EVAL3KW2LLCC720TOBO1

3.0 kW Dual LLC Evaluation Board EVAL_3kW_2LLC_C7 TO-220 TO-247 Di Domenico Francesco Zechner Florian Table of contents 1 General description 2 Efficiency results 3 Design concept 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 2 Table of contents 1 General description 2 Efficiency results 3 Design concept 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 3 General Description: The “EVAL_3kW_2LLC_C7“ - evaluation board shows how to design a dual phase LLC system solution of a telecom/industrial SMPS with the target to meet highest efficiency requirements. On this purpose there has been applied latest CoolMOS™ technology IPP60R040C7 600 V Power MOSFET on the primary side and OptiMOS™ low voltage Power MOSFET in SuperSO8 BSC093N15NS5 in the synchronous rectification secondary stage, in combination with QR CoolSET™ ICE2QR2280Z, 1EDI60N12AF EiceDRIVER™ high voltage, high speed driver ICs for MOSFETs, low side gate driver 2EDN7524R and digital LLC controller XMC4400 Summary of features: › Output voltage: 44 VDC – 58 VDC › Output current max: 55 A › Peak efficiency @ 50% load > 98.5% › Efficiency @ 10% load > 97% The following variants are available: › EVAL_3kW_2LLC_C7 version with CoolMOS™ C7 TO-220, IPP60R040C7, EVAL_3kW_2LLC_C7_220 › EVAL_3kW_2LLC_C7 version with CoolMOS™ C7 TO-247, IPW60R040C7, EVAL_3kW_2LLC_C7_247 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 4 Example of system understanding: Infineon demo solution for highest efficiency HV DC-DC stage Half-bridge LLC with synchronous rectification in center tap configuration Vin 350 VDC - 400 VDC Vin_nom 380 VDC Vout 44 VDC - 58 VDC Iout 55 A Po 3 kW Cr 66 nF Lr 12 uH Lm 62 uH Primary HV MOSFETs CoolMOSTM IPP60R040C7 Reduced gate charge (Qg) › Reduced Eoff › High body diode ruggedness Transformer SP-PQ 40/40 core LLC controller digital XMC4400 7/6/2016 Bias QR Flyback controller ICE2QR2280Z Copyright © Infineon Technologies AG 2016. All rights reserved. SR MOSFETs OptiMOSTM BSC093N15NS5 New generation › Best FOM RDS(on) x Qg › Best FOM RDS(on) x Qoss Resonant inductor SP-PQ 35/35 core HV MOSFETs IPP60R040C7 TO-220 IPP60R040C7 TO-247 5 Digital control board Infineon`s solution to control the 3 kW dual phase LLC evaluation board Digital XMC4400-F64K512 AB Summary of features: › ARM® Cortex®-M4, 120 MHz, incl. single cycle DSP MAC and floating point unit (FPU) › 8-channel DMA + dedicated DMAs for USB and Ethernet › USB 2.0 full-speed on-the-go › CPU Frequency: 120 MHz › eFlash: 512 kB including hardware ECC › 80 kB SRAM › Package: PG-LQFP-64 Target applications: › Motor control › Position detection › IO devices › HMI › Solar inverters › SMPS › Sense & control systems › PLC › UPS › Light networks 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 6 Main power board schematic 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 7 Digital control board schematic Digital Controller XMC4400-F64K512 AB 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 8 Bias board schematic Zechner Florian (IFAT PMM ACDC AE) 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 9 Connection instruction + 44 VDC - 58 VDC Zechner Florian (IFAT PMM ACDC AE) 350 VDC - 400 VDC 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 10 + - Table of contents 1 General description 2 Efficiency results 3 Design concept 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 11 Efficiency plot measured with IPP60R040C7/ IPW60R040C7 3 kW Dual Phase LLC efficiency Efficiency (without Bias & fans absorption) 98,00% Peak η: 98.5% at Iout=29 A 96,00% 94,00% 3kW Dual Phase LLC 92,00% 90,00% 88,00% 86,00% 84,00% 82,00% 0.1% total accuracy 80,00% 5 7 @ Vin_nom=380 VDC, Vout_nom=54.3 VDC 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 Load current [A] 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 12 Table of contents 1 General description 2 Efficiency results 3 Design concept 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 13 Design concept 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 14 Basic components positioning in the PCB 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 15 Two daughter boards Microcontroller board 7/6/2016 Auxiliary converter board Copyright © Infineon Technologies AG 2016. All rights reserved. 16 Final shape and overall dimensions H=45 mm L=230 mm W=140 mm 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 17 Evaluation board EVAL_3kW_2LLC_C7 Zechner Florian (IFAT PMM ACDC AE) 7/6/2016 Copyright © Infineon Technologies AG 2016. All rights reserved. 18 Support slides 3 KW Dual LLC evaluation board › Evaluation board page › › › › › EVAL_3kW_2LLC_C7 Technical Description Datasheets Parameters Related material Videos Product family pages › IPP60R040C7 › › › › › › › XMC4400-F64K512 AB › BSC093N15NS5 Product Brief Application Notes Selection Guides Datasheets and Portfolio Videos Simulation Models › 2EDN7524R › ICE2QR2280Z › 1EDI60N12AF › IFX1763XEJ V50 › IFX1763XEJ V33 7/20/2016 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 19