TIDUF64A December   2023  – August 2024

 

  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. 1System Description
    1. 1.1 Key System Specifications
    2. 1.2 PV Input with Boost Converter
    3. 1.3 Bidirectional DC/DC Converter
    4. 1.4 DC/AC Converter
  8. 2System Design Theory
    1. 2.1 Boost Converter
      1. 2.1.1 Inductor Design
      2. 2.1.2 Rectifier Diode Selection
      3. 2.1.3 MPPT Operation
    2. 2.2 Bidirectional DC/DC Converter
      1. 2.2.1 Inductor Design
      2. 2.2.2 Low-Voltage Side Capacitor
      3. 2.2.3 High-Voltage Side Capacitor
    3. 2.3 DC/AC Converter
      1. 2.3.1 Boost Inductor Design
      2. 2.3.2 DC-Link Capacitor
  9. 3System Overview
    1. 3.1 Block Diagram
    2. 3.2 Design Considerations
      1. 3.2.1 Boost Converter
        1. 3.2.1.1 High-Frequency FETs
        2. 3.2.1.2 Input Voltage and Current Sense
      2. 3.2.2 Bidirectional DC/DC Converter
        1. 3.2.2.1 High-Frequency FETs
        2. 3.2.2.2 Current and Voltage Measurement
        3. 3.2.2.3 Input Relay
      3. 3.2.3 DC/AC Converter
        1. 3.2.3.1 High-Frequency FETs
        2. 3.2.3.2 Current Measurements
        3. 3.2.3.3 Voltage Measurements
        4. 3.2.3.4 Auxiliary Power Supply
        5. 3.2.3.5 Passive Components Selection
    3. 3.3 Highlighted Products
      1. 3.3.1  TMDSCNCD280039C - TMS320F280039C Evaluation Module C2000™ MCU controlCARD™
      2. 3.3.2  LMG3522R030 650-V 30-mΩ GaN FET With Integrated Driver, Protection and Temperature Reporting
      3. 3.3.3  TMCS1123 - Precision Hall-Effect Current Sensor
      4. 3.3.4  AMC1302 - Precision, ±50-mV Input, Reinforced Isolated Amplifier
      5. 3.3.5  ISO7741 Robust EMC, Quad-channel, 3 Forward, 1 Reverse, Reinforced Digital Isolator
      6. 3.3.6  ISO7762 Robust EMC, Six-Channel, 4 Forward, 2 Reverse, Reinforced Digital Isolator
      7. 3.3.7  UCC14131-Q1 Automotive, 1.5-W, 12-V to 15-V VIN, 12-V to 15-V VOUT, High-Density > 5-kVRMS Isolated DC/DC Module
      8. 3.3.8  ISOW1044 Low-Emissions, 5-kVRMS Isolated CAN FD Transceiver With Integrated DC/DC Power
      9. 3.3.9  ISOW1412 Low-Emissions, 500kbps, Reinforced Isolated RS-485, RS-422 Transceiver With Integrated Power
      10. 3.3.10 OPA4388 Quad, 10-MHz, CMOS, Zero-Drift, Zero-Crossover, True RRIO Precision Operational Amplifier
      11. 3.3.11 OPA2388 Dual, 10-MHz, CMOS, Zero-Drift, Zero-Crossover, True RRIO Precision Operational Amplifier
      12. 3.3.12 INA181 26-V Bidirectional 350-kHz Current-Sense Amplifier
  10. 4Hardware, Software, Testing Requirements, and Test Results
    1. 4.1 Hardware Requirements
    2. 4.2 Note
    3. 4.3 Test Setup
      1. 4.3.1 Boost Stage
      2. 4.3.2 Bidirectional DC/DC Stage - Buck-Mode
      3. 4.3.3 DC/AC Stage
    4. 4.4 Test Results
      1. 4.4.1 Boost Converter
      2. 4.4.2 Bidirectional DC/DC Converter
        1. 4.4.2.1 Buck Mode
        2. 4.4.2.2 Boost Mode
      3. 4.4.3 DC/AC Converter
  11. 5Design and Documentation Support
    1. 5.1 Design Files
      1. 5.1.1 Schematics
      2. 5.1.2 BOM
    2. 5.2 Tools and Software
    3. 5.3 Documentation Support
    4. 5.4 Support Resources
    5. 5.5 Trademarks
  12. 6About the Authors
  13. 7Revision History

DC/AC Converter

Figure 1-2 shows a block diagram for the DC/AC stage. The inverter stage is bidirectional, enabling power conversion from DC stage to AC stage and vice versa. The topology is constituted by an H-Bridge with each group of diagonal switches operating at high frequency during one half-wave of output voltage. Additional switches placed in parallel to the grid allows an additional voltage-level across the output filter making this power conversion system a three-level topology, thus reducing the switching losses and COSS losses across the FETs. This also enables constant common-mode voltage leading to negligible leakage current since the PV input stage is decoupled from the AC grid in the freewheeling phase.

TIDA-010938 DC/AC Converter Block
                    Diagram Figure 1-5 DC/AC Converter Block Diagram

This topology is a good choice for transformer-less string inverter applications where there is no isolation available between the AC grid and the PV panels. The common-mode currents are a well-known challenge in PV applications due to PV surfaces exposed over grounded roof or other surfaces in the proximity. The large surface areas can lead to high values of stray capacitance between the PV panel and ground, which can go as high as 200nF / kWp in damp environments or on rainy days, as seen in Figure 1-6. This parasitic capacitance can cause high common-mode current flowing into the system when common-mode voltage of the converters is not well mitigated and can lead to EMI and issues such as grid current distortion.

TIDA-010938 PV Panel Parasitic
                    Capacitance Figure 1-6 PV Panel Parasitic Capacitance

Microinverters containing transformers present high impedance return path for current, however, that is not the same case with cost-sensitive applications such as string inverters. String inverters usually present low impedance paths for return currents, hence leading to very high values of currents as shown in Figure 1-7. The leakage currents to the ground thus constitute an important issue in transformer-less concepts. Special single-phase transformer-less topologies with reduced oscillations can be implemented for such purposes and is later discussed. In addition, the introduction of frame-less panels further contributed to the reduction of such problems.

TIDA-010938 Common-Mode Noise Figure 1-7 Common-Mode Noise

This DC/AC converter stage is operated at a high switching frequency of 87kHz for sinusoidal grid current control, thus allowing the EMI filter design to be compact. With the signle-phase 230VRMS grid, an output power of 4.6kW can be achieved with an output current of 20ARMS. The EMI filter is composed of a boost inductor split between both rails for better common-mode rejection capability, two common-mode chokes, Cx capacitors, and Cy capacitors. The EMI filter has been designed to attenuate both the differential-mode and common-mode noise injected into the grid. Additionally, electrolytic capacitors are present at the DC- link to compensate for the 100Hz power ripple present in such single-phase applications. Note that both of the half-bridges need to have a dead-time to avoid shoot-through. The current in the grid is measured and then controlled by the MCU using Proportional Resonant (PR) controllers. High-accuracy measurement of the current flowing in the Point of Common Coupling (PCC) is required to control active and reactive power. The current control requires the implementation of a Phase Locked Loop (PLL) which is synchronized with the grid voltage frequency. A DC-link voltage control loop is used to control the amplitude of the active current sink or source from the grid.