UCC28180: UCC28180 failure issue

user5010576

Part Number: UCC28180

We have encountered one issue on the UCC28180 which was used in our production at our lab. The PF value became very low and the waveform was distorted.

The distorted waveform:

The normal waveform:

From the Gate PWM output waveform, we can see the abnormal performance on the position of the distorted waveform. Could you give us some possible failure reason. Thanks!

Follow is the sch:

over 6 years ago

0 John Griffin1 over 6 years ago

TI__Mastermind 34465 points

Hello user5010576,

What were the test conditions when you captured this waveform and what is the design specification for your requirements?

Did you use the Excel calculator ?

If so can you please attach the results ?

Regards

John

0 user5010576 over 6 years ago in reply to John Griffin1

Prodigy 80 points

The test condition is : normal operating with the power about 3KW. The load is BLDC motor.

I did use the calculator. Please check it as below:

INPUT:

Minimum Input Voltage from AC Line:

V_ACIN(min)

176

V_RMS

Maximum Input Voltage from AC Line:

V_ACIN(max)

265

V_RMS

Minimum Line Frequency:

f_LINE(min):

Maximum Line Frequency:

f_LINE(max):

Minimum Rectified AC Line Voltage:

V_{IN_PEAK(min)}

248.902

Maximum Rectified AC Line Voltage:

V_{IN_PEAK(max)}

374.767

OUTPUT:

Maximum Output Power of PFC Stage:

P_OUT(max)

6000

Output Voltage (Note: Must be > V_{IN_RECTIFIED(max)}):

V_OUT

375

Target Power Factor, V_IN(nom), Full Load:

0.99

Predicted Efficiency:

0.9

Maximum Ambient Temperature:

T_AMB(max)

°C

Maximum Average Output Current of PFC Stage:

I_OUT

16.000

Desired Switching Frequency:

f_SW(target)

kHz

Recommended Resistor value on FREQ to Set the Switching Frequency, f_SW:

R_{FREQ(recommended)}

105.000

kΩ

Actual Value For R_FREQ Used:

R_FREQ =

100

kΩ

Resultant Switching Frequency, f_SW:

f_SW

22.640

kHz

Line Current:

Maximum Input Power Drawn from the Line:

P_IN(max)

6666.667

Maximum RMS AC Line Current:

I_{IN_RMS(max)}

38.261

Maximum Peak AC Line Current, assuming sinusoidal:

I_{IN_PEAK(max)}

54.110

Maximum Average AC Line Current, assuming sinusoidal:

I_{IN_AVG(max)}

34.447

Minimum Input Fuse Rating:

I_FUSE

57.392

BRIDGE RECTIFIER:

Bridge Rectifier Forward Voltage, at I_{IN_PEAK(max)}:

V_{F_BRIDGE}

Bridge Rectifier Thermal Resistance, Junction to Case:

R_q_JC(Bridge)

2.2

°C/W

Case to Heatsink Thermal Resistance:

R_{θCHS(Bridge)}

0.61

°C/W

Bridge Rectifier Maximum Junction Temperature:

T_J(max)

125

°C

Bridge Rectifier Minimum Average Current Rating:

I_{BRIDGE(rated)}

51.671

Bridge Rectifier Minimum DC Blocking Voltage Rating:

V_{DC_BLOCKING(rated})

412.243

Bridge Rectifier Power Dissipation:

P_BRIDGE

68.895

Required Heat Sink Thermal Impedance:

R_q_{HS_AMB(Bridge)}

-1.721

°C/W

INPUT CAPACITOR:

Inductor Peak-to-Peak Current Ripple Factor (i.e. 0.2 for 20%, 0.3 for 30%). Percentage of minimum input, maximum load, inductor current at 50% duty cycle operating point, not recommended to be > 0.4:

L_{I_ripple_factor(target)}

0.3

Maximum High Frequency Voltage Ripple Factor (i.e. 0.03 for 3%, 0.09 for 9%):

V_{Cin_ripple_factor}

0.07

Target Maximum Allowable Inductor Current Ripple:

I_{RIPPLE(target)}

16.233

Maximum Inductor Voltage Ripple:

V_{IN_RIPPLE}

17.423

Recommended Input Capacitor Value:

C_{IN(recommended)}

4.700

Actual Value of Input Capacitor Used:

C_IN

0.330

µF

Required Minimum Voltage Rating for C_IN:

V_CIN(rating)

412.243

BOOST INDUCTOR DESIGN:

Maximum Duty Cycle:

DUTY_(max)

0.336

Maximum Inductor Peak Current:

I_{L_PEAK(max)}

62.226

Minimum Recommended Boost Inductor Value:

L_{BST(recommended)}

0.255

Actual Boost Inductor Value Used:

L_BST(actual) =

0.5

Actual Maximum Inductor Ripple Current:

I_{RIPPLE(actual)}

8.282

Actual Maximum Inductor Peak Current:

I_{L_PEAK(actual)}

58.251

Resultant Inductor Current Ripple Factor:

L_{I_ripple_factor(actual)}

0.153

BOOST DIODE:

Forward Voltage Drop, at I_{L_PEAK(max)},125°C:

V_F

Reverse Recovery Charge:

Q_RR

Boost Diode Maximum Junction Temperature:

T_J(max)

125

°C

Boost Diode Thermal Resistance, Junction to Case:

R_q_JC(Diode)

1.5

°C/W

Boost Diode Thermal Resistance, Case to Heatsink:

R_q_CHS(Diode)

0.32

°C/W

Boost Diode Conduction Losses:

P_DIODE(cond)

16.000

Reverse Recovery Losses:

P_REVERSE

0.000

Total Boost Diode Losses:

P_DIODE(total)

16.000

Required Heat Sink Thermal Impedance:

R_q_{HS_AMB(Diode)}

2.868

°C/W

Required Diode Blocking Voltage:

V_BLOCKING

412.500

SWITCHING ELEMENT:

VCC Bias Voltage to the UCC28180:

VCC

Gate-Source Voltage:

V_GS

15.2

Drain-Source RMS Current:

I_{DS_RMS}

22.526

FET On-Resistance at T_J = 125°C:

R_DSon

0.35

FET Gate Charge at V_GS:

Q_g

FET Rise Time:

t_r

FET Fall Time:

t_f

4.5

FET Output Capacitance:

C_OSS

780

FET Maximum Junction Temperature:

T_J(max)

125

°C

FET Thermal Resistance, Junction to Case:

R_q_JC(FET)

0.61

°C/W

FET Thermal Resistance, Case to Heatsink:

R_q_CHS(FET)

0.32

°C/W

Gate Drive Losses (actually dissipated in the gate drive circuitry):

P_GATE

0.030

FET Conduction Losses:

P_COND

177.595

FET Switching Losses:

P_SW

3.424

FET Losses, Total:

P_FET

181.019

Required Heat Sink Thermal Impedance:

R_q_{HS_AMB(FET)}

-0.516

°C/W

CURRENT SENSE RESISTOR:

Ideal Value for R_SENSE, for 110% Inductor SOC Threshold:

R_SENSE(ideal)

0.004

Actual Value for R_SENSE: Current Sense Resistor:

R_SENSE

0.003

Inductor Current at Soft Over-Current Threshold:

I_OVERCURRENT__SOC

86.333

Power Dissipated in R_SENSE:

P_Rsense

4.392

Theoretical Output Over-Current Inception Point:

I_{OUT_OVERCURRENT}

24.435

Maximum ISENSE Peak Current Limit Threshold:

I_PCL

146.000

Resistance of Thermistor at 25°C:

R_THERM

Maximum Inrush Current:

I_INRUSH

74.953

Recommended ISENSE Series Resistor:

R_ISENSE

220

Recommended ISENSE Filter Capacitor:

C_ISENSE

3900

OUTPUT CAPACITOR:

Required Minimum Output Voltage:

V_{OUT_HOLDUP(min)}

280

Desired Number of Line Cycles For Output Holdup Time (typ one line cycle):

N_{HOLD_UP}

Minimum Output Voltage Holdup Time:

t_{Hold_UP(min)}

21.277

Recommended Minimum Output Capacitor Value:

C_{OUT(recommended)}

3900.000

µF

Actual Output Capacitor Value:

C_OUT

2790

µF

Output Voltage Peak to Peak Ripple:

V_{OUT_RIPPLEpp}

9.710

Good! Output voltage peak-peak ripple is less than 5% VOUT

Output Capacitor Ripple Current at Twice Line Frequency:

I_{Cout_2fline}

11.314

A_RMS

Output Capacitor High Frequency Ripple Current:

I_{Cout_HF}

16.455

A_RMS

Total Output Capacitor Ripple Current:

I_{Cout_RMS(total)}

19.969

A_RMS

OUTPUT VOLTAGE SET POINT:

Recommended Value for the Top Divider Resistor:

R_{FB1(recommended)}

Actual Value of the Top Divider Resistor:

R_FB1(actual)

1.32

Recommended Value for the Bottom Divider Resistor (E48 Series):

R_{FB2(recommended)}

17.800

Actual Value of the Bottom Divider Resistor:

R_FB2(actual)

Actual Nominal Output Voltage:

V_OUT

371.667

Minimum Output Voltage with respect to V_REF:

V_OUT(min)

366.463

Maximum Output Voltage with respect to V_REF:

V_OUT(max)

376.870

OVP Set Point: Typical DC Output Voltage to Trigger OVP:

V_OVP

405.117

UVD Set Point: Typical DC Output Voltage to Trigger UVD:

V_UVD

353.083

Recommended Value for Filter Capacitor on VSENSE:

C_VSENSE

560.000

Power Dissipated in Voltage Divider:

P_RfB1+RFB2

0.103

DO NOT PROCEED UNTIL RFB2 IS DECREASED SO MINIMUM OUTPUT VOLTAGE > MAXIMUM RECTIFIED INPUT VOLTAGE

COMPENSATION:

The Loop will be Optimized at a Selected Specific Line Voltage. For a Wide Input Range, Optimization is Recommended at the Mean of Min and Max Input. For a Design with a Specific Nominal Line Voltage, Optimize at that Nominal Voltage. VCOMP at Any Line Voltage or as a Function of Load is Shown at Right

Line Voltage for Optimized Loop Design:

V_INnom

220.5

Open Loop Transfer Function for Current Loop:

Product of the Voltage Loop Variables:

M₁M₂

0.060

V/ms

VCOMP Voltage at V_INnom:

VCOMP

2.457

Internal Current Loop Gain Factor M₁:

M₁

0.368

Internal Voltage Loop PWM Ramp Slope M₂:

M₂

0.163

V/ms

Non-Linear Gain Voltage Loop Variable M₃:

M₃

0.112

V/ms

Maximum Recommended ICOMP Capacitor Value:

C_{ICOMPmax(recommended)}

0.015

µF

Minimum Recommended ICOMP Capacitor Value:

C_{ICOMPmin(recommended)}

6800.000

Actual Value Used for ICOMP Capacitor:

C_{ICOMP(actual)}

1000

Resultant Actual Current Averaging Pole Frequency:

f_IAVG(actual)

7.949

kHz

Open Loop Transfer Function for Voltage Loop:

PWM to Power Stage Pole:

f_{PWM_PS(pole)}

2.729

Desired Voltage Loop Crossover Frequency ( f_V < 20Hz):

f_V

Open Loop Voltage Gain at Desired f_V:

G_VLdB(f_V)

9.607

Recommended Value for the Voltage Compensation Capacitor:

C_{VCOMP(recommended)}

10.000

µF

Actual Value Used for C_VCOMP Capacitor:

C_{VCOMP(actual)}

Recommended Value for the Voltage Compensation Resistor:

R_{VCOMP(recommended)}

5.900

Actual Value Used for R_VCOMP Resistor:

R_{VCOMP(actual)}

Resultant Value of Voltage Compensation Zero:

f_ZERO

1.592

Desired Voltage Compensation Pole (f_Pole < 50Hz):

f_POLE

Recommended Value for the Parallel Voltage Compensation Capacitor:

C_{VCOMP_P(recommended)}

1.000

µF

Actual Value for the Parallel Voltage Compensation Capacitor:

C_{VCOMP_P(actual)}

INPUT:
Minimum Input Voltage from AC Line:	V_ACIN(min)	176	V_RMS
Maximum Input Voltage from AC Line:	V_ACIN(max)	265	V_RMS
Minimum Line Frequency:	f_LINE(min):	47	Hz
Maximum Line Frequency:	f_LINE(max):	63	Hz
Minimum Rectified AC Line Voltage:	V_{IN_PEAK(min)}	248.902	V
Maximum Rectified AC Line Voltage:	V_{IN_PEAK(max)}	374.767	V


OUTPUT:
Maximum Output Power of PFC Stage:	P_OUT(max)	6000	W
Output Voltage (Note: Must be > V_{IN_RECTIFIED(max)}):	V_OUT	375	V
Target Power Factor, V_IN(nom), Full Load:	PF	0.99
Predicted Efficiency:	h	0.9
Maximum Ambient Temperature:	T_AMB(max)	50	°C
Maximum Average Output Current of PFC Stage:	I_OUT	16.000	A
Desired Switching Frequency:	f_SW(target)	22	kHz
Recommended Resistor value on FREQ to Set the Switching Frequency, f_SW:	R_{FREQ(recommended)}	105.000	kΩ
Actual Value For R_FREQ Used:	R_FREQ =	100	kΩ
Resultant Switching Frequency, f_SW:	f_SW	22.640	kHz


Line Current:
Maximum Input Power Drawn from the Line:	P_IN(max)	6666.667	W
Maximum RMS AC Line Current:	I_{IN_RMS(max)}	38.261	A
Maximum Peak AC Line Current, assuming sinusoidal:	I_{IN_PEAK(max)}	54.110	A
Maximum Average AC Line Current, assuming sinusoidal:	I_{IN_AVG(max)}	34.447	A
Minimum Input Fuse Rating:	I_FUSE	57.392	A


BRIDGE RECTIFIER:
Bridge Rectifier Forward Voltage, at I_{IN_PEAK(max)}:	V_{F_BRIDGE}	1	V
Bridge Rectifier Thermal Resistance, Junction to Case:	R_q_JC(Bridge)	2.2	°C/W
Case to Heatsink Thermal Resistance:	R_{θCHS(Bridge)}	0.61	°C/W
Bridge Rectifier Maximum Junction Temperature:	T_J(max)	125	°C
Bridge Rectifier Minimum Average Current Rating:	I_{BRIDGE(rated)}	51.671	A
Bridge Rectifier Minimum DC Blocking Voltage Rating:	V_{DC_BLOCKING(rated})	412.243	V
Bridge Rectifier Power Dissipation:	P_BRIDGE	68.895	W
Required Heat Sink Thermal Impedance:	R_q_{HS_AMB(Bridge)}	-1.721	°C/W


INPUT CAPACITOR:
Inductor Peak-to-Peak Current Ripple Factor (i.e. 0.2 for 20%, 0.3 for 30%). Percentage of minimum input, maximum load, inductor current at 50% duty cycle operating point, not recommended to be > 0.4:	L_{I_ripple_factor(target)}	0.3
Maximum High Frequency Voltage Ripple Factor (i.e. 0.03 for 3%, 0.09 for 9%):	V_{Cin_ripple_factor}	0.07
Target Maximum Allowable Inductor Current Ripple:	I_{RIPPLE(target)}	16.233	A
Maximum Inductor Voltage Ripple:	V_{IN_RIPPLE}	17.423	V
Recommended Input Capacitor Value:	C_{IN(recommended)}	4.700	mF
Actual Value of Input Capacitor Used:	C_IN	0.330	µF
Required Minimum Voltage Rating for C_IN:	V_CIN(rating)	412.243	V


BOOST INDUCTOR DESIGN:
Maximum Duty Cycle:	DUTY_(max)	0.336
Maximum Inductor Peak Current:	I_{L_PEAK(max)}	62.226	A
Minimum Recommended Boost Inductor Value:	L_{BST(recommended)}	0.255	mH
Actual Boost Inductor Value Used:	L_BST(actual) =	0.5	mH
Actual Maximum Inductor Ripple Current:	I_{RIPPLE(actual)}	8.282	A
Actual Maximum Inductor Peak Current:	I_{L_PEAK(actual)}	58.251	A
Resultant Inductor Current Ripple Factor:	L_{I_ripple_factor(actual)}	0.153


BOOST DIODE:
Forward Voltage Drop, at I_{L_PEAK(max)},125°C:	V_F	1	V
Reverse Recovery Charge:	Q_RR	0	nC
Boost Diode Maximum Junction Temperature:	T_J(max)	125	°C
Boost Diode Thermal Resistance, Junction to Case:	R_q_JC(Diode)	1.5	°C/W
Boost Diode Thermal Resistance, Case to Heatsink:	R_q_CHS(Diode)	0.32	°C/W
Boost Diode Conduction Losses:	P_DIODE(cond)	16.000	W
Reverse Recovery Losses:	P_REVERSE	0.000	W
Total Boost Diode Losses:	P_DIODE(total)	16.000	W
Required Heat Sink Thermal Impedance:	R_q_{HS_AMB(Diode)}	2.868	°C/W
Required Diode Blocking Voltage:	V_BLOCKING	412.500	V


SWITCHING ELEMENT:
VCC Bias Voltage to the UCC28180:	VCC	16	V
Gate-Source Voltage:	V_GS	15.2	V
Drain-Source RMS Current:	I_{DS_RMS}	22.526	A
FET On-Resistance at T_J = 125°C:	R_DSon	0.35	W
FET Gate Charge at V_GS:	Q_g	87	nC
FET Rise Time:	t_r	5	ns
FET Fall Time:	t_f	4.5	ns
FET Output Capacitance:	C_OSS	780	pF
FET Maximum Junction Temperature:	T_J(max)	125	°C
FET Thermal Resistance, Junction to Case:	R_q_JC(FET)	0.61	°C/W
FET Thermal Resistance, Case to Heatsink:	R_q_CHS(FET)	0.32	°C/W
Gate Drive Losses (actually dissipated in the gate drive circuitry):	P_GATE	0.030	W
FET Conduction Losses:	P_COND	177.595	W
FET Switching Losses:	P_SW	3.424	W
FET Losses, Total:	P_FET	181.019	W
Required Heat Sink Thermal Impedance:	R_q_{HS_AMB(FET)}	-0.516	°C/W


CURRENT SENSE RESISTOR:
Ideal Value for R_SENSE, for 110% Inductor SOC Threshold:	R_SENSE(ideal)	0.004	W
Actual Value for R_SENSE: Current Sense Resistor:	R_SENSE	0.003	W
Inductor Current at Soft Over-Current Threshold:	I_OVERCURRENT__SOC	86.333	A
Power Dissipated in R_SENSE:	P_Rsense	4.392	W
Theoretical Output Over-Current Inception Point:	I_{OUT_OVERCURRENT}	24.435	A
Maximum ISENSE Peak Current Limit Threshold:	I_PCL	146.000	A
Resistance of Thermistor at 25°C:	R_THERM	5	W
Maximum Inrush Current:	I_INRUSH	74.953	A
Recommended ISENSE Series Resistor:	R_ISENSE	220	W
Recommended ISENSE Filter Capacitor:	C_ISENSE	3900	pF


OUTPUT CAPACITOR:
Required Minimum Output Voltage:	V_{OUT_HOLDUP(min)}	280	V
Desired Number of Line Cycles For Output Holdup Time (typ one line cycle):	N_{HOLD_UP}	1
Minimum Output Voltage Holdup Time:	t_{Hold_UP(min)}	21.277	ms
Recommended Minimum Output Capacitor Value:	C_{OUT(recommended)}	3900.000	µF
Actual Output Capacitor Value:	C_OUT	2790	µF
Output Voltage Peak to Peak Ripple:	V_{OUT_RIPPLEpp}	9.710	V
Good! Output voltage peak-peak ripple is less than 5% VOUT
Output Capacitor Ripple Current at Twice Line Frequency:	I_{Cout_2fline}	11.314	A_RMS
Output Capacitor High Frequency Ripple Current:	I_{Cout_HF}	16.455	A_RMS
Total Output Capacitor Ripple Current:	I_{Cout_RMS(total)}	19.969	A_RMS


OUTPUT VOLTAGE SET POINT:
Recommended Value for the Top Divider Resistor:	R_{FB1(recommended)}	1	MW
Actual Value of the Top Divider Resistor:	R_FB1(actual)	1.32	MW
Recommended Value for the Bottom Divider Resistor (E48 Series):	R_{FB2(recommended)}	17.800	kW
Actual Value of the Bottom Divider Resistor:	R_FB2(actual)	18	kW
Actual Nominal Output Voltage:	V_OUT	371.667	V
Minimum Output Voltage with respect to V_REF:	V_OUT(min)	366.463	V
Maximum Output Voltage with respect to V_REF:	V_OUT(max)	376.870	V
OVP Set Point: Typical DC Output Voltage to Trigger OVP:	V_OVP	405.117	V
UVD Set Point: Typical DC Output Voltage to Trigger UVD:	V_UVD	353.083	V
Recommended Value for Filter Capacitor on VSENSE:	C_VSENSE	560.000	pF
Power Dissipated in Voltage Divider:	P_RfB1+RFB2	0.103	W

0 John Griffin1 over 6 years ago in reply to user5010576

TI__Mastermind 34465 points

Please test your circuit with a resistive load.

It may be that your BLDC load is non-linear and causing the strange waveform on the input.

What were the test conditions for your so-called "normal" and "distorted" waveforms ?

Regards

John

Power management

Power management forum

UCC28180: UCC28180 failure issue