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Demonstration System EPC9112 Quick Start Guide 6.78 MHz, ZVS Class-D Wireless Power System using EPC2007C / EPC2038 QUICK START GUIDE Demonstration System EPC9112 DESCRIPTION The EPC9112 wireless power demonstration system is a high efficiency, A4WP compatible, Zero Voltage Switching (ZVS), Voltage Mode class-D wireless power transfer demonstration kit capable of delivering up to 35 W into a DC load while operating at 6.78 MHz (Lowest ISM band). The purpose of this demonstration system is to simplify the evaluation process of wireless power technology using eGaN® FETs. The EPC9112 wireless power system comprises the three boards (shown in Figure 1) namely: 1) A Source Board (Transmitter or Power Amplifier) EPC9507 2) A Class 3 A4WP compliant Source Coil (Transmit Coil) 3) A Category 3 A4WP compliant Device Coil with rectifier and DC smoothing capacitor. The amplifier board features the EPC2007C and EPC2038 enhancement mode field effect transistors (FET) in an optional half-bridge topology (single ended configuration) or default full-bridge topology (differential configuration), and includes the gate driver/s and oscillator that ensures operation of the system at 6.78 MHz. This revision of the wireless demonstration amplifier includes a synchronous bootstrap FET supply for the upper FETs of the ZVS class-D amplifier that eliminates the reverse recovery losses of the gate driver’s internal bootstrap diode that dissipates energy in the upper FET. This circuit has been implemented using the new EPC2038 eGaN FET specifically designed for this function. To learn more about the synchronous bootstrap supply please refer to the following [1, 2, 3]. The EPC9507 amplifier board can also be operated using an external oscillator or by using the included new ultra low power Diashinku oscillator. This revision can operate in either Single ended or Differential mode by changing a jumper setting. This allows for high efficiency operation with load impedance ranges that allow for single ended operation. Finally, the timing adjust circuits for the ZVS class-D amplifiers have been separated to further ensure highest possible efficiency setting and includes separate ZVS tank circuits. [1] Wireless Power Handbook [2] Performance Comparison for A4WP Class-3 Wireless Power Compliance between eGaN FET and MOSFET in a ZVS class-D Amplifier Source Coil 220 mm 45 mm Amplifier Board 80 mm Device Board 1 168 mm 2 | The device board includes a high frequency schottky diode based full bridge rectifier and output filter to deliver a filtered unregulated DC voltage. The device board comes equipped with two LED’s, one green to indicate the power is being received with an output voltage equal or greater than 4 V and a second red LED that indicates that the output voltage has reached the maximum and is above 37 V. For more information on the EPC2007C or EPC2038 eGaN FET please refer to the datasheet available from EPC at www.epc-co.com. The data-sheet should be read in conjunction with this quick start guide. The Source coil used in this wireless power transfer demo system is provided by NuCurrent (nucurrent.com). Reverse Engineering of the Source coil is prohibited and protected by multiple US and international patents. For additional information on the source coil, please contact NuCurrent direct or EPC for contact information. Table 1: Performance Summary (TA = 25 °C) EPC9507 Symbol Parameter VDD Control Supply Input Range Conditions Min 7 Max Units 12 V VIN Bus Input Voltage Range – Pre-Regulator Mode Bus Input Voltage Range – Bypass Mode 8 36 V 0 80 V VOUT Switch Node Output Voltage VIN - 2 V V IOUT Vextosc Switch Node Output Current (ea.) A V External Oscillator Input Threshold VPre_Disable Pre-regulator Disable Voltage Range IPre_Disable Pre-regulator Disable Current VOsc_Disable Oscillator Disable Voltage Range Oscillator Disable Current IOsc_Disable Input ‘Low’ -0.3 6* 0.8 Input ‘High’ 2.4 5 V Open drain/ collector Open Drain/ Collector Open Drain/ Collector Open Drain/ Collector -0.3 5.5 V -1 1 mA -0.3 5 V -25 25 mA * Assumes inductive load, maximum current depends on die temperature – actual maximum current with be subject to switching frequency, bus voltage and thermals. Table 2: Performance Summary (TA = 25 °C) Category 3 Device Board 50 mm Figure 1: EPC9112 Demonstration System The Source and Device Coils are Alliance for Wireless Power (A4WP) compliant and have been pre-tuned to operate at 6.78 MHz with the EPC9507 amplifier. The source coil is class 3 and the device coil is category 3 compliant. VIN [3] EPC2038 datasheet 64 mm The amplifier board is equipped with a pre-regulator that limits the DC current of the supply to the amplifier. As the amplifier draws more current, which can be due to the absence of a device coil, the pre-regulator will reduce the voltage being supplied to the amplifier that will ensure a safe operating point. The pre-regulator also monitors the temperature of the main amplifier FETs and will reduce current if the temperature exceeds 85°C. The pre-regulator can be bypassed to allow testing with custom control hardware. The board further allows easy access to critical measurement nodes that allow accurate power measurement instrumentation hookup. A simplified diagram of the amplifier board is given in Figure 1. Symbol Parameter VOUT IOUT Conditions Min Max Units Output Voltage Range 0 38 V Output Current Range 0 1.5# A # Actual maximum current subject to operating temperature limits | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 QUICK START GUIDE Demonstration System EPC9112 MECHANICAL ASSEMBLY ZVS Timing Adjustment The assembly of the EPC9112 Wireless Demonstration kit is simple and shown in Figure 1. The source coil and amplifier have been equipped with reverse polarity SMA connectors. The source coil is simply connected to the amplifier. Setting the correct time to establish ZVS transitions is critical to achieving high efficiency with the EPC9507 amplifier. This can be done by selecting the values for R71, R72, R77, and R78 respectively. This procedure is best performed using potentiometers P71, P72, P77, and P78 installed that is used to determine the fixed resistor values. The procedure is the same for both single ended and differential mode of operation (as applicable per operating mode). The timing MUST initially be set WITHOUT the source coil connected to the amplifier. The timing diagrams are given in Figure 4 and should be referenced when following this procedure. Only perform these steps if changes have been made to the board as it is shipped preset. The device board does not need to be mechanically attached to the source coil. DESCRIPTION The Amplifier Board (EPC9507) Figure 1 shows a diagram of the EPC9507 ZVS class-D amplifier with preregulator. The pre-regulator is set to a specified DC current limit (up to 1.5 A) by adjusting P49 and operates from 8 V through 36 V input. The output voltage of the pre-regulator is limited to approximately 2 V below the input voltage. The pre-regulator can be bypassed by moving the jumper (JP60) over from the right 2 pins to the left 2 pins. To measure the current the amplifier is drawing, an ammeter can be inserted in place of the jumper (JP60) in the location based on the operating mode (pre-regulator or bypass). The amplifier comes with its own oscillator that is pre-programmed to 6.78 MHz ± 678 Hz. It can be disabled by placing a jumper into J70 or can be externally shutdown using an externally controlled open collector / drain transistor on the terminals of J70 (note which is the ground connection). The switch needs to be capable of sinking at least 25 mA. An external oscillator can be used instead of the internal oscillator when connected to J71 (note which is the ground connection) and the jumper (JP70) is moved from the right 2 pins to the left 2 pins. The pre-regulator can also be disabled in the same manner as the oscillator using J51. The pre-regulator can be bypassed, to increase the operating voltage (with no current or thermal protection) to the amplifier or to use an external regulator, by moving the jumper JP60 from the right 2 pins to the left 2 pins. Jumper JP60 can also be used to connect an ammeter to measure the current drawn by the amplifier (make sure the ammeter connects to the pins that correspond to the mode of operation either bypass or pre-regulator). Single Ended Operation Hardware implementation The amplifier can be configured for single ended operation where only devices Q1 and Q2 are used. In this mode only LZVS1 and CZVS are used to establish ZVS operation. If a permanent single ended configuration is required and Q11 and Q12 are populated, then the following changes need to be made to the board: 1) Remove R77 and R78 OR P77 and P78 2) Short out C42_2 and C43_2 3) Short the connection of JMP1 (back side of the board) 4) Remove LZVS12 (if populated) 5) Add LZVS2 (390 nH) The steps are: 1. Remove the jumper in JP60 and insert it into J51 to place the EPC9507 amplifier in bypass mode. With power off connect the main input power supply (+) bus to the center pin of JP60 (pin 2) and the ground of the main power to the ground (-) connection of J50 -VIN. 2. With power off, connect the control input power supply bus to +VDD (J90). Note the polarity of the supply connector. 3. Connect a LOW capacitance oscilloscope probe to the probe-hole J2 between the two eGaN FETs Q10_x and Q11_x and lean against the ground post as shown in Figure 3. 4. Turn on the control supply – make sure the supply is between 7 V and 12 V range (7.5 V is recommended). 5. Turn on the main supply voltage to the required predominant operating value (such as 24 V but NEVER exceed the absolute maximum voltage of 36 V). 6. While observing the oscilloscope adjust P71 or P77 for the rising edge of the waveform so achieve the green waveform of figure 4. Repeat for the falling edge of the waveform by adjusting P72 or P78. Repeat for the other eGaN FET pair if using differential mode operation. 7. Check that the setting remains optimal with a source coil attached. In this case it is important that the source coil is TUNED to resonance WITH an applicable load. Theoretically the settings should remain unchanged. Adjust if necessary. 8. Replace the potentiometers with fixed value resistors. Configure the EPC9507 amplifier back to normal operation by removing the power connections to J50 and JP60, removing the jumper in J51 and inserting it back into JP60 (right 2 pins 2 & 3). Determining Component Values for LZVS The ZVS tank circuit is not operated at resonance, and only provides the necessary negative device current for self-commutation of the output voltage at turn off. The capacitance CZVS is chosen to have a very small ripple voltage component and is typically around 1 µF. The amplifier supply voltage, switch-node transition time will determine the value of inductance for LZVSx which needs to be sufficient to maintain ZVS operation over the DC device load resistance range and coupling between the device and source coil range and can be calculated using the following equation: 6) Check that CZVS2 is populated, if not then install. 7) R71 and R72 may need to be adjusted for the new operating condition to achieve maximum efficiency (see section on ZVS timing adjustment). EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 | LZVS = ∆tvt (1) 8 ∙ fsw∙ COSSQ | 3 QUICK START GUIDE Demonstration System EPC9112 Where: Δtvt = Voltage transition time [s] fsw = Operating frequency [Hz] COSSQ = Charge equivalent device output capacitance [F]. Note that the amplifier supply voltage VAMP is absent from the equation as it is accounted for by the voltage transition time. The charge equivalent capacitance can be determined using the following equation: COSSQ = 1 VAMP ∙ ∫ VAMP COSS (v) ∙ dv (2) 0 To add additional immunity margin for shifts in coil impedance, the value of LZVS can be decreased to increase the current at turn off of the devices (which will increase device losses). Typical voltage transition times range from 2 ns through 12 ns. For the differential case the voltage and charge (COSSQ) are doubled. The Source Coil Figure 3 shows the schematic for the source coil which is Class 3 A4WP compliant. The matching network includes both series and shunt tuning. The matching network series tuning is differential to allow balanced connection and voltage reduction for the capacitors. The Device Board Figure 4 shows the basic schematic for the device coil which is Category 3 A4WP compliant. The matching network includes both series and shunt tuning. The matching network series tuning is differential to allow balanced connection and voltage reduction for the capacitors. The device board comes equipped with a kelvin connected output DC voltage measurement terminal and a built in shunt to measure the output DC current. Two LEDs have been provided to indicate that the board is receiving power with an output voltage greater than 4 V (green LED) and that the board output voltage limit has been reached (greater than 36 V using the red LED). QUICK START PROCEDURE The EPC9112 demonstration system is easy to set up and evaluate the performance of the eGaN FET in a wireless power transfer application. Refer to Figure 1 to assemble the system and Figures 5 and 7 for proper connection and measurement setup before following the testing procedures. The EPC9507 can be operated using any one of two alternative methods: 9. For shutdown, please follow steps in the reverse order. Start by reducing the main supply voltage to 0 V followed by steps 6 through 2. a. Using the pre-regulator b. Operation bypassing the pre-regulator b. Bypassing the pre-regulator In this mode, the pre-regulator is bypassed and the main power is connected directly to the amplifier. This allows the amplifier to be operated using an external regulator or to test at higher voltages. a. Operation using the pre-regulator The pre-regulator is used to supply power to the amplifier in this mode and will limit the DC current to the amplifier based on the setting. The pre-regulator also monitors the temperature of the amplifier and will limit the current in the event the temperature exceeds 85°C. 1. Make sure the entire system is fully assembled prior to making electrical connections and make sure jumper (JP60 is set to pre-regulator – right 2 pins). 2. With power off, connect the main input power supply bus to +VIN (J50). Note the polarity of the supply connector. 3. With power off, connect the control input power supply bus to +VDD (J90). Note the polarity of the supply connector. In this mode there is no current or thermal protection for the eGaN FETs. 1. Make sure the entire system is fully assembled prior to making electrical connections and remove the jumper JP60 and insert it into J51 to place the EPC9507 amplifier in bypass mode. Never connect the main power positive (+) to J50 when operating in bypass mode. 2. With power off, connect the main input power supply ground to the ground terminal of J50 (-) and the positive (+) to the center pin of JP60. 3. With power off, connect the control input power supply bus to +VDD (J90). Note the polarity of the supply connector. 4. Select and connect an applicable load resistance to the device board. 4. Select and connect an applicable load resistance to the device board. 5. Make sure all instrumentation is connected to the system. 5. Make sure all instrumentation is connected to the system. 6. Turn on the control supply – make sure the supply is between 7 V and 12 V range (7.5 V is recommended). 6. Turn on the control supply – make sure the supply is between 7 V and 12 V (7.5 V is recommended). 7.Turn on the main supply voltage to the required value (it is recommended to start at 8 V and do not exceed the absolute maximum voltage of 32 V). 4 | 8. Once operation has been confirmed, adjust the main supply voltage within the operating range and observe the output voltage, efficiency and other parameters on both the amplifier and device boards. 7. Turn on the main supply voltage to the required value (it is recommended to start at 2 V and do not exceed the absolute maximum voltage of 80 V). | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 QUICK START GUIDE Demonstration System EPC9112 8.Once operation has been confirmed, adjust the main supply voltage within the operating range and observe the output voltage, efficiency and other parameters on both the amplifier and device boards. See Pre-Cautions when operating in the bypass mode their relatively smaller size does magnify the thermal management requirements. The operator must observe the temperature of the gate driver and eGaN FETs to ensure that both are operating within the thermal limits as per the datasheets. 9.For shutdown, please follow steps in the reverse order. Start by reducing the main supply voltage to 0 V followed by steps 6 through 2. NOTE. The EPC9112 demonstration system has limited current and thermal protection only when operating off the Pre-Regulator. When bypassing the pre-regulator there is no current or thermal protection on board and care must be exercised not to over-current or over-temperature the devices. Wide coil coupling and load range variations can lead to increased losses in the devices. NOTE. When measuring the high frequency content switch-node (Source Coil Voltage), care must be taken to avoid long ground leads. An oscilloscope probe connection (preferred method) has been built into the board to simplify the measurement of the Source Coil Voltage (J2 and J3 as shown in Figure 3). SWITCHING BETWEEN SINGLE-ENDED AND DIFFERENTIAL MODE OPERATION The ZVS class-D amplifier can be operated in either single-ended or differential mode operation by changing the jumper setting of J75. When inserted the amplifier operates in the single-ended mode. Using an external pull down with floating collector/ drain connection will have the same effect. The external transistor must be capable of sinking 25 mA and withstand at least 6 V. THERMAL CONSIDERATIONS The EPC9112 demonstration system showcases the EPC2007C and EPC2038 eGaN FETs in a wireless energy transfer application. Although the electrical performance surpasses that of traditional silicon devices, Bypass Mode Connection Pre-Cautions The EPC9112 demonstration system has no controller or enhanced protections systems and therefore should be operated with caution. Some specific precautions are: 1. Never operate the Source Coil within 6 inches in any direction of any solid metal objects as this will shift the tuning of the coil. Please contact EPC should the tuning of the coil be required to change to suit specific conditions so that it can be correctly adjusted for use with the ZVS class-D amplifier. 2. There is no heat-sink on the devices and during experimental evaluation it is possible present conditions to the amplifier that may cause the devices to overheat. Always check operating conditions and monitor the temperature of the EPC devices using an IR camera. Pre-Regulator Jumper VAMP JP60 PreRegulator Coil Connection L ZVS12 Q1 VIN Q 11 L ZVS2 L ZVS1 Single Ended Operation Jumper Q2 J50 C ZVS1 PreRegulation Connection C ZVS2 Q 12 Figure 2: Diagram of EPC9507 Amplifier Board Matching Impedance Network Matching Impedance Network Coil Connection Class 3 Coil Un-Regulated DC output Cat. 3 Coil Device Board Source Coil Figure 3: Diagram of the A4WP Class 3 Source Coil Figure 4: Basic Schematic of the A4WP Category 3 Device Board EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 | | 5 QUICK START GUIDE Demonstration System EPC9112 7 -12 VDC Gate Drive and Control Supply (Note Polarity) 6 -36 VDC V IN Supply (Note Polarity) Amplifier Voltage Source Jumper Bypass Connection Pre -Regulator Jumper Switch -Node Main Oscilloscope Probe Pre-Regulator Timing Setting (Not Installed) Source Coil Connection Amplifier Timing Setting (Not Installed) Ground Post Switch -Node Secondary Oscilloscope Probe Pre-Regulator Current Setting Disable Oscillator Jumper Disable Pre-Regulator Jumper Single Ended / Differential Mode Operation Selector Oscillator Selection Jumper External / Internal External Oscillator Figure 5: Proper Connection and Measurement Setup for the Amplifier Board Source Board Connection Matching with trombone tuning External Load Connection Output Voltage > 5 V LED Output Voltage > 37 V LED Standoffs for Mechanical attachment to Source Coil to these locations (x5) Device Output mV Current (300 m Shunt) Device Output Voltage (0 V – 38 Vmax) A Load Current V (See Notes for details) * ONLY to be used with Shunt removed Matching Half / Full Bridge Mode Jumper Figure 6: Proper Connection for the Source Coil 6 | Figure 7: Proper Connection and Measurement Setup for the Device Board | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 QUICK START GUIDE Demonstration System EPC9112 Do not use probe ground lead Ground probe against post Place probe tip in large via Minimize loop Figure 8 : Proper Measurement of the Switch Nodes Using the Hole and Ground Post Q1 turn-off Q2 turn-off VAMP VAMP Q2 turn-on 0 Partial Shoot- ZVS through Q1 turn-on time ZVS 0 Partial Shoot- ZVS through ZVS + Diode Conduction time ZVS ZVS + Diode Conduction Figure 9: ZVS Timing Diagrams EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 | | 7 QUICK START GUIDE Demonstration System EPC9112 Table 3: Bill of Materials - Amplifier Board Item Qty Reference Part Description ManµFacturer Part # 1 2 C1_1, C1_2 4.7 µF, 10 V Samsung CL05A475MP5NRNC 2 3 4 4 2 2 100 nF, 25 V DNP 22 nF, 25 V Murata Murata TDK GRM155R71C104KA88D GRM155R71C104KA88D C1005X7R1E223K050BB 5 8 10 nF, 100 V TDK C1005X7S2A103K050BB 6 7 2.2 µF 100 V Taiyo Yuden HMK325B7225KN-T 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 1 2 2 4 1 3 6 1 2 1 3 2 2 22 pF, 50 V 1 µF, 50 V 4.7 µF, 16 V 2.2 nF, 50 V 10 nF, 100 V 1 nF, 50 V 100 nF, 25 V 100 nF, 25 V 22 pF, 25 V 100 pF, 25 V 47 pF, 50 V 1 µF, 25 V 1 µF, 50 V 40 V, 300 mA Kemet Taiyo Yuden TDK Yageo TDK Yageo TDK TDK DNP TDK Yageo TDK Taiyo Yuden ST C0402C220J5GACTU UMK107AB7105KA-T C1608X5R1C475K CC0402KRX7R9BB222 C1005X7S2A103K050BB CC0402KRX7R9BB102 C1005X7R1E104K050BB C1608X7R1E104K DNP C1608C0G1H101J080AA CC0402JRNPO9BN470 C1608X7R1E105K C2012X7R1H105K125AB BAT54KFILM 21 10 40 V, 30 mA Diodes Inc. SDM03U40 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 2 2 3 1 1 6 1 1 1 1 2 1 6 1 2 DNP 5 V 1, 150 mW .1 Male Vert. SMA Board Edge .156 Male Vert. .1 Male Vert. DNP .1 Male Vert. Jumper 100 10 µH DNP 500 nH DNP DNP 100 V, 2.8 Ω Diodes Inc. Bournes Würth Linx Würth Würth SDM03U40 CD0603-Z5V1 61300111121 CONREVSMA013.062 645002114822 61300211121 Würth Würth Würth CoilCraft CoilCraft Murata Murata EPC 61300311121 60900213421 744314101 DNP 2929SQ-501JEB PV37Y102C01B00 PV37Y103C01B00 EPC2038 37 6 100 V, 6 A, 30 mW EPC EPC2007C 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 2 2 2 4 1 1 1 1 1 1 1 3 1 1 1 2 1 C2_1, C2_2, C4_1, C4_2 C5_1, C5_2 C3_1, C3_2 C11_1, C11_2, C12_1, C12_2, C13_1, C13_2, C14_1, C14_2 C15_1, C15_2, C16_1, C16_2, C62, C64, C65 C42_1, C42_2, C43_1, C43_2, C75 C50 C52, C60 C53, C54 C55, C66, C67, C68 C56 C57, C63, C70 C71, C72, C77, C78, C80, C81 C73 C82, C83 C84 C90, C91, C92 Czvs1, Czvs2 D1_1, D1_2 D2_1, D2_2, D71, D72, D77, D78, D82, D83 D3_1, D3_2 D4_1, D4_2 GP1_1, GP1_2, J61 J1 J50 J51, J70, J71, J75, J90, JP70 JMP1 JP60 JP61 L60 Lzvs1, Lzvs2 Lzvs12 P71, P72, P77, P78, P82, P83 P49 Q4_1, Q4_2 Q10_1, Q10_2, Q11_1, Q11_2, Q60, Q61 R2_1, R2_2 R3_1, R3_2 R4_1, R4_2 R10_1, R10_2, R11_1, R11_2 R47 R48 R49 R50 R51 R52 R54 R55, R56, R84 R57 R58 R59 R60, R61 R62 20 Ω 27k Ω 4.7 Ω 2.2 Ω 6.04k Ω 2.74k Ω 3.3k Ω 40.2k Ω 280k Ω 10k Ω 15k Ω 10 Ω 909k Ω 300k Ω 45.3k Ω 2.2 Ω 24 mW, 1 Ω Stackpole Panasonic Stackpole Yageo Panasonic Panasonic Panasonic Yageo Panasonic Yageo Yageo Yageo Panasonic Panasonic Panasonic Yageo Susumu RMCF0402JT20R0 ERJ-2GEJ273X RMCF0402FT4R70 RC0402JR-072R2L ERJ-2RKF6041X ERJ-2RKF2741X ERJ-2RKF3301X RC0402FR-0740K2L ERJ-2RKF2803X RC0402FR-0710KL RC0402JR-0715KL RC0402FR-0710RL ERJ-3EKF9093V ERJ-2RKF3003X ERJ-2RKF4532X RC0402JR-072R2L PRL1632-R024-F-T1 (continued on next page) 8 | | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 QUICK START GUIDE Demonstration System EPC9112 Table 3: Bill of Materials - Amplifier Board (continued) Item Qty 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 1 2 2 1 1 1 1 1 2 3 1 1 3 3 1 Reference Part Description Manufacturer Part # R70 R71, R78 R72, R77 R73 R75 R82 R83 RT1 TP1, TP2 U1_1, U1_2, U60 U50 U70 U71, U77, U81 U72, U78, U80 U90 47k Ω 390 Ω 124 Ω 10k Ω 10k Ω 31.6 Ω 191 Ω 470k Ω @ 25°C SMD Probe Loop 100 V eGaN Driver Step Down Controller Programmable Oscillator 2 In NAND 2 In AND 5.0 V, 250 mA DFN Stackpole Stackpole Panasonic Yageo Panasonic Panasonic Panasonic Murata Keystone National Semiconductor Linear KDS Daishinku America Fairchild Fairchild Microchip RMCF0603JT47K0 RMCF0603FT390R ERJ-3EKF1240V RC0603JR-0710KL ERJ-2GEJ103X ERJ-3EKF31R6V ERJ-3EKF1910V NCP15WM474E03RC 5015 LM5113TM LT3741EΜF#PBF DSO221SHF 6.780 / 1XSF006780EH NC7SZ00L6X NC7SZ08L6X MCP1703T-5002E/MC EPC would like to acknowledge Würth Electronics (www.we-online.com/web/en/wuerth_elektronik/start.php) and KDS Daishinku America (www.kdsamerica.com) for their support of this project. Table 4: Bill of Materials - Source Coil Item Qty Reference Part Description Manufacturer Part # 1 2 3 4 5 6 7 8 1 1 1 1 1 2 1 1 Ctrombone C1 C2 C3 PCB1 C4, C6 C5 J1 680 pF, 300 V DNP 15 pF, 1500 V 560 pF, 300 V Class 3 Coil Former 0 Ω, 0612 DNP SMA PCB Edge Vishay – Vishay Vishay NuCurrent Vishay – Linx VJ1111D681KXDAR – VJ1111D150JXRAJ VJ1111D561KXDAR R26_RZTX_D1 RCL06120000Z0EA – CONREVSMA003.031 Reference Part Description Manufacturer Part # C84 C85 PCB1 CM1, CM11 CM2, CM12, CMP1, CMP2 CM5, CM7, CMP3 CM6, CM8 CMP4 D80, D81, D82, D83 D84 D85 D86 D87 J81, J82 LM1, LM11 R80 R81 R82 TP1, TP2, TP3, TP4 JPR1 100 nF, 50 V 10 µF, 50 V Cat3PRU 300 pF DNP DNP 56 pF 100 pF 40 V, 1 A LED 0603 Green 2.7 V 250 mW LED 0603 Red 33 V, 250 mW .1" Male Vert. 82 nH 300 mΩ, 1 W 4.7k Ω 422 Ω SMD Probe Loop Wire Jumper at CM11 Murata Murata Coastal Circuits Vishay Vishay Vishay Vishay Vishay Diodes Inc. Lite-On NXP Lite-On NXP Würth Würth Stackpole Stackpole Yageo Keystone GRM188R71H104KA93D GRM32DF51H106ZA01L Cat3DeviceBoard VJ1111D301KXLAT VJ1111D101JXRAT, VJ1111D560JXRAJ VJ0505D101JXCAJ VJ0505D560JXPAJ VJ0505D101JXCAJ PD3S140-7 LTST-C193KGKT-5A BZX84-C2V7,215 LTST-C193KRKT-5A BZX84-C33,215 61300211121 744912182 CSRN2512FKR300 RMCF1206FT4K70 RMCF0603FT422R 5015 Table 5: Bill of Materials - Device Board Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 1 1 2 4 3 2 1 4 1 1 1 1 2 2 1 1 1 4 1 – EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 | – | 9 QUICK START GUIDE Demonstration System EPC9112 Q4 EPC2038 100 V, 2.8 Ω 5V 5V 1 R4 5 VHS 2 4.7 Ω C2 100 nF, 25 V D4 CD0603-Z5 V1 C4 100 nF, 25 V Gbtst OUT D3 EMPTY SDM03U40 Synchronous Bootstrap Power Supply 1 4.7 V C5 EMPTY 100 nF, 25 V R3 27k VAMP VAMP 2 C3 22 nF, 25 V VAMP VAMP C12 10 nF, 100 V C15 2.2 µF, 100 V 1 C11 10 nF, 100 V D2 SDM03U40 R2 20 Ω 2 VAMP GLH VAMP C13 10 nF, 100 V VAMP C14 10 nF, 100 V C16 2.2 µF, 100 V VAMP U1 LM5113TM HIN HIN D1 BAT54KFILM Out C43 22 pF, 50 V C1 4.7 µF, 10 V GUL Q10 EPC2007C GLH Out 1 5V GLH GLL LIN LIN LIN 2 PH1 4.7 V C42 22 pF, 50 V 1 GUH GUH GUL HIN R10 2.2 Ω 5 VHS OUT ProbeHole R11 2.2 Ω 1 2 GLL Q11 EPC2007C Gate Driver GP1 GND 1 GND .1" Male Vert. Ground Post 1 OSC U71 NC7SZ00L6X A R71 JP60 .1" Male Vert. J50 .156" Male Vert. 2 390 Ω P71 VIN 1 2 Deadtime Right H Sig1 3 2 1 5V VIN VOUT B 5V C71 100 nF, 25 V 1 C73 22 pF, 25 V 2 U72 NC7SZ08L6X OSC A V7IN 2 124 Ω 5V Deadtime Left P72 Y B R72 5V 1 VCC OUT IntOsc 3 GND TP1 D72 40 V, 30 mA SDM03U40 1 EPC9507_SE_ZVSclassD_Rev3_0.SchDoc 5V VAMP HIN OUT IntOsc SMD probe loop TP2 1 VAMP SMD probe loop J1 SMA Board Edge H Sig1 J71 OSC OSC 1 2 L Sig1 .1" Male Vert. Internal / External Oscillator C70 100nF, 25 V VAMP 1 Pre-Regulator 5V 2 VOUT PreRegulator EPC9507PR_Rev3_S0.SchDoc 1 2 4 U70 DSO221SHF 6.780 OE VIN LIN External Oscillator OutA Lzvs1 EMPTY GND 2 1 2 .1" Male Vert. Vout JP70 .1" Male Vert. 1 5V R70 47k Vin GND 5V 5V V7in 5V L Sig1 1k C72 100nF, 25 V J70 Jumper 100 Temp T em p 1 5V R73 10k Pre-Regulator Bypass JP61 D71 40 V, 30 mA SDM03U40 OSC OSC VAMP Main Supply 6 V ~ 36 V, 2 A max 1k Oscillator Disable Temp J90 1 2 .1" Male Vert. A OSC .1" Male Vert. GND IN C90 1 µF, 25 V P77 C77 100 nF, 25 V 1 U78 NC7SZ08L6X 5V C91 1 µF, 25 V C92 1 µF, 25 V OSC A nSD B 5V FD1 FD2 Local Fiducials t° 2 EPC9507_SE_ZVSclassD_Rev3_ 0.SchDoc 5V 5V VAMP HIN OUT VAMP Lzvs2 EMPTY Czvs2 1 µF, 50 V ZVS Tank Circuit H Sig2 2 OutB 390 Ω Deadtime Left P78 H Sig2 L Sig2 LIN 1k C87 100 nF, 25 V Logic Supply Regulator Y R78 Single Ended Operation Only L Sig2 D77 40 V, 30 mA SDM03U40 5V OUT RT1 470k @ 25°C 1k U90 5.0 V, 250 mA DFN MCP1703T-5002E/MC V7IN 2 B 5V Single / Differential Mode V7IN 1 2 J75 nSD C75 22 pF, 25 V R77 124 Ω Deadtime Right GND 2 Logic Supply 7.5 VDC - 12 VDC U77 NC7SZ00L6X 2 1 1 nSD Lzvs12 500 nH 1 5V R75 10k JMP1 DNP Czvs1 1 µF, 50 V Oscillator 5V D78 40 V, 30 mA SDM03U40 FD3 Figure 10: EPC9507 -ZVS Class D Amplifier Schematic Rev 3.0 10 | | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 C54 2.2 nF, 50 V 1 R54 15k 2 VREF .1" Male Vert. 1 2 PreDis R49 3.3k P49 1 2 Current Set 10 k 1 2 1 R58 300k Temp R47 6.04k R48 2.74k 1 40.2k R50 VREF C55 10 nF, 100 V 2 PreDis VREF C57 100 nF, 25 V R59 45.3k C53 2.2 nF, 50 V 2 J51 1 2 1 2 R57 909k 6 3 Cnt1 5 SS Cnt2 1.5 V VC Rt EN/UVLO VREF Sync 10 12 1 2 13 Osc U50 LT3741EUF#PBF GND 4 PreRegulator Disable GND 11 VIN 1 EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 | 2 V7IN GND 14 V7IN Cnt UVLO 20 GND 21 1.2 V C56 1 nF, 50 V 1 7 1 9 LG 18 Vccint 8 HG 17 15 16 19 C50 1 µF, 50 V V7IN R56 10 Ω R55 10 Ω 2 Vfdbk VOUT 2 Sns+ C52 4.7 µF, 16 V 1 2 1 2 R52 10k R51 280k VOUT PWM HG PWM 1 5V B Y 5V LGPR HGPR Buffer U81 NC7SZ00L6X Buffer U80 NC7SZ08L6X 5V PWM A C81 100 nF, 25 V C84 47 pF, 50 V 10E 2 C80 100 nF, 25 V R84 5V B A 5V R82 31.6 Ω 2 191 Ω R83 2 Gate Driver U60 LM5113TM D83 SDM03U40 C83 100 pF, 25 V 1k P83 Deadtime Lower 1 C60 4.7 µF, 16 V 5V C82 100 pF, 25 V D82 SDM03U40 1k P82 Deadtime Upper 1 LGPR HGPR SW GLPH GLPL 5V SW GUPH GUPL 5 VUP C63 100 nF, 25 V 5 VUP 1 1 R60 2.2 Ω R61 2.2 Ω 2 GND Q60 EPC2007C GLPL SW Q61 EPC2007C GUPL ProbeHole 1 J62 2 VIN Sns+ 1 Ground Post .1" Male Vert. 1 J61 C66 10 nF, 100 V VIN L60 10CH C64 2.2 µF, 100 V VIN R62 2 C67 10 nF, 100 V VIN 24.1 mΩ Pre-Regulator for ZVS Class D Wireless Power Transfer Source GLPH GUPH VIN C65 2.2 µF, 100 V VIN VOUT C62 2.2 µF, 100 V VOUT C68 10 nF, 100 V VIN QUICK START GUIDE Demonstration System EPC9112 Figure 11: EPC9507 Pre-Regulator Schematic | 11 QUICK START GUIDE Demonstration System EPC9112 Ctrombone 680 pF 1111 C6 Adjust on trombone 0 Ω 0612 J1 SMA PCB Edge PCB1 Cls3PTU C3 560 pF 1111 Amplifier Connection C4 0 Ω 0612 Coil Matching C2 15 pF 1111 C5 DNP C1 DNP Figure 12: Class 3 Source Board Schematic 1 TP3 SMD probe loop 1 Kelvin Output Current TP4 SMD probe loop J81 .1" Male Vert. 2 1 Shunt Bypass VRECT 1 2 R80 300 mΩ,1W RX Coil DNP 56 pF Output 1 SMD probe loop TP2 LM 1 Kelvin Output Voltage 1 82 nH SMD probe loop VRECT CM P4 100 pF CMP2 DNP CM 11 CM 7 300 pF DNP C84 100 nF, 50V Matching LM 11 CM 8 56 pF VOUT C85 10 µF, 50 V D81 40 V, 1 A VOUT R81 4.7k D84 LED 0603 Green 82 nH CM 12 DNP VRECT 1 CM 6 .1" Male Vert. TP1 R82 422 Ω 2 CMP3 DNP CM 2 D82 40 V, 1A 2 Cl1 Cat3PRU CMP1 DNP D80 40 V, 1 A CM1 300 pF 2 1 1 CM 5 DNP J82 VOUT D86 LED 0603 Red D83 40 V, 1 A D85 2.7 V, 250 mW D87 33 V, 250 mW Receive Indicator Over-Voltage Indicator V OUT > 4 V V OUT > 36 V Figure 13: Category 3 Device Board Schematic 12 | | EPC – EFFICIENT POWER CONVERSION CORPORATION | WWW.EPC-CO.COM | COPYRIGHT 2017 For More Information: Please contact [email protected] or your local sales representative Visit our website: www.epc-co.com Sign-up to receive EPC updates at bit.ly/EPCupdates or text “EPC” to 22828 EPC Products are distributed through Digi-Key. www.digikey.com Demonstration Board Warning and Disclaimer The EPC9112 board is intended for product evaluation purposes only and is not intended for commercial use. Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Quick Start Guide. Contact an authorized EPC representative with any questions. This board is intended to be used by certified professionals, in a lab environment, following proper safety procedures. Use at your own risk. As an evaluation tool, this board is not designed for compliance with the European Union directive on electromagnetic compatibility or any other such directives or regulations. As board builds are at times subject to product availability, it is possible that boards may contain components or assembly materials that are not RoHS compliant. Efficient Power Conversion Corporation (EPC) makes no guarantee that the purchased board is 100% RoHS compliant. The Evaluation board (or kit) is for demonstration purposes only and neither the Board nor this Quick Start Guide constitute a sales contract or create any kind of warranty, whether express or implied, as to the applications or products involved. Disclaimer: EPC reserves the right at any time, without notice, to make changes to any products described herein to improve reliability, function, or design. EPC does not assume any liability arising out of the application or use of any product or circuit described herein; neither does it convey any license under its patent rights, or other intellectual property whatsoever, nor the rights of others.