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
Table of Contents ........................................................................................................................... 1
1 Abstract ........................................................................................................................ 3
2 Demonstrator board ...................................................................................................... 4
3 Specifications of demonstrator board .............................................................................. 5
4 Features of IDP2308 ....................................................................................................... 6
5 Circuit description ......................................................................................................... 7
5.1 Introduction............................................................................................................................................. 7
5.2 Mains input and rectification .................................................................................................................. 7
5.3 Multi-mode PFC converter ...................................................................................................................... 7
5.4 Half-bridge LLC resonant converter ....................................................................................................... 8
6 Circuit diagram.............................................................................................................. 9
7 PCB layout ................................................................................................................... 10
8 Bill-of-material ............................................................................................................. 11
9 Transformer construction .............................................................................................. 20
9.1 PFC choke, LP1 ...................................................................................................................................... 20
9.2 LLC transformer, T1 ............................................................................................................................... 21
9.3 Common mode choke, LX1 and LX2 ..................................................................................................... 22
10 Test results .................................................................................................................. 23
10.1 Efficiency................................................................................................................................................ 23
10.2 Standby power ...................................................................................................................................... 23
10.3 Surge immunity (EN61000-4-5) ............................................................................................................. 23
10.4 Conducted emissions (EN55022 class B) .............................................................................................. 24
10.5 Thermal measurement ......................................................................................................................... 26
10.6 PFC with valley switching...................................................................................................................... 27
10.7 Multi-mode PFC with unity power factor ............................................................................................. 27
10.8 PFC dynamic response .......................................................................................................................... 28
10.9 PFC over current protection ................................................................................................................. 29
Application Note Revision 1.0
www.infineon.com 2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Abstract
10.10 PFC over voltage protection ................................................................................................................. 29
10.11 PFC redundant OVP protection............................................................................................................. 30
10.12 PFC brown-in/brown-out protection.................................................................................................... 31
10.13 PFC/LLC start-up behavior .................................................................................................................... 31
10.14 LLC line regulation ................................................................................................................................ 33
10.15 LLC load regulation ............................................................................................................................... 33
10.16 LLC zero voltage switching ................................................................................................................... 34
10.17 PFC and LLC operation during holdup time ......................................................................................... 34
10.18 Burst mode operation ........................................................................................................................... 35
10.19 LLC over current protection .................................................................................................................. 36
10.20 X-Capacitor discharge during burst mode ........................................................................................... 37
11 Configuration tools ....................................................................................................... 38
12 References ................................................................................................................... 39
Revision history............................................................................................................................. 39
Application Note 2 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 3 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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)
IPD50R1K4CE
IPD60R1K5CE
CE 2
IPD60R400CE
IDP2308
Figure 2 DEMO-IDP2308-120W PFC+LLC converter (bottom view)
Application Note 4 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 5 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 6 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 7 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 drive the half bridge’s high side and 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 8 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Circuit diagram
6 Circuit diagram
Figure 3 Schematics of 120 W PFC + LLC converter
Application Note 9 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 10 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
8 Bill-of-material
Table 3 Bill of material
Item Circuit code Qty Description / value Package Manufacturer
1 12 V, 24 V (output socket) 2 Banana socket, Red,'571-0500 2pin
Earth1,Earth2 (output
2 2 Banana socket, black,'571-0100 2pin
socket)
12V-I1, 12V-I2, 24V-I1, 24V-
I2, JP2, JP4, JP5, JP6, JP9,
3 15 JP-THT-1.00_2.20_10_0.80-2P axial
JP12, JP18, JP19, JP20,
JP21, JP23
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
JP-THT-1.00_2.20_12.5_0.80-
7 JP22 1 axial
2P
JP-THT-1.00_2.20_17.5_0.80-
8 JP7 1 axial
2P
3.3/5V, 12_V, 24_V, AC-L,
AC-N, Data, FB, HB, HGD,
HV, LCS, LGD, NT1, NT2,
NT3, NT4, NT5, NT6, NT7,
9 NT8, OVP-VS, PFC-CS, 32 Test point, THT, '5003 pin
PFC-GD, PFC-GD1, PFC-
GD2, PFC-VDS, PFC-VS,
PFC-ZCD, SBY, VBUSS,
VCC, VCC1
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 11 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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 12 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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
MBRS360BT3G 3 A 60 V
55 D12 1 SMD
schottky diode
MBRS360BT3G 3 A 60 V
56 D13 1 SMD
schottky diode
57 D14 1 1N4148W-7-F, diode SMD
58 D18 1 1N4148W-7-F, diode SMD
Application Note 13 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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
MBRF30100CT, 30 A 100 V
TO-220
66 D3 1 schottky diode (dual diodes) in
FullPAK
TO220 FullPAK
67 D5 1 1N4148W-7-F, diode SMD
MUR460, 4 A 600 V ultra fast
68 D7 1 axial
diode
69 D8 1 UF4007, 1 A 1 KV diode axial
MBRF2060CT, 20 A 60 V
TO-220
70 D9 1 schottky diode (dual diode) in
FullPAK
TO220 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
18 mH x2, CMC toroid Φ20, wire toroid with
74 LX1 1
Φ0.43 holder
18 mH x2, CMC toroid Φ20, wire toroid with
75 LX2 1
Φ0.43 holder
Infineon
76 Q1 1 IPD60R1K5CE, 600 V 1.5 Ω DPAK
Technologies
Infineon
77 Q2 1 IPD60R1K5CE, 600 V 1.5 Ω DPAK
Technologies
Application Note 14 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
Infineon
78 Q3 1 IPD60R400CE, 600 V, 0.4 Ω DPAK
Technologies
Infineon
79 Q4 1 IPD60R400CE, 600 V, 0.4 Ω DPAK
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 1k 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 15 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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 1k SMD 0805
117 R43 1 1k SMD 0805
118 R44 1 909 k 1%, 1206 SMD 1206
119 R45 1 1k 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 16 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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 3k 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 17 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
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
EFD38, Lp=1100 uH, Lr=240 uH,
154 T1 1 EFD38
51T:6T:3T:4T
Infineon
155 U1 1 IDP2308 SO16
Technologies
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
add to lead
163 FB2 1 Ferrite bead
of Y cap
add to lead
164 FB4 1 Ferrite bead
of Y cap
165 FB5 1 Ferrite bead add to lead
Application Note 18 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Bill-of-material
of Y cap
For JP2, JP15, JP17, +ve
166 lead of CE3 and CE4, +ve 1 Heat shrinkable tube
lead of C19
Heat sink (refer to the real
167 For D3 and D9 1
system with slope in one side)
168 For D3 and D9 2 screw
thermal grease to smooth the
169 For D3 and D9 2
contact surface
Application Note 19 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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)
1 6
5
3 4
Figure 6 PFC choke electrical diagram
Pin 1 Pin 6
TOP VIEW Pin 5
Pin 3 Pin 4
Figure 7 LLC resonant transformer complete – top view
Pin 6
5 turns Φ0.2mm // tight Pin 4
Pin 1
Pin 3 39 turns 30x0.1mm Litz//tight
Core Center Limb
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
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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
1 13
12
2 11
4
9
5
8
6
7
Figure 9 LLC resonant transformer electrical diagram
Pin 1 Pin 13
Pin 2 Pin 12
Pin 11
TOP VIEW Pin 10
Pin 4 Pin 9
Pin 5 Pin 8
Pin 6 Pin 7
Figure 10 LLC resonant transformer complete – top view
Pin 5
Pin 6
Pin 4
Pin 2
Pin 11
Pin 7
Pin 8
Pin 13
Pin 9
Pin 1 Pin 12
Core Center Limb
Primary Secondary Auxiliary
winding winding winding
Insulation tape
Figure 11 LLC resonant transformer winding position
Application Note 21 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
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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.
4 1
3 2
Figure 12 Common mode choke electrical diagram
Pin 4 Pin 1
TOP VIEW
Pin 3 Pin 2
Figure 13 Common mode choke complete – top view
Application Note 22 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
10 Test results
10.1 Efficiency
95%
93%
91%
89%
Efficiency (%)
87%
85%
83%
81%
79%
110Vac
77%
230Vac
75%
30 60 90 120
Load (W)
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
Input power
Loading Input voltage
(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).
Application Note 23 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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
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Test results
Figure 17 Conducted emissions(line) at 230 VAC and maximum load
Figure 18 Conducted emissions(neutral) at 230 VAC and maximum load
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
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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
MOSFETs IDP2308
LLC transformer PFC choke
Figure 19 Infrared thermal image of DEMO-IDP2308-120W
Application Note 26 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 27 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
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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 28 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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
Application Note 29 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
Figure 24 PFC over voltage protection
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.
Application Note 30 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
PFC ROVP @ 230 VAC and standby load PFC ROVP @ 230 VAC and full load
Figure 26 PFC redundant OVP protection
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 kΩ HV resistor connected 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
Application Note 31 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
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.
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
Application Note 32 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
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.
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
Application Note 33 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
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.
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
Application Note 34 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
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
power consumption, the default target bus voltage during burst mode is around 350 V (the VS reference is set at
2.2 V).
In Figure 34, during burst mode operation, when VHBFB drops to the burst off threshold V_burst_off, which is 0.3 V,
the switching signals will be disabled and the IC will enter sleep mode after a certain blanking time. VHBFB will
then increase as Vout starts to decrease due to the absence of an LLC switching signal. Once VHBFB reaches the
burst on threshold V_burst_on, which is 1.65 V, the IC wakes up and resumes switching. The default LLC switching
frequency under burst mode is set to 110 kHz, which is configurable and should be based on the LLC resonant
tank design. For a detailed description of burst mode operation, please refer to the IDP2308 datasheet.
LLC burst mode operation @ 110 VAC, standby load LLC burst mode operation @ 230 VAC, standby load
Figure 34 Burst mode operation at standby load
As shown in Figure 35, the LLC enters burst mode when the load jumps from full load to standby load. At the
same time the Power_On signal is switched off (switch SW1 pin 1 disconnects from pin 3), The system leaves
burst mode when full load returns. At the same time the Power_On signal is switched on (switch SW1 pin 1
connects to pin 3). There is a 10ms blanking time before the system enters burst mode as shown in the left side
waveform. In the right side waveform, the system is leaving burst mode. It can be seen that another quick soft-
start is implemented for the LLC when the system is leaving burst mode. Thus, the LLC output may drop slightly
during the load jump from standby load to full load.
Application Note 35 Revision 1.0
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120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
LLC Jumps from full load to standby load @ 110 VAC LLC Jumps from standby load to full load @ 110 VAC
Figure 35 LLC entering/leaving burst mode operation
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.
Application Note 36 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
Test results
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.
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 37 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
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 38 Revision 1.0
2019-4-1
120 W 24 V 3.5 A 12 V 3 A SMPS demonstrator with IDP2308
Order code: DEMO-IDP2308-120W
References
12 References
[1] IDP2308 datasheet, Infineon Technologies AG, 2016
[2] IDP60R400CE datasheet, Infineon Technologies AG, 2014
[3] IDP60R1K5CE datasheet, Infineon Technologies AG, 2015
Revision history
Major changes since the last revision
Page or reference Description of change
Application Note 39 Revision 1.0
2019-4-1
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