URGENT : ICL5102 Infineon Part - Dual Stage PFC+LLC TopologySolution Required

[Ravindra]

One of our customers (Konark) is working on an ICL5102 device for 200W, and they need your help regarding transformer design for LLC and PFC. below are the required details.

“We need your support on transformer design data (PFC Boost Transformer & LLC transformer) which is the major crucial aspect of any LLC-based design.

Please find the below-mentioned requirements and give support on transformer design.

AC input Voltage:               100V – 290V

Input Frequency:               47Hz – 63Hz

Required Efficiency                         :               >93%

Rated LED Voltage:               48V – 60V

LED Current range:               0.032 - 3.2A

LED Power:               192W (Maximum)

Analog Dimmable:               YES (0-10V analog dimming)

THD                                                        :               <10%

PF                                                           :               >0.95

I also have some other queries regarding the LLC topology:

Q1: Should we design a Split Bobbin transformer (Lr & Lm) for the LLC stage, or should we use a separate standard transformer for Lr & Lm.?

Q2: Can we design an LED driver with higher output voltage and low output currents like a 200W LLC driver with only 700mA/750mA output current only or must we shift from LLC to LCC topology.?

Please share the transformer designs for the PFC Boost stage & LLC stage so that we can design the PCB accordingly.

Need your support ASAP.”

[Kanahaiya_K · Accepted solution]

Hi @Ravindra ,

Thanks for posting on the Infineon Developer community.

Please share the transformer designs for the PFC Boost stage & LLC stage so that we can design the PCB accordingly.

We have the Design guide for dual-stage PFC+LLC LED driver using ICL5102 for 130 watts design.Please use this document for your refrence and adapt the design to the needs of your application.

Should we design a Split Bobbin transformer (Lr & Lm) for the LLC stage, or should we use a separate standard transformer for Lr & Lm.?

There is no hard & fast rule for the selection of the split bobbin transformer or separate standard transformer.It depends on the space reuirement & layout design . Choose the core material accordingly as per your application.

Can we design an LED driver with higher output voltage and low output currents like a 200W LLC driver with only 700mA/750mA output current only or must we shift from LLC to LCC topology.?

When the voltage range and current range are quite broad, LCC is preferable than LLC. LCC can accomplish broader operating within the constrained frequency range.As per your application,it is recommended to use the LLC topology.

Please feel free to reach us in case of any further clarifications.

Best regards,
Kanahaiya

[radhamohan605]

Dear Sir,

I am in need of a fast forward solution on this. so if you have pre-designed transformer data for (PFC Boost + LLC)  for 200W/250W then please share with me. Output voltage/current range is can be anything as long as required Power rating is met.

Also, please also share the PCB design file if any for fast development.

Thanks.

[Ravindra]

Hi Kanahaiya,

 Thank you for your response to our above queries, but our customer needs transformer design for PFC and LLC section at the below-mentioned parameters,

We need your support on transformer design data (PFC Boost Transformer & LLC transformer) which is the major crucial aspect of any LLC-based design.

Please find the below-mentioned requirements and give support on transformer design.

AC input Voltage:               100V – 290V

Input Frequency:               47Hz – 63Hz

Required Efficiency                         :               >93%

Rated LED Voltage:               48V – 60V

LED Current range:               0.032 - 3.2A

LED Power:               192W (Maximum)

Analog Dimmable:               YES (0-10V analog dimming)

THD                                                        :               <10%

PF                                                           :               >0.95

  Please revert soon.

Thanks & Regards,

Ravindra Pratap Singh

8826443894

[Kanahaiya_K]

Hi @Ravindra ,

ICL5102 has two additional features named Burst mode and  Over temperature protection in comparison to ICL5101.

Excel Design calcuator is available for ICL5101.It will help to calculate the LLC parameter.

For the external components calculation ,refer to the  mentioned design guide.

Please feel free to contact us in case of any further clarifications.

Best Regards,

Kanahaiya

[Kanahaiya_K]

Hello,
There is no predesigned data  available with us for 200 watts.

The four boards and designs that are currently available are listed below.

1.REF_ICL5102_U100W_LCC

2. REF_LLC_BUCK_4CH_320W

3.REF-ICL5102-U130W-CC

4. REF-ICL5102-U52W-CC

Please feel free to reach out to us if you need any further information.

Regards,
Kanahaiya