LLC switcher delivers 1650 W of continuous power

Power Integrations has recently announced a significant advancement in its HiperLCS chipset, doubling the power output to provide up to 1650W of continuous power for power tools. The new HiperLCS-2 chipset features a half-bridge switch and enhanced package, boasting over 98 percent efficiency for LLC resonant power converters. This latest addition to the family is designed to cater to industrial power supplies, chargers for e-scooters, and outdoor power tools. Its high efficiency and integration capabilities contribute to reducing enclosure volume, eliminating the need for air vents and fans, thereby enhancing reliability and resistance to dust and moisture.

The primary-side HiperLCS2-HB devices within the chipset incorporate 600 V FREDFETs in a half-bridge configuration. With self-bias and start-up control, these devices can operate without an external bias supply, ultimately reducing system cost and complexity. On the other hand, the companion chip, HiperLCS2-SR, includes a secondary-side master controller that optimizes synchronous rectification (SR) to minimize output rectification losses. Additionally, it features a FluxLink isolator for feedback to the primary-side IC, eliminating the need for an optocoupler. This comprehensive solution controls multi-mode burst operation, ensuring optimal performance under light- and no-load conditions while reducing audible noise and output ripple, and providing extensive fault protection.

Overall, the HiperLCS-2 chipset significantly reduces component count and board area of half-bridge LLC resonant power converters by 30 to 60 percent in applications of 50 W and higher. The peak power of 2.5 kW for the LLC switcher is made possible by a new, thermally efficient POWeDIP package. This package is based on an electrically insulating, thermally conductive ceramic pad that can be easily attached to any flat, heat-sinking surface. It offers sufficient creepage to the package pins, enabling an overall thermal performance of less than 1 degree Celsius per watt.

Zeeshan Kabeer, the product marketing manager at Power Integrations, emphasized the importance of high power and high efficiency in fully sealed chargers and adapters. He highlighted that for individuals relying on power tools or personal transportation for their livelihood, charger failure due to environmental factors is unacceptable. The 1650 W HiperLCS-2 device enables the manufacture of completely sealed chargers for these mission-critical applications, ensuring reliability and durability.

For those interested, reference designs for a 1650 W DC-DC LLC switcher half-bridge resonant converter (DER-1060), a 720 W DC-DC LLC half-bridge resonant converter (DER-978), and a 720 W PFC LLC PSU with constant voltage and constant current mode control (DER-984) are available for download. The pricing for HiperLCS-2 POWeDIP ICs starts at $5.39 for 10,000-unit quantities, making this advanced chipset an attractive option for various power applications.