2kW, 48 to 400V, >93% Efficiency, Isolated Bidirectional ...

1 36- 60-V 300- to 400-V DCT1SN6505 BSN6505 BUCC21520 UCC21520 UCC27211 AUCC27211 AUCC27517 AINA240IB_HSISO3082 ISO1541 ISO1050 CSD19536 TMP300 OPA376lB_LSIB_HSVB_senseRS-485I2 CCANAMC1301 OPA376C2000 TMDigital Signal ProcessorTMS32 OF28033 TIDA-01159 TIDA-01159 TLV1117-50+12V_ISO+5V_ISOLM4041A12 TLV1117-33+ VTPS62160+5 V+12 VTIDA-01141+-TIDA-01281 Copyright 2017, Texas Instruments Incorporated1 TIDUD04 June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93% Efficiency, IsolatedBidirect ionalDC-DCConverterReferenceDesignforUPS TI Designs:TIDA-009512-kW,48- to 400-V,>93% Efficiency, IsolatedBidirection alDC-DCConverterReferenceDesignfor UPSD escriptionThe TIDA-00951designprovidesa referencesolutionfor a 2-kWisolatedbidirectionalDC-DCconverterc apableof powertransferbetweena 400-VDC busand a 12- to 14-cellLithiumbatterypackfor use inUPS,batterybackupand TI Designworksas a >93%efficient,currentfed.

2 Activeclampedboostconverterwith ZVSin thebackupmodeand voltagefed full-bridgebatterchargerwith >93%efficiencyin the TIDesignhas built-inprotectionfor DC bus overcurrentand overvoltageand E2E ExpertsFeatures DigitallyControlledIsolatedBidirectional DC-DCConverter Operatesas ActiveClampedFull BridgeBoostConverterWithZVSFor All Low-VoltageSwitchesat HighLoads Operatesas ActiveClampedVoltageFed BuckConverterWithSynchronousRectificatio ntoImproveEfficiencyWhenChargingBattery WideOperatingRangeFrom36- to 60-VBatteryand 300-to 400-VDC Bus CostOptimizedDesignUsing100-VFET on Low-VoltageSide,EliminatesRequirementfor ParallelingMultipleFETsup to 2 kW Built-inColdStartProcedureand FastModeTransfer(< 100 S) FromBatteryChargertoBackupPowerSupply OnboardIsolatedCommunicationInterfaceforCAN,I2C, and RS-485 Applications ServerPSUsand TelecomRectifiers UninterruptiblePowerSupplies(UPS) IndustrialPowerSupplies BatteryChargers EnergyStorageSystemsGrid PowerPFCC onverterDC-ACInverterPower ConditionerSolar Power, Wind Power, and Fuel CellsElectric/Electronic Devices (DC Input)Electric/Electronic Devices (AC Input) Bidirectional DC-DCConverterRechargeable Battery (48 V)DischargeChargePower Supply during blackouts or peak cut timeNormal Power SupplyDC BUS300 TO 400 VCopyright 2017, Texas Instruments June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48-to400-V,>93% Efficiency, IsolatedBidirectionalDC-DC ConverterReferenceDesignforUPSAn IMPORTANTNOTICEat the end of this TI referencedesignaddressesauthorizeduse, intellectualpropertymattersand otherimportantdisclaimersand DC inverters,homeinverters,industrialDC-UPS ,and energystoragebanksrequirean exchangeof powerfromthe batteryto the load and vice batterybackupis shownin Figure1:Figure1.

3 Top-LevelArchitectureof TypicalUPSS ystemDuringnormaloperation,the mainDC bus is regulatedbetween300 and 400 V throughthe grid sourceofa building,factory,or ,the DC bus can be poweredthrougha renewableenergysourcesuchas solarpowergenerationor windpowergeneration,whichis conditionedthrougha powerconditionerto feedthe DC bus. The batteryacts as an energystorageunit, and it can be chargedeitherthroughthe grid or an ,charginga batterythrougha DC bus and dischargingthe batteryduringpowerblackoutsare implementedwith two unidirectionalconverters,eachprocessingt he powerin one compactand efficientpowersystems,thereis increasinginterestin usingbidirectionalconverters,especiallyi n DC inverters,homeinverters,and ,capableof bilateralpowerflow,providesthe functionalityof twounidirectionalconvertersin a TIDA-00951designis an isolatedbidirectionalDC-DCconverterdesig nedto exchangethe powerbetweena 300-to 400-VDC Bus and designhas a full-bridgepowerstageon thehigh-voltage(HV)side,whichis isolatedfroma current-fedfull-bridgestageon the low-voltage(LV) presenceof the DC bus (normalconditions)

4 ,the designoperatesin buckmodeand chargesthe batterywith constantcurrentuntil the batteryvoltageis in ,thedesignoperatesas the current-fedfull-bridgeconverterto boostthe powerfroma 48-Vbattery(36- to60-Vinput)to the 380-VDC bus and supportsthe load with transitionor changeovertime fromthe chargeto backupmodeis very criticalfor ensuringcontinuityof powerto the TIDA-00951has transitiontime of less than100 s, whichreducesthe amountof bulk capacitanceneededfor the systemto providepowerduringthe TI Designoperatesat peakefficiencyof 93%in buckmode(as charger)and 94%in boostmode(duringdischarge).The high dischargeefficiencyprovidesa high run time fromthe ahigh switchingfrequencyof 100 kHz,the designhas a compactformfactorof 185 mm 170 mm for thepowerlevelof 2 TIDA-00951designis optimizedfor componentcount,cost,and designlike regulation, Efficiency, outputripple,trans itiontime,startup,and switchingstressacrossthedeviceswereteste dand documentedin the June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93%Efficiency, SystemSpecificationsTable1.

5 Key SystemSpecificationsPARAMETERTESTCONDITI ONSMINNOMMAXUNITBACKUPSUPPLYMODEINPUTCON DITIONSI nputbatteryvoltage(VBAT) (IBAT_MAX) 60 AOUTPUTCONDITIONSO utputbus voltage(VBUS) current(IBUS_MAX)VBAT> 40 V 5 ALine regulation 1%Loadregulation10%to 100%load 1%Outputvoltageripple Inputvoltageripple Averageefficiency20%to 100% %Full load efficiency %BATTERYCHARGERINPUTCONDITIONSI nputbus voltage(VBUS) current(IBUS_MAX) 60 AOUTPUTCONDITIONSO utputbatteryvoltage(VBAT) (IBAT) 16 ASYSTEMSPECIFICATIONSO peratingambient 102555 CBoardsizeLength Width Height185 173 8mm36- 60-V 300- to 400-V DCT1SN6505 BSN6505 BUCC21520 UCC21520 UCC27211 AUCC27211 AUCC27517 AINA240IB_HSISO3082 ISO1541 ISO1050 CSD19536 TMP300 OPA376lB_LSIB_HSVB_senseRS-485I2 CCANAMC1301 OPA376C2000 TMDigital Signal ProcessorTMS32 OF28033 TIDA-01159 TIDA-01159 TLV1117-50+12V_ISO+5V_ISOLM4041A12 TLV1117-33+ VTPS62160+5 V+12 VTIDA-01141+-TIDA-01281 Copyright 2017, Texas Instruments June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93%Efficiency.

6 Showsthe high-levelblockdiagramof the DC-DCconverteris madeof acurrent-fedfull-bridgeconverteron the batteryside and a full-bridgeon the 380-Vbus controlofthe systemis throughthe C2000 presenton the TIDA-01159isolatedgatedrivercardis usedto drivethe full bridgeon the 380-Vbus BlockDiagramof TIDA-0951referencedesignfeaturesthe followingdevices,whichwereselectedbasedo n key featuresof the highlightedproductsare mentionedin the moreinformationon eachof thesedevices,see theirrespectiveproductfoldersat clickon the linksfor the productfoldersin the CSD19536 KCSis a 100-VNexFET MOSFEThas a very low RDSONof m with an ultra-lowQgand Qgdof 118 nC and 17 nC, the TIDA-00951design,five of theseMOSFET sare usedon the batteryside or LV side to formthe LV full bridgeand the LV FETis turnedon at ZVSat high loads,the RDSON parameterbecomesimportantin determiningthe loss on CSD19536 KCSwas chosenfor its very low June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93%Efficiency, UCC27211 Ais a robust120-Vhalf-bridgegatedrivercapableo f deliveringup to a 4-A sourceandsink currentfor low pullupand pulldownresistances,this devicereducesthe transitiontime of the powerMOSFET throughthe Millerregion,whichminimizesthe switchingloss on the deviceis a robusthalf-bridgegatedrivewith inputpins capableof toleratingupto a TI Designtakesadvantageof this device s abilityto minimizethe switchingloss on the powerMOSFETon the LV side at turnoffto operateat a high switchingfrequencyof 100 kHzper this driverfromthe devicedatasheet(SLUSBL4).

7 SN6505 Bis a low-noise,low-EMIpush-pulltransformerdri ver,specificallydesignedfor smallformfactor, driveslow-profile,center-tappedtransform ersfroma 5-V EMI are achievedby slewrate controlof the outputswitchvoltageandthroughspreadspect rumclocking(SSC).The SN6505consistsof an oscillatorfollowedby a gatedrivecircuitthat providesthe complementaryoutputsignalsto deviceincludestwo 1-A Power-MOSFET switchesto switchingclockcan also be providedexternallyfor accurateplacementof switcherharmonicsor whenoperatingwith internalprotectionfeaturesincludea ,undervoltagelockout,thermalshutdown,and SN6505 Bincludesa soft-startfeaturethat preventshigh inrushcurrentduringpowerup with largeload OP376familyof low-noiseoperationalamplifiers(op amp)with e-trimoffersoutstandingDC precisionand AC OPA376is singleop ampwith rail-to-railinputand output,low offset(25 Vmax),and an abilityto operatewith common-modevoltagesup to 100 mV belowthe noise( nV/ Hz)

8 , a quiescentcurrentof 950 A max,and a bandwidthof MHzmakethis part a goodfit forthis TI the TIDA-00951,the OPA376is usedfor low-sidebidirectionalcurrentsensing,wher elow offsetvoltageand high gain bandwidthproductare importantin minimizingthe LM4041-Nis a precisionvoltagereference,whichgivesa LM4041-N device s advanceddesigneliminatesthe needfor an externalstabilizingcapacitorwhileensurin gstabilitywith any capacitiveload,whichmakesthe LM4041-Neasyto use. Curvaturecorrectionin theband-gapreferencetemperaturedrift and low-dynamicimpedanceensurestablereverseb reakdownvoltageaccuracyovera widerangeof operatingtemperaturesand is usedtoprovidea precisereferenceoffsetvoltageto the currentsenseamplificationcircuit(basedon the OPA376)to TIDA-01281is a TSM320F28033-basedcontroland acts as thecontrolcardfor the TMS320F28033presenton-boardsamplesthe variousvoltagesand currentson the TIDA-00951boardand generatesthe controlsignalsand PWMrequiredforproperfunctioningof the the boardalso containsisolatecommunicationinterfaceICs for implementingisolatedI2C, CANand TIDA-01141is a bidirectionalhigh-sidecurrentsensingcard basedon the INA240is a voltageoutputcurrentsenseamplifierwith an operatingwith a common-modevoltagefrom 4 to 80 V with a DC CMRRof 132 dB, thisdeviceis well suitedfor high-sidecurrentmeasurementin SMPSand June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93%Efficiency, TIDA-01159is an isolatedhalf-bridgegatedrivecardbasedon the UCC21520and isusedon the TIDA-00951to drivethe isolatedbidirectionalDC-DCconverterhas two majormodesof is workingas abackuppowersupply.

9 It operatesas an activeclampedcurrent-fedboostconvertertr ansferringpowerfromthe batteryto the 380-VDC bus. Whenoperatingas a batterycharger,the DC-DCconverterworksas a buckconvertertransferringpowerfromthe 380-VDC bus to the two majormodes,thereis an additionalmodefor the cold startingthe modeisusedto startup the TIDA-00951in casethe HV DC bus is workingof the isolatedbidirectionalDC-DCconverterdesig nis detailedin the boostmode,the systemneedsto boostan inputvoltagebetween36 to 60 V to a 380-VDC multipletopologiesthat can be consideredfor this TI ,the possibletopologiescan be classifiedinto voltage-or current-fedtopologieshaveaninputinductor ,whichis connectedto the ,a voltage-fedconverterconnectstheinputfilt er capacitorto the presenceof this inputinductorgivesthe followingbenefits: Boostedvoltagereducesthe stressin the transformerand betterutilization Avoidsflux imbalanceissuesin the powerstage Lowerstresson the inputfilter capacitorsdue to reductionin the currentrippledue to the inputinductorThe TIDA-00951worksas an activeclampedcurrent-fedfull-bridgeconve rterin severaladvantagesin usinga current-fedconverter,one primarydisadvantageis the hugespikein the current-fedconverterat turnoffrequiressomeformof snubbingusingeitheran activeor the TIDA-00951design,an activeclampcompromisingof a capacitorand a MOSFEThas beenusedtoimplementan advantageof this activeclampis that not only doesit recovertheleakageenergy,but it also helpsin achievingZVSfor the primaryLV MOSFETat turnon,therebyreducingthe a batterycharger,the TIDA-00951worksas a transferspowerfromthe HV DC bus and chargesthe batteryin constant-current/constant-voltage(CC/CV)

10 Modewith a currentlimit of 16 followingtwo sectionsexplainhow the converterin the to 60-V DC300- to 400-V DCQclampL1 CclampC1C2Q8Q7Q9Q6C1Q4Q1Q3Q2T1 Copyright 2017, Texas Instruments June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93%Efficiency, :ActiveClampThe powerstageof the TIDA-00951is shownin PowerStageof TIDA-00951 The switchesQ1 to Q4 are the switchesQ6 to Q9 formthe capacitorCclampand switchQclampformthe systemworksas a current-fedfull bridge,transferringpowerfromthe batteryto the DC bus, theactiveclampstoresthe additionalleakageenergywhenthe MOSFETQ1 to Q4 turnoff,therebylimitingthe turnoffspikeon the ,by controllingthe switchingof the MOSFETQ5, theprimaryLV MOSFETcan be turnedon in or closeto 0 V, therebyreducingthe 2017, Texas Instruments June2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporated2-kW,48 -to400-V,>93% Efficiency, IsolatedBidirect ionalDC-DCConverterReferenceDesignforUPS The modalityof implementingthis schemeis shownin ActiveClampWaveformsTakethe switchpair Q1 and Q3 as an exampleto describethe workingof the Q1 to Q3 turn off.