Infineon D2 PAK, D2 PAK-7 User Manual

UG_1801_PL16_1802_225559

Full-bridge converter for UPS

D2PAK/D2PAK-7 kit

About this document

This user guide describes the Infineon full-bridge demo board for UPS. The current design considers only the power section including drivers and power devices with D2packages. D27-pin packages can also be used in this demo board, which enables users to evaluate the performance of power MOSFETs and their drivers.

Scope and purpose

This document is intended to describe the functionalities of UPS converting DC to AC voltages. Users can then evaluate the performance of power MOSFETs with gate driver ICs. With Infineon low-R board can help reduce system cost and time-to-market.

Intended audience

This document addresses the market for UPS manufacturers with the goal of providing a high-performance system solution at low cost.

MOSFETs the demo

DS(on)

Table of contents

About this document ............................................................................................................................1

Table of contents..................................................................................................................................1

1 Full-bridge converter for UPS with D2PAK/D2PAK-7 kit .......................................................... 2

1.1 Overview ............................................................................................................................................2

1.1.1 Key features ..................................................................................................................................3

1.2 Schematic ..........................................................................................................................................4

1.3 Layout ................................................................................................................................................4

1.4 Power-up procedure...........................................................................................................................6

1.4.1 PWM signal selections...................................................................................................................6

1.5 Performance evaluations....................................................................................................................6

1.5.1 Performance with heatsink at the front .........................................................................................6

1.5.2 Performance with heatsink at the back .......................................................................................10

1.6 Power loss estimations of MOSFETs and CS resistor ........................................................................11

1.7 Bill of Materials (BOM) .....................................................................................................................13

1.8 Additional results with D2PAK-7 (IRFS7430-7P).................................................................................14

1.8.1 Performance with heatsink at the back with 420 W load .............................................................14

1.8.2 Performance with heatsink at the back with 500 W.....................................................................15

1.8.3 Performance with heatsink at the front with 500 W..................................................................... 17

Revision history..................................................................................................................................19

User Guide Please read the Important Notice and Warnings at the end of this document Revision 1.0

www.infineon.com 2018-03-01

Full-bridge converter for UPS

UG_1801_PL16_1802_225559

D2PAK/ D2PAK-7 kit

1 Full-bridge converter for UPS with D2PAK/D2PAK-7 kit

1.1 Overview

The full-bridge converter kit is a demo board for UPS applications. It contains two sections of half-bridge drivers and power devices, as shown in Figure 1.

in+

out2

out1

in-

bias+

- +

PWM1

+ -

PWM2

bias-

Figure 1 Full-bridge converter demo board (120 mm × 120 mm)

The demo board needs two power supplies to provide an input voltage and a bias voltage. The voltages of both power supplies are typically 12 V, which can be changed based on an application. The outputs can be connected to a transformer. In this user guide, a transformer is used to get an AC voltage of 220 V with the input voltage of 12 V. In order to power up the demo board, two synchronized PWM signals are needed to control switching of four power MOSFETs.

User Guide 2 Revision 1.0

2018-03-01

Full-bridge converter for UPS

UG_1801_PL16_1802_225559

D2PAK/ D2PAK-7 kit

1.1.1 Key features

The capabilities of the full-bridge converter for UPS with D2/D27-pin kit are as follows:

• D2/D27-pin kit for MOSFETs

• Separate Vinand bias voltages (12 V is used in this user guide)

• 600 V gate driver IC with +/- 4 A peak drive current (IRS2186)

• Current Sense (CS) information

• A heatsink can be mounted with four screws, which can be placed at the back or at the front

Figure 2 Heatsink (4 × 2.5 × 0.5 inches) mounted at the front or back with thermal pad

(Heatsink: ACCEL Thermal 914; Thermal pad: Berguist Gap Pad 5000S35, 20 mils)

User Guide 3 Revision 1.0

2018-03-01

Full-bridge converter for UPS

UG_1801_PL16_1802_225559

D2PAK/ D2PAK-7 kit

1.2 Schematic

A schematic of the demo board is shown in Figure 3. In the demo board, four MOSFETs (IRFS7430) are used. D27pin packages can be used if they are desired for evaluation. Two IRS2186 drivers are used to drive four MOSFETs. Only two PWM signals are needed to control timing of the switching of the four MOSFETs. D1~4 four diodes are used to have a slow turn-off to avoid high Vdsspike during turn-off.

PowerIN

2700uFx50V

PRTN

PRNT

R15

1.2

BIAS +15V

GND

TP5

0.1uF 50V

PowerIN

1 2

R14

BIAS +15V

TP4

C5 47 uF, 35V

R13

R17

VbU1

1mOhm

open

HOV1

PWM2

HOV1

PRTN

47uF, 50V

BIAS+15V

TP3

PWM2

GND

G_Q1

R5 10 K

G_Q3

Vcc

IRS2186SPBF

PWM1

R6 10 K

COM

LIN

HIN

R10

0.1uF 50V

5.1

4239567

TP6 GND

4 3 2 1

IRFS7430

Q3 IRFS7430

BIAS +15V

Top_Q1_S

R16

47 uF, 35V

1.2

R3 47

C10

0.1uF 50V

1 2

47 uF, 50V

PWM1

TP1

TP2 GND

R7 10 K

G_Q4

BIAS +15V

HOV2

VbU2

G_Q2HOV2

R8 10 K

PWM1

Vcc

IRS2186SPBF

PWM2

4239567

Top_Q2_S

4239567

COM

R11

R12

Q4 IRFS7430

LIN

HIN

5.1

Q2 IRFS7430

4 3 2 1

Vout1

Vout2

Figure 3 Schematic of the demo board

1.3 Layout

The demo board PCB has only two layers, as shown in Figure 4. Fabricated with FR4 material, both layers are 2 oz. copper with a board thickness of 62 mils (1.58 mm).

User Guide 4 Revision 1.0

2018-03-01

Full-bridge converter for UPS

UG_1801_PL16_1802_225559

D2PAK/ D2PAK-7 kit

Top

Bottom

Figure 4 PCB top and bottom layers

User Guide 5 Revision 1.0

2018-03-01

Full-bridge converter for UPS

UG_1801_PL16_1802_225559

D2PAK/ D2PAK-7 kit

1.4 Power-up procedure

Always connect the bias, two PWM signals and load first, then increase the input voltage from zero.

1.4.1 PWM signal selections

This user guide describes a set-up providing a 50 Hz square-wave AC output. Therefore, both PWM signals are set with 50 Hz. The dead-time between the two legs has to be set high enough that the reset of the transformer is completed. A shorter dead-time increases total turn-on time, which may saturate the transformer. A value of

0.9 ms was selected to do the tests. Both PWM signals have an amplitude of 10 V.

1.5 Performance evaluations

Test conditions: Vin: 12 V V

: 12 V

bias

PWM 1, 2: 50 Hz, 10 V, with 10 ms delay between them plus 0.7 ms dead-time Load: Transformer (primary connected to V

bulbs, load of 420 W)

Airflow: No

out1

and V

, secondary connected to incandescent light

out2

1.5.1 Performance with heatsink at the front

Figure 5 Front thermal image after 1 hour

43°C

A:45°C

70.0°C

20.0°C

User Guide 6 Revision 1.0

2018-03-01

+ 14 hidden pages

Infineon D2 PAK, D2 PAK-7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual