TIDUES0E June   2019  – April 2024 TMS320F28P550SJ , TMS320F28P559SJ-Q1

 

  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. 1System Description
    1. 1.1 Key System Specifications
  8. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 Highlighted Products
      1. 2.2.1  UCC21710
      2. 2.2.2  UCC14141-Q1
      3. 2.2.3  AMC1311
      4. 2.2.4  AMC1302
      5. 2.2.5  OPA320
      6. 2.2.6  AMC1306M05
      7. 2.2.7  AMC1336
      8. 2.2.8  TMCS1133
      9. 2.2.9  TMS320F280039C
      10. 2.2.10 TLVM13620
      11. 2.2.11 ISOW1044
      12. 2.2.12 TPS2640
    3. 2.3 System Design Theory
      1. 2.3.1 Dual Active Bridge Analogy With Power Systems
      2. 2.3.2 Dual-Active Bridge – Switching Sequence
      3. 2.3.3 Dual-Active Bridge – Zero Voltage Switching (ZVS)
      4. 2.3.4 Dual-Active Bridge - Design Considerations
        1. 2.3.4.1 Leakage Inductor
        2. 2.3.4.2 Soft Switching Range
        3. 2.3.4.3 Effect of Inductance on Current
        4. 2.3.4.4 Phase Shift
        5. 2.3.4.5 Capacitor Selection
          1. 2.3.4.5.1 DC-Blocking Capacitors
        6. 2.3.4.6 Switching Frequency
        7. 2.3.4.7 Transformer Selection
        8. 2.3.4.8 SiC MOSFET Selection
      5. 2.3.5 Loss Analysis
        1. 2.3.5.1 SiC MOSFET and Diode Losses
        2. 2.3.5.2 Transformer Losses
        3. 2.3.5.3 Inductor Losses
        4. 2.3.5.4 Gate Driver Losses
        5. 2.3.5.5 Efficiency
        6. 2.3.5.6 Thermal Considerations
  9. 3Circuit Description
    1. 3.1 Power Stage
    2. 3.2 DC Voltage Sensing
      1. 3.2.1 Primary DC Voltage Sensing
      2. 3.2.2 Secondary DC Voltage Sensing
        1. 3.2.2.1 Secondary Side Battery Voltage Sensing
    3. 3.3 Current Sensing
    4. 3.4 Power Architecture
      1. 3.4.1 Auxiliary Power Supply
      2. 3.4.2 Gate Driver Bias Power Supply
      3. 3.4.3 Isolated Power Supply for Sense Circuits
    5. 3.5 Gate Driver Circuit
    6. 3.6 Additional Circuitry
    7. 3.7 Simulation
      1. 3.7.1 Setup
      2. 3.7.2 Running Simulations
  10. 4Hardware, Software, Testing Requirements, and Test Results
    1. 4.1 Required Hardware and Software
      1. 4.1.1 Hardware
      2. 4.1.2 Software
        1. 4.1.2.1 Getting Started With Software
        2. 4.1.2.2 Pin Configuration
        3. 4.1.2.3 PWM Configuration
        4. 4.1.2.4 High-Resolution Phase Shift Configuration
        5. 4.1.2.5 ADC Configuration
        6. 4.1.2.6 ISR Structure
    2. 4.2 Test Setup
    3. 4.3 PowerSUITE GUI
    4. 4.4 LABs
      1. 4.4.1 Lab 1
      2. 4.4.2 Lab 2
      3. 4.4.3 Lab 3
      4. 4.4.4 Lab 4
      5. 4.4.5 Lab 5
      6. 4.4.6 Lab 6
      7. 4.4.7 Lab 7
    5. 4.5 Test Results
      1. 4.5.1 Closed-Loop Performance
  11. 5Design Files
    1. 5.1 Schematics
    2. 5.2 Bill of Materials
    3. 5.3 Altium Project
    4. 5.4 Gerber Files
    5. 5.5 Assembly Drawings
  12. 6Related Documentation
    1. 6.1 Trademarks
  13. 7Terminology
  14. 8About the Author
  15. 9Revision History

4.2 Test Setup

To test the efficiency of this reference design, use the setup shown in Figure 4-7.

  • 10-kW DC power supply: 800 V, 12.5 A
  • 10-kW resistive load: 500 V, 20 A
  • Auxiliary power supply to provide 12 V, 2 .5 A
  • TMDSCNCD280039C control card
  • Power Analyzer
  • Oscilloscope with isolated probes for voltage and current
  • 12-V fans to provide sufficient airflow to the heat sinks
TIDA-010054 Test Setup Figure 4-7 Test Setup
TIDA-010054 Board Image Figure 4-8 Board Image

Before powering the board to perform open-loop testing, use the following steps to set up the board:

  1. Connect the terminals J11 and J13 to the input power supply and terminals J12 and J14 to the output load bank. Use a 4-mm2 wire to make these connections so that the wire can handle high currents without getting heated quickly.
  2. Connect the auxiliary power supply to terminal J15 using a PJ-002 female connector to power the controller, gate driver, and sense circuits

There is a cut-out area provided at the center of the board to mount the transformer. The transformer is directly connected to the board using M3 screws. Take care while mounting the transformer so that the primary and secondary sides are not interchanged.

The control card is programmed using a USB connection from the laptop to generate PWM pulses at 100 kHz. Once programmed, the auxiliary power supply is set to 12 V. Do not apply voltage across terminals J2 and J4. In this state the current consumption on the 12-V rail is supposed to be approximately 700 mA. This consumption increases after relays are closed and fans are enabled.

Connect two 12-V fans to the fan connectors J1 and J3. The polarity is marked on the PCB and in the schematics.

Follow Lab 1 to Lab 7 to get familiar with the design and provide proper operation.

CONNECTOR TERMINALS FUNCTION COMMENTS
J11–J13 Input high-voltage power supply 800-V DC power supply capable of sourcing 10-kW power
J12–J14 Output load terminals 10-kW resistive load bank is connected here
J15 Auxiliary power supply for gate driver, control card, and sense circuits 15-V DC power supply current limited to 700 mA
J2 TMDSCNCD280049C Control card Insert the control card here
J6 CAN Connector Not supported in current revision
J1, J3 Fan connector 12-V fan connectors for cooling