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

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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, EVAL_600W_LLC_12V_C7_D

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Example of system understanding: Infineon
demo solution for Titanium HV DC/DC stage
Half-Bridge LLC with Primary HV MOSFETs SR MOSFETs
synchronous rectification in CoolMOS TM IPP60R180C7 OptiMOSTM BSC010N04LS
center tap configuration Reduced gate charge (Qg) New generation
› Reduced Eoff › Best FOM RDS(on) x Qg
Vin 350-410 VDC › High body diode ruggedness › Best FOM RDS(on) x Qoss

Vin_nom 380 VDC HB Gate Drive IC Bias QR Flyback SR MOSFETs

2EDL05N06PF controller BSC010N04LS
Vout_nom 12 VDC Non isolated LS Gate Drive ICE2QR2280Z
2EDN7524F
Iout 50 A LLC controller
Digital XMC4200 / Analog ICE2HS01G
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
Resonant inductor Transformer
Lm 195 uH RM12 core PQ35/35 core

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Control board analog & digital

Two possible solution to control Infineon`s 600 W LLC evaluation board

Analog - ICE2HS01G Digital - XMC4200-Q48K256 AB

› Resonant mode controller for Half-Bridge LLC › ARM® Cortex®-M4, 80 MHz, incl. single cycle
resonant converter with synchronous DSP MAC and floating point unit (FPU)
rectification drives › 8-channel DMA + dedicated DMA for USB
› Driving signal for synchronous rectification › USB 2.0 full-speed device
which support full operation of Half-Bridge LLC › CPU Frequency: 80 MHz
resonant converter
› eFlash: 256 kB including hardware ECC
› 20-pin DSO package
› 40 kB SRAM
› 30 kHz to 1MHz switching frequency
› Package: PG-LQFP-48
› 50% duty cycle for both primary and secondary
gate drives
› Adjustable dead time with high accuracy

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PCB boards layout: main power board and
control and bias daughter boards

 Power density >20 W/inch3

Controller board Bias board

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Main power board schematic (digital)

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Bias board schematic

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Analog control board schematic

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Digital control board schematic

Digital controller

Q48K256 AB
XMC4200-
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PCB structure

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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

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 IFX

C3 R19 & R20 R36

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Table of contents

I General description

II Efficiency results

III Design concept

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Automated efficiency measurement

Combination of converter design Proper selection of SR LV device and

(resonant tank, transformer) and secondary side
proper HV device election
0,99
97.8% peak efficiency!
0,985
› Output voltage: 12 VDC
0,98
0,975
› Output current: 50 A
0,97 › Efficiency: > 95% @ 10%
0,965 load, Vin = 380 VDC
0,96 › Efficiency max: 97.8%, Vin
0,955 = 380 VDC
Highest Efficiency standard in
Efficiency

0,95
0,945 Computing applications
0,94 (HV DC/DC stage)
0,935 C7 180mOhm
0,93
0,925
0,92
0,915
0,91
0,905
0,9 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]

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Table of contents

1 General description

2 Efficiency results

3 Design concept

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Design procedure: input data

Vin _ nom
n
2  Vout _ nom
n Vo _ min
M min  K min(Q, m, Fx ) 
Vin _ max
2
n Vo _ max
M max  K max (Q, m, Fx ) 
Vin _ min
2
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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 1
fo   157kHz fp   42.7kHz
2  Lr  Cr 2  ( Lr  Lm)  Cr

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Gain curves

DC - gain curve (600W LLC hardware revision C7)

1,2
n  Vo _ max
M max 
Vin _ min
1,1 2

1
5A

15
gain

n Vo _ min
0,9 A
M min  25
Vin _ max A

0,8 2

0,7

0,6

frequency [Hz]

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Energy related calculations
(Ref. IPP60R180C7 device parameters)

2 2 n  Vo
Im ag _ min    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

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Qoss, Imag,pk, tdead,min, tecs relationship

IQ2
Im,pk
t
IQ 2(t )  Im, pk  (1  ) t  tecs
tecs Cds
tecs  f ( Rg , tot,Vgs, th, )
IQ 2(t )  0 t  tecs 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

1 tdead, min 

t 2  Q

ecs oss, @ 400 V

2 Im, pk
tecs tdead,min

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Time related calculations
(Ref. IPP60R180C7 device parameters)

2 2 n  Vo
Im ag _ min    0.672 A
 2  fsw _ max  Lm
2 2 n  Vo
Im ag _ max    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

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Main transformer structure:
PQ35/35 core with TDK PC95 ferrite material

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Resonant choke:
RM12 core, material N87

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Evaluation board
EVAL_600W_12V_LLC_C7

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Support slides
600W LLC evaluation board

Evaluation board page – EVAL_600W_12V_LLC_C7

– Technical description
– Datasheets
– Parameters
– Related material
– Videos

– 650V CoolMOS™ C7
Product family pages – XMC 32-Bit Industrial Microcontroller
– Resonant Mode Controller
– Product brief – OptiMOS™ 5 40V and 60V
– Application notes
– Selection guides
– Datasheets and portfolio
– Videos
– Simulation models

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