A new very-high-efficiency R4 converter for high-power fuel cell applications

A new very high efficiency 10 kW isolated R4 boost converter for low-voltage high-power fuel cell applications is presented. Using a new concept for partially paralleling of isolated boost converters, only the critical high ac-current parts are paralleled. Four 2.5 kW power stages, consisting of full-bridge switching stages and power transformers, operate in parallel on primary side and in series on secondary side. Current sharing is guaranteed by series connection of transformer secondary windings and three small cascaded current balancing transformers on primary side. The detailed design of a 10 kW prototype converter is presented. Input voltage range is 30-60 V and output voltage is 800 V. Test results, including voltage- and current waveforms and efficiency measurements, are presented. A record high converter efficiency of 98.2 % is achieved. The proposed R4 boost converter thus constitutes a low cost solution to achieve very high conversion efficiency in high input current applications.