48-V to 3.3-V Forward Converter with
Active Clamp Reset Using the
UCC2891 Active Clamp Current Mode
PWM Controller
User's Guide
December 2006
Power Supply MAN
SLUU178A
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User's Guide
SLUU178A–November 2003–Revised December 2006
Using the UCC2891 Active Clamp Current Mode PWM
Controller
1
Introduction
The UCC2891EVM evaluation module (EVM) is a forward converter providing a 3.3-V regulated output at
30 A of load current, operating from a 48-V input. The EVM operates over the full 36 V to 72 V telecom
input range, and is able to fully regulate down to zero load current. The module uses the UCC2891 current
mode active clamp PWM controller for effectively demonstrating the active clamp transformer reset
technique.
Benefits of the active clamp include a control driven transformer reset scheme allowing zero voltage
switching (ZVS) to increase overall efficiency, lower drain-to-source voltage stress, extended duty cycle
beyond 50% and reduced electromagnetic radiated emissions. Combined with synchronous rectification,
this EVM is configured to operate at 300 kHz and exhibits a peak efficiency of just over 92%, with a full
load efficiency of 89%. The EVM displays many features that might be typical of a more complex design,
yet its compact board layout and low component count make it elegantly simple.
2
Description
The UCC2891 controller family provides advanced active clamp control features such as programmable
maximum duty cycle clamp, programmable dead time between the two primary switches and the ability to
drive either a P-channel, or N-channel MOSFET in either a high-side or low-side active clamp
configuration. The UCC2891 also allows the ability to start-up directly from the 48-V telecom bus voltage,
eliminating the need for external start-up circuitry. It includes programmable soft start, internal slope
compensation for peak current mode control, internal low-line voltage sensing, internal syncronizable clock
input, cycle-by-cycle current limiting, and a robust 2-A sink/source TrueDrive™ internal gate drive circuit.
The result is a highly efficient design loaded with features, requiring very few external components.
The TrueDrive™ hybrid output architecture used in the UCC2891 uses TI's unique TrueDrive™
Bipolar/CMOS output. To the user, this simply means ultra-fast rise and fall times by providing the highest
possible drive current where it is needed most, at the MOSFET Miller plateau region.
The UCC2891/2/3/4 is available in either a 16-pin SOIC or 16-pin TSSOP package for applications where
absolute minimal board space is required.
The UCC2891EVM highlights the many benefits of using the UCC2891 active clamp current mode PWM
controller. This user's guide provides the schematic, component list, assembly drawing, artwork and test
set up necessary to evaluate the UCC2891 in a typical telecom application. More detailed design
information can be found listed in the References section.
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Description
2.1 Applications
The UCC2891 is suited for use in isolated telecom 48-V input systems requiring high-efficiency and
high-power density for very low-output voltage, high-current converter applications, including:
•
•
•
•
Server Systems
Datacom
Telecom
DSP's, ASIC's, FPGA's
2.2 Features
The UCC2891EVM features include:
•
•
•
•
•
•
•
•
•
•
•
•
•
ZVS transformer reset using active clamp technique in forward converter
All surface mount components, double sided half brick (2.2 × 2.28 × 0.5) inches
Complementary auxilliary drive for active clamp with programmable dead time for ZVS
Current mode control with synchronization function
Internal PWM slope compensation
Start-up directly from telecom input voltage
Synchronous rectifier output stage allows high-efficiency operation
Programmable soft-start
Up to 30-A dc output current
Regulation to zero load current
Non-latching, output overcurrent and short circuit protection
Non-latching, Input undervoltage protection
1500-V isolation primary to secondary
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UCC2891EVM Electrical Performance Specifications
3
UCC2891EVM Electrical Performance Specifications
Table 1. UCC2891EVM Performance Summary
PARAMETER
Input Characteristics
Input voltage range
No load intput current
Maximum input current
Input voltage ripple
TEST CONDITIONS
MIN
TYP
MAX
UNITS
36
48
72
V
mA
A
VIN = 36 V, IOUT = 0 A
75
3.00
1.50
100
3.25
1.75
VIN = 36 V, IOUT = 30 A
VIN = 72 V, IOUT = 30 A
VP-P
Input voltage ripple
Output voltage
36 V ≤ VIN ≤ 72 V, 0 A ≤ IOUT ≤ 30 A
Line regulation (36 V ≤ VIN ≤ 72 V, IOUT = 0 A)
Load regulation (0 A ≤ IOUT ≤ 30 A, VIN = 48 V)
VIN = 48 V, IOUT = 30 A
3.25
3.30
0.003%
0.060%
30
3.35
V
Output voltage regulation
Output voltage ripple
Output load current
Output current limit
Output current limit
Switching frequency
Control loop bandwidth
Control loop bandwidth
Peak efficiency
35 mVP-P
VIN = 48 V, IOUT = 30 A
0
30
A
36 V ≤ VIN≤ 72 V
32
275
5
325
kHz
36 V ≤ VIN ≤ 72 V, IOUT = 10 A
8
36 V ≤ VIN ≤ 72 V, 2 A ≤ IOUT ≤ 30 A
30
50
°C
92%
89%
Full load efficiency
VIN = 48 V, IOUT = 30 A
4
Schematic
A schematic of the UCC2891EVM is shown in Figure 1. Terminal block J1 is the 48-V input voltage source
connector and J8 is the output and return for the 3.3-V output voltage.
On the primary side, U1 is the UCC2891 shown with the necessary discrete circuitry for configuring the
controller to operate at 300 kHz with the maximum duty clamp set for 0.65. The EVM is programmed to
start at VIN=36 V, as determined by R11 and R12. To minimize power dissipation in the current sense, a
current sense transformer, T1 is used, as opposed to simply using a sense resistor between the source of
Q2 and power ground. Q2 is the primary switching MOSFET and is selected based upon VDS and low
RDS(on). Q1 is the AUX (active reset) MOSFET and is selected based upon preferred package only, with
only minor consideration given for RDS(on) and Qg. Since the active clamp used in this design is low-side
referenced, Q1 must be a P-channel type MOSFET. The reason for this is further explained in application
note SLUA299[2]. C9 is the clamp capacitor used to maintain a constant dc voltage. The input voltage is
subtracted from the clamp voltage to allow transformer reset during the active clamp period.
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Schematic
Figure 1. UCC2891EVM Schematic
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EVM Test Setup
High efficiency is achieved using self-driven synchronous rectification on the secondary side. Q3 and Q4
are placed in parallel and make up the forward synchronous rectifier (SR), while the reverse SR is made
up of the parallel combination of Q5, Q7 and Q8. If the duty cycle were limited to 50% then the reverse SR
could be reduced to only two parallel MOSFETs, but since these devices are operating near 60% duty
cycle during the freewheel mode, they carry a higher average current than seen by Q3 and Q4. The
output inductor L1 has a coupled secondary, referenced to the primary side, used to provide bootstrapping
voltage to U1. A stable bias for the optocoupler, U2 is provided by the series pass regulator made up of
D6, Q6 and some associated filtering.
Scope jacks J2 and J3 allow the user to measure the gate-to-source and drain-to-source signals for Q2,
the primary MOSFET. J4 and J5 allow convenient access to the gate drive signals of each SR on the
secondary side. J6 and J7 are available allowing the option of using a network analyzer to non-invasively
measure the control to output loop gain and phase.
5
EVM Test Setup
V2
-
+
+VOUT
J10
-Vout
J9
+Vout
+VIN
-VIN
-
LOAD1
J8
+
+
3.3V/30A
J1
+
-
+
V1
VIN
V-Clamp
-VOUT
SR-QF Gate
J4
J3
A1
J5
Q2 Gate
J2
SR-QR Gate
J6 Loop+
J7 Loop-
Texas Instruments
HPA034
UCC2891 Active Clamp Converter
DANGER HIGH VOLTAGE
FAN
Figure 2. Recommended EVM Test Configuration
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EVM Test Setup
5.1 Output Load (LOAD1)
For the output load to VOUT, a programmable electronic load set to constant current mode and capable of
sinking between 0ADC and 30ADC, is used. Using a dc voltmeter, V2, it is also advised to make all output
voltage measurements directly at J9 and J10 pins. Unless the load has remote sense capability,
measuring VOUT at LOAD1 results in some voltage measurement error, especially at higher load current,
due to finite voltage drops across the wires between J8 and the electronic load.
5.2 DC Input Source (VIN)
The input voltage is a variable DC source capable of supplying between 0 VDC and 72 VDC at no less than
3.5 ADC, and connected to J1 and A1 as shown in Figure 2. For fault protection to the EVM, good common
practice is to limit the source current to no more than 4 ADC for a 36 V input. A dc ammeter, A1 should
5.3 Network Analyzer
A network analyzer can be connected directly to J6 and J7. The UCC2891EVM provides a 51.1-Ω resistor
(R25) between the output and the voltage feedback to allow easy non-invasive measurement of the
control to output loop response.
5.4 Recommended Wire Guage
The connection between the source voltage, VIN and J1 of the EVM can carry as much as 3.25ADC. The
minimum recommended wire size is AWG #20 with the total length of wire less than 8 feet (4 feet input, 4
feet return). The connection between J8 of the EVM and LOAD1 can carry as much as 30ADC. The
minimum recommended wire size is AWG #16, with the total length of wire less than 8 feet (4 feet output,
4 feet return).
5.5 Fan
Most power converters include components that can be hot to the touch when approaching temperatures
of 605C. Because this EVM is not enclosed to allow probing of circuit nodes, a small fan capable of
200-400 LFM is recommended to reduce component temperatures when operating at or above 50%
maximum rated load current.
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Power Up/Down Test Procedures
6
Power Up/Down Test Procedures
The following test procedure is recommended primarily for power up and shutting down the EVM.
Whenever the EVM is running above an output load of 15 ADC, the fan should be turned on. Also, never
walk away from a powered EVM for extended periods of time.
1. Working at an ESD workstation, make sure that any wrist straps, bootstraps or mats are connected
referencing the user to earth ground before power is applied to the EVM. Electrostatic smock and
safety glasses should also be worn.
2. Prior to connecting the DC input source, VIN, it is advisable to limit the source current from VIN to
4. Connect voltmeter (can optionally use voltmeter from VIN source if available), V1 across VIN as shown
5. Connect LOAD1 to J8 as shown in Figure 2. Set LOAD1 to constant current mode to sink 0 ADC before
VIN is applied.
7. Increase VIN from 0 V to 36 VDC
.
8. Observe that VOUT is regulating when VIN is at 36 V.
9. Increase VIN to 48 V.
10. Increase LOAD1 from 0 A to 15 ADC
.
11. Turn on fan making sure to blow air directly on the EVM.
12. Increase LOAD1 from 15 ADC to 30 ADC
.
13. Decrease LOAD1 to 0 A.
14. Decrease VIN from 48 VDC to 0 V.
15. Shut down VIN.
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Power Up/Down Test Procedures
7
Power Up/Down Test Procedures
OVERALL EFFICIENCY
vs
OUTPUT CURRENT
93
V
= 48 V
IN
91
89
V
= 72 V
IN
V
= 36 V
IN
87
85
83
81
V
= 3.3 V
OUT
f
= 300 kHz
S
79
2
6
10
I
14
18
22
26
- Output Current - A
OUT
Figure 3.
POWER LOSS
vs
OUTPUT CURRENT
GAIN AND PHASE
vs
FREQUENCY
12
10
60
40
180
120
V
= 3.3 V
OUT
Phase
f
= 300 kHz
S
20
60
8
6
Gain
0
0
-20
-40
-60
-60
-120
V
= 72 V
IN
V
= 36 V
IN
I
= 10 A
OUT
V
= 48 V
IN
g
= -8 dB
4
M
F
= 50°
M
-180
10
100
1 k
10 k
100 k
V
= 36 V
18
IN
2
f - Frequency - Hz
2
6
10
I
14
22
26
30
- Output Current - A
OUT
Figure 5.
Figure 4.
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Power Up/Down Test Procedures
Input Ripple Voltage
GAIN AND PHASE
vs
FREQUENCY
60
40
180
120
V
= 36 V
= 30 A
IN
I
OUT
Phase
500 mV/div
1 V peak-to-peak
20
60
0
0
Gain
-20
-60
-120
-180
V
= 48 V
IN
I
= 10 A
-40
-60
OUT
g
= -10 dB
M
F
= 50°
M
10
100
1 k
10 k
100 k
t − Time − 2.5 µs/div
f - Frequency - Hz
Figure 8.
Figure 6.
Output Ripple Voltage
GAIN AND PHASE
vs
FREQUENCY
V
= 72 V
= 30 A
IN
60
40
180
120
I
OUT
Phase
50 mV/div
36 mV peak-to-peak
20
60
0
0
Gain
-20
-40
-60
-60
-120
-180
V
= 72 V
IN
I
= 10 A
OUT
g
= -9 dB
M
F
= 50°
M
10
100
1 k
10 k
100 k
t − Time − 2.5 µs/div
f - Frequency - Hz
Figure 9.
Figure 7.
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Power Up/Down Test Procedures
Output Ripple Voltage
SR Gate Drive
V
IN
= 36 V
V
OUT
= 36 V
= 30 A
IN
I
6.3 V, QF Gate (J5)
(5 V/div)
50 mV/div
23 mV peak-to-peak
8.4 V, QR Gate (J6)
(5 V/div)
t − Time − 1 µs/div
t − Time − 2.5 µs/div
Figure 12.
Figure 10.
SR Gate Drive
Transformer Primary
V
IN
= 48 V
I
= 10 A
OUT
V
PRI
(40 V/div)
I
PRI
(0.5 A/div)
t − Time − 1 µs/div
t − Time − 2.5 µs/div
Figure 13.
Figure 11.
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EVM Assembly Drawing and Layout
8
EVM Assembly Drawing and Layout
well as device pin numbers where necessary. A four layer PCB was designed using the top and bottom
layers for signal traces and component placement along with an internal ground plane. The PCB
dimensions are 3.6" x 2.7" with a design goal of fitting all components within the industry standard
half-brick format, as outlined by the box dimensions 2.28" x 2.20" shown in Figure 15. All components are
standard OTS surface mount components placed on the both sides of the PCB. The copper-etch for each
layer is also shown.
Figure 14. Top Side Component Assembly
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EVM Assembly Drawing and Layout
Figure 15. Top Side Silk Screen
Figure 16. Top Signal Trace Layer
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EVM Assembly Drawing and Layout
Figure 17. Internal Split Ground Plane
Figure 18. Internal Signal Trace Layer
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EVM Assembly Drawing and Layout
Figure 19. Bottom Signal Trace Layer
Figure 20. Bottom Side Component Assembly
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List of Materials
9
List of Materials
The following table lists the UCC2891EVM components corresponding to the schematic shown in
Table 2. List of Materials
QT
REF
C1, C2, C4
DESCRIPTION
MFR
PART NUMBER
C4532X7R2A225M
Y
3
3
1
2
1
1
2
2
1
1
1
2
5
1
1
1
1
4
4
1
1
1
Capacitor, ceramic, 2.2 µF, 100 V, X7R, 20%, 1812
Capacitor, ceramic, 0.1 µF, 50 V, X7R, 20%, 805
Capacitor, ceramic, 100 pF, 50 V, NPO, 10%, 805
Capacitor, ceramic, 0.22 µF, 50 V, X7R, 20%, 805
Capacitor, ceramic, 10 nF, 50 V, X7R, 20%, 805
Capacitor, ceramic, 33 nF, 250 V, X7R, 10%, 1206
Capacitor, tantalum chip, 47 µF, 16 V, C
TDK
C3, C14, C17
Vishay
Vishay
TDK
VJ0805Y104MXAA
VJ0805A101KXAA
C2012X7R1H224M
VJ0805Y103MXAA
GRM31CR72E333KW03L
595D476X9016C2T
C3216X5R1C106M
C2012X5R1A155M
VJ0805Y823KXAA
VJ0805A221KXAA
6TPD330M
C5
C6, C7
C8
Vishay
MuRata
Vishay
TDK
C9
C10, C11
C12, C18
Capacitor, ceramic, 10 µF, 16 V, X5R, 20%, 1206
Capacitor, ceramic, 1.5 µF, 10 V, X5R, 20%, 805
Capacitor, ceramic, 82 nF, 50 V, X7R, 10%, 805
Capacitor, ceramic, 220 pF, 50 V, NPO, 10%, 805
Capacitor, POSCAP, 330 µF, 6.3 V, 20%, 7343 (D)
Diode, schottky, 200 mA, 30 V, SOT23
C13
TDK
C15
Vishay
Vishay
Sanyo
Vishay
Philips/NXP
Vishay
TI
C16
C19, C20
D1, D2, D3, D4, D5
BAT54
D8
Diode, switching, 200 mA, 200 V, SOT23
BAS21
D6
Diode, zener, 5.1 V, 350 mW, SOT23
BZX84C5V1
D7
Adjustable precision shunt regulator, 0.5%, SOT23
Terminal block, 2 pin, 15 A, 5.1 mm, 0.40 × 0.35
TLV431BCDBZ
ED500/2DS
J1
OST
J2, J3, J4, J5
Adaptor, 3.5 mm probe clip (or 131-5031-00), 3.5 mm Tektronix
131 4244 00
J6, J7, J9, J10
Printed circuit pin, 0.043 hole, 0.3 length, 0.043
Terminal block, 4 pin, 15 A, 5.1mm, 0.80 × 0.35
Inductor, 2 µH, 1 pri, 1 sec, 0.920 × 0.780
Mill Max
OST
3103-1-00-15-00-00-0X-0
ED500/4DS
J8
L1
Q1
Pulse
IR
PA0373
MOSFET, P-channel, 150 V, 2.2 A, 240 mΩ, SO-8
IRF6216
MOSFET, N-channel, 150 V, 6.7 A, 50 mΩ,
PowerPak SO-8
Q2
1
Vishay
Si7846DP
Q3, Q4, Q5, Q7, Q8
Q6
5
1
MOSFET, N-channel, 30 V, 55 A, 2.5 mΩ, LFPAK
Renesas
Vishay
HAT2165H
Bipolar, NPN, 40 V, 600 mA, 225 mW, SOT23
MMBT2222A
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References
Table 2. List of Materials (continued)
QT
Y
REF
DESCRIPTION
MFR
PART NUMBER
R1
R2
R3
1
1
1
Resistor, chip, 8.45 kΩ, 1/10 W, 1%, 805
Resistor, chip, 57.6 kΩ, 1/10 W, 1%, 805
Resistor, chip, 76.8 kΩ, 1/10 W, 1%, 805
Vishay
Vishay
Vishay
CRCW0805-8451-F
CRCW0805-5762-F
CRCW0805-7682-F
R4, R10, R15, R16,
R20, R23, R24
7
Resistor, chip, 2.21 Ω, 1/10 W, 1%, 805
Vishay
CRCW0805-2R21-F
R5
1
1
3
1
1
1
1
2
1
2
1
1
1
1
1
1
Resistor, chip, 158 kΩ, 1/10 W, 1%, 805
Resistor, chip, 1.82 kΩ, 1/10 W, 1%, 805
Resistor, chip, 1 kΩ, 1/10 W, 1%, 805
Resistor, chip, 11.8 Ω, 1/10 W, 1%, 805
Resistor, chip, 26.7 kΩ, 1/10 W, 1%, 805
Resistor, chip, 2 kΩ, 1/10 W, 1%, 805
Resistor, chip, 10 Ω, 1/10 W, 1%, 805
Resistor, chip, 499 Ω, 1/10 W, 1%, 805
Resistor, chip, 665 Ω, 1/10 W, 1%, 805
Resistor, chip, 10 kΩ, 1/10 W, 1%, 805
Resistor, chip, 51.1 Ω, 1/10 W, 1%, 805
Resistor, chip, 28.7 kΩ, 1/10 W, 1%, 805
Resistor, chip, 12.1 kΩ, 1/10 W, 1%, 805
Resistor, chip, 4.99 kΩ, 1/10 W, 1%, 805
Transformer, current sense, 10-A, 1:100, SMD
Transformer, high-frequency planar, planar
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Pulse
CRCW0805-1583-F
CRCW0805-1821-F
CRCW0805-1001-F
CRCW0805-11R8-F
CRCW0805-2672-F
CRCW0805-2001-F
CRCW0805-10R0-F
CRCW0805-4990-F
CRCW0805-6650-F
CRCW0805-1002-F
CRCW0805-51R1-F
CRCW0805-2872-F
CRCW0805-1212-F
CRCW0805-4991-F
P8208
R6
R7, R8, R12
R9
R11
R13
R14
R17, R18
R19
R21, R22
R25
R26
R27
R28
T1
T2
Pulse
PA0810
IC, current mode active clamp PWM controller,
SO-16
U1
U2
1
1
TI
UCC2891D
SFH690BT
IC, phototransistor, CTR 100%-300%, SOP-4
Vishay
10
References
1. UCC2891 Current Mode Active Clamp PWM Controller, Datasheet, (SLUS542)
2. Designing for High Efficiency with the UCC2891 Active Clamp PWM Controller, by Steve Mappus,
Application Note (SLUA299)
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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 tobe fitfor commercialuse. Assuch,
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 kitmay
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 © 2003--2006, Texas Instruments Incorporated
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DYNAMIC WARNINGS AND RESTRICTIONS
It is important to operate this EVM within the input voltage range of 0 Vdc to 72 Vdc.
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. Whenplacing
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 © 2003--2006, Texas Instruments Incorporated
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