EVAL-2HS01G-300W

Application Note, V1.1, May 2012
EVAL-2HS01G-300W
300W LLC Evaluation Board with LLC
controller ICE2HS01G
BDTIC
Power Management & Supply
www.BDTIC.com/infineon
N e v e r
s t o p
t h i n k i n g .
BDTIC
Edition 2012-05-07
Published by Infineon Technologies Asia Pacific,
168 Kallang Way,
349253 Singapore, Singapore
© Infineon Technologies AP 2010.
All Rights Reserved.
Attention please!
The information herein is given to describe certain components and shall not be considered as a guarantee
of characteristics.
Terms of delivery and rights to technical change reserved.
We hereby disclaim any and all warranties, including but not limited to warranties of non-infringement,
regarding circuits, descriptions and charts stated herein.
Information
For further information on technology, delivery terms and conditions and prices please contact your 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 your nearest Infineon Technologies Office.
Infineon Technologies Components may only be used in life-support devices or systems 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.
www.BDTIC.com/infineon
EVAL2HS01G300W
Revision History:
Previous Version:
2012-05
NA
300W LLC Evaluation Board with LLC controller ICE2HS01G
License to Infineon Technologies Asia Pacific Pte Ltd
Li Dong
Ke Chunshan
V2.0
AN-PS0060
BDTIC
www.BDTIC.com/infineon
Page
Table of Content
1 Introduction......................................................................... 5 2 Evaluation Board ................................................................ 5 Technical Specifications ................................................................ 5 3 Control Circuit Diagram ..................................................... 6 4 Power Circuit Diagram ....................................................... 7 5 PCB Layout – Top............................................................... 8 6 PCB Layout – Bottom......................................................... 8 7 Component List .................................................................. 9 8 Magnetic components...................................................... 11 8.1 Main transformer ......................................................................................................................... 11 8.2 Resonant choke .......................................................................................................................... 12 8.3 Pulse transformer ....................................................................................................................... 13 9 Efficiency Test .................................................................. 14 10 Test Waveforms ................................................................ 14 10.1 Soft start at full load and light load ........................................................................................... 14 10.2 Burst mode operation at no load ...............................................................................................16 10.3 SR soft start at full load ............................................................................................................. 16 10.4 Zero Voltage Switching .............................................................................................................. 17 10.5 Main under voltage protection ................................................................................................... 18 10.6 Dynamic load response .............................................................................................................. 19 10.7 Hold up time test ......................................................................................................................... 20 BDTIC
Application Note
4
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2012-05-07
1
Introduction
The evaluation board presented is a 300W LLC Converter with 400VDC input and 12V output. It is
controlled by Infineon’s 2nd generation half-bridge LLC controller ICE2HS01G. The ICE2HS01G is
designed especially for high efficiency application with its synchronous rectification (SR) control for
the secondary side. With its new driving techniques, SR can be realized for half-bridge LLC converter
operated with secondary switching current in both CCM and DCM conditions.
In this application note, the schematic circuit, PCB layout and BOM for the evaluation board are
shared, followed by the performace of the board, such as the efficiency and operation waveforms. For
the detailed step-by-step design procedure of this converter, please refer to our design guide.
BDTIC
2
Evaluation Board
Technical Specifications
Input voltage Vin
400VDC
Output voltage and current Vo , I o
12VDC, 25A
Output power Pin
~ 300W
Efficiency 
>97% at 100% load
>97% at 50% load
~96% at 20% load
85kHz
Resonant frequency f r
Application Note
5
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2012-05-07
3
BDTIC
Control Circuit Diagram
Application Note
6
2012-05-07
www.BDTIC.com/infineon
4
BDTIC
Power Circuit Diagram
400V INPUT
1
1
RT100
2.5R
D103
C100
+
P_VBUS
C103
2n2/Y1
1N4148
Q100
270uF/450V
P_GND
P_HG
R100 4.7R 1%
33nF/630V
P_HS
Q101
IPB011N04N
R102
S_HG
TR100
1R0
R101
10k
R103
10k
L100
40uH//RM10
P_VCC
C104
+
C102
IPA60R190E6
12V
C105
P_VCr
47u/35V 100n/100V
D104
47uF/16V
1N4148
Q102
IPA60R190E6
P_LG
R104 4.7R 1%
C107 +
S_LG
R110
R112
10R
10R
1R0
R108
10k
10R
1
470R 1%
12V
IC300
NC
ZD100
5V1
*
2
R111
10R
1N4148
Q106
BC53
1
D101
R113
470R1%
1N4148
C113
1u0
3
R109
R106
R114
1k1%
Q104
BCX56
P_SLG
D100
3
P_SHG
R115
1k 1%
Q105
BC53
ZD101
5V1
C116
100n
NC
INA
OUTA
GND
VDD
INB
OUTB
12V
+ C121
47uF/35V
C122
100n
UCC27324_1
12V
S_LG
C114 10n
R116
560R
R118
56R
1
N.C.
R117
R122
820
7
2012-05-07
www.BDTIC.com/infineon
C120
NC
IC101
1
TL431
SFH617A-2
Application Note
NC
2
2
C119
+
3
3
ZD102
N.C.
R120
1k 1%
C115
100p
2
4
C118
220nF
IC100
510R
R119
13k 1%
20K
R124
R121
0R
C117
10nF
S_HG
R123
P_Vreg
47uF/16V
C111 +
Q103
IPB011N04N
R107
C112
Q107
BCX56
47uF/16V
C110 +
*
R105
10k
TR101
C109 +
C106
33nF/630V
100n
47uF/16V
47uF/16V
C108 +
R125
3k6 1%
5
PCB Layout – Top
1
2
1
2
1
1
2
1
2
1
1
12
2
11
3
10
4
9
5
8
6
7
1
2
2
0
1
3
1
2
1
2
2
2
1
BDTIC
1
1
2
1
1
2
2
4
2
7
8
11
12
6
5
2
1
2
1
1
2
1
2
2
2
2
3
1
3
3
2
4
1
1
2
1
1
2
0
1
1
3
1
2
0
1
6
PCB Layout – Bottom
1
2
1
1
2
1
2
2
1
1
1
12
2
11
2
2
1
1
1
3
3
2
3
2
3
3
10
3
3
2
4
1
2
1
2
1
9
2
1
3
3
5
0
1
1
8
2
2
3
3
3
6
7
2
1
1
1
2
2
1
1
2
2
4
2
1
1
7
8
11
12
6
5
2
1
1
2
2
1
2
1
2
1
2
1
1
3
2
2
3
1
2
1
3
2
1
3
2
1
2
1
2
2
1
4
5
3
6
2
2
2
2
1
2
7
1
1
1
2
2
1
2
1
2
2
1
2
1
1
2
2
1
2
3
1
3
1
1
1
2
1
2
1
1
2
2
1
2
2
1
1
2
1
1
2
2
1
2
8
20
1
19
2
18
3
17
4
16
5
15
6
14
7
13
8
12
9
1
2
1
7
2
6
3
5
4
1
2
1
2
2
1
1
1
2
2
1
2
2
1
1
1
1
2
1
2
2
1
1
2
1
1
2
2
1
1
2
1
1
2
1
2
1
2
2
1
1
2
1
2
2
1
2
1
2
1
1
2
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
10
2
1
2
Application Note
1
2
2
0
2
4
1
1
2
1
2
1
2
2
1
2
1
1
11
0
1
3
1
2
2
1
2
8
2
1
2
1
8
1
1
1
1
2
1
1
2
2
1
2
1
2
1
2
2
1
3
1
2
2
2
www.BDTIC.com/infineon
2012-05-07
7
Component List
Designator
Description
PCB
Double Layer
Footprint
Description
Quantity
2 ounce copper
1
C100
270uF/450V
RB30
Aluminum Electrolyte
1
C102,
C106
C103
33nF/630V
MKT6/13/10
CERAMIC
2
2n2/Y1
CY10
CERAMIC
1
C104
47u/35V
RB6.5
Aluminum Electrolyte
1
C105
100n/100V
1206C
CERAMIC
1
C107,
C108,
C109,
C110,
C111
47uF/16V
RB10
Aluminum Electrolyte
5
C112,
C116
C113
100n
1206C
CERAMIC
2
1u0
1206C
CERAMIC
1
C114
47n
1206C
CERAMIC
1
C115
100p
1206C
CERAMIC
1
C117,
C118
C119
10nF
1206C
CERAMIC
2
1u
1206C
Aluminum Electrolyte
1
C120
NC
1206C
C121
47uF/35V
RB6.5
Aluminum Electrolyte
1
C122,
C200,
C205
100n
MKT2/7/5
CERAMIC
3
C201,
C204,
C207
100n
MKT2/7/5_0M8
CERAMIC
3
C203
820p
MKT2/7/5
CERAMIC
1
C206
47nF
0805C
CERAMIC
1
C208
220p/1kv
MKT2/7/5
CERAMIC
1
C209
1u
0805C
CERAMIC
1
C210
1n0
0805C
CERAMIC
1
C211
2.2u
0805C
CERAMIC
1
C212
NC
0805C
CERAMIC
1
C213
10n
0805C
CERAMIC
1
C214
220n
0805C
CERAMIC
1
D100,
D101,
D201,
D202
1N4148
1206D
DIODE
4
IC100
SFH617A-2
DIP4/10
OPTO COUPLER
1
IC101
TL431
TO92-CBE
IC200
IC-ST-L6385
SO-8
BDTIC
Application Note
0
1
Half-bridge driver
9
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1
2012-05-07
IC201
ICE2HS01G
SOL-20
1
IC300
UCC27324_1
SO-8
1
L100
40uH//RM10
RM10
Resonant-Mode
Controller
CHOKE
Q100,
Q102
Q101,
Q103
Q104,
Q107
Q105,
Q106
R100,
R104,
R109,
R111,
R112
IPA60R199C6
T0-220
MOSFET
2
IPB011N04N
TO-263
MOSFET
2
BCX56
SOT-89
NPN Transistor
2
BC53
SOT-89
PNP Transistor
2
10R
1206R
RESISTOR
5
R101,
R103,
R105,
R108
10k
1206R
RESISTOR
4
R102,
R107
R106,
R113
R110
1R0
1206R
RESISTOR
2
2k0
1206R
RESISTOR
2
10R
1206
RESISTOR
1
1
BDTIC
R114,
R115
R116
4k7
1206R
RESISTOR
2
560
1206R
RESISTOR
1
R117
3k9
1206R
RESISTOR
1
R118
56R
1206R
RESISTOR
1
R119
11k
1206R
RESISTOR
1
R120
2k7
1206R
RESISTOR
1
R121
0R
1206R
RESISTOR
1
R122
820
1206R
RESISTOR
1
R123
2k2
1206R
RESISTOR
1
R124
NC
1206R
RESISTOR
1
R125
3k6
1206R
RESISTOR
1
R200,
R202
R201,
R203
R205
10R
0805r
RESISTOR
2
11k
0805r
RESISTOR
2
0M2
0805r
RESISTOR
1
R206
5k6/1%
0805r
RESISTOR
1
R207
12k/0.1%
0805r
RESISTOR
1
R208
240k
0805r
RESISTOR
1
R209
150k/1%
0805r
RESISTOR
1
R210
470k
0805r
RESISTOR
1
Application Note
10
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2012-05-07
R211
110k/1%
0805r
RESISTOR
1
R212
200R
1206R
RESISTOR
1
R213,
R214
R215
1M0
0805r
RESISTOR
2
2M0
0805r
RESISTOR
1
R216
24k/1%
0805r
RESISTOR
1
R217
NC
0805r
RESISTOR
1
R218
51k/1%
0805r
RESISTOR
1
R219
100k
0805r
RESISTOR
1
R220
820R
0805r
RESISTOR
1
R221
N.C.
0805r
RESISTOR
1
R222
0R
0805r
RESISTOR
1
R223,
R224,
R225,
R226
1M5/1%
1206R
RESISTOR
4
R227
24k
0805R
RESISTOR
1
R228
62R
0805R
RESISTOR
1
RT100
2.5R
NTC7.5
NTC THERMISTOR
1
PQ3230
1
BDTIC
TR100
TR101
ZD100,
ZD101
ZD102
8
WNP12048LM4
LLC Resonant
Transformer
Pulse Transformer
5V1
1206D
Zener Diode
2
9v1
1206D
Zener Diode
1
1
Specifications for Magnetic components
8.1
Main transformer
Core: PC95 PQ3230 (TDK)
Primary inductance Lp: 690uH±3% , between Pin 3 and Pin 4 (Gapped)
Leakage inductance: <2% of Lp with either Pin 7&11 shorted or Pin9&11 shorted
Teflon tube used for the pinout.
Application Note
11
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2012-05-07
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 12
Pin 11
Pin 10
Pin 9
Pin 8
Pin 7
TOP VIEW
7
4
3
11
9
BDTIC
Pin 4
Winding 4: 19 turns//60x0.1//2layers//tight
Pin 7
Winding 3: 2 turns//Cooper foil 0.3mm*15mm
Pin 11
Winding 2: 2 turns//Cooper foil 0.3mm*15mm
Pin 9
1.Pin 7/9/11 out wire should be 0.3x1.5mm
copper foil,
2. Copper foil for the secondary winding with
length 26cm, middle pin out at 12.5cm.
3. Teflon tube used in the pinout wire for safety
Winding 1: 14 turns//60x0.1Litz//2layers//tight
Pin 3
Core Center Limb
No
Margin
tape
No
Margin
tape
Length 18mm
Windings
1
Start
3
End
float
Wire
60x0.1mm Litz
Turns
14
Layers
2
Method
Tight
2
9
11
0.3mm*15mm
2
NA
Tight
3
11
7
0.3mm*15mm
2
NA
Tight
4
float
4
60x0.1mm Litz
19
2
Tight
8.2
Resonant choke
Core: RM10
Material: N87
Inductance: L=40uH
Application Note
12
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2012-05-07
Wingdings
Start-End
Wire
N1
10,11 — 7,8
2UEW,φ0.10mm *50p
Turns
Method
44
tight
BDTIC
8.3
Pulse transformer
Core: T14*8*7
Material: Ferrite
Inductance: 2.0mH Min ( no gap)
8
12
N3
N1
1
2
7
5
N4
N2
6
11
Teflon tube
Winding
Start
Finish
N1
8
7
Wire
Turns(Ts)
TLW-B, Φ0.20mm*1P
22TS
N2
5
6
TLW-B, Φ0.20mm*1P
18TS
N3
12
1
TLW-B, Φ0.20mm*1P
15TS
N4
2
11
TLW-B, Φ0.20mm*1P
15TS
Application Note
13
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Winding
2 wires in parallel
2012-05-07
9
Efficiency Test
Vout(V)
12.17 12.17 Iout(A)
1.25 2.49 12.17 12.16 12.16 4.98 12.41 24.87 Pout(W)
Load(%)
15.21 30.31 60.59 150.95 302.42 5% 10% 20% 50% 101% Vin(V)
399.99 399.89 Iin(A)
0.04 0.08 399.77 399.34 399.22 0.16 0.39 0.78 Pin(W)
17.06 32.17 62.70 154.46 310.84 Vcc(V)
15.00 15.00 15.00 15.00 15.00 Ivcc(A)
Pvcc(W)
Eff.(%)
0.03 0.03 0.03 0.03 0.03 0.375 0.375 0.375 0.375 0.375 87.2 93.1 96.1 97.5 97.2 BDTIC
10
Test Waveforms
10.1
Soft start at full load and light load
A. Full load
The output voltage rises up to nominal value in around 15ms. The overshoot is less than 5%. The
soft start is achieved by decreasing the switching frequency gradually from 280 KHz to 80kHz
until stable operation is reached.
Application Note
14
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2012-05-07
BDTIC
B. No load
The output voltage rises up to nominal value in around 15ms. The overshoot is less than 5%. IC
operates in burst mode after softstart.
Application Note
15
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2012-05-07
10.2
Burst mode operation at no load
When IC is operating in burst mode, the ripple of out voltage is less than 250mV.
BDTIC
10.3
SR soft start at full load
The SR operaton is enabled after the output voltage has been built up. In ICE2HS01G, SR operation will start
with small duty, around one-tenth of its normal duty, which will be kept same for 16 consective switching cycles.
Then, the duty is increased gradually step by step to the full duty. Total 7 steps are built for the softstart and
each step includes 16 switching cycles.
Application Note
16
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2012-05-07
10.4
Zero Voltage Switching
With proper design of LLC converter, ZVS can be realized over all load range. Channel 1 shows the resonant
current flowing through the resonant capacitor. Channel 2 and 4 represent the gate-source voltage and drain
source voltage of Q102.
A. Full load BDTIC
B. Light load(Iout=1A) Application Note
17
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2012-05-07
10.5
Main under voltage protection
A. IC starts operation when Vbus resumes to normal value Vbus‐on=368Vdc. BDTIC
B. IC stop switching when Vbus drops to designed value Vbus‐off=312V Application Note
18
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2012-05-07
10.6
Dynamic load response
A. [email protected]~20A, 5KHz, 800m A/u S
The ripple of output voltage is around 0.8V. BDTIC
B. 12V@ 2.5A~20A, 100Hz, 800m A/u S The ripple of output voltage is around 0.8V. Application Note
19
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2012-05-07
10.7
Hold up time test
The hold up time is about 22mS at full load after the input is disconnected from the board.
BDTIC
Application Note
20
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2012-05-07