Flyback Converters,Active Clamp Vs. Hard-Switched .

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User GuideUCC3580EVM Flyback Converters,Active Clamp vs Hard-SwitchedEvaluation Board and List ofMaterialsUser’s Guide1

EVM IMPORTANT NOTICETexas Instruments (TI) provides the enclosed product(s) under the following conditions:This evaluation kit being sold by TI is intended for use for ENGINEERING DEVELOPMENT OR EVALUATIONPURPOSES ONLY and is not considered by TI to be fit for commercial use. As such, the goods being providedmay not be complete in terms of required design-, marketing-, and/or manufacturing-related protectiveconsiderations, including product safety measures typically found in the end product incorporating the goods.As a prototype, this product does not fall within the scope of the European Union directive on electromagneticcompatibility and therefore may not meet the technical requirements of the directive.Should this evaluation kit not meet the specifications indicated in the EVM User’s Guide, the kit may be returnedwithin 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVEWARRANTY 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 ANYPARTICULAR PURPOSE.The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the userindemnifies TI from all claims arising from the handling or use of the goods. Please be aware that the productsreceived may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). Due to the open constructionof the product, it is the user’s responsibility to take any and all appropriate precautions with regard to electrostaticdischarge.EXCEPT TO THE EXTENT OF THE INDEMNITY SET FORTH ABOVE, NEITHER PARTY SHALL BE LIABLETO 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 notexclusive.TI assumes no liability for applications assistance, customer product design, software performance, orinfringement of patents or services described herein.Please read the EVM User’s Guide and, specifically, the EVM Warnings and Restrictions notice in the EVMUser’s Guide prior to handling the product. This notice contains important safety information about temperaturesand voltages. For further safety concerns, please contact the TI application engineer.Persons handling the product must have electronics training and observe good laboratory practice standards.No license is granted under any patent right or other intellectual property right of TI covering or relating to anymachine, process, or combination in which such TI products or services might be or are used.Mailing Address:Texas InstrumentsPost Office Box 655303Dallas, Texas 75265Copyright 2001, Texas Instruments Incorporated2

EVM WARNINGS AND RESTRICTIONSIt is important to operate this EVM within the input voltage range of 0 VAC to 135 VAC and the output voltageof 0 VDC to 14 VDC.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 connectingthe input power.Applying loads outside of the specified output range may result in unintended operation and/or possiblepermanent damage to the EVM. Please consult the EVM User’s Guide prior to connecting any load to the EVMoutput. 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 60 C. The EVMis designed to operate properly with certain components above 125 C as long as the input and output rangesare maintained. These components include but are not limited to linear regulators, switching transistors, passtransistors, and current sense resistors. These types of devices can be identified using the EVM schematiclocated 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 InstrumentsPost Office Box 655303Dallas, Texas 75265Copyright 2001, Texas Instruments Incorporated3

SLUU085 – November 2001UCC3580EVMFlyback Converters, Active Clamp vs Hard-SwitchedEvaluation Board and List of MaterialsPower Supply Control ProductsContents1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Added Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Re-Configuration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Test Setup and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Application Drawings and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.1 Active Clamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 Hard-Switched Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Traces and Silkscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136.1 Traces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136.2 Silkscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145566Figures1Recommended Test Setup for the UCC3580 Flyback Evaluation Board . . . . . . . . . . . . . . . . . . . . . . . . . 72Flyback Converter Populated for Active Clamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Flyback Converter Populated for Hard-Switched Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114UCC3580EVM Layout, Top Traces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135UCC3580EVM Layout, Bottom Traces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136UCC3580EVM Silk Screen (only top layer has a silk screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Tables1List of Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Parts List for Active Clamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Conversion From Active Clamp to Hard-Switched Configuration: Remove List . . . . . . . . . . . . . . . . . 124Conversion From Active Clamp to Hard-Switched Configuration: Add List . . . . . . . . . . . . . . . . . . . . 124UCC3580EVM

SLUU085 – November 20011IntroductionThis user’s guide describes the UCC3580EVM flyback converter evaluation board for comparing anactive-clamp configuration with a hard-switched configuration. The UCC3580EVM is originally configured asan active-clamp flyback converter. Instructions and parts list are included in order to reconfigure theUCC3580EVM as a hard-switched flyback converter. Both configurations use the UCC3580 PWM controller.The active clamp configuration operates noticeably more efficiently than the hard switched configuration. Mostof the efficiency differences will be seen in the primary-side components.2FeaturesDDDDDDDProvides auxiliary-switch activation complementary to main-power switch driveProgrammable dead time (turnon delay) between activation of each switchVoltage mode control with feedforward operationProgrammable limits for both transformer volt-second product and PWM duty cycleHigh-current gate driver for both main and auxiliary outputsMultiple protection features with latched shutdown and soft restartLow supply current (160-µA startup, 2.5-mA operation)3Description3.1Operating GuidelinesWARNING:DANGER: HIGH VOLTAGE! This evaluation board is intended for professional useonly. It has exposed high voltages. Do not operate this board without properisolation and high-voltage/high-current safety practices.Refer to the recommended test setup, as shown in Figure 1, and the test points in Table 1. Connect theUCC3580EVM, configured for either active clamp operation or hard-switched operation, as shown in Figure 1.Close the ac line switch and verify that the UCC3580EVM is operating correctly (12 V should be measured bythe hand-held DVM on the converter output). Using the appropriate oscilloscope probes, observe the maintransistor drain source voltage (TP14 to TP13) and the cathode to anode voltage of the output rectifier (TP6 toTP8). The active clamp implementation will have crisp, clamped voltages and no overshoot on the outputrectifier. Converter dynamics can be observed [1] using TP3, 4 and 5.Other test points are included to observe voltages and currents that are of interest for a specific application.Table 1 describes the intended purpose of the test points that are installed in the board and how they shouldbe used.UCC3580EVM5

SLUU085 – November 20013.2Added FeaturesFlyback converters require a voltage clamp in order to limit the main switch voltage at turnoff. The effect is dueto energy that is stored in the primary leakage inductance of the power transformer. Older hard-switchedtechnology captures the excess leakage inductance energy at turnoff and merely dissipates it in a resistor. Incontrast, the active clamp uses the leakage inductance energy to facilitate zero voltage transitions. Efficient ZVStransitions occur at turnon of both the main MOSFET and the auxiliary MOSFET.Active-clamp technology is made possible here with the UCC3580 single ended active clamp/reset PWMcontroller. Essentially, this controller is a voltage mode PWM controller with complementary outputs andprogrammable delay between output transitions. The controller also includes over-current protection,volt-seconds protection and a soft-start feature. The programmable delay is set to be long enough for theleakage inductance energy to forward bias the power MOSFETs before their respective turnon, thus achievingzero voltage switching.The schematic for the active clamp configuration is shown in Figure 2 and its parts list is in Table 2. Theschematic for the hard-switched configuration is shown in Figure 3. Both configurations operate with the sameinput voltage (110 VAC 10%) and produce the same output voltage (12 V) and current (10 A). Heat sink HS1is selected to accommodate the hard-switched configuration and it is thus over-sized for active clamp operation.The thermal resistance of HS1 is 6.5 C/W, which is required for hard-switched operation. In contrast, heat sinkHS1 only needs a thermal resistance of 10 C/W for active-clamp operation, which was verified in the laboratory.Thus transistor QM operates more efficiently, and it requires a smaller heat sink in the active-clampconfiguration. Also, notice that the active-clamp configuration does not require secondary rectifier snubbercomponents (R31 and C30). These features are the result of efficient active clamp technology.For more information, pin descriptions and specifications for the UCC3580 single ended active clamp/resetPWM, please refer to the UCC3580 data sheet.3.3Re-Configuration InstructionsWARNING:Danger: Remove power from the UCC3580EVM before removing or installingcomponents.These instructions describe how to reconfigure the UCC3580EVM from the active clamp configuration to thehard switched configuration. This section requires components, de-soldering, soldering, and assemblyequipment and skills. The components are listed in Table 4.Begin with an UCC3580EVM in the active-clamp configuration (original configuration). Refer to Table 3 andTable 4 for the components to remove and add, respectively in order for the UCC3580EVM to match theschematic in Figure 3. The additional components in Table 4 are supplied in the kit that is included with theUCC3580EVM.De-solder the components listed in Table 3. Solder the components listed in Table 4.Conversion is now complete and comparisons can be made using the test setup in Figure 1 and the test pointsin Table 1.6UCC3580EVM

SLUU085 – November 20014Test Setup and Test eACNEUTRALJ1–2NeutralUCC3580EVMDemonstration1.2 Ω, minimum120 Watts10 AmpsJ2–2GND2J1–1ChassisSAFETYGROUNDJ2–1 12V– Hand–Held 5100MHzHigh VoltageDifferentialProbe –1TektronixP5100 100XProbe,2500V,peak2NOTES:Warning, High Voltage!This test setup is connected to the acline, observe isolation requirements.TektronixP6138A10X Probe,300V,peak31Use the P5202 for all differential observations,both high and low voltage.2Use the P5100 for all voltage observations thatare more than 200V and ground referenced.3Use the P6138A for all voltage observationsthat are less than 200V and groundreferenced.Figure 1. Recommended Test Setup for the UCC3580EVMTable 1. List of Test PointsTest PointSignal NameTP1GND2TP212 VVoltage RangeGND REFMeasurementSECSecondary ground12 VSEC12 V, observe relative to TP1TP3TP4TP512 V, 0.1 VACSECInjection and observation points for control loop. Refer to [1]TP6TP7TP812 V50 V50 VSECDifferentially observe V(D17) between TP6 and TP8.Differentially observe snubber power between TP6 and TP7.TP9PRI GNDPRIPrimary ground for controller observationsTP10OUT112 VPRIMain MOSFET (QM) gate control signalTP11OUT212 VPRIAuxiliary MOSFET (QA) gate control signalTP12EAOUT5VPRIError amplifier output to PWM comparatorTP13PRI GNDPRIPRI GND reference for QM and CSENSE observationsTP14DRAIN300 VPRIObserve QM drain voltage relative to PRI GNDTP15CSENSE1VPRIObserve drain current of QMTP16TP17TP18SOURCEBULKDRAIN300 V300 V300 VPRIDifferentially observe QA drain–source voltage between TP18 andTP16Differentially observe clamp voltage, V(C25) between TP18 and TP17TP19TP20PRI GNDBULK200 VPRIObserve bulk capacitor voltage ( the dc input voltage to the converter)UCC3580EVM7

C4 0.1µF250VC14700pF250VCAUTION:LINE VOLTAGEAC INPUT115V60HzJ1–1J1–3J1–2 CHASSISLINE NEUTRALF13AC3 50.1µFTP10OUT1T1D61N5819D71N581958C11 0.1µFTP19TPI GNDTP20BULK C71000µFR7R63.92k 5.62kGND 89 RAMPC5 0.1µF250VD11N5406D31N5406CLK 710 OSC2R168k1WOUT2 611 OSC1D21N540612 EAOUT PGND 5D41N5406R833.2kR4 47k2WQ22N3904D111N5819R17130kQ32N3904456421HS322 kIC3 1TL4313IC2CNY17–2 C34180µFR263.01kD17MBRF2545CT1143 TURNS133HIGHTEMPERATURE–SEE EVM WARNINGSAND RESTRICTIONSTP12 CONDARYC271.0nF 250VAC3 TURNSC240.1µFD141N4744C19100µF3D16MUR460R22 20TP13PRI GNDTP15CSENSE4TP14DRAIND13 1N4148R240.103WM.E.QMIRF740HS12L3 16µHTP16SOURCEQAIRF740HS2C25TP17240.068µFBULK R2310kC120.01µFTP9PRI GNDR163.32kR21 1kR1020.0kR184.7kQ12N3906R154.7kQ42N3906D10 1N4148C210.1µF400VD9R1915 1N5819R11 511kC18C14 C171µF 0.047µF �SEE EVM WARNINGSAND RESTRICTIONSR5 30C60.1µFOUT1 4UCC3580EVM13 EAINTP3J2–2RETURNJ2–1 12VActive Clamp ConfigurationVDD 35.114 REFApplication Drawings and Parts ListLINE 2515 SS816 SHDN DELAY 1UCC3580–4IC1HIGHTEMPERATURE–SEE EVM WARNINGSAND RESTRICTIONSSLUU085 – November 2001Figure 2. Flyback Converter Populated for Active Clamp OperationUDG–00014Note: High-temperature component. See EVM Warnings and Restrictions at the front of this document.

SLUU085 – November 2001Table 2. Parts List for Active Clamp ConfigurationCapacitorDiodeRef DesQtyC1,22Y Cap, 4700 pF, 250 VacDescriptionSpragueMFGSize6.5 mmPart Number5GAD4715 mm222 330 401045 mmECU–S1H104KBBC3 – C53X Film Cap, 0.1 µF, 250 VacPhilipsC6, C11,C15, C244Ceramic, 0.1 µF, 50 VPanasonicC71Aluminum electrolytic, 1000 µF,200 VUnited Chemi–con10 mmKMH200VN102M35X35T2C81Ceramic, 470 pF, 50 VPanasonic2.5 mmECU–S1H471JCA2.5 mmECK–F1H681KB5 mmD331K20Y5PLAAEUC91Ceramic, 680 pF, 50 VPanasonicC101Ceramic Disk, 330 pF, 500 VPhilipsC121Ceramic, 0.01 µF, 50 VPanasonic2.5 mmECU–S1H103KBAC141Ceramic, 1 µF, 50 VPanasonic5 mmECU–S1H105MEBC171Ceramic, 47 nF, 50 VPanasonic2.5 mmECU–S1H473MEAC181Ceramic, 2200 pF, 50 VPanasonic2.5 mmECK–F1H222KBC191Aluminum Electrolytic, 100 µF, 25 VPanasonic2 mmECE–A1EU101C211Foil, 0.1 µF, 400 VPanasonic20 mmECQ–P4104JUC251Foil, 0.068 µF, 400 VPanasonic20 mmECQ–P4683JUC261Ceramic, 220 pF, 50 VPanasonic2.5 mmECU–S1H221JCAC271Y1 Ceramic, 1000 pF, 250 VacPanasonic10 mmECK–DNA102MBC281Ceramic, 4.7 nF, 50 VPanasonic2.5 mmECU–S1H472KBAC291Ceramic, 470 pF, 50 VPanasonic7.5 mmECU–S1H471JCAC31 – C344Os–Con, 180 µF, 20 VSanyo5 mm20SP180MDO–201AD1N5406D1 – D44General Purpose, 3 A, 600 VD5, D10,D133Switching, 75 mA, 75 VDO–351N4148D6, D7,D9, D114Schottky, 1 A, 40 VDO–411N5819D141Zener, 15 V, 1 WDO–411N4744AD151Ultra Fast, 1 A, 200 VDO–41MUR120D161Ultra Fast, 4 A, 400 VDO–201ADMUR460D171Schottky, Dual, 25 A, 45 VITO–220ABMBRF2545CTFuseF113 A, AGC3A Buss, 3 ABuss31.75 mmAGC3AFuse clipsFCa,b22 required, spacing per dwgKeystone7.62 mm3510HS11For QM, 6.5 C/WThermalloy50.44 mm7022B–MTHeatsinkHS21For QA, 13 C/WThermalloy24.38 mm6021PBHS31For D53, 4.4 C/WThermalloy27.94 mm7023B–MTPWMIC11IC 2.495 VTITO–226AATL431CLPConnectorChokeMOSFETJ212 pos, 5.08 mm spacingPhoenix ContactL11Toroid, 18 µHMagnetek5.08 mm173061212.06 mmFIT68–7L21Common mode, 2 mHPanasonic10X16.5 mmELF–18N032AL31E25/10/6–3F3 core, 10-pins, 16 µHCentury Magnetics5.1X15.6 mmCMI–2408QA, QM2400 V, 0.55 Ω, 10 AIRTO–220ABIRF740UCC3580EVM9

SLUU085 – November 2001Ref DesQtyDescriptionMFGScrew3#4–40 x 3/8” round head, philips, for QA, QM & D17Nut3#4–40 hex for QA, QM & D17Washer3#4, flat for QA, QM & D17Washer3#4, split lock, for QA, QM & D17Heat sink pad2TO220, for QA, QMBergquistShoulderwasher2Hi temp plastic, for QA, QM & D17BivarTTransistori tSP600–58for #4 screwSW–031–145Q1, Q42PNP, 40 V, 200 mATO–226AA2N3906Q2, Q32NPN, 40 V, 200 mATO–226AA2N3904R111 W, Metal Oxide, 68 kΩ, 5%Panasonic20 mmP68kW–1BK–NDR211/4 W, carbon comp, 470 kΩ, 5%Multicomp15.24 mmRC1/4G474JTR311 W, Metal Oxide, 240 kΩ, 5%Panasonic20 mmP240kW–1BK–NDR412 W, 47 kΩ, 5%Panasonic25.4 mmP47kW–2BK–NDR511/4 W, 30 Ω, 5%10.16 mmR611/4 W, 5.62 kΩ, 1%10.16 mmR711/4 W, 3.92 kΩ, 1%10.16 mmR811/4 W, 33.2 kΩ, 1%10.16 mmR1011/4 W, 20.0 kΩ, 1%10.16 mmR1111/4 W, 511 kΩ, 1%10.16 mmR12, R2321/4 W, 10 kΩ, 5%10.16 mmR1311/4 W, 1.62 kΩ, 1%10.16 mm11/4 W, 33.2 kΩ, 1%10.16 mmR1511/4 W, 4.7 kΩ, 5%10.16 mmR1611/4 W, 3.32 kΩ, 1%10.16 mmR1711/4 W, 130 kΩ, 1%10.16 mmR1811/4 W, 4.7 kΩ, 5%10.16 mmR1911/4 W, 15 Ω, 5%10.16 mmR2111/4 W, 1 kΩ, 1%10.16 mmR22, R3221/4 W, 20 Ω, 5%R2413 W, Metal Element, 0.1 Ω, 1%R26, R29

Flyback converters require a voltage clamp in order to limit the main switch voltage at turnoff. The effect is due to energy that is stored in the primary leakage inductance of the power transformer. Older hard-switched technology captures the excess leakage inductance energy at turnoff and merely dissipates it in a resistor. In

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