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Microchip MCP1632 | Demoboard dsPIC33C 4kW DC-DC Demonstration DS70005619A
dsPIC33C DSP digital signal microcontroller
Overview
| Topology | Full-Bridge Converter symmetrical isolated |
| Input voltage | 400-900 V |
| Output 1 | 16 V / 100 A |
| Output 2 | 16 V / 200 A |
| IC revision | 1 |
Description
This document serves as a user guide for the new 4kW Phase-Shifted Full-Bridge (PSFB) with Current DoublerRectifier (CDR), DC-DC converter demonstrator application board utilizing the dsPIC33C DSP digital signalmicrocontroller. The PSFB-CDR board is a 800V to 12V DC-DC converter intended to support power conversionapplications from HV 800 VDC battery to 12 VDC Electric Vehicle bus. The DC-DC converter uses a highlyefficient and wide input voltage range, Phase-shifted-full-bridge topology which demonstrates partial to fullZVS (Zero Volts Switching) at the primary HV SiC full bridge. The option to add an external shim inductanceis available to tune peak efficiency operating point. The secondary side uses robust current doubler topologywhich reduces the current requirements for system magnetics. Smart reverse current detection is implementedin firmware to safely operate the current doubler stage and automatically enable synchronous rectification toincrease efficiency. In light load conditions, switching losses at primary side full bridge are quite significant;therefore, Burst mode is implemented to increase system efficiency.The user guide provides an in-depth review of the hardware, converter theory of operation and an overviewof the digital control implementation. Test results and measurements for this design are covered in thecorresponding operational manual document. The converter is designed as a dual-rail solution, offeringredundancy and maximizing light load efficiency. Each rail can transfer 1700W continuous and 2700W peakpower for short durations (> 10s with 20s breaks) outputting a total power of over 4000W to the 12 VDC bus
Typical applications
- 4kW DC-DC Converter
- EV Chargers
More information
Products
Order Code | Datasheet | Simulation | Downloads | Status | Product series | λDom typ.(nm) | Emitting Color | λPeak typ.(nm) | IV typ.(mcd) | VF typ.(V) | Chip Technology | 2θ50% typ.(°) | C | Tol. C | VR(V (DC)) | Size | Operating Temperature | Q(%) | DF(%) | RISO | Ceramic Type | L(mm) | W(mm) | Fl(mm) | Packaging | L(µH) | IRP,40K(A) | ISAT(A) | fres(MHz) | Version | ISAT,10%(A) | ISAT,30%(A) | Wire Type | Mount | Ø ID(mm) | Ø f(mm) | Thread | Qty. | IRIPPLE(mA) | ILeak(µA) | RESR(mΩ) | Ø D(mm) | dV/dt(V/µs) | DF @ 1 kHz(%) | Pins | VIN | VOut1(V (DC)) | IOut1(A) | Type of Insulation | fswitch(kHz) | ∫Udt(Vµs) | NPRI : NSEC | VT(V (RMS)) | Center pin Ø (Value)(mm) | Plug OD(mm) | IR(mA) | Working Voltage(V (DC)) | H(mm) | Operation Force(g) | Electrical Life(Cycles) | Actuator Color | Ø OD(mm) | IR(mA) | Ti | Tl(mm) | Vaporphase process | Z @ 100 MHz(Ω) | Zmax(Ω) | Test Condition Zmax | IR 2(mA) | RDC max.(Ω) | Type | Samples | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
 | WL-SMCW SMT Mono-color Chip LED Waterclear, 525 nm, Green | Downloads26 files RAY files
| Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWL-SMCW SMT Mono-color Chip LED Waterclear | Dominant Wavelength [typ.]525 nm | Emitting ColorGreen | Peak Wavelength [typ.]515 nm | Luminous Intensity [typ.]430 mcd | Forward Voltage [typ.]3.2 V | Chip TechnologyInGaN | Viewing Angle Phi 0° [typ.]140 ° | – | – | – | Size0603 | Operating Temperature -40 °C up to +85 °C | – | – | – | – | Length1.6 mm | Width0.8 mm | – | PackagingTape and Reel | – | – | – | – | – | – | – | – | MountSMT | – | – | – | Packaging Unit4000 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Height0.7 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | |||
| WL-SMCW SMT Mono-color Chip LED Waterclear, 625 nm, Red | Downloads26 files RAY files
| Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWL-SMCW SMT Mono-color Chip LED Waterclear | Dominant Wavelength [typ.]625 nm | Emitting ColorRed | Peak Wavelength [typ.]630 nm | Luminous Intensity [typ.]250 mcd | Forward Voltage [typ.]2 V | Chip TechnologyAlInGaP | Viewing Angle Phi 0° [typ.]140 ° | – | – | – | Size0603 | Operating Temperature -40 °C up to +85 °C | – | – | – | – | Length1.6 mm | Width0.8 mm | – | PackagingTape and Reel | – | – | – | – | – | – | – | – | MountSMT | – | – | – | Packaging Unit4000 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Height0.7 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | |||
 | WE-CBF SMT EMI Suppression Ferrite Bead, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-CBF SMT EMI Suppression Ferrite Bead | – | – | – | – | – | – | – | – | – | – | Size0603 | Operating Temperature -55 °C up to +125 °C | – | – | – | – | Length1.6 mm | Width0.8 mm | Pad Dimension0.3 mm | – | – | – | – | – | VersionSMT | – | – | – | MountSMT | – | – | – | Packaging Unit4000 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Rated Current800 mA | – | Height0.8 mm | – | – | – | – | Rated Current1000 mA | – | – | – | Impedance @ 100 MHz600 Ω | Maximum Impedance800 Ω | Maximum Impedance200 MHz | Rated Current 21000 mA | DC Resistance0.2 Ω | TypeHigh Current | ||||
 | WE-PD SMT Power Inductor, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-PD SMT Power Inductor | – | – | – | – | – | – | – | – | – | – | Size1210 | Operating Temperature -40 °C up to +125 °C | – | – | – | – | Length12 mm | Width12 mm | – | – | Inductance68 µH | Performance Rated Current3.9 A | – | Self Resonant Frequency5.5 MHz | VersionStandard | Saturation Current @ 10%3.6 A | Saturation Current @ 30%4.4 A | – | MountSMT | – | – | – | Packaging Unit250 | – | – | – | – | – | – | Pins2 | – | – | – | – | – | – | – | – | – | – | Rated Current3200 mA | – | Height10 mm | – | – | – | – | – | – | – | – | – | – | – | – | DC Resistance0.089 Ω | – | ||||
| WCAP-CSGP MLCCs 50 V(DC), –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWCAP-CSGP MLCCs 50 V(DC) | – | – | – | – | – | – | – | Capacitance47 pF | Capacitance±5% | Rated Voltage50 V (DC) | Size0603 | Operating Temperature -55 °C up to +125 °C | Q-Factor1000 % | – | Insulation Resistance10 GΩ | Ceramic TypeNP0 Class I | Length1.6 mm | Width0.8 mm | Pad Dimension0.4 mm | Packaging7" Tape & Reel | – | – | – | – | – | – | – | – | – | – | – | – | Packaging Unit4000 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Height0.8 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | |||||
 | WR-DC Power Jacks, –, – | Simulation– | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWR-DC Power Jacks | – | – | – | – | – | – | – | – | – | – | – | Operating Temperature -40 °C up to +85 °C | – | – | Insulation Resistance100 MΩ | – | – | – | – | PackagingBag | – | – | – | – | – | – | – | – | MountTHT | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Center pin Ø2 mm | Recommended Plug outer Ø5.5 mm | Rated Current5000 mA | Working Voltage30 V (DC) | – | – | – | – | – | Rated Current5000 mA | – | – | – | – | – | – | – | – | TypeRight Angled | |||
 | WE-LHMI SMT Power Inductor, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-LHMI SMT Power Inductor | – | – | – | – | – | – | – | – | – | – | Size1365 | Operating Temperature -40 °C up to +125 °C | – | – | – | – | Length13.65 mm | Width12.5 mm | – | – | Inductance100 µH | Performance Rated Current3.2 A | – | Self Resonant Frequency2.4 MHz | – | Saturation Current @ 10%3.45 A | Saturation Current @ 30%6.8 A | – | MountSMT | – | – | – | Packaging Unit500 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Height6.2 mm | – | – | – | – | – | – | – | – | – | – | – | – | DC Resistance0.165 Ω | – | ||||
 | WP-SMBU REDCUBE SMT with internal through-hole thread, –, – | Simulation– | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWP-SMBU REDCUBE SMT with internal through-hole thread | – | – | – | – | – | – | – | – | – | – | – | Operating Temperature -55 °C up to +150 °C | – | – | – | – | – | – | – | PackagingBulk | – | – | – | – | – | – | – | – | MountSMT | – | – | ThreadM4 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Rated Current50000 mA | – | Height3 mm | – | – | – | Outer Diameter7 mm | Rated Current50000 mA | Inner ThreadM4 | Thread Length4 mm | – | – | – | – | – | – | – | |||
 | WE-HCF SMT High Current Inductor, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-HCF SMT High Current Inductor | – | – | – | – | – | – | – | – | – | – | Size2815 | Operating Temperature -40 °C up to +125 °C | – | – | – | – | Length27 mm | Width28 mm | – | – | Inductance4.7 µH | Performance Rated Current44 A | Saturation Current44 A | Self Resonant Frequency21.56 MHz | VersionSMT | Saturation Current @ 10%44 A | Saturation Current @ 30%48 A | Wire TypeFlat | MountSMT | – | – | – | Packaging Unit20 | – | – | – | – | – | – | Pins2 | – | – | – | – | – | – | – | – | – | – | Rated Current44000 mA | – | Height15.4 mm | – | – | – | – | – | – | – | – | – | – | – | – | DC Resistance0.00144 Ω | – | ||||
 | WS-TASV J-Bend SMT Tact Switch 4.2x3.2 mm, –, – | Simulation– | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWS-TASV J-Bend SMT Tact Switch 4.2x3.2 mm | – | – | – | – | – | – | – | – | – | Rated Voltage16 V (DC) | – | Operating Temperature -40 °C up to +85 °C | – | – | Insulation Resistance100 MΩ | – | – | – | – | PackagingTape and Reel | – | – | – | – | – | – | – | – | – | – | – | – | Packaging Unit2900 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Rated Current50 mA | – | Height2.5 mm | Operation Force260 g | Electrical Life50000 Cycles | Actuator ColorWhite | – | Rated Current50 mA | – | – | Vaporphase processnot specified | – | – | – | – | – | – | |||
Simulation– | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWA-SMSA SMT Spacer Studs Automotive | – | – | – | – | – | – | – | – | – | – | – | Operating Temperature -55 °C up to +150 °C | – | – | – | – | Length3 mm | – | – | PackagingTape and Reel | – | – | – | – | – | – | – | – | – | Inner Diameter4.2 mm | – | ThreadM3 | Packaging Unit800 | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | Outer Diameter6 mm | – | – | – | – | – | – | – | – | – | – | |||||
 | WCAP-HSAH Advanced High Temperature 125°C, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWCAP-HSAH Advanced High Temperature 125°C | – | – | – | – | – | – | – | Capacitance470 µF | Capacitance±20% | Rated Voltage25 V (DC) | – | Operating Temperature -55 °C up to +125 °C | – | Dissipation Factor14 % | – | – | Length12.4 mm | Width10.3 mm | – | Packaging15" Tape & Reel | – | – | – | – | – | – | – | – | MountV-Chip SMT | – | – | – | – | Ripple Current2260 mA | Leakage Current117.5 µA | ESR16 mΩ | Diameter10 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||||
 | WCAP-FTDB DC-Link, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWCAP-FTDB DC-Link | – | – | – | – | – | – | – | Capacitance1 µF | Capacitance±5% | Rated Voltage1200 V (DC) | – | Operating Temperature -40 °C up to +105 °C | – | – | Insulation Resistance10 GΩ | – | Length32 mm | Width11 mm | – | PackagingCarton | – | – | – | – | – | – | – | – | MountTHT | – | Hole Diameter1.1 mm | – | – | Ripple Current3500 mA | – | ESR39.5 mΩ | – | Rate of Voltage Rise90 V/µs | Dissipation Factor0.07 % | Pins2 | – | – | – | – | – | – | – | – | – | – | – | – | Height20 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||||
| WCAP-FTDB DC-Link, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWCAP-FTDB DC-Link | – | – | – | – | – | – | – | Capacitance5 µF | Capacitance±5% | Rated Voltage1200 V (DC) | – | Operating Temperature -40 °C up to +105 °C | – | – | Insulation Resistance2 GΩ | – | Length32 mm | Width22 mm | – | PackagingCarton | – | – | – | – | – | – | – | – | MountTHT | – | Hole Diameter1.1 mm | – | – | Ripple Current10400 mA | – | ESR12.7 mΩ | – | Rate of Voltage Rise90 V/µs | Dissipation Factor0.07 % | Pins2 | – | – | – | – | – | – | – | – | – | – | – | – | Height37 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||||
 | WE-PPTI Push-Pull Transformers, –, – | Simulation– | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-PPTI Push-Pull Transformers | – | – | – | – | – | – | – | – | – | – | Size1209 | Operating Temperature -40 °C up to +125 °C | – | – | – | – | Length9.14 mm | Width12.7 mm | – | – | Inductance340 µH | – | – | – | VersionPush-Pull | – | – | – | MountSMT | – | – | – | – | – | – | – | – | – | – | – | Input Voltage 3.3 V (DC) | Output Voltage 15 V (DC) | Output Current 10.65 A | Type of InsulationReinforced | Switching Frequency 250 - 550 | Voltage-µSecond11 Vµs | Turns Ratio1:1.56 | Insulation Test Voltage5000 V (RMS) | – | – | – | – | Height7.62 mm | – | – | – | – | – | – | – | – | – | – | – | – | – | – |