HT45F0059 Low Power Continuous Heating Induction Cooker Application Note

HT45F0059 Low Power Continuous Heating

Induction Cooker Application Note

D/N: AN0591EN

Introduction
Induction cookers are now common cooking appliances that are found in many households due to
their precise temperature and heating control. In addition to energy saving benefits, they also
possess the advantage of safer flame free cooking. The continuous power output of single IGBT
induction cookers normally operate within a power range of 50% and 100%. For lower power
demands, in addition to reducing the time that the IGBT is on, it is also required to use an
intermittent heating mode to output a lower power level. The disadvantage here is that the heating
is discontinuous, therefore making it almost impossible to achieve good operation for low power
conditions. It will take longer and will consume more power when compared with continuous
heating for food cooking.

The Holtek HT45F0059 integrates hardware circuits for low power continuous heating. The
induction cooker output power can be adjusted using program settings to provide continuous output
at low power below 1000W, thus achieving the same effects for traditional stove stew heating.

This application note will describe the hardware circuits used with the HT45F0059 and how to
achieve low power continuous heating in induction cooker applications. This application note also
provides relevant test data for development reference.

Function Description

Low Power Continuous Heating Induction Cooker

Generally for induction cookers, when operating in a low power heating mode for a power less than
1000W, this lower output power is usually achieved by heating intermittently. Although the average
power output can reach a predetermined power level, as the induction cooker heating cycle will be
switched slowly, the heating output will be discontinuous. These disadvantages will result in
uneven and inefficient heating making it difficult to achieve slow cooking effects.

The main reason that causes the induction cooker to not heat continuously under low power
conditions is that the heating power is proportional to the time that the IGBT is on. The longer the
IGBT is on, the greater is the inverse voltage generated by the LC resonance, resulting in a greater

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heating power. When the induction cooker needs to output a lower power level, the IGBT on time
will be reduced by reducing the PPG drive signal pulse width. However here an LC resonant back
voltage will be generated if the PPG pulse width is at a lower limit. Due to the lower energy
provided, the resonant voltage oscillates by a small margin, ensuring the voltage cannot fully drop
to zero when oscillating downwards. As a result, the next IGBT will be turned on before the
collector-emitter voltage, VCE, has dropped to zero, forming a condition known as "hard switching".
This can result in greater IGBT damage, higher temperature rises and consequently reduce the IGBT
life. Ideally, the IGBT should only be turned on when VCE is equal to 0, in which case any switching
damage is minimal, this is known as "soft switching".

When the induction cooker operates at power levels less than 1000W, if the continuous heating
drive mode is adopted, the IGBT can be easily damaged due to the heat generated due to hard
switching. To improve the low power intermittent heating situation which results in the
disadvantage of low efficiency, it is required to increase the heating cycle switching frequency,
however this will result in more frequent IGBT hard switching.

HT45F0059 Hardware Circuit Description

The HT45F0059 includes an integrated PPG hardware circuit which can control the output voltage
rise rate, this allows the IGBT to be driven using a high or low voltage rise rate waveform. Even
during IGBT hard switching, as the collector current is small during the early IGBT on time, the
effects of IGBT hard switching will be reduced. The switching heat losses will also be greatly
reduced.
8-bit Timer Counter 8-bit Timer Counter 8-bit Timer Counter
Preload Register T1 Preload Register T2 Preload Register T3

b0~b7
b0~b7 b0~b7
PPGTPSC[1:0]

fH/128 PPGTMMD[1:0]
fH /128
fH/256
/256 M
fH/512 U
/512 Reload
X
fH/1024 Reload Counter
/1024

OVPINT Edge Detector

PPGHTMD 8-bit Timer Counter
PPGTMINT
(PPGTIMER)
PPGTON Timer Control Circuit
PPGTEG PPGACF
PPGATCDINT
PPGADF
PPGCNT[1:0] PPGSA[2:0] PPGSAEN PPG2I[5:0] PPG2EN PPG2M[1:0]

RLBF PPGTC[8:0] PPGTD[8:0] PTSYN

PSPEN
PPGSAMD
PPG2CT[7:0] PPG2
fPPG PPG2 PPG2
C1VOD PPGTA Approach Control Circuit Output
Counter
Control
fSYS

PPGTRG PPG
PPGASA[1:0] PPGACNT[1:0] PPGTIMES[2:0] PPG Control Circuit PPG Counter Output
C2VOD PPG2S[7:0] PPG2E[7:0]
Control
C3VOD PPGADJF PPG

Over Voltage Protection Circuit PPGOUT

PPGRTEN PPGRT[6:0]
C1RLEN DVS PPGDEC[3:0] PST PRSEN
fSYS /8 PPGSCD PPGTA[8:0] PPGTB[8:0] PPGPC[7:0] PWLT[7:0]
PPG
/8
Retrigger Counter PPGRNINT

fSYS /2
fSYS /2
M fPPG
fSYS U /2
X

PCSD

Figure 1. Programmable Pulse Generator – PPG

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The PPG function and operation is controlled using a series of registers, refer to the HT45F0059
datasheet for details. The following table provides a brief description of the register functions.

Function Register Register Description

OVPC0 Used to control OVP enable, OVP output polarity and others
OVP
OVPDA OVP negative reference voltage selection
PPGTMRD PPGTIMER counter register
PPGTA PPG counter preload register
PPGTC PPG counter approach register
PPGRT PPG software re-trigger period setting register
PPG PPGRN PPG software re-trigger times setting register
PPG2C0 PPG2 output mode control register
PPG2C1 PPG2 starts value setting register
PPG2C2 PPG2 ending value setting register
PPG2C3 PPG2 increment value setting register

Table 1. OVP/PPG Related Register List

Operating Principles

Reduce IGBT Thermal Power Consumption

When the output power of a low power continuous heating induction cooker is less than 1000W,
the IGBT is controlled by a waveform driven by an output voltage rise rate which is set by the
Programmable Pulse Generation (PPG) registers. The following diagram can be divided into five
stages.

Stage 1 Stage 2 Stage 3 Stage 5

OVP signal

Software zero-
crossing

t0 t1 t2 t3 t4 t5

Figure 2. HT45F0059 PPG Control Division

1. An AC zero signal is detected by the OVP detector at time t0,, the device will control the PPG
trigger signal according to the PPGRT and PPGRN registers, at which point the PPG2M[1:0]=00,
the PPGH output voltage will rise quickly.

2. At time t1, when the PPG trigger value reaches the value in the PPGRN register, a PPGRN
interrupt will be triggered. The interrupt subroutine will set the PPG2M[1:0] bits to 01. The
PPG2 output width is consistent with the PPG and the PPGH output voltage rises slowly. At
this stage, the time between t1 and t2 is set by the Timer2 counter.

3. At time t2, PPG2M[1:0]=10 and the PPG2 operates in the output fixed width mode. Here the
fixed width is set by the PPG2S[7:0] bits in the PPG2C1 register. When PPGTA < PPG2S, the
PPGH output is driven by PPG2 and the PPGH output voltage rises slowly. When PPGTA >

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PPG2S, the PPGH output voltage rises quickly. In this approach mode, and by setting the
corresponding registers, the PPG width gradually increases until it is equal to the PPGTC value.
The duration is from t2 to t3.

4. At time t3, PPG2M[1:0 ]=00, the PPG2 output voltage is 0V and the PPGH output voltage will
rise quickly. The output width will have a fixed value set by the PPGTC bits until the next OVP
interrupt is triggered for a duration between t3 to t4.

5. At time t4, an OVP interrupt is triggered, PPG2M[1:0]=10, repeat the t2 to t3 process until time
t5, after which PPG2M[1:0]=00. Here the PPGH output voltage rises quickly. Power control
should now be determined at this point. According to different power settings, the PPGH will
turn on different cycles after time t5.

The settings provided below apply only to the hardware circuits designed for this example. In
practice, the control effects may fluctuate due to different conditions in different applications. The
settings should be adjusted according to the actual application. The actual waveform of the example
is shown as follows.

Stage 1: The PPG will be turned on after an OVP interrupt is detected by the software zero-crossing
detect at time t0. The IGBT will be driven by the PPGH output voltage and will rise fast. During
this period, the PPGH width is gradually increased from 1μs to 3μs. This stage is from time t0 to
t1, which is about 930μs.

Note: The following waveform shows the PPGH output signal in yellow, the OVP input signal in
green, the PPG2 output signal in pink and the IGBT VCE sampling signal in blue.

Figure 3. Stage 1 Waveform

Stage 2: Stage 1 ends at time t1, at which point the IGBT is controlled by a PPGH output voltage
drive waveform which rises slowly. The width of the PPGH control waveform is gradually
increased from 3μs to 13μs. The duration of this stage is approximately 1.25ms from time t1 to t2.

Figure 4. Stage 2 Waveform

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Stage 3: The IGBT will be turned on by the PPGH output voltage drive waveform, which rises
slowly during the first half and rises fast during the second half. The width of the PPGH control
waveform is gradually increased from 13μs to 17μs. The duration of this stage is approximately
3ms from time t2 to t3.

Figure 5. Stage 3 Waveform

Stage 4: The IGBT will be turned on by a PPGH output voltage drive signal that rises fast. The
PPGH waveform is continued for 17µs, with the first half PPGH output voltage rising slowly and
the second half rising quickly. The duration of this stage is approximately 5.2ms from time t3 to t4.

Figure 6. Stage 4 Waveform

Stage 5: The IGBT will be turned on by the PPGH output voltage drive waveform which rises slowly
in the first half and rises fast in the second half. The PPGH waveform maintains a slow rise of 8.5µs
and a fast rise of 8.5μs. The duration of this stage is approximately1.8ms from time t4 to t5.

Figure 7. Stage 5 Waveform

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After stage 5, the PPGH output voltage drive waveform rises fast and is maintained in each AC
cycle until the IGBT is turned off due to power control. Repeat Stage 1 to Stage 5 after an OVP
interrupt is triggered in the next cycle.

Power Control
Different power levels can be output by the power control function, which is implemented by
controlling the drop-wave number in a fixed AC cycle. It is different from the previous intermittent
heating power control. The HT45F0059 drop wave control can be completed in a very short time,
therefore continuous heating can be achieved in low power induction cooker applications. The drop-
wave number for different power are shown in the table below.

For example, taking 10 AC cycles in a power cycle. During this power cycle, the IGBT will be turned
on for a certain time until the output power reaches its rated power and then the IGBT will be turned
off for discharge. For example, if the drop wave control in the table below is 10:7, this indicates that
there are seven IGBT on cycles and three IGBT off cycles within a total of 10 AC cycles.

Low Power Differential Drop Wave Control

Level Power
120W ±20W 10:1
300W ±20W 10:3
600W ±30W 10:5
900W ±40W 10:7

Table 2. Power and Drop Wave Control

Figure 8. Drop Wave Control

The blue waveform represents the IGBT and the green waveform represents the AC. There are
seven IGBT on cycles and three IGBT off cycles within the total 10 AC cycles.

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Setting Process
The following diagram provides an overview of how to setup the HT45F0059 in the low power
continuous heating process.

START
Set PPG2C0

Set PPG
Set PPGTC

Set
PPGTC0.1.2
Set OVP

Set PPGRT.
PPGRN
Set Timer2

Set PPG2C1
END

1. Initialise the PPG related registers, including the PPG trigger mode, the counter frequency, the
output power and others.

2. Setup the PPGTA hardware approach mode by setting the PPGATC0, PPGATC1 and
PPGATC2 registers.

3. After the zero-crossing interrupt is triggered, the PPG trigger times and periods are set by the
PPGRT and PPGRN registers between times t0 and t1.

4. Setup the PPG2C1 register, determine the starting width of PPG2.

5. Setup the PPG2C0 register to select the PPG2 output mode.

6. Setup the PPGTA and PPGTC registers, determine the starting width and maximum width of
the PPG signal.

7. Initialise the OVP related registers.

8. Initialise the Timer2 related registers.

The following are the settings of the related registers in this example.

Register Value Setup Description

PPGTA 512~4 PPG initial width is 0.25µs
PPGTC 512~285 PPG end width in the PPG approach mode is 17.812µs
PPG2C0 0x80 PPG2 is enabled and the device operates in Mode 1 by default
PPG2C1 139 PPG2 starting width is 8.75µs
PPGRN 29 PPG is triggered 29 times via the software
PPGRT 65 The software trigger of the PPG cycle is 33µs
TMR2C 0x05 TIMER2 timer frequency is divided into fSYS/32
TMR2 255~75 TIMER2 timer interrupt cycle is 150µs

Table 3. Register Setting

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Test Data
Environment: Room temperature @ 27 ℃.

Power: Chroma 6530 series programmable AC power supply.

Oscilloscope: KEYSIGHT DSOX3014T.

Hardware Circuits

According to this application example to design and establish a prototype for testing, the power
value and the IGBT temperature are read after operating for 10 minutes at each power level. It
should be noted that the component parameters have a large impact on the data, the data in the table
below only conforms to the prototype established by the example.

Low Power Level (W) Actual Power Error Range IGBT Operating Temperature
120W ±20W 33.2°C
300W ±20W 35.0°C
600W ±30W 37.3°C
900W ±40W 41.7°C

Conclusion
This application note has explained the HT45F0059 hardware circuit and especially how to achieve
low power continuous heating in induction cooker applications. The HT45F0059 can drive the
IGBT by controlling the PPGH output voltage waveform, which can effectively reduce heat losses
due to IGBT "hard switching". At the same time, when combined with the loss wave control method,

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induction cooker continuous heating in the low power condition can be implemented. This can
further improve the efficiency when compared with traditional control methods.

Reference File
Reference file: HT45F0059 Datasheet.

For more information refer to the Holtek’s official websitewww.holtek.com.

Versions and Modification Information

Date Author Issue Release Modification
2021.06.25 曾增祥 V1.00 First version

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