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Texas Instruments PFC23338EVM-107 User Manual
Texas Instruments PFC23338EVM-107 User Manual

Texas Instruments PFC23338EVM-107 User Manual

Evaluation motherboard

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EVM User's Guide: PFC23338EVM-107
PFC23338EVM-107 Evaluation Motherboard
Description
This reference design is a Gallium nitride (GaN)
based, 3.6kW, single-phase, continuous conduction
mode (CCM) totem-pole bridgeless power factor
correction (PFC) converter targeting M-CRPS
server power supply. This design includes E-meter
functionality with 0.5% accuracy using AMCx306
as current sensing device, eliminating the need for
external power metering ICs. An alternative low
cost current sensing option using TMCS1133 is also
provided in this design. The supply is designed
to support a maximum input current of 16-ARMS
and peak power of 3.6kW. The power stage is
followed by a baby boost converter, which helps
to greatly reduce the size of the bulk capacitor.
This design works with TI GaN half bridge daughter
cards (E.g. LMG3522EVM-042, LMG3422EVM-043,
LMG3650EVM-113). LMG3522R030, LMG3422R030,
LMG3650R025 are TI 25-30mΩ high-voltage GaN
FET with integrated driver and protections, enable
high efficiency and high power density. The F28003x
C2000
real-time microcontroller is used for all the
advanced controls including re-rush current limit,
baby boost operation during AC drop out event,
e-metering, and communication between PFC and
house-keeping controller. In addition, the F28003x
microcontroller has built-in Sigma-Delta filter module
to interface with AMC1306 precision current sensing
Board Side View
SNOU215 – JANUARY 2025
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reinforced isolated modulator to achieve industry
leading low total harmonic distortion (iTHD) and
high measurement accuracy. The PFC operates at
a switching frequency of 65kHz and achieves peak
efficiency of 98.93%.
Features
Integrated e-metering function with 0.5% accuracy
<10% iTHD at 0–10% load, <5% iTHD at 10%–
20% load, <3% iTHD at 20%–50% load, <2% iTHD
at 50%–100% load
Peak efficiency of 98.93% at 230Vac
Smart re-rush current control when AC comes
back from dropout, meet M-CRPS re-rush current
specification
Include baby boost converter to extend holdup
time and allow only 720µF bulk cap
Two current sense options: Isolated Delta-Sigma
Modulator (default) or Hall Sensor
GaN optimized with driver integration
3.6kW rated power targeting 73.5mm M-CRPS
PSU
Applications
Rack and server PSU with 48V output
Server PSU with 12V output
Merchant telecom rectifiers
Industrial AC-DC
Single phase online UPS
Copyright © 2025 Texas Instruments Incorporated
Board Top View
PFC23338EVM-107 Evaluation Motherboard
Description
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Summary of Contents for Texas Instruments PFC23338EVM-107

  • Page 1 Sigma-Delta filter module • Industrial AC-DC to interface with AMC1306 precision current sensing • Single phase online UPS Board Side View Board Top View SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 2: Kit Contents

    The EVM requires a C2000 control card. Please order and use the TMDSCNCD280039C. The PFC23338EVM-107 uses the standard TI GaN daughter card pin interface. Any of the TI GaN daughtercards following this pin out work with the PFC23338EVM-107 (E.g. LMG3522EVM-042, LMG3422EVM-043, LMG3650EVM-113).
  • Page 3 System Description Figure 1-2. TI GaN Daughter Card Pinout SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 4: Voltage And Current Requirements

    High Flux core is able to achieve our inductance target with less number of turns over the inductor using Kool Mμ Max core. Therefore, inductor with high flux core is selected in this design. PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 5 GaN device is applicable. A screen shot of the calculation results is shown in Figure 1-4. 30mΩ GaN devices (LMG3522R030 or LMG3422R030) are eventually selected for this design. SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 6 The line and the neutral voltages are sensed by resistor divider to the ground of the board as shown in Figure 1-5. The two readings are subtracted on the controller to get the Vac sensing. PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 7 SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 8 (Figure 1-9). For details of AMC1306 and E-meter, please refer to [2]. Figure 1-7. Use AMC1306 for Current Sensing Figure 1-8. AMC1306 Output PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 9 / black out event for a few ms. Due to the fast response time, the SSR is controlled to do a rapid on/off operation to limit the re-rush currrent. Details of re-rush control can be found in [1][2]. SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 10 Over current protection is achieved through on-chip comparator. It can be configured as shut down and latch (default), or cycle-by-cycle current limit. User can choose which protection to be used by changing the compiling flag and then re-download the code. PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 11: Download Firmware

    → docs → pmp23338_software_guide.pdf. This guide goes through the steps for testing with the PFC23338EVM-107 and the different labs included in the software for this EVM. The guide also includes helpful information on the design of the control for the system.
  • Page 12 5. For downloading and flashing the code, connect the control card with PC using the USB cable. 6. Now click on debug icon to download the code to the control card. PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 13 Software 7. Click on update if prompted. 8. After the code is downloaded/flashed, disconnect the control card from the PC. 9. Install the control card to PFC23338EVM-107 board SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 14: Start-Up Sequence

    6. Set AC output at 115V/60Hz, turn on AC, you see DC output voltage is regulated at about 385V 7. Graduate increase load. Full load: 1800W@115VAC, 3600W@230VAC PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 15: Thd Performance

    Figure 4-2. PFC starts up at 230 VAC, no load Note Blue: Vout, Yellow: Iin 4.2 THD Performance Figure 4-3. THD Graph at 120 VAC Input SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 16: Power Factor

    Implementation Results www.ti.com Figure 4-4. THD Graph at 240 VAC Input 4.3 Power Factor Figure 4-5. Power Factor at 120 VAC input PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 17 GaN Slew Rate: 100V/ns • Output: 385V • Power analyzer: WT5000 • Relay and BB bypass FETs shorted • Auxiliary supply not included Figure 4-7. Efficiency Graph SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 18 Implementation Results www.ti.com 4.5 E-meter Performance Power analyzer used in the test: WT5000 PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 19: Load Transients

    Figure 4-13. 115VAC, 100% -> 50% load Figure 4-12. 115VAC, 50% -> 100% load Figure 4-14. 230VAC, 0% -> 50% load Figure 4-15. 230VAC, 50% -> 0% load SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 20 Figure 4-16. 230VAC, 25% -> 75% load Figure 4-17. 230VAC, 75% -> 25% load Figure 4-19. 230VAC, 100% -> 50% load Figure 4-18. 230VAC, 50% -> 100% load PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 21 Implementation Results 4.7 Input Current Waveforms Figure 4-20. 120VAC 10% Load Figure 4-21. 120VAC 50% Load SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 22 Implementation Results www.ti.com Figure 4-22. 120VAC 100% Load Figure 4-23. 240VAC 10% Load PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 23 Implementation Results Figure 4-24. 240VAC 50% Load Figure 4-25. 240VAC 100% Load SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 24 Figure 4-26. AC Drop at 120 VAC, 1800 W Load (Blue: Vout, Pink: Iin) Figure 4-27. AC Drop at 240 VAC, 3600 W Load (Blue: Vout, Pink: Iin) PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 25 Implementation Results Figure 4-28. Re-rush Current When AC Comes Back From 10ms Drop Out (Green: Iin, Blue: Vout) Figure 4-29. Zoom In of Re-rush Current SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 26 Test Conditions: Vin:230 VAC Vout: 385V Load: 3.6KW Air flow: same as "Start-Up Sequence" Figure 4-30. Thermal Image Figure 4-31. Relay Bypass Switch Thermal Image PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 27 Hardware Design Files 5 Hardware Design Files 5.1 Design Files PFC23338EVM-107 design files are available on product page for this EVM on TI.com. SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 28 PMP23338 Software Guide: In the folder downloaded when installing Digital Power Software Development Kit select: C2000Ware_DigitalPower_SDK_x_xx_xx_xx → solutions → pmp23338 → docs → pmp23338_software_guide.pdf • Digital Power SDK Getting Started Guide PFC23338EVM-107 Evaluation Motherboard SNOU215 – JANUARY 2025 Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 29: External Reference

    “Five major trends in power supply design for servers”, August 2022, EDN [8] B. Sun, “How to improve the power factor of a PFC”, January 2024, EDN SNOU215 – JANUARY 2025 PFC23338EVM-107 Evaluation Motherboard Submit Document Feedback Copyright © 2025 Texas Instruments Incorporated...
  • Page 30 STANDARD TERMS FOR EVALUATION MODULES Delivery: TI delivers TI evaluation boards, kits, or modules, including any accompanying demonstration software, components, and/or documentation which may be provided together or separately (collectively, an “EVM” or “EVMs”) to the User (“User”) in accordance with the terms set forth herein.
  • Page 31 www.ti.com Regulatory Notices: 3.1 United States 3.1.1 Notice applicable to EVMs not FCC-Approved: FCC NOTICE: This kit is designed to allow product developers to evaluate electronic components, circuitry, or software associated with the kit to determine whether to incorporate such items in a finished product and software developers to write software applications for use with the end product.
  • Page 32 www.ti.com Concernant les EVMs avec antennes détachables Conformément à la réglementation d'Industrie Canada, le présent émetteur radio peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur) approuvé pour l'émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à...
  • Page 33 www.ti.com 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. 4.2 User must read and apply the user guide and other available documentation provided by TI regarding the EVM prior to handling or using the EVM, including without limitation any warning or restriction notices.
  • Page 34 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 © 2023, Texas Instruments Incorporated...
  • Page 35 TI products. TI’s provision of these resources does not expand or otherwise alter TI’s applicable warranties or warranty disclaimers for TI products. TI objects to and rejects any additional or different terms you may have proposed. IMPORTANT NOTICE Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2025, Texas Instruments Incorporated...