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UCC256303: VCR high amplitude and output shutdown at nominal current

Part Number: UCC256303
Other Parts Discussed in Thread: UCC256403

Good day,

I'm currently working on custom design of LLC DCDC converter with the following specifications: Vout = 13V, Pout = 260W, Vin (min) = 280V, Vin (max) = 440V, frequency (LLC) = 150kHz.

Using the UCC2564x Design Calculator, I get the following results for the schematic: 

After completing a first board, the output voltage is as expected but the output keeps shutting down at higher current output. Increasing the voltage input also decreases the output current available. I investigated the signals and here are some of the signals:

350V/14A: Error is detected on RVCC and system goes into fault (CH1 = LO, CH2 = RVCC)

Close-up on LO and RVCC on the left:

350V/1A (stable 13V output): (CH1 = LO, CH2 = VCR)

Increasing the current output (12A), only increases the occurence of LO switching but it never gets to constant switching: (CH1 = LO, CH2 = VCR)

Close up at 350V/2A: (CH1 = LO, CH2 = VCR)

Close up at 350V/6A: (CH1 = LO, CH2 = VCR)

Finally, the output voltage was probed and it doesn't seem to be stable: (CH1 = LO, CH2 = Vout)

Since the frequency of LO doesn't change much (96kHz to 125kHz from 280V to 410V) and the excel calculator shows operating frequency from 94-296kHz, I suspect that there is something wrong with the feedback pin.

Any ideas on what could cause this behaviour on VCR pin and output voltage?
Is the excel calculator appropriate for UCC25630x?

Thanks!

  • Hi Marc,

    If you are still in the evaluation phase, could you switch the controller from UCC256303 to UCC256403 which has much improved features. Also, they are pin to pin compatible.

    UCc25630x is not recommended for new designs. We are going to update our website soon.

    Could you share the design calculator and schematics. I will have a look at it.

    Regards

    Manikanta P

  • Unfortunately, our team has already acquired a substantial quantity of UCC256303 that needs to be utilized. While the board that I assembled proved to have issues, other boards that we received from our CM are working fine.  I tested additional units from the CM and some units had a behaviour similar to the one shown in the pictures which raises concerns regarding the yield rate and performances. Once our current supply is depleted, I can advocate for transitioning to the UCC256403.

    I sent you the details over email. 

  • Hi Marc,

    Thanks for sharing the files. I will look into this get back to you by tomorrow. Since we are discussing through email, I am closing this thread.

    Regards

    Manikanta P