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Texas Instruments UCD3138PFCEVM-026 User Manual

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Using the UCD3138PFCEVM-026
User's Guide
Literature Number: SLUU885B
March 2012 – Revised July 2012

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Summary of Contents for Texas Instruments UCD3138PFCEVM-026

  • Page 1 Using the UCD3138PFCEVM-026 User's Guide Literature Number: SLUU885B March 2012 – Revised July 2012...
  • Page 2 Any other use and/or application are strictly prohibited by Texas Instruments. If you are not suitably qualified, you should immediately stop from further use of the HV EVM.
  • Page 3 The EVM is a standalone Power Factor Correction (PFC) pre- regulator of single-phase AC input. The EVM UCD3138PFCEVM-026 is used together with its control card, UCD3138CC64EVM-030, also an EVM on which is placed UCD3138RGC.

  • Page 4: Typical Applications

    Description UCD3138PFCEVM-026 together with UCD3138CC64EVM-030 is an EVM of PFC pre-regulator with digital control using UCD3138 device in boost converter topology and in the application of single-phase AC input. UCD3138 device is located on the board of UCD3138CC64EVM-030. UCD3138CC64EVM-030 is a daughter card and serves all PFC required control functions with preloaded single-phase boost PFC firmware.

  • Page 5: Electrical Performance Specifications

    Electrical Performance Specifications www.ti.com Electrical Performance Specifications Table 1. UCD3138PFCEVM-026 Electrical Performance Specifications PARAMETER TEST CONDITIONS UNITS Input Characteristics Voltage range Line frequency Input current, peak Input = 90 VAC, 60 Hz, full load = 0.92 A Input current, RMS Input = 90 VAC, 60 Hz, full load = 0.92 A...
  • Page 6 Schematics www.ti.com Schematics Figure 1. UCD3138PFCEVM-026 Schematic Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 7 Schematics www.ti.com Figure 2. UCD3138PFCEVM-026 Schematic SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 8: Test Equipment

    8 feet (4 feet input and 4 feet return). Recommended Test Setup Electronic Load TP17 TP22 AC Source Figure 3. UCD3138PFCEVM-026 Recommended Test Setup Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 9 Test Setup www.ti.com UCD3138CC64EVM-030 Figure 4. EVM Orientation of UCD3138PFCEVM-030 on the UCD3138PFCEVM-026 SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 10: List Of Test Points

    External 12-V bias and sync signal, 3 pins Chassis Chassis ground, or earth connection, single-pin connection – screw type Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 11: Test Procedure

    USB-TO-GPIO. In this measurement, the board of UCD3138PFCEVM-026 and UCD3138CC64EVM-030 is needed. 4. First install the board of UCD3138CC64EVM-030 onto the board of UCD3138PFCEVM-026. Care must be given to the alignment and the orientation of two boards, or damage may occur. Refer to Figure 4 for UCD3138CC64EVM-030 board orientation.

  • Page 12: Performance Data And Typical Characteristic Curves

    Performance Data and Typical Characteristic Curves www.ti.com Performance Data and Typical Characteristic Curves Figure 5 through Figure 18 present typical performance curves for UCD3138PFCEVM-026. Efficiency 95.0% 90.0% 85.0% 115VAC 60Hz 230VAC 50Hz 80.0% Load Current (A) Figure 5. UCD3138PFCEVM-026 Efficiency Power Factor 1.050...
  • Page 13 Figure 7. Input Current and Voltage 115 V and Half Load Figure 8. Input Current and Voltage 115 V and Full Load SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 14 Figure 9. Input Current and Voltage 230 V and Half Load Figure 10. Input Current and Voltage 230 V and Full Load Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 15: Output Voltage Ripple

    Figure 11. Output Voltage Ripple 115 V and Full Load Figure 12. Output Voltage Ripple 230 V and Full Load SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 16 Figure 13. Output Turn On 115 V and No Load Figure 14. Output Turn On 115 V and Full Load Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 17: Total Harmonic Distortion (Thd)

    Total Harmonic Distortion (THD) Figure 15. UCD3138PFCEVM-026 Input Current THD Other Waveforms Figure 16. UCD3138PFCEVM-026 Sensing Signal AC_L (TP14) or AC_N (TP7) SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 18 Performance Data and Typical Characteristic Curves www.ti.com Figure 17. UCD3138PFCEVM-026 Sensing Signal I (TP20) SENSE Figure 18. UCD3138PFCEVM-026 MOSFET V (top) and V Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 19: Evm Assembly Drawing And Pcb Layout

    PCB dimensions: L x W = 9.0 inch x 6.0 inch, PCB material: FR4 or compatible, four layers and 2-oz copper on each layer. Figure 19. UCD3138PFCEVM-026 Top Layer Assembly Drawing (top view) Figure 20. UCD3138PFCEVM-026 Bottom Assembly Drawing (bottom view) SLUU885B –...
  • Page 20 EVM Assembly Drawing and PCB Layout www.ti.com Figure 21. UCD3138PFCEVM-026 Top Copper (top view) Figure 22. UCD3138PFCEVM-026 Internal Layer 1 (top view) Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 21 EVM Assembly Drawing and PCB Layout www.ti.com Figure 23. UCD3138PFCEVM-026 Internal Layer 2 (top view) Figure 24. UCD3138PFCEVM-026 Bottom Copper (top view) SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 22: List Of Materials

    List of Materials www.ti.com List of Materials The List of Materials is Based on Figure 1 Figure Table 4. UCD3138PFCEVM-026 List of Materials REF DES DESCRIPTION PART NUMBER Capacitor, tantalum, 25 V, 20%, 10 µF, 3528 TPSB106M025R180 AVX C10, C11...
  • Page 23 List of Materials www.ti.com Table 4. UCD3138PFCEVM-026 List of Materials (continued) REF DES DESCRIPTION PART NUMBER Fuse, 250 VAC, SLO-BLO, 3 AG, 7-A cart, 0.250 inch x 1.250 0313007.HXP Littlefuse inch Ffuse holder, 1/4 inch, board mount, 1.54 inch x 0.30 inch...
  • Page 24 List of Materials www.ti.com Table 4. UCD3138PFCEVM-026 List of Materials (continued) REF DES DESCRIPTION PART NUMBER R37, R38, R56, Resistor, chip, 1/10 W, 1%, 10 kΩ, 0805 R57, R70, R73, R39, R58 Resistor, chip, 1/10 W, 1%, 2 kΩ, 0805 Resistor, chip, 1/10 W, 1%, 5.01 kΩ, 0805...
  • Page 25 Signal Signal Signal I_shunt Conditioning Conditioning Conditioning Vin_N Vbus_ov Figure 25. Digitally Controlled Single-Phase PFC System Block Diagram SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 26 DPWM1B Vbus_sen Vin_l Signal Signal Conditioning Conditioning Vin_n Vbus_ov Figure 27. Digitally Controlled Bridgeless PFC System Block Diagram Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 27 Vbus_sen UCD3138 Single-phase PFC PMBus UART Configuration Interface Interface Figure 28. Definition of UCD3138 in Single-Phase PFC Control SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 28 AD _ 03 Vbus_sen Configuration PMBus UART Interface Interface Figure 30. Definition of the UCD3138 in Bridgeless PFC Control Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 29 3.3 V. Figure 31. AC Power Filtering, Inrush Current Limit and AC Voltage Sense SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 30 T2 and T3 is rectified, scaled and conditioned to a range of 0 V to 1.6 V corresponding to the range of the on-chip DAC associated with the error ADC1 (EADC1) and error ADC2 (EADC2). Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 31 Digital PFC Description www.ti.com Figure 32. PFC Power Stage SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 32 It is also used to monitor some of the parameters, debug and test firmware functions. Figure 33. Non-Isolated PFC Module to Host PC Interface Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 33 DC-to-DC converter application. Figure 34. Isolated UART and AC_DROP Signal Interface SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 34 The interface connector between the PFC board and the UCD3138 controller board is shown in Figure Figure 35. UCD3138 Controller Board and PFC Board Signal Interface Connector Diagram Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 35 Not used Not used J4-03 AGND Analog ground GND2 J4-04 AD_00 PMBus address J4-05 AGND Analog ground GND2 SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 36 J4-38 EAP1 PFC MOSFET Q3 current sense J4-39 EAN0 Analog ground GND2 J4-40 EAP0 PFC Input current sense Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 37 PMBus tasks, which occur in the background, and the Over Voltage Protection (OVP), which is handled by the FIQ. For more details, please refer to the source code and training material. SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 38 IRQ contains the state machine and most of the PFC control firmware. • FIQ is used in relation to implementing OVP protections. Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 39: State Machine

    • Current reference calculation • AC drop detection • UART receive data • Frequency dithering • ZVS control SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 40: System Protection

    Figure 38. Single-Phase PFC System Control Diagram Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 41 Analog - to - PWM Gain = 1 Iref and T Figure 39. Single-phase PFC Feedback Loop Using PID Control SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 42 = w ´ w w ´ w w + w The complex conjugate zeros become real zeros when: £ Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 43 ´ w - w w ´ w ´ w ´ w + (16) ´ w ´ w (17) SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 44 5%, digital control can adapt this high-transient requirement to use a different set of PI coefficients. Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 45: Graphical User Interface (Gui)

    Evaluating the Single-Phase PFC with GUI www.ti.com Evaluating the Single-Phase PFC with GUI Further evaluation of UCD3138PFCEVM-026 can be made with the designer GUI while no need to directly access the firmware codes. The designer GUI, called Fusion Digital Power Designer is described in Section 13.1.
  • Page 46 UCD3138 single-phase PFC. These variables are communicated through PMBus. Adding more variables in Monitoring is possible but has to be executed through the firmware code change and re-compile process. Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 47 If click Design or Configure two more different pages will be brought up to the front. These pages provide more functions and described in the following section. SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 48 After all connections are made, apply an AC source voltage with a specified value to the board AC input and refer to the other steps in the UCD3138PFCEVM-026 user’s guide. Open and start the “Fusion Digital Power Designer” GUI following the steps described in Section 13.2...
  • Page 49 SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 50 Between the two vertical lines, the show is the firmware recompilation indicator. The last six digits are date of the last time the recompilation was made. Figure 45. Page of Configuration Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 51 After click the tab of Designer, the page is shown as in Figure 46. In the UCD3138PFCEVM-026, this page is dedicated to the feedback loop design. This page including two sub-pages. One is for the current loop PID coefficients and the other is for the voltage feedback loop which uses PI control.
  • Page 52 Figure 47. Schematics of Single-Phase PFC. Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 53 Q and ωr have to be generated instead of real zeros. In this case, the users may need to calculate the complex conjugate zeros based on Equation Figure 48. Current Loop Re-Tuning SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 54 5% of the output set point, or within 20 V on 390-V output. Figure 49. Voltage Loop PI Control Re-Tuning Digitally Controlled Single-Phase PFC Pre-Regulator SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...
  • Page 55 9. UCD3138 ARM and Digital System Programmer’s Manual (please contact TI) 10. UCD3138 Isolated Power Fusion GUI User Guide (please contact TI) SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated...

  • Page 56: Evaluation Board/Kit/Module (Evm) Additional Terms

    Any exceptions to this are strictly prohibited and unauthorized by Texas Instruments unless user has obtained appropriate experimental/development licenses from local regulatory authorities, which is responsibility of user including its acceptable authorization.
  • Page 57 FCC Interference Statement for Class B EVM devices This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
  • Page 58 Also, please do not transfer this product, unless you give the same notice above to the transferee. Please note that if you could not follow the instructions above, you will be subject to penalties of Radio Law of Japan. Texas Instruments Japan Limited (address) 24-1, Nishi-Shinjuku 6 chome, Shinjuku-ku, Tokyo, Japan http://www.tij.co.jp...

  • Page 59: Evaluation Board/Kit/Module (Evm) Warnings, Restrictions And Disclaimers

    FDA Class III or similar classification, then you must specifically notify TI of such intent and enter into a separate Assurance and Indemnity Agreement. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2012, Texas Instruments Incorporated...
  • Page 60 STANDARD TERMS AND CONDITIONS FOR EVALUATION MODULES Delivery: TI delivers TI evaluation boards, kits, or modules, including any accompanying demonstration software, components, or documentation (collectively, an “EVM” or “EVMs”) to the User (“User”) in accordance with the terms and conditions set forth herein. Acceptance of the EVM is expressly subject to the following terms and conditions.
  • Page 61 FCC Interference Statement for Class B EVM devices NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
  • Page 62 【無線電波を送信する製品の開発キットをお使いになる際の注意事項】 開発キットの中には技術基準適合証明を受けて いないものがあります。 技術適合証明を受けていないもののご使用に際しては、電波法遵守のため、以下のいずれかの 措置を取っていただく必要がありますのでご注意ください。 1. 電波法施行規則第6条第1項第1号に基づく平成18年3月28日総務省告示第173号で定められた電波暗室等の試験設備でご使用 いただく。 2. 実験局の免許を取得後ご使用いただく。 3. 技術基準適合証明を取得後ご使用いただく。 なお、本製品は、上記の「ご使用にあたっての注意」を譲渡先、移転先に通知しない限り、譲渡、移転できないものとします。 上記を遵守頂けない場合は、電波法の罰則が適用される可能性があることをご留意ください。 日本テキサス・イ ンスツルメンツ株式会社 東京都新宿区西新宿６丁目２４番１号 西新宿三井ビル 3.3.3 Notice for EVMs for Power Line Communication: Please see http://www.tij.co.jp/lsds/ti_ja/general/eStore/notice_02.page 電力線搬送波通信についての開発キットをお使いになる際の注意事項については、次のところをご覧くださ い。http://www.tij.co.jp/lsds/ti_ja/general/eStore/notice_02.page SPACER EVM Use Restrictions and Warnings: 4.1 EVMS ARE NOT FOR USE IN FUNCTIONAL SAFETY AND/OR SAFETY CRITICAL EVALUATIONS, INCLUDING BUT NOT LIMITED TO EVALUATIONS OF LIFE SUPPORT APPLICATIONS.
  • Page 63 Notwithstanding the foregoing, any judgment may be enforced in any United States or foreign court, and TI may seek injunctive relief in any United States or foreign court. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2015, Texas Instruments Incorporated...

  • Page 64: Important Notice

    IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue.

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