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

In Figure 4-12, around 4.4kW output power was sourced from 400V DC-link to 230VAC. The line voltage is present in yellow and the line current in pink color respectively. Notice that no important current ripple is injected into the resistor. The figure also shows the DC-link power ripple present at 100Hz in green color.

C1 - Output voltage, C2 - Output current, C4 - DC bus voltage

TIDA-010938 DC/AC Line Voltage, Line Current and DC Bus VoltageFigure 4-12 DC/AC Line Voltage, Line Current and DC Bus Voltage

Figure 4-13 and Table 4-4 show the overall efficiency converting from DC Bus to 230VAC output. The results are discussed for comparison of all three modulation schemes, H-Bridge in unipolar, H-Bridge in bipolar and HERIC modes.

The table shows that the reference design in H-Brideg Unipolar mode achieves a ηpeak = 98.4% at approximately 2.4kW and 400V input, ηfull-load of 98.2% and ηCEC = 98.3% .

The table shows that the reference design in H-Brideg Bipolar mode achieves a ηpeak = 98.1% at approximately 2.8kW and 400V input, ηfull-load of 97.9% and ηCEC = 97.8%.

The table shows that the reference design in HERIC mode achieves ηpeak = 98.5% at approximately 2.4kW and 400V input, ηfull-load of 98.2% and ηCEC = 98.4%.

TIDA-010938 DC/AC Efficiency
                    Comparison Figure 4-13 DC/AC Efficiency Comparison
Table 4-4 DC/AC Efficiency
OUTPUT POWEREFFICIENCY FOR

H-BRIDGE UNIPOLAR

OUTPUT POWEREFFICIENCY FOR

H-BRIDGE BIPOLAR

OUTPUT POWEREFFICIENCY FOR

HERIC

0.2kW93.1%0.2kW92.7%0.1kW92.7%
0.4kW96.0%0.4kW95.9%0.4kW97.1%
0.8kW97.5%0.8kW97.2%0.8kW98.1%
1.2kW98.3%1.2kW97.7%1.2kW98.3%
1.6kW98.2%1.6kW97.9%1.2kW98.4%
2.0kW98.3%2.0kW98.0%1.6kW98.5%
2.4kW98.4%2.4kW98.0%2.0kW98.5%
2.8kW98.4%2.8kW98.1%2.4kW98.5%
3.2kW98.4%3.2kW98.0%2.8kW98.5%
3.5kW98.4%3.5kW97.9%3.2kW98.5%
3.9kW98.3%3.9kW97.9%3.4kW98.5%
4.1kW98.3%4.1kW97.9%3.6kW98.4%
4.3kW98.2%4.3kW97.9%4.0kW98.4%
4.5kW98.2%4.5kW97.8%4.2kW98.4%
4.3kW98.3%
4.5kW98.2%

Furthermore, the voltage of the switching node of the H-Bridge with Unipolar modulation scheme was measured as shown in Figure 4-14. Observe from the image that no important overvoltage was detected even when the switching was at 60kV / μs. A rise-time of around 6ns can be observed.

C1 - Line voltage, C2 - Line current, C3 - DC bus voltage, C4 - Switching node voltage

TIDA-010938 DC/AC Switching Node in H-Bridge UnipolarFigure 4-14 DC/AC Switching Node in H-Bridge Unipolar

The voltage of the switching node of the H-Bridge with Bipolar modulation scheme was measured as shown in Figure 4-15. Observe from the image that no important overvoltage was detected even when the switching was at 60 kV / μs. A rise-time of around 6.5ns can be observed.

C1 - Line voltage, C2 - Line current, C3 - DC bus voltage, C4 - Switching node voltage

TIDA-010938 DC/AC Switching Node in H-Bridge BipolarFigure 4-15 DC/AC Switching Node in H-Bridge Bipolar

The voltage of the switching node of the HERIC molulation scheme was measured as shown in Figure 4-16. From topology point of view, in HERIC mode, due to additional zero-voltage states in positive and negative half-cycles, the voltage across the FETs is also halved. So, we can see the switching node voltage rises from 200V to 400V. The other switching node in this scenario can be from 0V to 200V.

C1 - Line voltage, C2 - Line current, C3 - Switching node voltage, C4 -DC bus voltage

TIDA-010938 DC/AC Switching Node in HERICFigure 4-16 DC/AC Switching Node in HERIC

The Total Harmonic Distortion (THD) profiles for the corresponding modulation schemes can also be seen in Figure 4-17.

TIDA-010938 Total Harmonic Distortion for
                    DC/AC Figure 4-17 Total Harmonic Distortion for DC/AC

Furthermore, the junction temperature of the GaN FETs for the unipolar topology can be seen in Figure 4-18. The other H-Bridge GaNs have a similar temperature profile. This operation corresponds to a conversion of a DC-link voltage of 400V to 230V grid. It can be seen that the temperature does not go higher than 54°C.

TIDA-010938 GaN v/s Heatsink Temperature
                    for H-Bridge Unipolar Figure 4-18 GaN v/s Heatsink Temperature for H-Bridge Unipolar

The junction temperature of the GaN FETs for the bipolar topology can be seen in Figure 4-19. The other H-Bridge GaNs have a similar temperature profile. This operation corresponds to a conversion of a DC-link voltage of 400V to 230V grid. It can be seen that the temperature does not go higher than 70°C.

TIDA-010938 GaN v/s Heatsink Temperature
                    for H-Bridge Bipolar Figure 4-19 GaN v/s Heatsink Temperature for H-Bridge Bipolar

The junction temperature of the GaN FETs for the HERIC topology can be seen in Figure 4-20. The other H-Bridge GaNs have a similar temperature profile. This operation corresponds to a conversion of a DC-link voltage of 400V to 230V grid. The temperature does not go higher than 54°C.

TIDA-010938 GaN v/s Heatsink Temperature
                    for HERIC Figure 4-20 GaN v/s Heatsink Temperature for HERIC

In summary, both H-Bridge in unipolar modulation and HERIC are 3-level topologies which leads to lower switching losses across the FETs, compared to H-Bridge in bipolar modulation which is a 2-level topology. HERIC and H-Bridge in bipolar modulation have better common-mode rejection capabilities. Unipolar offers high common-mode voltage and for a transformer-less system such as the string inverter, this can lead to high leakage current. However, the unipolar is run at half the switching frequency and has doubled frequency at the output for a comparable EMI filter design. Hence, there are multiple points to consider when comparing the three topologies.