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User Guide

13

Revision 1.0

2018-03-01

Full-bridge converter for UPS
D

2

PAK/ D

2

PAK-7 kit

UG_1801_PL16_1802_225559

1.7

Bill of Materials (BOM)

Item

Quantity

Part reference Part

description

Value

Part

number

Manufacture

r

1

1

C1

Electrolytic

2700 µF 35 V

2700 µF, 35 V

Nichicon

2

2

C3, C4, C5, C6

Electrolytic 5 ×

11mm

47 µF, 35 V

UVK1V470

MED

Nichicon

3

4

C7, C8, C9, C10 0.1 µF × 50 V

1206 C0G

0.1 µF, 50 V

CGA5L2C

OG1H104J

TDK

4

4

D1, D2, D3, D4 Diode, 100 VM,

300 MA

1N4148W

1N4148W-

7-F

Diodes Inc.

5

2

D5, D6

Diode, 100 V, 2

A

MURS 210T3

MURS

210T3

OnSemi

6

8

J2, J3, TP1,

TP2, TP3, TP4,

TP5, TP6

Test point 218

mils, 90 mils

BIAS +15 V

1502-2

Keystone

7

4

PRTN,
POWERIN,

VOUT1,

VOUT2

CONN TERM
RECT LUG 4/0-

2AWG 5/16

CX225-56HK-
QY

CXS70-14-
C

Panduit Corp

8

4

Q1, Q2, Q3,
Q4

MOSFET 40 V,
0.75 m

Ω

, 305 nC

IRFS7430-
7PPBF

IRFS7430

Infineon

9

4

R1, R2, R3, R4

Resistor

1206, 1/4 W, 1

percent

47

Ω

RC1206FR-

0747RL

Yageo

10

4

R5, R6, R7, R8

Resistor

1206, 1/4 W, 1

percent

10 k

RK73H2BT

TE1002F

KOA

11

4

R9, R10, R11,

R12

Resistor

1206, 1/4 W, 1

percent

5.1

Ω

MCR10EZ

HJ5R1

Rohm

12

1

R13

Resistor
4 W

2 m

Ω

EBWB-
N0020GET

Ohmite

Summary of Contents for D2 PAK

Page 1: ...on low RDS on MOSFETs the demo 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 perform...

Page 2: ...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...

Page 3: ...D2 D2 7 pin kit for MOSFETs Separate Vin and 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 mount...

Page 4: ...material both layers are 2 oz copper with a board thickness of 62 mils 1 58 mm C1 2700uFx50V C6 47 uF 35V C8 0 1uF 50V C7 0 1uF 50V D1 1 2 D2 1 2 D3 1 2 D4 1 2 C4 47 uF 50V D5 1 2 U2 IRS2186SPBF Vb 8...

Page 5: ...User Guide 5 Revision 1 0 2018 03 01 Full bridge converter for UPS D2 PAK D2 PAK 7 kit UG_1801_PL16_1802_225559 Top Bottom Figure 4 PCB top and bottom layers...

Page 6: ...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 Bot...

Page 7: ...thermal image after 1 hr Comparing the temperature readings at points A and B between the front and back sides at the corner in Figures 6 and 7 shows that they are the same Case temperatures of the MO...

Page 8: ...bout 13 W The reset time for the transformer is about 20 s as shown in Figure 9 which is much less than the dead time of 700 s The MOSFET turn off waveforms are shown in Figure 10 Since Ids was measur...

Page 9: ...d time t1 t2 Figure 10 Turn off waveforms C1 Vout1 Vout2 5 V div C2 IIoad 0 5 A div C3 Vds3 5 V div C4 Vds4 5 V div 20 s reset C1 Itr 20 A div C2 Ids_Q1 10 A div C4 Vds_Q1 5 V div 27V C21 0 27 V I21 2...

Page 10: ...t indicates that the heatsink placed at the front is slightly more effective Its average efficiency is 96 4 percent shown in Table 2 which is 0 1 percent lower than that shown in Table 1 with the heat...

Page 11: ...rent for the transformer is 39 2 A Therefore the conduction power loss for each MOSFET can be estimated as 39 22 0 72 2 0 55 W which is much higher than the switching loss of 15 mW shown in Figure 11...

Page 12: ...User Guide 12 Revision 1 0 2018 03 01 Full bridge converter for UPS D2 PAK D2 PAK 7 kit UG_1801_PL16_1802_225559 Figure 13 Transformer RMS current measurement 39 2 A C1 Itr 20 A div...

Page 13: ...100 VM 300 MA 1N4148W 1N4148W 7 F Diodes Inc 5 2 D5 D6 Diode 100 V 2 A MURS 210T3 MURS 210T3 OnSemi 6 8 J2 J3 TP1 TP2 TP3 TP4 TP5 TP6 Test point 218 mils 90 mils BIAS 15 V 1502 2 Keystone 7 4 PRTN PO...

Page 14: ...C the temperature reading is 7 C lower which shows that the source bond wires in the D2 7 pin package result in lower power dissipation This is consistent with the higher efficiencies shown in Table 4...

Page 15: ...both case temperature readings at the resistor 78 C and PCB location A 49 C are higher than those 64 C and 44 C with same parts at 420 W in Figure 15 and also higher than the 69 C and 46 C with D2 at...

Page 16: ...ll bridge converter for UPS D2 PAK D2 PAK 7 kit UG_1801_PL16_1802_225559 Figure 16 Front thermal image after 1 hour with 500 W Figure 17 Back thermal image after 1 hour with 500 W B 49 C 55 C C 64 C 7...

Page 17: ...those 43 C and 45 C shown in Figure 6 due to the additional 80 W of load With the same load at 500 W the temperature reading 52 C at A shown in Figure 19 is higher than that 49 C in Figure 17 while t...

Page 18: ...ull bridge converter for UPS D2 PAK D2 PAK 7 kit UG_1801_PL16_1802_225559 Figure 18 Front thermal image after 1 hour Figure 19 Back thermal image after 1 hour 20 0 C 80 0 C 20 40 60 80 20 0 C 80 0 C 2...

Page 19: ...Guide 19 Revision 1 0 2018 03 01 Full bridge converter for UPS D2 PAK D2 PAK 7 kit UG_1801_PL16_1802_225559 Revision history Major changes since the last revision Page or reference Description of cha...

Page 20: ...ation note must verify any function and other technical information given herein in the real application Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind inclu...

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