STDES-6KWHVDCDC

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6 kW high voltage DC-DC converter for EV charging

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Product overview

Description

The STDES-6KWHVDCDC reference design is a 6 kW high voltage DC-DC converter mainly for battery charging in an EV infrastructure.

The reference design consists of a full bridge LLC resonant converter, digitally controlled.

For the output rectification, SiC diodes have been used. Depending on the output voltage requirement, the LLC transformer output configuration is interchangeable between center tapped and full-wave.

This results in frequency fold-back that increases efficiency by a wide margin over an entire output voltage range.

The dual transformer variant is more suited for limited output voltage: 200-500 or 500-1000 V depending on the secondary winding scheme. This scheme also uses smaller cores. The single transformer variant is usable for 200-1000 V with the frequency foldback scheme.

STW40N95DK5 MDmesh DK5 Power MOSFETs are used in the LLC stage while STPSC40H12CWL SiC diodes are used in rectification. The STM32G474RET6 MCU manages the control functions.

The auxiliary power supply is referred to a secondary GND to supply MOSFET gate driver, microcontroller, and signal conditioning.

The gate driving of LLC MOSFETs is isolated through a gate drive transformer in addition to the PM8834MTR gate driver ICs.

Formal testing and measurement results confirm the ability of performance ST power products combined with comprehensive digital control to deliver high efficiency across wide input voltage and load conditions.

  • All features

    • 6 kW high voltage DC-DC converter based on fully digital LLC topology
    • 2 variants: dual transformer (smaller core) for limited voltage, single transformer for wide output
    • Same PCB to accommodate different magnetics for each variant
    • Unique patented control scheme to address output voltage ranging from 200–1000 V DC, with 12 A maximum limit
    • 700–800 V DC input voltage range
    • Peak efficiency: 98%
    • Digitally controlled, based on STM32G474 microcontroller
    • Comprehensive safety mechanism

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The current status of a product:
Active: Product is in volume production
Evaluation: Product is under characterization. Limited Engineering samples available
Preview: Product is in design stage
Target: Product is in design feasibility stage.No commitment taken to produce
Proposal: Marketing proposal for customer feedback.No commitment taken to design or produce
NRND: Not Recommended for New Design.Product is in volume production only to support customers ongoing production.
Marketing description of the package type.Compliancy of the device with industry requirement domains (IRD)The RoHS status of a product:
ECOPACK 1: Initial grade to identify European RoHS compliant products.
ECOPACK 2: New grade to identify brominated chlorinated and antimony oxide flame retardant free products.
ECOPACK 3: Halogen free RoHS exemptions free products.
(*): ECOPACK 2 version available upon request.
(**): Some versions still existing in ECOPACK 1 or not compliant.
Compliancy with WEEE Directive (2012/19/EU)The current status of a product:
Active: Product is in volume production
Evaluation: Product is under characterization. Limited Engineering samples available
Preview: Product is in design stage
Target: Product is in design feasibility stage.No commitment taken to produce
Proposal: Marketing proposal for customer feedback.No commitment taken to design or produce
NRND: Not Recommended for New Design.Product is in volume production only to support customers ongoing production.
Budgetary PriceMain country of assembly or fabrication of the product.ECCNs are five character alpha-numeric designations used on the Commerce Control List to identify dual-use items for export control purposes. ECCNs are five character alpha-numeric designations used on the Commerce Control List to identify dual-use items for export control purposes.