99.1% Efficient 10 kV SiC-Based Medium-Voltage ZVS Bidirectional Single-Phase PFC AC/DC Stage

Due to their extremely high energy demand, data centers are directly supplied from a medium-voltage (MV) grid. However, a significant part of this energy is dissipated in the power supply chain since the MV is reduced step-by-step through multiple power conversion stages down to the chip-voltage level. In order to increase the efficiency of the power supply chain, the number of conversion stages must be substantially reduced. In this context, solid-state transformers (SSTs) are considered as a possible solution, as they could directly interface the MV AC grid to a 400 V DC bus, whereby server racks with a power consumption of several tens of kilowatts could be directly supplied from an individual SST. With a focus on the lowest system complexity, the SST, ideally, should be built as simple two-stage system consisting of an MV AC/DC power factor correction (PFC) rectifier stage followed by an isolated DC/DC converter. Accordingly, this paper focuses on the design and realization of a 25 kW, 3.8 kV single-phase AC to 7 kV DC PFC rectifier unit based on the 10 kV SiC MOSFETs. By simply adding an LC circuit between the switch nodes of the well-known full-bridge-based pulse width modulated AC/DC rectifier, the integrated triangular current-mode concept is implemented, which only internally superimposes a large triangular current ripple on the AC mains current and, therefore, enables zero-voltage switching over the entire AC mains period. Special attention is paid to the realization of the MV inductors and their electrical insulation, the AC-input LCL filter to limit electromagnetic interference emissions, and the challenges arising due to cable resonances when connecting the SST to the MV grid via an MV cable. Despite the large insulation distances required for MV, the realized 25 kW MV PFC rectifier achieves an unprecedented power density of 3.28 kW/L (54 W/in3) and a full-load efficiency of 99.1%, determined using a calorimetric measurement setup, which is discussed in detail in the Appendix.