AN- EVAL- 1H S01G -1 - 200 W 2 00 W 24 V 6 A & 12 V 5 A S MP S de mons trator wi th I CE1 H S 01 G - 1 Application Note About this document Scope and purpose This document is a 200 W 24 V 6 A & 12 V 5 A 280 VAC input off-line half bridge LLC resonant converter demonstrator board using Infineon ICE1HS01G-1. Intended audience This document is intended for users of the ICE1HS01G-1 who wish to design a system of high efficiency, simple in design, low cost and high reliable in half bridge (HB) LLC resonant converter for application of LED/OLED/LCD/PDP TV, AC-DC adapter and audio SMPS. Table of Contents About this document ................................................................................................................... 1 Table of Contents ........................................................................................................................ 1 1 Abstract ..................................................................................................................... 3 2 Demonstrator board.................................................................................................... 3 3 Specifications of demonstrator board ........................................................................... 5 4 Features of ICE1HS01G-1.............................................................................................. 5 5 Circuit description....................................................................................................... 6 6 6.1 6.2 Circuit Operation ........................................................................................................ 7 Startup Operation ..................................................................................................................................... 7 Output Voltage Regulation....................................................................................................................... 8 7 7.1 Protection Features..................................................................................................... 9 VCC Under Voltage Protection ................................................................................................................... 9 8 8.1 Circuit Diagram and Components List ......................................................................... 12 Schematics...............................................................................................................................................12 1 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Abstract 8.2 8.3 PCB Layout ...............................................................................................................................................13 Components List .....................................................................................................................................14 9 9.1 Transformer Construction.......................................................................................... 17 Mains Transformer ..................................................................................................................................17 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 Electrical Test Results ............................................................................................... 19 Efficiency Measurements........................................................................................................................19 Zero Voltage Switching ...........................................................................................................................19 Soft Start ..................................................................................................................................................20 Over Current Protection .........................................................................................................................21 Over Load Protection ..............................................................................................................................21 Output Short Circuit Protection ............................................................................................................22 Mains Under Voltage Protection ............................................................................................................23 Burst Mode Operation at No Load .........................................................................................................23 Dynamic Load Response ........................................................................................................................24 11 References ............................................................................................................... 25 Revision History........................................................................................................................ 25 Application Note 2 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Abstract 1 Abstract The demo board described in this paper is a 200W half bridge LLC resonant converter using LLC controller ICE1HS01G-1, which is an 8-pin LLC controller developed by Infineon Technologies. ICE1HS01G-1 is specially designed for applications of switch mode power supplies used in LED / OLED / LCD / PDP TV, AC/DC adapter and Audio system. ICE1HS01G-1 is an 8-pin DSO-8 controller IC, the PCB layout can be easily implemented. Moreover, it includes all necessary control strategies for HB LLC resonant converter. ICE1HS01G-1 allows the designer to choose suitable operation frequency range by programming the oscillator with an external resistor. And the built-in soft-start function to limit both the inrush current and the overshoot of output voltage is also provided. In addition, ICE1HS01G-1 performs all necessary protection functions in HB LLC resonant converters. All of these make ICE1HS01G-1 an outstanding product for HB LLC resonant converter in the market. 2 Demonstrator board The 200W half bridge LLC resonant converter demo board with ICE1HS01G-1 is implemented as shown in Figure 1. The LLC stage’s full load efficiency reaches >93.9%. Figure 1 EVAL-1HS01G-1-200W half bridge LLC resonant converter (top view) Application Note 3 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Figure 2 EVAL-1HS01G-1-200W half bridge LLC resonant converter (bottom view) Application Note 4 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Specifications of demonstrator board 3 Specifications of demonstrator board Table 1 Specifications of EVAL-1HS01G-1-200W Nominal AC Input voltage 280 VAC Nominal DC Input voltage 380 VDC Mains under voltage protection point 285 VDC Auxiliary power supply for IC VCC 15 VDC Nominal output full load 24 V 6 A, 12 V 5 A Switching frequency 95kHz @ 24 V 6 A,12 V 5 A and 380 VDC input Form factor case size (L x W x H) 200mm x 120mm x 32mm 4 Features of ICE1HS01G-1 Table 2 Features of ICE1HS01G-1 Maximum 600kHz switching frequency Adjustable minimum switching frequency with high accuracy 50% duty cycle Mains input under voltage protection with adjustable hysteresis Two levels of over-current protection: frequency shift and latch off Open-loop/over load protection with extended blanking time Built-in digital and nonlinear soft start Adjustable restart time during fault protection period Application Note 5 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit description 5 Circuit description In actual application, the LLC stage is used to follow a PFC pre-regulator. In this demo board, in order to simplify and speed up the LLC controller’s feature evaluation, the conventional bridge rectifier BR100, instead of PFC, is used to provide high input DC voltage for the downstream LLC stage. Thus, around 280 VAC input voltage is recommended to feed this demo board, and accordingly 380 VDC voltage across bulk capacitor C100 can be achieved. The AC line input side comprises the input fuse FUSE100 as over-current protection. The X2 Capacitors CX100, CX101 and Choke L101 and Y1 capacitors CY100 and CY101 forms a main filter to minimize the feedback of RFI into the main supply. NTC resistor RT100 is placed in series with input to limit the initial peak inrush current. After the bridge rectifier BR100, together with a smoothing capacitor C100, a voltage of 300 VDC to 400 VDC is provided, depending on mains input voltage, to simulate the real operation condition with front end PFC pre-regulator. Also, the bulk capacitor C100 can be directly connected to an external DC power supply, thus the 380 VDC can be obtained. This measure makes sense when the customers want to evaluate the LLC stage’s efficiency. The second stage is a half bridge LLC resonant converter, operating in zero voltage switching mode. The controller ICE1HS01G-1 is an 8 pin LLC controller, which incorporates the necessary functions to drive the half bridge’s high side and low side MOSFETs (Q100 and Q101) by a 50% duty cycle with dead time. The switching frequency can be changed by ICE1HS01G-1 to regulate the output voltage against the load and input voltage variations. During operation, the primary MOSFETs Q100 and Q101 are turned-on under ZVS condition and the secondary rectifier diodes D100~D103 are turned-on and turned-off under ZCS condition. Hence high power conversion efficiency can be achieved. The Driver Circuit can be implemented by cost-effective pulse transformer. As shown in Figure-7, Pulse transformer TR200 is used to transmit the driver signal to MOSFETs for isolation purpose. The mains transformer TR100 uses the magnetic integration approach, incorporating the resonant series and shunt inductances. Thus, no additional external coils are needed for the resonance. The transformer configuration chosen for the secondary winding is center-tapped, and the output rectifiers D100~D103 are schottky diodes, in order to limit the power dissipation. In case of a short circuit, the current flowing through the primary winding is detected by the lossless circuit (C106, C111, D104, D105, R102, and R107) and the resulting signal is fed into CS Pin. In case of overload, the voltage on CS pin will overpass an internal threshold 0.8V that triggers a protection mode which keeping the current flowing in the circuit at a safe level. In addition, the blanking time and the restart time can be adjusted by external components. Application Note 6 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Operation 6 Circuit Operation 6.1 Startup Operation The controller ICE1HS01G-1 is targeting at applications with auxiliary power supply. In most cases, a frontend PFC pre-regulator with a PFC controller is used in the same system. After IC supply voltage is higher than 12V, and if the voltage on VINS pin is higher than 1.25V, IC will start switching with soft start. The soft start function is built inside the IC with a digital manner. During soft start, the switching frequency of the MOSFET is controlled internally by changing the current I SS instead of by the feedback voltage. The charging current ISS during soft start, which determines the switching frequency, is reduced step by step as shown in product datasheet [1]. The maximum duration of soft start is 32ms with 1ms for each step. Figure 3 illustrates the actual switching frequency vs start time when RFMIN=25kΩ. During soft start, the frequency starts from 209 kHz, and step by step drops to normal operation point. Switching Frequency (KHz) 220.0 200.0 180.0 160.0 140.0 120.0 100.0 80.0 60.0 40.0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Time (ms) Switching frequency during soft start @ RFmin=25kΩ Soft Start 1st step Frequency (KHz) Figure 3 500.0 450.0 400.0 350.0 300.0 250.0 200.0 150.0 100.0 5 10 15 20 25 30 35 40 RFmin (Kohm) Figure 4 Soft start 1st step switching frequency vs RFmin The soft start 1st step switching frequency, maximum frequency during soft start, is also closely related to the minimum switching frequency fixed by external RFmin resistance. Figure 4 illustrates the relationship between the 1st step frequency and RFmin. During soft start, the overload protection is disabled because FB voltage is high. Application Note 7 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Operation 6.2 Output Voltage Regulation The minimum switching frequency is a very important factor to guarantee the LLC topology output voltage regulation at low line input and full load condition. ICE1HS01G-1 allows the minimum switching frequency easily programmed by connecting an external resistor RFMIN between FMIN pin and ground. The FMIN pin provides a precise 1.5V reference. The resistor RFMIN, connected from FMIN pin to GND, determines the current (IFMIN) flowing out of FMIN pin. Around one-tenth of IFMIN is defined as the minimum charging current (Ichg_min), which in turn defines the minimum switching frequency. The maximum switching frequency during normal operation and the switching frequency variation range during soft start and over current protection are all related to this current flowing out of FMIN pin, which is discussed in the product datasheet [1]. Figure 5 Minimum switching frequency VS RFMIN The output load information is fed into the controller through feedback voltage V FB. Inside the IC, the feedback (FB) pin is connected to the 5V voltage source through a pull-up resistor RFB. Outside the IC, this pin is connected to the collector of opto-coupler. Normally, a ceramic capacitor CFB can be put between this pin and ground for signal smoothing purpose, also CFB is used to determine the extended blanking time for over load protection, which will be discussed in section 7.3. If the output load is increased, and consequently VFB is higher, ICE1HS01G-1 will reduce the switching frequency to regulate the output voltage and vice versa. The regulation of switching frequency is achieved by changing the charging current IFB. The relationship between IFB and VFB can be found in product datasheet [1]. The effective range of feedback voltage VFB is from 1V to 4V. Figure 6 graphs the relationship between the actual switching frequency and feedback voltage VFB when RFMIN=25kΩ. 160 Frequency (KHz) 140 120 100 80 60 40 0.80 1.30 1.80 2.30 2.80 3.30 3.80 4.30 FB voltage (V) Figure 6 Switching frequency VS feedback @ RFmin=25kΩ Application Note 8 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Protection Features 7 Protection Features 7.1 VCC Under Voltage Protection The controller ICE1HS01G-1 is targeting at applications with auxiliary power supply. In most cases, a frontend PFC pre-regulator with a PFC controller is used in the same system. The controller starts to operate when the supply voltage VCC reaches the on-threshold, typically 12V. The minimum operating voltage after turn-on, VVCCoff, is typically 11V. The maximum supply voltage VVCCmax is 18V. It is suggested that IC is supplied with a regulated dc power supply for stable operation. At the same time, a small bypass filter capacitor is suggested to be put between VCC and GND pins, as closely as possible. 7.2 Over Current Protection Current sense pin in ICE1HS01G-1 is only for protection purpose. ICE1HS01G-1 features two-level over current protection. In case of over-load condition, the lower OCP level，0.8V，will be triggered, the switching frequency will be increased according to the duration and power of the over load. The higher OCP level，1.6V，is used to protect the converter if transformer winding is shorted. When V CS reaches 1.6V, the IC will be latched immediately. If VCS is higher than 0.8V, IC will boost up the switching frequency. If V CS is lower than 0.75V, IC will resume to normal operation gradually. If VCS is always higher than 0.8V for 1.5ms, the frequency will rise to its maximum level and vice versa. To sum up, ICE1HS01G-1 will increase the switching frequency to limit the resonant current in case of temporary over-load and will also decrease the switching frequency to its normal value after over-load condition goes away. 7.3 Over Load Protection In case of output over load or open control loop fault, the FB voltage will increase to its maximum level. If FB voltage is higher than VFBH and this condition last longer than a fixed blanking time of T OLP (20ms), the IC will start the extended blanking timer. The extended blanking timer is realized by charging and discharging the filter capacitor CFB via the internal pull up resistor RFB and switch QFB. Accordingly the voltage across CFB varies between VFBL and VFBH. The time needed for CFB being charged from VFBL to VFBH can be calculated as: V VFBH tchg _ olp ln dd Vdd VFBL RFB CFB The time needed for CFB being discharged from VFBH to VFBL can be calculated as: V tdischg_ olp ln FBH VFBL RQFB C FB Thanks to an internal counter, the total extended blanking time can be calculated as: text _ blank 512 tchg _ olp tdischg_ olp where RQFB is switch QFB‘s on resistance, RQFB=900ohm, VFBH =4.5V, VFBL =0.5V. Application Note 9 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Protection Features For example, if CFB is 680pF, tchg _ olp is about 30us, tdischg_ olp is about 1.4us, text _ blank is about 16ms. If the converter returns to normal operation during the extended blanking time, IC will reset all faults timer to zero and return to normal operation. After IC enters into OLP, both switches will be stopped. However, the IC remains active and will try to start with soft start after an adjustable period. This period is realized by charging and discharging the capacitor CINS, connected to VINS pin, for N OLP_R times (NOLP_R=2048), accordingly the voltage across CINS varies between VINSH and VINSL. The charging and discharging time of CINS can be approximated as: tch arg ing R VBUS eq I INST Req VINSH RINS1 Req C INS ln Req I INST Req VINSL VBUS RINS1 t dicharg ing R VBUS eq 2 VINSL RINS1 Req 2 CINS ln Req 2 VINSH VBUS RINS1 where Req is the equivalent resistance for paralleling of RINS1 and RINS2, Req RINS1 // RINS 2 Req2 is the equivalent resistance for paralleling of RINS1, RINS2 and RQ3 (900ohm typically). Req 2 RINS1 // RINS 2 // RQ 3 IINST is an internal constant current source IINST=680μA. VINSL and VINSH is the min. and max voltage at VINS pin: VINSL=0.5V, VINSH=4.5V. For example, if assume RINS1=5MΩ, RINS2=22kΩ, then tcharging=158µs, tdischarging=44µs. IC will repeat the charging and discharging process for N OLP_R times (NOLP_R=2048). After that, IC will turn off the switches for both charging and discharging. In addition, the current source for hysteresis will be turned on and another blanking time of TBL_VINS (TBL_VINS=20ms) will be added so that VINS pin fully recovers and represents the bus voltage information. IC will start the soft start after the additional blanking time in case VVINS is higher than the VVINSon. The total restart time can be calculated as: trestart 2048 tch arg ing tdischarg ing 20ms 7.4 Mains Under Voltage Protection The working range of mains input voltage needs to be specified for LLC resonant converter. It is important for the controller to have input voltage sensing function and protection feature, which allow the IC to stop switching when the input voltage drops below the specified range and restart with soft start when the input voltage resumes to its normal level. The mains input voltage sensing circuit is shown in product datasheet [1]. Thanks to the internal current source Ihys (12µA) connected between VINS pin and Ground, an adjustable hysteresis between the on and off threshold of mains input voltage can be created as: Application Note 10 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Protection Features Vhys RINS1 I hys The mains input voltage is divided by RINS1 and RINS2. If the on and off threshold for mains input voltage is Vmainon and Vmainoff, the resistors RINS1 and RINS2 can be selected as: RINS1 Vmainon Vmainoff I hys , RINS 2 RINS1 VVINSon Vmainoff VVINSon where Ihys=12µA, VVINSon=1.25V. For example, if RINS1=5MΩ and RINS2=22kΩ, the calculated Vmainon=345V, Vmainoff=285V. 7.5 Open Load Protection At very light load condition, eg. open load, the designed maximum frequency may not be high enough to regulate the output voltage, the output voltage may loss control and cause damages. In order to avoid this issue, the feedback signal VFB is continuously monitored. When VFB drops below VFB_off (typical 0.2V), the switching signal is disabled after a fixed blanking time, TFB (typical 200ns). VFB will then rise as VOUT starts to decrease due to no switching signal. Once VFB exceeds the threshold VFB_on (typical 0.3V), IC resumes to normal operation. Application Note 11 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Diagram and Components List 8 Circuit Diagram and Components List 8.1 Figure 7 Schematics Schematics of 200W half bridge LLC resonant Application Note 12 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Diagram and Components List 8.2 PCB Layout Figure 8 Component side - View from component side Figure 9 Solder side - View from solder side Application Note 13 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Diagram and Components List 8.3 Components List Table 3 Bill of Materials Item Circuit code C100 Part value KBU8G (8A / 400V) 220µF/450V 1 BR100 2 Aluminum Electrolyte 3 4 C101 C102 1000µF/35V 1000µF/35V Aluminum Electrolyte Aluminum Electrolyte 5 C103 10µµF/50V Aluminum Electrolyte 6 C104 100nF/50V CERAMIC 7 C105 22nF/630V CERAMIC 8 9 C106 C107 220pF / 630V 1000µF/25V CERAMIC Aluminum Electrolyte 10 C108 1000µF/25V Aluminum Electrolyte 11 C109 470µF/25V Aluminum Electrolyte 12 C110 470µF/35V Aluminum Electrolyte 13 14 C111 C112 220nF/50V 680pF/50V CERAMIC CERAMIC 15 C113 22nF/50V CERAMIC 16 C114 33nF/50V CERAMIC 17 C115 N.C. CERAMIC 18 19 C116 C117 1µF/50V 1µF/50V Aluminum Electrolyte CERAMIC 20 CX100 100nF/305 VAC CERAMIC 21 CX101 220nF/305 VAC CERAMIC EPCOS / B32922C3224K000 22 CY100 2n2/500Vac Y1 CERAMIC EPCOS / B81123C1222M000 23 24 CY101 CY102 2n2/500Vac Y1 2n2/500Vac Y1 CERAMIC CERAMIC EPCOS / B81123C1222M000 EPCOS / B81123C1222M000 25 D100 MBR2035CT Vishay / MBR2035CT 26 D101 MBR2560CT SCHOTTKY DIODE SCHOTTKY DIODE 27 28 D102 D103 MBR2560CT MBR2035CT SCHOTTKY DIODE Vishay / MBR2560CT Vishay / MBR2035CT 29 D104 1N4148 DIODE 30 D105 1N4148 DIODE 31 D106 1N4148 DIODE 32 D107 1N4148 33 D202 MBR160 DIODE SCHOTTKY DIODE 34 D204 MBR160 SCHOTTKY DIODE 35 FUSE100 5A/250V RESISTOR FUSE 36 IC100 ICE1HS01G-1 Resonant-Mode Application Note Description Supplier / Part No. BRIDGE RECTIFIER SCHOTTKY DIODE 14 EPCOS / B43304C5227M000 EPCOS / B41821A6106M000 EPCOS / B32621A6223J000 Vishay / MBR2560CT INFINEON / ICE1HS01G-1 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Diagram and Components List Controller 37 IC101 SFH617A-2 OPTO COUPLER 38 IC102 TL431 ERROR AMPLIFIER 39 L100 1.2µH/7.5A CHOKE 40 L101 3.3mH/4.6A COMMON MODE CHOKE 41 L102 1.2µH/7.5A CHOKE 42 Q100 IPA50R299CP POWER MOSFET INFINEON / IPA50R299CP 43 Q101 IPA50R299CP POWER MOSFET INFINEON / IPA50R299CP 44 R100 2M /1% RESISTOR 45 R102 150R RESISTOR 46 R103 2M / 1% RESISTOR 47 R104 1M / 1% RESISTOR 48 R105 22k / 1% RESISTOR 49 50 R106_1 R106_2 24k / 1%, 0805 1k / 1% RESISTOR RESISTOR 51 R107 75R RESISTOR 52 R108 5k6 RESISTOR 53 R109 1k1 RESISTOR 54 55 R110 R111 10k / 1% 680R / 1% RESISTOR RESISTOR 56 R112 13k / 1% RESISTOR 57 R113 1k0 / 1% RESISTOR 58 R114 30k / 1% RESISTOR 59 R115 3k6 / 1% RESISTOR 60 R116 3k6 / 1% RESISTOR 61 R117 2k2 RESISTOR 62 R200 8R2 RESISTOR 63 R201 10R RESISTOR 64 R202 11K RESISTOR 65 R205 8R2 RESISTOR 66 R206 10R RESISTOR 67 R207 11K RESISTOR 68 RT100 S237/5 Thermister 69 TR100 TRANS-LLC-TWO LLC Transformer 70 TR200 71 VR100 72 ZD100 JP1, JP2, JP3, JP4, JP5, JP6, 73 Application Note Pulse Transformer S10k/275 Pulse transformer VDR 15V Zener diode Jumper Jumper 15 EPCOS / B82734R2462B30 EPCOS / B57237S509M000 Wurth Electronics Midcom Inc. (Model:750342784) Wurth Electronics Midcom Inc. (Model:750342109) EPCOS / B72210S271K101 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Circuit Diagram and Components List 74 JP7, JP8, JP9, JP10, JP11, JP12 HS1 For Q100, Q101 Heatsink 75 HS2 For D101, D102 Heatsink 76 HS3 For D100, D103 Heatsink 77 CN1 For AC 2-pin connector 78 CN2 For 15V 2-pin connector 79 CN3 For 12V 2-pin connector 80 CN4 For 24V 2-pin connector Application Note 16 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Transformer Construction 9 Transformer Construction 9.1 Mains Transformer Bobbin: type ER34 Core: TP4 ER34 from TDG Primary inductance: 636µH±5%, Gapped between Pin3 and Pin5 (measured at 50kHz) Leakage inductance: 100µH±5%, measured between Pin3 and Pin5 by shorting (Pin 8 & 10 and Pin 12 &14) or (Pin 8& 9 and Pin 12 & 13) (measured at 100kHz) Manufacturer and part number : Wurth Electronics Midcom 750342784 Figure 10 LLC resonant transformer electrical diagram Figure 11 LLC resonant transformer complete – bottom view Pin 14 Pin 13 Pin 13 Pin 12 Pin 5 Pin10 Pin 9 Pin9 Pin 8 Pin 3 Core Center Limb Primary winding Secondary winding 1 Secondary winding 2 Insulation tape Figure 12 LLC resonant transformer winding position Application Note 17 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Transformer Construction Table 4 LLC resonant transformer winding characteristics Pins 3~5 8~9 9~10 12~13 13~14 9.2 winding primary Secondary 1 Secondary 2 Secondary 3 Secondary 4 turns 34 4 4 2 2 wire 7*0.20 19*0.20 19*0.20 19*0.20 19*0.20 Pulse Transformer Bobbin: E16/8/5, Vertical version from TDG Core: E16/8/5 TP4 from TDG Manufacturer and part number : Wurth Electronics Midcom 750342109 Pin 8 Pin 1 Pin 7 Pin 5 Pin 4 Pin 6 Figure 13 Pulse Transformer electrical diagram Vertical bobbin Figure 14 1 2 3 4 TOP VIEW Pin Pin Pin Pin Pin Pin Pin Pin 8 7 6 5 Pulse transformer complete – top view Insulation tape Pin 8 Pin 7 22 turns 1XAWG28 Pin 4 Pin 1 18 turns 1XAWG28 Pin 6 Pin 5 22 turns 1XAWG28 Core Centre Figure 15 Pulse transformer winding position Application Note 18 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Electrical Test Results 10 Electrical Test Results 10.1 Efficiency Measurements Table 5 shows the output voltage measurements at the nominal input voltage 380 VDC, with different load conditions. The input voltage 380 VDC is supplied from a high voltage DC power supply. Table 5 Efficiency measurements @ input voltage =380 VDC Load(%) Vout1(V) Iout1(A) Vout2(V) Iout2(A) Pout(W) Vin(V) Iin(A) Pin(W) VCC(V) Ivcc(A) Pvcc(W) Eff.(%) 100% 24.02 6.01 11.80 5.00 203.31 379.9 0.57 216.20 14.18 0.0199 0.28 93.91% 82% 23.99 5.00 11.82 4.00 167.30 379.9 0.47 177.53 14.18 0.0200 0.28 94.09% 65% 23.96 4.00 11.83 3.01 131.45 379.9 0.37 139.39 14.18 0.0202 0.29 94.11% 50% 23.97 3.01 11.82 2.50 101.77 379.9 0.28 108.04 14.18 0.0203 0.29 93.94% 47% 23.93 3.01 11.84 2.00 95.83 379.9 0.27 101.78 14.18 0.0203 0.29 93.90% 29% 23.89 2.01 11.86 1.00 59.89 379.9 0.17 64.13 14.18 0.0205 0.29 92.98% 20% 23.93 1.20 11.84 1.00 40.57 379.9 0.12 44.14 14.18 0.0206 0.29 91.30% 15% 23.89 1.01 11.86 0.51 30.08 379.9 0.09 33.17 14.18 0.0207 0.29 89.90% 10% 23.92 0.60 11.84 0.51 20.35 379.9 0.06 23.36 14.18 0.0207 0.29 86.00% 5% 23.90 0.30 11.85 0.25 10.15 379.9 0.03 12.88 14.18 0.0208 0.30 77.02% The power losses due to IC and driver circuit are both included. In addition, the efficiency values were measured after 30 minutes of warm-up at full load. 100% 95% 90% Efficiency 85% 80% 75% 70% 65% 60% 55% 0 50 100 150 Pout (W) Figure 16 LLC stage efficiency 10.2 Zero Voltage Switching Application Note 19 200 250 Eff @ 380Vdc Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Electrical Test Results The LLC system can achieve ZVS over a very wide range of load. Vd_Q101 Vd_Q101 Ip_TR100 Ip_TR100 VLDS VLDS VHGS VHGS Figure 17 Zero Voltage switching (Left: @ 380 VDC input voltage and 100% full load, Right : @ 380 VDC input voltage and 10% full load) 10.3 Soft Start During start-up at full load or no load, the primary resonant current is strictly limited, and the 24 V output voltage smoothly rises to its regulated value. The overshoot is less than 10%, the start-up time is less than 30ms. fsw f sw Vout_24V Vout_24V Ip Ip Vgate Vgate VFB VFB Figure 18 Soft start at full load and no load (Left: Soft start @ 380 VDC input voltage and full load, Right : Soft start @ 380 VDC input voltage and no load) Application Note 20 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Electrical Test Results 10.4 Over Current Protection Figure 19 shows the over current protection. Two kinds of OCP are avilable. The 1st is VCS > 0.8 V and the switching frequency increase according to the exceeded duration. Then it would return to normal switching frequency when VCS < 0.75 V (left side waveform). The 2nd one is VCS > 1.6 V, the system enters latch mode (right side waveform). o Vout_12V Vlg V_out_12V 2 V Vout_12V 4 VVlg Vout_12V V V fsw I fsw N S VCS VCS V V I N S Figure 19 Over Current Protection (Left : 12 V @ 5 A, 24 V @ 6 A – 9 A - switching frequency increase when VCS > 0.8 V and then drop to normal when V CS < 0.75 V. The system enters AR after over load protection reached. Right : 24 V @ 6 A, 12 V short circuit - system enter OCP latch mode when the VCS > 1.6 V.) 10.5 Over Load Protection Blanking time in case of over load protection can be adjusted as discussed before, the charging time t chg_olp and discharging time tdischg_olp of CFB is 31.6µs and 1.62µs respectively, this measured result is closely equal to the calculated result which is mentioned at section 7.3. Vo_24V VFB Vg VVINS VFB Figure 20 Adjustable extended blanking time in case of over load protection Restart time in case of over load protection can also be adjusted as discussed before, the charging time tcharge and discharging time tdischarge of Cvins is 118.4µs and 51.8µs respectively, this measured result is closely equal to the calculated result which is mentioned at section 7.3. Application Note Vo_24V 21 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Electrical Test Results Vo_24V VFB VFB Vg V o Vg _V VVINS VVINS 2 F 4 B VVINS V V V I N VVINS S V V I N S Figure 21 Adjustable restart time in case of over load protection (Left : CVINS charging time, Right : CVINS discharging time) 10.6 Output Short Circuit Protection When the output load is short circuit, VFB jumps to a higher value. When this condition lasts longer than the internal fixed blanking time 20ms, the extended adjustable blanking time will be initiated. After these two blanking times the IC will enter restart mode and stops switching if the short circuit condition still exists. After an adjustable restart time plus an internal fixed restart time 20ms, the IC resumes to normal operation with soft start. During soft start, the over load protection is disabled. When soft start process completed, if the output short circuit condition still exists, IC will enter auto restart mode again. When the output short circuit condition disappears, IC will resume to normal operation and the 24 V output voltage is established again. Vo_24V VFB Vg VVINS Internally fixed blanking time 20ms Figure 22 Adjustable blanking time Adjustable restart time Internally fixed restart time 20ms Output short circuit protection Application Note 22 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 Electrical Test Results 10.7 Mains Under Voltage Protection When Vbus drops lower than 285 VDC, IC stops switching; When Vbus rises up to 356 VDC, IC starts normal operation after a 500.8us blanking time. These measured results are closely equal to the calculated results mentioned at section 7.4. Vbus Vbus Vgate Vgate VVINS VVINS V o _ V 2 F 4 B V V V I N S V V I N S Figure 23 Mains under voltage protection (Left : IC starts operation when Vbus resumes to normal value, Right : IC stops switching when Vbus drops to designed value) 10.8 Burst Mode Operation at No Load Burst mode operation is implemented in ICE1HS01G-1 to avoid possible over output voltage issue in case of light load or no load operation. When VFB drops below VFB_off (measured value 0.180 V), the switching signal will be disabled. VFB will then rise as Vout starts to decrease due to no switching signal. Once VFB exceeds the threshold VFB_on (measured value 0.285 V), IC resumes to normal operation. Vout_24V VFB Vgate Figure 24 Burst mode operation Application Note 23 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 10.9 Dynamic Load Response Figure 25 shows the dynamic behavior of this demo board during a load variation from around 10% to 100% full load on one output, with the other output at its full load. The output voltage ripple of 24 V and 12 V are both less than 5%. Vout_24V Vout_24V o _ 2 V Vout_12V Vout_12V 4 V V V I Iout_24V Iout_12V N S V V I N S Figure 25 Dynamic load response (Left : 24 V @ 6 A, 12 V @ 0.5 A – 5 A, Right : 24 V @ 0.5 A - 6 A, 12 V @ 5 A) Application Note 24 Revision 2.1a, 2015-11-06 200 W 24 V 6 A & 12 V 5 A SMPS demonstrator with ICE1HS01G-1 References 11 References [1] Datasheet ICE1HS01G-1 Half-Bridge Resonant Controller, Infineon Technologies AG, 2011 [2] Application Note ANPS0031 -ICE1HS01G Half Bridge LLC Resonant Converter Design using ICE1HS01G, Infineon Technologies, 2009 [3] RW ERICKSON, D MAKSIMOVIC: ‘Fundamentals of power electronics’ (Kluwer Academic Publishers, 2001), pp. 705–755 [4] B Yang: ‘Topology investigation for front end DC/DC power conversion for distributed power system’, PhD thesis, Virginia Polytechnic Institute and State University, 2003 [5] Mingping Mao, Dimitar Tchobanov, Dong Li, Martin Maerz, Tobias Gerber, Gerald Deboy, Leo Lorenz.: ‘Analysis and design of a 1MHz LLC Resonant Converter with Coreless transformer driver’. PCIM Conference, Shanghai. 2007 [6] M Mao, D Tchobanov, D Li, M Maerz.: ‘Design optimization of a 1MHz half bridge CLL resonant converter’. IET Power Elec Revision History Major changes since the last revision Page or Reference 12, 13, 14, 15, 16 Application Note Description of change Revise schematic value, add PCB solder side legend and revise BOM typo 25 Revision 2.1a, 2015-11-06 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, CoolMOS™, CoolSET™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPIM™, EconoPACK™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, I²RF™, ISOFACE™, IsoPACK™, MIPAQ™, ModSTACK™, myd™, NovalithIC™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PRO -SIL™, PROFET™, RASIC™, ReverSave™, SatRIC™, SIEGET™, SINDRION™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, 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. AUTOSAR™ is licensed by AUTOSAR development partnership. Bluetooth™ of Bluetooth SIG Inc. CAT-iq™ of DECT Forum. COLOSSUS™, FirstGPS™ of Trimble Navigation Ltd. EMV™ of EMVCo, LLC (Visa Holdings Inc.). EPCOS™ of Epcos AG. FLEXGO™ of Microsoft Corporation. FlexRay™ is licensed by FlexRay Consortium. HYPERTERMINAL™ of Hilgraeve Incorporated. IEC™ of Commission Electrotechnique Internationale. IrDA™ of Infrared Data Association Corporation. ISO™ of INTERNATIONAL ORGANIZATION FOR STANDARDIZATION. MATLAB™ of MathWorks, Inc. MAXIM™ of Ma xim Integrated Products, Inc. MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS Technolo gies, Inc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of Applied Wave Research Inc., OmniVision™ of OmniVis ion Technologies, Inc. Openwave™ Openwave Systems Inc. RED HAT™ Red Hat, Inc. RFMD™ RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc. SO LARIS™ 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 Cade nce Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™ of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited. Last Trademarks Update 2011-11-11 www.infineon.com Edition 2015-11-06 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? Email: [email protected] Document reference ANDEMO_2015xx_PL21_xxx Legal Disclaimer THE INFORMATION GIVEN IN THIS APPLICATION NOTE (INCLUDING BUT NOT LIMITED TO CONTENTS OF REFERENCED WEBSITES) IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT. THE RECIPIENT OF THIS APPLICATION NOTE MUST VERIFY ANY FUNCTION DESCRIBED HEREIN IN THE REAL APPLICATION. INFINEON TECHNOLOGIES HEREBY DISCLAIMS ANY AND ALL WARRANTIES AND LIABILITIES OF ANY KIND (INCLUDING WITHOUT LIMITATION WARRANTIES OF NONINFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF ANY THIRD PARTY) WITH RESPECT TO ANY AND ALL INFORMATION GIVEN IN THIS APPLICATION NOTE. Information For further information on technology, delivery terms and conditions and prices, please contact the nearest Infineon Technologies Office (www.infineon.com). Warnings Due to technical requirements, components may contain dangerous substances. For information on the types in question, please contact the nearest Infineon Technologies Office. Infineon Technologies components may be used in life-support devices or systems only with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered.