CURRENT SHARING IN POWER ARRAYS By JohnHarding Designing For Current Sharing In Power Arrays Analog And Synchronous Design —_| cy "eirect gee Methods Offer A Range Of Options | tmihecmonnttien For Attaining Higher Power Output | cusesimtnemesrmeattie And Fault Tolerance. Sha vunetrintutuesprilrioete a Gan cease henever power supplies | more of the converters will try tos. | array supply jst fraction ofa. or converters are opar- | sume. disproportionate or exeossive | Consider a situation where one ‘ted in partie config. | fraction ofthe load unloss fore eur | morile ina two-mode array is pro- tior—forhigher oa | rent-sharing contre is designed into | siding all ofthe la fit fas, the load put power, fault tolerartee, or | thosystem. fon the second module mast go from m0 both~eurent sharngisanimporcant | One converter typically the one | lal to fal oad. Daring tat time, tie consideration. Most current-sharing | withthe higher output voltage, ay | output vltago sil to droop tem Schemes employed with power con” | deliver arent up tits eurent lint | porariy. This cou result in system verters involve analog approach ‘setting, which is beyond itsrated max- | problems, including shutdown orreset. One analog method artificially in- | imum. Then, the voltage will drop to | On the other han, if beth modules ‘creases the output impedance of the | ‘the point where another converter in| were sharing the load and one failed, converter modules, while another ae: tually senses the output current of | cach module and forces all ofthe car- ‘rents to be equal by feedback control, Synedironous current staring offers analternativetoanalog teenies. In Syehrorons seheme, thors isn0 neal fora carrent sensing or eurent- ‘measuring device on each mode, Nor is there a noed to artifical inerease ovatput impedance, which eompro- ‘mises load regulation. ‘There are advantages and disad wantages associated with eneh sp proach to cuarent sharing. In choosing the best approach fora given applica tion esinersshotld be aeare ofthe tradeoffs as well as tips for imple menting a successful design. ‘Most paralleled power components, such as transistors, rectifiers, power sonversion modules, andotine power | 1, Droop-share current sharing artificially increases converter output applies, wil notinhererty share the | impedance to force the currents to be equal. Diodes on the output of load. With power converters, one ar | each converter provide current sensing and fault protection.the surviving module would experi- ‘ence a much leas severe transient (one-half ofall oad), Ako, the cutpat valtage would be likely to experience no more than a slight momentary droop, The dynamic response charac teristicofall forward converters, reso- nant or pulse-width modulated, is de ‘graded when the load is stepped from ro (no load) where the output induce torearrent is diseontinaous. Im the same two-medule array ex- ample, the module carrying al ofthe load also is generating lof the heat. ‘That results in a much lower mean time betiveen failure for that module. An often-quoted rule of thumb says that for each 10°C ineroase in operat- ing tempernture, average component lifeis eat nba, Tn a current shaving system, the converters or supplies all run at the same temperature. This temperature ‘slower than that of the hot-running heavily loaded) modules in x system without eurrent sharing. Further- ‘more, same-temperature operation ‘means that all ofthe mola in &.eur- rent-sharing arrangement age equally. ‘Current shaving, ther, is important because it improves system perfor- tance. It eptimiaes transient and dy- namie response and minimizes thermal problems, which improves reliskility ‘nd helps extond the lifetimes ofall the modules in an array. Current shat: ing is an essential ingredient in mos: systems that use multiple power sup- plies or converters to achieve higher ‘outpat power or faul tolerance. ‘When parallel supplies or convert- ers are used to inerease power, cur- rent sharing is achieved through a number of apprcaches, One scheme simply als resistance in series with the load, A more practical variant of that is the “droop-share” method, ‘which zetvely eanses the outpat vot: sige to drop in response to ineressing load. Nevertheless, the two most com- rmoniy used approsehes to paralleling converters for power expansion are Aiverfbooster arvays and analog eat rent shaving control. They appear to be similar, but the implementation of cach ia quite diferent. Driversbooster arrays usally con- tain one intelligent module or driver, and one oF more power-train-only mollules or hoosters. Analog carrent- sharing control involves paralleling two or more identical modules, each containing intelligence. ‘One of the common methods of fore- ing load sharing in an array of parallel corverters isto sense the output eur= rent of each converter and compare it to the average current. Then, the out- put ofa given converter is adjusted so ‘that its contribution is equal to the ay= erage. This isusually accomplished by current-sense resistors in series with the lead, a sensing amplifier for each converter mosiale, anda summing am- plifier. Load sharing is accomplished by actively trimming the output volt= age using tram or sonse pins. ‘Occasionally, a designer is tempted to avoid the expense of a current- sense resistor by using the IR drops in the wire as a means of sensing the eur- rent. Unfortunately, there are a num- ber of negative issues associated with, CURRENT SHARING IN POWER ARRAYS ‘The resistor values typically range from a few millickms up to about 100, ‘m2, depending on the power level or current range of cperation. Selecting, the right value requires a tradeoff be- tween power dissipation and sensi ity (signal-to-noise ratio or noise i munity). The larger the resistor value, tthe better the noise immunity—and the greater the power dissipation, Determining the si needed to generate a signal above the noise ea be. bit tricky. Another po- tential pitfall with this (or, forthat mat- ter, any other) approach is the need for of the resistor good electrical and mechanical design ‘hat idea, Pirst ofall, there's the tem- | perature coefficient of copper. As the ‘wire heats up, its resistance increases, negating its Value as a stable current” sersing device. Second, there are ox!- mand carresien issues, which also cause parametrie changes. Canse- quently, 2 high-precision eurrent- sensing device, sueh as a precision re- sistor, 82 must, a seein Beat ty sand layout. This requires adequate trace widths, minimized trace lengths, and decoupling to reduce noise. An ex perienced designer should have no dif: ficulty with this, but it is an area rich ‘with opportunities for error. ‘The droop-share method artificially increases the output impedance to force the currents to be equal. I's a ‘complished by injecting an error sig nal Into the control loop of the eon- verter, causing the output voltage 10 | vary as 2 fuetion of load carvent. As load eurrent increases, ontput voltage decreases. All ofthe modules will de- | iver approximately the same current eve. sw ie eat. swing se tenewt. mttiagbse nd se ne tes Ao sese vine tame Aout 2. Most converters can use the driver/booster array to increase output power. Driver/booster arrays usually contain one intelligent module or driver, and one or more power-train-only modules or boosters.3. The synchronous current-sharing architecture simplifies current- sharing control and enhances fault tolerance. In this arrangement, each module can control the array by transmitting a pulse that synchronizes the switching frequencies of all the modules in the array. because they are all being summed into one node. Tfone supply is delivering more current than another supp! put voltage will be forced down alittle so that it will be delivering equal eur- rent for an equal voltage at the sum- ming node, A simple implementation of the droop-share scheme uses the ‘ollage dropped aeross an auctioneer~ ing diode, which s proportional to cur- rent, to adjust the output voltage of thezssociated converter (Fig. 1. Droop share has advantages and disadvantages. One ofthe advantages is that it ean work with any topology. It's also fairly simple and inexpensive to implement. A major drawback, though, isthatitroqures that the eur” rent be sensed, A current-sensing de- viee is needed in each of the convert- ersor power supplies. Additionally, a small penalty is paid in load regula- tion, though in many applications thi isan issue, In general, mixing and matching converters isn't recommeniled—espe- cially those with incompatible current sharing sehemes. The droop-share method, however, is more forgiving in this regard than any of the other tech- niques. Witha itle external eireuitry, current sharing ean be achieved using arrays construeted from different con- verter models or even from different ‘Most systems can employ the dri- ver/booster (or master/slave) array for inereased power (Fig. 2). The dr vers used to set and eontrel output voltage, while booster modules, as slaves to the master, are used to ex- nant converters with Mertical power trains inherently current share be- cause the per-pulse energy of each converter is the same. Ifthe inputs and outputs are tied together and the tits operate at the same frequeney, all mociules will deliver equal current (within component tolerances). ‘Thosingle intelligent module in the array determines the transient re- ‘sponse, which does not change as mod- ules are added. Slaved modules re- quire only one connection between units when their outputs are con- nected, No trimming, adjustments, or ‘external components are required to achieve load sharing, The load sharing is dynamic and usually guaranteed within 5% IU’ important to remember that when using boosters, the input and ontput voltage and output power specifications of the boosters must bo the same as the driver. Driver/booster arrays have two advantages. They have only a single eontrol loop, $0 there are no loop- ‘within-a-loop stability issues. And, they have exeollont transient re- sponse. Howover, this arrangement. isn't fault tolerant. the driver mod tle falls, the ray won't maintain its ‘output voltage. ‘Analog curvent-sharing control in- ‘volvesparalleling two or more identical ‘modules, sch containing intelligence. ‘The cnet actively adjusts the output ‘voltage of ench supply so the multiple supplies deliver equal carrents, This ‘method, though, has number of disad- ‘vantages. Each converter in the array has its oven vokage regulation lop, and ‘each requires a currentsensing device are] current-control oop. Analog carrent-sharing contro! ‘does support a level of redundaney. tures within the enrrent-sharing bus that at best ean defeat current shar- ing, and at worst ean destroy every ‘movil in the array. The major reascn for this isthe single-wire galvanic oon- nection between madules. ‘Current sharing an éscential ele- ‘ment in fault-tolerant arrays, Yet re- gundless ofthe approach, there isan inherent cost incurred by the addl- tion of at least one redundant con- verter or supply. Tncidentally, most applieations to- | day that require fault tolerance or re- ddundaney also require hot-swap eae bility to ensure continuous system operation, Hot-swappabie ears mast be designed so the operator won't come ineontact with angereuspoten- tials and currents, It's also essontial that when a mod- ule fail, the failure is detected and identified by an alarm or notice to pro- vide service. A hot swap system mast censure that during sivap-out, there is rminimal disturbance of the power bus. Specifically the affected voltage bus must not drop enough to cause errors in the system, either onthe input bus orthe output bus, A power-supply failure ean ripple aneniire system, so the addition ofane- dundant converter or supply is often justified by the need to Keep the sys- temoperating.Addinganextra mole (+1) to agroap of paralleled medles will signifeantly increase reliability ‘with only a modest inerease incest. ‘The implementation of redundant converters is detormined in part by the available space and cost require- ments, For example, two 200-W full sizo modules coal be used to provide -2400-W output with an adiitional 200CURRENT SHARING IN POWER ARRAYS ‘W ave For 2-1 redundaney (a toigl | control ofthe anvay. In other words, | Synchronous eurrent sharing lini- of 600 Wina volume ofaboat 16.5in2. | they eonstitwtea democruticarray. The | nates the need for current-sensing oF Alternatively four 100-W half-size | module that assumes command doesso | current-measuring devices on each moles mightbeused witha fiNh 100- | bytransmittingapulse, which synchrw- | mode. Load regulation isnt eompro- W module to provide 4+1 zecundaney | nizes the high-frequency switehing of | mised, either. Additional advantages (atotal of 300 W and 14 in, Although | each converter‘inthe ara of the synehronons eurrent-sharing ‘the second solution uses ess space, it | The synchronization pilse istrans- | architecture include excellent tran- ‘increases the aceumnlated fallure rite | mitted over ssingle-wire, parallel eur | sient response, the elimination of loop ‘eeause it employs more converters, | rent-sharing-conirol bus that links all | within-a-loop control problems, and, more ORing diodes, more monitoring | of the modes. The bus is bidiree. | as stated earlie, a high degree of im: céreuitry, and mere assembly. tional, allowing each module to send | munity from system noise, ORingdiodesmay be inserted inse- | and receive pulses. Soifthe ead mod-| The synchronous eurrent-shaving ‘ies with the output of each module in | ule relinquishes control, anew module | method described above applies only an N+ array to provide output fault | can transparently take command with | to quasi-resonant, variable frequency Aeleranice (Fig 1, gen). They'voim- | noperturbation ofthe output, ‘converters such as Vieors second gen- portant in aredundant power system | A pulsed signal also gives design- | eration of high-density de-de convert- to maintain fault isclation, Without | ers the option of using capacitors or | ers. These have the nevessary intelli ‘them,a short-circuit failure in the ut- | transformers to obtain de-blocked | gence while providing fixed amounts put of one converter could bring down | coupling between the modules and | of energy per eurrent-sharing pulse, the entire array, the current-sharing-control bus. Such | The secontl-generaton families eover But ORing diodes aid losses to the | coupling prevents certain failure | some ofthe inpat voltages most in d= power-system, reducing overall ef | modes internal toa single module | mand, such as 48, 300, and 375 V, with ‘iency and decreasing reliability. To | from affecting the other modules in | output voltages at 2, 83,5, 12, 15,24, ameliorate the negative effect om eff- | the array, providing an increased | 25, and 48 V. These converters come in ciency, ORing diodes should run hot, | level of fault tolerance. micro, mini, and maxisize packages, thereby reducing forward voltage | Use of transformer eoupling per- | which produce output power lovels up ‘drop and inereasing effieioney, Re- | mits anays of varable-frequeney eon- | 10150, 300, and GO) W, respectively, 3 ‘verso loakage current will bean issue | verter modules to earrent share when ‘only ifthe output of aconvertor shorts | they are widely soparated or operated | John Harting ia senior applica and the diode is reverse biased, This | from independent cources (Fig. $). | tions engineer with product line an important consideration with re- | ‘Transformer-conpling this pulsed sig” | responsibility at Vieor Corp. He has sar to operating temperature, nal provides. high level of common- | more than 2 years of professional ‘Synehronous current ehuring,both | mode noise immunity while maintain- | engineering experience,tcith particular for power expansion and fault toler- | ing safety extra-low voltage (SELV) | emphasis on the design and decetop- ance, is available with variable-fre- | isolation from the primary souree. | meu of power sustems. Harding quency converters—vonverters that | This is especially useful when board- | received h's BSEE deyree from Fitel- use the zero-current-switehing topol-| to-board laud shaving isrequired in re- | Gury State Colege in Massachusetts gy (Fig. 3). Each module can assume | dundant applications. 25 Frontage Road Andover, MA 01810 ‘Tel: 800 735 6200 Fax: 978 475 6715 www.vicrcom 4. in the synchronous current-sharing architecture, transformer ‘coupling of the current-sharing-control bus provides a high degree of common noise immunity while maintai primary source. As a result, the converters can be placed physically far ‘apart and operate from independent sources. ‘Copyright © 1999 by Penton Media, Inc., Cleveland, Ohio 44114 Part # 22061