600W halfbridge LLC evaluation board EVAL-600W-12V-LLC-A EVAL-600W-12V-LLC-D Analog Digital Di Domenico Francesco (IFAT PMM ACDC AE) Zechner Florian (IFAT PMM ACDC AE) Table of contents 1 General description 2 Efficiency results 3 Design concept 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 2 Table of contents 1 General description 2 Efficiency results 3 Design concept 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 3 General Description: The “EVAL-600W-12V-LLC-x“ - Evaluation board in the Analog version “-A” or digital controlled “-D” shows how to design a Half-Bridge LLC stage of a server SMPS with the target to meet 80+ Titanium standard efficiency requirements. On this purpose there has been applied CoolMOS™ P6 technology IPP60R190P6 600V Power MOSFET on the primary side and OptiMOS™ low voltage Power MOSFET in SuperSO8 BSC010N04LS in the synchronous rectification secondary stage, in combination with QR CoolSET™ ICE2QR2280Z, Hi-Low Side Driver 2EDL05N06PF, in the newest version a Low Side Gate Driver 2EDN7524F. The system is controlled by a LLC Controller ICE2HS01G for the analog or XMC4200 in the digital version. Summary of features: › Output voltage: 12 V › Output current: 50 A › Peak efficiency @ 50% load > 97,8% › Efficiency @ 10% load > 95% The following variants are available: › 600W 12 V LLC analog version with CoolMOS™ P6, IPP60R190P6 , EVAL-600W-12V-LLC-A › 600W 12 V LLC digital version with CoolMOS™ P6, IPP60R190P6 , EVAL-600W-12V-LLC-D 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 4 Example of system understanding: Infineon demo solution for Titanium HV DC/DC stage Half Bridge LLC with synchronous rectification in center tap configuration Vin 350-410 VDC Vin_nom 380 VDC Vout_nom 12 VDC Iout 50 A Po 600 W fres=f0 157 kHz fmin 90 kHz fmax 210 kHz Transformer turns ratio 16:1 Cr 66 nF Lr 15.5 uH Lm 195 uH 09.10.2015 Primary HV MOSFETs SR MOSFETs TM CoolMOS IPP60R190P6 OptiMOSTM BSC010N04LS New generation Reduced gate charge (Qg) › Best FOM RDS(on) x Qg › Reduced Eoff › High body diode ruggedness › Best FOM RDS(on) x Qoss HB Gate Drive IC Bias QR Flyback 2EDL05N06PF controller Non isolated LS Gate Drive ICE2QR2280Z 2EDN7524F LLC controller Digital XMC4200 / Analog ICE2HS01G SR MOSFETs BSC010N04LS Resonant inductor Transformer PQ35/35 core RM12 core Copyright © Infineon Technologies AG 2015. All rights reserved. 5 Control board analog & digital Two possible solution to control Infineon`s 600 W LLC evaluation board Analog - ICE2HS01G › Resonant mode controller for Half-Bridge LLC resonant converter with synchronous rectification drives › Driving signal for synchronous rectification which support full operation of Half-Bridge LLC resonant converter › 20-pin DSO package › 30 kHz to 1MHz switching frequency › 50% duty cycle for both primary and secondary gate drives › Adjustable dead time with high accuracy 07.10.2015 Digital - XMC4200-Q48K256 AB › ARM® Cortex®-M4, 80 MHz, incl. single cycle DSP MAC and floating point unit (FPU) › 8-channel DMA + dedicated DMA for USB › USB 2.0 full-speed device › CPU Frequency: 80 MHz › eFlash: 256 kB including hardware ECC › 40 kB SRAM › Package: PG-LQFP-48 Copyright © Infineon Technologies AG 2015. All rights reserved. 6 PCB boards layout: main power board and control and bias daughter boards › Controller Board 09.10.2015 Power Density>20W/inch3 Bias Board Copyright © Infineon Technologies AG 2015. All rights reserved. 7 Main power board schematic 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 8 Bias board schematic 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 9 Analog control board schematic 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 10 Digital Controller XMC4200-Q48K256 AB Digital control board schematic 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 11 BOM (rework from analog to digital) Part Value Pcs Tolerance Device Package Description Assembling info C3 10 n/50 V 1 C-EU_C0805 C0805 CAPACITOR, Replace 470 n/50 V with 10 n/50 V R19 330R 1 ±1% R-EU_R0805 R0805 RESISTOR Replace 4K3 with 330R R20 330R 1 ±1% R-EU_R0805 R0805 RESISTOR Replace 4K3 with 330R n.a. n.a. 1 ±1% R-EU_R0805 R0805 RESISTOR Assemble 56R with n.a. IC1 Board 1 Board PCB Digital_ Controlcard 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. Supplier IFX 12 PCB structure 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 13 Table of contents 1 General description 2 Efficiency results 3 Design concept 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 14 Automated efficiency measurement Efficiency Combination of converter design (resonant tank, transformer) and proper HV device election 0,99 0,985 0,98 0,975 0,97 0,965 0,96 0,955 0,95 0,945 0,94 0,935 0,93 0,925 0,92 0,915 0,91 0,905 0,9 Proper selection of SR LV device and secondary side 97.8% peak efficiency! › › › › Highest Efficiency standard in Computing applications (HV DC/DC stage) Output voltage: 12 VDC Output current: 50 A Efficiency: > 95% @ 10% load, Vin = 380 VDC Efficiency max: 97.8%, Vin = 380 VDC C7 180mOhm 0.1% Total accuracy 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 IOUT [A] 07.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 15 10% Pmax Vin=380 Vdc 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 16 50% Pmax Vin=380 Vdc 1,2 1 0,8 Turn-off losses 0,6 Body diode losses Driving losses 0,4 Conduction Losses 0,2 0 Losses spread on each device at 50%Pmax [W] 2014-11-04 Copyright © Infineon Technologies AG 2014. All rights reserved. 17 100% Pmax Vin=380 Vdc 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 18 Table of contents 1 General description 2 Efficiency results 3 Design concept 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 19 Design procedure: input data Vin _ nom n 2 Vout _ nom n Vo _ min M min K min(Q, m, Fx ) Vin _ max 2 M max 09.10.2015 n Vo _ max K max (Q, m, Fx ) Vin _ min 2 Copyright © Infineon Technologies AG 2015. All rights reserved. 20 Resonant tank components and related resonant frequencies › n=Vin_nom/(2xVo)=380/(2*12)≈16 › Lm=195 µH › Lr=15.5 µH › Ln=Lm/Lr=12.5 › Cr=66 nF 1 fo 157kHz 2 Lr Cr 09.10.2015 1 fp 42.7kHz 2 ( Lr Lm) Cr Copyright © Infineon Technologies AG 2015. All rights reserved. 21 Gain curves DC - gain curve (600 W LLC hardware revision P6) 1,2 M max 1,1 n Vo _ max Vin _ min 2 1 5A gain 15 A 0,9 0,8 25 A n Vo _ min M min Vin _ max 2 35 A 50 A 0,7 0,6 frequency [Hz] 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 22 Energy related calculations (Ref. IPP60R190P6 device parameters) Im ag _ min 2 2 n Vo 0.672 A 2 fsw _ max Lm 1 Enres _ min ( Lm Lr ) I ² mag _ min 95.1 J 2 1 Encap _ max (2Co (er )) V ² DS _ max 9 J 2 09.10.2015 Enres _ min Encap _ max Copyright © Infineon Technologies AG 2015. All rights reserved. 23 Qoss, Imag, pk, tdead,min, tecs relationship Im,pk IQ2 IQ 2(t ) Im, pk (1 IQ 2(t ) 0 t tecs ) t tecs t tecs tecs f ( Rg , tot,Vgs, th, Cds ) Cgd ICHB Im,pk tdead , min 1 0 IC (t )dt 2 Im, pk tecs Im, pk (tdead, min tecs ) 2 Qoss , @ 400 V HB VHB VBULK tecs 09.10.2015 tdead,min t ecs 2 Q oss, @ 400 V 1 tdead, min 2 Im, pk Copyright © Infineon Technologies AG 2015. All rights reserved. 24 Time related calculations (Ref. IPP60R190P6 device parameters) Im ag _ min Im ag _ max 2 2 2 2 n Vo 0.672 A 2 fsw _ max Lm n Vo 1.66 A 2 fsw _ min Lm tecs 2 Qoss, @ 400V tdead, min 130 n sec 2 Im ag , max tecs 2 Qoss, @ 400V tdead, max 311 n sec 2 Im ag, min 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 25 Main transformer structure: PQ35/35 core with TDK PC95 ferrite material 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 26 Resonant choke: RM12 core, material N87 09.10.2015 Copyright © Infineon Technologies AG 2015. All rights reserved. 27 Support slides 600 W LLC evaluation board Evaluation board page – – – – – Technical description Datasheets Parameters Related material Videos – www.infineon.com/600w-llc-evaluationboard-a – www.infineon.com/600w-llc-evaluationboard-d Product family pages – – – – – – Product brief Application notes Selection guides Datasheets and portfolio Videos Simulation models 09.10.2015 – – – – www.infineon.com/p6 www.infineon.com/xmc Resonant Mode Controller www.infineon.com/optimos5-40v60v Copyright © Infineon Technologies AG 2015. All rights reserved. 28