INTERNATIONAL RECTIFIER - THE POWER MANAGEMENT LEADER

DC Bus Converter Chip Sets: Redefining On-Board Power Management

IR’s DC Bus Converter chip set family is aimed at simplifying and improving on-board power management for today's networking & communications and high end computing systems. IR’s DC Bus converter chip sets redefine what was previously possible in standard brick footprints, addressing power levels up to 350W without having to parallel converters. The Half-Bridge chip set offers designers up to 95.7% efficiency at 27.5A/8V/220W output, up to 126W/in2 power density in 48% smaller footprint compared to standard quarter-bricks. The Full-Bridge chip set offers designers up to 97% efficiency at 35A/9.6V/330W output, up to 142W/in2 power density in a 29% smaller footprint, compared to standard quarter-bricks.
The DC Bus chipset allows for significant component count reduction up to 60% versus standard full-featured isolated DC-DC brick solutions.

iP1001 Building Block for Single Phase Buck Converter

FEATURES
Optimized IC & MOSFETs for best electrical and thermal performance
DC Bus primary side controllers
+/- 1A gate drive current
Optimized for IR’s low charge MOSFETs
Adjustable dead-time (50nsec to 200nsec)
High & low pulse-width matching to within +/-25nsec
Programmable switching frequency up to 500kHz
Integrated soft-start
Vcc supply under-voltage lock-out
Current limit
IR2085S
- Self-oscillating, 50% duty cycle design with 100V offset half-bridge driver in a single 8 pin SOIC package
IR2086S
- Self-oscillating, 50% duty cycle design with 100V offset full-bridge driver in a single 16 pin SOIC package


THE IR ADVANTAGE
Optimized solution for 2-stage 48V distributed power architectures
Dramatic space savings with increased efficiency versus standard isolated brick solutions
Significant component count reduction, and simplification of design
Single isolated 48V bus converter to generate unregulated low output voltage in 6V-12V range
Bus voltage can be optimized according to power level, input voltage range, and POL switching losses:
- Select higher bus voltage for higher power systems to reduce distribution losses
- Select lower bus voltage for reduced switching losses in the POL

APPLICATIONS
48V input Isolated DC-DC Converter Applications
- 48V +/-10%
- ETSI (36V-60V)
Networking & Telecommunications systems
48V Servers & High End Computing
HALF-BRIDGE DC BUS CONVERTER SCHEMATIC

FULL-BRIDGE DC BUS CONVERTER SCHEMATIC

The DC Bus chip sets are designed for the isolated front-end of two-stage distributed power architectures (DPA) with an intermediate bus voltage feeding non-isolated point-of-load (POL) converters. Two-stage DPA schemes do not require a tightly regulated intermediate bus voltage, since the POL will typically accept a relatively wide input voltage, and the POL provides the needed regulation to the load. In addition, multiple DC Bus Converter Chip Sets can be placed in parallel for higher power requirements.

The chip sets consist of either a primary side half-bridge or full-bridge controller combined with optimized primary side & secondary side DirectFET MOSFETs see selector table below. In addition, the IRF7380 can be used for deriving primary side bias, and the IRF6621 can be used for the secondary side gate clamp. SO-8 packaged MOSFETs can be used on the primary side and secondary side for lower power applications.

The half-bridge IR2085S and full-bridge IR2086S control ICs are at the heart of the DC Bus converter architecture, based around a 50% fixed duty cycle, self-oscillating control scheme. The IR2085S replaces two SO-8 packaged devices, and the IR2086S replaces three, and are optimized for DPA applications. Features include an integrated soft-start capacitor that gradually increases duty cycle from zero to 50% over 2000 cycles to limit in-rush current during start-up, and maintains equal pulse-widths for the high- and low-side MOSFETs throughout the start-up sequence.

The low-side and high-side pulses for the half- and full-bridge are matched to within ±25nsec to prevent transformer imbalances during operation. Other features include ±1A gate drive current optimized to work with IR’s next generation low charge primary side MOSFETs, and includes adjustable dead-time from 50nsec to 200nsec to protect against shoot-through current. The deadtime can also be adjusted to limit the amount of body diode conduction on the secondary side, therefore maximizing efficiency.

The IR2085S and IR2086S both have programmable switching frequency up to 500kHz for design flexibility. Higher switching frequency decreases output voltage ripple and allows use of smaller, lower loss magnetic components. Circuit designers can control switching frequency and deadtime independently with just two external components to customize circuits for their particular application.

A floating channel designed for bootstrap operation up to +100V DC and VCC supply under-voltage lockout is included. The IR2085S and IR2086S both use a new high voltage, high frequency level shift technology with high dv/dt immunity. The immunity is in the range of 50V/nsec to prevent unwanted turn-on of the lower MOSFET in the half- or full-bridge, and enables faster switching speed.

On the primary side, either 80V or 100V MOSFETs can be selected depending on required voltage derating in the application. IR’s new 80V & 100V DirectFET MOSFETs provide optimized performance for both the half- and full-bridge topologies bringing benchmark on-state resistance and gate charge specifications as well as allowing improved thermal performance versus competing solutions.

On the secondary side, either 30V or 40V MOSFETs can be selected depending on required voltage derating in the application. IR’s new 30V & 40V DirectFETs provide optimized performance in the self-driven synchronous rectification topology bringing benchmark on-state resistance as the primary key figure of merit as well as allowing improved thermal performance versus competing solutions.

IR’s new architecture uses two biasing components. The IRF9956 or IRF6621 can be used to provide a gate clamp for the secondary side synchronous rectification MOSFETs, clamping the drive voltage to 7.5V.


Single isolated 48V Bus Converter to generate unregulated low output voltage in 8V range, ideal for powering Point of Load (POL) Converters

Click here for more efficiency curves.

Thermal Image at 35A, 48VIN, 330W, 400LFM


Optimised IC and MOSFETs for best electrical and thermal performance


The DC Bus Converter Chip Set simplifies and improves on-board power management for networking and communications systems.
DC Bus Converter Control ICs
Part Number Description Package TJ Drive Currentt Adjustable Deadtime Fixed Duty Cycle Hiccup Current Limit Soft Start Programmable Frequency
IR2085S Primary-side half-bridge control IC, fixed 50% duty cycle, self-oscillating SO-8 -40 to 125° +/- 1.0A  
IR2086S Primary-side full-bridge control IC, fixed 50% duty cycle, self-oscillating SO-16 -40 to 125° +/- 1.2A

Primary Side DirectFET MOSFETs
Part Number Voltage Package Typical RDS(on) @10VGS Maximum RDS(on) @10VGS Typical QG Typical QGD
IRF6644 100V M-can DirectFET 10.3mOhms 13mOhms 35nC 11.5nC
IRF6662 M-can DirectFET 17.5mOhms 22mOhms 22nC 6.8nC
IRF6645 S-can DirectFET 28mOhms 35mOhms 14nC 4.8nC
IRF6655 S-can DirectFET 53mOhms 62mOhms 8.7nC 2.8nC
IRF6646 80V M-can DirectFET 7.6mOhms 9.5mOhms 36nC 12nC
IRF6668 M-can DirectFET 12mOhms 15mOhms 22nC 7.8nC
IRF6648 60V M-can DirectFET 5.5mOhms 7.0mOhms 36nC 14nC

Secondary Side DirectFET MOSFETs
Part Number Voltage Package Typical RDS(on) @10VGS Maximum RDS(on) @10VGS Typical QG Typical QGD
IRF6613 40V M-can DirectFET 2.6mOhms 3.4mOhms 42nC 12.6nC
IRF6616 M-can DirectFET 3.7mOhms 5.0mOhms 29nC 9.4nC
IRF6614 S-can DirectFET 5.9mOhms 8.3mOhms 19nC 6.0nC
IRF6635 30V M-can DirectFET 1.3mOhms 1.8mOhms 47nC 17nC
IRF6678 M-can DirectFET 1.7mOhms 2.2mOhms 43nC 15nC
IRF6618 M-can DirectFET 1.7mOhms 2.2mOhms 43nC 15nC
IRF6611 M-can DirectFET 2.0mOhms 2.6mOhms 37nC 12.5nC
IRF6612 M-can DirectFET 2.5mOhms 3.3mOhms 30nC 10nC

 
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