600 W Ha lf B ridg e L L C E v alu ati on B o ar d wi th 600 V C o ol MOS™ C7 Authors: Steiner Alois Di Domenico Francesco Catly Johnald Stückler Franz Application Note About this document Scope and purpose The present 600 W Evaluation Board is a great example of a full Infineon solution, including high voltage and low voltage power devices, controllers and drivers in order to demonstrate the most flexible and effective way to design the High Voltage DC/DC stage of a Server PSU fulfilling the 80Plus® Titanium Standard. Furthermore the reader will get additional information how the 600 V CoolMOS™ C7 behaves in this LLC board and what benefits will be achieved. Intended audience This document is intended for design engineers who want to improve their high voltage power conversion applications. Table of Contents 1 Introduction ................................................................................................................................... 3 2 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.7 2.8 2.9 HB LLC Converter Design Considerations ...................................................................................... 4 Principle of operation ......................................................................................................................... 4 Input design data ................................................................................................................................ 5 Selection of the inductance factor m ................................................................................................. 6 Gain curve ............................................................................................................................................ 6 Resonant components calculation..................................................................................................... 6 The ZVS behavior: energy and time considerations .......................................................................... 7 Energy related equations.............................................................................................................. 7 Time related equations ................................................................................................................. 7 The main transformer design ............................................................................................................. 8 The resonant choke design ............................................................................................................... 10 The Synchronous Rectification Stage .............................................................................................. 11 3 3.1 3.2 3.2.1 Board description ........................................................................................................................ 12 General overview............................................................................................................................... 12 Infineon BOM ..................................................................................................................................... 13 Primary HV MOSFETs CoolMOSTM IPP60R180C7......................................................................... 13 1 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Introduction 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.3 3.3.1 3.3.2 3.3.3 LLC analog controller ICE2HS01G .............................................................................................. 13 Half Bridge Gate Drive 2EDL05N06PF ......................................................................................... 13 Advanced dual-channel Gate Drive 2EDN7524F ........................................................................ 14 Bias QR Flyback controller ICE2QR2280Z................................................................................... 15 Synchronous Rectification MOSFETs OptiMOSTM BSC010N04LS............................................... 15 Board schematic................................................................................................................................ 16 Mainboard schematic ................................................................................................................. 16 Control board schematic ............................................................................................................ 17 Biasboard schematic .................................................................................................................. 18 4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 Typical characteristics with 600 V CoolMOS™ C7.......................................................................... 20 Critical LLC operation - hard commutation ..................................................................................... 20 Full ZVS area ...................................................................................................................................... 21 Burstmode operation ........................................................................................................................ 21 Efficiency ........................................................................................................................................... 22 Titanium Efficiency ..................................................................................................................... 22 Efficiency comparison in resonant LLC Half Bridge ................................................................... 23 5 Test/powerup procedure ............................................................................................................. 24 6 Useful material and links.............................................................................................................. 26 7 References ................................................................................................................................... 27 8 List of abbreviations..................................................................................................................... 28 Application Note 2 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Introduction 1 Introduction The opportunity to significantly reduce the size of power converters by increasing the switching frequency created by the MOSFET technology has recently focused topology development and optimization on the reduction of switching losses of the semiconductor devices, which are perceived as the major obstacle to maximizing the switching frequency of PWM converters. This has triggered studies on the resonant power conversion, which allows minimizing the switching losses through the achievement of zero-voltage (ZVS) or zero-current (ZCS) switching behavior. An important example of resonant power conversion is provided by the LLC topology, which is able to address the requirements of high efficiency and power density through the achievement of a true Zero Voltage Switching. Last but not least, its bill of material is significantly reduced compared to the other very popular soft switching topology, the phase shift Full Bridge. These arguments bring the LLC resonant converter more and more in usage in the server/telecom market. This document will describe an analog controlled 600 W Half Bridge (HB) LLC converter designed using Infineon products. Order information for ISAR: EVAL_600W_12V_LLC_C7 Application Note 3 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations 2 HB LLC Converter Design Considerations In the present chapter the most relevant design decisions are explained and documented with related calculations. 2.1 Principle of operation The principle schematic of a Half Bridge LLC converter is shown in the Figure 1. Cr, Lr and Lm represent the so called “resonant tank”: together with the main transformer they are the key components in the LLC design. The primary Half Bridge and the secondary synchronous rectification are the other two stages to be defined. Figure 1 Principle schematic of a Half Bridge LLC converter The LLC is a resonant converter that means it operates with frequency modulation, instead of the Pulse Width Modulation (PWM), traditional approach to power conversion. Starting point in a resonant converter design is the definition of an energy transfer function, which can be seen as a voltage gain function, so a mathematical relationship between input and output voltages of the converter. Trying to get this function in an “exact” way involves several nonlinear circuital behaviors governed by complex equations. However, under the assumption that the LLC operates in the vicinity of the series resonant frequency important simplifications can be introduced. In fact, under this assumption, the current circulating in the resonant tank can be considered purely sinusoidal, ignoring all higher order harmonics: this is the so called First Harmonic Approximation Method (FHA), which is the most common approach to the design of a LLC converter. In the FHA the voltage gain is calculated with reference to the following equivalent resonant circuit, shown in Figure 2. Figure 2 First Harmonic Approximation equivalent resonant circuit Application Note 4 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations The mathematical expression of the gain K is: K (Q, m, Fx) Vo _ ac( s) Fx ²(m 1) Vin _ ac( s) (m Fx ² 1)² Fx ² ( Fx ² 1)² (m 1)² Q² (1) where: m Lr Lm ; Lr fr 1 Lr Cr ; Fx fs ; fr Rac Lr 8 Np ² Ro ; ² Ns ² Q Cr ; Rac (2) So the resonant tank gain K can be plotted in function of the normalized switching frequency fx for different values of the Quality factor Q and any single value of the inductance factor m. In this chapter it will be shown a design procedure for the selection of the main LLC parameters, with the goal to achieve the best performance while fulfilling input and output regulation requirements. At same time, Zero Voltage Switching operation of the primary Half Bridge MOSFETs must be ensured, in order to get full benefits out of the soft switching behavior, especially at light load. 2.2 Input design data In Table 1 an overview of the major design parameter is displayed. Table 1 Design parameters Description Input Voltage Output Voltage Output Power Minimum 350 VDC 11.9 VDC Efficiency at 50% Pmax 97.5% Switching Frequency Dynamic Output Voltage regulation (0-90% Load step) Vout_ripple 90 kHz Nominal 380 VDC 12 VDC Maximum 410 VDC 12.1 VDC 600 W 150 kHz 250 kHz Max. overshoot = 0.1 V Max. undershoot= 0.3 V 150 mVpk-pk From the table above, the first important design parameters can be derived: Main transformer turn ratio Minimum needed Gain Maximum needed Gain Application Note n Np Vin _ nom 16 Ns 2 Vout _ nom (3) K min(Q, m, Fx) n Vo _ min 0.95 Vin _ max 2 (4) K max (Q, m, Fx) n Vo _ max 1.08 Vin _ min 2 (5) 5 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations 2.3 Selection of the inductance factor m The inductance factor (Equation 2) has an important impact on the converter operation. Lower values of m achieve higher boost gain and narrower range of the frequency modulation, that means more flexible control and regulation, which is valuable in applications with very wide input voltage range. On the other hand, this means also smaller values of Lm which leads into significantly high magnetizing current circulating in the primary side: this current doesn’t contribute to the power transferred, but mainly generates conduction losses on the primary side. In other words, there is a trade-off between flexible regulation and overall efficiency requirements, especially at light load. In the case of our demo board, main goal is to achieve high efficiency, so relatively high m is selected, also because the input range is relatively narrow and in any case we rely in the bulk capacitor in case of specific hold up time requirement at the complete AC/DC SMPS level - so in our case m≈12. 2.4 Gain curve The resulting gain curves, Figure 3, for loads between 10% and 100% Pmax are in the following plot: Figure 3 Gain curve Both the Mmin and Mmax limits cross all the gain curves of our LLC converter: that means the regulation is fully achieved in the specified ranges. 2.5 Resonant components calculation Combining equations (1) and (2), we get a system where the unknown are Lr, Cr and Lm. Solving it, the following values are set for the LLC converter: n Application Note Np Vin _ nom 16 Np 16; Ns 1 Ns 2 Vout _ nom 6 (6) Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations m Lr Lm 12 Lm 195H ; Lr 17 H Lr (7) Cr 66nF fr 2.6 1 (8) 150 KHz 2 Lr Cr (9) The ZVS behavior: energy and time considerations The ZVS calculations involve two kind of analysis, the one in the energy domain and the other in the time domain. The goal is to have enough energy in the resonant tank able to discharge the output capacitance of the primary MOSFET, but also an appropriate dead time between the turn-off of each device and the corresponding turn-on of the one at the other side of the Half Bridge. Co(er) is the Coss energy related component of the used High Voltage MOSFET, in our case IPP60R180C7. Qoss is the charge stored in Coss at Vin(nom)=380 VDC 2.6.1 Energy related equations Im ag _ min Enres _ min 2 2 n Vo 0.672 A 2 fsw _ max Lm (10) 1 ( Lm Lr ) I ² mag _ min 95.1J 2 (11) 1 (2Co(er )) V ² DS _ max 9J 2 (12) Encap _ max (13) Encap _ max Enres _ min 2.6.2 Time related equations It can be demonstrated that: tdead tecs 2 Qoss@ Vin_nom tecs 2 Co(tr )@ Vin_nom* Vin_nom 2 2 Im,pk Im,pk (14) where tdead is the dead time set between the conduction time of the two HB devices and tecs is the time when the channel of each MOSFET is still in conduction after turning it off (linear mode operation), which is function of device parameters like Vgs(th), Rg(tot) and Cgs/Cgd. Using that equation, together with the min and max values of the magnetizing current: Im ag _ min Application Note 2 2 n Vo 2 fsw _ max Lm 7 0.672 A (10) Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations Im ag _ max tdead , min 2 2 tecs n Vo 2 fsw _ min Lm 2 Qoss, @ 400V 2 tdead , max tecs (11) 130 ns (14) Im,ag , max 2 Qoss, @ 400V 2 2.7 1.66 A 311 ns (15) Im ag , min The main transformer design As explained more in details in the chapter 2.6 of the present document, the target efficiency of this design is fixed by the 80PLUS® Titanium Standard; that means fixing certain minimum requirements for the High Voltage DC/DC stage at 10%, 20%, 50%, 100% load conditions. The most critical condition for the main transformer is the full load, mainly due to thermal reasons. The selection of the core size and material is done according to this condition along with the power density (thus switching frequency) target and the available airflow. Keeping a margin in the design, the minimum efficiency requirement at full load is fixed for the Half Bridge LLC converter to 97%, which means our goal is to keep the total dissipated power in that condition below 18 W. In order to guarantee a balanced spread of power and heating, a good rule in the design of the LLC Converter is to keep the total power dissipated on the main transformer below 1/6 of the total dissipated power, which means the max allowed power on it shall be below 3 W. This is our first important design input. The max operating temperature is 55°C, as in typical server applications. Due to transformer safety insulation approvals, the max operating temperature of the transformer must be lower than 110°C, thereof: Ttrafo _ MAX (110 55)C 55C (16) From (16) and (17) the max thermal resistance of the core shape can be easily derived: Rth _ trafo _ MAX Ttrafo _ MAX 55 C 18.3C W W Ptrafo _ MAX 3 (17) So our selected core shape must have thermal resistance lower than 18.3°C/W. This requirement can be fulfilled with different choices: the preferred will allow maximizing the ratio between available winding area and effective volume, of course compatibly with the eq. (18). Also considering the power density target (in the range of 20 W/inch³), the most suitable selection is PQ 35/35, shown in Figure 4. The related coil form shows a minimum winding area of 1.58 cm² and a thermal resistance of 16.5°C/W, thus able to dissipate up to 3.33 W by keeping the ΔTMAX <55°C. Once verified that the thermal equations are fulfilled, we can proceed with the design of the primary and secondary windings and the core material selection, with some important goals: Fitting the geometry/overall dimensions of the core Fulfilling the condition (16) Try to split as much equally as possible the losses between core and windings: ideally “fifty-fifty” should be achieved at full load, but any percentage close to it would be acceptable. Application Note 8 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations Figure 4 TDK-Epcos PQ35/35 core The selected core material is the ferrite TDK PC95, showing a very interesting plot of Core Losses (PCV) vs. Flux Density vs. frequency (see Figure 5 below): The final structure of the main transformer is reported in Figure 6 below. This has been developed in cooperation with the partner company Kaschke Components GmbH, Göttingen – Germany. So the primary is realized in a “sandwich” technique using 16 turns of 4 layers of litz wire 45 strands 0.1 mm diam. This allows minimizing the AC losses due to skin and proximity effect. The secondary is done with copper band 20x0.5 mm. Figure 5 Ferrite core material TDK PC95 Application Note 9 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations With this choice, at full load condition the total copper losses will be (primary + secondary, DC+AC components) are 1.1 W, the core losses are 1.8 W, so overall: Ptrafo Pcopper Pcore 2.9W Ptrafo _ MAX (18) In other words, the equation (18) fulfils the thermal equation (17). Figure 6 Winding structure of the PQ 35/35 LLC transformer (Kaschke Components GmbH) An important transformer parameter involved in the LLC design is the primary or magnetizing inductance Lm, which, according to eq. (7) must be 195 µH. This value is obtained with distributed air-gap on the side legs of the PQ core: this construction is preferred since it minimizes the effect of the so called “fringing flux” which generates additional losses in the windings close to the inner limb. 2.8 The resonant choke design In LLC designs with stringent power density requirements, the resonant choke is typically embedded in the transformer, in the sense that the leakage inductance is utilized according this purpose. This technique has the big advantage to save space and the cost of an additional magnetic component, but also some drawbacks, like the not easy controllability of the Lr value in mass production. In the case of the present design, it has been decided to use an external Lr.This is due to the fact that the demo board is intended to be primarily used for test and benchmarking and therefore high power density is not in the main focus: having the resonant inductance externally allows to change the resonant tank in a more flexible way. According to equation (7), the overall value of Lr shall be 17 µH, including the contribution of the transformer leakage inductance + the external resonant choke. The external resonant choke is realized using a RM-12 core and a winding construction illustrated in Figure 7 below and implemented by the partner company Kaschke Components GmbH, Göttingen - Germany. Figure 7 Winding structure of the RM 12 resonant choke (Kaschke Components GmbH) Application Note 10 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 HB LLC Converter Design Considerations 2.9 The Synchronous Rectification Stage In applications that target high efficiency both at low and high loads –such as 80PLUS® Titanium- while often requiring high power densities, it is critical to select for the Synchronous Rectification Stage MOSFETs that combine multiple key characteristics. First of all, these Sync Rec MOSFETs should exhibit very low RDS(on). Indeed, due to the low voltages observed on the secondary side of server power supplies, large currents flow through the Sync Rec MOSFETs. Moreover, compared with hard switching topologies such as ZVS PS FB (Zero Voltage Switching PhaseShifted Full Bridge), using LLC topology leads not only to increased peak currents for the Sync Rec MOSFETs, but also higher root-mean-square currents IRMS. Since the conduction losses Pcond,SR of each Sync Rec MOSFET are defined by: Pcond _ SR RDS , on ( IRMS ) 2 (19) These losses can only be mitigated through the use of a part with very low RDS(on). Secondly, it is critical for these Sync Rec MOSFETs to exhibit low gate charges Qg: At lower loads, the switching losses of the Sync Rec MOSFETs predominate over the already mentioned conduction losses. In the case of LLC topology, the main contributor of these switching losses is related to Qg. Most of the time, a driving voltage of 12 V is applied to Sync Rec MOSFETs. Although 12 V is not necessary the optimized driving voltage for Sync Rec MOSFETs (more on this below), this driving voltage is very popular in server PSUs because it is readily available: there is no need to derive it from another voltage rail. Therefore, we decided to follow this trend for this demo board by driving the Sync Rec MOSFETs with 12 V. This requirement for low Qg puts extra-strain on MOSFET manufacturers, especially considering that Sync Rec MOSFETs need to exhibit at the same time a very low RDS(on). Such a feat was however possible for Infineon thanks to the new Infineon OptiMOSTM 40 V generation, whose gate charges have been significantly reduced in comparison with the previous generation. Thirdly, the paralleled Sync Rec MOSFETs should turn on almost simultaneously. This can be achieved thanks to a tightening of the threshold voltage VGS(th) range. In the case new OptiMOSTM 40 V generation, its datasheet guarantees a very narrow VGS(th) range, with min and max values equal to 1.2 V and 2.0 V respectively. Finally, the MOSFET package is critical for a variety of reasons. The package should exhibit low parasitic inductances in order to confine its contribution to the VDS overshoot to a strict minimum. This is even more critical in server applications using LLC topology, due to the limited headroom for the VDS overshoot between the transformer secondary voltage (25 V) and the 90% derating (36 Vmax) or even 80% derating (32 Vmax) applied to the VDS of the Sync Rec MOSFETs; Moreover, due to the conflicting requirements for high power density and high current capability, the package should combine a minimum footprint with good power dissipation. Because of the high current densities arising at the source pins, which can lead to electro-migration and thereafter destruction of the Sync Rec MOSFETs, the package should provide an enlarged source connection. While the first two sub-items are tackled by standard SuperSO8 packages, it is the addition of source fused leads implemented in the new Infineon OptiMOSTM 40 V generation that reduces the high current densities above mentioned. Application Note 11 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description 3 Board description 3.1 General overview Figure 1 is the top view, bottom view and the assembly of 600W Half Bridge LLC evaluation board. Key components are: (1) heat sink with the assembly of primary side switches IPP60R180C7 (2) Resonant capacitor (3) LLC analog controller ICE2HS01G (4) Resonant inductor (5) Main DC-DC transformer (6) PCB assembly of the auxiliary circuit with bias QR Flyback controller ICE2QR2280Z (7) Heat sink assembly for cooling the synchronous rectifier (8) Output capacitor (9) Output inductor (10) Half Bridge MOSFET gate driver 2EDL05N06PF and (11) Synchronous rectifier OptiMOS™ BSC010N04LS (12) Advanced dual-channel Gate Drive 2EDN7524F. 12 11 10 600 W LLC Top View 1 Figure 8 2 600 W LLC Bottom View 3 4 5 6 7 8 9 IFX 600W LLC Evaluation Board Application Note 12 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description 3.2 Infineon BOM This HB LLC 600 W demonstration board is a full Infineon solution, meeting the highest efficiency standard 80PLUS® Titanium using the following parts: 3.2.1 Primary HV MOSFETs CoolMOSTM IPP60R180C7 The 600 V CoolMOS™ C7 is the next step of Silicon improvement based on the 650 V CoolMOS™ C7. It stays with the strategy to increased switching performance in order to enable highest efficiency in any kind of target applications as for boost topologies like PFC’s (power factor correction) and high voltage DC/DC stages like LLC’s (DC/DC stage with resonant tank in order to maintain zero voltage switching). Although the 600 V CoolMOS™ offers very fast switching, it also kept the ease of use level (how easy to control the switch) of the 650 V C7 “parent technology”. Therefore the 600 V CoolMOS™ C7 is optimized device for highest efficiency SMPS (switched mode power supply). The 600 V C7 represents the new standard of SJ MOSFET. In LLC application, converter is in resonant operation with guaranteed ZVS even at a very light load condition. Switching loss caused by Eoss during turn-on can be considered negligible in this topology. With this consideration, CoolMOS™ C7 family of parts offers superior price/performance ratio with low FOMs (Ron*Qg and Ron*QOSS), which means that MOSFET switching transitions can happen in a shorter dead time period. This will result to a lower turn-off losses pushing further the efficiency. The following are the additional features and benefits of CoolMOS™ C7 making it suitable and advantageous for resonant switching topologies like LLC: • Suitable for hard and soft switching (PFC and high performance LLC) • Increased MOSFET dv/dt ruggedness to 120 V/ns • Increased efficiency due to Best-in-Class FOM RDS(on)*Eoss and RDS(on) *Qg • Best-in-class RDS(on)/package • Qualified for industrial grade applications according to JEDEC (J-STD20 and JESD22) 3.2.2 LLC analog controller ICE2HS01G ICE2HS01G is Infineon’s 2nd generation HalfBridge LLC controller designed especially for high efficiency Half Bridge or FullBridge LLC resonant converter with synchronous rectification (SR) control for the secondary side. With its new driving techniques, the synchronous rectification can be realized for LLC converter operated with secondary switching current in both CCM and DCM conditions. No special synchronous rectification controller IC is needed at the secondary side. The maximum switching frequency is supported up to 1 MHz. Apart from the patented SR driving techniques, this IC provides very flexible design and integrates full protection functions as well. It is adjustable for maximum/minimum switching frequency, soft-start time, frequency, dead time between primary switches, turn-on and turn-off delay for secondary SR MOSFETs. The integrated protections include input voltage brownout, primary three-levels over current, secondary over load protection and no-load regulation. It also includes a burst mode function which offers an operation with low quiescent current maintaining high efficiency at low output load while keeping output ripple voltage low. 3.2.3 Half Bridge Gate Drive 2EDL05N06PF 2EDL05N06PF is one of the drivers from Infineon’s 2EDL EiceDRIVER™ Compact 600V Half Bridge gate driver IC family with monolithic integrated low-ohmic and ultrafast bootstrap diode. Its level-shift SOI technology supports higher efficiency and smaller form factors of applications. Based on the used SOI-technology there is an excellent ruggedness on transient voltages. No parasitic thyristor structures are present in the device. Hence, no parasitic latch up may occur at all temperature and voltage conditions. The two independent Application Note 13 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description drivers outputs are controlled at the low-side using two different CMOS resp. LSTTL compatible signals, down up to 3.3 V logic. The device includes an under-voltage detection unit with hysteresis characteristic which are optimised either for IGBT or MOSFET. 2EDL05N06PF (DSO-8) and 2EDL05N06PJ (DSO-14) are driver ICs with undervoltage-lockout for MOSFETs. These two parts are recommended for server/telecom, low-voltage drives, e-bike, battery charger and Half Bridge based switch mode power supply topologies. − Individual control circuits for both outputs − Filtered detection of under voltage supply − All inputs clamped by diodes − Off line gate clamping function − Asymmetric undervoltage lockout thresholds for high side and low side − Insensitivity of the bridge output to negative transient voltages up to -50 V given by SOI-technology − Ultra fast bootstrap diode 3.2.4 Advanced dual-channel Gate Drive 2EDN7524F The Fast Dual Channel 5 A Low-Side Gate Driver is an advanced dual-channel driver optimized for driving both Standard and Superjunction MOSFETs, as well as GaN Power devices, in all applications in which they are commonly used. The input signals are TTL compatible (CMOS 3.3 V) with an input voltage range from 3 V to +20 V. The ability to operate with -10 VDC at the input pins protects the device against ground bounce conditions. Each of the two outputs is able to sink and source a 5 A current utilizing a true rail-to-rail stage, that ensures very low impedances of 0.7 Ω up to the positive and 0.55 Ω down to the negative rail respectively. Very low channel to channel delay matching, typ. 1 ns, enables the double source and sink capability of 10 A, by paralleling both channels. Different logic input/output configurations guarantee high flexibility in all applications; e.g. with two paralleled switches in a boost configuration (see Figure below). The gate driver is available in the three package options: A standard PG-DSO-8, a thin PG-WSON-8-1 and PG-TSSOP-8-1 (minimized DSO 8 package). Main Features − Industry-Standard Pinout − Two Independent Low-Side Gate Drivers − 5 A Peak Sink/Source Output Driver at VDD = 12 V − -10 VDC Negative Input Capability against GND-Bouncing − Enhanced operating robustness due to High Reverse Current Capability − True Low-Impedance Rail-To-Rail Output (0.7 Ω and 0.55 Ω) − Very Low Propagation Delay (19 ns) − Typ. 1 ns Channel to Channel Delay Matching − Wide Input and Output Voltage Range up to 20 V − Active Low Output Driver even on Low Power or Disabled Driver − High Flexibility through Different Logic Input Configurations (LVTTL and CMOS 3.3 V) − PG-DSO-8, PG-WSON-8-1 and PG-TSSOP-8-1 Package − Extended Operation from -40 °C to 150 °C (Junction Temperature) − Particularly Well-Suited for Driving Standard, Superjunction MOSFETs, IGBTs or GaN Power Devices Application Note 14 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description Typical Applications − SMPS − DC/DC Converters − Motor Control − Solar Power, Industrial Applications 3.2.5 Bias QR Flyback controller ICE2QR2280Z ICE2QRxxxx is a second generation quasi-resonant PWM CoolSET™ with power MOSFET and startup cell in a single package optimized for off-line power supply applications such as LCD TV, notebook adapter and auxiliary/housekeeping converter in SMPS. The digital frequency reduction with decreasing load enables a quasi-resonant operation till very low load. As a result, the system average efficiency is significantly improved compared to conventional solutions. The active burst mode operation enables ultra-low power consumption at standby mode operation and low output voltage ripple. The numerous protection functions give a full protection of the power supply system in failure situation. Main features of ICE2QR2280Z which make it suitable as an auxiliary converter of this LLC demonstration board are: High voltage (650 V/800 V) avalanche rugged CoolMOS™ with startup cell Quasi-resonant operation Load dependent digital frequency reduction Active burst mode for light load operation Built-in high voltage startup cell Built-in digital soft-start Cycle-by-cycle peak current limitation with built-in leading edge blanking time Foldback Point Correction with digitalized sensing and control circuits VCC undervoltage and overvoltage protection with Autorestart mode Over Load /open loop Protection with Autorestart mode Built-in Over temperature protection with Autorestart mode Adjustable output overvoltage protection with Latch mode Short-winding protection with Latch mode Maximum on time limitation Maximum switching period limitation 3.2.6 Synchronous Rectification MOSFETs OptiMOSTM BSC010N04LS For the synchronous rectification stage the selected device is BSC010N04LS, from the latest OptiMOS™ 40 V family. SR is in fact naturally the best choice in high efficiency designs of low output voltage and high output current LLC, as in our case. In applications that target high efficiency both at light and heavy loads – such as 80PLUS® Titanium- while often requiring high power densities, it is critical to select SR MOSFETs that combine following key characteristics: Very low RDS(on): BSC010N04LS provides the industry’s first 1mΩ 40 V product in SuperSO8 package. Low gate charge Qg, which is important in order to minimize driving losses, with benefits on light load efficiency Very tight VGS(th) range: in fact, in case of paralleling this allows the MOSFETs to turn-on almost simultaneously. Selected OptiMOSTM offer very close min and max of VGS(th), respectively 1.2 and 2 V. Application Note 15 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description Monolithically integrated Schottky like diode, in order to minimize the conduction losses on it. Package; BSC010N04LS in SuperSO8 with source fused leads is able to address all the typical crucial requirements for a suitable SR MOSFET package: − Minimizing parasitic inductances − Combining compact footprint with good power dissipation − Enlarged source connection in order to minimize electro-migration occurrence. 3.3 Board schematic 3.3.1 Mainboard schematic Figure 9 Mainboard schematic Application Note 16 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description 3.3.2 Control board schematic Figure 10 Control board schematic Application Note 17 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description 3.3.3 Biasboard schematic Figure 11 Biasboard schematic Application Note 18 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Board description Figure 12 Mainboard PCB with Control – and Bias Board Application Note 19 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Typical characteristics with 600 V CoolMOS™ C7 4 Typical characteristics with 600 V CoolMOS™ C7 4.1 Critical LLC operation - hard commutation In LLC converter, hard commutation of the body diode normally only occurs during the start-up, burst mode, overload and short circuit condition. These conditions can be minimized if not avoided in the design using an analog controller with proper selection of resonant components and properly setting of the minimum and maximum operating frequency. Hard commutation happens in LLC during the commutation period of the body diode. During this time, resonant inductor current is flowing through body diode of the MOSFET creating ZVS condition upon this MOSFET’s turn-on. When the current is not able to change its direction prior to the turn-on of the other MOSFET, more charges will remain in the P-N junction of that MOSFET. When the other MOSFET turns on, a large shoot-through current will flow due to the reverserecovery current of the body diode. This results to a high reverse recovery peak current IRRM and high reverse recovery dv/dt which sometimes could result to a MOSFET breakdown. In this 600 W LLC analog controlled demonstration board, only the burst mode condition has the tendency of undergoing hard commutation. In Figure 13, hard commutation at burst mode is minimal that IPP60R180C7 was able to withstand without any problem. 528V Ch1: VDS_LS Ch2: VGS_LS Ch4: IDS_LS 26V 11A Figure 13 Hard commutation during burst mode operation, VDS_pk , VGS_max/min and IRMM Application Note 20 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Typical characteristics with 600 V CoolMOS™ C7 The voltage spike on the gate VGS and drain VDS can be influenced by varying both turn-on and turn-off gate resistors up to 10 ohm without affecting the efficiency, thanks to the switching behavior of the C7 technology. Thanks to the very carefully design and control loop on this 600 W Analog LLC Demonstration board, there is neither during start-up nor for short-circuit condition any hard commutation observed. 4.2 Full ZVS area Nearly full ZVS is achieved on the entire output load range as shown in Figure 14. Ch1: VDS_LS Ch2: VGS_LS Ch4: IDS_LS Nearly full ZVS achieved starting at 5A load Figure 14 Nearly Full Zero Voltage Switching (ZVS) starting at 5 A load 4.3 Burstmode operation At no load or a very light load condition, LLC controller provides frequency approaching to its maximum setting. In this condition, in order to still achieve full ZVS, magnetizing current should be high enough to discharge the output capacitances. Due to magnetizing current limitation, switching loss especially turn-off loss is relatively high if the devices will continue to switch at the highest frequency. In order to overcome this phenomenon, burst mode function is enabled and implemented. This results to an effective lower switching losses and driving losses because of the low burst frequency. Additionally, this helps to achieve regulation even at no load condition. In Figure 15 one can see the waveform of Burst Mode Operation at noload and/or very light load condition Application Note 21 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Typical characteristics with 600 V CoolMOS™ C7 Ch1: VDS_LS Ch3: VOUT Ch4: IDS_LS Burst Mode Operation at a Very Light Load Condition Ch2: VGS_LS Figure 15 Burst Mode Operation at no-load and/or very light load condition 4.4 Efficiency 4.4.1 Titanium Efficiency Figure 16 shows the efficiency comparison of this 600 W LLC evaluation board in relation to the Titanium Efficiency Standard. At the most important efficiency point (50% load), this LLC board offers 0.3 % efficiency benefit compared to the Titanium Efficiency Line. Application Note 22 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Typical characteristics with 600 V CoolMOS™ C7 Measurement without Auxiliary Bias Figure 16 IFX 600 W LLC Demonstration Board Efficiency vs Titanium STD Efficiency 4.4.2 Efficiency comparison in resonant LLC Half Bridge Figure 17 shows the efficiency comparison in a 600 W LLC circuit, Vin=380 V, Vo=12 V, running at resonant frequency fo=157 kHz. The 0.1 % improvement across the load range is mostly related to the low turn off losses and the low COSS dissipation, since other switching losses are minimal when operating at the resonant frequency. Furthermore, it’s expected to gain more efficiency benefit when operating above the resonant frequency, where turn off losses start to engage. Figure 17 Efficiency comparison in 600W LLC Half Bridge Application Note 23 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Test/powerup procedure 5 Test/powerup procedure Table 2 Test/Powerup procedure Test Test procedure Condition 1. Auxiliary Circuit Turn-On Apply 30 VDC on the input. Vin: ~30 VDC Orange LED will light up Apply 350 VDC. Converter will give Vout =12 VDC. Vin: 350 VDC 3. Operational switching frequency Using voltage probe, monitor switching frequency at following test conditions: Vin:380 VDC 2. LLC Converter Turn-On Vout:12 V Vout:12 V @5 A Output Load 10%Load - ~ 155 kHz* Iout: 5 A @25 A Output Load 50%Load - ~ 142 kHz* Iout: 25 A @50 A Output Load 100%Load - ~ 132 kHz* Iout: 50 A (*measure freq. at “Pri_LS_VGS“connector) [* +/-10 kHz] 4. Fan enable Switch the load from 50 A to 5 A. Increase the output load current from 11-14 A, fan should turn on. Vin =380 VDC Iout= 5 A ÞFan is off Vin =380 VDC Iout= 11-14 A ÞFan is on 5. Switch off Input Start-up at No load 6. Switch off Input; Start-up at Full load Switch off the Input Vin= 0 VDC Iout= 0 A Switch at 380 VDC on no load output. Operation should be in burst mode. Vin =380 VDC Switch off the Input Vin= 0 VDC Iout = 0 A Vout = 11,5 – 12,5 Iout= 0A Apply 380 VDC with full load @50 A Vin =380 VDC output. Vout is in between 11.8 – Vout: 11,8 – 12,3 VDC 12.2 VDC* Iout = 50 A (*measure on the board-connector) 7. Running No Load -> Output Short Circuit Application Note Switch off load from 380 VDC 50 A to 380 VDC 0 A. Vin =380 VDC Short circuit the load using the short circuit function of the eload. Converter should latch. (after short circuit) Vout = 0 VDC 24 Iout = 0 A Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Test/powerup procedure Test Test procedure Condition 8. Switch off Input & remove short circuit Switch off the Input. Vin= 0 VDC 9. Running Full Load -> Over Current Protection Remove short circuit function on the load. Iout= 0 A Apply 380 VDC 50 A with full load output. Increase the current on the output 1 A each step until the converter goes into protection starting from 50 A. OCP occurs between 55 A and 62 A. Vin =380 VDC Iout = 50 A OCP = between 55 A – 62 A 10. Running Full Load -> Output Short Circuit Apply 380 VDC 50 A with full load Iout= 0 A output. Short circuit the load Vin =380 VDC using the short circuit functions of Iout = 50 A the load. Converter should latch. (after short circuit) Vout=0 VDC 11. Switch off Input; Start- Up -> Output Short Circuit Switch off the Input. Iout= 0 A Apply 380 VDC with output load short circuit. Converter should be in hiccup/latch mode. 12. Switch off Input & remove short Switch off the Input. circuit Remove short circuit function on the load. 13. Dynamic Loading Vin= 0 VDC Vin =380 VDC Iout = short circuit Vout = 0 V short circuit (hiccup/latch) Vin= 0 VDC Iout= 0 A Apply 380 VDC. Set the electronic load to dynamic loading mode with the following settings: Vin =380 VDC CCDH1: Iout 5 A Iout = 5 A…50 A Vout = 11,5 – 12,5 VDC CCDH2: Iout 50 A Dwell time: 10 ms Load slew rate: 1 A/µS Application Note 25 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 Useful material and links 6 Useful material and links With the following links you can find more detailed information about the used devices from Infineon and the magnetic components. Primary HV MOSFETs CoolMOSTM IPP60R180C7: http://www.infineon.com/dgdl/Infineon-IPP60R180C7DS-v02_00EN.pdf?fileId=5546d4624cb7f111014d483fe4ba707b LLC Analog Controller ICE2HS01G http://www.infineon.com/dgdl/ICE2HS01G_PDS_v2.1_20110524_Public.pdf?folderId=db3a304412b4079 50112b408e8c90004&fileId=db3a30432a40a650012a458289712b4c Advanced Dual-Channel Gate Drive 2EDN7524F http://www.infineon.com/dgdl/Infineon-2EDN752x_2EDN852x-DS-v01_00EN.pdf?fileId=5546d4624cb7f111014d672f9fbb5142 Bias QR Flyback Controller ICE2QR2280Z http://www.infineon.com/dgdl/Datasheet_ICE2QR2280Z_v21_20110830.pdf?folderId=db3a304412b4079 50112b408e8c90004&fileId=db3a30432a7fedfc012a8d8038e00473 SR MOSFETs OptiMOSTM BSC010N04LS http://www.infineon.com/dgdl/BSC010N04LS_rev2.0.pdf?folderId=db3a304313b8b5a60113cee8763b02 d7&fileId=db3a3043353fdc16013552c1c63647c4 Main Transformer and Resonant Choke Ferrite Cores http://en.tdk.eu/blob/519704/download/2/ferrites-and-accessories-data-book-130501.pdf Half Bridge Gate Drive 2EDL05N06PF http://www.infineon.com/cms/en/product/power/gate-driver/eicedrivershigh-voltage-gate-driver-icsand-boards/gate-driver-ic-eicedriver-compact/2EDL05N06PF/power/gatedriver/2EDL05N06PF/power/gatedriver/2EDL05N06PF/productType.html?productType=db3a30443e36c802013e3c260fb915fd Application Note 26 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 References 7 References [1] T. Fujihira: “Theory of Semiconductor Superjunction Devices”, Jpn. J. Appl. Phys., Vol.36, pp. 62546262, 1997 [2] Francesco Di Domenico and others: “Design of 600 W HB LLC Demo Board using 600 V CoolMOS™ P6”, Infineon Technologies AN 2015 [3] Lawrence Lin, Gary Chang: “Consideration of Primary side MOSFET Selection for LLC topology”, Infineon Technologies AN 2014 [4] Anders Lind: “LLC Converter Design Note”, Infineon Technologies AN 2013-03 [5] Liu Jianwei, Li Dong: “Design Guide for LLC Converter with ICE2HS01G”, Infineon Technologies AN V1.0, July 2011 [6] F. Stückler, S. Abdel-Rahman, K. Siu: “600 V CoolMOS™ C7 Design Guide”, Infineon Technologies Application Note 27 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 List of abbreviations 8 List of abbreviations Table 3 Abbreviation and symbols used CGD ................................................................................................... internal gate drain capacitance CGD=Crss Ciss ................................................................................................................. input capacitance Ciss=CGS+CGD Co(er) .................................................................................................................... effective output capacitance Cr ................................................................................................................................... resonant capacitance di/dt ...................................................................................... steepness of current slope at turn off / turn on DUT......................................................................................................................................... device under test dv/dt ..................................................................................... steepness of voltage slope at turn off / turn on Eoff ....................................................................................................................... power loss during switch off Eon ........................................................................................................................power loss during switch on Eoss.................................................................. stored energy in output capacitance (Coss) at typ. VDS=400V FHA.................................................................................................... First Harmonic Approximation Method FOM ......................................................................................................................................... Figures of Merit fr ....................................................................................................................................... resonand frequency ID ................................................................................................................................................... drain current IRMS ............................................................................................................ effective root mean square current Imag ..................................................................................................................................... magnatizing current Im,pk.................................................................................................................................................. peak current K ...................................................................................................................................................... gain factor Lr ..................................................................................................................................... resonant inductance Lm ............................................................................................................................... magnatizing inductance m ................................................................................................................................................... voltage gain Np ............................................................................................................................................. primary winding NS .........................................................................................................................................secondary winding n .................................................................................................................................... transformer turn ratio MOSFET ........................................................................... metal oxide semiconductor field effect transistor Pcond_SR .......................................................................................................... synchronos conduction losses PFC .............................................................................................................................. power factor correction PNP ....................................................................................................... bipolar transistor type (pnp vs. npn) QOSS .........................................................................................................................Charge stored in the COSS Q ................................................................................................................................................... quality factor Rac ................................................................................................................................total equivalent resistor RDS(on) ........................................................................................................... drain-source on-state resistance Rg,tot ....................................................................................................................................... total gate resistor Ro ................................................................................................................................................ output resistor Rth ............................................................................................................................................. thermal resistor tdead .....................................................................................................................................................dead time tecs ..................................................................................................................... early channel shut down time VDS ...................................................................................... drain to source voltage, drain to source voltage Vgsth ............................................................................................................ drain to source threshold voltage VO_AC ......................................................................................................... output voltage, alternating current VIn_AC ............................................................................................................ input voltage, alternating current Application Note 28 Revision1.2, 2015-06-24 600 W Half Bridge LLC Evaluation Board with 600 V CoolMOS™ C7 List of abbreviations VIn_nom ........................................................................................................................... nominale input voltage Vout_nom ..................................................................................................................................... nominale output ZCS ................................................................................................................................ zero current switching ZVS ................................................................................................................................zero voltage switching Revision History Major changes since the last revision Page or Reference -- Description of change First Release Revision 1.1 Update on Layout and Structure Revision 1.2 Update on Section 3.2.4 Application Note 29 Revision1.2, 2015-06-24 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, CoolGaN™, CoolMOS™, CoolSET™, CoolSiC™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, DrBLADE™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPACK™, EconoPIM™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, ISOFACE™, IsoPACK™, iWafer™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OmniTune™, OPTIGA™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PROFET™, PRO-SIL™, RASIC™, REAL3™, ReverSave™, SatRIC™, SIEGET™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, SPOC™, TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™. Other Trademarks Advance Design System™ (ADS) of Agilent Technologies, AMBA™, ARM™, MULTI-ICE™, KEIL™, PRIMECELL™, REALVIEW™, THUMB™, µVision™ of ARM Limited, UK. ANSI™ of American National Standards Institute. AUTOSAR™ of AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CATiq™ of DECT Forum. COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™ of Epcos AG. FLEXGO™ of Microsoft Corporation. HYPERTERMINAL™ of Hilgraeve Incorporated. MCS™ of Intel Corp. IEC™ of Commission Electrotechnique Internationale. IrDA™ of Infrared Data Association Corporation. ISO™ of INTERNATIONAL ORGANIZATION FOR STANDARDIZATION. MATLAB™ of MathWorks, Inc. MAXIM™ of Maxim Integrated Products, Inc. MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS Technologies, Inc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of Applied Wave Research Inc., OmniVision™ of OmniVision Technologies, Inc. Openwave™ of Openwave Systems Inc. RED HAT™ of Red Hat, Inc. RFMD™ of RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc. SOLARIS™ of Sun Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software Limited. TAIYO YUDEN™ of Taiyo Yuden Co. TEAKLITE™ of CEVA, Inc. TEKTRONIX™ of Tektronix Inc. TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™ of Cadence Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™ of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited. Last Trademarks Update 2014-07-17 www.infineon.com Edition 2015-05-01 Published by Infineon Technologies AG 81726 Munich, Germany © 2015 Infineon Technologies AG. All Rights Reserved. Do you have a question about any aspect of this document? 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