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User’s Guide
SLUU068C
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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
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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
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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 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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 kΩ, 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 kΩ, ¼ W
1.5 kΩ, ¼ W
3.92 kΩ, ¼ W
750 Ω, ¼ W
7.5 kΩ, ¼ W
392 kΩ, ¼ W
1 kΩ, ¼ W
22.1 kΩ, ¼ W
8.25 kΩ, ¼ W
562 kΩ, ¼ W
200 kΩ, ¼ W
100 Ω, ¼ W
100 kΩ, ¼ W
30.1 kΩ, ¼ W
33.2 kΩ, ¼ W
4.75 kΩ, ¼ W
221 kΩ, ¼ W
16.2 kΩ, ¼ W
1 kΩ, 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 Ω, 1 W, 5%
0.33 Ω, 3 W, 5%
20 Ω, ¼ W
51 kΩ, 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
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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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