336-w auxless ac/dc power supply reference design

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January 2018 336W Auxless AC/DC Power Supply Reference Design with 80 PLUS Platinum Performance 1 Copyright © 2018, Texas Instruments Incorporated

Test Report: PMP21160

336W Auxless AC/DC Power Supply Reference Design with 80 PLUS Platinum Compatible Performance

Description

The PMP21160 reference design uses UCC28056 CRM/DCM PFC controller and UCC256304 enhanced LLC controller with integrated driver to provide 24-V/10-A output (continuous, 14-A peak) from universal AC input. This design achieves 92.8% peak efficiency at 115-Vac input and 94.9% peak efficiency at 230-Vac input. The efficiency and power factor numbers also meet both 115-V and 230-V internal 80 PLUS Platinum specifications and DoE level VI requirement.

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2 336W Auxless AC/DC Power Supply Reference Design with 80 PLUS Platinum Performance STTT###-January 2018 Copyright © 2018, Texas Instruments Incorporated

1 System Specification

1.1 Board Dimension: 75mm x 180mm x 30mm.

1.2 Input Characteristics

1.2.1 AC Input Voltage and Frequency Limitations:

1.2.2 AC Input Current:

4A Max. at 100VAC.

2A Max. at 200VAC.

Current total harmonic distortion should be less than 20% from 5A to 10A load.

1.2.3 Power Factor:

Power factor should be greater than 0.95 at 50% load with either 115VAC/60Hz or 230VAC/50Hz input.

1.2.4 Inrush Current:

Cold start: <50A at both 100VAC and 230VAC input and 25degC ambient temperature.

Hot start: no component damage.

1.3 Output Characteristics The power supply unit should be able to supply 24V+/-5%, 240W output power continuously and 24V+/-5%, 336W peak power for 20second with 10% duty cycle.

Minimum Nominal Maximum

90 100~240 265 VAC

47 50~60 63 Hz

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2 Testing and Results

2.1 Board Photos The photographs below show the top and bottom view of the PMP21160Rev B board.

2.1.1 Top Side

2.1.2 Bottom Side

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2.2 Efficiency Data 4-point average efficiency: 92.1% @ 115VAC/60Hz and 94.2% @ 230VAC/50Hz

2.2.1 100VAC/60Hz Efficiency Measurement

Vin (V) Iin (A) Pin(W) P.F. THD(%) Vout(V) Iout(A) Pout(W) Efficinecy (%)

100.01 2.653 263.30 0.992 11.7% 24.110 10.0000 241.10 91.57%

99.99 2.382 236.10 0.991 12.5% 24.110 9.0000 216.99 91.91%

100.07 2.115 209.50 0.990 13.5% 24.110 8.0000 192.88 92.07%

100.01 1.984 196.24 0.989 14.1% 24.110 7.5020 180.87 92.17%

100.05 1.854 183.28 0.988 14.7% 24.110 7.0020 168.82 92.11%

99.93 1.597 157.31 0.986 16.1% 24.110 6.0180 145.09 92.23%

100.01 1.336 131.21 0.982 17.9% 24.110 5.0100 120.79 92.06%

100.09 1.081 105.68 0.977 19.9% 24.110 4.0170 96.85 91.64%

100.07 0.815 80.34 0.985 11.0% 24.110 3.0130 72.64 90.42%

100.01 0.682 67.05 0.984 9.3% 24.110 2.5030 60.35 90.00%

100.05 0.553 54.21 0.979 10.2% 24.110 2.0070 48.39 89.26%

100.09 0.425 41.18 0.968 9.4% 24.110 1.5078 36.35 88.28%

100.13 0.375 27.61 0.736 48.8% 24.110 1.0062 24.26 87.86%

100.17 0.271 14.79 0.545 71.7% 24.110 0.5066 12.21 82.58%

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115.06 2.285 260.70 0.992 12.6% 24.110 10.0000 241.10 92.48%

115.03 2.055 234.10 0.990 13.5% 24.110 8.9990 216.97 92.68%

115.00 1.834 208.40 0.988 14.7% 24.110 8.0090 193.10 92.66%

115.04 1.716 194.90 0.987 15.3% 24.110 7.4990 180.80 92.77%

115.07 1.602 181.80 0.986 15.9% 24.110 6.9990 168.75 92.82%

115.05 1.380 155.99 0.983 17.4% 24.110 6.0010 144.68 92.75%

115.02 1.156 130.16 0.979 19.1% 24.110 5.0000 120.55 92.62%

115.09 0.928 105.38 0.987 8.4% 24.110 4.0030 96.51 91.59%

115.05 0.705 79.61 0.982 9.7% 24.110 3.0070 72.50 91.07%

115.09 0.592 66.53 0.977 10.2% 24.110 2.4970 60.20 90.49%

115.02 0.482 53.72 0.969 9.1% 24.110 1.9970 48.15 89.63%

115.06 0.373 40.92 0.953 7.9% 24.120 1.5075 36.36 88.86%

115.09 0.318 28.20 0.721 17.7% 24.120 1.0040 24.22 85.87%

115.02 0.231 14.83 0.537 56.3% 24.120 0.4926 11.88 80.13%


230.00 1.127 254.40 0.982 7.2% 24.110 10.0100 241.34 94.87%

230.00 1.017 229.10 0.979 7.3% 24.110 8.9960 216.89 94.67%

230.00 0.910 204.00 0.975 7.1% 24.110 7.9970 192.81 94.51%

229.90 0.856 191.24 0.972 6.9% 24.110 7.5030 180.90 94.59%

230.00 0.799 178.17 0.969 7.7% 24.110 6.9970 168.70 94.68%

230.00 0.692 152.80 0.960 7.7% 24.110 6.0030 144.73 94.72%

230.00 0.587 127.69 0.946 7.9% 24.110 5.0100 120.79 94.60%

230.00 0.485 102.79 0.921 8.5% 24.110 4.0030 96.51 93.89%

230.00 0.390 77.69 0.866 9.9% 24.110 3.0030 72.40 93.19%

230.00 0.351 64.94 0.805 11.3% 24.120 2.4950 60.18 92.67%

230.10 0.360 52.95 0.640 14.0% 24.120 2.0150 48.60 91.79%

230.00 0.293 39.48 0.586 19.5% 24.120 1.4959 36.08 91.39%

230.00 0.252 26.69 0.461 31.1% 24.120 0.9962 24.03 90.03%

230.00 0.205 14.07 0.298 33.6% 24.120 0.4945 11.93 84.77%

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2.3 No Load Power Consumption No load power consumption was measured with under below two conditions with two different setups: Standby input power measurement was done with Voltech PM1000+ power meter using 3-minute-average and California Instruments 1251P AC source. A Schneider Electric 2KVA isolated transformer is placed in between the AC source and PMP21160 board. External shunt was using for current meter with scaling factor 0.0125.

115VAC/60Hz: Pin=185.39mW. 230VAC/50Hz: Pin=212.3mW.

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2.4 Thermal Images The thermal images below show a top view and bottom view of the board. The board is placed vertically during the test. The ambient temperature was 25ºC with no air flow. The output was loaded with 24V/10A.

2.4.1 100VAC/60Hz, Top Side

Spot analysis Value

Amb Temperature

26.0°C

Area analysis Value

D101Max 97.3°C

L101Max 80.2°C

D100Max 82.8°C

L100Max 75.8°C

T200Max 68.0°C

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2.4.2 100VAC/60Hz, Bottom Side

Spot analysis Value

Amb Temperature

25.4°C

Area analysis Value

D101_BottomMax

81.9°C

U202Max 59.4°C

Q200, Q202Max 57.7°C

Q201, Q203Max 60.2°C

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Spot analysis Value

Amb Temperature

24.4°C

Area analysis Value

D101Max 89.4°C

L101Max 70.0°C

D100Max 76.6°C

L100Max 75.5°C

T200Max 69.9°C

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Spot analysis Value

Amb Temperature

23.7°C

Area analysis Value

D101_BottomMax

77.1°C

U202Max 59.9°C

Q200, Q202Max 58.5°C

Q201, Q203Max 59.7°C

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Spot analysis Value

Amb Temperature

25.7°C

Area analysis Value

D101Max 66.3°C

L101Max 51.2°C

D100Max 61.2°C

L100Max 63.2°C

T200Max 73.9°C

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Spot analysis Value

Amb Temperature

24.7°C

Area analysis Value

D101_BottomMax

59.0°C

U202Max 59.1°C

Q200, Q202Max 59.1°C

Q201, Q203Max 62.0°C

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2.5 Startup The voltages at startup are shown in the images below, where Channel 2 is HV to GND, Channel 3 is output voltage, and Channel 4 is T200 Primary winding current.

2.5.1 100VAC/60Hz – No Load

2.5.2 100VAC/60Hz –24V/10A

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2.5.4 115VAC/60Hz –24V/10A

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2.5.6 230VAC/50Hz – 24V/10A

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2.6 Ripple Voltages Ripple voltages are shown in the images below, where Channel 2 is HV to GND voltage in AC level and Channel 3 is Vout to GND voltage in AC level.

2.6.1 100VAC/60Hz – 24V/0A

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2.6.2 100VAC/60Hz – 24V/10A

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2.6.3 115VAC/60Hz – 24V/0A

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2.6.4 115VAC/60Hz – 24V/10A

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2.6.5 230VAC/50Hz – 24V/0A

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2.6.6 230VAC/50Hz – 24V/10A

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2.7 Load Response Load response is tested at 230VAC/50Hz input, where Channel 3 is the output voltage in AC level and Channel 4 is output current.

2.7.1 Load step from 5A to 10A:

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2.8 Frequency Response Frequency response of the LLC-SRC stage is tested with 230VAC/50Hz input and 24V/10A output. Signal was injected on R215.

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2.9 Key Waveforms

2.9.1 SR FET conduction at 100VAC/60Hz input, 24V/2.5A output: C1: Q201 VDS, C2: Q201 VGS, C3: Q203 VGS, C4: IPRI.

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2.9.2 SR FET conduction at 100VAC/60Hz input, 24V/5A output: C1: Q201 VDS, C2: Q201 VGS, C3: Q203 VGS, C4: IPRI.

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2.9.3 SR FET conduction at 100VAC/60Hz input, 24V/10A output: C1: Q201 VDS, C2: Q201 VGS, C3: Q203 VGS, C4: IPRI.

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2.9.4 SR FET conduction at 100VAC/60Hz input, 12V/10.8A output: C1: VOUT, C2: Q203 VGS, C3: Q203 VDS, C4: VCR.

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336-w auxless ac/dc power supply reference design

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