1600 W high efficiency PSU
Optimized form, fit and function
platform for server application
EVAL_1K6W_PSU_G7_DD
Meneses Herrera David (IFAT PMM ACDC AE)
Kutschak Matteo-Alessandro (IFAT PMM ACDC AE)
Zechner Florian (IFAT PMM ACDC AE)
Table of content
1 Introduction
2 Measurements and specifications
3 Summary and outlook
2018-06-04 Copyright © Infineon Technologies AG 2018. All rights reserved. 2
Table of content
1 Introduction
2 Measurements and specifications
3 Summary and outlook
2018-06-04 Copyright © Infineon Technologies AG 2018. All rights reserved. 3
Introduction
Introduction
› This Infineon evaluation board (EVAL_1K6W_PSU_G7_DD) represents a complete system solution for a
1600 W server power supply (PSU), which achieves the 80Plus® Titanium® standard. The power supply
is composed of a continuous conduction mode (CCM) bridgeless power factor corrector (PFC) using a bi-
directional switch and a half-bridge LLC DC-DC resonant converter.
› To achieve the high efficiency results the evaluation board features several Infineon key components:
› 600 V CoolMOS™ G7 superjunction MOSFET
› CoolSiC™ Schottky diode 650 V G6
› OptiMOS™ 6 40 V MOSFET
› 1EDI20N12AF isolated and 2EDN7524F non-isolated gate drivers (EiceDRIVER™)
› XMC1402 and XMC4200 microcontrollers
› CoolSET™ quasi-resonant flyback controller
Summary of features:
› Input voltage: 176-265 Vac
› Output voltage: 12.2 Vdc
› Output power: 1600 W
› Switching frequency: PFC 65 kHz
LLC 160 kHz (resonant frequency)
› Peak efficiency: 96%
2018-06-04 Copyright © Infineon Technologies AG 2018. All rights reserved. 4
Introduction
Simplified diagram
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Introduction
Placement of the different sections in the 1600 W PSU with Infineon’s
CoolMOS™ and CoolSiC™ products in Double DPAK (DDPAK) package
Power board: PFC AC/DC DC/DC
and half-bridge LLC Bridgeless PFC LLC
semiconductors
DC out
AC in
Input Bias
Control board
Inrush limiter
EMI-Filter
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Introduction
Power module: PFC and half-bridge LLC semiconductors
Mounting scheme for the DDPAK Infineon semiconductors in the PFC and half-
bridge LLC configuration is shown below:
Spring
PCB
LLC half-bridge
PFC switch Heatsink
(Back-to-back)
PFC diodes
› The power board integrates eight DDPAK semiconductors - CoolMOS™ G7 switches and CoolSiC™ G6
Schottky diodes used for the PFC, in combination with the CoolMOS™ G7 half-bridge switches for the LLC
› It is designed for mass production as a single module by using a customized copper heatsink with a tinned
surface and isolation foil which provides thermal conductivity and electrical isolation
› The module is soldered vertically into the main PCB of the PSU and positioned in front of the fan to
optimize airflow.
2018-06-04 Copyright © Infineon Technologies AG 2018. All rights reserved. 7
Table of content
1 Introduction
2 Measurements and specifications
3 Summary and outlook
2018-06-04 Copyright © Infineon Technologies AG 2018. All rights reserved. 8
Measurements and specifications
Summary of specifications and test conditions for the 1600 W PSU
Test Conditions Specification
Efficiency test 230Vrms 50Hz/60Hz, 10% to 80Plus® Titanium® efficiency.
100% load ηpk = 96% at 800W (50% load)
Current THD 230Vrms 50Hz/60Hz, 10% to THDi < 10% from 20% load
100% load
Power factor 230Vrms 50Hz/60Hz, 10% to PF > 0.95 from 20% load
100% load
Output voltage 12.2V
Steady state Vout 230Vrms 50/60Hz, 10% to 100% |∆Vout| < 120 mVpk-pk
ripple load
Inrush current 230Vrms, 50Hz/60Hz, measured Iin_peak < 30A
on the first AC cycle
Power line AC lost 230Vrms 50Hz, |∆Vout| < 240 mVpk No damage:
disturbance (Hold-up 10ms at 100% load, 20ms at 50% * PSU soft start if
time) load bulk voltage
Voltage 200Vrms 50Hz/60Hz, under 310V
sag Different sag conditions; 100% * PSU soft start if
load Vac out of range
for certain time
Brown out 174V ON; 168V OFF
Load transient 1 A 66 A, 0.5 A/µs
|∆Vout| < 240 mVpk
66 A 133 A, 0.5 A/µs
Over current protection 30 s at 141 A LLC OFF.
10 s at 149 A Resume of operation requires bulk voltage
1ms at 168 A to drop under 310V
Output terminals in shortcircuit Detection within switching cycle.
Resume of operation requires bulk voltage
to drop under 310V
EMI 230Vrms 50Hz, full load, resistive Complies with Class B limits
load, lab set-up
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Measurements and specifications
Efficiency results
97 12
96
10 0,9835
95
8 ITHD 50Hz 0,9668
94
Efficiency (%)
Power Factor
ITHD 60Hz
THD (%)
PF 50Hz
93 6 PF 60Hz 0,9501
92 Eff 50Hz
4 0,9334
80Plus_Titanium
91
2 0,9167
90
89 0 0,9
0 500 1000 1500 2000 0 400 800 1200 1600
Output power (W) Output power (W)
Measured efficiency at 230 V 50 Hz input voltage. Measured total harmonic distortion (THD) and power factor at 230 V input
voltage for both 50 Hz and 60 Hz.
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Table of content
1 Introduction
2 Efficiency results
3 Summary and outlook
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Summary and outlook
› The trend in the field of switched mode power supplies (SMPS) is a move towards power
density and optimized cost. To reach the required higher power density levels, heat
dissipation must be minimized, making efficiency key parameter in the process
› The 800 W server power supply EVAL_800W_PSU_3P_P7 and EVAL_800W_PSU_4P_C7
evaluation boards developed with Infineon semiconductors, are great examples how to
achieve high efficiency, similar to the 80Plus® Platinum® efficiency standards
› Infineon’s new EVAL_1K6W_PSU_G7_DD PSU evaluation board keeps the same form
factor as the previously described 800W server PSU, while providing twice the power.
Therefore, the power density increased to 44 W/in3 in the 1600 W design
› There is always a relationship between form factor and increasing power density.
Reducing the heat dissipation is a result of higher efficiency
› This server power supply allows the implementation and test of future Infineon devices
and technologies. Further modifications of the presented power supply will be possible by
updating different Infineon products such as EiceDRIVER™ 2EDF isolated drivers for the
LLC stage, 5th generation CoolSET™ in the bias supply or CoolMOS™ as a relay
replacement. In the case of OptiMOS™ 6, those who would like more information are
requested to check the Infineon website
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Summary and outlook
Dimension
~67 mm
~36 mm
~195 mm
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Support
Technical › Application Notes
› https://www.infineon.com/eval-1k6w-psu-g7-dd
Material › Datasheets
› Evaluation Boards
Evaluation
› Demoboards › www.infineon.com/evaluationboards
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Videos
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