TIDA-00951

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

TIDA-00951

Design files

Overview

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

Industrial

A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

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Design guide — TIDA-00951

PDF | HTML

TIDUD04A.PDF (1880 K)

Reference design overview and verified performance test data

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Schematic — TIDA-00951

TIDRR65.PDF (676 K)

Detailed schematic diagram for design layout and components

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Bill of materials (BOM) — TIDA-00951

TIDRR66A.PDF (114 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

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Assembly drawing — TIDA-00951

TIDRR67.PDF (226 K)

Detailed overview of design layout for component placement

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CAD/CAE symbol — TIDA-00951

TIDRR69.ZIP (6563 K)

Files used for 3D models or 2D drawings of IC components

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Gerber file — TIDA-00951

TIDCDH6.ZIP (1995 K)

Design file that contains information on physical board layer of design PCB

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PCB layout — TIDA-00951

TIDRR68.PDF (1699 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Buck converters (integrated switch)

TPS62160 — 3V-17V 1A Step-Down Converters with DCS-Control™

Data sheet: PDF | HTML

C2000 real-time microcontrollers

TMS320F28033 — C2000™ 32-bit MCU with 60 MHz, 64 KB flash, 4.6 MSPS ADC, CLA

Data sheet: PDF

C2000 real-time microcontrollers

TMS320F28033-Q1 — Automotive C2000™ 32-bit MCU with 60 MHz, 64 KB flash, 4.6 MSPS ADC, CLA

Data sheet: PDF

Current sense amplifiers analog output

INA240 — -4 to 80V, bidirectional, ultra-precise current sense amplifier with enhanced PWM rejection

Data sheet: PDF | HTML

Half-bridge drivers

UCC27211A — 4-A, 120-V half bridge gate driver with 8-V UVLO and negative voltage handling

Data sheet: PDF | HTML

Isolated amplifiers

AMC1301 — ±250 mV-Input Precision Reinforced Isolated Amplifier for Current Sensing

Data sheet: PDF | HTML

Isolated gate drivers

UCC21520 — 5.7kVrms, 4A/6A dual-channel isolated gate driver w/ dual input, disable pin, 8V UVLO in DW package

Data sheet: PDF | HTML

Isolated gate drivers

UCC21540 — 5.7kVrms 4A/6A dual-channel isolated gate driver with dual inputs, DT pin & 8V UVLO in DW or DWK pkg

Data sheet: PDF | HTML

Linear & low-dropout (LDO) regulators

TLV1117 — 800-mA, 15-V, linear voltage regulator

Data sheet: PDF | HTML

Low-side drivers

UCC27517A — 4-A/4-A single-channel gate driver with 5-V UVLO and negative input voltage handling

Data sheet: PDF | HTML

N-channel MOSFETs

CSD19536KCS — 100-V, N channel NexFET™ power MOSFET, single TO-220, 2.7 mOhm

Data sheet: PDF | HTML

Noninverting buffers & drivers

SN74LVC126A — 4-ch, 1.65-V to 3.6-V buffers with 3-state outputs

Data sheet: PDF | HTML

Precision op amps (Vos<1mV)

OPA376 — Precision (0.025mV), low noise (7.5nV/rtHz), low quiescent current (760uA) op amp

Data sheet: PDF | HTML

Shunt voltage references

LM4041A12 — 1.2-V precision micropower shunt voltage reference with 0.1% accuracy

Data sheet: PDF

Temperature switches

TMP300 — Resistor-Programmable, up to 18V-Capable Temp Switch and Analog Out Sensor

Data sheet: PDF | HTML

Transformer drivers

SN6505B — Low-noise, 1-A, 420-kHz transformer driver with soft start for isolated power supplies

Data sheet: PDF | HTML

Technical documentation

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	Type	Title		Date
*	Design guide	2-kW, 48- to 400-V, >93% Eff., Isolated Bidi. DC/DC Converter Ref. Des. for UPS (Rev. A)	PDF \| HTML	Aug. 06, 2021
	Technical article	For efficiencies’ sake – how to integrate bidirectional power flow into your UPS design (part 2)		Sep. 19, 2017
	Technical article	For efficiencies’ sake – how to integrate bidirectional power flow into your UPS design (part 1)		Jun. 07, 2017

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