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UG_1801_PL16_1802_225559
Full-bridge converter for UPS
2
2
D
PAK/D
PAK-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 D
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.
Table of contents
About this document ............................................................................................................................1
Table of contents ..................................................................................................................................1
1
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
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
www.infineon.com
2
2
Please read the Important Notice and Warnings at the end of this document
2
2
packages. D
7-pin packages can also be used in this
2
PAK-7 kit .......................................................... 2
MOSFETs the demo
DS(on)
Revision 1.0
2018-03-01
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Summary of Contents for Infineon D2 PAK
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Page 1: Table Of Contents
PAK/D PAK-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 D packages. D 7-pin packages can also be used in this demo board, which enables users to evaluate the performance of power MOSFETs and their drivers. -
Page 2: Full-Bridge Converter For Ups With D
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Full-bridge converter for UPS with D PAK/D PAK-7 kit 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. out2 out1 bias+... -
Page 3: Key Features
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 1.1.1 Key features The capabilities of the full-bridge converter for UPS with D 7-pin kit are as follows: • 7-pin kit for MOSFETs • Separate V and bias voltages (12 V is used in this user guide) •... -
Page 4: Schematic
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Schematic A schematic of the demo board is shown in Figure 3. In the demo board, four MOSFETs (IRFS7430) are used. D pin 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. - Page 5 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Bottom Figure 4 PCB top and bottom layers User Guide Revision 1.0 2018-03-01...
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Page 6: Power-Up Procedure
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 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. - Page 7 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 B:45°C 7 0 .0 °C 60°C 57°C 2 0 .0 °C Figure 6 Back thermal image after 1 hour 7 0 .0 °C 58°C (FET) 68°C Resistor 2 0 .0 °C Figure 7 Side 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...
- Page 8 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 C1: I t (20 A/div) C2: V (10 V/div) out2 out1 C3: I (20 A/div) C4: V (5 V/div) Figure 8 Typical input and output power measurement after 1 hour Table 1 Efficiency after 1 hour Efficiency (percent)
- Page 9 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 C1: V (5 V/div) out1 out2 C2: I (0.5 A/div) Ioad 20 µs C3: V (5 V/div) ↔ (reset) C4: V (5 V/div) Figure 9 Waveforms during the dead-time C21 = 0.27 V (I21 = 27 A) C1: I (20 A/div) C2: I...
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Page 10: Performance With Heatsink At The Back
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 1.5.2 Performance with heatsink at the back D: 57°C C:60°C 7 0 .0 °C 69°C 54°C (top) 55°C (bottom) A: 46°C 2 0 .0 °C Figure 11 Front thermal image after 1 hour As shown in Figure 12, the corner temperature reading (A) is 1°C higher than that with the heatsink at the front in Figure 6. -
Page 11: Power Loss Estimations Of Mosfets And Cs Resistor
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Table 2 Efficiency after 1 hour Efficiency (percent) 96.6 96.3 96.4 96.5 96.4 96.4 96.3 96.3 Average 96.4 Stdev Power loss estimations of MOSFETs and CS resistor Table 3 shows the average R at 12 V is 0.72 mΩ. - Page 12 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 C1: I (20 A/div) Figure 13 Transformer RMS current measurement (39.2 A) User Guide Revision 1.0 2018-03-01...
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Page 13: Bill Of Materials (Bom)
CXS70-14- Panduit Corp POWERIN, RECT LUG 4/0- VOUT1, 2AWG 5/16 VOUT2 Q1, Q2, Q3, MOSFET 40 V, IRFS7430- IRFS7430 Infineon 0.75 mΩ, 305 nC 7PPBF R1, R2, R3, R4 Resistor 47 Ω RC1206FR- Yageo 1206, 1/4 W, 1 0747RL percent... -
Page 14: Additional Results With D 2 Pak-7 (Irfs7430-7P)
Not fitted Not fitted U1, U2 Hi/Lo gate IRS2186SPBF IRS2186SP Infineon driver Additional results with D PAK-7 (IRFS7430-7P) 1.8.1 Performance with heatsink at the back with 420 W load Figure 15 shows temperature readings at the front side with a heatsink at the back. Compared with the readings shown in Figure 12, the hottest point of the sense resistor is 5°C lower. -
Page 15: Performance With Heatsink At The Back With 500 W
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 96.5 0.65 96.5 0.67 96.6 0.65 96.7 0.65 96.6 Average 0.65 96.6 Average Stdev 0.01 Stdev B: 43°C 7 0 .0 °C 47°C 2 0 .0 °C Figure 15 Back thermal image after 1 hour 1.8.2 Performance with heatsink at the back with 500 W As shown in Figure 17, both case temperature readings at the resistor (78°C) and PCB location A (49°C) are higher... - Page 16 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 C: 64°C 78°C (resistor) 60°C (top) 62°C (bottom) A: 49°C Figure 16 Front thermal image after 1 hour with 500 W B: 49°C 55°C Figure 17 Back thermal image after 1 hour with 500 W User Guide Revision 1.0 2018-03-01...
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Page 17: Performance With Heatsink At The Front With 500 W
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Table 6 Efficiency after 1 hour Efficiency (percent) 97.1 97.0 97.1 96.9 97.0 97.1 97.0 97.1 Average 97.0 Stdev 1.8.3 Performance with heatsink at the front with 500 W As shown in Table 7, the average efficiency is 97 percent, which is 0.4 percent higher than that with the heatsink at the back, shown in Table 4. - Page 18 Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 8 0 .0 °C 47°C A: 52°C 2 0 .0 °C Figure 18 Front thermal image after 1 hour B:48°C 8 0 .0 °C 69°C 65°C 2 0 .0 °C Figure 19 Back thermal image after 1 hour User Guide Revision 1.0...
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Page 19: Revision History
Full-bridge converter for UPS PAK/ D PAK-7 kit UG_1801_PL16_1802_225559 Revision history Major changes since the last revision. Page or reference Description of change User Guide Revision 1.0 2018-03-01... - Page 20 Trademarks of Infineon Technologies AG AURIX™, C166™, CanPAK™, CIPOS™, CoolGaN™, CoolMOS™, CoolSET™, CoolSiC™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, DrBlade™, EasyPIM™, EconoBRIDGE™, EconoDUAL™, EconoPACK™, EconoPIM™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, Infineon™, ISOFACE™, IsoPACK™, i-Wafer™, MIPAQ™, ModSTACK™, my-d™, NovalithIC™, OmniTune™, OPTIGA™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PROFET™, PRO-SIL™, RASIC™, REAL3™, ReverSave™, SatRIC™, SIEGET™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, SPOC™,...