TI Designs: TIDA-00951

2-kW, 48- to 400-V, >93% Efficiency, Isolated Bidirectional

DC-DC Converter Reference Design for UPS

1 Description 3 Features
The TIDA-00951 design provides a reference solution • Digitally Controlled Isolated Bidirectional DC-DC
for a 2-kW isolated bidirectional DC-DC converter Converter
capable of power transfer between a 400-V DC bus • Operates as Active Clamped Full Bridge Boost
and a 12- to 14-cell Lithium battery pack for use in Converter With ZVS For All Low-Voltage Switches
UPS, battery backup and power storage applications. at High Loads
This TI Design works as a >93% efficient, current fed, • Operates as Active Clamped Voltage Fed Buck
active clamped boost converter with ZVS in the Converter With Synchronous Rectification to
backup mode and voltage fed full-bridge batter charger Improve Efficiency When Charging Battery
with >93% efficiency in the charging mode. This TI • Wide Operating Range From 36- to 60-V Battery
Design has built-in protection for DC bus overcurrent and 300- to 400-V DC Bus
and overvoltage and battery overcurrent.
• Cost Optimized Design Using 100-V FET on Low-
Voltage Side, Eliminates Requirement for
2 Resources Paralleling Multiple FETs up to 2 kW
• Built-in Cold Start Procedure and Fast Mode
TIDA-00951 Design Folder
Transfer (< 100 µS) From Battery Charger to
SN6505B Product Folder
Backup Power Supply
CSD19536KCS Product Folder
• Onboard Isolated Communication Interface for
UCC27211A Product Folder
CAN, I2C, and RS-485
UCC27517A Product Folder
AMC1301 Product Folder
TMP300 Product Folder 4 Applications
LM4041A12 Product Folder • Server PSUs and Telecom Rectifiers
TPS62160 Product Folder • Uninterruptible Power Supplies (UPS)
TLV1117 Product Folder
• Industrial Power Supplies
OPA376 Product Folder
TIDA-01281 Design Folder
• Battery Chargers
TIDA-01141 Design Folder • Energy Storage Systems
TIDA-01159 Design Folder

ASK Our E2E Experts

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+5 V +12 V
TPS62160
+12V_ISO +5V_ISO +3.3 V
TLV1117-50 TLV1117-33

TIDA-01159 TIDA-01159 INA240

SN6505B SN6505B
IB_HS

300- to TIDA-01141
400-V DC + 36-
UCC UCC UCC27517A 60-V
UCC UCC 27211A 27211A -
21520 21520 T1

CSD19536 TMP300
OPA376

LM4041A12
AMC1301

lB_LS
OPA376
IB_HS
C2000TM
RS-485 ISO3082
Digital Signal Processor
VB_sense
TMS32 OF28033
I 2C ISO1541

CAN ISO1050
TIDA-01281

Copyright © 2017, Texas Instruments Incorporated

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.

5 System Description
Most backup power equipment such as DC inverters, home inverters, industrial DC-UPS, and energy
storage banks require an exchange of power from the battery to the load and vice versa. Typical power-
system distribution architecture with battery backup is shown in Figure 1:
Power Solar Power, Wind
Conditioner Power, and Fuel Cells
PFC
Converter

DC-AC DC BUS Electric/Electronic

Grid Power
Inverter 300 TO 400 V Devices (DC Input)
Power Supply
Normal Power
during blackouts Discharge
Supply Bidirectional DC-DC Rechargeable
or peak cut time
Converter Battery (48 V)
Electric/Electronic Charge

Devices (AC Input)

Copyright © 2017, Texas Instruments Incorporated

Figure 1. Top-Level Architecture of Typical UPS System

During normal operation, the main DC bus is regulated between 300 and 400 V through the grid source of
a building, factory, or house. Alternatively, the DC bus can be powered through a renewable energy
source such as solar power generation or wind power generation, which is conditioned through a power
conditioner to feed the DC bus. The battery acts as an energy storage unit, and it can be charged either
through the grid or an external renewable energy source.
Conventionally, charging a battery through a DC bus and discharging the battery during power blackouts
are implemented with two unidirectional converters, each processing the power in one direction. With a
growing emphasis on compact and efficient power systems, there is increasing interest in using
bidirectional converters, especially in DC inverters, home inverters, and energy storage banks. A
bidirectional DC-DC converter, capable of bilateral power flow, provides the functionality of two
unidirectional converters in a single converter unit.
The TIDA-00951 design is an isolated bidirectional DC-DC converter designed to exchange the power
between a 300- to 400-V DC Bus and 48-V battery banks. The design has a full-bridge power stage on the
high-voltage (HV) side, which is isolated from a current-fed full-bridge stage on the low-voltage (LV) side.
During the presence of the DC bus (normal conditions), the design operates in buck mode and charges
the battery with constant current until the battery voltage is in regulated limits. During blackouts, the
design operates as the current-fed full-bridge converter to boost the power from a 48-V battery (36- to
60-V input) to the 380-V DC bus and supports the load with backup.

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The transition or change over time from the charge to backup mode is very critical for ensuring continuity
of power to the loads. The TIDA-00951 has transition time of less than 100 µs, which reduces the amount
of bulk capacitance needed for the system to provide power during the transition time.
This TI Design operates at peak efficiency of 93% in buck mode (as charger) and 94% in boost mode
(during discharge). The high discharge efficiency provides a high run time from the battery. Operating at a
high switching frequency of 100 kHz, the design has a compact form factor of 185 mm × 170 mm for the
power level of 2 kW.
The TIDA-00951 design is optimized for component count, cost, and performance. Various parameters of
the design like regulation, efficiency, output ripple, transition time, startup, and switching stress across the
devices were tested and documented in the following sections.

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5.1 Key System Specifications

Table 1. Key System Specifications

PARAMETER TEST CONDITIONS MIN NOM MAX UNIT
BACKUP SUPPLY MODE
INPUT CONDITIONS
Input battery voltage (VBAT) — 36 44.4 60 V
Input battery current (IBAT_MAX) — — — 60 A
OUTPUT CONDITIONS
Output bus voltage (VBUS) — 300 380.0 400 V
Output bus current (IBUS_ MAX) — — 5 A
VBAT > 40 V
Line regulation — — 1 %
Load regulation 10% to 100% load — — 1 %
Output voltage ripple — — — — —
Input voltage ripple — — — — —
Average efficiency 20% to 100% — — — %
Full load efficiency — — — — %
BATTERY CHARGER
INPUT CONDITIONS
Input bus voltage (VBUS) — 300 380.0 400 V
Input bus current (IBUS_ MAX) — — — 60 A
OUTPUT CONDITIONS
Output battery voltage (VBAT) — 36 44.4 60 V
Output battery current (IBAT) — — — 16 A
SYSTEM SPECIFICATIONS
Operating ambient — –10 25 55 °C
Board size Length × Width × Height 185 × 173 × 8 mm

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6 System Overview

6.1 Block Diagram

Figure 2 shows the high-level block diagram of the TIDA-00951. The DC-DC converter is made of a
current-fed full-bridge converter on the battery side and a full-bridge on the 380-V bus side. The control of
the system is through the C2000™ present on the TIDA-01281 control card. The TIDA-01159 isolated
gate driver card is used to drive the full bridge on the 380-V bus side. High-side inductor current sensing is
performed using the TIDA-01141 board.
+5 V +12 V
TPS62160
+12V_ISO +5V_ISO +3.3 V
TLV1117-50 TLV1117-33

TIDA-01159 TIDA-01159 INA240

SN6505B SN6505B
IB_HS

300- to TIDA-01141
400-V DC + 36-
UCC UCC UCC27517A 60-V
UCC UCC 27211A 27211A -
21520 21520 T1

CSD19536 TMP300
OPA376

LM4041A12
AMC1301

lB_LS
OPA376
IB_HS
C2000TM
RS-485 ISO3082
Digital Signal Processor
VB_sense
TMS32 OF28033
I 2C ISO1541

CAN ISO1050
TIDA-01281

Copyright © 2017, Texas Instruments Incorporated

Figure 2. Block Diagram of 2-kW Isolated Bidirectional DC-DC Converter

6.2 Highlighted Products

This TIDA-0951 reference design features the following devices, which were selected based on their
specifications. The key features of the highlighted products are mentioned in the following subsections.
For more information on each of these devices, see their respective product folders at http://www.TI.com
or click on the links for the product folders in the Section 2 section.

6.2.1 CSD19536KCS
The CSD19536KCS is a 100-V NexFET™ MOSFET has a very low RDSON of 2.3 mΩ with an ultra-low Qg
and Qgd of 118 nC and 17 nC, respectively. In the TIDA-00951 design, five of these MOSFETs are used
on the battery side or LV side to form the LV full bridge and the active clamp circuit. Because the LV FET
is turned on at ZVS at high loads, the RDSON parameter becomes important in determining the loss on the
FET. The CSD19536KCS was chosen for its very low RDSON.

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6.2.2 UCC27211A
The UCC27211A is a robust 120-V half-bridge gate driver capable of delivering up to a 4-A source and
sink current for driving power MOSFETs. With very low pullup and pulldown resistances, this device
reduces the transition time of the power MOSFET through the Miller region, which minimizes the switching
loss on the MOSFET. The device is a robust half-bridge gate drive with input pins capable of tolerating up
to a –10-V input voltage. This TI Design takes advantage of this device’s ability to minimize the switching
loss on the power MOSFET on the LV side at turnoff to operate at a high switching frequency of 100 kHz
per phase. Find more details on this driver from the device datasheet (SLUSBL4).

6.2.3 SN6505B
The SN6505B is a low-noise, low-EMI push-pull transformer driver, specifically designed for small form
factor, isolated power supplies. It drives low-profile, center-tapped transformers from a 2.25- to 5-V DC
power supply. Ultra-low noise and EMI are achieved by slew rate control of the output switch voltage and
through spread spectrum clocking (SSC). The SN6505 consists of an oscillator followed by a gate drive
circuit that provides the complementary output signals to drive ground referenced N-channel power
switches. The device includes two 1-A Power-MOSFET switches to ensure start-up under heavy loads.
The switching clock can also be provided externally for accurate placement of switcher harmonics or when
operating with multiple transformer drivers. The internal protection features include a 1.7-A current limiting,
undervoltage lockout, thermal shutdown, and break-before-make circuitry. The SN6505B includes a soft-
start feature that prevents high inrush current during power up with large load capacitors.

6.2.4 OPA376
The OP376 family of low-noise operational amplifiers (op amp) with e-trim offers outstanding DC precision
and AC performance. The OPA376 is single op amp with rail-to-rail input and output, low offset (25 µV
max), and an ability to operate with common-mode voltages up to 100 mV below the ground. Low noise
(7.5 nV/√Hz), a quiescent current of 950 µA max, and a bandwidth of 5.5 MHz make this part a good fit for
this TI Design.
For the TIDA-00951, the OPA376 is used for low-side bidirectional current sensing, where low offset
voltage and high gain bandwidth product are important in minimizing the current sense resistor value.

6.2.5 LM4041-N
The LM4041-N is a precision voltage reference, which gives a fixed 1.2-V reference voltage. The LM4041-
N device’s advanced design eliminates the need for an external stabilizing capacitor while ensuring
stability with any capacitive load, which makes the LM4041-N easy to use. Curvature correction in the
band-gap reference temperature drift and low-dynamic impedance ensure stable reverse breakdown
voltage accuracy over a wide range of operating temperatures and currents. The LM4041-N 1.2 is used to
provide a precise reference offset voltage to the current sense amplification circuit (based on the OPA376)
to enable bidirectional current sensing.

6.2.6 TIDA-01281
The TIDA-01281 is a TSM320F28033-based control and communications reference design. It acts as the
control card for the TIDA-00951 design. The TMS320F28033 present on-board samples the various
voltages and currents on the TIDA-00951 board and generates the control signals and PWM required for
proper functioning of the TIDA-00951 design.Apart from this the board also contains isolate
communication interface ICs for implementing isolated I2C, CAN and RS485 communication.

6.2.7 TIDA-01141
The TIDA-01141 is a bidirectional high-side current sensing card based on the INA240 current sense
amplifier. The INA240 is a voltage output current sense amplifier with an enhanced PWM rejection feature.
Capable of operating with a common-mode voltage from –4 to 80 V with a DC CMRR of 132 dB, this
device is well suited for high-side current measurement in SMPS and motor control applications.

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6.2.8 TIDA-01159
The TIDA-01159 is an isolated half-bridge gate drive card based on the UCC21520 and SN6505B. It is
used on the TIDA-00951 to drive the isolated HV-side full-bridge power stage.

6.3 System Design Theory

The isolated bidirectional DC-DC converter has two major modes of operation. When it is working as a
backup power supply, it operates as an active clamped current-fed boost converter transferring power
from the battery to the 380-V DC bus. When operating as a battery charger, the DC-DC converter works
as a buck converter transferring power from the 380-V DC bus to the battery.
Apart from the two major modes, there is an additional mode for the cold starting the system. This mode is
used to start up the TIDA-00951 in case the HV DC bus is completely discharged before board start-up.
The working of the isolated bidirectional DC-DC converter design is detailed in the following sections.

6.3.1 Boost Mode

6.3.1.1 Topology Description

When working in boost mode, the system needs to boost an input voltage between 36 to 60 V to a 380-V
DC output. There are multiple topologies that can be considered for this TI Design.
Broadly speaking, the possible topologies can be classified into voltage- or current-fed topologies have an
input inductor, which is connected to the power stage. However, a voltage-fed converter connects the
input filter capacitor to the power stage. The presence of this input inductor gives the following benefits:
• Boosted voltage reduces the stress in the transformer and better utilization
• Avoids flux imbalance issues in the power stage
• Lower stress on the input filter capacitors due to reduction in the current ripple due to the input inductor
The TIDA-00951 works as an active clamped current-fed full-bridge converter in boost mode. Although
there are several advantages in using a current-fed converter, one primary disadvantage is the huge spike
in the current-fed converter at MOSFET turnoff. This turnoff requires some form of snubbing using either
an active or passive snubber.
In the TIDA-00951 design, an active clamp compromising of a capacitor and a MOSFET has been used to
implement an active snubber. The advantage of this active clamp is that not only does it recover the
leakage energy, but it also helps in achieving ZVS for the primary LV MOSFET at turnon, thereby reducing
the switching losses.
When working as a battery charger, the TIDA-00951 works as a voltage-fed buck converter. It transfers
power from the HV DC bus and charges the battery in constant-current/constant-voltage (CC/CV) mode
with a current limit of 16 A.
The following two sections explain how the converter in the backup supply mode works.

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6.3.1.2 Boost Mode Working: Active Clamp

The power stage of the TIDA-00951 is shown in Figure 3.

L1
Q9 Q8
Q4 Q3 C1 Cclamp

C1
300- to
400-V DC 36- to
60-V DC
T1
Qclamp
C2

Q6 Q7 Q1 Q2

Copyright © 2017, Texas Instruments Incorporated

Figure 3. Power Stage of TIDA-00951

The switches Q1 to Q4 are the LV-side full-bridge MOSFET. The switches Q6 to Q9 form the HV-side full-
bridge MOSFET. The capacitor Cclamp and switch Qclamp form the active clamp.
When the system works as a current-fed full bridge, transferring power from the battery to the DC bus, the
active clamp stores the additional leakage energy when the MOSFET Q1 to Q4 turnoff, thereby limiting
the turnoff spike on the MOSFET. Additionally, by controlling the switching of the MOSFET Q5, the
primary LV MOSFET can be turned on in or close to 0 V, thereby reducing the turnon switching losses.

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The modality of implementing this scheme is shown in Figure 4.

Vds_Q1

Id_Q1

Vds_Q2

Iclamp

Vgs_Q1

Vgs_Q2

Vgs_Qclamp

IL

Tdelay_1 Tdelay_2

Copyright © 2017, Texas Instruments Incorporated

Figure 4. Active Clamp Waveforms

Take the switch pair Q1 and Q3 as an example to describe the working of the active clamp. When the
switch pair Q1 to Q3 turn off, the current through FETs before turnoff get transferred and start flowing into
the clamp capacitor and the body diode of Qclamp. Because the clamp current is flowing through the body
diode of Qclamp, it can be turned on after a short time (Tdelay_1) in ZVS condition as shown in Figure 4.
Now, before the switch pair Q1 and Q3 is turned on again, the clamp FET Qclamp is turned off. Because the
direction of the Iclamp has reversed and it is now flowing through the channel of the Qclamp, Iclamp instantly
comes to zero.
Because the current through the leakage inductor cannot change instantly, a portion of the current flowing
through the FET Qclamp, begins to flow through the body diode of FET Q1 and Q3. This begins to discharge
the COSS of FETs Q1 and Q3 and causes ZVS to occur. After this, FETs Q1 and Q3 can be turned on
under ZVS or close to ZVS condition, thereby reducing the turnon loss. The delay from the point of turnoff
of the clamp FET Qclamp and turnon of Q1 and Q3 is marked as Tdelay_2 in Figure 4.

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6.3.1.3 Boost Mode Working: Cold Start

Figure 5 shows the LV-side full-bridge converter along with the start-up clamp circuit.
L3 D11

D10 Ccold_start Q10 HV DC Bus

L1

Q4 Q3
Ccla
mp
36 to 60 V
Battery T1

Qcla
mp
Q1 Q2

Copyright © 2017, Texas Instruments Incorporated

Figure 5. Cold Start Clamp Circuit

During the system start-up, if the HV DC bus is completely discharged. The TIDA-00951 starts up using
an additional flyback winding present on the inductor L1. In this mode, the LV-side full bridge does not
work as a current-fed converter but as a flyback converter. It works in this mode until the HV bus reaches
270-V DC and then the system switches over to working as a current-fed converter.
In Figure 5, the MOSFETs Q1, Q2, Q3, and Q4 form the LV-side full bridge. Qclamp and Cclamp form the
active clamp. The flyback winding on the inductor L1 is used to temporarily charge a small capacitor,
which is then boosted and fed to the HV DC bus output capacitors using the boost converter formed by
Q10, D10, and L3.

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Figure 6 shows the PWM waveforms of the LV MOSFETs Q1 to Q4, clamp MOSFET QClamp, and the boost
MOSFET Q10. The figure also shows the current-fed inductor current waveform and the drain-to-source
voltage waveform of the low-side bridge MOSFET.

Vds_Q1,
Q2, Q3, Q4

Vgs_Q1,
Q2, Q3, Q4

Vgs_Q10

Vgs_Qclamp

IL1

Copyright © 2017, Texas Instruments Incorporated

Figure 6. TIDA-00951 Cold Start Clamp Circuit Working

All the MOSFETs on the LV bridge are turned on simultaneously. This charges the current-fed inductor.
When these MOSFETs are turned off, the current in the current-fed inductor is transferred to the flyback
winding and energy is stored in the capacitor Ccold_start.
The boosted MOSFET Q10 is then turned on to charge the boost inductor L3. This energy is then
transferred to the HV bus output capacitors.

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6.3.1.4 Current-Fed Inductor Calculation

The maximum input battery voltage VBAT_max = 60 V. The maximum voltage appearing across the primary
winding of the transformer has to be chosen to be higher than this voltage so as to maintain the boost
action of the current-fed power stage.
In order to maintain a minimum boost ratio, the reflected voltage on the primary when the HV bus is at 400
V is set as Equation 1:
VPRI = 1.1 ´ VBAT _ max = 66 V (1)
The average voltage on the clamp VCLAMP will be the same as the VPRI.
By choosing the VPRI= 66 V, one can maintain sufficient voltage margin on the 100-V FET after accounting
for voltage spikes at turnoff.
The switching frequency fSW is selected as 100 kHz to get a good optimization in magnetic size reduction
at the same time, maintaining high efficiency.
The maximum output power of the system is POUT_max = 2 kW. Assuming a 92% efficiency, this gives the
maximum input power as PIN_max = 2 kW/0.92 = 2.173 kW.
POUT _ max
PIN _ max = = 2173 W
0.92 (2)
The average maximum input current Iin_max = Pin_max / VBAT_min = 60.3 A.
PIN _ max
IIN _ max = = 60.3 A
VBAT _ max (3)
The design equations for the current-fed inductor (L1) are similar to that of a boost converter. The two
parameters that need to be used to calculate the value of the current-fed inductor are DMAX_overlap and
IIN_maxripple.
The DMAX_overlap defines the period for which the four full-bridge MOSFET on the LV side are on
simultaneously. In order to calculate this, DMAX needs to be calculated first.
DMAX can be calculated using Equation 4.
VBATmin
VPRI =
2 (1 - DMAX ) (4)
This leads to DMAX = 0.728.
The DMAX_overlap is given by Equation 5:
D MAX _overlap = D MAX - 0.5 = 0.228 (5)
The maximum ripple current is set as Equation 6:
IIN _ max ripple = 0.3 ´ IIN _ max = 18.1 A (6)
Substituting the known values for Equation 7, L1 can be calculated.
VBAT _ min ´ DMAX _ overlap
L1 = = 4.5 mH
FSW ´ I IN _ max ripple (7)
The peak current in the inductor can be calculated as Equation 8:
I IN _ max ripple
I IN _ pk = I IN _ max + = 69.4 A
2 (8)

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6.3.1.5 Transformer Calculation

The turns ratio for the transformer is given as Ns / Np = VBUS_max / VPRI = 400 / 66 = 6:1
The primary (LV side) RMS current through the transformer can be given by Equation 9:
(3 - 2 ´ Dmin )
(
ITX PRI _ rms = æç 3 ´ I IN _ max ) + I IN _ max ripple2 ÷ö ´
2

è ø 4
3 (9)
ITXPRI_rms = 47 A
The required turns ratio of the transformer is given by Equation 10. The turns ratio is chosen as 6 to help
account for the conduction losses on the LV full bridge.
Ns 380
= = 5.75
Np 66 (10)
The secondary (HV side) RMS current through the transformer is estimated to be ITXSEC_rms = 7.5 A.

6.3.1.6 Low-Side Current Sensing Circuit

In the TIDA-00951, low-side current sensing is implemented to measure the battery current on the LV side
using the OPA376.
Because the battery current is bidirectional in nature, the output of the OPA376 is 1.2 V by using the
LM4041A12 shunt voltage reference. This is shown in Figure 7.
R23 100k

LV_AUX_3.3V
LV_AUX_5V

R24 1.00k PGND

5

R26
4
1.00k
IBAT_LS 1 PGND
3 VREF_1.2
U5
C42
C51

R27 1.00k
VBAT-
2

3
1µF
1000pF

R28 R19
U6
100k
2 LM4041A12IDBZR
VREF_1.2
SGND

Low Side Current Sensing

SGND

Copyright © 2017, Texas Instruments Incorporated

Figure 7. Low-Side Current Sensing Circuit Schematic

The OPA376 difference amplifier measures the current across a 0.25-mΩ current sense resistor formed by
the parallel combination of resistors of R20 and R29.

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6.3.1.7 Isolated Voltage Sensing

The control electronics (TIDA-01281) on the TIDA-00951 board is referred to the LV battery-side ground.
In order to sense the voltage across the isolated 400-V bus, an isolation amplifier circuit based around the
AMC1301 isolated amplifier and OPA376 op amp is used.
The differential output of the AMC1301 is scaled and converted into a single-ended output for connecting
directly to the MCU. Figure 8 shows this circuit.
HV_AUX_5V LV_AUX_5V C73

C45
C43 180pF
C41
C49 R61 R62
10µF 1nF

1nF
10µF
0 7.50k
U2 LV_AUX_3.3V C74
SGND
1 8

2
HV_GND VDD1 VDD2 R63 R64 0.1µF
2 7 4.70k 4.70k 3 U5 SGND
VBUS_SEC VINP VOUTP
C75 1 VBUS_S
C10 180pF VBUS_S
3 VINN VOUTN 6 4
1000pF R65 R66
4 5 4.70k 4.70k
GND1 GND2

5
AMC1301DWVR C76 R67 R68
HV_GND 180pF DNP 7.50k SGND
Iso Bus Voltage Sensing SGND VREF_1.2
HV_GND
C77

SGND 0.1µF

SGND

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Figure 8. Isolated Voltage Sensing Circuit Schematic

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www.ti.com Getting Started Hardware

7 Getting Started Hardware

7.1 Hardware
This section explains the power supply requirement and connectors used to set up the TIDA-00951 board
for testing.
For testing the TIDA-00951, three other TI Designs are used. The TIDA-01281 is a TMS320F28033-based
control and communication card. It is used as the control unit for TIDA-00951. The TIDA-01159 based on
the UCC21520 is the half-bridge gate driver that will be used to drive the HV full-bridge MOSFET. The
TIDA-01141 is the high-side current sensing card based on the INA240 and is used for sensing the
inductor current.
Mount the TIDA-00951 on connector J5. Mount the TIDA-01141 on connector J14.
The TIDA-00951 requires two TIDA-00159 boards on the HV-side full bridge. Each TIDA-01159 board
needs to be mounted on three connectors. The connectors J3, J1, and J4 form one set of connectors on
which one of the TIDA-01159 board is mounted. The connectors J2, J13, and J15 form the other set on
which the second TIDA-01159 board is mounted.
For providing auxiliary power to the TIDA-00951 board, a 12-V DC supply needs to be connected to
connector J6.

7.2 Test Setup

This section describes the test setup required and the test procedure. For conducting bidirectional power
transfer and mode change over experiments, the test setup is shown in Figure 9.

12-V AUX

J6
36- to 60-V J9 J8 400-V
DC supply DC supply
TIDA-00951

J11 J10

36- to 60-V 400-V

load load

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Figure 9. Test Setup for Bidirectional Power Flow

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7.3 Test Equipment Needed to Validate Board

• DC source: 0- to 400-V DC, 5 A rated
• DC source: 0- to 60-V DC > 70 A rated
• DC source: 12 V, 1 A
• Four-channel digital oscilloscope
• Current probe: 0 30 A, 50 MHz
• Electronic or resistive load capable of working up to 400 V, 5 A
• Electronic or resistive load capable of working up to 60 V, 16 A

7.4 Test Procedure

1. Prepare the test setup as shown in Figure 9.
2. Connect one DC supply on the battery input side (connectors J9 and J11) through the diode with
voltage set anywhere from 36 to 60 V.
3. Connect another DC supply on the bus input side (connectors J8 and J10) through a diode with
voltage set to 380 V.
4. Connect an electronic load to the bus input terminal with load set to draw 100 W.
5. Connect an electronic load to the battery input terminal with load set to draw 100 W.
6. Connect a DC fan and position it in such a way that the TIDA-00951 board receives about 400 LFM.
7. Connect a 12-V auxiliary supply to connector J6.
8. Turn on the DC supply connected to the bus input terminal.
9. Turn on the DC supply connected to the battery input terminal.
10. The TIDA-00951 will start working in charger mode and start supplying power to the electronic load
on the battery side.
11. Now disconnect the DC power supply connected to the bus input terminal.
12. The TIDA-00951 board will start working in the backup supply mode and power the load connected to
the bus input terminal.
13. Now increase the load in steps up to 2 kW to test the backup supply mode.
14. The necessary functional performance characteristics can be measured now.
15. Turn off the DC supply and disconnect the DC supply from the board.

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8 Testing and Results

8.1 Boost Mode Hard Start at 36-V Battery Voltage

In Figure 10, the yellow waveform is the drain-to-source voltage of an LV MOSFET, and the blue
waveform is the current-fed inductor current. The maximum spike on the drain-to-source voltage reaches
< 70 V. The inductor current is in excess of 50 A. This test is conducted to show that the maximum spoke
on the LV MOSFET remains well under the 100-V rating of the MOSFET.

Figure 10. Boost Mode Hard Start at 36-V Battery Voltage

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A zoomed waveform for hard startup at a 36-V battery voltage is shown in Figure 11.

Figure 11. Boost Mode Hard Start at 36-V Battery Voltage (Zoomed In)

8.2 Boost Mode Hard Start at 60-V Battery Voltage

In Figure 12, the yellow waveform is the drain-to-source voltage of an LV MOSFET, and the blue
waveform is the current-fed inductor current. The maximum spike on the drain-to-source voltage reaches
< 65 V.

Figure 12. Boost Mode Hard Start at 60-V Battery Voltage

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A zoomed in startup waveform is shown in Figure 13. The voltage spike at turnoff does not cross 10 V.

Figure 13. Boost Mode Hard Start at 60-V Battery Voltage (Zoomed In)

8.3 Boost Mode ZVS Waveform

Figure 14 and Figure 15 show the boost mode working waveforms. Figure 14 shows a full ZVS operation,
and Figure 15 shows a near ZVS turnon. The yellow trace is the LV MOSFET drain-to-source voltage, the
blue trace is the current-fed inductor current, and the rose waveform is the gate driver output.

Figure 14. Boost Mode Working Waveform With ZVS Turnon

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Figure 15. Boost Mode Working Waveform With Valley Switching Turnon

When the inductor current increases, one can get ZVS operation at turnon. At lower input currents, the LV
MOSFET is turned close to 0 V at turnon.

8.4 Active Clamp Working Waveform

The LV MOSFET drain-to-source voltage and gate voltage is shown along with the active clamp current in
Figure 16. When the LV MOSFET turns off, the current through it transfers to the active clamp.

Figure 16. TIDA-00951 Active Clamp Working Waveform

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Before the MOSFET is turned on again, the clamp MOSFET is turned off; this causes the current through
the clamp to come to zero. Because the current through the transformer leakage inductor cannot change
instantaneously, the current that was flowing through the clamp circuit (clamp MOSFET) begins to free
wheel through the LV MOSFET's body diode, thereby enabling it to turn at the ZVS condition.

8.5 Buck Mode Working Waveform

Figure 17 shows the switching waveform on the LV MOSFETs when operated in the buck mode. The LV
MOSFET turns on under ZVS condition.

Figure 17. Buck Mode Switching Waveform

The yellow trace represents the HV-side MOSFETs gate drive PWM input signal; the blue trace
represents the current-fed inductor; the green trace is the PWM input signal fed to the LV gate driver; and
the red waveform is the LV MOSFET's drain-to-source voltage. The red waveform goes to 0 V before the
green PWM trace goes high.

8.6 Buck-to-Boost Mode Transition Waveform

Initially, the system works in buck mode as a battery charger. In this mode, it takes power from a 400-V
DC bus and charges the LV battery pack.
When a power failure occurs on the 400-V bus, the voltage on the 400-V bus starts to drop. This triggers a
mode transition from buck-to-boost mode, where the power is taken from the battery pack and fed into the
400-V bus.
The timing for this transition is very critical because it determines how quickly and seamlessly the system
can provide backup power and also the sizing of the capacitors on the 400-V bus required for providing
the necessary holdup time.
Figure 18 shows the mode transition. When the 400-V bus voltage falls below 370 V, the TIDA-00951
stops charging the battery and goes into a boost soft start. When the 400-V bus voltage falls below 360 V.
It goes into hard start boost mode and immediately pumps the required power to bring the 400 V bus
voltage back to 370 V and regulates it at this point. The red trace represents the 400-V bus voltage, the
blue trace represents the inductor current, the green trace is the LV MOSFET PWM signal, and the yellow
trace represents the HV-side MOSFET PWM signal.

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Figure 18. TIDA-00951 Battery Charging to Backup Mode Transition

Figure 19 shows the zoomed out mode transition waveform, which shows the actual mode transition
period of 80 µs.

Figure 19. TIDA-00951 Battery Charging to Backup Mode Transition Zoomed

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8.7 Cold Start Waveform

When the TIDA-00951 is started for the first time, the 400-V bus can be completely discharged. This is a
special situation and does not occur during normal working conditions.
In order to startup under this condition, the TIDA-00951 uses a modified Weinberg clamp to pre-charge
the 400-V bus to 270 V. After charging to 270 V, the system moves complete the startup is normal boost
mode operation. In Figure 20, the red trace represent the 400-V bus voltage, the green trace is the PWM
signal sent to the modified Weinberg clamp, and the blue trace is the current taken from the battery for
pre-charging process.

Figure 20. Cold Start Using Weinberg Clamp

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Figure 21 shows the zoomed in switching waveform during the cold start process. The LV (battery side)
full bridge is being operated in DCM, and the energy in the current-fed inductor is transferred to the
secondary through the Weinberg clamp. This energy stored in a small capacitor on the HV side, which is
boosted to pre-charge the 400-V DC bus capacitors. The green trace shows the PWM signals for the
auxiliary low-power boost converter.

Figure 21. Cold Start Working Waveform (Zoomed)

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8.8 Boost Mode Efficiency

Figure 22 shows the boost mode output power versus efficiency data captured for various battery voltage.
96%

94%

92%

90%

Efficiency
88%

86%

84%

82%
VBAT = 36 V
80% VBAT = 48 V
VBAT = 60 V
78%
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Output Power (W) D001

Figure 22. Boost Mode Output Power versus Efficiency

8.9 Buck Mode Efficiency

Figure 23 shows the buck mode efficiency at various battery voltage and charging current. The 400-V bus
voltage was fixed at 380-V DC for conducting this test.
96%

94%

92%

90%
Efficiency

88%

86%

84%

82% VBAT = 36 V
VBAT = 48 V
VBAT = 60 V
80%
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Output Power (W) D002

Figure 23. Buck Mode Charging Current versus Efficiency

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8.10 Thermal Images

The thermal image of the TIDA-00951, working at 1500 W is shown in Figure 24.

Figure 24. TIDA-00951 Thermal Image at 1500 W

The maximum temperature on the board is on the isolation transformer. The board is force cooled with a
400LFM airflow.

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9 Design Files

9.1 Schematics
To download the schematics, see the design files at TIDA-00951.

9.2 Bill of Materials

To download the bill of materials (BOM), see the design files at TIDA-00951.

9.3 PCB Layout Recommendations

For the power stage layout:
1. Minimize the loop formed by the LV full bridge, the active clamp, and the transformer primary to keep
the leakage inductances very low and the loop area small.

Figure 25. LV Full-Bridge Layout Including Active Clamp

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2. The traces have to be as thick as possible to minimize the trace inductances.

3. Place the additional RC snubber if required in such a way as to minimize the spikes due to the FET led
inductances.
4. The loop formed on the secondary side between the transformer secondary winding, HV full-bridge
FETs, and the filter capacitor has to be as small as possible.
5. Place the gate driver on the LV side very close to the FET and at almost equal distance from the top
and bottom FET in each arm (see Figure 26).

Figure 26. Low-Voltage Side Half-Bridge Gate Driver Placement

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6. The GND pad on the bottom of the gate driver IC should be connected to a solid plane on the PCB to
help with thermal management for the gate driver and reduce the spikes on the gate driver IC’s pins.
7. Use multiple low ESR ceramic capacitors in the battery input section of the board to support the
required ripple current.
For current sensing:
1. Take a Kelvin connection from the current sense resistor as much as possible to connect to the
amplifier section.
2. Place the low-pass filter components just before the input of the amplifier.
3. The lines taken from the current sensor resistor need to be shielded with the GND plane wherever
possible to limit noise pickup on the lines.
A snapshot of the low-side current sense implementation is shown in Figure 27.

Figure 27. High-Side Battery Current Sensing Circuit Layout

For the control section:

1. Buffer the PWM outputs from the control card before connecting em to the gate driver input.
2. Separate the GND of the control card from the power GND to make sure that the switching current
flowing in the power GND does not affect the PWM signals being fed to the gate drivers.

9.3.1 Layout Prints

To download the layer plots, see the design files at TIDA-00951.

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9.4 Altium Project

To download the Altium project files, see the design files at TIDA-00951.

9.5 Gerber Files

To download the Gerber files, see the design files at TIDA-00951.

9.6 Assembly Drawings

To download the assembly drawings, see the design files at TIDA-00951.

10 Software Files
To download the software files, see the design files at TIDA-00951.

11 Related Documentation
1. IEEE, Operation principles of bi-directional full-bridge DC/DC converter with unified soft-switching
scheme and soft-starting capability, 15th Annual IEEE Applied Power Electronics Conference and
Exposition, 2000
2. IEEE, Extended Range ZVS Active-Clamped Current-Fed Full-Bridge Isolated DC/DC Converter for
Fuel Cell Applications: Analysis, Design, and Experimental Results, IEEE Transactions on Industrial
Electronics (Volume: 60, Issue: 7, July 2013)
3. Texas Instruments, Bidirectional DC-DC Converter, TIDM-BIDIR-400-12 Design Guide (TIDUAI7)
4. IEEE, Isolated full bridge boost DC-DC converter designed for bidirectional operation of fuel
cells/electrolyzer cells in grid-tie applications, 15th European Conference on Power Electronics and
Applications (EPE), 2013

11.1 Trademarks
C2000, NexFET are trademarks of Texas Instruments.
All other trademarks are the property of their respective owners.

12 About the Authors

RAMKUMAR S is a systems engineer at Texas Instruments, where he is responsible for developing
reference design solutions for the industrial segment. Ramkumar brings his diverse experience in analog
and digital power supplies design to this role. Ramkumar earned his master of technology (M.Tech) from
the Indian Institute of Technology in Delhi.
SALIL CHELLAPPAN is a systems manager, member, and group technical staff at Texas Instruments,
where he is responsible for developing reference design solutions for the industrial segment. Salil brings
to this role his extensive experience in power electronics, power conversion, EMI and EMC, power and
signal integrity, and analog circuits design spanning many high-profile organizations. Salil holds a bachelor
of technology degree from the University of Kerala.

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