Using the UCD3138PFCEVM-026 User's Guide Literature Number: SLUU885B March 2012 – Revised July 2012
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User's Guide SLUU885B – March 2012 – Revised July 2012 Digitally Controlled Single-Phase PFC Pre-Regulator 1 Introduction This EVM is to help evaluate the UCD3138 64-pin digital control device in off-line power converter application and then to aid its design. The EVM is a standalone Power Factor Correction (PFC) preregulator 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.
Description 2 www.ti.com 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.
Electrical Performance Specifications www.ti.com 3 Electrical Performance Specifications Table 1. UCD3138PFCEVM-026 Electrical Performance Specifications PARAMETER TEST CONDITIONS MIN TYP MAX UNITS Input Characteristics Voltage range 90 264 VAC Line frequency 47 63 Hz 6.5 7.0 A 4.5 5.5 Input current, peak Input = 90 VAC, 60 Hz, full load = 0.92 A Input current, RMS Input = 90 VAC, 60 Hz, full load = 0.
J2 J11 F2 4.7nF C5 (J3-26) LED_3 (J3-25) LED_2 LED_1 (J3-13) LN1371GTR R8 1k + BUS+ Digitally Controlled Single-Phase PFC Pre-Regulator Copyright © 2012, Texas Instruments Incorporated J7 J10 MBR0530 1 C6 4.7nF R81 1k 10uF OUT 2 OUT 4 7 GND 5 VIN_MONITOR6 VAUX_S R31 1.5k 10k R72 1.
SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated C4 2 R5 1k R69 1.6k BAT54S D4 +3_3V C18 0.1uF (J3-7) DPWM-3A SYNC_IN (J3-15) 6 49.9k R59 4 R60 49.9k 3 2 100pF C36 R2 3.3M 2 R58 R39 IPM +3_3V R61 1k HS1 TP21 TP18 D2 BAT54S 1 47nF C22 1 C32 150pF R45 Interleaved PFC: Jump across E6 and E4, and E1 and E5. D17 GBU8J C23 1 SH1 D7 MURS160T3 0.02 0.02 1 1 1 4.
Test Setup www.ti.com 5 Test Setup 5.1 Test Equipment AC Voltage Source:capable of single-phase output AC voltage 85 VAC to 265 VAC, 47 Hz to 63 Hz, adjustable, with minimum power rating 400 W, the AC voltage source to be used should meet IEC60950 reinforced insulation requirement. DC Multimeter: capable of 0-V to 500-V input range, four digits display preferred. Output Load: DC load capable of 400 VDC or greater, 1 A or greater, and 400 W or greater, with display such as load current and load power.
Test Setup www.ti.com UCD3138CC64EVM-030 Figure 4.
List of Test Points 6 www.ti.com List of Test Points Table 2. List of Test Points 7 TEST POINTS NAME DESCRIPTION TP1 T1OUT TP2 R1IN TP3 DGND Digital GND of J3 connection TP4 +3_3V 3.3-V LDO output on board from 12 V TP5 RC-PWM-0A TP6 CT_2 Second phase current sensing signal TP7 AC_N Input voltage sensing signal of Neutral wire TP8 DGND Digital GND and same as TP3 TP9 VAUX_S Secondary side 12 V on board. Not used, but can be used for external circuit.
Test Procedure www.ti.com 8 Test Procedure 8.1 Efficiency Measurement Procedure 1. Refer to Figure 3 for basic setup to measure power conversion efficiency. The required equipment to do this measurement is listed in Section 5.1. 2. Before making electrical connections, visually check the boards to make sure there are no suspected spots of damages. 3. In this EVM package, three EVMs are included, UCD3138PFCEVM-026, UCD3138CC64EVM-030, and USB-TO-GPIO.
Performance Data and Typical Characteristic Curves 9 www.ti.com Performance Data and Typical Characteristic Curves Figure 5 through Figure 18 present typical performance curves for UCD3138PFCEVM-026. 9.1 Efficiency 95.0% 90.0% 85.0% 115VAC 60Hz 230VAC 50Hz 80.0% 0.1 0.3 0.5 Load Current (A) 0.7 0.9 Figure 5. UCD3138PFCEVM-026 Efficiency 9.2 Power Factor 1.050 1.000 0.950 115VAC 60Hz 230VAC 50Hz 0.900 0.1 0.3 0.5 Load Current (A) 0.7 0.9 Figure 6.
Performance Data and Typical Characteristic Curves www.ti.com 9.3 Input Current at 115 VAC and 60 Hz 11.000% 115VAC 60Hz 230VAC 50Hz 6.000% 1.000% 0.1 0.3 0.5 Load Current (A) 0.7 0.9 Figure 7. Input Current and Voltage 115 VAC and Half Load Figure 8.
Performance Data and Typical Characteristic Curves 9.4 www.ti.com Input Current at 230 VAC and 50 Hz Figure 9. Input Current and Voltage 230 VAC and Half Load Figure 10.
Performance Data and Typical Characteristic Curves www.ti.com 9.5 Output Voltage Ripple Figure 11. Output Voltage Ripple 115 VAC and Full Load Figure 12.
Performance Data and Typical Characteristic Curves 9.6 www.ti.com Output Turn On Figure 13. Output Turn On 115 VAC and No Load Figure 14.
Performance Data and Typical Characteristic Curves www.ti.com 9.7 Total Harmonic Distortion (THD) Figure 15. UCD3138PFCEVM-026 Input Current THD 9.8 Other Waveforms Figure 16.
Performance Data and Typical Characteristic Curves www.ti.com Figure 17. UCD3138PFCEVM-026 Sensing Signal ISENSE (TP20) Figure 18.
EVM Assembly Drawing and PCB Layout www.ti.com 10 EVM Assembly Drawing and PCB Layout The following figures (Figure 19 through Figure 24) show the design of the UCD3138PFCEVM-026 printed circuit board. 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.
EVM Assembly Drawing and PCB Layout www.ti.com Figure 21. UCD3138PFCEVM-026 Top Copper (top view) Figure 22.
EVM Assembly Drawing and PCB Layout www.ti.com Figure 23. UCD3138PFCEVM-026 Internal Layer 2 (top view) Figure 24.
List of Materials 11 www.ti.com List of Materials The List of Materials is Based on Figure 1 and Figure 2. Table 4. UCD3138PFCEVM-026 List of Materials QTY 22 REF DES DESCRIPTION PART NUMBER MFR 1 C1 Capacitor, tantalum, 25 V, 20%, 10 µF, 3528 TPSB106M025R180 AVX 0 0 C10, C11 Capacitor, ceramic, 50 V, X7R, 10%, open, 1206 Std Std 2 C12, C20 Capacitor, ceramic, 50 V, X7R, 10%, 1 nF, 0805 Std Std 1 C16 Capacitor, ceramic, 50 V, X7R, 10%, 0.
List of Materials www.ti.com Table 4. UCD3138PFCEVM-026 List of Materials (continued) QTY REF DES DESCRIPTION PART NUMBER MFR 1 F1 Fuse, 250 VAC, SLO-BLO, 3 AG, 7-A cart, 0.250 inch x 1.250 inch 0313007.HXP Littlefuse 1 F2 Ffuse holder, 1/4 inch, board mount, 1.54 inch x 0.30 inch BK/1A3398-07 Bussmann 1 HS1 Heatsink, TO-220, vertical mount, 15 x C/W, 0.5 inch x 0.95 inch 593002B00000G Aavid 2 HS2, HS3 Heatsink, TO-220, vertical mount, 5 x C/W, 0.5 inch x 1.
List of Materials www.ti.com Table 4. UCD3138PFCEVM-026 List of Materials (continued) QTY 24 REF DES DESCRIPTION PART NUMBER MFR 7 R37, R38, R56, Resistor, chip, 1/10 W, 1%, 10 kΩ, 0805 R57, R70, R73, R74 Std Std 2 R39, R58 Resistor, chip, 1/10 W, 1%, 2 kΩ, 0805 Std Std 1 R4 Resistor, chip, 1/10 W, 1%, 5.01 kΩ, 0805 Std Std 2 R45, R79 Resistor, chip, 1/10 W, 1%, 100 Ω, 0805 Std Std 3 R47, R48, R50 Resistor, chip, 1/10 W, 1%, 1.
Digital PFC Description www.ti.com 12 Digital PFC Description 12.1 1PFC Block Diagram 12.1.1 Single-Phase PFC Block Diagram Single-phase PFC function block diagram is shown in Figure 25. The digital controlled single-phase PFC has the same power stage as those seen in other analog controlled devices. The main difference is the line voltage is sensed then rectified inside the UCD3138 digital controller. All signals interact with UCD3138 and explained in section Section 12.2.
Digital PFC Description 12.1.2 www.ti.com 2-Phase PFC Block Diagram A functional block diagram of a 2-phase interleaved PFC is shown in Figure 26. The digital controlled 2phase interleaved PFC has the same power stage seen in other analog controlled devices. All signals interact with UCD3138 and are explained in section 12.2.
Digital PFC Description www.ti.com 12.2 UCD3138 Pin Definition In this EVM, the PFC DC bus voltage feedback loop control is implemented using firmware execution by the ARM7 microcontroller, while the high-speed current loop control is implemented in the digital power peripherals in the UCD3138. The DC bus voltage, AC line and AC neutral voltages are sensed using the general purpose ADC in the ARM block.
Digital PFC Description 12.2.2 www.ti.com UCD3138 Pin Definition in 2-Phase PFC UCD3138 pin definition in 2-phase interleaved PFC control, shown in Figure 29.
Digital PFC Description www.ti.com 12.3 EVM Hardware – Introduction 12.3.1 PFC Pre-Regulator Input The power entry section, PFC pre-regulator input, as shown in Figure 31, consists of EMI input filter, AC voltage sense circuit and inrush relay control circuit. The series resistor R3 limits the inrush current. The inrush control relay K1, controlled by the UCD3138 controller, is used to bypass this resistor.
Digital PFC Description 12.3.2 www.ti.com PFC Power Stage The PFC power stage shown in Figure 32 employs a 2-phase boost PFC topology, even though the default configuration of the EVM is single phase PFC. The power MOSFETs, Q3 and Q4, are driven by the controller’s DPWM signals, DPWM1B and DPWM2B, through UCC27324 MOSFET gate drive device. The schematic also shows that four additional signals are sensed and eventually connected to UCD3138 controller’s 12-bit ADC input pins.
SLUU885B – March 2012 – Revised July 2012 Submit Documentation Feedback Copyright © 2012, Texas Instruments Incorporated C4 2 R5 1k R69 1.6k BAT54S D4 +3_3V C18 0.1uF (J3-7) DPWM-3A SYNC_IN (J3-15) 6 49.9k R59 4 R60 49.9k 3 2 100pF C36 R2 3.3M 2 R58 R39 +3_3V R61 1k HS1 TP21 TP18 BAT54S D2 1 47nF C22 1 C32 150pF R45 Interleaved PFC: Jump across E6 and E4, and E1 and E5. D17 GBU8J C23 1 SH1 D7 MURS160T3 0.02 0.02 1 1 1 1 4.
Digital PFC Description 12.3.3 www.ti.com Non-Isolated UART Interface The non-isolated UART interface shown in Figure 33 is used to control the PFC module from the host PC over the serial port. It is also used to monitor some of the parameters, debug and test firmware functions. Figure 33.
Digital PFC Description www.ti.com 12.3.4 Isolated UART Interface The isolated UART interface shown in Figure 34 is used to communicate with another digital controller, for example one used in a secondary referenced isolated DC-to-DC converter application. Figure 34.
Digital PFC Description 12.3.5 www.ti.com Interface Connector of Control Card The interface connector between the PFC board and the UCD3138 controller board is shown in Figure 35. Figure 35.
Digital PFC Description www.ti.com 12.3.6 UCD3138 Resource Allocation for PFC Control Table 5.
Digital PFC Description www.ti.com Table 5.
Digital PFC Description www.ti.com 12.4 EVM Firmware – Introduction The referenced firmware provided with the EVM is intended to demonstrate basic PFC functionality, as well as some basic PMBus communication and primary and secondary communication. A brief introduction to the firmware is provided in this section. There are three timing levels in the current version of the firmware, as shown in Figure 36: 1. Fast Interrupt (FIQ) 2. Standard Interrupt (IRQ) 3.
Digital PFC Description 12.4.1 www.ti.com Background Loop The firmware starts from function main(). In this function, after the system initialization, it goes to an infinite loop. All the non-time critical tasks are put in this loop, it includes: • Calculate voltage feed forward. • Clear current offset at zero load. • System monitoring. • PMBus communication. • Primary and secondary UART communication. NOTE: User can always add any non-time critical functions in this loop. 12.4.
Digital PFC Description www.ti.com 12.5 State Machine The PFC hiccups once an over-voltage condition is detected. Only very serious over voltage causes PFC shut down and latch. Figure 37 is the PFC state machine diagram shown below. Idle Vin > 90V Vin Relay close after Vout >420 V PFC shutdown and latch < 85 V 100ms Ramp up Vout = 390V Vout >420V PFC hiccup PFC on Vout >435V Vout < 380 V Figure 37. PFC State Machine 12.
Digital PFC Description www.ti.com 12.7 System Protection 12.7.1 Cycle-by-Cycle Current Protection (CBC) The cycle-by-cycle current protection is achieved through AD04 (Comparator D) and AD13 (Comparator E). Once the current signal has exceeded the threshold, the PWM is chopped to limit the current. 12.7.2 Over-Voltage Protection (OVP) There are two levels of OVP that exist. Under fault condition if the output voltage reaches 420 V, a nonlatched OV protection is activated.
Digital PFC Description www.ti.com 12.8.1 Average Current Mode Control The current loop is shown in the dashed line of Figure 38. The current reference signal IREF is calculated as: æ 1 IREF = K m ´ A ´ C ´ B = K m ´ (Uv )´ (K f ´ VIN )´ ç ç V2 è RMS ö ÷ ÷ ø where • • • • Km – multiplier gain A – voltage loop output B – 1/(VIN(rms))2 C – VIN (1) For sine wave input, the multiplier gain Km is expressed as, K m = 0.5 ´ K f ´ VMIN(pk) (2) In Figure 27, Ks and Kf are scaling factors.
Digital PFC Description 12.9.1 www.ti.com Loop Compensation from Poles and Zeros in s-Domain PID control in the UCD3138 CLA for current control loop in single-phase PFC is formed in the following equation in z-domain: Gc (z) = KP + KI 1 + z -1 1 - z -1 + KD 1 - z -1 1 - a´z -1 (3) If Equation 3 is converted to the s-domain equivalent using the bilinear transform, the result has two forms.
Digital PFC Description www.ti.com The sensing circuit in the current loop forms a low-pass filter and adds a pole to the loop: 1 wpcs = R 4 ´ Cp2 R Hcs (s) = Rs ´ 4 R3 (10) 1 s +1 wpcs (11) The current closed-loop transfer function is then shown below: GM (s) ´ GPID (s) Gcs (s) = 1 + GM (s) ´ GPID (s) ´ Hcs (s) where • GM(s) is the transfer function of current loop before adding in PID.
Digital PFC Description 12.9.2 www.ti.com Feedback Loop Compenstaion Tuning with PID Coefficients When fine tuning the feedback control loop, one would like to know each parameter in PID how to affect the control loop characteristics without going through complicated description of the above equations. Table 6 below helps this and is visually shown in Figure 40. Table 6.
Evaluating the Single-Phase PFC with GUI www.ti.com 13 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. The description is given on how to use the GUI to make further evaluation of UCD3138PFCEVM-026. 13.
Evaluating the Single-Phase PFC with GUI www.ti.com 13.3 Overview of the Designer GUI When the designer GUI is open, it identifies the connected board by the ID in the firmware. Figure 42 shows the opened GUI. The Designer GUI provides various assistance to access the firmware codes indirectly. For the full set of the functions that the Designer GUI can provide, please refer to the user’s manual.
Evaluating the Single-Phase PFC with GUI www.ti.com 13.3.2 Status When click tab Status, its corresponding page is shown in Figure 43. What can be seen is all entries are grayed out. This means nothing was designed to show from this tab. The page of Status provides all possible PMBus supported variables in communication. To activate these variables in communication, corresponding firmware codes need to be in place.
Monitoring, Re-configuring and Re-tuning with Designer GUI 14 www.ti.com Monitoring, Re-configuring and Re-tuning with Designer GUI In this section, we describe how to use the Designer GUI to evaluate the single-phase PFC board, UCD3138PFCEVM-026 14.1 Power On and Test Procedure Power stage connection is the same as described earlier. Additionally to that setup, PMBus connection is required through USB-to-GPIO as shown in Figure 44.
www.ti.com Monitoring, Re-configuring and Re-tuning with Designer GUI 14.2 Monitoring with GUI The page shows three variables in monitoring: • VOUT – PFC output bulk voltage. • OV Fault – PFC output bulk voltage over voltage fault threshold. • Freq – switching frequency in normal operation. Among three monitoring variables, we can see VOUT and OV Fault can be accessed by write to change them to a different value into the firmware.
Monitoring, Re-configuring and Re-tuning with Designer GUI www.ti.com 14.3 Configuration and Re-configuring with GUI After click the tab of “Configure”, the corresponding page called “Configuration” is shown as in Figure 45. The variables shown in the page are the existing configuration. Most of them are fixed and can only be modified through firmware codes. One can designate which and how many variables can be re-configured in this page through firmware codes change.
www.ti.com Monitoring, Re-configuring and Re-tuning with Designer GUI 14.4 Feedback Control Loop Tuning and Re-Tuning with GUI 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. Figure 46.
Monitoring, Re-configuring and Re-tuning with Designer GUI 14.4.1 www.ti.com Current Loop Evaluation Figure 46shows the current control loop. To evaluate the design or to re-tune the current loop PID coefficients, the first thing to do is to check all the parameters up to date in use. This can be done by click Schematic View to bring out a new window with the schematics shown in Figure 47.
Monitoring, Re-configuring and Re-tuning with Designer GUI www.ti.com 14.4.2 Current Loop Re-Tuning The current loop PID coefficients can be re-tuned following the approaches described in section 1.4. Scroll down the window that is shown in Figure 46, then Figure 48 is obtained. Figure 37 shows the current loop compensation details. There are two sets of PID coefficients used in the current control loop, Set A and Set B. In Figure 48 Set A is shown.
Monitoring, Re-configuring and Re-tuning with Designer GUI 14.4.3 www.ti.com Voltage Loop Evaluation and Re-tuning Voltage loop can be evaluated and re-tuned in a similar way. Figure 49 shows voltage loop PI control coefficients and corresponding bode plots. The voltage loop PI control is implemented with software and has the below form, 1 GPI (z) = KP + KI 1 - z -1 (19) There are two sets of the PI coefficients for voltage loop control. In normal operation, the control is with Linear Coefficients.
Digital PFC Firmware Development www.ti.com 15 Digital PFC Firmware Development Please contact TI for additional information regarding UCD3138 digital PFC firmware development. 16 References 1. 2. 3. 4. 5.
EVALUATION BOARD/KIT/MODULE (EVM) ADDITIONAL TERMS Texas Instruments (TI) provides the enclosed Evaluation Board/Kit/Module (EVM) under the following conditions: 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.
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.
【Important Notice for Users of this Product in Japan】 】 This development kit is NOT certified as Confirming to Technical Regulations of Radio Law of Japan If you use this product in Japan, you are required by Radio Law of Japan to follow the instructions below with respect to this product: 1. 2. 3. Use this product in a shielded room or any other test facility as defined in the notification #173 issued by Ministry of Internal Affairs and Communications on March 28, 2006, based on Sub-section 1.
EVALUATION BOARD/KIT/MODULE (EVM) WARNINGS, RESTRICTIONS AND DISCLAIMERS For Feasibility Evaluation Only, in Laboratory/Development Environments. Unless otherwise indicated, this EVM is not a finished electrical equipment and not intended for consumer use.
EVALUATION BOARD/KIT/MODULE (EVM) ADDITIONAL TERMS Texas Instruments (TI) provides the enclosed Evaluation Board/Kit/Module (EVM) under the following conditions: 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.
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.
【Important Notice for Users of this Product in Japan】 】 This development kit is NOT certified as Confirming to Technical Regulations of Radio Law of Japan If you use this product in Japan, you are required by Radio Law of Japan to follow the instructions below with respect to this product: 1. 2. 3. Use this product in a shielded room or any other test facility as defined in the notification #173 issued by Ministry of Internal Affairs and Communications on March 28, 2006, based on Sub-section 1.
EVALUATION BOARD/KIT/MODULE (EVM) WARNINGS, RESTRICTIONS AND DISCLAIMERS For Feasibility Evaluation Only, in Laboratory/Development Environments. Unless otherwise indicated, this EVM is not a finished electrical equipment and not intended for consumer use.
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. Buyers should obtain the latest relevant information before placing orders and should verify that such information is current and complete.
