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User Guide 

5 of 46 

 Rev. 1.0  

2022-03-09 

48V Battery Switch Reference Design 

R 48V BATT Switch10

The kit at a glance

1

The kit at a glance

1.1

Scope of supply

The 48V battery switch reference design consists of 

Power board mounted on a heatsink 

Adaptor board in Arduino shield form factor 

XMC4700 Relax Kit Lite microcontroller board 

Flat ribbon cable for connecting the adaptor board to the power board 

Figure 1

48V battery switch power board on heat sink 

Figure 2

The 48V battery switch with control board 

Содержание R 48V BATT Switch10

Страница 1: ...teries with hall sensor and shunt based current measurement using the following Infineon components OptiMOS 5 Power Transistors IAUT300N08S5N011 and IAUZ40N10S5N130 48V dual channel high side MOSFET gate driver 2ED4820 EM with SPI Hall based current sensor TLE4972 AE35D5 Intended audience Users of the 48V battery switch reference design R 48V BATT SWITCH10 Reference Board Kit Product s embedded on...

Страница 2: ...omer The customer shall ensure that all Evaluation Boards and Reference Boards will be handled in a way which is compliant with the relevant requirements and standards of the country in which they are operated The Evaluation Boards and Reference Boards as well as the information provided in this document are addressed only to qualified and skilled technical staff for laboratory usage and shall be ...

Страница 3: ...ion and subsequently service the system Failure to comply may result in personal injury and or equipment damage Caution The evaluation or reference board contains parts and assemblies sensitive to electrostatic discharge ESD Electrostatic control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not follow...

Страница 4: ...ased current sensing 12 2 2 6 Hall based current sensor 14 2 2 7 Freewheeling 16 2 2 8 Microcontroller interface 17 2 3 Basic operation 18 2 3 1 Operating the switch via buttons and status LEDs 18 2 3 2 Operating the switch via command line interface 20 2 4 Configuration 23 3 System design 27 3 1 Power board 27 3 1 1 Power board schematics 29 3 1 2 Power board layout 30 3 1 3 Power board bill of m...

Страница 5: ...pply The 48V battery switch reference design consists of Power board mounted on a heatsink Adaptor board in Arduino shield form factor XMC4700 Relax Kit Lite microcontroller board Flat ribbon cable for connecting the adaptor board to the power board Figure 1 48V battery switch power board on heat sink Figure 2 The 48V battery switch with control board ...

Страница 6: ... and hall based current sensing with the TLE4972 AE35D5 on the high side The switch is controlled by a XMC4700 microcontroller kit which also provides a user interface via USB port Figure 3 Block diagram 1 3 Main features Bidirectional 48V battery switch for continuous currents up to 300 A Precharge path for capacitive loads e g DC Link capacitor EMC filter Passive freewheeling active freewheeling...

Страница 7: ...oard L x W x H Including heat sink 75 x 100 x 31 mm Board size adaptor board L x W x H 53 x 64 x 19 mm Operating voltage VBAT 24 54 V Maximum supply voltage Vmax 70 V Digital supply voltage VDD Provided by microcontroller kit 3 3 V Continuous Current Capability Imax Forced air cooling 300 A Combined MOSFET on state resistance RDSON typ 25 C 400 µW Precharge resistor Rprecharge 10 W Shunt resistanc...

Страница 8: ... is connected to the screw terminals marked LD and LD For driving high currents use properly sized cables and cable lugs Use a maximum 9 Nm mounting torque for tightening the nuts on the screw terminals Figure 4 Connecting supply and load Note Note Please ensure the right supply polarity as there isn t any reverse polarity protection implemented Connecting the microcontroller To connect the XMC470...

Страница 9: ...2 2 1 Power supply The kit requires two power supplies the battery voltage VBAT and the digital supply voltage VDD VBAT can be provided by a 48 V DC power source like a 48 V battery or a lab power supply It supplies the gate driver 2ED4820 EM and the power stage The digital supply voltage VDD is derived from the 3 3 V supply of the microcontroller kit which is powered via the USB connector VDD sup...

Страница 10: ...source resistors R9 R13 as well as equal trace length for each current branch in the layout Figure 7 Even current distribution by equal trace length for each current branch 2 2 3 Precharge circuit Figure 8 Precharge circuit Many loads on the 48V power domain have a big capacitance like a DC link capacitor or EMC filter at their input Switching onto an uncharged capacitor will cause a high inrush c...

Страница 11: ...calculated as 𝐸 1 2 𝐶𝑉2 1 2 10 𝑚𝐹 48 𝑉 2 11 52 𝐽 According to the specification the resistor can handle five times the rated power for five seconds This would amount to 5 7 W 5 s 175 J and should give us enough headroom for charging even bigger DC link capacitors A problem however might occur when there is a short circuit or a low ohmic load at the output of the switch and the precharge switch is ...

Страница 12: ...only by the inductance of the cables Assuming 1 m cable with an inductance of 1 µH the slewrate dI dt will be 48 A µs for a supply voltage of 48V dI dT V L The high current slew rate will lead to a voltage drop in the shunt inductance This is added to the voltage drop at the resistive part and introduces a measurement error According to the datasheet the parasitic inductance of the selected shunt ...

Страница 13: ...e 10 In this circuit the voltage across the capacitor is the arithmetic mean value of the two shunt voltages while the RC filter time constant remains the same Figure 10 Paralleled shunt resistors with parasitic impedance compensation The chosen shunt resistors don t have separate sense pins Instead there is only a recommendation in the datasheet on where to attach the sense lines to the footprint...

Страница 14: ...s The sensor itself actually measures the magnetic field caused by a current conductor Only in conjunction with that conductor or current rail it becomes a current sensor In our case the conductor is a short piece of PCB trace in the middle layer right below the sensor where all the load current is forced through The trace is only 3 mm wide but also only 1 mm short and 800 µm thick with a resistan...

Страница 15: ...connected to the adaptor board as shown in Figure 14 Figure 14 Connection of the current sensor programmer The hall sensor on each board is calibrated and set to the following values Table 4 TLE4972 AE35D5 Configuration Parameter Setting Value Output Mode Fully differential Sensitivity Range S2 46 5 mV mT OCD1 Threshold 6 389 A OCD2 Treshold 10 246 A Sensitivity single ended 2 4 mV A Sensitivity f...

Страница 16: ...on of the current sensor the solder jumper needs to be open because the OCD1 may be pulled low during calibration which would cause an unintended switch off via the SAFESTATEN signal 2 2 7 Freewheeling When the MOSFETs are switched off the sudden drop in current flow will induce a large voltage in the output inductance which pulls the output LD below ground potential LD To protect the switch MOSFE...

Страница 17: ...e Output 2 AOUT TLE4972 AE35D5 Analog Out 3 VDD_S TLE4972 AE35D5 Sensor Supply 4 OCD1 TLE4972 AE35D5 Overcurrent Detection Output 1 5 GND_S TLE4972 AE35D5 Sensor Ground 6 OCD2 TLE4972 AE35D5 Overcurrent Detection Output 2 7 NTC1 Thermistor 8 VLD_F Load Voltage 9 VBAT_F Battery Voltage 10 FW Freewheeling Gate of freewheeling MOSFET 11 SAF 2ED4820 EM SAFESTATEN Safe State Enable 12 INT 2ED4820 EM IN...

Страница 18: ...tch can be controlled by the buttons mounted on the XMC4700 Relax Lite Kit Several LEDs provide status and diagnosis information For extended configuration control and diagnosis there is a command line interface available see chapter 2 3 2 After power up or after a reset the microcontroller will load the driver configuration from the internal flash The configuration can be changed by the user see ...

Страница 19: ...ed precharge time to charge up the load capacitor When the precharge time is expired the power switch channel A is activated and the precharge path is switched off The status of the 2ED4820 EM outputs channel A power switch and channel B precharge path is displayed by the respective status LEDs on the adaptor board LED1 next to button 1 on the XMC Relax Lite Kit shows the status of channel A Switc...

Страница 20: ...mmunication The COM port gets assigned automatically when the USB cable to the XMC4700 Relax Lite Kit is plugged in To locate the COM port number on a Windows PC check the port assignment in the device manager Figure 21 The assigned virtual COM port number is shown in brackets next to the port named JLink CDC UART Port Figure 21 Locating the virtual COM port in the device manager Following setting...

Страница 21: ...igure 23 Welcome message As mentioned in the welcome message the command will list all available commands with a short explanation on how to use them Figure 24 Command Overview Arrow Keys The left and right arrow keys behave like the Delete or Space keys With the up and down arrow keys you can scroll through the last ten commands ...

Страница 22: ...and to avoid unintended switching with the wrong configuration The failure flag has to be cleared with the command cf clear failures before attempting to switch on The default configuration after reset most likely isn t the desired target configuration so it has to be reprogrammed any time the gate driver is enabled To avoid having to set every parameter individually the stored configuration see c...

Страница 23: ...h its name is printed in inverse font Reporting of changed bits The register content is constantly monitored for changes If a bit is set or cleared it will be reported Failure reporting In case of an interrupt or if the failure bit is set the diagnosis bits are checked and the failures are reported Figure 26 Example for reporting of failures and changed bits 2 4 Configuration Displaying the config...

Страница 24: ...settings for the gate driver 2ED4820 EM Table 7 Driver configuration settings Command Description Setting Value ovrt VBAT overvoltage auto restart time 0 10 µs 1 50 µs 2 200 µs 3 1 ms uvrt VBAT undervoltage auto restart time 0 1 ms 1 5 ms 2 20 ms 3 50 ms blk a b MOSFET voltage blank time 0 10 µs 1 20 µs 2 50 µs 3 100 µs flt a b MOSFET voltage filter time 0 0 5 µs 1 1 µs 2 2 µs 3 5 µs dsov a b Drai...

Страница 25: ...gain csag and the overcurrent detection threshold setting octh Table 8 shows the resulting values for a 50 µW shunt resistor The default factory setting is csag 6 and octh 2 which amounts in an overcurrent threshold of 413 A Table 8 Overcurrent threshold values vs csag and octh setting csag 0 csag 1 csag 2 csag 3 csag 4 csag 5 csag 6 csag 7 octh 0 660 A 440 A 330 A 264 A 210 A 189 A 165 A 138 A oc...

Страница 26: ...mand lc load configuration the saved configuration can be restored manually Restoring the factory settings To restore the default configuration for this switch use the command fc factory configuration Don t forget to save this configuration with the command sc to make it permanent Table 9 Factory configuration settings Command Description Setting Value ovrt VBAT overvoltage auto restart time 0 10 ...

Страница 27: ...User Guide 27 of 46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design 3 System design 3 1 Power board Figure 28 Power board dimensions ...

Страница 28: ...46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design Figure 29 Heatsink dimensions The heatsink is based on the SK 81 75 SA from Fischer Elektronik with a specified Rth of 2 5 K W ...

Страница 29: ...User Guide 29 of 46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design 3 1 1 Power board schematics Figure 30 Power board schematics ...

Страница 30: ...ection between the top layer and the copper core densly stitched microvias are used Since these microvias are copper filled by design SMD components can be soldered right on top of them providing an excellent electrical and thermal connection to the thick copper layer in the middle Figure 31 Power board PCB Layer Stack Between the mid layer and the bottom layer a thermal prepreg with a conductivit...

Страница 31: ...User Guide 31 of 46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design Figure 33 Power board middle layer Figure 34 Power board bottom layer ...

Страница 32: ...M188R71H224KAC 4 1 C6 220nF 805 Multilayer Ceramic Capacitor Kemet C0805F224K5RACTU 4 C7 C8 C9 C10 6 8nF CAPC160 8X90N CAP CERA 6 8nF 25V 10 X7R EIA 55 C to 125 C 0603 1608 SMD MuRata GCM188R71E682KA37 1 C11 2 2uF 805 CAP CERA 2 2uF 6 3V 10 X7R EIA 55 C to 125 C 0805 SMD Würth Elektronik 885012207001 1 D1 BAS16J 1 15 SOD323F SC 90 High Speed Switching Diode 100V Nexperia BAS16J 115 3 D2 D3 D4 18V ...

Страница 33: ...stor Vishay CRCW060347K0FK 1 R21 10R SMD Precision Power Wirewound SMD Resistor ARCOL RWS7 10R J 2 R32 R33 100uR 5931 RES STD 100uR 15W 1 300ppm K 65 C to 170 C 5931 SMD Vishay WSLP5931L1000FEA 1 R37 10k 603 NTC for Temperature Sensor MuRata NCP18XH103F03RB 1 U1 2ED4820 EM PG TSDSO 24 21 2 Channels High Side Gate Driver Infineon 2ED4820 EM 1 U2 TLE4972 AE35D5 PG TDSO 16 High precision coreless cur...

Страница 34: ...Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design 3 2 Adaptor board Figure 35 Adaptor board dimensions 3 2 1 Adaptor board schematics Figure 36 Adaptor board connector to power board ...

Страница 35: ... 35 of 46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design Figure 37 Adaptor board connectors to microcontroller Figure 38 Adaptor board current sensor programmer interface ...

Страница 36: ...ev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design Figure 39 Adaptor board analog input filters Figure 40 Adaptor board status LEDs Figure 41 Adaptor board hall sensor connection of OCD ...

Страница 37: ...ev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 System design 3 2 2 Adaptor board layout Figure 42 Adaptor board layer 1 TOP Figure 43 Adaptor board layer 2 GND Figure 44 Adaptor board layer 3 3V3 ...

Страница 38: ...C to 125 C 0603 1608 SMD Würth Elektronik 8 85012E 11 1 C6 100nF 603 CAP CERA 100nF 50V 10 X7R EIA 55 C to 125 C 0603 1608 SMD Kemet C0603C104K5RACAUT O 4 D1 D2 D3 D4 Green 603 EXCELED Series Chip LED Green 560nm ROHM Semiconduct ors SML D12P8WT86 1 D5 Red 1608 0603 EXCELED Series Chip LED Red 620nm ROHM Semiconduct ors SML D12U8WT86 1 Q1 BSS215P PG SOT23 3 5 OptiMOS P2 Small Signal Transistor Inf...

Страница 39: ...KL 1 R28 47k 603 Standard Thick Film Chip Resistor Vishay CRCW060347K0FK 1 X1 TSM 112 01 L DV SMT 025 SQ Post Header 2 54mm Pitch 24 Pins Vertical Double Row Samtec TSM 112 01 L DV 2 X2 X3 SSW 108 01 G S Through hole 025 SQ Post Socket 2 54mm pitch 8 pin vertical single row Samtec SSW 108 01 G S 1 X5 SSW 110 03 T S THT SMT 0 25 SQ post Socket Strip 10 Pins Single row Samtec SSW 110 03 T S 2 X6 X8 ...

Страница 40: ...t adding thermal grease the performance is sufficient With moderate air flow provided by a standard 12V PC fan running at low speed located 20 cm away from the board the maximum board temperature settles at 80 C after 30 minutes at 25 C ambient temperature Figure 46 shows the temperature distribution across the board at the end of this test Figure 46 Temperature distribution after 30 min at 300 A ...

Страница 41: ...me when switching on with a 10 millifarad capacitor as load with a precharge time of 500 ms First the precharge path channel B is switched on and the current is limited by the 10 W precharge resistor As the capacitor charges up the current decreases exponentially After the precharge time has expired the main path channel A is activated and the remaining capacity gets charged with only the switch a...

Страница 42: ...d by the cable inductance As soon as the overcurrent threshold is reached the gate driver 2ED4820 EM generates an interrupt signal red curve INT and switches off the MOSFETs Figure 50 Overcurrent detection 2ED4820 EM and shunt Since there is a digital glitch filter time implemented of typically 1 5 µs the actual overcurrent detection value is the current value at 1 5 µs before the INT signal goes ...

Страница 43: ...he 2ED4820 EM needs to be disabled by setting it to a significantly higher value in order not to interfere with the hall sensor measurement The overcurrent detection threshold OCD1 of the hall sensor is factory set to 389 A see Table 4 Depending on the current slew rate the actual current value at start of the switch deactivation may be higher as can be seen in Figure 52 This is caused by time con...

Страница 44: ... 2ED4820 EM DataSheet v01_00 EN pdf 3 Infineon Technologies AG Datasheet TLE4972 high precision coreless current sensor for automotive applications Rev 1 02 2021 12 21 Infineon TLE4972 AE35D5 DataSheet v01_02 EN pdf 4 Infineon Technologies AG Datasheet IAUT300N08S5N011 OptiMOS 5 Power Transistor Rev 1 1 2021 01 26 Infineon IAUT300N08S5N011 DataSheet v01_00 EN pdf 5 Infineon Technologies AG Datashe...

Страница 45: ...e 45 of 46 Rev 1 0 2022 03 09 48V Battery Switch Reference Design R 48V BATT Switch10 Revision history Revision history Document version Date of release Description of changes Rev 1 0 2022 03 09 Initial release ...

Страница 46: ...onditions and prices please contact your nearest Infineon Technologies office www infineon com WARNINGS Duetotechnical requirementsproductsmaycontain dangerous substances For information on the types in question please contact your nearest Infineon Technologies office Except as otherwise explicitly approved by Infineon Technologies in a written document signed by authorized representatives of Infi...

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