Design Considerations

for an LLC Resonant Converter

Hangseok Choi
Power Conversion Team

www.fairchildsemi.com

1. Introduction
Growing demand for higher power
density and low profile in power
converter has forced to increase
switching frequency

High frequency
operation

However, Switching Loss has been

an obstacle to high frequency
operation

Overlap of voltage and current

Capacitive loss

Reverse recovery loss

1. Introduction

Resonant converter: processes power in a sinusoidal manner and

the switching devices are softly commutated
9 Voltage across the switch drops to zero before switch turns on (ZVS)
Remove overlap area between V and I when turning on
Capacitive loss is eliminated

Series resonant converter / Parallel resonant converter

1. Introduction
Series Resonant (SR) converter
resonant network

Q1

Ip

Vin
Vd

n:1
Ro

Lr

VO

Q2
Lm
Ids2

Cr

The resonant inductor (Lr) and resonant capacitor (Cr) are in series
The resonant capacitor is in series with the load
9 The resonant tank and the load act as a voltage divider DC gain is always
lower than 1 (maximum gain happens at the resonant frequency)
9 The impedance of resonant tank can be changed by varying the frequency
of driving voltage (Vd)
4

1. Introduction
Series Resonant (SR) converter
Advantages
9 Reduced switching loss and EMI through ZVS Improved
efficiency
9 Reduced magnetic components size by high frequency operation

Drawbacks
9 Can optimize performance at one operating point, but not with wide
range of input voltage and load variations
9 Can not regulate the output at no load condition
9 Pulsating rectifier current (capacitor output): limitation for high
output current application

1. Introduction
Parallel Resonant (PR) converter

resonant network

Q1

Ip

Vin
Vd
Q2

n:1
Ro

Llkp
Cr

+
VO
-

Ids2

The resonant inductor (Lr) and resonant capacitor (Cr) are in series
The resonant capacitor is in parallel with the load
9 The impedance of resonant tank can be changed by varying the
frequency of driving voltage (Vd)

1. Introduction
Parallel Resonant (PR) converter
Advantages
9 No problem in output regulation at no load condition
9 Continuous rectifier current (inductor output): suitable for high
output current application

Drawbacks
9 The primary side current is almost independent of load condition:
significant current may circulate through the resonant network,
even at the no load condition
9 Circulating current increases as input voltage increases: limitation
for wide range of input voltage

1. Introduction
What is LLC resonant converter?
9 Topology looks almost same as the conventional LC series
resonant converter
9 Magnetizing inductance (Lm) of the transformer is relatively small
and involved in the resonance operation
9 Voltage gain is different from that of LC series resonant converter

LC Series resonant converter

resonant network

Q1

Ip

Vin
Vd

Ro

Lr

Ids2

+
VO

Lm

resonant network

Q1

n:1

Q2

LLC resonant converter

Ip

Vin
Vd
Q2

Ids2

Io

ID
Ro

Lr

+
VO

Im
Lm

Cr

n:1

Cr

1. Introduction
Features of LLC resonant converter
- Reduced switching loss through ZVS: Improved efficiency
- Narrow frequency variation range over wide load range
- Zero voltage switching even at no load condition

- Typically, integrated transformer is used instead of discrete magnetic

components

1. Introduction
Integrated transformer in LLC resonant converter
9 Two magnetic components are implemented with a single core (use
the primary side leakage inductance as a resonant inductor)
9 One magnetic components (Lr) can be saved
9 Leakage inductance not only exists in the primary side but also in
the secondary side
9 Need to consider the leakage inductance in the secondary side

Q1

Integrated transformer

Q1

Vin

n:1
Vd
Q2

Io

ID
Ro

Lr

+
VO

Lm

Ip

Vin
Vd
Q2

10

Cr

Ids2

Ro

+
VO

Im
Lm

Ids2

Llks

Llkp

Io

ID

n:1

Cr

2. Operation principle and Fundamental Approximation

Square wave generator: produces a square wave voltage, Vd by driving switches,

Q1 and Q2 with alternating 50% duty cycle for each switch.

Resonant network: consists of Llkp, Llks, Lm and Cr. The current lags the voltage
applied to the resonant network which allows the MOSFETs to be turned on
with zero voltage.

Rectifier network: produces DC voltage by rectifying AC current

Ip
Im

Square wave generator

resonant network

Q1

Ip

Vin
Vd
Q2

Llks

Llkp

Ro

+
VO

Im
Lm

Ids2

Io

ID

n:1

Ids2

Rectifier network

ID
Vd
(Vds2)

Cr

Vgs1
Vgs2
11

Vin

2. Operation principle and Fundamental Approximation

The resonant network filters the higher harmonic currents. Thus, essentially
only sinusoidal current is allowed to flow through the resonant network even
though a square wave voltage (Vd) is applied to the resonant network.

Fundamental approximation: assumes that only the fundamental component of

the square-wave voltage input to the resonant network contributes to the power
transfer to the output.

The square wave voltage can be replaced by its fundamental component

Vd

Resonant
netw ork

12

Isec

Ip

Isec

Ip

Vd

Resonant
netw ork

2. Operation principle and Fundamental Approximation

Because the rectifier circuit in the secondary side acts as an impedance

transformer, the equivalent load resistance is different from actual load resistance.

The primary side circuit is replaced

by a sinusoidal current source (Iac)
and a square wave of voltage (VRI)
appears at the input to the rectifier.

The equivalent load resistance is

obtained as

I ac

pk

Io
+
Iac

+
VRI

VO

Ro

Rac =

8 Vo
8
VRI
VRI
=
=
=
Ro
2
2
F
Io
I ac
I ac

I ac =

Iac
VRIF
VRI

13

Vo

Io

VRI F =

sin( wt )

4Vo

sin( wt )

2. Operation principle and Fundamental Approximation

AC equivalent circuit (L-L-L-C)

Vin

Vd
+

Cr

Llks

Llkp

+
+

n:1

Rac =

Ro
-

VdF

2 Lm Rac Cr

2
2
2
j (1 2 ) ( Lm + n Llks ) + Rac (1 2 )
o
p

Ro
n2Llks

Cr

VRI

Lm

8n 2

VO

4n Vo

sin(t )
VRO
2n Vo
n VRI

M= F =
=
=
4 Vin
Vd
Vd F
Vin
sin(t )
2
F

Rac =

Llkp
Lm

Rac

VROF

o =

8n 2

Ro

1
, p =
Lr Cr

1
L p Cr

Lp = Lm + Llkp , Lr = Llkp + Lm //(n 2 Llks )

- Lr is measured in primary side with secondary winding short circuited
- Lp is measured in primary side with secondary winding open circuited

14

2. Operation principle and Fundamental Approximation

Simplified AC equivalent circuit (L-L-C)

Cr

Vd
+

Vin

Llks

Llkp

+
+

Ro

2 k
( 2)
p k +1

VO

VRI

Lm

Assuming Llkp=n2Llks

n:1

M=

2n VO
=
Vin

2
2
(k + 1) 2
j ( ) (1 2 ) Q
+ (1 2 )
o
o
p
2k + 1

Lr = Llkp + Lm //(n Llks )

2

= Llkp + Lm // Llkp

L p = Llkp + Lm
Cr

VinF

1:

Q=

Lp
L p Lr

Rac

VROF

M=
- Lr is measured in primary side with secondary winding short circuited
- Lp is measured in primary side with secondary winding open circuited

15

k=

Lm
Llkp

Expressing in terms of Lp and Lr

Lr
Lp-Lr

Lr / Cr
Rac

2n VO
=
Vin

2 Lp Lr
( 2)
Lp
p
Lp

2
2
+ (1 2 )
j ( ) (1 2 ) Q
Lr
o
o
p

2. Operation principle and Fundamental Approximation

Gain characteristics

LLC resonant C onverter

fp

9 Two resonant frequencies (fo and fp)

exist
9 The gain is fixed at resonant frequency
(fo) regardless of the load variation

fo

2.0

Q=

Q=0.2

1.8

Lr / Cr
Rac
Q= 1
Q = 0.8

1.6

Q = 0.6

Lp
Lp Lr

Q = 0.4

1.4
G ain

M @ =o

k +1
=
=
k

Q = 0.2
1.2

9 Peak gain frequency exists between fo

and fp
9 As Q decreases (as load decreases),
the peak gain frequency moves to fp and
higher peak gain is obtained.
9 As Q increases (as load increases),
peak gain frequency moves to fo and the
peak gain drops

16

Q=1

1.0

M=

0.8

k +1
=
k

Lp
Lp Lr

0.6
40

50

60

70

80

90
freq (kH z)

100

110

120

130

140

2. Operation principle and Fundamental Approximation

Peak gain (attainable maximum gain) versus Q for different k values

2.4

2.2

Peak Gain

2.0

k=1.5
1.8

k=1.75
k=2

1.6

k=2.5
1.4

k=3

1.2

k=4
k=5
k=7
k=9

1
0.2

0.4

0.6

0.8

Q
17

1.2

1.4

3. Design procedure
Design example
- Input voltage: 380Vdc (output of PFC stage)
- Output: 24V/5A (120W)
- Holdup time requirement: 17ms
- DC link capacitor of PFC output: 100uF

PFC

DC/DC
ID

Q1
Ip

VDL
CDL

Vd
Q2

Np:Ns
Llks

Llkp
Im

Lm
Ids2

18

VO
+

Cr

Ro

3. Design procedure
[STEP-1] Define the system specifications
9 Estimated efficiency (Eff)
9 Input voltage range: hold up time should be considered for minimum input voltage

Vin min = VO. PFC 2

19

2 PinTHU
CDL

3. Design procedure
[STEP-2] Determine the maximum and minimum voltage gains of the
resonant network by choosing k ( k = Lm / Llkp )
- it is typical to set k to be 5~10, which results in a gain of 1.1~1.2 at fo
M

min

max

VRO
Lm + n 2 Llks Lm + Llkp k + 1
= max =
=
=
Vin
Lm
Lm
k
2

Vin max min

= min M
Vin

Gain (M)
Peak gain (available maximum gain)

1.36

Mmax

for Vinmin

1.14

Mmin

M=

k +1
= 1.14
k

fo

20

for Vinmax

fs

3. Design procedure
[STEP-3] Determine the transformer turns ratio (n=Np/Ns)
Vin max
n=
=
M min
N s 2 (Vo + VF )
Np

[STEP-4] Calculate the equivalent load resistance (Rac)

8n 2 Vo 2
Rac = 2
Po

21

3. Design procedure
[STEP-5] Design the resonant network
- With k chosen in STEP-2, read proper Q from gain curves

k = 7 , M max = 1.36
peak gain = 1.36 110% = 1.5

22

3. Design procedure
[STEP-6] Design the transformer
- Plot the gain curve and read the minimum switching frequency. Then, the minimum
number of turns for the transformer primary side is obtained as
N p min =

23

n(Vo + VF )
2 f s min B Ae

3. Design procedure
[STEP-7] Transformer Construction
- Since LLC converter design results in relatively large Lr, usually sectional bobbin is typically
used
- # of turns and winding configuration are the major factors determining Lr
- Gap length of the core does not affect Lr much
- Lp can be easily controlled with gap length

Np=52T

Ns1=Ns2=6T
Bifilar

Design value: Lr=234uH, Lp=998uH

24

3. Design procedure
[STEP-8] Select the resonant capacitor
I Cr

25

RMS

Io

n(V + 2 VF ) 2
[
] +[ o
]
2 2n
4 2 f o Lm
2

VCr

max

Vin max
2 I Cr RMS

+
2
2 f o Cr

4. Conclusion
Using a fundamental approximation, gain equation has
been derived
Leakage inductance in the secondary side is also
considered (L-L-L-C model) for gain equation
L-L-L-C equivalent circuit has been simplified as a
conventional L-L-C equivalent circuit
Practical design consideration has been presented

26

Appendix - FSFR-series

Variable frequency control with 50% duty cycle for half-bridge resonant
converter topology
High efficiency through zero voltage switching (ZVS)
Internal Super-FETs with Fast Recovery Type Body Diode (trr=120ns)
Fixed dead time (350ns)
Up to 300kHz operating frequency
Pulse skipping for Frequency limit (programmable) at light load condition
Simple remote ON/OFF control
Various Protection functions: Over Voltage Protection (OVP), Over Current
Protection (OCP), Abnormal Over Current Protection (AOCP), Internal Thermal
Shutdown (TSD)

27

Appendix - FSFR-series demo board

28

Appendix - FSFR-series demo board

29