EPC’s 1kW, 48VDC/12VDC Converter Offers a Power Density of 1226 W/in3

The EPC9149 from Efficient Power Conversions (EPC) is sized at 2.3 x 0.9 inches, about half the size of devices employing increasingly outdated silicon semiconductors

The EPC9149. Image courtesy of EPC

 

The converter is intended for evaluation purposes only and can’t be used as part of OEM products. However, to simplify the task of replicating the design in actual products, EPC provides schematics, BOMs, and Gerber files on their website. 

 

EPC2218 and EPC2024 eGaN FETs

The EPC9149 is an LLC converter employing four 100 volt EPC2218 eGaN FETs for the primary rectification, and for the secondary synchronous rectification eight 40 volt rated EPC2024 eGaN FETs are employed. These fast-switching devices, while only 1/3 the size of silicon MOSFETs with similar RDS(ON)s, make it possible for the converter to operate at 1 MHz, with a corresponding decrease in the size and weight of filtering components. 

In addition to the eGaN FETs, the other star of the show is the Microchip dsPIC33CKMP102T-I/M6. This 16-bit digital controller, measuring 4 x 4 mm, allows for programmability, communications and configuration flexibility. 

 

Operational Efficiency

The EPC9149 delivers up to 83.4 amps at 12 volts at full load, and operates from an input voltage range of 36 to 60 VDC. Peak efficiency is 98%, and only drops down to 97% at full load. Using the available heatsink, airflow of 400 LFM is required for the full 83 amp output. Without the heatsink, 1700 LFM is required.

 

Soft Startup

The EPC9149 employs a soft startup to limit the input current drawn while powering up and while the output voltage is low or zero. To achieve this, both the four EPC2218s in the primary circuit (Q1 … Q4) and the eight EPC2024s (SR1 … SR8) are, at first, commanded with a minimum pulse width. 

Simplified schematic for the EPC9149 LLC Module. Modified image courtesy of Quick Start Guide

 

As output voltage quickly reaches 12 volts, the duty cycle increases. In this manner, excessive currents and voltage stresses can be avoided. 

 

The EPC9149 Operates in an Open Loop

The consequence of open loop design is that the output voltage can droop downwards with a higher load. With a 48 volt input and a full 83 amp output, the output drops to ≈11.8 volts

 

The Microchip dsPIC33CK32MP102 Digital Signal Controller (DSC)

This DSP is an100 MHz single core unit equipped with dedicated peripheral modules for switched Mode Power Supply (SMPS) applications. These include:

• Digital Signal Processing (DSP) core 
• A 4-channel (8x output)
• 250 ps resolution PWM logic
• Three 3.5 Msps ADCs
• Three 15 ns propagation delay analog comparators, including DACs, to support ramp signal generation
• Three Op Amps

The DSC can be readily reprogrammed.

 

EPC’s Commitment to Higher Power and Smaller Size 

As per Alex Lidow, CEO of EPC, “eGaN FETs and integrated circuits increase power density for 48 V to 12 V converters and address data center application demands for higher power in a small size.” He goes on to state that, “The use of a Microchip digital controller allows flexibility for programming and configuration of the EPC9149 demonstration board.” 

 

Applications

Designs derived from the EPC9149 demo board include power for:

• Data Centers
• Server racks

 

Getting to Market Faster

EPC also provides a motherboard on which to mount the EPC9149, greatly facilitating testing and evaluation.