CTX33-18428

UCC28810EVM-002 TI1 | Alldatasheet

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Technical content

User's Guide Literature Number: SLUU355A March 2009 Revised June 2009

Description

2.1 Typical

Applications

2.2

Features

User's Guide SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting a constant current non-isolated power supply for LED lighting applications. It will convert universal mains (90 VRMS to 264 VRMS) to a 0.9-A constant current into a 100-W load. This evaluation module will allow the customer evaluate the UCC28810/11 in a typical LED lighting application. The evaluation module uses a two stage approach to controlling the output current. The first stage is a transition mode PFC circuit. This ensures the design meets the harmonic current or power factor requirements set out by various standards, such as EN61000-3-2. The PFC circuit converts the AC input to a regulated DC voltage. This DC voltage can be configured in one of two ways. The default configuration of the module is that of a boost follower type PFC. The boost follower PFC is where the PFC regulated output DC voltage tracks the AC input peak voltage. The second configuration requires removing some components and changing a resistor value see below for more details. This second configuration removes the tracking element of the PFC circuit. The PFC DC output voltage will then be regulated to a fixed value in the region of 396 VDC. The second stage also uses transition mode but is configured as a buck converter. It converts the PFC output voltage to a fixed constant current. This circuit is capable of supplying 0.9 A into a 100-W load. It also accepts PWM dimming inputs. Alternatively the user can use the PWM circuit on the module to see the dimming function. This module will work with most high brightness LED s (HB-LED) that operate with 0.9 A and a total string voltage drop of between V and 110 AC Input General Lighting s Industrial, Commercial and Residential Lighting Fixtures Outdoor Lighting: Street, Roadway, Parking, Construction and Ornamental LED Lighting Fixtures VRMS to 264 VRMS operation Boost Follower or Fixed Output PFC Stage PFC Disable Output Current Disable External or Internal PWM Dimming A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com Electrical Performance Specifications Table UCC28810EVM-002 Electrical Performance Specifications SYMBOL PARAMETER CONDITIONS MIN NOM MAX UNITS INPUT CHARACTERSTICS V IN Input voltage 264 V RMS I IN Input current 0.175 1.1 A RMS PF Power factor P OUT W to 100 W 0.95 0.97 OUTPUT CHARACTERSTICS PFC Stage V OUT PFC output voltage 235 415 VDC LED Driver Stage P OUT Output power 100 W I OUT Output current 0.84 0.9 0.96 A Line regulation 0.03 Frequency 128 kHz SYSTEMS CHARACTERSTICS η Full load efficiency 90% 93% PWM Dimming (1) Threshold 0.72 1.3 V Frequency range 200 1000 Hz Duty cycle 90% (1) The PWM dimming signal is inverted, duty cycle is 100% LED current. SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com Figure UCC28810EVM-002 PFC Stage Schematic A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com Schematic Figure UCC28810EVM-002 Buck Stage Schematic SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

5.1 Test Equipment 5.1.1 Voltage Source: 5.1.2 Multimeters 5.1.3 Output Load 5.1.4 Oscilloscope 5.1.5 Signal Generator 5.1.6 Fan 5.1.7 Recommended Wire Gauge Test Setup www.ti.com WARNING High voltages, that may cause injury, exist on this evaluation module (EVM). Please ensure all safety procedures are followed when working on this EVM. Never leave a powered EVM unattended. The use of isolated test equipment is highly recommended. See Figure for recommended test set up. Source Isolated AC voltage source or VARIAC, capable of VRMS to 264 VRMS at 150 Source A 3.3-V DC source capable of 100 mA. Three digital multimeters are recommend, one for current measurement, A1, and two for voltage measurements, and V2. It is recommended that actual high brightness LED s (HB-LED are used for the load. They should be rated at 0.9 The HB-LED s should be connected in series. Their voltage drop should be between VDC and 110 VDC. Alternatively a constant voltage electronic load could be used. If using a constant voltage electronic load a 1000- µ F/250 VDC capacitor is required at the input to the electronic load. The 1000 µ F capacitor should not be used if using HB-LED s as the load. A digital or analog oscilloscope with current probe is required to view the AC current in the PFC inductor or buck inductor. A signal generator that can produce a square wave pulse train at between 200 Hz and kHz is required to do external PWM dimming. Forced air cooling is not required A minimum of AWG wire is recommended. Also the wire connections between the AC source and the EVM, and the EVM and load should be less than two feet long. The AC input connector accepts a standard IEC320-C13 connector with ground pin. A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

5.2 Recommended Test Setup TP3 Buck□bias□voltage□monitor TP4□&□TP5 PFC□output□voltageTP1□&□TP2 Loop□injection□point CL2 Current□Probe: Buck□inductor ripple□current monitor Short□pins□to□Enable On□Board□Dimming L N CL1 Current□Probe: PFC□inductor ripple□current monitor 1000uF 250V Pin□1:□Buck□Shutdown Pin□2:□GND Pin□3□External□PWM□dimming□input Pin□1:□PFC□Shutdown Pin□2:□GND IEC320 -C13 Plug 90□-□265 VRMS AC□Source Constant Voltage Load + - 5.3 List of Test Points www.ti.com Test Setup Figure UCC28810EVM-002 Recommended Test Set Up Note: The 1000- µ F/250-V capacitor on the output is not required if the load is a string of HB-LED Table Test Point Functions TEST POINTS NAME point, PFC output TP3 VCC_BK Buck bias voltage output TP4 PFC+ PFC output voltage TP5 PFC- PFC output voltage ground TP6 VCC_BK Buck bias voltage input TP7 GND Buck bias voltage ground TP8 GND Ground connection TP9 EN Buck enable TP10 GND Buck input voltage ground TP11 BK_IN Buck input voltage J2-1 PFC shutdown Apply 3.3 V to this pin to shutdown PFC stage J2-2 GND J4-1 BK_Shutdown Apply 3.3 V to this pin to shutdown buck stage J4-2 GND J4-3 PWM Dim Input for external PWM dimming Short the two pins on to enable on board PWM diming. R26 On board dim varies dimming duty cycle SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

6.1 Applying Power to the EVM 6.2 Line/Load Regulation and Efficiency Measurement Procedure 6.3 PFC Disable Test Procedure www.ti.com All tests will use the set up described in Section of this user guide. Ensure potentiometer R26 is rotated completely clockwise. WARNING HIGH VOLTAGE levels are present on this evaluation module whenever it is energized. Proper precautions must be observed whenever working with this module. There is an energy storage capacitor (C17) on this module which must be discharged before the board can be handled. Serious injury can occur if proper safety procedures are not followed. Set up the EVM as described in Section of this user guide. Ensure the AC source is off. Ensure potentiometer R26 is rotated completely clockwise. Set constant voltage load to between V and 110 If using a HB-LED string ensure the voltage drop, when operating, is between V to 110 V nominal. Note the 1000- µ F/250 V capacitor is not required on the output if using a HB-LED string. Set AC source to VRMS. Turn on AC source. Monitor PFC output voltage at TP4 and TP5, V2. Monitor output current at A1. Monitor output voltage at V1. 10. The EVM is now ready for testing. Apply power to the EVM per Section 6.1 Vary the constant voltage load from 110 V to Observe output current on stays constant. Vary AC source from VRMS to 264 VRMS. Observe output current on stays constant. PFC inductor ripple current can be measured at CL1 using an oscilloscope and current probe. The buck output inductor current can be measured at CL2 using an oscilloscope and current probe. See Section for some typical test results. Ensure the AC source is off. Connect a DC source to J2. Set DC source to Apply power to the EVM per Section 6.1 Increase DC source to 3.3 This input can accept up to Observe PFC output voltage reduces, V2. PFC inductor ripple current looses high frequency component. A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

6.4 Buck Disable 6.5 Internal Dimming Function 6.6 External Dimming Function 6.7 Configuring the PFC Stage for Fixed Output 6.8 Equipment Shutdown www.ti.com Test Procedure Ensure the AC source is off. Connect a DC source to J4, pins and Set DC source to Apply power to the EVM per Section 6.1 Increase DC source to 3.3 This input can accept up to Observe output current, A1, drops to zero. PFC voltage, V2, does not change. Ensure the AC source is off. Ensure jumper is present on J3. Apply power to the EVM per Section 6.1 Rotate R26 potentiometer slowly anti clockwise. Observe output current on reduce from nominal 0.9 A to 0.1 If LED string is attached observe LED s dim. Ensure the AC source is off. Ensure jumper is removed from J3. Connect signal generator to J4, pins and Set signal generator to generator a pulse from V to 3.3 V at 200 Hz with variable duty cycle. Note when the PWM signal is high the LED light is reduced. 100% duty cycle will turn LED off. Apply power to the EVM per Section 6.1 Vary the duty cycle of the signal generator output. Observe output current, A1, changes. If an LED string is attached observe LED s dim. The EVM ships configured as a boost follower PFC. Using a soldering iron some simple component modifications can change the PFC configuration from boost follower to fixed output voltage. Remove R1, R3, R4, R6, and Q1. Change R11 to 6.49 k Ω The EVM now uses a fixed output voltage PFC stage. Repeat tests to see functionality. If DC sources are connected to shutdown pins, and J4, ensure they are set to Ensure load is at maximum, this will help discharge C17. Turn off AC source. Monitor PFC output voltage V2. Do not handle EVM until reads less than VDC. SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

80 100 120 140 200 220 260 VRMS -□Line□Voltage□-□V 0.88 0.98 1.00 160 180 240 0.92 0.94 PF - Power Factor and Efficiency - % EFFICIENCY/POWER□FACTOR vs LINE□VOLTAGE Efficiency Power□Factor 0.90 0.96 THD - Total Harmonic Distortion - % 80 100 120 140 200 220 260 VRMS -□Line□Voltage□-□V 160 180 240 TOTAL HARMONIC□DISTORTION vs LINE□VOLTAGE 7.1 Transient Ch2: Buck□VDS Ch4: LED□Voltage 0.5 A/div. Ch3: LED□Current Ch1: Buck□VIN TRANSITION□MODE□BUCK□PWM□RESPONSE (Ch1□and□Ch□4□share□GND□reference) Ch2: Buck□VDS Ch4: LED□Voltage 0.5 A/div. Ch3:□LED Current Ch1: Buck□VIN TRANSITION□MODE□BUCK□PWM□RESPONSE□EXPANDED (Ch1□and□Ch4□share□GND□reference) Performance Data and Typical Characteristic Curves www.ti.com Figure through Figure present some typical performance curves for the UCC28810EVM-002 with Cree XRE LED s at 900 mA. Figure Figure Figure Figure A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

7.2 Input Current Ch2: Buck□VDS Ch4: LED□VOUT Ch3: AC□Input Current Ch1: Buck□VIN TRANSITION□MODE□BUCK□PWM AND□LINE□INPUT□CURRENT (Ch1□and□Ch4□share□GND□reference) www.ti.com Performance Data and Typical Characteristic Curves Figure SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com Figure through Figure show the design of the UCC28810EVM-002 printed circuit board. Figure UCC28810EVM-002 Top Layer Assembly Drawing (top view) Figure 10. UCC28810EVM-002 Top Copper (top view) Figure 11. UCC28810EVM-002 Bottom Layer (viewed through top layer) A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com List of Materials The EVM components list according to the schematic shown in Figure and Figure Table List of Materials QTY REF DES Capacitor, ceramic, µ X5R, 20%, 1206 Std Std C2, Capacitor, metallized polyester film, 0.1 µ 275 VAC, Std Std 10%, X2, 17.5 mm x 5.5 mm C3, Capacitor, ceramic disc, nF, 250 Y1/X1 Panasonic ECK-ANA102MB Capacitor, ceramic, 2.2 µ X7R, 10%, 0805 Std Std C7, C9, Capacitor, ceramic, nF, NPO, 5%, 0805 C10, C21, Std Std C23, C25 Capacitor, ceramic, 330 nF, X7R, 10%, 0805 Std Std C11 Capacitor, ceramic, pF, NPO, 5%, 1206 Std Std C12, C28, Capacitor, ceramic, µ X5R, 10%, 0805 Std Std C34 C13, C20, Capacitor, ceramic, 0.1 µ X7R, 10%, 0805 Std Std C29 C14 Capacitor, polypropylene film, 0.56 µ 400 Panasonic ECW-F4564JL C15, C16 Capacitor, aluminum electrolytic, 100 µ 20%, 6.3 Std Std mm x 11.5 mm C17 Capacitor, aluminum electrolytic, µ 450 TS-HB Panasonic ECO-S2WB820BA C18 Capacitor, ceramic, µ X7R, 10%, 1210 Std Std C19, C22 Capacitor, ceramic, nF, X7R, 10%, 0805 Std Std C24 Capacitor, ceramic, 100 pF, 200 NPO, 5%, 0805 Std Std C26 Capacitor, ceramic, pF, NPO, 5%, 0805 Std Std C27 Capacitor, ceramic, pF, NPO, 5%, 1206 Std Std C30 Capacitor, polypropylene film, 0.56 µ 630 Panasonic ECW-F6564JL C31, C32 Capacitor, metallized polyester film, 1.0 µ 250 10% Panasonic ECQ-E2105KF C33 Capacitor, ceramic, 470 pF, NPO, 5%, 0805 Std Std CL1, CL2 Current loop, wire, AWG., stranded, 3.0 in. Std NA D1, Diode, 1.5 600 V Std BYG10J Diode, bridge rectifier, 600 V Std GBJ606 D4, D16 Diode, Schottky, 1.5 V Std SL13-E3/61T D5, Diode, Schottky, V Std BYS11-90-E3/TR D6, D17 Diode, switching, 225 mA Ifm, high speed Rohm 1SS355 D8, D18 Diode, ultra fast, 600 V IR HFA08TB60S D9, D10 Diode, Zener, W Std SMAZ18-13 D11, D13, Diode, signal, 300 mA, mW Std 1N4148W D15 D12, D21 Diode, dual Schottky, 200 mA, V Std BAT54C D14 Diode, Zener, 5.1 W Std SMAZ5V1-13-F D19, D20, Diode, Zener, 500 mW, V Std MMSZ5267BT1 D22, D23 SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com Table List of Materials (continued) QTY REF DES Fuse, SMP, 1.25 A Bel SMP 1.25 Fuse 250 V UL fast X MM Std Std FH1 Fuse clip, x mm, PC mount Wickmann 01000056H HS1, HS2 Heatsink, TO-220, vertical mount, C/W Aavid 593002 Connector, AC receptacle, board mount, R/A, mm Qualtek Electronics 703W-00/54 J2, Header, male pin, 100-mil spacing, (36-pin strip) Sullins PTC36SAAN Header, male pin, 100-mil spacing, (36-pin strip) Sullins PTC36SAAN Terminal block, pin 9.52-mm spacing OST OSTT7022150 Inductor, thru hole, 1.3 126 m Ω muRata 33331C Transformer, prim, sec, mH, 3.1 A Coiltronics CTX16-18484 Transformer, prim, sec, 400 µ A Coiltronics CTX33-18428 Q1, Q2, Transistor, NPN, 500 mA Std MMBT2222A Q4, MOSFET, N-channel 400 A IR IRF840 MOSFET, N-channel, 500 A ST STP6NK50Z Bipolar, PNP, -500 -500 mA Zetex FMMT560 R1, Resistor, chip, 301 k Ω 1%, 1206 Std Std R2, Resistor, chip, 1.00 M Ω 1%, 1206 Std Std Resistor, chip, 4.02 k Ω 1%, 0805 Std Std Resistor, chip, 6.19 k Ω 1%, 0805 Std Std R7, R28 Resistor, chip, 4.75 k Ω 1%, 0805 Std Std R8, R11, Resistor, chip, 10.7 k Ω 1%, 0805 R29, R30, Std Std R33, R44 Resistor, chip, 24.3 k Ω 1%, 0805 Std Std R10 Resistor, chip, 6.81 k Ω 1%, 0805 Std Std R12 Resistor, chip, 332 Ω 1%, 0805 Std Std R13, R15, Resistor, chip, 511 k Ω 1%, 1206 Std Std R39, R40 R14, R16 Resistor, chip, 100 k Ω 1%, 1206 Std Std R17 Resistor, chip, 47.5 Ω 1%, 0805 Std Std R18, R37 Resistor, chip, 21.5 k Ω 1%, 0805 Std Std R19, R36 Resistor, chip, 10.0 Ω 1%, 0805 Std Std R20, R35 Resistor, chip, 0.40 Ω 1%, 2512 Std Std R22, R23 Resistor, chip, 200 Ω 1%, 1812 Std Std R24, R42 Resistor, chip, 10.0 k Ω 1%, 0805 Std Std R25, R46 Resistor, chip, 100 k Ω 1%, 0805 Std Std R26 Potentiometer, cermet, single turn, flat Bourns 3362P-504 R27 Resistor, chip, 665 Ω 1%, 1206 Std Std A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

www.ti.com List of Materials Table List of Materials (continued) QTY REF DES R31, R32, Resistor, chip, 15.0 k Ω 1%, 0805 Std Std R45 R34 Resistor, chip, 560 Ω 1%, 0805 Std Std R38 Resistor, chip, 0.47 Ω 1%, 2512 Std Std R41 Resistor, chip, 4.75 k Ω 1%, 1206 Std Std R43 Resistor, chip, 221 k Ω 1%, 0805 Std Std R47, R48 Resistor, chip, 221 k Ω 1%, 1206 Std Std LED Lighting Power Controller TI UCC28810D Timer, Low-Power CMOS TI TLC555D LED Lighting Power Controller TI UCC28811D PCB, 10.4 in x in x 0.062 in Any HPA439 REVA Washer, #4, shoulder, nylon Keystone Heatpad TO-220 0.009" SP900 Bergquist SP900S-90 Washer, split, ss Std Std Nut, #4-40, ss Std Std Screw, 40, SS, 0.5 in. Std Std JP1 Connector, jumper, shorting, gold, 0.100" Sullens SLUU355A March 2009 Revised June 2009 A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting

(TI) provides the enclosed product(s) under the following conditions: This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives. Should this evaluation board/kit not meet the specifications indicated in the User s Guide, the board/kit may be returned within 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. 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 assistance, customer product design, software performance, or infringement of patents or services described herein. Please read the User s Guide and, specifically, the Warnings and Restrictions notice in the User s Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For additional information on TI s environmental and/or safety programs, please contact the TI application engineer or visit www.ti.com/esh 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. FCC Warning This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. EVM WARNINGS AND RESTRICTIONS It is important to operate this EVM within the input voltage range of VRMS to 264 VRMS and the output voltage range of VRMS to 110 VRMS. 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 The EVM is designed to operate properly with certain components above 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 2008, Texas Instruments Incorporated

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