2kW, 48V to 400V, >93% Efficiency, Isolated Bidirectional DC-DC Converter Reference Design for UPS

(ACTIVE) TIDA-00951

Description & Features

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Key Document

Description

The 2-kW isolated bidirectional DC-DC converter reference design (TIDA-00951) is capable of power transfer between a 400-V DC-BUS and a 12-14 cell lithium battery pack for use in UPS, battery backup and power storage applications. This reference design works as active clamped boost converter with ZVS in the backup mode, transferring power from the 48V battery to the 400V DC-BUS. Operating as a voltage fed full-bridge battery charger, this reference design enables you to achieve >93% efficiency when charging a 48V battery from the 400V DC BUS. This reference design also has built-in protection for DC BUS and battery overcurrent as well as overvoltage protection.

Features
  • Digitally controlled isolated bidirectional DC/DC converter
  • Operates as active clamp full bridge boost converter with ZCS turn on along with ZVS at high load for the low-voltage FET and ZVS for high-voltage switches
  • Wide operating range from 36- to 60-V battery and 300- to 400-V DC bus
  • Cost optimized design using 100-V FET on low-voltage side, eliminates need for paralleling multiple FETs up to 2kW
  • Fast mode transfer from battery charging to back-up mode in less than 100uS
  • Uses the TMS320F28033 digital controller present on the TIDA-01281 reference design for controlling the working
  • High side current sensing for monitoring the battery current based on the INA240 on-board the TIDA-01141 reference design
  • Uses the reinforced isolated gate-driver UCC21520 present in the TIDA-01159 design for driving the high voltage full-bridge

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Bill of Materials (BOM)

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TIDA-00951-SW:
Firmware for TIDA-00951 by Request


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TI Devices (14)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
AMC1301  Precision Reinforced Isolated Amplifier for Current Sensing  Special function amplifiers  Sample & Buy View Design Kits & Evaluation Modules
CSD19536KCS  100V, N-Channel NexFET™ Power MOSFET  MOSFETs  Sample & Buy Not Available
INA240  80V, Low-/High-Side, Bi-Directional, Zero-Drift, Current Sense Amp w/Enhanced PWM Rejection  Current sense amplifiers  Sample & Buy View Design Kits & Evaluation Modules
LM4041A12  1.2-V Precision Micropower Shunt Voltage Reference, 0.1% accuracy  Voltage references  Sample & Buy Not Available
OPA376  Precision, Low Noise, Low Iq Operational Amplifier  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
SN6505B  Low-Noise 1-A , 420kHz Transformer Driver for Isolated Power Supplies  Isolation  Sample & Buy View Design Kits & Evaluation Modules
SN74LVC126A  Quadruple Bus Buffer Gate With 3-State Outputs  Buffer/driver  Sample & Buy Not Available
TLV1117  Single Output LDO, 800mA, Fixed and Adj., Internal Current limit, Thermal Overload Protection  Power management  Sample & Buy View Design Kits & Evaluation Modules
TMP300  Resistor-Programmable, up to 18V-Capable Temp Switch and Analog Out Sensor  Temperature sensors  Sample & Buy Not Available
TMS320F28033  Piccolo™ 32-bit MCU with 60 MHz, 64 KB Flash, CLA  C2000 real-time control MCUs  Not Available View Design Kits & Evaluation Modules
TPS62160  3V-17V 1A Step-Down Converters with DCS-Control™  Step-down (buck)  Sample & Buy View Design Kits & Evaluation Modules
UCC21520  4A/6A, 5.7 kVrms Isolated Dual Channel Gate Driver  Gate Drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC27211A  120-V Boot, 4-A Peak, High Frequency High-Side and Low-Side Driver   Gate Drivers  Sample & Buy Not Available
UCC27517A  4A/4A Single Channel High-speed Low-side Gate Driver with 5V Negative Input Voltage Handling Ability  Gate Drivers  Sample & Buy Not Available

CAD/CAE symbols

Part # Package | Pins CAD File (.bxl) STEP Model (.stp)
AMC1301 Download -
CSD19536KCS Download
INA240 Download
Download
LM4041A12 Download Download
Download -
Download Download
OPA376 Download Download
Download Download
Download Download
SN6505B Download Download
SN74LVC126A Download Download
Download Download
Download -
Download Download
Download -
Download Download
TLV1117 Download Download
Download
Download -
Download Download
Download Download
Download -
TMP300 Download Download
Download Download
TMS320F28033 Download
Download
Download Download
TPS62160 Download Download
Download Download
UCC21520 Download Download
UCC27211A Download
UCC27517A Download

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Technical Documents

View the Important Notice for TI Designs covering authorized use, intellectual property matters and disclaimers.

User guides (1)
Title Abstract Type Size (KB) Date Views TI Recommends
PDF 3623 02 Jun 2017 615
Design files (6)
Title Abstract Type Size (KB) Date Views
PDF 114 27 Mar 2018 180
ZIP 1995 02 Jun 2017 32
ZIP 6563 02 Jun 2017 118
PDF 1699 02 Jun 2017 113
PDF 226 02 Jun 2017 78
PDF 676 02 Jun 2017 542

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