IPD60R400CE

DEMO-IDP2308-120W INFINEON | Alldatasheet

Document overview

• Manufacturer or author: Provided By ALLDATASHEET.COM(FREE DATASHEET DOWNLOAD SITE)
• PDF pages: 41

Technical content

Application Note Please read the Important Notice and Warnings at the end of this document Revision 1.0 www.infineon.com 1 2019-04-01 AN_1904_PL21_1904_051730 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Order code: DEMO -IDP2308 -120W About this document Scope and purpose This document describes the 120 W 24 V 3.5 A 12 V 3 A 85 VAC ~ 265 VAC input off-line PFC - LLC converter demoboard featuring Infineon's digital PFC-LLC combi controller IDP2308 and MOSFETs IPD60R400CE and IPD60R1K5CE. Intended audience This document is intended for users of the IDP2308 who wish to design a PFC plus LLC converter with a non- auxiliary power supply for LED TV SMPS applications. Table of Contents

Application Note 2 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Table of Contents

Application Note 3 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Abstract

1 Abstract

The demo board described in this document is a 120 W SMPS using a digital PFC-LLC combi controller (the IDP2308), which is the second generation of digital combi controller with a 16pin package developed by Infineon Technologies. TheIDP2308 is specially designed for switch mode power supplies used in TV power system applications. The IDP2308 is a highly integrated multi-mode power factor correction (PFC) and half-bridge LLC (HB LLC) controller. Multi-mode operation of the PFC controller and zero voltage switching of the LLC MOSFETs can significantly increase the power conversion efficiency, especially light load efficiency, while the system costs are minimized by the integrated high-voltage start-up cell, regulator for the PFC converter, MOSFET drivers and internal communication between the PFC and LLC controllers. The auxiliary power supply can be eliminated by the integrated high-voltage start-up cell and advanced burst mode control. With an active X-CAP discharge function, low stand-by power consumption during burst mode is supported. A comprehensive set of built-in protection features can greatly enhance the system operation and safety. Up to 40 different parameters ensure flexibility during system design and achieve optimal performance. All of these features make the IDP2308 a very competitive AC-DC controller for PFC-HB LLC resonant converter. DPAK power MOSFETs are used in this reference design. For LED TVs, a slim SMPS board is a desire and also a challenge due to the limitations of active and passive components. Compared to FullPAK MOSFETs which are used in conventional TV SMPS design, DPAK MOSFETs have the advantage of being thinner and also easier to assemble. In this reference design, two IPD60R400CE are used in parallel for the PFC stage, and two IPD60R1K5CE are used in the LLC stage.

Application Note 4 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Demonstrator board

2 Demonstrator board

This document contains a list of features, the power supply specification, schematic, bill of material and the transformer construction documentation. Typical operating characteristics such as performance curves and oscilloscope waveforms are shown at the end of the document. Figure 1 DEMO-IDP2308-120W PFC+LLC converter (top view) Figure 2 DEMO-IDP2308-120W PFC+LLC converter (bottom view) IPD60R400CE IDP2308 IPD50R1K4CE CE 2 IPD60R1K5CE

Application Note 5 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Specifications of demonstrator board

3 Specifications of demonstrator board

Table 1 Specifications of DEMO-IDP2308-120W Input voltage 85 VAC ~ 265 VAC Input frequency 50/60 Hz Output load Full load : 12 V 3 A 24 V 3.5 A; Min load : 12 V 0.1 A 24 V 0.1 A; Stand by load : 10 V 17 mA 24 V 0 A Power efficiency >90% @230 VAC Power factor >0.95 ( 230 VAC ) Controller IC IDP2308 PFC/LLC MOSFET IPD60R400CE/IPD60R1K5CE Form factor (L x W x H) 200 mm x 150 mm x 14 mm

Application Note 6 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Features of IDP2308

4 Features of IDP2308

Table 2 Features of IDP2308 Integrated 600 V start-up cell Integrated floating driver for HB high-side MOSFET Multi-mode operation of PFC Integrated PIT regulator for PFC controller Active X-CAP discharge function supports low stand-by power consumption Comprehensive set of PFC/LLC protection features Internal communication between PFC and LLC controller Plenty of configurable parameters and failure protection modes UART interface for communication and in-circuit configuration Adaptive burst mode Low ripple during standby Parameter patching during DV/PV/production

Application Note 7 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Circuit description

5 Circuit description

5.1 Introduction

The circuit consists of two power stages; a front-end PFC pre-regulator and a half-bridge LLC resonant converter based on the IDP2308controller.

5.2 Mains input and rectification

The AC line input side comprises the input fuse F1 as an over current protection device. The X capacitors (CX1, CX2), chokes (LX1, LX2), and Y capacitors (CY1-CY3) form a mains filter to minimize the feedback of RFI into the main supply. An NTC thermistor (RT1) is placed in series with the input to limit the initial peak inrush current.

5.3 Multi-mode PFC converter

After the bridge rectifier, there is a boost type PFC converter consisting of Q3, Q4, D7, CE3 and CE4. Two CoolMOSTM IPD60R400CE are used as the power switch Q3 and Q4. Due to its low Rdson and low output capacitance, the MOSFET conduction and switching loss can be effectively reduced. Output capacitor CE3 and CE4 provides energy buffering to reduce the PFC output voltage ripple. The PFC choke current is sensed by the external shunt resistors RCS2 and RCS4. The sense voltage is fed into the CS0 pin and compared to the internal voltage level for current limiting. Multi-mode operation is implemented by the IDP2308. Based on constant on time control, it does not require a direct sine wave reference signal. At heavy loads, it is beneficial for the PFC to work in CrCM mode. However, with CrCM operation, the PFC switching frequency may increase to a quite a high value at light load, which leads to high switching losses. In this controller, the PFC can lower the switching frequency by adding an additional delay into each switching cycle through selecting further PFC MOSFET drain-source voltage valleys to achieve QR2, QR3 and up to QR10 operation. In this way, the switching frequency is limited between a minimum and maximum value. The IDP2308 provides enhanced PFC output overvoltage protections with two different levels. Thus, it can effectively monitor and protect the PFC bus voltage against any overshoot in the case of the abrupt load or input voltage variations. The IDP2308 provides a redundant PFC output overvoltage protection through the MFIO pin. During certain fault conditions, such as the resistance of the VS voltage divider low-side resistor being reduced by 30% after long term operation, the PFC bus voltage could exceed the limit of its output capacitor, leading to a serious failure. With the PFC redundant OVP feature, an independent bus voltage sensing path is used to protect against this type of failure in the PFC output. The IDP2308 features VS pin open loop protection, which can effectively protect the whole system in the case of the VS pin external high side resistor becoming open circuit. Brown-in and brown-out protections are provided with the integrated startup cell via the HV pin to avoid the system working at extremely low AC input. In order to meet the increasingly stringent system safety requirements, the IDP2308 also features VS pin open circuit protection and VS pin short to adjacent pin protection. In addition, the IDP2308 features long term continuous conduction mode protection, which can help to protect the whole system in the case of a shorted PFC bypass diode or heavy load condition.

Application Note 8 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Circuit description

5.4 Half-bridge LLC resonant converter

The second stage is a half bridge LLC resonant converter, operating with zero-voltage switching. The PFC-LLC combi controller (IDP2308) incorporates the necessary functions to riv th h lf ri g ’s high si n low side MOSFETs (Q1 and Q2) with a 50% duty cycle including a configurable dead time. The switching frequency can be changed by the IDP2308 to regulate the output voltage against the load and input voltage variations. During operation, the primary MOSFETs Q1 and Q2 are turned-on under a ZVS condition and the secondary rectifier diodes D3 and D9 are turned-on and turned-off under a ZCS condition. Hence, high power conversion efficiency is achieved. As the IDP2308 has the half bridge high side MOSFET driver built-in based on Infineon coreless transformer technology, there is no requirement to add an external driver module, such as a pulse transformer or driver IC, to drive the high side MOSFET. Hence, the system BOM cost and design effort is greatly reduced. The mains transformer (T1) uses a magnetic integration approach, incorporating the resonant series and shunt inductances. Thus, no additional external coils are required for resonance. The transformer configuration for the secondary winding is center-tapped, and the output rectifiers, D3 and D9, are schottky type diodes, in order to reduce the power dissipation. The voltage across the half bridge shunt resistors (RCS1 and RCS3) is fed into the CS1 pin of the IDP2308. Thus, the current flowing through the primary winding is strictly controlled to ensure the system max power limitation and over current protection. Since the IDP2308 has an internal voltage reference and pull-up resistor for the HBFB pin, the feedback signal from the opto-coupler (U2) can be directly fed into this pin, which also minimizes the BOM cost and design effort. Thus, with the feedback information, the IDP2308 is able to regulate the LLC frequency to achieve the LLC load regulation and line regulation. In the case of an overload condition, the HBFB pin voltage will rise and may reach V_OlpHB, which will trigger the overload protection. As a result, the LLC will stop switching after a blanking time and enter the auto-restart mode, with a configurable break time to protect the whole power supply system. In the case of an extremely light load condition, the voltage on the HBFB may drop and reach another threshold (V_burst_enter), which will cause the LLC to stop switching and enter the burst mode after a blanking time. When the voltage on the HBFB pin increases to reach the threshold V_burst_on, the LLC will resume switching. Thus, at extremely light load conditions, with this burst mode feature, the LLC output will still be under regulation. When a heavy load is applied, the HBFB pin voltage exceeds V_burst_exit or the burst on time reaches its maximum setting t_burst_on_max, the LLC will leave burst mode and resume normal operation. To achieve good cross regulation, a weighted voltage control is adopted. R23, NR3, R27, NR4, R32 and R33 form a voltage divider network that senses both of the output voltages. When the Power_On signal (switch SW1 pin 1 connects to pin 3) is high, transistor Q5 is turned on, and R32 and R33 are connected in parallel, thus the output voltage is regulated at the target level during normal operation. On the other hand, during standby operation (switch SW1 pin 1 disconnects from pin 3), Q5 is off, and R32 is disconnected, which will reduce the output voltage to lower standby power consumption. Output voltage regulation is controlled through the shunt regulator TL431 (U3) and the optocoupler (U2) provides electrical isolation between the primary and secondary sides. Resistor R29 provides the bias current required by U3 and is placed in parallel with U2 to ensure that the bias current to the TL431 does not become a part of the feedback current. Resistor R21 sets the overall DC loop gain and limits the current through U2 during transient conditions. R22, C10 and C11 set the frequency response for the feedback circuit.

Application Note 9 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Circuit diagram

6 Circuit diagram

Figure 3 Schematics of 120 W PFC + LLC converter

Application Note 10 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 PCB layout

7 PCB layout

Figure 4 Top side component legend– View from component side Figure 5 Bottom side component legend– view from solder side

Application Note 11 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials

8 Bill of materials

Item Circuit code Qty Description / value Package Manufacturer 1 12 V, 24 V (output socket) 2 Banana socket, Red,'571-0500 2pin

2 Earth1,Earth2 (output

socket) 2 Banana socket, black,'571-0100 2pin 12V-I1, 12V-I2, 24V-I1, 24V- I2, JP2, JP4, JP5, JP6, JP9, JP12, JP18, JP19, JP20, JP21, JP23 15 JP-THT-1.00_2.20_10_0.80-2P axial 4 IL, JP3, JP10, JP11 4 JP-THT-1.00_2.20_15_0.80-2P axial 5 JP1, JP8, JP13, JP15 4 JP-THT-1.00_2.20_20_0.80-2P axial 6 JP14 1 JP-THT-1.00_2.20_5_0.80-2P axial 2P axial 2P axial AC-N, Data, FB, HB, HGD, HV, LCS, LGD, NT1, NT2, NT3, NT4, NT5, NT6, NT7, NT8, OVP-VS, PFC-CS, PFC-GD, PFC-GD1, PFC- GD2, PFC-VDS, PFC-VS, PFC-ZCD, SBY, VBUSS, VCC, VCC1

32 Test point, THT, '5003 pin

10 E1, E2, GND5, GND6 4 Test point, THT, '5004 pin

11 GND1, GND2, GND3, GND4 4 Test point, THT, '5002 pin

12 HS3 1 heatsink for D3, D9 4 holes

13 CN1 1 3pin heasder, TSW-103-05-L-S 3pin

14 CN2 1 Input socket, DF22-3P- 3pin socket

Application Note 12 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials 7.92DS(05) 15 CN3 1 3pin header. TSW-103-05-L-S, 3-pin

16 CN4 1 2pin header, TSW-102-05-L-S, 2-pin

17 BD1 1 3 A 1 KV diode, 1N5408 axial

18 BD2 1 3 A 1 KV diode, 1N5408 axial

19 BD3 1 3 A 1 KV diode, 1N5408 axial

20 BD4 1 3 A 1 KV diode, 1N5408 axial

21 C1 1 1 u/450 V, mpp flim radial

22 C10 1 47 n SMD 0805

23 C11 1 2.2 u SMD 0805 24 C12 1 0.10 u SMD 0805

25 C13 1 1000 p SMD 0805

26 C14 1 1000 p SMD 0805

27 C15 1 0.10 u SMD 0805 28 C18 1 n.a SMD 0805

29 C19 1 100 n/1 kV, mpp flim radial

30 C2 1 1800 p SMD 0805

31 C20 1 220 p 1 kV ceramic radial

32 C3 1 0.47 u SMD 0805

33 C4 1 nil SMD 0805

34 C5 1 1000 p SMD 0805

35 C6 1 10 nF 5% 1 kV, mpp film cap radial

36 C7 1 1000 p/50 V, 1206 SMD 1206

Application Note 13 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials 37 C8 1 0.10 u SMD 0805 38 C9 1 4.7 n SMD 0805 39 CE1 1 1000 uF/35 V, HV 12.5x20, E-cap 12.5x20 40 CE10 1 220 u/35 V, KMG 8x11.5, E-cap 8x11.5 41 CE2 1 1000 uF/35 V, HV 12.5x20 E-cap 12.5x20 42 CE3 1 68 uF/450 V, KXJ 12.5x50, E-cap 12.5x50 43 CE4 1 68 uF/450 V, KXJ 12.5x50, E-cap 12.5x50

44 CE5 1 1000 uF/25 V, VZ 10x20, E-cap 10x20

45 CE6 1 1000 uF/25 V, VZ 10x20, E-cap 10x20

46 CE8 1 33 u/50 V, YXG, 6.3x11, E-cap 6.3x11 47 CE9 1 47 u/50 V, YXG, 6.3x11, E-cap 6.3x11 48 CX1 1 0.47 u/275 VAC, X2-cap radial 49 CX2 1 0.47 u/275 VAC, X2-cap radial

50 CY1 1 470 p/330 VAC, Y1-cap radial

51 CY2 1 470 p/300 VAC, Y1-cap radial

52 CY3 1 470 p/300 VAC, Y1-cap radial

53 D1 1 M7, 1 A 1 kV diode SMD

54 D11 1 1N4148W-7-F, diode SMD

55 D12 1 MBRS360BT3G 3 A 60 V

56 D13 1 MBRS360BT3G 3 A 60 V

57 D14 1 1N4148W-7-F, diode SMD

58 D18 1 1N4148W-7-F, diode SMD

Application Note 14 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials

59 D19 1 1N4148W-7-F, diode SMD

60 D2 1 M7, 1 A 1 KV diode SMD

61 D20 1 1N4148W-7-F, diode SMD

62 D21 1 1N5408, 3 A 1 KV diode axial

63 D22 1 1N4148W-7-F, diode SMD

64 D23 1 1N4148W-7-F, diode SMD

65 D24 1 1N4148W-7-F, diode SMD

66 D3 1

MBRF30100CT, 30 A 100 V schottky diode (dual diodes) in TO220 FullPAK TO-220 FullPAK

67 D5 1 1N4148W-7-F, diode SMD

68 D7 1 MUR460, 4 A 600 V ultra fast

69 D8 1 UF4007, 1 A 1 KV diode axial

70 D9 1

MBRF2060CT, 20 A 60 V schottky diode (dual diode) in TO220 FullPAK TO-220 FullPAK

71 F1 1 5 A, 250 V time lag TR5 fuse TR5

72 JM1 1 0 R, 1206 SMD 1206

73 LP1 1 200 uH, EQ30/ER30, 39T:5T EQ30/ER30

74 LX1 1 18 mH x2, CMC toroid Φ20, wire

Φ0.43 toroid with holder

75 LX2 1 18 mH x2, CMC toroid Φ20, wire

Φ0.43 toroid with holder 76 Q1 1 IPD60R1K5CE, 600 V 1.5 Ω DPAK Infineon Technologies 77 Q2 1 IPD60R1K5CE, 600 V 1.5 Ω DPAK Infineon Technologies

Application Note 15 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials 78 Q3 1 IPD60R400CE, 600 V, 0.4 Ω DPAK Infineon Technologies 79 Q4 1 IPD60R400CE, 600 V, 0.4 Ω DPAK Infineon Technologies

80 Q5 1 MMBT4401L, NPN transistor SMD

81 Q7 1 2SC2655Y, NPN Transistor TO92

82 Q8 1 MMBT4401L, NPN transistor SMD

83 R1 1 11 k 1%, 1 W/0.5 W axial 84 R10 1 3.3 M 1%, 1206 SMD 1206 85 R11 1 2.7 R SMD 0805

86 R12 1 47 k SMD 0805

87 R13 1 63.4 k 1% SMD 0805

88 R14 1 Nil SMD 0805

89 R16 1 10 R SMD 0805

90 R17 1 2.7 R SMD 0805

91 R18 1 10 k SMD 0805

92 R19 1 47 k SMD 0805

93 R2 1 11 k 1%, 1 W/0.5 W axial

94 R20 1 510 R SMD 0805

95 R21 1 5.1 k SMD 0805

96 R22 1 1 k SMD 0805

97 R23 1 90.9 k 1% SMD 0805

98 R26 1 10 R SMD 0805

99 R27 1 10.2 k 1% SMD 0805

Application Note 16 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials

100 R28 1 10 R SMD 0805

101 R29 1 2.7 k SMD 0805 102 R3 1 11 k 1%, 1 W/0.5 W axial

103 R30 1 10 k SMD 0805

104 R31 1 510 R/200 V/1%, 1206 SMD 1206

105 R32 1 9.76 k 1% SMD 0805 106 R33 1 2.67 k 1% SMD 0805

107 R34 1 10 k SMD 0805

108 R35 1 1 M 1%, 1206 SMD 1206

109 R36 1 10 k SMD 0805

110 R37 1 10 k SMD 0805

111 R38 1 1 M 1%, 1206 SMD 1206

112 R39 1 10 k SMD 0805

113 R4 1 10 R SMD 0805

114 R40 1 10 k SMD 0805

115 R41 1 10 k SMD 0805

116 R42 1 1 k SMD 0805

117 R43 1 1 k SMD 0805

118 R44 1 909 k 1%, 1206 SMD 1206

119 R45 1 1 k SMD 0805

120 R46 1 10 k SMD 0805

121 R47 1 7.32 k 1% SMD 0805

122 R48 1 Nil SMD 0805

Application Note 17 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials

123 R49 1 10 k SMD 0805

124 R5 1 3.3 M 1%, 1206 SMD 1206

125 R50 1 120 k SMD 0805

126 R51 1 10 R SMD 0805

127 R52 1 100 SMD 0805

128 R53 1 3 k SMD 0805

129 R54 1 680 k, 1206 SMD 0805

130 R55 1 680 k, 1206 SMD 1206

131 R56 1 680 k, 1206 SMD 1206

132 R58 1 18 k 1%, 1206 SMD 1206

133 R59 1 18 k 1%, 1206 SMD 1206

134 R6 1 120 R SMD 0805

135 R60 1 1 M, ¼ W axial axial

136 R61 1 1k SMD 0805

137 R62 1 1M, 1/4W axial axial

138 R63 1 2M 1%, 1206 SMD 1206

139 R7 1 3.3 M 1%, 1206 SMD 1206

140 R8 1 10 k SMD 0805

141 R9 1 10 R, 1206 SMD 1206

142 RCS1 1 0.36 R 1% /2 W axial 143 RCS2 1 0.24 R 1% /2 W axial 144 RCS3 1 0.36 R 1% /2 W axial 145 RCS4 1 0.24 R 1% /2 W axial

Application Note 18 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials

146 NR1 1 10 R SMD 0805

147 NR2 1 10 R SMD 0805

148 NR3 1 10 R 1% SMD 0805

149 NR4 1 10 R 1% SMD 0805

150 NR5 1 10 R SMD 0805

151 RT1 1 NTC, 5 R/220 V/20% radial

152 RV1 1 MOV, 10D561K/560 V/10% radial

153 SW1 1 3pin SW, '09.03290.01 3pin

154 T1 1 EFD38, Lp=1100 uH, Lr=240 uH,

51T:6T:3T:4T EFD38

155 U1 1 IDP2308 SO16 Infineon

156 U2 1 PC817C DIP-4

157 U3 1 AS431BZ TO-92

158 U5 1 PC817C DIP-4

159 ZD1 1 ZMM22 (22 V) SMD

160 ZD2 1 ZMM22 (22 V) SMD

161 ZD5 1 SZ25B275M (27 V) SMD

162 ZD6 1 ZMM22 (22 V) SMD

163 ZD7 1 SZ25B135M (13 V) SMD

163 FB2 1 Ferrite bead add to lead

164 FB4 1 Ferrite bead add to lead

165 FB5 1 Ferrite bead add to lead

Application Note 19 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Bill of materials of Y cap 166 For JP2, JP15, JP17, +ve lead of CE3 and CE4, +ve lead of C19

1 Heat shrinkable tube

167 For D3 and D9 1 Heat sink (refer to the real

system with slope in one side)

168 For D3 and D9 2 screw

169 For D3 and D9 2 thermal grease to smooth the

Application Note 20 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Transformer construction

9 Transformer construction

9.1 PFC choke, LP1

Core: ER30, PC40 or equivalent Primary inductance Lp: 200 uH, between pin 1 and pin 3 (Gapped) Figure 6 PFC choke electrical diagram TOP VIEW Pin 1 Pin 3 Pin 6 Pin 5 Pin 4 Figure 7 LLC resonant transformer complete – top view Pin 3 Core Center Limb Pin 1 39 turns 30x0.1mm Litz//tight 5 turns Φ0.2mm // tight Pin 4 Pin 6 Figure 8 PFC choke winding position Table 4 LLC resonant transformer winding characteristics Windings Start End Wire Turns Method 1 3 1 30 x 0.1 mm Litz 39 Tight 2 4 6 Φ0.2 mm 5 Tight

Application Note 21 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Transformer construction

9.2 LLC transformer, T1

Core: EFD38, PC40 or equivalent Primary inductance Lp: 1.1 mH±3%, between pin 1 and pin 2 (Gapped) Leakage inductance: 260 uH with shorted all other pins Figure 9 LLC resonant transformer electrical diagram TOP VIEW Pin 1 Pin 2 Pin 4 Pin 5 Pin 6 Pin 13 Pin 12 Pin 11 Pin 10 Pin 9 Pin 8 Pin 7 Figure 10 LLC resonant transformer complete – top view Core Center Limb Pin 2 Pin 1 Primary winding Secondary winding Auxiliary winding Pin 12 Pin 9 Insulation tape Pin 13 Pin 7 Pin 8 Pin 5 Pin 4 Pin 6 Pin 11 Figure 11 LLC resonant transformer winding position

Application Note 22 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Transformer construction Table 5 LLC resonant transformer winding characteristics Windings Start End Wire Turns Method 1 1 2 20 x 0.1 mm Litz 51 Tight 2 12 9 60 x 0.1 mm Litz 3 Tight 3 13 8 60 x 0.1 mm Litz 3 Tight 4 9 7 60 x 0.1 mm Litz 3 Tight 5 8 11 60 x 0.1 mm Litz 3 Tight 6 4 6 Φ0.2 mm TIW 4 Tight 7 6 5 Φ0.2 mm TIW 4 Tight

9.3 Common mode choke, LX1 and LX2

Core: T18 x x10 x 6 , holder : 21 x 21, wire dia : 0.43 mm Inductance: 18 mH min. Figure 12 Common mode choke electrical diagram TOP VIEW Pin 4 Pin 3 Pin 1 Pin 2 Figure 13 Common mode choke complete – top view

Application Note 23 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10 Test results

10.1 Efficiency

Figure 14 Efficiency measurments The overall effiency curve is higher than 87% for both high and low line over the load range from 25% to 100%. The full load efficiency at 230 VAC reaches 90.2%.

10.2 Standby power

The standby power consumption is less than 270 mW at 230 VAC with 125 mW load. Standby power consumption Loading Input voltage Input power (mW) +24 V / 0 A, +9 V/14 mA 110 VAC 241.9 +24 V / 0 A, +9 V/14 mA 230 VAC 261.3

10.3 Surge immunity (EN61000-4-5)

The surge immunity test was measured with a Noiseken LSS-15AX lightning surge simulator. The output common was connected to the primary side PE. Pass 4.5 kV common mode test (line to earth) and Pass 2 kV differential mode test (line to line). 75% 77% 79% 81% 83% 85% 87% 89% 91% 93% 95% 120906030 110Vac 230Vac Efficiency (%) Load (W)

Application Note 24 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.4 Conducted emissions (EN55022 class B)

The conducted EMI was measured by a Schaffner SMR25503 in accordance with EN55022 (CISPR 22) class B. The demoboard was set up at maximum load (120 W) with an input voltage of 115 VAC and 230 VAC. To further improve conducted EMI performance at high frequency, two ferrite beads are added to the output rectifier diodes, which are not shown in the BOM. The system passes CISPR22 class B with over 6 dB margin. Note: The system has a metal chasis during the measurement. Figure 15 Conducted emissions(line) at 115 VAC and maximum load Figure 16 Conducted emissions(neutral) at 115 VAC and maximum load

Application Note 26 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.5 Thermal measurement

The thermal test of the open frame demoboard was performed using an infrared thermography camera (TVS- 500EX) at an ambient temperature of 25°C. The measurements were taken after two hours running at full load. Table 6 Hottest temperature of demo board No. Major component 90 VAC (°C) 1 LLC transformer 61.1 2 PFC inductor 58.1 3 12 V output diode 65.2 4 24 V output diode 68.2 6 IDP2308 45.3 7 PFC MOSFET 60.5 8 PFC MOSFET 63.6 9 LLC high-side MOSFET 59.8 10 LLC low-side MOSFET 58.2

11 Ambient 25

Figure 19 Infrared thermal image of DEMO-IDP2308-120W

Application Note 27 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.6 PFC with valley switching

The IDP2308 features a multi-mode PFC, which has a default frequency range from 60 kHz to 120 kHz. The PFC MOSFET is determined to turn on by the PFC ZCD signal, when the PFC ZCD signal falls below 40mV and after a certain blanking time, the PFC MOSFET turns on to charge up the PFC choke again. Due to this simple mechanism, PFC MOSFET valley switching is achieved, as shown in Figure 20, hence the PFC turns on loss can be significantly reduced. Moreover, with multi-mode operation, the PFC switching frequency is limited to the design range, which breaks down the switching loss under high line and light load. PFC Valley switching @ 110 VAC and full load PFC Valley switching @ 230 VAC and full load Figure 20 Multi-mode PFC with valley switching

10.7 Multi-mode PFC with unity power factor

As described in the IDP2308 datasheet, constant on time control is applied to achieve unity power factor. In Figure 21, the AC input current is sinusoidal and synchronous with the AC input voltage. Hence, unity power factor has been achieved. AC input current @ 110 VAC and full load AC input current @ 230 VAC and full load Figure 21 PFC AC input current

Application Note 28 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.8 PFC dynamic response

As described in the IDP2308 datasheet, the PFC regulator is built-in to modulate the PFC MOSFET on time to regulate the PFC bus voltage under control. In Figure 22, even in the case of an extremely dynamic load change between minimum and full load, the PFC bus voltage only varies within the acceptable range. Accordingly the following LLC stage will vary its switching frequency to maintain the LLC output under regulation. PFC Bus ripple @ full load to min load and 110 VAC PFC Bus ripple @ full load to min load and 230 VAC PFC Bus ripple @ min load to full load and 110 VAC PFC Bus ripple @ min load to full load and 230 VAC Figure 22 PFC Bus voltage ripple when load changes

Application Note 29 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.9 PFC over current protection

In order to limit the current flowing through the PFC choke, PFC over current protection is built-in to the IDP2308. In Figure 23, the voltage across RCS2 and RCS4 is used to sense the PFC current. When the CS0 voltage exceeds 0.6 V (typ.), and after a propagation delay, the PFC MOSFET will be turned off to stop the current increasing. PFC over current protection Figure 23 PFC over current protection @ 90 VAC and full load

10.10 PFC over voltage protection

As described in the IDP2308 datasheet, the PFC features over voltage protection (OVP1 and OVP2) to strictly limit the bus voltage overshoot. In the case of an extreme load or line jump, the PFC output may suffer significant overshoot. In Figure 24, under a load jump from full to min load, the PFC OVP1 is triggered and PFC switching is stopped immediately. The measured OVP1 threshold is 2.57 V in the waveform, which is the same as the value set by the firmware in the controller IC. The LLC continues switching, and once the PFC bus voltage drops to below its regulation target, the PFC resumes switching with a soft-start. For PFC OVP2, the threshold is fixed by hardware comparator at 2.8 V, which will respond immediately once the threshold is triggered. The response and delay time of OVP2 will be much shorter than OVP1 as it is designed to prevent serious failures. Load jump from full load to min load @110 VAC Figure 24 PFC over voltage protection

Application Note 30 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.11 PFC redundant OVP protection

To further improve the reliability of the system, the IDP2308 provides an independent bus overvoltage protection via the MFIO pin to prevent a serious PFC output failure resulting from damage to the voltage divider on the VS pin. The MFIO pin is a multi-function pin, which can be used to sense the redundant PFC OVP and to provide a UART communication IO interface for parameter configuration. However, the requirements on standby power consumption are becoming tighter. Thus, in order to reduce the power consumed by the voltage divider on the MFIO pin, a lossless sensing circuit with a BSS127 is recommended as shown in Figure 25. Lossless sensing circuit for PFC ROVP Figure 25 PFC over voltage protection As shown in Figure 26, in order to clearly demonstrate the PFC redundant OVP (ROVP) feature, a resistor is deliberately placed in parallel with the VS divider low-side resistor R13 to create the fault condition. Thus, the bus voltage increases immediately since the PFC is working in a closed loop and trying to regulate the VS voltage to 2.45 V. When voltage on the MFIO pin hits the threshold V_ROVP_set, the PFC stops switching but LLC continues. After the bus voltage drops and the MFIO pin voltage reaches its reset threshold V_ROVP_reset, the PFC resumes switching with a soft-start. If the fault condition is not removed, after ten continuous triggers of an ROVP event, the system will enter auto-restart mode. For more details, please refer to the IDP2308 datasheet. PFC ROVP @ 230 VAC and standby load PFC ROVP @ 230 VAC and full load Figure 26 PFC redundant OVP protection

Application Note 31 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.12 PFC brown-in/brown-out protection

To prevent the system working under extremely low AC input voltages, brown-in/brown-out protection is designed with configurable thresholds via the HV pin. It is implemented with a 51 Ω HV r sistor onn t to the AC input, where the default thresholds are: brown-in 70 VAC (RMS) and brown-out 60 VAC (RMS). In Figure 27, with AC slew rate of 1 V/s, the brown-in/brown-out protection is demonstrated. The measured brown-in threshold is 99 V peak (around 70 VAC RMS), and the brown-out threshold is 85 V peak (around 60 VAC RMS). Brown-in @ 20% full load Brown-in @ 20% full load Figure 27 Brown-in/brown-out protection

10.13 PFC/LLC start-up behavior

As described in the IDP2308 datasheet, both PFC and LLC soft-start features are implemented. In Figure 28 and Figure 29, the PFC bus voltage smoothly increases until reaching the target regulation value. To shorten the start-up time, the default svp (PFC PIT1 P coefficient) is set to 4 during the start-up phase. While under normal operation, svp is set to 6 to achieve more stable operation. Moreover, during the PFC start-up phase, its gate driver voltage is set to 7.5 V, when bus voltage reaches the LLC start-up threshold, the PFC gate driver voltage is reset to 10.5 V. Accordingly, when the VS voltage reaches 2.05 V, the LLC starts switching with configurable soft-start behaviour. Its default maximum soft-start frequency is 270 kHz, and the LLC switching frequency smoothly sweeps from a high level to a low level and finally enters normal operation. For more details, please refer to the IDP2308 datasheet.

Application Note 32 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results PFC start-up @ 110 VAC and full load PFC start-up @ 230 VAC and full load Figure 28 PFC startup behavior LLC start-up @ 110 VAC and full load LLC start-up @ 230 VAC and full load Figure 29 LLC startup behaviour

10.14 LLC line regulation

The LLC switching frequency will vary with reference to the PFC bus voltage ripple to regulate the LLC output. For example, at 110 VAC and 20% of full load, the LLC switching frequency (fsw) varies by 1.4 kHz from 106.7 kHz to 108.1 kHz to regulate its output. At 110 VAC and 100% full load, the LLC fsw varies by 2.6 kHz to regulate the output.

Application Note 33 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results LLC fsw @ 110 VAC and 20% full load LLC fsw @ 110 VAC and 100% full load Figure 30 LLC switching frequency varies against the PFC bus voltage

10.15 LLC load regulation

Figure 31 shows the dynamic behavior of the LLC stage during a load variation between 20% and 100% of full load. It can be seen that the LLC switching frequency varies against the load changes, and the measured output voltage ripple at 12 V is around 210 mV. LLC fsw @ 110 VAC and 20% ~ 100% full load LLC fsw @ 110 VAC and 20% ~ 100% full load Figure 31 LLC switching frequency varies against the load changes

10.16 LLC zero voltage switching

From the test results of Figure 32, it can be seen that the LLC zero voltage switching (ZVS) can be achieved over a very wide load range which ensures high power conversion efficiency.

Application Note 34 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results LLC ZVS @ 110 VAC and 20% full load LLC ZVS @ 110 VAC and 100% full load Figure 32 LLC zero voltage switching

10.17 PFC and LLC operation during holdup time

In order to meet the holdup time requirement, the LLC stage is required to cover a wide PFC bus voltage range. During the holdup time, the LLC switching frequency drops to regulate the output voltage against the bus voltage drop. As shown in Figure 33, after shutting down the AC input, the LLC keeps switching until the PFC bus voltage drops the undervoltage protection threshold. The measured holdup time is around 24 ms, which meets most of the power supply specification. When the undervoltage threshold is triggered, the PFC and LLC both stop switching and the IC keeps active until Vcc reaches its UVLO threshold. PFC/LLC operation @ 110 VAC off, full load PFC/LLC operation @ 230 VAC off, full load Figure 33 PFC and LLC operation after shutdown AC input with full load

10.18 Burst mode operation

Burst mode operation is implemented in the IDP2308 to achieve low power consumption during standby operation. For this advanced burst mode control, the PFC and LLC are synchronized. However, during the burst on period if the bus voltage is higher than its target, then the PFC will not switch. To achieve ultra-low standby

Application Note 36 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results

10.19 LLC over current protection

The IDP2308 features two different over current protections: a first level overcurrent protection with the threshold V_OCP1 (there are 3 different V_OCP1 thresholds during soft-start, normal operation and burst mode, please refer to the datasheet) by software and a second level over current protection with the threshold VOCP2 by hardware, where the threshold V_OCP1 is lower than the threshold VOCP2. Overcurrent protection triggered by these two thresholds has different reactions in the HB LLC converter. During LLC operation, the voltage across the shunt resistors RCS1 and RCS3 is compared with the threshold V_OCP1. Once the voltage is higher than the threshold, the LLC frequency will be increased to 200 kHz immediately, which is configurable and should be based on the LLC resonant tank design, followed by a soft- start. If during the soft-start, the over current situation is removed, the LLC will change from TCO to VCO and enters normal operation. But, if the overcurrent condition remains, after eight continuous OCP1 event triggers, the PFC and LLC will be stopped and enter auto-restart. The second level over current protection is designed to prevent an extremely large current flowing through the shunt resistor. Once the LLC OCP2 is triggered, the PFC and LLC will immediately stop switching and enter auto- restart by default, which can be configured as a latch based on system requirements. In Figure 36, during normal operation, the first level OCP is triggered when the 24 V output is shorted to ground. Accordingly, the LLC switching frequency jumps to 200 kHz to limit the primary current. After eight continuous OCP1 triggers, the system enters auto-restart mode with two seconds break time. Once the overcurrent condition is removed, the system will recover with a soft-start. OCP1 @ 110 VAC and 24 V output shorted OCP1 @ 110VAC and 24 V output shorted Figure 36 LLC 1st level over current protection

10.20 X-Capacitor discharge during burst mode

In order to achieve low standby power consumption, the IDP2308 provides an active X-Capacitor discharge feature to remove the passive discharge resistor. The AC input voltage is measured via the HV pin during burst mode, and once the AC is unplugged, the IC detects the event, and after a blanking time, it turns on the start-up cell to discharge the X-Capacitor. For details, please refer to the IDP2308 datasheet. In Figure 37, the X-Capacitor discharge feature during burst mode with typical standby loading is demonstrated, where it takes less than 1 s to detect and discharge the X-Capacitor after the AC is unplugged.

Application Note 37 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Test results X-Capacitor discharge @ 230 VAC and burst mode X-Capacitor discharge @ 264 VAC and burst mode Figure 37 X-Capacitor discharge during burst mode

Application Note 38 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 Configuration tools

11 Configuration tools

The configurable parameters can be set via dpVision as shown in Figure 38. With selected applications, the table of its configurable parameters can be loaded as shown in the right side of the figure. In order to provide a clear understanding, the parameters are explained with images, waveforms and descriptions. Detailed information about the configurable parameters is shown in the datasheet, and a detailed description of the configuration tool is shown in the dpVision user manual. Configuration tool dpVision setup dpVision parameter configuration page Figure 38 Parameter configuration tool – dpVision

Application Note 39 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308 References

12 References

[1] IDP2308 datasheet, Infineon Technologies AG, 2016 [2] IDP60R400CE datasheet, Infineon Technologies AG, 2014 [3] IDP60R1K5CE datasheet, Infineon Technologies AG, 2015

Application Note 40 Revision 1.0 2019-04-01 120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308

Revision history

Major changes since the last revision Page or reference Description of change

All referenced product or service names and trademarks are the property of their respective owners. AN_201701_PL21_005owners. Edition 2019-04-01 AN_201701_PL21_005 Published by Infineon Technologies AG

81726 Munich, Germany

© 2022 Infineon Technologies AG. All Rights Reserved. Do you have a question about this document? Email: erratum@infineon.com Document reference IMPORTANT NOTICE The information contained in this application note is given as a hint for the implementation of the product only and shall in no event be regarded as a description or warranty of a certain func tionality, condition or quality of the product. Before implementation of the product, the recipient of this application note must verify any function and other technical information given herein in the real application. Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind (including without limitation warranties of non-infringement of intellectual property rights of any third party) with respect to any and all information given in this application note. The data contained in this document is exclusively intended for technically trained staff. It is the r sponsi ility of ustom r’s t hni l p rtm nts to evaluate the suitability of the product for the intended application and the completeness of the product information given in this document with respect to such application. For further information on the product, technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies o ffice (www.infineon.com). WARNINGS Due to technical requirements products may contain dangerous substances. For information on the types in question please contact your nearest Infineon Technologies office. Except as otherwise explicitly approved by Infineon Technologies in a written document signed by authorized representatives of Infineon T hnologi s, Infin on T hnologi s’ pro u ts m y not be used in any applications where a failure of the product or any consequences of the use thereof can rea sonably be expected to result in personal injury.