48V 12V设计指导

TI Designs
BidirectionDCDC converter
Design Overview Design Features

TIDA-00653 is a non-isolated 48 to 12-V bi-  >96% efficiency
directional converter reference design for 48V  No air or liquid cooling needed
battery applications enabled by the UCD3138 digital  Multi phases interleaved
power controller. The design has the flexibility to  12V reverse connection prevention ( 20V
work in either a ZVS transition-mode topology to maximum reversed voltage)
optimize light-load efficiency, or a hard-switching  Protection including OCP, OVP,OTP
topology for a simple system design. The bi-  100uA quiescent current when disabled (
directional converter features auto-phase shedding, after 48V is disconnected)
offset for light-load, and adaptive dead-time
optimization for compounding efficiency gains Featured Applications
greater than 96%. Due to the significant efficiency
improvements, heat loss is reduced and no air or  HEV’s
liquid cooling are needed automotive applications.  EV’s
Additionally, the use of the UCD3138 high-control  Battery testing
frequency controller and hardware-based state
machine enable a small form factor and frees the Board Image
system CPU for other functions such as battery
management.
Design Resources
TIDA-00653 Design Folder
UCD3138A Product Folder
UCC27201A Product Folder
TLV3202 Product Folder
CSD17570Q5B Product Folder
REF1112
OPA2211
SN74AHC1G
Optional: Key Test Result Graph

Block Diagram
TIDUBM6 – April 2016 BidirectionDCDC converter 1
Copyright © 2016, Texas Instruments Incorporated

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1 Key System Specifications
PARAMETER 2 TEST CONDITION Min Typ Max Units

48 V POWER NET
48V Power Net voltage range 20 48 60 V
48V Power Net OV 56 57 58 V

48V Power Net Operating voltage without functional 36 52 V
limitation
48V Power Net Operating voltage with functional 24 54 V
limitation
Load dump transient 100mS 70 V
Max output power 1.6 KW
Max output current 42 A
12V POWER NET ( LEAD ACID BATTERY)
12V Power Net voltage range ( Minimum voltage occurs at cold 4.5 12 V
cranking)
12V Power Net OV 13.00 13.5 14.00 V

12V Power Net Operating voltage without functional 12.3 12.7 V
limitation
12V Power Net Operating voltage with functional 11.75 V
limitation
Max output power 1.6 KW
Max intput current 133 A
Quiescent current 100 uA

Ambient temp 125 C
Current reporting accuracy @ 12V output 1% 2%
Current reporting accuracy @ 48V output Calculated from 12V output current 2% 3%
Current sharing tolerance 10%
Current control accuracy 5%
Efficiency in Buck mode 25% load and above 97%
In Boost mode 94 %
Figure 1: Key System specification
TIDUBM6 - April 2016 BidirectionDCDC converter 2

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3 System Description
The BidirectionDCDC converter employs a digital controller that is optimized for power supply
applications. This converter has four phases, each capable of performing either a Buck or a Boost
operation. The power level for each phase is rated at 400 W. Once of the phase is a master phase that
dictates the switching frequency.
3.1 UCD3138A
Control Architecture optimized for Power Supply Applications
Separation of High Speed Power Supply Control Loop from Housekeeping
- Programmable hardware for High Speed Functions

• Advanced Power Peripherals operating autonomous from the processor, No need to
rely on slower firmware decisions
• Enhanced 2p / 2z Digital Compensator with Simplified PID Structure
• Protection features, Mode Switching, Constant Current, Peak current mode, voltage
feed forward
- Ease of Firmware Development
• Dedicated resources for high speed functions hence No need for complex time‐
slicing of shared resources
- Highest Levels of Integration
• Enhanced EADC (DAC Accuracy) with Hardware Dithering (3x 16 MHz, 1mV
resolution offers best in class current sharing accuracy)
• ADC
- 12 bit SAR
- Internal temp sensor
- Dual sample and hold
- Averaging
- Digital comparators
- PMBus addressing current sources
• Flexibility
- Digital Core enabling flexibility and manage housekeeping function.
- Support on‐the‐Fly firmware update without power supply interruption
• DPWM
- Hardware mapped shut‐down due to faults
- Fixed or adaptive sample trigger positioning
- Sync FET soft on/off and Ideal Diode Emulation
- Mode switching and Light Load Burst mode
• Advanced Power Control
- Current Share
- CPCC
- Synchronization
- Primary side Vtg sensing
- Flex and Current Balancing
• Communications
- Several communication peripherals (e.g. PMBus, UART, SPI) providing
flexibility for host communication.
- Lower Power Consumption
• ~70mA‐100mA during normal operation
• Can shut down portions of chip for lower power ~25mA standby power capable

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- Cost and Package Size Optimized

• Capable of fitting in high density applications (i.e. 1/8th brick)
Figure 2: To insert a caption, right click picture > Insert Caption

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4 Block Diagram
Figure 3: To insert a caption, right click picture > Insert Caption
4.1 Highlighted Products
4.1.1 UCD3138A
• 3 Independent Feedback Loops
• 16MHz Error Analog to Digital Converter (EADC)
• 14‐bit (effective) DAC for Control Loop Reference
• Synchronous Rectifier Dead Time Optimization Peripheral
• Dedicated PID Hardware (2p/2z configurable)
• 8 High Resolution DPWM Outputs (250ps Pulse Width Resolution)
• 2MHz Max Switching Frequency
• 14 Channel, 12‐bit, 265ksps General Purpose ADC
• 2 UARTs (HW Auto Baud)+ PMBus Interface
• 7 50ns Analog Comparators, Cycle‐by‐cycle ILIMIT
• On‐chip (BOD / POR), Single Supply Operation (3.3V)
• External Interrupt + Fault Input & Output
• Input Voltage Feed‐forward
5 System Design Theory

The Bidirection DCDC converter can operate in synchronous buck and boost mode to transfer power
in both the direction. This converter is designed to operate with a 48 V and a 12 V battery.
The Bidirection DCDC converter uses a UCD3138128 digtal power controller. It can control 4 phases
using a single current loop. The current that is sensed is an average of all the 4 phases. The board
allows current to be sensed from individual phases for current monitoring. It has a bias supply to power
up the UCD device and otherIC’s.

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5.1 Device blocks used for control operation
Device
Initializations Firmware
Current command Main loop 100 uS Interrupt
Current Feedback
Front End 0 Peripheral Buck
Error Value Initializations Initializations
Initializations
Boost
Initializations
PMBus handler
Buck handler
Filter Duty Initializations
Phase 0 DPWM 0 Filter 0
Current handler Boost handler
Phase shifted by IDE calculations

90 ADC readings
Initializations ADC based fault

Phase 1 DPWM 1 protections
Calculated
Phase shifted by value
90 IDE_KD
Initializations
Phase 2 DPWM 2
Phase shifted by
90
Initializations
Phase 3 DPWM 3
Initializations
Scaled 48 V
Scaled 12 V
Phase 0 current reading
ADC ADC Readings
Figure 4 Internal working of the device.
The block diagram above shows the working of the UCD3138128 device on the Bidirection board. It
uses a single front end for the current loop control. The DPWM’s provide the appropriate PWM
signals to the phases. The PWM signals from the DPWM’s are phase shifted by 90 each to provide
interleaving. A single filter (filter 0 ) provides the filter duty value for all the DPWM’s. The DPWM’s
are configured in such a way that the a DPWM provides phase trigger to the other DPWM. For
example DPWM 0 provides phase trigger to DPWM 1 and then DPWM1 provides the phase trigger
to DPWM2. The phase trigger makes the DPWM module to restart its counter there by maintaining a
phase difference between itself and the module that is sending the phase trigger.
The ADC of the device senses the 48 V,12 V and individual phase currents. The firmware then
collects the ADC readings and calculates the average value. There are some protections being
placed by the device using firmware based on the reading from the ADC.They are over voltage and
under voltage protection, both for the 12 V and the 48 V battery.
The usual values are shown below in the table:

Protection limit 48 V Battery 12V Battery
Over voltage 56 V 14 V
Under voltage 36 V 9V

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Other protections are available in the device based on the cycle by cycle value of the current. These
are implemented by the hardware and uses the fault mux and the DPWM module to make
appropriate adjustment to the output waveform.
The IDE_KD hardware in the fault mux provide the DPWM modules with the ratio of the turn on and
turn off times. The DPWM B is now a ratio of the size of DPWM A pulse .We can say that :
DPWM B pulse = IDE_KD * DPWM A pulse.
The IDE_KD value is calculated in firmware using the ADC reading of the 48 V and the 12 V battery.

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6 Getting Started Hardware

The Bidirection DCDC converter is used to charge either the 12 V Battery or the 48 V Battery. But for
demo purposes, user can use a power supply/load configuration to simulate a battery. The image
shown below illustrates how the connections have to be made:
Bidirection
Power Supply Power Supply
DCDC
at 48 V at 12 V
converter
Electronic load in Electronic load in

constant voltage constant voltage
mode set at 48 V mode set at 12 V
Figure 5 Basic setup for testing the converter.
After setting up the board as shown above, connect the PMBus connector to the converter.
Follow the below steps to get the Bidirection DCDC converter running:
1) Turn on the 48 V supply.

3) Press the reset button on the converter to clear any operation to be pending.
4) Download the provided firmware.

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7 Getting Started Firmware

Download and install the latest Fusion GUI from this link:
http://www.ti.com/tool/fusion_digital_power_designer
After installing the software go to the location as shown in the figure:
Figure 4
The window as shown should appear:

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Figure 5
Click on the “Scan Device in ROM Mode” as shown. Then the device should be detected as
shown in the Geen highlighted line.
If an error occurs then the device might be in program mode. Click on “Device ID” as shown in
figure 17.
If the device was found in ROM mode then click on “Firmware Download” :

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Figure 6
Click on “Select File…” and point it to the x0 file . The x0 file is usually located in the
“Debug_Hardswitching” folder.
Keep the setting as shown in the figure above and click on the button “Download”. Once
downloaded, the device has the firmware that can run the board. Now close the Download
window.

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Figure 7
After detecting the device in program mode, click on the “Debug” tab as shown:

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Figure 8
Click “Memory Debugger”. If you are opening the memory debugger for the first time then the GUI
will ask for a password. Please enter “forestln” as the password.
Once the memory debugger is opened, click on the “File” tab as shown:

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Figure 9
Click on the “Select Folder Containing the Map/PP Files” button and point it to the folder
containing the project. Click “OK”.

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Figure 10
In the “All” tab, click on the “RAM” Radio button. Following that , all the RAM variables used in the
device are displayed as shown. We are interested in only a few of the RAM varaibles. They are
highlighted as shown. Click on the star icon on the left of those variables to make them available in
the “Watch list”.
Now , click on the tab “Watch list” and click on the “RAM” Radio button.

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Figure 11
The variables that we had earlier “starred” will appear in this window as shown above. The
three important variables are I_CMD, converter_state and error_state. The meaning of these
variables is described in the table below:
Variable Description Read / write

I_CMD This variable is used to set the current output of
the converter.
Positive values make the 48 V battery discharge

and charge the 12 V battery. Hence the
direction of current flow is from 48 V to 12 V . Write
This direction is considered positive. For these
values the board is operating in BUCK mode.
Negative values make the 12 V battery

discharge and charge the 48 V battery. The
direction of current flow is from 12 V to 48 V.

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For these values the board is operating in

BOOST mode.
converter_state This variable simply indicates which state the Read only
board is .
error_state This variable gives a error if any during the
operation of the converter.
It has nine values:
UNDER_INPUT_VOLTAGE
OVER_INPUT_VOLTAGE
UNDER_OUTPUT_VOLTAGE Read only
OVER_OUTPUT_VOLTAGE
SYNC_CRAZY
NO_BATTERY_CONNECTED
OPAMP_LOCK_UP
FEED_BACK_ERROR
NO_ERROR
Table 1. RAM variables description.

To run the converter, enter values between -120 to 120 for I_CMD variable. It is advised that you
should start with smaller values like -20 to 20 to check if the connections are made well.
Also, before changing the sign of the current command, it is better to go to zero first and then change
the command.
Click on the “Watch List” to read the values of the variables.

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7.1 Compiling the firmware

To compile the given code, TI’s Code Composer Studio has to be used. The latest version of
Code composer Studio can be downloaded here:
http://www.ti.com/tool/CCSTUDIO
The steps below show how to compile the BidirectionDCDC code.
1) Identify the location of the project folder. These are the folders named “BiDirectionDCDC”.
They can be found under the device named folder like “UCD3138128”.
2) Add the project to Code Composer Studio:
Go to the project menu in Code Composer studio as shown in the figure and click
“Import CCS Project…”
Figure 12 Project import for CCS
Select the folder and click on “OK”.

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Figure 13 Project selection
Once added, the project will show up in the Projects Explorer. The default build
configuration that Code Composer Studio sets is “Release”. We need to change it to the
required build configuration. In our case, we have to set it to “Debug_Hardswitching” as
shown in the figure.

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Figure 14 Build configuration setting
Now build the project as shown in the figure below:

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Figure 15 Compiling the project
If the compilation process was successful, then the output would be an x0 file which can be
downloaded to the device.
Figure 16 Compilation result and output

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8 Test Setup
The Bidirection DCDC converter is used to charge either the 12 V Battery or the 48 V Battery. But for
demo purposes, user can use a power supply/load configuration to simulate a battery. The image
shown below illustrates how the connections have to be made:
Bidirection
Power Supply Power Supply
DCDC
at 48 V at 12 V
converter
Electronic load in Electronic load in

constant voltage constant voltage
mode set at 48 V mode set at 12 V
Figure 17
After setting up the board as shown above, connect the PMBus connector to the converter.
Follow the below steps to get the bidirection DCDC converter running:
3) Press the reset button on the converter to clear any operation to be pending.
4) Download the provided firmware.

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9 Test Data
9.1 Efficiency plots
The efficiency for the hardswitching Bidirection DCDC converter in Buck operation is
as shown below :
Figure 18 Efficiency plot for Hardswitching Buck operation
The data collected above was at an input voltage of 48 V and an output voltage of 12
V.The data was collected after deadtime optimization for each output current intervals
of 4 Amps. The board was fitted on to a heat sink and placed in room temperature and
no air cooling was provided.
The hardswitching Buck operation has a good efficiency at lower currents and this is
because of the DCM operation. However, at higher currents the efficiency starts to
take a slight dip.

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Figure 19 Efficiency plot for ZVS Buck operation
The data for the ZVS Buck operation was collected with the same conditions as the
hardswitching Buck operation. As shown above, the efficiency at light load is not very
impressive, but at higher loads, the efficiency is really flat and the higest efficiency of
96.28 % is achieved at its peak load of 110 A.

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Figure 20 Efficiency plot for Hardswitching Boost operation
The data collected above was at an input voltage of 12 V and an output voltage of 48
V.The data was collected after deadtime optimization for each output current intervals
of 4 Amps. The board was fitted on to a heat sink and placed in room temperature and
no air cooling was provided.

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Figure 21 Efficiency plot for ZVS Boost operation
9.2 Loss analysis
Figure 22 Different losses for Hardswitching and ZVS topologies.

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The above bar graph shows losses from different components for the hardswitching and ZVS
modes. From the data shown, we can see that there is more switching loss from the FETs in
the Hardswitching Buck than the ZVS Buck. However, the ZVS buck has more core loss. This is
because of high current ripple. This core loss can be minimized by using a better inductor
having lower conduction loss.
Total Loss
Hardswitching Buck ZVS Buck
70.8 W 65.3 W
9.3 Thermal data
Figure 23 Thermal image of the BidirectionDCDC board on a heat sink performing Hard switching
Buck operation at 110 A.

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The above image is a thermal image of the top view of the board operating in
Hardswitching Buck mode at a total current of 110 A. The center of the image shows
the FETs and the inductors of different phases. It can seen that the active FETs are
relatively hot compared to the sync FETs.
Figure 24 Thermal image of the BidirectionDCDC board on a heat sink performing ZVS Buck operation
at 110 A.

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9.4 Operating the board in Buck and Boost mode.
Figure 25 Output current and switch node waveforms

IL (Inductor current of a phase) Vsw ( Switching node wave form )
The above image shows the switching node waveform, 12 V battery current and the
inductor current for a single phase. The Board is made to switch between Buck and
Boost mode. The total current at the 12 V battery is ramped up or ramped down to
have a smooth transition between Buck and Boost operation.

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Figure 26 Battery voltage waveforms and total current for Buck and Boost operations.
The 48 V battery and the 12 V battery voltage wave forms are displayed for the buck
and boost operation. As seen in the image, the 12 V battery’s voltage ramps up during
the Buck operation and the 48 V battery voltage ramps down. And during the Boost
operation, the 48 V battery voltage ramps up and the 12 V battery voltage ramps down.
Also the 12 V battery current waveform shows that the battery charging happens in
constant current mode.

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10 Design Files
10.1 Schematics
To download the Schematics for each board, see the design files at http://www.ti.com/tool/DESIGNNUMBER
Figure 27
The schematic shown above represents the master phase, phase 1. Similar configuration is used for the rest of the three phases.

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10.2 Bill of Materials
To download the Bill of Materials for each board, see the design files at http://www.ti.com/tool/DESIGNNUMBER
Table 1: To insert a table caption, right click picture > Insert Caption
Designator Quantity Value Description PackageReference PartNumber Manufacturer
!PCB 1 Printed Circuit Board XX#### Any
C1 1 3300pF CAP, CERM, 3300pF, 100V, +/- 0603 06031C332JAT2A AVX
5%, X7R, 0603
C2, C8, 3 10uF CAP, CERM, 10uF, 16V, +/- 0805 0805YD106MAT2A AVX
C11 20%, X5R, 0805
C3 1 0.1uF CAP, CERM, 0.1uF, 50V, +/- 0603 06035C104KAT2A AVX
10%, X7R, 0603
C4, C28, 6 0.1uF CAP, CERM, 0.1uF, 25V, +/- 0603 06033C104JAT2A AVX
C91, C93, 5%, X7R, 0603
C95, C97
C5, C114 2 100pF CAP, CERM, 100pF, 50V, +/- 0603 C0603C101J5GAC Kemet
5%, C0G/NP0, 0603
C6 1 2.2uF CAP, CERM, 2.2uF, 100V, +/- 1206_190 GRM31CR72A225KA73L MuRata
10%, X7R, 1206_190
C7 1 0.47uF CAP, CERM, 0.47uF, 100V, +/- 1206 C3216X7R2A474K TDK
10%, X7R, 1206
C9, C61, 9 2.2uF CAP, CERM, 2.2uF, 16V, +/- 0805 0805YD225KAT2A AVX
C70, C79, 10%, X5R, 0805
C88, C99,
C100,
C101,
C102
C10 1 100pF CAP, CERM, 100pF, 50V, +/- 0603 06035A101JAT2A AVX
5%, C0G/NP0, 0603

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C12 1 10uF CAP, CERM, 10uF, 25V, +/- 0805 C2012X5R1E106K125AB TDK
10%, X5R, 0805
C13 1 10uF CAP, CERM, 10uF, 6.3V, +/- 0603 C0603C106M9PACTU Kemet
20%, X5R, 0603
C14, C15 2 33pF CAP, CERM, 33pF, 100V, +/- 0603 06031A330JAT2A AVX
5%, C0G/NP0, 0603
C16, C25, 7 0.01uF CAP, CERM, 0.01uF, 100V, +/- 0603 06031C103JAT2A AVX
C27, C63, 5%, X7R, 0603
C72, C81,
C115
C17, C20, 3 1uF CAP, CERM, 1uF, 16V, +/- 0603 C0603C105K4PACTU Kemet
C23 10%, X5R, 0603
C18, C19, 5 0.1uF CAP, CERM, 0.1uF, 16V, +/- 0603 0603YC104JAT2A AVX
C21, C24, 5%, X7R, 0603
C90
C22, C71, 5 2.2uF CAP, CERM, 2.2uF, 10V, +/- 0603 C0603C225K8PACTU Kemet
C80, C89, 10%, X5R, 0603
C94
C26, C103 2 0.022uF CAP, CERM, 0.022uF, 25V, +/- 0603 C0603C223K3RACTU Kemet
10%, X7R, 0603
C29, C30, 3 2.2uF CAP, CERM, 2.2uF, 6.3V, +/- 0603 C0603C225K9PACTU Kemet
C31 10%, X5R, 0603
C33 1 100pF CAP, CERM, 100pF, 25V, +/- 0603 06033C101KAT2A AVX
10%, X7R, 0603
C37, C38, 8 22uF CAP, CERM, 22uF, 50V, +/- 6x5x5mm CKG57NX5R1H226M500JH TDK
C40, C41, 20%, X5R, 6x5x5mm
C49, C50,
C52, C53
C39 1 0.1uF CAP, CERM, 0.1uF, 25V, +/- 0603 GRM188R71E104KA01D MuRata
10%, X7R, 0603
C39, C45, 4 1000pF CAP, CERM, 1000pF, 100V, +/- 0603 06031C102JAT2A AVX
C51, C57 5%, X7R, 0603

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C42, C54, 8 10uF CAP, CERM, 10uF, 100V, +/- 2220 C5750X7S2A106M TDK
C64, C66, 20%, X7S, 2220
C73, C75,
C82, C84
C43, C46, 4 1uF CAP, CERM, 1uF, 16V, +/- 0805 B37941K9105K62 EPCOS Inc
C55, C58 10%, X7R, 0805
C44, C56, 16 47uF CAP, CERM, 47uF, 16V, +/- 1210 GRM32ER61C476ME15L MuRata
C65, C67, 20%, X5R, 1210
C74, C76,
C83, C85,
C116,
C117,
C118,
C119,
C120,
C121,
C122,
C123
C47 1 330uF CAP, AL, 330uF, 100V, +/-20%, MN0 EMVE101GTR331MMN0S Nippon Chemi-Con
ohm, SMD
C48 1 470uF CAP, AL, 470uF, 25V, +/-20%, JA0 EMVA250ADA471MJA0G Nippon Chemi-Con
ohm, SMD
C59, C68, 4 330pF CAP, CERM, 330pF, 50V, +/- 0603 06035A331JAT2A AVX
C77, C86 5%, C0G/NP0, 0603
C60, C69, 4 0.1uF CAP, CERM, 0.1uF, 25V, +/- 0603 06033C104KAT2A AVX
C78, C87 10%, X7R, 0603
C62 1 4.7uF CAP, CERM, 4.7uF, 25V, +/- 0805 C2012X5R1E475K125AB TDK
10%, X5R, 0805
C104 1 22pF CAP, CERM, 22pF, 50V, +/- 0603 06035A220JAT2A AVX
5%, C0G/NP0, 0603
C106, 4 1uF CAP, CERM, 1 µF, 25 V, +/- 0603_095 C0603C105K3RACTU Kemet
C108, 10%, X7R, 0603_095
C109,
C112

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C107, 4 1000pF CAP, CERM, 1000 pF, 50 V, +/- 0603 C0603X102K5RACTU Kemet
C110, 10%, X7R, 0603
C111,
C113
D1, D3, D4 3 200V Diode, Switching, 200V, 0.2A, SOT-23 BAS21-7-F Diodes Inc.
SOT-23
D2, D7, 3 Red LED, Red, SMD LED_0805 LTST-C170KRKT Lite-On
D16
D5, D6, 3 40V Diode, Schottky, 40 V, 0.5 A, SOD-123 MBR0540T1G ON Semiconductor
D17 SOD-123
D8, D9, 8 12V Diode, Zener, 12V, 500mW, SOD-123 MMSZ4699-V Vishay-Semiconductor
D10, D11, SOD-123
D12, D14,
D15, D18
D13, D19, 8 15V Diode, Schottky, 15 V, 1 A, DO- DO-216-AA UPS115UE3/TR7 Microsemi
D20, D21, 216-AA
D22, D23,
D24, D25
FID1, FID2, 3 Fiducial mark. There is nothing Fiducial N/A N/A
FID3 to buy or mount.
H1, H2, H3, 7 Machine Screw, Round, #4-40 Screw NY PMS 440 0025 PH B&F Fastener Supply
H4, H5, H6, x 1/4, Nylon, Philips panhead
H7
J1 1 Header (shrouded), 100mil, 5x2 Shrouded header 5103308-1 TE Connectivity
5x2, Gold, TH
J2, J3, J4, 6 Connector Lug, wire range #6 - Connector Lug, 90562 Morris Products
J5, J6, J7 4/0, 600V 1.075x0.45x0.45 inch
J8, J9, J11 3 Header,2x1, 100mil, TH Header, 2x1, 100mil, TH 22-27-2021 Molex
J10 1 Header, 2x1, 100mil, SMT Header, 2x1, 100mil, TH 800-10-002-10-001000 Mill-Max

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J12 1 Header, TH, 100mil, 4x1, Gold 4x1 Header TSW-104-07-G-S Samtec
plated, 230 mil above insulator
L1, L2 2 1uH Inductor, Shielded, Composite, 15.2x8x16.2mm XAL1580-102MEB Coilcraft
1uH, 57.5A, 0.000929 ohm,
SMD
L3, L4, L5, 4 4.7uH Inductor, Shielded E Core, 29.7x15.36x27.94mm SER2915H-472KL Coilcraft
L6 Ferrite, 4.7 µH, 30 A, 0.00186
ohm, SMD
LBL1 1 Thermal Transfer Printable PCB Label 0.650"H x THT-14-423-10 Brady
Labels, 0.650" W x 0.200" H - 0.200"W
10,000 per roll
Q1 1 -20V MOSFET, P-CH, -20V, -2.4A, SOT-23 FDN302P Fairchild Semiconductor
SOT-23
Q4, Q7, 8 30V MOSFET, N-CH, 30V, 51A, SON 5x6mm CSD17570Q5B Texas Instruments
Q8, Q9, SON 5x6mm
Q20, Q26,
Q30, Q39
Q5, Q6, 8 100V MOSFET, N-CH, 100V, DDPAK-7 IPB017N10N5 Infineon Technologies
Q18, Q22, 1.7mOhm, DDPAK-7
Q28, Q32,
Q38, Q42
Q11, Q14 2 60V MOSFET, N-CH, 60V, 0.24A, SOT-23 2N7002E-T1-E3 Vishay-Siliconix
SOT-23
Q15, Q25, 4 -100V MOSFET, P-CH, -100V, -0.6A, SOT-23 ZXMP10A13FTA Diodes Inc.
Q35, Q45 SOT-23
Q16, Q17, 8 30 V Transistor, PNP, 30 V, 12 A, SMD-8 ECH8102-TL-H ON Semiconductor
Q24, Q27, SMD-8
Q36, Q37,
Q46, Q47
R1, R16 2 330 RES, 330 ohm, 1%, 0.1W, 0603 0603 RC0603FR-07330RL Yageo America
R2 1 39.0k RES, 39.0k ohm, 1%, 0.1W, 0603 RC0603FR-0739KL Yageo America
0603
R3 1 150k/1% RES, 150k ohm, 1%, 0.1W, 0603 CRCW0603150KFKEA Vishay-Dale
0603

www.ti.com
R4 1 120k RES, 120k ohm, 1%, 0.1W, 0603 RC0603FR-07120KL Yageo America
0603
R5, R122 2 49.9 RES, 49.9 ohm, 1%, 0.1W, 0603 CRCW060349R9FKEA Vishay-Dale
0603
R6 1 27.0k RES, 27.0k ohm, 1%, 0.1W, 0603 RC0603FR-0727KL Yageo America
0603
R7, R118 2 10.0k RES, 10.0k ohm, 1%, 0.1W, 0603 CRCW060310K0FKEA Vishay-Dale
0603
R8 1 1k_1% RES, 1.0k ohm, 5%, 0.1W, 0603 CRCW06031K00JNEA Vishay-Dale
0603
R9 1 330 RES, 330, 5%, 0.1 W, 0603 0603 CRCW0603330RJNEA Vishay-Dale
R10 1 560 RES, 560 ohm, 1%, 0.1W, 0603 0603 RC0603FR-07560RL Yageo America
R11 1 3.0k RES, 3.0k ohm, 5%, 0.1W, 0603 CRCW06033K00JNEA Vishay-Dale
0603
R12, R112, 3 100k RES, 100 k, 5%, 0.1 W, 0603 0603 CRCW0603100KJNEA Vishay-Dale
R116
R13, R14 2 1.50k RES, 1.50k ohm, 0.1%, 0.1W, 0603 RG1608P-152-B-T5 Susumu Co Ltd
0603
R15, R20, 5 0 RES, 0 ohm, 5%, 0.1W, 0603 0603 MCR03EZPJ000 Rohm
R21, R22,
R23
R17, R111, 5 1.00k RES, 1.00k ohm, 1%, 0.1W, 0603 CRCW06031K00FKEA Vishay-Dale
R115, 0603
R117,
R119
R19, R38, 6 1.0k RES, 1.0k ohm, 5%, 0.1W, 0603 CRCW06031K00JNEA Vishay-Dale
R124, 0603
R125,
R126,
R127
R24, R26 2 100 RES, 100 ohm, 1%, 0.1W, 0603 0603 CRCW0603100RFKEA Vishay-Dale

www.ti.com
R27, R36, 8 0.002 RES, 0.002, 1%, 1 W, 2512 2512 ERJ-M1WTF2M0U Panasonic
R52, R57,
R71, R76,
R90, R95
R28 1 33.0k RES, 33.0 k, 1%, 0.1 W, 0603 0603 CRCW060333K0FKEA Vishay-Dale
R30, R39, 8 10.0k RES, 10.0k ohm, 0.1%, 0.1W, 0603 RG1608P-103-B-T5 Susumu Co Ltd
R53, R59, 0603
R72, R78,
R91, R97
R33 1 1.10k RES, 1.10 k, 1%, 0.1 W, 0603 0603 RC0603FR-071K1L Yageo America
R34, R41, 8 10.0k RES, 10.0 k, 1%, 0.1 W, 0603 0603 CRCW060310K0FKEA Vishay-Dale
R56, R63,
R75, R82,
R94, R101
R40, R43, 13 1.0k_1% RES, 1.0k ohm, 5%, 0.1W, 0603 CRCW06031K00JNEA Vishay-Dale
R45, R46, 0603
R61, R64,
R65, R80,
R83, R84,
R99, R102,
R103
R42, R60, 4 120 RES, 120, 5%, 0.1 W, 0603 0603 CRCW0603120RJNEA Vishay-Dale
R79, R98
R43, R135 2 0 RES, 0 ohm, 5%, 0.125W, 0805 0805 CRCW08050000Z0EA Vishay-Dale
R49, R62, 0603
R66, R68,
R81, R85,
R87, R100,
R104,
R106

www.ti.com
R86, R105 0603
R51, R70, 4 1.64k_1% RES, 1.65k ohm, 1%, 0.1W, 0603 CRCW06031K65FKEA Vishay-Dale
R89, R108 0603
R109, 4 2.00k RES, 2.00k ohm, 1%, 0.1W, 0603 CRCW06032K00FKEA Vishay-Dale
R110, 0603
R113,
R114
R120 1 0 RES, 0 ohm, 5%, 0.1W, 0603 0603 ERJ-3GEY0R00V Panasonic
R121 1 31.6k_1% RES, 31.6k ohm, 1%, 0.1W, 0603 CRCW060331K6FKEA Vishay-Dale
0603
R128 1 75.0 RES, 75.0, 1%, 0.1 W, 0603 0603 CRCW060375R0FKEA Vishay-Dale
R130 1 10.0 RES, 10.0 ohm, 1%, 0.1W, 0603 CRCW060310R0FKEA Vishay-Dale
0603
S1 1 Switch, Push Button, SMD 2.9x2x3.9mm SMD SKRKAEE010 Alps
T1 1 60 uH xfmr, ?0% 12x12.5 mm 750342460 WURTH ELEKTRONIK

www.ti.com
TP1, TP2, 55 White Test Point, Miniature, White, TH White Miniature Testpoint 5002 Keystone
TP4, TP5,
TP6, TP7,
TP8, TP9,
TP10,
TP11,
TP13,
TP14,
TP15,
TP16,
TP17,
TP18,
TP19,
TP20,
TP21,
TP22,
TP23,
TP24,
TP25,
TP26,
TP27,
TP28,
TP29,
TP31,
TP32,
TP33,
TP35,
TP36,
TP37,
TP38,
TP39,
TP40,
TP41,
TP42,
TP43,
TP44,

www.ti.com
TP45,
TP46,
TP47,
TP48,
TP49,
TP50,
TP51,
TP52,
TP53,
TP55,
TP56,
TP57,
TP58,
TP59,
TP60

www.ti.com
TP3 1 SMT Test Point, Compact, SMT Testpoint_Keystone_Compact 5016 Keystone
U1 1 LM34927MR IC, Integrated Secondary Side PSOP LM34927MR TI

Bias Regulator
U2 1 FIXED LOW-DROPOUT DCY0003A TLV1117-33IDCY Texas Instruments
VOLTAGE REGULATOR,
DCY0003A
U3 1 UCD3138128PFC, PFC0080 PFC0080A UCD3138128PFC Texas Instruments
U4, U6, U8, 4 UCC2721xDRM IC, 120V Boot, 4A Peak, High QFN-8 UCC2721xDRM TI
U10 Frequency High-Side Low-Side
Driver
U5 1 1.1 nV/rtHz Noise, Low Power, DDA0008C OPA2211AIDDA Texas Instruments
Precision Operational Amplifier,
4.5 to 36 V, -40 to 125 degC, 8-
pin SOP (DDA0008C), Green
(RoHS & no Sb/Br)
U7, U9, 3 1.1 nV/rtHz Noise, Low Power, D0008A OPA211AID Texas Instruments
U11 Precision Operational Amplifier,
4.5 to 36 V, -40 to 125 degC, 8-
pin SOIC (D0008A), Green
(RoHS & no Sb/Br)
U12 1 40-ns, microPOWER, Push-Pull D0008A TLV3202AID Texas Instruments
Output Comparators, D0008A
U13 1 Single 2-Input Positive-AND DBV0005A SN74AHC1G08DBV Texas Instruments
Gate, DBV0005A
U14 1 DUAL BUFFER GATE, DRL0006A SN74LVC2G34DRL Texas Instruments
DRL0006A
U15, U16, 4 1 uA Shunt Voltage Reference, DBZ0003A REF1112AIDBZT Texas Instruments
U17, U18 1.25 V, 10 ppm / degC, 5 mA, -
40 to 85 degC, 3-pin SOT-23
(DBZ), Green (RoHS & no
Sb/Br)
U19 1 3.3V CAN Transceiver with D0008A SN65HVD233D Texas Instruments
Standby Mode, Loop-back, 6
mA, -40 to 125 degC, 8-pin

www.ti.com
SOIC (D), Green (RoHS & no

Sb/Br)
XF1, XF3, 4 FuseHolder 780x320x345mil 3587 Keystone

XF5, XF7
C32, C34, 0 22pF CAP, CERM, 22pF, 50V, +/- 0603 06035A220JAT2A AVX
C35, C36 5%, C0G/NP0, 0603
C105 0 330pF CAP, CERM, 330pF, 100V, +/- 0603 06031C331JAT2A AVX
5%, X7R, 0603
Q2, Q3, 0 60V MOSFET, N-CH, 60V, 0.24A, SOT-23 2N7002E-T1-E3 Vishay-Siliconix
Q12, Q23, SOT-23
Q34, Q43

www.ti.com
10.2.1 Layout files

To download the Layout Prints for each board, see the design files at
http://www.ti.com/tool/DESIGNNUMBER
Figure 28 Top overlay
Figure 29 Top Solder

www.ti.com
Figure 30 Top Layer
Figure 31 Midlayer 1

www.ti.com
Figure 32 Midlayer 2
Figure 33 Bottom Layer

www.ti.com
Figure 34 Bottom Solder
Figure 35 M2 Board Dimentions

www.ti.com
10.3 Altium Project

To download the Altium project files for each board, see the design files at
Figure 36: Altium Project

www.ti.com
10.4 Assembly Drawings

To download the Assembly Drawings for each board, see the design files at
Figure 37: Assembly Drawing

www.ti.com
11 Software Files
To download the software files for this reference design, please see the link at
12 References
1) Highly Integrated Digital Controller for Isolated Power (Rev. F)
http://www.ti.com/lit/gpn/ucd3138
2) UCD3138 Monitoring and Communications Programmer’s Manual (Rev. A)
http://www.ti.com/lit/pdf/sluu996
3) UCD3138 Digital Power Peripherals Programmer’s Manual (Rev. A)
4) UCD3138 ARM and Digital System Programmer’s Manual (Rev. A)
13 About the Author
Sanatan Rajagopalan is a Systems/Apps engineer at Texas Instruments, where he is responsible for

developing reference design solutions for the industrial and automotive segment. Sanatan earned his Master of
Science in Electrical Engineering (MSEE) from Texas Tech University in Lubbock, TX.

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48V 12V设计指导

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TI Designs

Design Overview Design Features

CSD17570Q5B Product Folder

Optional: Key Test Result Graph

TIDUBM6 – April 2016 BidirectionDCDC converter 1

Copyright © 2016, Texas Instruments Incorporated

1 Key System Specifications

PARAMETER 2 TEST CONDITION Min Typ Max Units

48V Power Net voltage range 20 48 60 V

48V Power Net OV 56 57 58 V

12V Power Net OV 13.00 13.5 14.00 V

Quiescent current 100 uA

Figure 1: Key System specification

TIDUBM6 - April 2016 BidirectionDCDC converter 2

Copyright © 2016, Texas Instruments Incorporated

- Programmable hardware for High Speed Functions

Copyright © 2016, Texas Instruments Incorporated

- Cost and Package Size Optimized

Figure 2: To insert a caption, right click picture > Insert Caption

TIDUBM6 - April 2016 BidirectionDCDC converter 4

Copyright © 2016, Texas Instruments Incorporated

Figure 3: To insert a caption, right click picture > Insert Caption

4.1 Highlighted Products

5 System Design Theory

TIDUBM6 - April 2016 BidirectionDCDC converter 5

Copyright © 2016, Texas Instruments Incorporated

5.1 Device blocks used for control operation

Phase shifted by IDE calculations

Initializations ADC based fault

Figure 4 Internal working of the device.

The usual values are shown below in the table:

TIDUBM6 - April 2016 BidirectionDCDC converter 6

Copyright © 2016, Texas Instruments Incorporated

DPWM B pulse = IDE_KD * DPWM A pulse.

TIDUBM6 - April 2016 BidirectionDCDC converter 7

Copyright © 2016, Texas Instruments Incorporated

6 Getting Started Hardware

Electronic load in Electronic load in

Figure 5 Basic setup for testing the converter.

1) Turn on the 48 V supply.

TIDUBM6 - April 2016 BidirectionDCDC converter 8

Copyright © 2016, Texas Instruments Incorporated

7 Getting Started Firmware

After installing the software go to the location as shown in the figure:

The window as shown should appear:

TIDUBM6 - April 2016 BidirectionDCDC converter 9

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 10

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 11

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 12

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 13

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 14

Copyright © 2016, Texas Instruments Incorporated

TIDUBM6 - April 2016 BidirectionDCDC converter 15

Copyright © 2016, Texas Instruments Incorporated