300W~500W High efficiency isolated ACDC converter

design with fast load transient response

Desheng, Guo
Industrial Systems – Power Delivery

1
Content
• Design challenges in 300W~500W AC-DC converter
• Methods to improve ACDC converter’s efficiency
• Optimizing efficiency @ light load
• Control for fast load transient response
• System solution reference -- TI design
Diagram of 300W~500W isolated AC-DC converter

From http://www.ti.com/applications/industrial/power-delivery/overview.html
Design Challenges in ACDC Power Converter
1. Higher Efficiency

2. Light Load Efficiency & No Load Power

3. Dynamic Response

4
Peak Efficiency Requirements in Various EE
Industrial AC/DC, DIN Rail Server PSU

Overall efficiency >96% @half load

~97% Efficiency
DC-DC Stage

Next Gen Gaming PC Adaptor

160x75x35 cm

60 x 75 x 35

~97% Efficiency, 50W/in3

DC-DC Stage
5

5
Light Load Efficiency Requirements in Various EE
PC Power Supply TV Power Supply

Eff spec (%) < 0.4W at Standby

Load

@115/230Vac NB Adapter Power Supply

No load < 75mW / 100mW
Eff spec (%)
> 52 % (Dell spec); Load
0.25W
> 50 % (must meet)
@115/230Vac

0.6W > 70 %
No load < 450mW
1.5W > 77 %
0.25W >50%
2.1W > 79 %

3W > 80 % 0.5W > 60 %

4W > 81 %

6
Dynamic Requirements
 Why dynamic response become strict?

+V - Vin

- V+

Load consumption
Vout
100%

0%

Larger didt generate more voltage drop, require

more strict dynamic response for power supply.

7
Methods to improve the efficiency

8
Methods to improve the efficiency
 Soft switching – resonant DCDC converter

 Bridgeless PFC & soft switching control;

 Better SR control at the secondary side;

 Replace MOSFET with GaN HEMT

9
Methods to improve the efficiency
 Soft switching – resonant DCDC converter

 Bridgeless PFC & soft switching control;

 Better SR control at the secondary side;

 Replace MOSFET with GaN HEMT

10
 Switching Losses
Turn-OFF
Turn-ON

VGATE
VGATE

VDS
VDS

IDS IDS
EON EOFF
ELOSS ELOSS

t0 t1 t2 t3

In hard-switched converters ─ Additional losses due to Output Capacitance (Coss).

─ Current & Voltage Overlap @ turn-on & turn-off. ─ In Half-Bridge configurations, Reverse Recovery
─ Results in significant switching losses (Qrr) losses can also be present.
─ Limits switching frequencies, power density

11
 Types of Soft-Switching
ZVS – Zero Voltage Switching ZCS – Zero Current Switching
─ Brings the switch voltage to ZERO before turn on. ─ Bring the switch current to ZERO before turn
VGATEon/off.

VDS

─ Ensuring NO voltage & current overlap @ turn on. ─ Quasi-Resonant, Transient Mode control
ELOSS
─ Coss (Output capacitance) also discharged. employs this technique.
IDS
─ Preferred technique for MOSFET, GaN ─ Can reduce switching losses in MOSFET
─ Best for IGBT @ turn-off

12
Why Soft Switching?
• As the demand for higher power density in power supplies increases:
– Need to increases switching frequency.
– Hence need to reduces losses associated with switching.

• An Example: Using a State of the Art SJ Mosfet in a, 400W Power Supply IPB60R180C7

• For a Hard Switched Half bridge Converter

Operating @ 200KHz

• Pon losses 2x2.1W = 4.2W

• A soft switched converter will have >1%

Efficiency improvement in this example.

• And the EMI signature?

Gate Resistance = 5 Ohm
Turn On Current = 3A
Data taken comparing CCM PFC with SiC Diode

13
DC-DC stage: Resonant Converter
• Resonant Converter is the most widely used soft-switching topology in DC/DC Converters.

L Vsw

Small current turn-off

L
ZVS turn-on
ILR
C

 Features of LLC ID1 ZCS turn-on/ turn-off

• Soft switching of both primary & secondary side
• Highest efficiency when fs = fr
• Can not widely adjust output voltage

14
Methods to improve the efficiency
 Soft switching – resonant DCDC converter

 Bridgeless PFC & soft switching control;

 Better SR control at the secondary side;

 Replace MOSFET with GaN HEMT

15
 Why Bridgeless PFC need?

Bridged boost PFC Dual boost bridgeless PFC

plus

A
B
110V 100V-1.6V

minus
Vf=0.8V

∆η ≈ 1.5%
Question: Is the total bridge loss saved?

16
Bridgeless PFC
Bridge PFC: Bridgeless PFC:
MOS on MOS on

D1

S
D4 S1
BD2

MOS off MOS off

D1
D1 D

D4
BD2

Bridgeless can remove one diode’s loss.

17
“Dual Boost Bridgeless PFC”
CM EMI noise coupling path
Vminus-neutral t
plus

line A VA-neutral t
B
neutral
VB-neutral t

minus
DC bus is floating to ac input
LISN Cs1 Cs2 Cb1 Cb2 HF voltage transition @DC bus
PE
DC bus is CM EMI noise source

Non isolated driver Large CM EMI noise

Deal with EMI issue

But, half PFC choke is shorted, PFC choke volume is doubled;

18
Totempole PFC
S1 BD1 D1  Features of Totempole PFC
• Simplest structure;
L • Si MOS can be used with CrM Control (soft switching);
• Can realize ZVS @ 230V input; (detail introduce later)
• With CCM mode, must use GaN, (reverse recovery issue);
• High side gate driving & Current sensing;
• Require input polarity sensing;
• PLD, lighting and surge need to be carefully verified;
LF
switch

S2 BD2 D2

TI Design: TIDA-00961 Highly Efficient, 1.6kW High Density GaN Based 1MHz CrM Totem-pole PFC Converter
Reference Design | TI.com

19
Asymmetric H bridgeless PFC
D1 D4  Features of Asymmetric H PFC
• CCM control can be employed;
L • No need concern about the PLD / surge issue;
S1 S2 • High side gate driving & Current sensing;
• Much more power devices;

neutral

D2 D3 Slow diodes clamp

Fast diodes
DC bus to AC input
operate at HF

One TI-Design TIDA-010028 is on going, will be released this November

20
Soft switching of PFC stage -- CrM control

D1 D3

D2 D4

 Boost PFC  TotemPole PFC

• Only ZVS @ low line • Can ZVS @ both high line & low line

NZVS Off time

Extend

@ Vin = 90Vac Vo=400Vdc @ Vin = 230Vac Vo=400Vdc

21
High Efficiency Topology

Bridged PFC (Boost PFC)

PFC Dual Boost PFC

Bridgeless PFC
TotemPole PFC (With GaN FET)
Asymmetric H PFC
Forward
(With CrM control)
DC-DC PSFB

LLC

22
Methods to improve the efficiency
 Soft switching – resonant DCDC converter

 Bridgeless PFC & soft switching control;

 Better SR control at the secondary side;

 Replace MOSFET with GaN HEMT

23
Secondary SR control of LLC

24
VDS Sensing and Proportional Drive
• UCC24612 turns on when VDS drops below -220mV
• Minimum turn on propagation delay dependent on
variant
• UCC24612-1 (Fast): 80ns
• UCC24612-2 (Slow): 170ns
• SR proportional gate drive is enabled after 50% of
conduction time based on previous cycle
• Gate drive voltage VG (VGATE) is reduced to
maintain -50mV across the SR
• This allows VGATE to be very close to threshold
voltage when turn off occurs, accelerating turn
off time

25
 UCC24612-x | Multi-Mode Synchronous Rectifier
Features Benefits
 Supports numerous topologies including Active Clamp  VDS sensing and adaptive off time reduces required parts and
Flyback, QR, DCM, CCM Flyback, and LLC eliminates design effort
 VDS sensing up to 230 V  High VDS rating supports large output voltages with overshoot
 Adaptive minimum off time to increase noise immunity and  Sleep mode enables low standby power consumption
efficiency  Near-ideal diode emulation enables compliance with EC CoC
 Wide VDD range allows for bias from 4.2V to 28V output Tier 2 and DoE Level VI efficiency standards
systems
 Operating frequency up to 1 MHz for -1 (/ 800kHz for -2)
 Automatic sleep mode
 Two variants for support of multiple topologies
 UCC24612-1 with 80ns turn on delay
 Best for GaN ACF, DCM, QR/TM, CCM flyback
 UCC24612-2 with 170ns turn on delay
 Best for Si ACF, LLC

Applications
• AC-to-DC Adapters
• USB Type-C and Power Delivery AC Adapters
• Server and Telecom Power Supply
• AC-to-DC Auxiliary Power Supply
Low Side High Side
SOT-23-5
Methods to improve the efficiency
 Soft switching – resonant DCDC converter

 Bridgeless PFC & soft switching control;

 Better SR control at the secondary side;

 Replace MOSFET with GaN HEMT

27
 GaN: Key Advantages Over Silicon FET
Low CG,QG gate capacitance/charge (1 nC-Ω vs Si 4 nC-Ω)
 faster turn-on and turn-off, higher switching speed
Drain  reduced gate drive losses

Low COSS,QOSS output capacitance/charge (5 nC-Ω vs Si 25 nC-Ω)

 faster switching, high switching frequencies
COSS  reduced switching losses
Gate QOSS
Low RDSON (5 mΩ-cm2 vs Si >10 mΩ-cm2)
CG QRR  lower conduction losses
QG
Zero QRR No ‘body diode’
 No reverse recovery losses
Source  Reduces ringing on switch node and EMI

28
LMG3410: 600V GaN Power Stage
Integrated direct gate driver with zero common
Slew rate control by one external source inductance
resistor: 30 V/ns to 100 V/ns
D
Direct- Drive
600V
Slew Rate S GaN
Digital PWM input
RDRV 70mΩ-600V GaN FET
IN
Only +12V unregulated supply
needed VDD
VNEG
Enable
5V LDO, UVLO, Switch
Built-in 5V LDO to power LPM BB OC,TEMP
external digital Isolator
Current
FAULT High speed over current protection
with <100ns response time
Low power mode for standby S

Fault feedback to system controller Integrated temperature

protection and UVLO
29
TI Information – Selective Disclosure
LMG3410: 600V GaN Power Stage
Features Functional Block Diagram
• 50mΩ and 70mΩ RDSon Drain to Source
• Integrated GaN Gate Driver
• TI Direct-Driver technology switches the GaN directly
• Internal buck-boost generates negative drive voltage
• Only single +12V unregulated supply needed
• 5V LDO to power external isolator
• External resistor sets drive strength (RDRV pin)
• 30 V/ns to 100 V/ns adjustability
• No compromise in gate-drive inductance
• Fault monitoring and protection
• UVLO protection
• Over-current protection (20nS)
• Over-temperature protection Packaging
• SPICE model and EVM at ti.com

Applications
• Totem-Pole CCM and CRM PFC
• High frequency LLC and PSFB converters
• Photo-voltaic inverters
• Motor Drives 8mm x 8mm QFN
TI Information – Selective Disclosure 30
LMG3410: 1.2kW Isolated Half-Bridge EVM

LMG3410
SN6505
12VH
5V
VDC
LMG3410 DGND SW
VDD
LMG3410

ISO7831
IN

Side 1
HS PWM
Signal Isolation FAULT

FAULT SW
LMG3410

Power Isolation ISO7831

IN
LS PWM
FAULT

SN6505
12VH
VDD
5V

Side 2 DGND SW
PGND

Available at www.ti.com
TI Information – Selective Disclosure 31
Other Methods to improve the efficiency
 Use interleaved winding structure to reduce the proximity effect;
 Use thinner Litz wire to reduce the skin effect;
 Change core material with lower loss @ fs;
 Trade off between ZVS current vs. ZVS condition;

32
Optimizing Efficiency @ Light Load UCC25630x

33
Bluestone| Efficiency Comparison
– Burst v.s. Non-Burst (Zoomed-In)
UCC25630x Burst Mode Operation Principle
• Burst mode threshold (BMT) is a programmable parameter through LL/SS Pin
• If Vcomp < BMT & the pulse number >= 15, UCC25630x will enter burst off mode,
which shuts down both low/high side gate pulses, and also shut down some internal
circuit to save the power consumption – The Vcomp used for generating pulses is the
higher value between BMT and FBreplica
• When Vcomp > BMT, UCC25630x will immediately exit the burst mode and deliver
pulses
BMT Pick
FBreplica
higher Vcomp
value
Vcomp
Minimal 15 pulses
Gate Pulses MUX Soft start finished

Burst mode
threshold (BMT)

35
UCC25630x Burst Mode Threshold Programming
• When soft start is finished, LL/SS pin voltage will be equal to BLK pin voltage
• Current flowing into LL/SS pin = (RVCC - VBLK)/R2 – VBLK/R1
• This current will be mirrored to go through RLL, BMT = VLL = I*RLL
• BMT = [(RVCC - VBLK)/R2 – VBLK/R1]*RLL
• Burst mode threshold is impacted by R1, R2 and BLK pin voltage
• There is a minimal voltage clamp on BMT, the minimal voltage is 0.6V
• Removing R2 is a most simple way to achieve the minimal burst mode threshold

RLL

36
 UCC25630x Key Design: Burst Mode Programming
─ By Adjusting R1 & R2, the Burst Mode threshold
can be adjusted.

• BMT = [(RVCC − VBLK)/R2 – VBLK/R1]∗RLL

─ The burst mode threshold can be adjusted to get

very high light load efficiency. Sometimes this can
lead to increased audible noise at medium loads.

─ One approach to work around this is to have a

dynamically adjustable burst threshold.

37
UCC25630x Key Design: Burst Mode Programming

• Original board burst threshold – Iout=0.75A

• Bluestone board burst threshold – Iout=0.7A

38
Methods to improve the dynamic response

-- Direct Frequency Control vs Hybrid Hysteretic Control

39
Direct Frequency Control (DFC)
• Analogous to voltage mode control
• Limited bandwidth and slow transient
response
S1
D1
• Complex power stage transfer function T1
Vo
R
• Power stage transfer function difficult to S2 Lm 0
Vin
express analytically Cr Lr
• Compensation strategy is typically Deadtime n:1:1 D2
begin with integrator and increase S1_DRV Optocoupler &
VCO VCOMP
bandwidth if enough phase margin is S2_DRV H(s)

available

40
Hybrid Hysteretic Control (HHC)
• Charge control with added frequency
compensation ramp
S1
T1 D1
Vo
• Analogous to current mode control with Inner loop
R
added slope compensation Vin S2 Lm 0

Cr Lr
n:1:1 D2
• 1st order power stage transfer function Deadtime
Optocoupler
VCR Charge VCOMP
Control & H(s)

Outer loop
• Higher bandwidth and fast transient S1_DRV
S2_DRV

response

41
Hybrid Hysteretic Control (HHC)
• HHC operating principle

• Gate turn off thresholds (VTH and VTL)

are derived from feedback

• Gate turn off determined by comparing

VCR to VTH and VTL

• Gate turn on determined by adaptive

dead time circuit

42
Hybrid Hysteretic Control (HHC)
AVDD To Resonant Cap
• Current sources on/off control synchronous to
HSON
gate signal turn off edge
VCR

• Inherent negative feedback for low side and high LSON

side gate signal balance

• Automatically maintain the bias voltage at 3V –

HSON
no need for extra resistor dividers
LSON

• Current sources are turned off during burst off

2mA
period – reduce standby power consumption Ramp
0
current
-2mA

43
Hybrid Hysteretic Control (HHC)

• ~1st order system

• Able to achieve higher

bandwidth
 Frequency control  HHC

44
Transient Response DFC vs HHC: 12V/3A Supply

Legacy: Direct Frequency Control TI: Hybrid Hysteretic Control

Output Voltage (AC coupling) Output Voltage (AC coupling)

V ~ 1V V ~ 0.1V

Load current Load current

Low side gate Low side gate

45
Transient Response: Competitor #1 vs UCC25630x

Competitor #1 TI: UCC25630x

CH1: LO
CH1: Vout 1.25% Vout dip from no load to full load
CH2: Vout 10.8% Vout dip from no load to full load CH2: LO
CH3: Iout CH3: HO-HS
CH4: HO-HS CH4: Iout

46
Transient Response: Competitor #2 vs UCC25630x

Competitor #2 using DFC Control TI: UCC25630x

Vout dip: 600mV Vout dip:250mV

47
Transient Response: Competitor #3 vs UCC25630x

Competitor #3 using DFC Control TI: UCC25630x

Vout dip:740mV Vout dip: 244mV

48
System solution reference -- TI Designs

(Can be clicked)
http://www.ti.com/reference-designs/index.html

49
80+ Platinum, 93% Efficiency, Super Transient, 450W AC/DC Reference Design with Single-Layer PCB
TI Design: TIDA-01501

Features Benefits
• CCM PFC + LLC topology based (UCC28180+UCC25630) • High efficiency over wide load and AC input range
• Full power delivery across wide AC input range: 85 – 265 VAC • Super transient performance, good for computing PSU
• Leading transient performance (half duty-cycle response for applications.
line transient & dynamic load) • Peak efficiency 92.4% @ 115VAC meets 80+ Platinum Specs
• Peak efficiency 92.4% @ 115VAC meets 80+ Platinum Specs Peak efficiency 94.0% @ 230VAC
Peak efficiency 94.0% @ 230VAC • Single layer PCB design to achieve low solution cost
• PF > 0.98 @ 230VAC from 50% to 100% load • Robust protection built-in
• Meets Norms: IEC61000-2-3 Class D

Target Applications
• Gaming PC • Desktop PC PSU
• Entry level server PSU • Other low cost AC-DC PSU

Tools & Resources

• TIDA-01501 and Tools Folder
• Design Guide
• Design Files: Schematics, BOM, Gerbers
• Device Datasheets:
‒ UCC256301, UCC28180, UCC24612
‒ CSD18540Q5B, LM258A
 24V, 480W Nominal 720W Peak, >93.5% Efficient, Robust AC/DC
Industrial Power Supply Reference Design/TI Design Number: TIDA-01494
Features Benefits
• 480W AC/DC Power Supply with CCM PFC and HB-LLC Power Stage. • High Efficiency Power stage with synchronous rectification meets
• Peak Output Power of up to 720W for a short duration of 3 seconds. 80 PLUS Platinum standard and works without forced cooling.
• Overall efficiency greater than 93.5% with peak efficiency > 94% • ZCS avoidance feature enables easier implementation of peak
• ZCS avoidance in the LLC stage, enabling wider input voltage range output power feature and improves robustness
operation and robustness. • Hybrid Hysteretic Control in the LLC controller enables fast
• Power factor > 0.99 and meets PF & Current THD as per IEC 61000-3- transient response reducing output capacitors.
2 Class A and EN55022 Class B Conducted Emission standard. • CCM PFC provides a cost effective PFC Power stage.
• Over Current, Short Circuit, Over Voltage and Over Temperature
Target Applications
Protections.
• Industrial Power Supply
• DIN Rail Power Supply
• Battery Charger
480W, Thin Profile (<17 mm), 94% Efficiency, Fast Transient Response AC/DC
SMPS Reference Design /Design Number: TIDA-01495
Features Benefits
• 480 W, AC/DC SMPS with Interleaved TM-PFC front-end and half • High Efficiency, thin profile SMPS with full load efficiency >93.3%
bridge LLC resonant converter. (230V AC) and >91.1% (115V AC) with peak efficiency 94.1%
• Thin profile <17 mm height for use in space constrained applications (230V AC) and 92% (115V AC) meets 80+ Platinum standard.
with small PCB form factor of 185 x 110 mm. • Hybrid Hysteretic Control enables fast transient response
• Overall efficiency of >93.3% at full load with 94.1% peak (230 VAC) minimizes the PFC Bulk and output capacitor.
Light load efficiency >85% (230 VAC) at 5% load. • ZCS avoidance feature and OVP sensing feature in the LLC
• power factor > 0.99 & iTHD as per IEC 61000-3-2 Class A. controller improves robustness, system protected for Over current,
• Output OCP, OVP, Short-circuit Protection. Short-circuit, Over Voltage ensuring safety..
• Designed to meet Conducted Emission standard – EN55011 class B • Interleaved TM-PFC, reduces input/output current ripple, EMI filter
requirements.
Target Applications • Phase shedding feature in the PFC power stage and advanced
• Industrial & Consumer AC/DC • Medical Power Supply burst mode feature in the LLC power stage enables high efficiency
• DIN Rail Power Supply • Battery Chargers at light load conditions.
93% Efficiency, 200W, Fast Transient, Desktop PC PSU Reference Design Design Stage
/TI Design: TIDA-01557
Features Benefits
• CrCM/DCM PFC + LLC topology based (UCC28056+UCC25630) • High efficiency over wide load and AC input range
• Full power delivery across wide AC input range: 85 – 265 VAC
• Super transient performance, good for computing PSU
• Leading light load efficiency: applications.
No Load <0.1W; >50% at 0.25W; > 79% at 2W;>81% at 4W
• Meets 80 PLUS Platinum efficiency specification
• Leading transient performance (half duty-cycle response for line
• Robust protection built-in: with OVP, OCP, SCP, CTP available
transient & dynamic load)
• Peak efficiency 93% @ 230VAC (80 PLUS PLATINUM) • Low no power consumption
• PF > 0.99 @ 230VAC from 50% to 100% load • SFX12 form-factor fit (125 x 100 x 40 mm)
• Output OCP, OVP, Short-circuit Protection, OTP
• Meets Norms: IEC61000-2-3 Class D, EN–55022 class B (CE)
Target Applications
• Gaming PC Adapter • Desktop PC PSU
• Entry level server PSU • Other low cost AC-DC PSU
Tools & Resources
• TIDA-015xx and Tools Folder
• Design Guide
• Design Files: Schematics, BOM,
Gerbers
• Device Datasheets:
‒ UCC28056, UCC25630, UCC24612
 Queries
Email: Desheng-guo@ti.com

54
Thank You

55
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