starpower Solution 1

For a 150kW DC fast charger, we recommend a two-stage topology: (1) Input stage - Three-phase Vienna PFC using GDS100M12B1 SiC modules. This provides unity power factor and 800V DC bus voltage with high efficiency. (2) DC-DC stage - Dual-active bridge (DAB) or LLC resonant converter using GDS100M12B1 for isolation and voltage regulation. This topology achieves >98% efficiency with SiC modules. Alternative: Use IGBT modules (GD100HFL120C2S) for cost-sensitive applications with slightly lower efficiency (~97%). The Vienna PFC + LLC combination offers the best balance of efficiency, power density, and cost for this power level.

Contact our FAE team for detailed topology analysis and design optimization for your specific requirements.

Gate drive design for Starpower SiC modules requires careful attention: (1) Voltage levels: Use +18V turn-on and -3V to -5V turn-off. The negative voltage is critical for dv/dt immunity. (2) Gate resistance: 5-10Ω for turn-on and turn-off to control switching speed and EMI. (3) Peak current: Gate driver must provide 5-10A peak current for fast switching. (4) Isolation: Use reinforced isolation (5kV+) due to high dv/dt. (5) Protection: Implement active Miller clamp and desaturation detection. (6) Layout: Minimize gate loop inductance (<10nH) with proper PCB design. Recommended drivers: 1EDI20N12AF, UCC21520, or 2EDF7275K. Starpower provides reference gate drive circuits in application notes.

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Thermal management for Starpower modules in EV chargers: (1) Heatsink selection: Target RthSA of 0.2-0.4K/W for 100A modules at full load. (2) Thermal interface: Use high-performance TIM with 0.1-0.2K·cm²/W thermal resistance. (3) Cooling method: Forced air cooling typically required

liquid cooling for high ambient temperatures. (4) Temperature monitoring: Use NTC thermistor integrated in module for over-temperature protection. (5) Thermal derating: Plan for 80% current rating at 60°C ambient. (6) Thermal simulation: Use Starpower's thermal models to verify design. Example: GDS100M12B1 at 100A produces ~120W loss

with RthJC=0.4K/W and RthSA=0.3K/W, Tj = Ta + 120W × (0.4+0.3+0.1) = 40°C + 96°C = 136°C (acceptable).

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Bidirectional operation for V2G using Starpower modules: (1) Topology: Use dual-active bridge (DAB) or CLLC resonant converter which are naturally bidirectional. (2) Control: Implement synchronous rectification on both sides with proper phase control. (3) Power flow: Control direction by adjusting phase shift between primary and secondary bridges. (4) Efficiency: Bidirectional operation maintains >97% efficiency in both directions with SiC modules. (5) Protection: Implement current limiting in both directions and DC bus voltage monitoring. (6) Grid synchronization: Ensure proper grid connection and anti-islanding protection for G2V operation. Starpower modules' fast switching enables efficient bidirectional power flow with minimal additional components.

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This solution includes a complete BOM with carefully selected power modules and components, thermal design guidelines, and application documentation.

Contact BeiLuo FAE team for personalized assistance.