7.3.1 Detailed Pin Description

This pin is also used to sense the output constant current under voltage (CCUV) level, used to shut down the converter in the case of a soft-short circuit at its output. Refer to Constant Current Under-Voltage Protection for further information.

7.3.2 Primary-Side Regulation (PSR)

Figure 12 illustrates a simplified flyback convertor with the main voltage regulation blocks of the device shown. The power train operation is the same as any DCM flyback circuit but accurate output voltage and current sensing is the key to primary-side control.

In primary-side control, the output voltage is sensed on the auxiliary winding during the transfer of transformer energy to the secondary. As shown in Figure 13 during this time, the auxiliary winding voltage has a down slope representing a decreasing total rectifier forward voltage drop V_F and resistance voltage drop (I_SR_S) as the secondary current decreases to zero. To achieve an accurate representation of the secondary output voltage on the auxiliary winding, the discriminator reliably blocks the leakage inductance reset and ringing, continuously samples the auxiliary voltage during the down slope after the ringing is diminished, and captures the error signal at the time the secondary winding reaches zero current. The internal reference on VS is 4.06 V; the resistor divider is selected as outlined in the VS pin description.

The UCC28704 VS signal sampler includes signal discrimination methods to ensure an accurate sample of the output voltage from the auxiliary winding. There are however critical details of the auxiliary winding signal to ensure reliable operation, specifically the reset time of the leakage inductance and the duration of any subsequent leakage inductance ring. Refer to Figure 14 for a detailed illustration of waveform criteria to ensure a reliable sample on the VS pin. The first detail to examine is the duration of the leakage inductance reset pedestal, T_{LK_RESET} in Figure 14. Since this can mimic the waveform of the secondary current decay, followed by a sharp downslope, it is important to keep the leakage reset time less than 750 ns for I_PRI minimum, and less than 3.0 µs for I_PRI maximum. The second detail is the amplitude of ringing on the V_AUX waveform following t_{LK_RESET}. The peak-to-peak voltage at the VS pin should be less than approximately 250 mV_p-p at least 250 ns before the end of the demagnetization time, t_DMAG. If there is a concern with excessive ringing, it usually occurs during light or no load conditions, when t_DMAG is at the minimum, t_DMAG(min). The tolerable ripple on VS is scaled up to the auxiliary winding voltage by R_S1 and R_S2, and is equal to 250 mV × (R_S1+R_S2) / R_S2. The snubber designs can be designed to allow the ripple voltage to meeting these requirements.

As mentioned in Device Functional Modes, when I_PP < I_PP(max), the device operation enters a “Wait” state during each switching cycle of its non-switching portion as shown in Figure 14. In the Wait state, the device bias current changes to I_WAIT (typical 70 µA) from I_RUN (typical 2.3 mA), reducing its bias power to help boost efficiency at light load and to reduce standby load power.

7.3.3 Primary-Side Constant Voltage (CV) Regulation

During voltage regulation (CV mode), the controller operates in frequency modulation mode and peak current amplitude modulation mode as illustrated in Figure 15 below. The UCC28704 incorporates internal voltage-loop compensation circuits so that external compensation is not necessary, provided that the value of C_OUT is high enough. The following equation determines a minimum value of C_OUT necessary to maintain a phase margin of about 40 degrees over the full-load range,

The internal operating frequency limits of the device are f_SW(max) and f_SW(min), typically 85 kHz and 1 kHz, respectively. The choice of transformer primary inductance and primary-peak current sets the maximum operating frequency of the converter, which must be equal to or lower than f_SW(max). Conversely, the choice of maximum target operating frequency and primary-peak current determines the transformer primary-inductance value. The actual minimum switching frequency for any particular converter depends on several factors, including minimum loading level, leakage inductance losses, switch-node capacitance losses, other switching and conduction losses, and bias-supply requirements. In any case, the minimum steady-state frequency of the converter must always exceed f_SW(min) or the output voltage may rise to the over-voltage protection level (OVP) and the controller responds as described in Fault Protection.

To achieve a regulated output voltage in the CV mode operation, energy balance has to be maintained. As the UCC28704 has a minimum switching frequency typical 1 kHz, together with the energy per switching cycle determined by converter parameters, such as the transformer primary inductance Lp and the selected R_CS resistor, the converter has a minimum input power. A proper pre-load needs to be selected to ensure that this minimum energy is balanced during the no-load condition. The selection of the line compensation resistor value (R_LC) connected to the CS pin can impact the energy per switching cycle based on low-line and high-line conditions. Typical Application section provides a design example to show how to implement these considerations.

In the CV mode operation, the cable compensation is in effect. The cable compensation is to adjust the output voltage at board-end to be higher than the no-load setup point, noted as V_OCV, then to compensate the voltage drop due to the cable resistance through which the load current I_O is flowing. The UCC28704 cable compensation is fixed at 6% of V_OCV at full load, and the board-end output voltage is described by Equation 6:

Due to the cable compensation, the output voltage at board-end is seen higher than V_OCV with a positive slope when load current I_O> 0. The output voltage at the cable's end can be flat, upturned, or downturned, depending on the cable total resistance in use. Primary-Side Constant Current (CC) Regulation has more descriptions on the cable compensation.

In CV mode operation, the control consists of four regions, namely, region 1 through 4. The device internal error op-amp output V_CL sets a particular region operation. Refer to Figure 12 for V_CL. The steady-state control-law voltage, V_CL, ranges between 1.3 V to 4.85 V. Heavy load operation is usually in region 4 where frequency modulation to output regulation is used and primary-peak current is controlled at its maximum. Region 3 is usually for medium-load range typically from 10% load and above. In this region switching frequency is fixed at nominal 25 kHz along with primary-peak current varying from 25% to 100% of its maximum. A low operating frequency range (region 2) is for lighter loads to achieve stable regulation at low frequencies. In region 2, peak-primary current is always maintained at I_PP(max)/4 in the lower frequency level. Transitions between levels are automatically accomplished by the controller depending on the internal control-law voltage, V_CL. During a load transient condition when V_CL > 4.85 V, the device operates in constant current mode. When load is in step-down transient demanding frequency lower than 4 kHz, first, the device stays at 4 kHz for up to 500 ms, or the output voltage reaches about 10% over the V_OCV within 500 ms, then the device adjusts the switching frequency to be lower than 4 kHz as needed. More details can be found in Load Transient Response.

7.3.4 Primary-Side Constant Current (CC) Regulation

Timing information at the VS pin and current information at the CS pin allow accurate regulation of the secondary average current. The control law dictates that as power is increased in CV regulation and approaching CC regulation the primary-peak current is at I_PP(max). Referring to Figure 16 below, the primary peak current (I_PP), turns-ratio (N_S/N_P), secondary demagnetization time (t_DMAG), and switching period (t_SW) determine the secondary average output current. Ignoring leakage inductance effects, the average output current is given by Equation 7. By regulating the secondary rectifier conduction duty cycle, the output average current is constant for given I_PP and transformer turns-ratio. When the load increases, the secondary-side rectifier conduction duty cycle keep increasing. Once it reaches preset value of 0.475, the converter switching frequency is then reduced to maintain 0.475 secondary-side duty cycle. Therefore, the output current is kept constant. Because the current is kept constant, the increasing load results in lower output voltage. Converter can shut down in this condition if the output voltage drops below CCUV protection level, or UCC28704 VDD drops below its UVLO turn-off threshold.

As shown in Figure 17 below, CV mode operation is from I_O = 0 to I_OCC; at I_O = I_OCC, the operation enters CC mode and V_O starts to drop as the load resistance becomes further lower while I_O is maintained at I_OCC until Vo reaches the CCUV threshold. Details of the CCUV operation are given in Constant Current Under-Voltage Protection. Figure 17 shows the output at board-end and at cable-end. The cable compensation nominally compensates 300 mV for a 5V-output at the I_OCC level.

7.3.5 Valley-Switching and Valley-Skipping

The UCC28704 utilizes valley switching to reduce switching losses in the MOSFET, reduce induced-EMI, and minimize the turn-on current spike at the sense resistor. The controller operates in valley-switching in all load conditions unless the V_DS ringing diminished.

Referring to Figure 18 below, the UCC28704 operates in a valley-skipping mode in most load conditions to maintain an accurate voltage or current regulation point and still switch on the lowest available V_DS voltage.

The UCC28704 forces a controlled minimum switching period corresponding to the power supply operating frequency. In each switching cycle, after the minimum period is expired, the UCC28704 looks for the next resonant valley on the auxiliary winding. The controller initiates a new power cycle at this valley point which corresponds to a reduced voltage level on the power MOSFET. If at the point in time when the minimum period expires ringing on the transformer winding has decayed such that no further resonant valleys can be detected a new power cycle is initiated following a fixed time, t_ZTO.

7.3.6 Start-Up Operation

Upon application of input voltage to the converter, the start up resistance connected to VDD from the bulk capacitor voltage (V_BULK) charges the VDD capacitor. During charging of the VDD capacitor, the device supply current is less than 1.5 µA. When VDD reaches the 21-V UVLO turn-on threshold, the controller is enabled and the converter starts switching. The peak-primary currents with initial three cycles are limited to I_PP(min). This allows sensing any initial input or output faults with minimal power delivery. When confirmed that the input voltage is above the programmed converter turn-on voltage and with no faults detected, the start-up process proceeds and normal power conversion follows. The converter remains in discontinuous conduction mode operation during charging of the output capacitor(s), maintaining a constant output current until the output voltage is in regulation.

Initial power-on to the UCC28704 device is achieved by one of the two approaches that are described in Initial Power-On with a Start-Up Resistor and Initial Power-On with A Depletion-Mode FET.

7.3.7 Fault Protection

There is comprehensive fault protection incorporated into the UCC28704. Protection functions include:

• Output Over-Voltage
• Input Under-Voltage
• Primary Over-Current Fault
• CS Pin Open Fault
• CS Pin Short-to-GND Fault
• VS Pin Fault
• External NTC Over-Temperature
• Device Internal Over-Temperature
• Constant Current Under Voltage Output Shutdown (CCUV) for Soft-Short Protection

Output Over-Voltage: The output over-voltage function is determined by the voltage feedback on the VS pin. If the voltage sample on VS exceeds 4.67 V, 115% of the nominal regulating level, for three consecutive switching cycles an OV fault is asserted. Once asserted the device stops switching, initiating a UVLO reset and re-start fault cycle. During the fault, the VDD bias current remains at the run current level, discharging the VDD pin to the UVLO turn-off threshold, V_VDD(off). After that, the device returns to the start state, VDD now charging to V_VDD(on) where switching is initiated. The UVLO sequence repeats as long as the fault condition persists.

Input Under-Voltage: The line input run and stop thresholds are determined by current information at the VS pin during the MOSFET on-time. While the VS pin is clamped close to GND during the MOSFET on-time, the current through R_S1, out of the VS pin, is monitored to determine a sample of the bulk capacitor voltage. A wide separation of run and stop thresholds allows clean start-up and shut-down of the power supply with the line voltage. From the start state, the sensed VS current, I_VSL, must exceed the run current threshold, I_VSL(run) (typical 220 µA), within the first three cycles after switching starts as VDD reaches V_VDD(on). If it does not, then switching stops and the UVLO reset and re-start fault cycle is initiated. Once running, I_VSL must drop below the stop level, I_VSL(stop) (typically 80 µA), for three consecutive cycles to initiate the fault response.

Primary Over-Current: The UCC28704 always operates with cycle-by-cycle primary-peak current control. The normal operating range of the CS pin is 0.75 V to 0.188 V. If the voltage on CS exceeds the 1.5-V over-current level, any time after the internal leading edge blanking time and before the end of the transformer demagnetization, for three consecutive cycles the device shuts down and the UVLO reset and re-start fault cycle begins.

CS Pin Open: The CS pin has a 2-µA minimum pull-up that brings the CS pin above the 1.5-V OC fault level if the CS pin is open. This causes the primary over-current fault after three cycles.

CS Pin Short to GND: On the first, and only the first cycle at start-up, the device checks to verify that the V_CST(min) threshold is reached at the CS pin within 4 µs of DRV going high. If the CS voltage fails to reach this level then the device terminates the current cycle and immediately enters the UVLO reset and re-start fault sequence.

VS Pin: Protection is included in the event of component failures on the VS pin. If the high-side VS divider resistor opens the controller stops switching. VDD collapses to its V_VDD(off) threshold, a start-up attempt follows with a single DRV on-time when VDD reaches V_VDD(on). The UVLO cycle will repeat. If the low-side VS divider resistor is open then an output over-voltage fault occurs.

NTC Over-Temperature: UCC28704 uses the NTC/SU pin to program thermal shutdown threshold with an external NTC thermistor on this pin. The NTC shutdown threshold is 0.95 V with an internal 105-µA current source which results in a 9.05-kΩ thermistor shutdown threshold. If the NTC/SU pin voltage is below 0.95 V at the end of the secondary current demagnetization time for three consecutive cycles switching stops and the UVLO reset and re-start fault sequence is initiated.

Device Internal OTP: The internal over-temperature protection threshold is 150°C. If the junction temperature of the device reaches this threshold the device initiates the UVLO reset and re-start fault cycle. If the temperature is still high at the end of the UVLO cycle, the protection cycle repeats.

Constant Current Under-Voltage: Output shutdown (CCUV) for soft-short protection. Constant Current Under-Voltage Protection provides detailed description for this fault and fault response.

7.3.8 Constant Current Under-Voltage Protection

The constant current output under voltage shutdown (CCUV) feature is to provide protection for USB connectors from over-heat or burn-out due to soft-short circuit fault. A partial or soft-short can happen due to the presence of foreign objects at the terminals of the USB upstream facing port, UFP, for example, smartphones with USB Micro-B or USB Type-C connectors. When this happens along with the converter operates in CC mode with enough VDD voltage (VDD > V_VDD(off)) available from auxiliary winding, the converter can sustain operation at this condition resulting in a potential USB burn-out condition which is named as soft-short fault to distinguish from a hard-short circuit fault. Traditional over-current protection and short-circuit protection cannot tell a soft-short fault. The UCC28704 provides protection when soft-short circuit fault occurs with the corresponding converter V-I characteristics as shown in Figure 21.

As shown in Figure 22, the CCUV feature of UCC28704 detects the operation of the converter under this condition when the controller is operating in CC mode and when the output voltage drops out of regulation, reaching the CCUV threshold. If the controller detects that the VS pin voltage is below V_CCUV threshold continuously for 120 ms, then it initiates a CCUV fault and sets the CCUV latch. Once the CCUV latch is set, the controller goes through 3 cycles of VDD-UVLO without any PWM operation and clears the latch on the 4th VDD UVLO power-up. If the CCUV condition still exists, then the controller enters into CCUV fault after 120 ms and repeats the UVLO cycles. This 120-ms time delay allows converter normal start up without triggering the CCUV protection. The flyback design should allow output voltage rise above CCUV protection level under normal operating conditions within 120ms or the CCUV fault may be triggered.

7.3.9 Load Transient Response

The UCC28704 can provide excellent transient performance for most load steps. However the response of PSR controller is always limited by the operating frequency of the converter, since the controller only samples or reads the output voltage once every switching cycle. At zero external load, or standby, the operating frequency is set by any preload together with the bias power needed. This frequency, f_SW(standby), sets a maximum incremental response delay. The preload can always be adjusted, at the expense of standby power, to increase the standby frequency.  The actual response delay depends on the relative timing of the load step within the switching cycle. Thus for a given load step, I_OUT(step), the output deviation can be as large as:

In the case of repeating load transients the situation is aggravated. Whenever the load steps from a modest current level to zero, there is a period of time when there is a slight over-shoot in the output voltage and the control loop saturates and force the converter operating at to its minimum switching frequency, f_SW(min), or 1 kHz regardless what preload setting is. If the next positive load step occurs during this time the output deviation will be larger, remembering that f_SW(standby) must be > f_SW(min).

A special transient response algorithm in this controller dynamically adjusts the minimum controlled switching frequency, such that during a mid to high current level condition the loop's minimum switching frequency is raised to f_SW(lim), typically 4 kHz.  This raised minimum switching frequency is maintained following a load step-down change until the output voltage rises momentarily to 10% above its normal regulating level or has stayed above its normal regulating level for 500 ms. During this time the response to a load step-up change benefits from the decreased response delay afforded by the 4-kHz switching frequency. This is illustrated in Figure 23. Application Curves provides test results and further description in regarding to this technique.

NOTE

In applications where standby power is not critical the minimum operating frequency of the loop can be kept higher than 4 kHz. In these cases controller will continuously maintain a 4-kHz minimum frequency.