600 W Half-Bridge LLC evaluation board EVAL_600W_LLC_12V_C7_D digital & analog Table of contents 1 General description 2 Efficiency results 3 Design concept 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 2 General Description: The “EVAL_600W_LLC_12V_C7“ - evaluation board 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 latest CoolMOS™ technology IPP60R180C7 600 V 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, low-side Gate Driver 2EDN7524F and a LLC Controller ICE2HS01G for the analog or XMC4200 in the digital version. Summary of features: › Output voltage: 12 V › Output current: 50 A › Efficiency @ 10% load > 95% › Peak efficiency @ 50% load > 97,8% The following variants are available: › 600W 12V LLC analog version with CoolMOS™ C7, IPP60R180C7, EVAL_600W_LLC_12V_C7 › 600W 12V LLC digital version with CoolMOS™ C7, IPP60R180C7, 2015-10-12 EVAL_600W_LLC_12V_C7_D Copyright © Infineon Technologies AG 2015. All rights reserved. 3 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 2015-10-12 Primary HV MOSFETs SR MOSFETs TM CoolMOS IPP60R180C7 OptiMOSTM BSC010N04LS Reduced gate charge (Qg) New generation › Reduced Eoff › Best FOM RDS(on) x Qg › 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. 4 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 2015-10-12 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. 5 PCB boards layout: main power board and control and bias daughter boards Power density >20 W/inch3 Controller board 2015-10-12 Bias board Copyright © Infineon Technologies AG 2015. All rights reserved. 6 Main power board schematic (digital) 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 7 Bias board schematic 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 8 Analog control board schematic 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 9 Digital controller XMC4200Q48K256 AB Digital control board schematic 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 10 PCB structure 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 11 BOM (rework from digital to analog) Part Value Pcs Tolerance Device Package Description Assembling info C3 470n/50V 1 C-EU_C0805 C0805 CAPACITOR Replace 10n/50V with 470n/50V R19 4K3 1 ±1% R-EU_R0805 R0805 RESISTOR Replace 330R with 4K3 R20 4K3 1 ±1% R-EU_R0805 R0805 RESISTOR Replace 330R with 4K3 R36 56R 1 ±1% R-EU_R0805 R0805 RESISTOR Assemble n.a. with 56R IC1 Board 1 Board PCB Analog_Controlcard C3 2015-10-12 R19 & R20 Supplier IFX R36 Copyright © Infineon Technologies AG 2015. All rights reserved. 12 Table of contents I General description II Efficiency results III Design concept 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 13 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] 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 14 Table of contents 1 General description 2 Efficiency results 3 Design concept 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 15 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 2015-10-12 n Vo _ max K max (Q, m, Fx ) Vin _ min 2 Copyright © Infineon Technologies AG 2015. All rights reserved. 16 Resonant tank components and related resonant frequencies › n=Vin_nom/(2xVo)=380/(2*12)≈16 › Lm=195µH › Lr=15.5µH › Ln=Lm/Lr=12.5 › Cr=66nF 1 fo 157kHz 2 Lr Cr 2015-10-12 1 fp 42.7kHz 2 ( Lr Lm) Cr Copyright © Infineon Technologies AG 2015. All rights reserved. 17 Gain curves DC - gain curve (600W LLC hardware revision C7) 1,2 M max 1,1 n Vo _ max Vin _ min 2 1 gain 5A 0,9 0,8 15 A n Vo _ min M min Vin _ max 2 25 A 0,7 0,6 frequency [Hz] 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 18 Energy related calculations (Ref. IPP60R180C7 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 Enres _ min Encap _ max 1 Encap _ max (2Co (er )) V ² DS _ max 9 J 2 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 19 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 2015-10-12 tdead,min t ecs 2 Q oss, @ 400 V 1 tdead, min 2 Im, pk Copyright © Infineon Technologies AG 2015. All rights reserved. 20 Time related calculations (Ref. IPP60R180C7 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 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 21 Main transformer structure: PQ35/35 core with TDK PC95 ferrite material 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 22 Resonant choke: RM12 core, material N87 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 23 Evaluation board EVAL_600W_12V_LLC_C7 2015-10-12 Copyright © Infineon Technologies AG 2015. All rights reserved. 24 Support slides 600W LLC evaluation board – EVAL_600W_12V_LLC_C7 Evaluation board page – – – – – Technical description Datasheets Parameters Related material Videos Product family pages – – – – – – Product brief Application notes Selection guides Datasheets and portfolio Videos Simulation models 2015-10-12 – – – – 650V CoolMOS™ C7 XMC 32-Bit Industrial Microcontroller Resonant Mode Controller OptiMOS™ 5 40V and 60V Copyright © Infineon Technologies AG 2015. All rights reserved. 25