information  
1-3  
 
Description  
Figure 1−1. DM38500 Evaluation Module Application Schematic  
UDG−00094  
Note: High-Voltage component. See EVM Warnings and Restrictions at the back of this document.  
Note: High-Temperature component. See EVM Warnings and Restrictions at the back of this document.  
1-4  
 
DM38500 EVM Performance  
1.4 DM38500 EVM Performance  
Figure 1−2 through 1−4 shows the typical evaluation module performance.  
Figure 1−2. DM38500 EVM Efficiency  
UCC38500 EFFICIENCY  
vs  
OUTPUT POWER  
90  
85  
80  
75  
70  
65  
60  
55  
50  
V = 265 V  
IN  
V = 175 V  
IN  
V = 85 V  
IN  
10 20 30 40 50 60 70 80 90 100  
P
OUT  
− W  
Figure 1−3. DM38500 Power Factor  
UCC38500 PF  
vs  
OUTPUT POWER  
1.00  
V
IN  
= 85 V  
V
IN  
= 265 V  
0.95  
V
IN  
= 175 V  
0.90  
0.85  
30 40 50 60 70 80 90 100  
10 20  
P
OUT  
− W  
General Information  
1-5  
 
DM38500 EVM Performance  
Figure 1−4. DM38500 Total Harmonic Distortion  
UCC38500 TOTAL HARMONIC DISTORTION  
vs  
OUTPUT POWER  
35  
30  
25  
V
IN  
= 265 V  
20  
15  
V
IN  
= 175 V  
10  
5
V
IN  
= 85 V  
0
30 40 50 60 70 80 90 100  
10 20  
P
OUT  
− W  
1-6  
 
Chapter 2  
Reference  
This chapter includes a parts list and PCB layout illustrations for the DM38500  
EVM.  
Topic  
Page  
2.1 DM38500 EVM Part Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−2  
2.2 DM38500 Board Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−4  
2-1  
 
DM38500 EVM Part Descriptions  
2.1 DM38500 EVM Part Descriptions  
Table 2−1.DM38500 Part Descriptions  
Part  
Number  
Description  
Reference Qty  
Value/Type Number  
Manufacturer  
C12, C20,  
3
1 µF, 50 V, polypropylene  
47 pF, 50 V, ceramic  
10 nF, 50 V, ceramic  
Panasonic  
Panasonic  
Panasonic  
ECQ−V1H105JL  
ECU−S2A470JCA  
ECU−S1H103JCB  
C29  
C13  
1
3
C7, C16,  
C14  
C17, C38  
C19  
2
1
100 pF, 50 V, ceramic  
2.2 nF, 50 V, ceramic  
Panasonic  
Panasonic  
ECU−S1H101JCA  
ECU−S1H222JCB  
470 nF, 400 V,  
polypropylene  
C2  
1
Panasonic  
ECQ−E4474KZ  
C21  
C22  
1
1
1
1
1
2
2
1
1
3
1
1
680 pF, 50 V, ceramic  
390 pF, 50 V, ceramic  
100 pF, 50 V, ceramic  
150 nF, 50 V, ceramic  
Panasonic  
Panasonic  
Panasonic  
Panasonic  
ECU−S1H681JCB  
ECU−S1H391JCA  
ECU−S1H101JCA  
ECU−S1H154KBB  
ECQ−E6473KF  
Capacitors  
C24  
C25  
C26  
47 nF, 600 V, polypropylene Panasonic  
C27, C18  
C28, C23  
C3  
100 pF, 50 V, ceramic  
2.2 µF, 50 V, ceramic  
100 µF, 450 V, electrolytic  
1800 µF, 25 V, electrolytic  
0.1 µF, 50 V, ceramic  
100 µF, 25 V, electrolytic  
6 A, 600 V, GI756CT  
Panasonic  
Panasonic  
Panasonic  
Panasonic  
Panasonic  
Panasonic  
General Inst.  
ECU−S1H105KBB  
ECU−S1H225MEB  
ECO−S2WB101BA  
ECA−IEFQ182  
C30  
C4, C5, C8  
C6  
ECU−S1H104KBB  
EEU−FCIE101S  
GI756CT  
D1  
6 A, 600 V, bridge rectifier,  
PB66  
D11  
1
Diodes Inc.  
PB66  
D12  
D13  
1
1
1
2
1
2
1 A, 40 V, Shottky  
TL431CLP  
SR103CT  
TL431C  
TI  
D14  
10 V, 1 W, Zener  
18 V, 1 W, Zener  
6 A, 600 V, ultra fast  
1 A, 600 V, fast recovery  
1N4740  
Diodes  
D15, D2  
D3  
1N4746  
IR  
HFA08TB60−ND  
BYV26C  
D4, D6  
Philips  
D5,D7,D9,  
D10, D16  
5
1
1 A, 40 V, Shottky  
1N5819  
6 A, 600 V, full wave  
rectifier  
D8  
IR  
HBR2045  
FH1, FH2  
F1  
2
1
1
2
2
1
1
2
1
1
3AG Fuse clip  
Fuses  
6 A, 250 V  
HS3  
For Q3  
Aavid  
Aavid  
Avid  
513201  
Heat sinks  
Inductors  
MOSFETs  
HS4, HS5  
HS1, HS2  
L1  
For D3 and D8  
For Q1 and Q2  
1.7 mH, 2.5 A, coupled  
35 µH, 8.3 A  
8 A, 500 V, n−channel  
14 A, 500 V, n−channel  
NPN transistor  
579302 B 0 00 00  
593002 B 0 34 00  
CTX08−14730  
CTX08−14279  
IRF840  
Cooper  
Cooper  
IR  
L2  
Q1,Q2  
Q3  
IR  
IRFP450  
Q5  
MJE13005  
Q4, R8, R9,  
C9, C15,  
C10  
Not used  
6
Not used  
2-2  
 
DM38500 EVM Part Descriptions  
Part  
Number  
Description  
Reference Qty  
Value/Type Number  
Short  
Manufacturer  
R1, R12  
2
2
R10, R36  
200 Ω, ¼ W  
R25, R29,  
R27  
3
10 k, ¼ W  
R13  
R14  
1
1
2
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2 k, ¼ W  
1.5 k, ¼ W  
3.92 k, ¼ W  
750 , ¼ W  
7.5 k, ¼ W  
392 k, ¼ W  
1 k, ¼ W  
22.1 k, ¼ W  
8.25 k, ¼ W  
562 k, ¼ W  
200 k, ¼ W  
100 , ¼ W  
100 k, ¼ W  
30.1 k, ¼ W  
33.2 k, ¼ W  
4.75 k, ¼ W  
221 k, ¼ W  
16.2 k, ¼ W  
1 k, 1 W  
R15, R19  
R16  
R17  
R18, R24  
R2, R11  
R20  
R21  
R22, R33  
R23  
Resistors  
R26  
R28  
R30  
R31  
R32  
R34  
R35  
R39  
R4  
1 , 1 W, 5%  
0.33 , 3 W, 5%  
20 , ¼ W  
51 k, 2 W, 400 V  
8 mH, 10 A, 10.8:1  
R5  
R6, R7  
R3  
T1  
Cooper  
CTX08−14226  
CTX08−14225  
Transformers  
ICs  
T2  
560−990 µH, 1:1 gate drive Cooper  
BiCMOS PFC/PWM  
combination controller  
Texas  
Instruments  
U4  
U3  
X1  
1
1
3
UCC38500N  
4N36  
Opto-isolator  
Thermal pad TO−220  
(@ Q1, Q2, D8)  
Thermal pad TO−247  
(@ Q3)  
X2  
1
Screw pan head #4−40 X  
7/16 (@Q1, Q2, Q3, D8)  
X3  
X4  
X5  
4
4
3
Miscellaneous  
Nut #4x40  
Nylon shoulder washer #4  
(@Q1, Q2, D8)  
X6  
1
1
Bevel washer #4 (@Q3)  
Bare board  
PCB  
PCB  
UCC38500 PCB  
Notes:  
1) The values of these components are to be determined by the user in accordance with the applica-  
tion requirements.  
2) Unless otherwise specified, all resistors have a tolerance of 1%.  
3) Capacitor C38 is located at reference designator R38 on the PCB.  
Reference  
2-3  
 
DM38500 Board Layouts  
2.2 DM38500 Board Layouts  
Board layout examples of the DM38500 EVM PCB are shown in the following  
illustrations. They are not to scale and appear here only as a reference.  
Figure 2−1. DM38500 EVM PC Board: Top Assembly  
2-4  
 

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