600 W Half-Bridge LLC evaluation board. EVAL_600W_LLC_12V_C7_D digital & analog
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1 600 W Half-Bridge LLC evaluation board EVAL_600W_LLC_1V_C7_D digital & analog
2 Table of contents 1 General description Efficiency results 3 Design concept
3 General Description: The EVAL_600W_LLC_1V_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 ICEQR80Z, hi-low side driver EDL05N06PF, low-side Gate Driver EDN754F and a LLC Controller ICEHS01G for the analog or XMC400 in the digital version. Summary of features: Output voltage: 1 V Output current: 50 A 10% load > 95% Peak 50% load > 97,8% The following variants are available: 600W 1V LLC analog version with CoolMOS C7, IPP60R180C7, EVAL_600W_LLC_1V_C7 600W 1V LLC digital version with CoolMOS C7, IPP60R180C7, EVAL_600W_LLC_1V_C7_D 3
4 Example of system understanding: Infineon demo solution for Titanium HV DC/DC stage Half-Bridge LLC with synchronous rectification in center tap configuration V in V DC Primary HV MOSFETs CoolMOS TM IPP60R180C7 Reduced gate charge (Q g ) SR MOSFETs OptiMOS TM BSC010N04LS New generation Reduced E off Best FOM R DS(on) x Q g High body diode ruggedness Best FOM R DS(on) x Q oss V in_nom V out_nom I out P o 380 V DC 1 V DC 50 A 600 W HB Gate Drive IC Bias QR Flyback EDL05N06PF controller Non isolated LS Gate Drive ICEQR80Z EDN754F LLC controller Digital XMC400 / Analog ICEHS01G SR MOSFETs BSC010N04LS f res =f khz f min 90 khz f max 10 khz Transformer turns ratio 16:1 C r 66 nf L r 15.5 uh L m 195 uh Resonant inductor RM1 core Transformer PQ35/35 core 4
5 Control board analog & digital Two possible solution to control Infineon`s 600 W LLC evaluation board Analog - ICEHS01G 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 0-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 Digital - XMC400-Q48K56 AB ARM Cortex -M4, 80 MHz, incl. single cycle DSP MAC and floating point unit (FPU) 8-channel DMA + dedicated DMA for USB USB.0 full-speed device CPU Frequency: 80 MHz eflash: 56 kb including hardware ECC 40 kb SRAM Package: PG-LQFP-48 5
6 PCB boards layout: main power board and control and bias daughter boards Power density >0 W/inch 3 Controller board Bias board 6
7 Main power board schematic (digital) 7
8 Bias board schematic 8
9 Analog control board schematic 9
10 Digital controller XMC400- Q48K56 AB Digital control board schematic 10
11 PCB structure 11
12 BOM (rework from digital to analog) Part Value Pcs Tolerance Device Package Description Assembling info Supplier 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 R0 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 IFX C3 R19 & R0 R36 1
13 Table of contents I II III General description Efficiency results Design concept 13
14 Efficiency Automated efficiency measurement Combination of converter design (resonant tank, transformer) and proper HV device election Proper selection of SR LV device and secondary side 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 0,95 0,9 0,915 0,91 0,905 0,9 97.8% peak efficiency! Highest Efficiency standard in Computing applications (HV DC/DC stage) I OUT [A] Output voltage: 1 V DC Output current: 50 A Efficiency: > 10% load, V in = 380 V DC Efficiency max: 97.8%, V in = 380 V DC C7 180mOhm 0.1% Total accuracy 14
15 Table of contents 1 General description Efficiency results 3 Design concept 15
16 Design procedure: input data n V in V _ nom out_ nom M M min max K K min max ( Q, m, F x ) ( Q, m, F x ) n V V o _ min in _ max n V V o _ max in _ min 16
17 Resonant tank components and related resonant frequencies n=v in_nom /(xv o )=380/(*1) 16 L m =195µH L r =15.5µH L n =L m /L r =1.5 C r =66nF 1 fo 157kHz LrCr 1 fp 4. 7kHz ( Lr Lm) Cr 17
18 gain Gain curves DC - gain curve (600W LLC hardware revision C7) 1, 1,1 M max n V V in _ o _ max min 1 5 A 0,9 0,8 M min n V V o _ min in _ max 15 A 5 A 0,7 0,6 frequency [Hz] 18
19 Energy related calculations (Ref. IPP60R180C7 device parameters) I m ag _ min n V fsw _ o max L m 0.67 A En En res _ min cap _ max 1 ( L 1 ( m Lr) I² Co( er)) V ² mag _ min DS _ max 95.1 J 9 J Enres _ min En cap _ max 19
20 Q oss, I mag,pk, t dead,min, t ecs relationship I m,pk I Q I Q IQ ( t) Im, ( t) 0 pk (1 t t ecs ) t tecs t tecs t ecs f ( Rg, tot, Vgs, th C, C ds gd ) I m,pk I CHB t dead,min 0 I C HB 1 ( t) dt Im, pk tecs Im, pk ( tdead, min tecs) 400 V V BULK V HB 1 t dead, min t m, pk t ecs t dead,min ecs Q I 400 V 0
21 Time related calculations (Ref. IPP60R180C7 device parameters) I I t t m ag _ min m ag _ max dead dead n V fsw _ n V fsw _ o min tecs 400V, min 130 nsec Im ag, max tecs 400V, max 311nsec Im ag, min o max L L m m 0.67 A 1.66 A 1
22 Main transformer structure: PQ35/35 core with TDK PC95 ferrite material
23 Resonant choke: RM1 core, material N87 3
24 Evaluation board EVAL_600W_1V_LLC_C7 4
25 Support slides 600W LLC evaluation board Evaluation board page EVAL_600W_1V_LLC_C7 Technical description Datasheets Parameters Related material Videos Product family pages Product brief Application notes Selection guides Datasheets and portfolio Videos Simulation models 650V CoolMOS C7 XMC 3-Bit Industrial Microcontroller Resonant Mode Controller OptiMOS 5 40V and 60V 5
26
27 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Infineon: EVAL_600W_1V_LLC_C7
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