Texas Instruments System Power Solutions -High efficiency LLC resonant controller and synchronous rectifier Texas Instruments Power Management AGENDA 1. UCC25710 Multi-strings LLC LED driver 1. Features and Application 2. Block Diagram 3. Operating descriptions and evaluation results: 2. UCC25600 LLC controller 1. LLC operating descriptions 2. Block diagram and features: 3. UCC24610 Synchronous driver: 1. Features and Application 2. EVM and test results: Typical High Watt (>100W) LED Lighting Driver Topology 2. Constant Current Driver Stage 1. AC/DC Power Stage AC PFC UCC28061( Inter TM PFC) UCC28810/1(TM PFC) LLC Converter ~54Vdc Bus UCC25600 (LLC) BUCK Control + TPS4021 1 TPS4020 0 TPS5416 0 BUCK Control TPS4021 1 TPS4020 0 TPS5416 0 ~15pcs LEDs in Series High Watt (>100W) LED Lighting Efficiency Budget Outdoor and Industrial >100W 400V EMI PFC Control Q 1 LLC Control Q 2 L r L m C Buck Control Buck Control r 97% 96% 95% <88% (Traditional solution) Conventional Topology Issues: High cost: PFC+LLC+CC BUCK (multi-chips!!) Low efficiency (<~88%) Low reliability (many components’ counts) EMI issues TI UCC28810EVM-003 - SIMPLEDrive™ Series Input, Multiple Parallel Equivalent LED Drive (SIMPLEDrive ) 3rd stage: 2nd stage: 1st stage: TM Buck for LED current Resonant Current Half Bridge TM Boost for PFC 97% 98% 98% >93% (Three stages multi-string transformer solution) Innovative two stages multi-string LLC topology for LED lighting EMI Input Bridge BUCK PFC Control PWM Control UCC28810 HV Gate Driver Outdoor and Infrastructure >100W UCC2881 1 UCC25600 new Outdoor and Infrastructure >100W 400Vdc EMI Input Bridge PFC Control UCC28810 ☺ High efficiency ~92% ☺ Low cost (no need CC DC/DC driver) ☺ High reliability ☺ Easy EMI ☺ PWM or analog dimming compatible Ga Gb Gate Driver Benefits for the proposed topology: CS UV OV PWM Control UCC25710 Why Transformer Can Balance Current 1 Ip T1 4 Np Ns 2 3 • Is1 • • Ip 1 Np 2 T2 • 4 Ns 3 Is2 • Transformer current is in reverse proportion to turn ratio Ip/Np = Is/Ns; Is=Ns*Ip/Np When transformer primary is connected together, their primary current must be the same When T1 is the same as T2 because of transformer operation principle their secondary current is the same Is1=Ns*Ip/Np=Is2 Multi-Transformer Architecture (TI Patented) AC input PWN dimming One transformer control two LED strings! UCC25710: LED driver Controller IC Industry first single chip LLC controller for driving multiple LED strings directly from PFC output Adjustable Fmin (3% accuracy), and Fmax 6% (accuracy) Closed Loop LED String Current Control PWM Dimming Input LLC and Series LED Switch Control for Dimming Programmable Dimming LLC ON/OFF Ramp for Elimination of Audible Noise Closed Loop Current Control at Low Dimming Duty-Cycles Programmable Soft Start Accurate VREF for Tight Output Regulation Over-voltage and Under-voltage and Input Overcurrent Protection with Auto-restart Response Second Over-current threshold with Latch-off Response +400-mA/-800mA Gate Drive Current Low Start-Up and Operating Currents 20 pin SO Lead (Pb)-Free Package General LED Lighting LED TV Backlighting T1 VIN – + LED String 1 T2 – + LED String 2 TN ON / OFF – + LED String N 20V-9.5V VCC DTY BLON DADJ GD1 GD2 GND CL CREF VREF DSR UCC25710 DIM DIM PWM Input FMIN FMAX SS ICOMP CS LEDSW OV UV VCC 1 UVLO + VVCCON/VCCOFF 9.3V/8.9V S* Q ENBL VVREF BLON 10 FAULT 5V Ref VREF 5 VVREF RST Gen R delay Supply Control 2.5uA RESET H Q L ENBL TRSTDLY 10ms ~4V 200K IDADJCH 20uA + SS-END 7 DTY 8 DADJ LED Switch and DIM Dimming Control VVREF GD Enable 9 OFF H UCC25710 Block Diagram GD1 2 200K LLC-OFF Dead Time GD2 3 Dimming PWM Edge Sync D ON 80K Q 2*F GND 4 FSW FMIN 20 LLC Control VCO FMAX CLR GD Toggle D 80K Q SS-END RESET Q LED-ON FMAX 19 FMIN VVCO 1V 0.9V CLR + + + ICOMP 17 2.4us S FAULT Q R + TSD Control Clamp GND I DSRCH 44uA SS Clamp L + le ab Dis SS-END H 13 Fault Control OV 12 VOVTH 2.6V/2.4V I DSRDC 44uA + VUVTH 2.4V/2.6V 11 Soft Start VSSTH 4.2V S Q * Q R RESET CL VCLTH 1V/0.5V + LLC -OFF 14 SS 18 + VVREF Current Regulation and DSR VCO Slew Control VVREF ISS 2.5uA UVLO VVREF H Dimming Slew Control ICOMP 4K Q LED-ON delay VCLLTH 1.9V Latch-Off LATCH-OFF Low ICC Current Amplifier GM ICOMP 510uS LEDSW Zero Frequency Command VCLREFCLO, 0.5V VCLREFCHI, 2.8V CS 16 6 4V VVCO CREF 15 Q UCC25710 UV UCC25710: DIMMING – LLC ON/OFF TRANSITION & CURRENT CONTROL • The DIM input controls the ILED-ON an ILED-ON` signals. VREF VVCO 5 • DSR capacitor C2 and internal 44uA currents control the slew rate of VVCO during dimming off and on transitions. – Turn-off: DSR is discharged to GND by 44uA – Turn-on: DSR is charged to ICOMP by 44uA. Charge level is clamped to 1Vbe above ICOMP LED RETURN R1 CREF R2 + + + CS 16 Current Amplifier + 17 C1 ICOMP VVREF H GMICOMP 510uS R3 • Control Clamp output, VVCO, tracks the lower of ICOMP and DSR Control Clamp VVREF Dimming Slew Control ICOMP 4K IDSRCH 44uA ILED-ON GND H 14 VVREF C2 VCC LEDSW • During LED-OFF times the ICOMP voltage is held by C1 VCLREFCLO, 0.5V VCLREFCHI, 2.8V 15 DSR • ICOMP is only driven by GM amp during LED-ON times. VVCO 6 L delay 2.4us ILED-ON IDSRDC 44uA UCC25710: START-UP & DIM WAVEFORMS • 10ms RESET initiates SoftStart (SS) • LLC Soft-Start, VCO control is clamped to SS until SS > ICOMP VCC 9.3V VREF UVLO RESET Controller Enabled 9.0V 10ms Dimming Enabled • Dimming is disabled during SS • DSR cap is used to limit LLC control slew rate during dimming • ICOMP voltage is maintained during dimming Soft-Start Over SS ICOMP DSR GD1,2 LEDSW DIM Soft-Start Operation Disabled UCC25710: DIMMING – WAVEFORMS • DIM input controls LEDSW • DIM input triggers soft turn-on and turn-off of LLC converter • LLC on-time is extended • On-time extension is proportional to 1-D, D is dimming duty-cycle • Extended on-time allows ICOMP to maintain current regulation at low D Dimming DIM DTY = 0.1V + 2.5V*(1-D) DTY DADJ Added LLC On-Time SS (VVCO) ICOMP LLC On/Off Slew Rate LEDSW 50% Dimming 10% Dimming UCC25710: LOW DUTY-CYLE ILLUSTRATION 1. LLC reaches power level equal to pedestal LED current in region B. Power is under delivered in region A, but is compensated for in region C 2. Region B is zero, but sum of A+C still deliveries correct energy. 3. Energy delivered in region A + C is too low, loop is open and realized peak LED current will drop 4. On-time is extended. A + C energy/pulse is correct to maintain same peak LED current LLC POWER RAMP DIMMING PWM SIGNAL D A B C D (1) B=0 LLC POWER RAMP DIMMING PWM SIGNAL D C D A (2) A C LLC POWER RAMP D D (3) DIMMING PWM SIGNAL LLC POWER RAMP DIMMING PWM SIGNAL D AC D (4) UCC25710: FAULT MANAGEMENT • Faults – – – – – • OV – highest LED string voltage UV – lowest LED string voltage CL(1V) – input current signal over-current CL(2V) – input current signal latch-off TSD – Chip thermal shutdown Response – OV, CL(1V) & TSD: The LLC converter and LEDSW are turned off. When the fault clears a RESET and SS are initiated. – UV: The LLC converter and LEDSW are turned off. A RESET and SS are immediately initiated, repeatedly, until fault clears. – CL(2V): The LLC and LEDSW are latched off until UVLO recycles. – During RESET the LLC converter and LEDSW are OFF – During SS the LLC converter and LEDSW are ON, i.e. no DIMMING PMP4302: Multi-string LLC AC/DC Driver for general LED lighting TI Parts Reference Design PMP4302: AC input Multi-string LLC converter for general LED lighting UCC28810 (TM PFC) UCC25710 (Multi-string LLC) UCC28610 (Aux Flyback) Vin Output 90V~2 64V 54V@500mA with 4 string Topology TM PFC+Multistring LLC converter Eff. Dimming 92% PWM dimming Features • • • • Outdoor and Infrastructure >100W 400Vdc PFC Control UCC28810 Ga Gb CS UV OV Gate Driver EMI Input Bridge PWM Control UCC25710 Lowest cost than AC/DC + DC/DC Highest efficiency to 92% PWM dimming compatible Integrate LED open/short protection and over current protection Applications • General LED lighting and LED backlight TV PMP4302 demo board Aux Power Input EMI LED light bar 4x15LEDs PFC Stage Multi-string LLC Stage PMP4302: Schematics for UCC25710 after PFC stage Multi-string transformer LLC topology PWM dimming & Total current sensing feedback PMP4302: LED current output tolerance LED output current Vs Input voltage w/ 100% dimming 0.515 230V ac input Io1 Io2 Io3 Io4 % 1% 4.9 4.8 5 5.1 3.030 2% 10 9.8 10.4 10.3 2.962 5% 25.2 24.1 25.2 25.1 2.208 10% 50.4 49.7 51.5 51.3 1.774 20% 100.9 100.1 102.7 102.5 1.280 30% 151.4 150.4 154.1 153.6 1.214 40% 201.9 200.9 205.1 204.9 1.033 50% 252.4 251.1 256.4 255.8 1.043 60% 302.9 301.4 307.7 307 1.033 70% 353.5 351.8 358.6 357.8 0.956 80% 403.9 402.2 409.7 408.8 0.923 90% 454.3 452.2 461.1 460.1 0.973 99% 499.3 496.7 507.2 506.2 1.045 100% 503.9 501.4 512.4 511.7 1.084 0.513 Output C urrent (A) PWM Dimming 0.511 0.509 0.507 0.505 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 Input Voltage(V) Current tolerance can achieve <+-3% with dimming range from 1% to 100% 0.9 0.92 0.89 0.91 0.88 0.9 Efficiency Efficiency PMP4302: Efficiency (TM PFC + Multi-string LLC + Aux power) 0.87 0.86 0.89 0.88 0.85 0.87 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 Input Voltage(V) Dimming version 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 Input Voltage(V) Non-Dimming version PMP4302: waveforms 1% dimming 50% dimming 5% dimming 90% dimming CH1: LEDSW MOSFET Vgs 5V/Div CH2: LED Output Current 1A/Div CH3: DSR 2V/Div CH4: Primary Current 1A/Div PMP4302: waveforms 2 1.8 1.6 1.4 1.2 M Full Load 1 Half Load 0.8 20% Load 0.6 0.4 0.2 90Vac input 0 0 CCM to get better current tolerance 230Vac input CH1: Primary MOSFET Vds 100V/Div CH2: LED Output Current 200mA/Div CH4: Primary Current 1A/Div 0.5 1 1.5 2 Wn Lm/Lk=6 Fs=100KHz Q=0.7 Lm1+Lm2=640uH Lr=100uH Cr=30nF PMP4302: Thermal and Bode Plot PMP6251: LED Backlighting for EdgeLite/ Group Dimming Digital TV Application Reference design Features Support to universal 90~264Vac range LED 4 outputs @120mA, 63V, 5Vsb@1A, 5V@3A, 13V@3A Eff 83.7%@110Vac, 85.2%@240Vac Secondary side 120Hz blanking control for dimming 8mm height and 6mmheight for LED magnetic component Board dimension 300mm(L) * 200mm(W) * 8mm(H) LED output common + and LED OVP and UVP Integrated the protection ckt to reduce the solution part count. Utility Dedicated controller for edge-lit/ group dimming base(90~265VAC) on the LLC topology – UCC25710 Providing design package – Schematic, Gerbo file, PCB file, Magnetic components… TM PFC UCC28051 Multi-Transformer UCC25710 LLC PWM UCC25600 GM PWM UCC28610 4 Channels/ 63V/120mA Audio 12.7V/3A AD Board 5V/3A System- MCU (+5VSB/2A) PMP6251: PFC+ Multi-string LLC Efficiency Efficiency Data of PFC+LLC Power Stage from 1% - 100% Dimming 92.00% Eff%(PFC+LLC) Rate of Dimming 90.00% 88.00% 86.00% 84.00% 82.00% 80.00% 0% 20% 40% 60% 80% 100% Eff% of (PFC+LLC) Efficiency exclude standby Power Converter at full load condition ~ 90% Summary • UCC25710 with multi-transformer LLC topology can achieve: ☺High efficiency ☺Low total BOM cost with high reliability ☺PWM or analog dimming compatible ☺Output LED strings open/short protection ☺Input over current protection ☺Support 1%~100% dimming range ☺Easy EMI Summary • LED backlight becomes a trend for flat screen TVs • TI proposed multi-transformer backlight solution – Simple current matching method – Single stage power processing – Fault tolerant capability • UCC25710 provides the IC solution for multitransformer architecture • • • • • Multi-Transformer LLC + LED switch control Precision LED current control Soft ramping of LLC for audible noise reduction Extended PWM dimming dynamic range Complete protection features TI UCC25600 8 Pin Resonant Half Bridge Controller Features Adjustable Soft start (1ms to 500ms) Adjustable dead time Td Adjustable Fswmax & Fswmin (3% accuracy) RT Io = +1A /-1.5A OC Enable (ON/OFF control) SS Protection functions Two levels over current protection auto recovery latch Bias voltage UV and OV protection Over temperature protection Soft start after all fault conditions SOT 8 pin package= Easy design and layout 1 8 GATE1 2 7 VCC 3 6 GND 4 5 GATE2 Ready to Order Application Circuit 360~400V Vcc DC_OUT Td Gate1 RT Vcc OC GND SS Gate2 1 1 1 1 Programmable dead time Frequency control with minimum/maximum frequency limiting Programmable soft start with on/off control Two level over current protection, auto-recovery and latch up Matching output with 50ns tolerance LLC Resonant Converter with Wide Operation Range 4 Q=0.1 Q=0.2 Q=0.5 Q=0.8 3.5 Cr n:1:1 Lr Vin Vo M=Vo/V in 3 2.5 2 ZVS Region 1.5 Q=1 Q=2 Q=5 Q=8 Q=10 ZCS Region 1 Lm RL 0.5 0 0.4 Resonant frequency f0 = 1 2π Lr Cr Transformer turns-ratio 0.6 n= Vin / 2 Vo At 400V input, switching frequency is resonant frequency During holdup time, switching frequency is reduced 0.8 fn 1 1.2 Operation Principles At Resonant Frequency Vg_Q1 t Vg_Q2 t Vp Q1 Cr Vin t ir D1 n:1:1 Lr Vo * Q2 Lm * RL * im D2 t is t t0 t1 t2 t3 t4 At resonant frequency, maximum efficiency is expected Operation Principle Below Resonant Frequency Vg_Q1 Vg_Q2 Q1 Vp Cr Vin Vo * Q2 ir D1 n:1:1 Lr Lm * RL * D2 im When switching frequency is below resonant frequency, magnetizing inductor begins to participate in resonant and increase voltage gain Secondary diode becomes discontinuous is t0 t1 t2 t3 Operation Principle Above Resonant Frequency Vg_Q1 Vg_Q2 Q1 Vp Cr Vin Vo * Q2 ir D1 n:1:1 Lr Lm * RL * D2 im When switching frequency is above resonant frequency, circuit behaves as SRC Secondary current becomes CCM, reverse recovery loss increases is t0 t1 t2 t3 Benefits of LLC Resonant Converter Cr 1:n:n Lr Lm ZVS can be achieved by utilizing transformer magnetizing inductor Capacitor filter, less voltage stress on rectifiers Smaller switching loss due to small turn off current Variable switching frequency control, not sensitive to load change Wide operation range without reducing normal operation efficiency UCC24610 Green Rectifier Controller • Secondary Side Synchronous Rectifier Controller for Flyback and LLC Converters • Operates in Continuous and Discontinuous Mode Flybacks and LLC Resonant • Automatic Light Load Management • Highly Integrated Control • Micro Power Sleep Current at light/No load • Enables 90%+ efficiency at full load and Optimized Efficiency Over Entire Load Range • Zero Glitch Transition between CCM and DCM Operation for varying Line or Load Changes • Turns MOSFETS Off to Maximize Light Load Efficiency • Reduces External Components with up to 5% Reduction in Power Supply Costs • Dissipates less than 1mW in Sleep Mode Making Energy Star Goals easily Achievable + • • • • • AC/DC Adaptors Mobile Chargers – Cell Phone, IPod Set Top Box Appliance Power Supplies Bias Supplies + VD GATE VCC VS TON EN/TOFF iSYNC_RESET CSYNC RSYNC iSYNC EVM Available +5V OUT C CM SYNC C PIN GND VCC rSYNC To Control Logic UCC24610 Adding Green Solutions to the Portfolio Green Rectifier UCC24610 LLC Or Flyback MOSFET Drivers Sync Rectifier Driver Isolated Feedback Green PWM Controllers UCC28610 Green Mode PWM UCC28600 Green Mode QR PWM UCC25600 Green Mode Resonant LLC Expand the Operation Range of UCC24610 • With 50V maximum rating, UCC24610 has trouble to use in 19V output LLC • LLC converter with voltage doubler can be used to extend the operation range of UCC24610 • No center tap, simpler transformer structure • Less voltage drop on the SR, better devices can be used • UCC24610 can be powered up using on aux power source with boots trap diode UCC24610 Competitive Analysis TI IR NXP (8) NXP ST ON ON Gren (9) Zerex Parameter/Device: UCC24610 IR1166S TEA1761T TEA1791T STSR30 NCP4302 NCP4303B GR8387 ZXGD3101T8 50 200 120 120 (ext. clamp) 95 200 200 180 Vdrain (V) DCM, QR DCM, QR, CCM DCM, QR, CCM DCM, QR, CCM DCM, QR, CCM DCM, QR, CCM Conduction Modes DCM, QR, CCM DCM, QR, CCM DCM, QR -1 -0.25 -0.25 -1.5 2.5 2.5 1 2.5 GATE Ion (Apk) -3 4 2.7 2.7 1.5 -2.5 -5 -4 -2.5 GATE Ioff (Apk) 3 600 500 ? ? 500 250 500 500 n/a Max Freq (kHz) SO-8 SO-8 SO-8 SO-8 SO-8 SO-8 SO-8 SO-8 Packages PwrQFN-8, SO-8 67, 147 128 150 150 160 178 180 128 250 Rthja (C/W) (5) (5) Unknown Unknown -40 to +125 -25 to +125 -20 to +128 -20 to +128 -40 to +125 -40 to +125 -40 to +125 Tj Range (C) Special Features: No No No No Enable function Yes Yes Yes Yes Yes No No No No No No Auto Light-Load Mode Yes Yes Yes No No No No No No No No Inductance Compensation Yes None Indicated None Indicated None Indicated None Indicated None Indicated None Indicated None Indicated None Indicated Open/Short Protections Yes No No No No No No No Regulated Opto-drive Yes Yes No No No No No Gate Voltage Reduction Yes Yes Yes Yes No No No No No No No No Over-temp Protection Yes Key Differentiators • High Gate Drive current • Auto Light Load Mode • Open/Short Protection 5.6V/3A AC Adapter: 12V/40A Server Application: 95% 94% 93% Efficiency 92% 91% 90% 89% 88% 87% 86% 85% 0 4 8 12 16 20 24 Load Current (Amps) 28 32 36 40 UCC24610 in 19.5V LLC AC Adapter Application Synchronous rectifier in LLC converter System implementation Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =320 V – IO =1.0 Adc (20 W) – fSW below resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =390 V – IO =1.0 Adc (20 W) – fSW close to resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 1 µs/Div Operating conditions – VI =420 V – IO =1.0 Adc (20 W) – fSW above resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =320 V – IO =2.3 Adc (45 W) – fSW below resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =390 V – IO =2.3 Adc (45 W) – fSW close to resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 1 µs/Div Operating conditions – VI =420 V – IO =2.3 Adc (45 W) – fSW above resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =320 V – IO =4.6 Adc (90 W) – fSW below resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) A/Div – BLU (Lower SR VDS) V/Div – GRN (Upper SR VGS) V/Div – RED (Lower SR VGS) V/Div Horizontal scale – 2 µs/Div Operating conditions – VI =390 V – IO =4.6 Adc (90 W) – fSW close to resonance 1 10 10 10 Test Results • • • Waveforms – YEL (Primary current) 1 A/Div – BLU (Lower SR VDS) 10 V/Div – GRN (Upper SR VGS) 10V/Div – RED (Lower SR VGS) 10V/Div Horizontal scale: 2 µs/Div Operating conditions – VI =420 V – IO =4.6 Adc (90 W) – fSW above resonance Operating Efficiency with UCC24610 90-W LLC Laptop Adapter (UCC24610) - Efficiency 95 90 Efficiency (%) VI (V) 85 SR Diode 80 75 70 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 IO (A) More than 6% efficiency improvement is achieved by using UCC24610 with Synchronous rectifier Thank You!