Texas Instruments UCC28780EVM-021 Bedienungsanleitung
Using the UCC28780EVM-021, 45-W, 20-V High-
Density Silicon (Si) Based, Active-Clamp
Flyback Converter/Evaluation Module
User's Guide
Literature Number: SLUUBV6
August 2018
WARNING
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General Texas Instruments High Voltage Evaluation (TI HV EVM) User Safety Guidelines
Always follow TI’s setup and application instructions, including use of all interface components within their
recommended electrical rated voltage and power limits. Always use electrical safety precautions to help
ensure your personal safety and those working around you. Contact TI's Product Information Center
http://support/ti./com for further information.
Save all warnings and instructions for future reference.
Failure to follow warnings and instructions may result in personal injury, property damage, or
death due to electrical shock and burn hazards.
The term TI HV EVM refers to an electronic device typically provided as an open framed, unenclosed
printed circuit board assembly. It is intended strictly for use in development laboratory environments,
solely for qualified professional users having training, expertise and knowledge of electrical safety
risks in development and application of high voltage electrical circuits. Any other use and/or
application are strictly prohibited by Texas Instruments. If you are not suitable qualified, you should
immediately stop from further use of the HV EVM.
1. Work Area Safety
1. Keep work area clean and orderly.
2. Qualified observer(s) must be present anytime circuits are energized.
3. Effective barriers and signage must be present in the area where the TI HV EVM and its interface
electronics are energized, indicating operation of accessible high voltages may be present, for the
purpose of protecting inadvertent access.
4. All interface circuits, power supplies, evaluation modules, instruments, meters, scopes and other
related apparatus used in a development environment exceeding 50Vrms/75VDC must be
electrically located within a protected Emergency Power Off EPO protected power strip.
5. Use stable and nonconductive work surface.
6. Use adequately insulated clamps and wires to attach measurement probes and instruments. No
freehand testing whenever possible.
2. Electrical Safety
As a precautionary measure, it is always a good engineering practice to assume that the entire EVM
may have fully accessible and active high voltages.
1. De-energize the TI HV EVM and all its inputs, outputs and electrical loads before performing any
electrical or other diagnostic measurements. Revalidate that TI HV EVM power has been safely
de-energized.
2. With the EVM confirmed de-energized, proceed with required electrical circuit configurations,
wiring, measurement equipment connection, and other application needs, while still assuming the
EVM circuit and measuring instruments are electrically live.
3. After EVM readiness is complete, energize the EVM as intended.
WARNING: WHILE THE EVM IS ENERGIZED, NEVER TOUCH THE EVM OR ITS ELECTRICAL
CIRCUITS AS THEY COULD BE AT HIGH VOLTAGES CAPABLE OF CAUSING ELECTRICAL
SHOCK HAZARD.
3. Personal Safety
1. Wear personal protective equipment (for example, latex gloves or safety glasses with side shields)
or protect EVM in an adequate lucent plastic box with interlocks to protect from accidental touch.
Limitation for safe use:
EVMs are not to be used as all or part of a production unit.
3
SLUUBV6–August 2018
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Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,
Active-Clamp Flyback Converter/Evaluation Module
User's Guide
SLUUBV6–August 2018
Using the UCC28780EVM-021, 45-W, 20-V High-Density
Silicon (Si) Based, Active-Clamp Flyback
Converter/Evaluation Module
1 Description
The UCC28780EVM-021 is a 45-W evaluation module (EVM) for evaluating an off-line active-clamp
flyback adapter for notebook charging and other applications. The EVM meets CoC Tier 2 and DoE Level
6 efficiency requirements. It is intended for evaluation purposes and is not intended to be an end product.
The UCC28780EVM-021 converts input voltage of 90-VRMS to 264-VRMS down to 20-VDC, with a 2.25-A
nominal output current rating and a 160-ms limit for over-power capability. The main devices used in this
design are active clamp flyback controller UCC28780, SR controller UCC24612, and Si MOSFETs.
Figure 1. UCC28780EVM-021 Top View
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Electrical Performance Specifications
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2 Electrical Performance Specifications
(1) The performance listed in this table is achieved using secondary resonance and based on the test results from a single board.
(2) Average efficiency of four load points, IOUT = 25%, 50%, 75% and 100% nom.
Table 1. UCC28780EVM-021 Electrical Performance Specifications(1)
PARAMETER TEST CONDITIONS MIN NOM MAX UNIT
INPUT CHARACTERISTICS
VIN Input line voltage (RMS) 90 115 / 230 264 V
fLINE Input line frequency 47 50 / 60 63 Hz
PSTBY Input power at no-load VIN = 115 VRMS, IOUT = 0 A 37.2 mW
PSTBY Input power at no-load VIN = 230 VRMS, IOUT = 0 A 40.1 mW
P0.25W Input power at 0.25W load VIN = 115 VRMS, POUT = 237mW 330 mW
P0.25W Input power at 0.25W load VIN = 230 VRMS, POUT = 237 mW 392 mW
OUTPUT CHARACTERISTICS
VOUT Output voltage VIN = 115 VRMS, IOUT = 2.249 A 19.928 V
VIN = 230VRMS, IOUT = 2.249 A 19.924 V
VOUT Output voltage VIN = 115 VRMS, IOUT = 0 A 19.937 V
VIN = 230VRMS, IOUT = 0 A 19.936 V
IOUT Full load rated output current VIN = 90 to 264 VRMS 2.25 A
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 to 2.25 652/600 mVpp
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 2.25 A 20/28 mVpp
VOUT_pp Output ripple voltage VIN = 115 V / 230 VRMS, IOUT = 0 A 20/21 mVpp
POUT_opp Over-power protection power
limit VIN = 90 to 264 VRMS 55 W
tOPP Over-power protection duration VIN = 90 to 264 VRMS, POUT = POUT_opp 160 ms
VOUT_ΔOutput voltage deviation due to
load step up IOUT step between 0 A and 2.25A < 5%
SYSTEMS CHARACTERISTICS
ηFull-load efficiency VIN = 115 VRMS, IOUT = 2.25A 94.06%
VIN = 230 VRMS, IOUT = 2.25A 93.82%
VIN = 90V RMS, IOUT = 2.25A 93.08%
η4-point average efficiency(2) VIN = 115 VRMS 92.82%
VIN = 230 VRMS 91.71%
ηEfficiency at 10% Load VIN = 115 VRMS, IOUT = 10% rated current 88.09%
VIN = 230 VRMS, IOUT = 10% rated current 85.08%
TAMB Ambient operating temperature
range VIN = 90 to 264 VRMS, IOUT = 0 to 2.25A 25 °C
Schematic Diagram
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3 Schematic Diagram
Figure 3. UCC28780EVM-021 Schematic Diagram
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Test Setup
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4 Test Setup
4.1 Test Setup Requirements
Safety: This evaluation module is not encapsulated and there are accessible voltages that are greater
than 50 VDC.
Isolation Input Transformer: A suitably rated 1:1 isolation transformer shall be used on the input(s) to
this EVM and be constructed in a manner in which the primary winding(s) are separated from the
secondary winding(s) by reinforced insulation, double insulation, or a screen connected to the protective
conductor terminal.
WARNING
If you are not trained in the proper safety of handling and testing
power electronics please do not test this evaluation module.
Read this user's guide thoroughly before making test.
Voltage Source: Isolated AC source or variable AC transformer capable of 264 VRMS cable of handling
100 W
Voltmeter: Digital voltage meter
Power Analyzer: Capable of measuring 1 mW to 100 W of input power and capable of handling 264-VRMS
input voltage. Some power analyzers may require a precision shunt resistor for measuring input current to
measure input power of 5 W or less. Please read the power analyzer’s user manual for proper
measurement setups for full power and for stand-by power.
Oscilloscope:
• 4-Channel, 500 MHz bandwidth.
• Probes capable of handling 600 V.
Output Load: Resistive or electronic load capable of handling 100 W at 20 V.
Recommended Wire Gauge: Insulated 22 AWG to 18 AWG.
WARNING
Caution: Do not leave EVM powered when unattended
UCC28780EVM-021
Test Setup
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Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,
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4.2 Test Setup Diagram
Figure 4. UCC28780EVM-021 Test Setup Diagram
4.3 Design Notes
In Table 6, a component list shows critical components to achieve stable ABM operation with secondary
resonance which provides better efficiency and output voltage ripple performance. Details on secondary
resonance can be found in the UCC28780 datasheet.
4.4 Test Points
Table 2. Test Point Functions
TEST POINTS NAME DESCRIPTION
J1-L Location J1 Terminal L AC line voltage input
J1-N N AC neutral input
J2+ Location J2 Terminal VOUT + Output supply
J2- VOUT – Output return
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Performance Data and Typical Characteristic Curves
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Using the UCC28780EVM-021, 45-W, 20-V High-Density Silicon (Si) Based,
Active-Clamp Flyback Converter/Evaluation Module
5 Performance Data and Typical Characteristic Curves
5.1 Efficiency Typical Result of 4-Point Average
Table 3. Efficiency Test Data
VIN RMS PIN VOUT IOUT POUT(%) EFFICIENCY EFFICIENCY
4pt-
AVERAGE
Switching
Frequency @
Full Load
90 48.210 19.927 2.252 100% 93.08% 92.57% 179kHz
90 35.875 19.930 1.680 75% 93.33%
90 24.240 19.932 1.123 50% 92.34%
90 12.720 19.935 0.584 25% 91.53%
115 47.670 19.928 2.250 100% 94.06% 92.82% 224kHz
115 35.760 19.930 1.680 75% 93.63%
115 24.290 19.931 1.123 50% 92.15%
115 12.710 19.935 0.583 25% 91.44%
230 47.780 19.924 2.250 100% 93.82% 91.71% 288kHz
230 36.130 19.925 1.681 75% 92.70%
230 24.970 19.926 1.131 50% 90.25%
230 12.950 19.933 0.585 25% 90.04%
264 47.930 19.923 2.249 100% 93.48% 91.47% 291kHz
264 36.310 19.924 1.683 75% 92.35%
264 24.870 19.93 1.131 50% 90.63%
264 13.060 19.93 0.586 25% 89.44%
5.2 Efficiency Typical Results
Figure 5. Efficiency Over Load Figure 6. Efficiency Over Input Voltage
19.4
19.58
19.76
19.94
20.12
20.3
20.48
75 105 135 165 195 225 255
Vout, V
AC Input Voltage, Vac
Full Load
Performance Data and Typical Characteristic Curves
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5.3 VI Characteristics
Figure 7. VOUT Line Regulation Figure 8. VOUT Load Regulation
5.4 Switching Frequency
Figure 9. Switching Frequency Over Input at Full Load
Figure 10. Maximum switching frequency about 500kHz at
high line and entering ABM
CH1 = PWML, CH4 = Transformer Primary Winding Current, CH3 = Switch Node Voltage
5.5 Key Switching Waveforms and Operation Mode Load Current
This section shows typical operation modes in Table 4 along with typical load currents in this design and
with Vin = 115Vac as an example.
• AAM: Adaptive Amplitude Modulation
• ABM: Adaptive Burst Mode
• LPM: Lower Power Mode
• SBP: Standby Power Mode
Table 4. Operation Mode and Load Current
Mode AAM AAM to ABM ABM End LPM SBP
Typical Load Current 1.50 A to 2.25 A 1.30 A to 1.60 A 0.15 A to 0.18 A 0.05 A to 0.15 A < 0.08 A
Typical Load % 67% to 100% 58% to 71% 6.7% to 8% 2.2% to 6.7% < 3.5%
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