Complete 30kW EV Charger Power Module
According to market analysis, DC fast chargers are expected to account for 33 percent of the public charger market share by 2034, so the DC fast charging market has a promising future. ST's 30kW power module solution for EV chargers includes the STDES-30KWVRECT, a reference design for a digitally-controlled 30 kW Vienna PFC rectifier. This design introduces a complete digital power solution for high-power three-phase active front-end (AFE) rectifier applications based on the three-level Vienna topology.
With the SCTWA90N65G2V-4 and STPSC40H12C, the platform achieves a peak efficiency of more than 98.5 percent. It features a fully digital control with the STM32G474RE mixed-signal, high-performance microcontroller, which can provide full control over power factor, DC voltage and soft-start programs. The STDES-30KWVRECT achieves low total harmonic distortion (THD less than 5% at full load) and high power factor (above 0.99 at full load) while providing high-bandwidth continuous conduction mode (CCM) current regulation.
This reference design includes a three-phase, three-level AC-DC power converter supporting 800 V DC voltage ratings, 400 V AC voltage ratings, featuring a maximum power of 30 kW, a power factor greater than 0.99, and a THD of less than 5 percent at surge control and soft-start rated operation.
The SiC MOSFET and SiC diode-based power section supports 70 kHz high-frequency operation with greater than 98.5% higher efficiency, and parallel SiC MOSFETs provide higher power and balanced shared current, reducing the weight and size of the passive components. Based on STM32G474RE microcontroller control section, including SWD-UART, I²C and DAC control and monitoring interfaces, as well as 64-pin digital power connector, LED status can be used as a user interface, four integrated high-performance operational amplifiers can provide more functions.
ST also introduces a 30 kW SiC MOSFET DC-DC converter using the STM32G4 for use in electric vehicle chargers. This DC charging module with digital control 30 kW three-phase LLC reference design (STDES-30KWLLC) has a rated output power of 30 kW, a switching frequency of 100-300 kHz, and supports DC input voltages of 650 VDC - 850 VDC with 200 VDC - 1000 VDC output with peak efficiency greater than 98%. It has a built-in STM32G474, a high-performance 32-bit MCU with PFM operation mode, and the inputs have under-voltage protection, over-voltage protection, and over-current protection, and the outputs support over-voltage protection and over-current protection functions.
This converter is based on a 1200 V SiC component and a high switching frequency for higher efficiency, using fewer SiC MOSFETs to achieve higher power from a single LLC converter with a wide range and high output voltage.
ST's other 30 kW three-phase Vienna rectifier for EV charging stations features a three-phase 345 VAC to 460 VAC, 47 Hz to 63 Hz input AC voltage, a maximum input voltage of 55 ARMS, a DC output voltage of 800 VDC, a rated output power of 30 kW, a switching frequency of 70 kHz, a peak efficiency of greater than 98.7 percent, and a full-load power factor of 0.99 at full load, THD of less than 5%, and a built-in STM32G474 high-performance 32-bit MCU. This 30 kW three-phase Vienna rectifier is a SiC component-based solution for higher efficiency with very low THD (Total Harmonic Distortion), higher reliability and low design complexity.
ST's other 60 kW three-phase shunt LLC with digitally controlled warm-up has a 650 VDC - 850 VDC DC input voltage, 200 VDC - 1000 VDC DC output, rated output power of 60 kW, peak efficiency of greater than 98%, and a built-in STM32G474 high-performance 32-bit MCU, which is a SiC component-based solution for higher efficiency, and parallel LLC using fewer SiC MOSFETs to achieve higher power with a wide range and high output voltage.
ST's STM32G4 and SiC-based solutions will help realize high-performance EV chargers, including total PFC and DCDC solutions that enable high-power EV chargers. ST also provides customers with a complete range of advanced components (SiC MOSFETs, SiC diodes, STGAP, STM32), and the 30 kW three-phase solution achieves 98% peak efficiency at 160 kHz 700 Vout half load.
