Technical note

STDES-BCBIDIR test report

Rev 2 - August 2025

Introduction

The STDES-BCBIDIR is an 11 kW bidirectional battery charger that provides a comprehensive solution for high-voltage charging applications in both industrial and automotive fields.

It features two power stages: a power factor correction (PFC) stage and an isolated DC-DC stage.

The PFC stage employs a three-phase full-bridge topology, while the DC-DC stage can be configured with two topologies by externally connecting the resonant cell. Both stages utilize ACEPACK DMT-32 SiC power modules.

The system is controlled by two dedicated control boards, one for the PFC stage and another for the DC-DC stage, each based on the STM32G4 microcontroller.

The PFC stage operates at a switching frequency of 70 kHz. The DC-DC stage operates at a fixed switching frequency of 100 kHz in dual active bridge (DAB) topology or a variable switching frequency ranging from 82 to 235 kHz in CLLC topology. This design achieves a peak system efficiency exceeding 96%.

The STDES-BCBIDIR has a single 11 kW magnetic component, which includes the high-frequency isolation transformer and resonant elements for the CLLC tank, or the isolation transformer and leakage inductance for the DAB topology.

The modular hardware architecture consists of the following components:

  • Main power board equipped with: ACEPACK DMT-32 SiC power modules, featuring a sixpack topology (M1P45M12W2-1LA) for the PFC stage, and two full-bridge modules (M1F45M12W2-1LA) for the DC-DC stage. The board also includes bulk capacitors, sensing circuits, and an auxiliary power supply.
  • Driver board: designed for the full-bridge and sixpack ACEPACK DMT-32 SiC power modules, it incorporates the STGAP2SiCD galvanically isolated 4 A dual gate driver optimized for SiC MOSFETs.
  • Control board: based on the STM32G4 microcontroller series, this board features connectors for communication and programming, test points, and status indicators to facilitate testing and monitoring.
Figure 1. STDES-BCBIDIR reference design


Features

  • Reference design modular kit consisting of:
    • Main power board - STDES-BCBIDIRP
    • Driver board (three for PFC stage, four for DC-DC stage) - STDES-GAP2SICD
    • STM32G474RET3 control board (one for PFC stage, one for DC-DC stage) - STDES-BCBIDIRC
  • PFC stage: 3-phase, 2-level bidirectional AC-DC power converter
    • Rated nominal AC voltage: 400 VAC at 50 Hz
    • Rated nominal DC voltage: 800 VDC
    • Nominal power: 11 kW
    • Switching frequency: 70 kHz
    • Rectifier mode:
      • Power factor: PF >0.99
      • Total harmonic distortion: THDi <5%
      • Inrush current control and soft startup
    • Inverter mode:
      • Active and reactive power control
      • Integrated grid connection solution
  • DC-DC stage: dual active bridge (DAB)/CLLC power converter
    • Nominal input voltage 800 V
    • Nominal output voltage 550 V to 800 V
    • Nominal power 11 kW
    • DAB: switching frequency 100 kHz
    • CLLC: switching frequency range 82 to 235 kHz
  • System key features
    • ACEPACK DMT-32 power module for high integration level
    • High frequency operation for weight and size reduction
    • Bidirectional capabilities
    • DAB soft switching behavior enabled by enhanced modulation management techniques.
    • Peak efficiency: greater than 96%

Specifications

Table 1. Main characteristics
Description Symbol Min. Typ. Max. Unit Comment
Three-phase input voltage VAC 208 400 V Line to line voltage
Output voltage VDC 550 800 850 V
Maximum output power POUTmax 11 kW At nominal voltages
AC line frequency fg 50 Hz
Power factor PF 0.9 0.996 -
Total harmonic distortion THDi <5 % At overall conditions
Switching frequency PFC stage fsw 70 kHz
Switching frequency DAB fsw 100 kHz
Switching frequency CLLC fsw 82 235 kHz

HFT connection to STDES-BCBIDIR

The high-frequency transformer (HFT) plus leakage inductor is crucial for the dual active bridge (DAB) topology as it enables efficient energy transfer with reduced losses and compact size.

The correct connection of the primary and secondary windings of the transformer to the power board is essential to ensure the optimal functioning of the board.

The connection of the transformer to the board is made through the connectors: J21, J22, J23, J24. Figure 2 HFT - 2446.0001 AQ magnetic cable labeling shows the electrical diagram of the transformer, and the various cables of the transformer are also shown. Figure 3 HFT - 2446.0001 AQ magnetic connection to the board shows the connection of the transformer to the power board.

Figure 2. HFT - 2446.0001 AQ magnetic cable labeling


The correct connection of the transformer cables to the power board is as follows:
  • 1 (red-marked cable) must be connected to the J21 connector of the STDES-BCBIDIRP
  • 4 must be connected to the J22 connector of the STDES-BCBIDIRP
  • 5 (red-marked cable) must be connected to the J23 connector of the STDES-BCBIDIRP
  • 6 must be connected to the J24 connector of the STDES-BCBIDIRP
Figure 3. HFT - 2446.0001 AQ magnetic connection to the board


Safety precautions

Attention: The STDES-BCBIDIR is designed for demonstration purposes only and is not intended for domestic or industrial installations.
DANGER: The high voltage levels used to operate the STDES-BCBIDIR could provoke a serious electrical shock. This reference design must be used in a suitable laboratory by qualified personnel only, familiar with the installation, use, and maintenance of power electrical systems. During operation, do not touch the board as some of its components could reach a very high temperature.

Preliminary test procedure

The preliminary test procedure includes a set of checks needed to verify the proper functionality of key sections: grid relays, sensing section on AC side and DC side, PLL routine, gate-source voltages, PFC (start-up), DAB (start-up). Successfully passing the aforementioned tests allows the board to operate at full load.

By powering the board with the auxiliary voltages (12 V, 7 V) the sensing sections and the relays can be checked

Equipment needed:

  • Programmable bidirectional AC source
  • Bidirectional DC electronic load
  • Low-power multichannel DC source
  • High-definition multichannel oscilloscope + probes
  • High precision power analyzer
Figure 4. Typical test bench


Grid relay

Grid relays test

To manage the grid connection the STDES-BCBIDIR presents four relays: three of them used for the three-phase connection and one for the neutral. Figure 5 Grid relays management show the section related to the command of the grid relays with a focus on the selectors.
Figure 5. Grid relays management


The selector highlighted allows the user the possibility of managing the control of the relays using the MCU or manually. The two configurations of the relays are allowed by the following jumpers connections:
Figure 6. Grid relay jumper configuration

image/svg+xml A B 12V GND MAN A B 12 V GND MCU A B 12V MCU Manual Control MCU Control Jumper A → PIN 1 - 2 Jumper B → A ny The control of the Grid relays are managed by MCU . Jumper A → PIN 2 - 3 Jumper B → PIN 2 - 3 The control of the Grid relays is manual and the relays are OPEN . Jumper A → PIN 2 - 3 Jumper B → PIN 1 - 2 The control of the Grid relays is manual and the relays are CLOSED .

Table 2. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP /
Multichannel DC power supply (12 V, 7 V)

Procedure to perform test

  1. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  2. Connect the jumpers to enable manual control of the relays in the CLOSED position (J39-J40-J41-J42 position 2-3, J35-J36-J37-J38 position 1-2). (Grid relays test, third configuration)
  3. Enable the auxiliary power supply output. Once the auxiliary system is powered with the indicated jumper configuration, the LEDs D8, D9, D10, and D11 will light up (Figure 7 Grid relay check)
    Figure 7. Grid relay check


    The test allows verifying that the network relays are properly powered.

Sensing section test

To verify correct operation of the voltage and current sensing, the voltage values on the test points shown in the following figures can be verified. The expected voltage values in specific test conditions are shown in the following figures.

Table 3. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP -
Multichannel DC power supply -
Multimeter -
Oscilloscope -
AC power supply -
DC power supply -
Table 4. Hardware and software configurations
Hardware Status
DC auxiliary power supply (12 V, 7 V) Connected

At each sensor, there are three test points: GND, the sensor BIAS, and the conditioned voltage that is sent to the MCU. The voltage values read at these test points, when the system is not powered (with only the auxiliary power enabled), must match the values indicated in PFC section–Grid voltage sensing, PFC section–Grid current sensing, PFC section – Line voltage sensing, PFC section–Line current sensing, DC-DC section–DC voltage sensing and DC-DC section–DC current sensing.

AC sensing

Figure 8. PFC section - Grid voltage sensing


Figure 9. PFC section - Grid current sensing


Figure 10. PFC section - Line voltage sensing


Figure 11. PFC section - Line current sensing


DC sensing

Figure 12. DC-DC section - DC voltage sensing


Figure 13. DC-DC section - DC current sensing


Procedure to perform test

  1. Connect the jumpers to enable manual control of the relays in the OPEN position (J39-J40-J41-J42 position 2-3, J35-J36-J37-J38 position 2-3) (Fig.6, second configuration)
  2. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  3. Enable the auxiliary power supply output
  4. Check that the voltages read on the test points match the values indicated in Figures 8 to 13 under the conditions respectively @V_ac=0V, @I_ac=0A, @V_dc=0V, and @I_dc=0A
  5. Connect the AC power supply (J15 → PHA, J17 → PHB, J18 → PHC, J27 → N)
  6. Connect a differential probe between J15 (PHA) and J27 (N) and a passive probe between TP58 (Vg_A) and TP55 (GND)
  7. Set an AC voltage of 110 Vrms and enable an AC power supply
  8. Check that the V_(s pk-pk)=G∙ V_(g pk-pk) =0,0044∙319,2=1,40 V (Measurement of the mains voltage and reading of the corresponding sensor)
    Figure 14. Measurement of the mains voltage and reading of the corresponding sensor


  9. Disconnect the AC power supply
  10. Connect of the DC power supply (J20 → +, J25 → -)
  11. Connect a differential probe between J20 (+) and J25 (-) and a passive probe between TP41 (Vbus) and TP39 (GND)
  12. Set a DC voltage of 200 Vdc and enable a DC power supply
  13. Check that the V_(s DC)=G∙ V_BUS =0,00343∙201,98=0,692 V (Figure 15)
    DANGER: Ensure that the voltage present on connectors J20 and J25 has dropped to zero before touching the connectors
    Figure 15. Measurement of the BUS voltage and reading of the corresponding sensor


PLL testing procedure

To test the proper functionality of the phase-locked loop (PLL), a comprehensive test environment and a series of steps must be followed.

The following outlines the necessary environment setup and the detailed steps for conducting the PLL test.

Table 5. Hardware and software requirements
Hardware Software
STDES-BCBIDIR STM32CubeIDE
STDES-PFCBIDIRC x3 STSW-BCBIDIR
STDES-PFCBIDIRC
Multichannel DC power supply
8 channel oscilloscope
AC power supply
ST-LINK/V2-ISOL + JTAG
Table 6. Hardware configurations
Hardware Status
AC input voltage Connected
DC load Disconnected
DC auxiliary power supply (12 V, 7 V) Connected
Table 7. Software configurations
Software Status
DPC_PWM_INIT PWM_Safe
DPC_TTC_MODE_INIT AC2DC_PFC_OPERATION
DAC_CH1_INIT 13
DAC_CH2_INIT 7
DAC_CH3_INIT 8
DAC_G_CH1_INIT 2048
DAC_G_CH2_INIT 2048
DAC_G_CH3_INIT 2048
DAC_B_CH1_INIT 2048
DAC_B_CH2_INIT 2048
DAC_B_CH3_INIT 2048

Procedure to perform test

  1. Connect the jumpers to enable manual control of the relays in the OPEN position (J39-J40-J41-J42 position 2-3, J35-J36-J37-J38 position 2-3). (Fig.6, second configuration)
  2. Connect the STDES-PFCBIDIRC at the connector J1
  3. Connect the AC power supply (J15 → PHA, J17 → PHB, J18 → PHC, J27 → N). Connection of the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  4. Connect the three differential probes (PHA-N/PHB-N/PHC-N) and three non isolated probes in the control board (DAC1-GND, DAC2-GND, DAC3-GND)(T29–TP31, T32–TP31, T33–TP31)
  5. Enable auxiliary power supply
  6. Open the firmware: STSW-BCBIDIR_PFC inside the STSW-BCBIDIR and, in the file project DPC_Application_Conf.h set:

    #define DPC_TTC_MODE_INIT AC2DC_PFC_OPERATION

    #define DPC_PWM_INIT PWM_Safe

    #define DAC_CH1_INIT 13

    #define DAC_CH2_INIT 7

    #define DAC_CH3_INIT 8

    #define DAC_G_CH1_INIT 2048

    #define DAC_G_CH2_INIT 2048

    #define DAC_G_CH3_INIT 2048

    #define DAC_B_CH1_INIT 2048

    #define DAC_B_CH2_INIT 2048

    #define DAC_B_CH3_INIT 2048
  7. Connect the STLINK to the control board of PFC (STDES-PFCBIDIRC on connector J1) section as is shown in Figure 16 and flash the code
  8. Power the board by supplying three-phase voltages (for instance 30 Vrms)
    Figure 16. ST-LINK/V2 connected to the control board


    The oscilloscope displays the three sinusoidal grid voltages and the theta angle which will appear as a sawtooth synchronized with the sinusoid relating to phase A. Furthermore, it is possible to see the d and q axis components of the voltage. When the steady state condition is reached, the d axis has a positive value while the q axis will be zero how is is shown in PLL test waveforms.

    Figure 17. PLL test waveforms


    Figure 18. PLL test environment and procedure


Gate-source voltages testing

This test allows to check if the driving signals of the switches are correct sent from the MCU to the driver board.

At the same time, it is possible to verify the correct behavior of the gate driver, and the driver boards in general.

To perform this test a multichannel DC source is needed to provide the auxiliary power supply to the power board

Table 8. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP STM32 CUBE IDE
STDES-GAP2SICD x3 FW: STSW-BCBIDIR
STDES-PFCBIDIRC
Multi-channel DC Power supply (12 V, 7 V)
8 channel oscilloscope
ST-linkV2 isol + JTAG

Procedure to perform test (PFC side)

  1. Connect the jumpers to enable manual control of the relays in the OPEN position (J39-J40-J41-J42 position 2-3, J35-J36-J37-J38 position 2-3). (Fig.6, second configuration)
  2. Connect the isolated voltage probes to the VGS of the devices
  3. Connect the STDES-PFCBIDIRC at the connector J1
  4. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  5. Power the auxiliary section of the board by providing both 12 V and 7 V
  6. Open the FW: STSW_BCBIDIR_PFC inside the STSW-BCBIDIR and verify that in the file project DPC_Application.c when PC_State==FSM_Debug only the following functions must be present:

    DPC_MISC_Relay_Cntl(RELAY_GRID_ABC, RELAY_OFF);

    DPC_ACT_OutEnable( &tDPC_PWM );

    DPC_ACT_Send_Duty_SPWM( &tDPC_PWM,0.0f, 0.0f, 0.0f );

    In the file project DPC_Application_Conf.h:

    macroDPC_PC_State_Initmust be set to FSM_Debug.

    macro DPC_PWM_INIT must be set to PWM_Armed.

  7. Connect the ST-link to the control board of the PFC (STDES-PFCBIDIRC on connector J1) stage as is shown in Figure 16 and flash the code.
    Figure 19. Testing procedure of gate to source voltages


    By setting an appropriate time base on the oscilloscope, considering a switching frequency of 70 kHz, square waves with a voltage range of +20 to -5 V and a duty cycle of 50% will be displayed, as shown in fig 20.

    Figure 20. Gate to source voltage PFC stage


Procedure to perform test (DC-DC side)

  1. Connect the isolated voltage probes to the VGS of the devices.
  2. Connect the STDES-PFCBIDIRC at the connector P1
  3. Connect the low voltage auxiliary power supply (12 V, 7 V ) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  4. Power the auxiliary section of the board by providing both 12 V and 7 V
  5. Open FW: STSW_BCBIDIR_DAB inside the STSW-BCBIDIR, and verify that in the file project DPC_Application.c in case PC_State==FSM_Debug only the following functions must be present:

    DPC_ACT_OutEnable(&DAB.tDPC_PWM);

    In the file project DPC_Application_Conf.h:

    #defineDPC_PC_State_Init FSM_Debug

    #define DPC_DAB_PWM_INIT PWM_Armed
  6. Connect the ST-link to the control board of the DAB (STDES-PFCBIDIRC on connector P1) stage as is shown in Figure 16 and flash the code

    By setting an appropriate time base on the oscilloscope, considering a switching frequency of 100 kHz, square waves with a voltage range of +20V to -5V and a duty cycle of 50% will be displayed, as shown in Figure 21.

    Figure 21. Gate to source voltage DC-DC stage


PFC startup

This test is used to verify the design functionalities up to full load. By following the procedure outlined below, the converter executes the startup phase, bringing both stages to nominal voltage conditions.

Subsequently, the load can be increased until the target conditions of the converter are reached.

Table 9. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP STM32 CUBE IDE
STDES-GAP2SICD x 3 FW: STSW-BCBIDIR
STDES-PFCBIDIRC x 1
Multichannel DC power supply (12 V, 7 V)
8 channel oscilloscope
ST-LINK/V2-ISOL + JTAG
AC power supply
DC load

Procedure to perform test

  1. Connect the jumpers to enable MCU control of the relays (J39-J40-J41-J42 position 1-2, J35-J36-J37-J38 not connected). (Fig.6, first configuration)
  2. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  3. Connect the AC power supply (J15 → PHA, J17 → PHB, J18 → PHC, J27 → N) without activation “output disabled”
  4. Connect the three differential voltage probes (PHA-N/PHB-N/PHC-N) and three current probes on the PHA, PHB, and PHC. Connect an additional isolated voltage probe on the DC bus J20-J25
  5. Connect the fan cables to U11 respecting the correct polarity. Connect a 12V power supply to the U10 and provide the power. Move selector J8 in position 2-3 (PFC_FAN)
  6. Connect the DC-Load taking care of the correct polarity at the connector. Positive cable to J20, negative cable to J25, the load must be set to Constant Current mode (CC) and must be disabled
  7. Open the firmware: STSW_BCBIDIR_PFC inside the STSW-BCBIDIR, and verify that in the file project DPC_Application_Conf.h:

    ///DPC finite state machine DEFINE of STDES-BCBIDIR

    #define DPC_PC_State_Init FSM_Idle

    #define DPC_PWM_INIT PWM_Armed

    #define DPC_TTC_MODE_INIT AC2DC_PFC_OPERATION

    #define DPC_CTRL_INIT VOLTAGE_LOOP

    ///AC MAIN DEFINE of STDES-BCBIDIR

    #define DPC_TTC_VAC_EU

    ///AC MAIN connection DEFINE of STDES-BCBIDIR

    #define DPC_AC_3W

    ///DC OUTPUT DEFINE of STDES-BCBIDIR

    #define DPC_PFC_VDC_OUT 800

    #define DPC_PFC_VDC_rampstart 760

    ///PROTECTION

    //AC-DC

    #define DPC_PFC_VAC_RMS_OVP 250

    #define DPC_PFC_VAC_RMS_UVLOP 10

    #define DPC_PFC_VAC_RMS_UVP 7

    #define DPC_PFC_IAC_OCP 7

    #define DPC_PFC_VDC_OVP 850

    #define DPC_PFC_IDC_OCP 7

  8. Connect the STLINK to the control board of the PFC (STDES-PFCBIDIRC on connector J1) stage as is shown in Figure 16 and flash the code
  9. Enable three-phase power supply (230 Vrms)

    After powering the board (230 Vrms), setting a time base of 1 second, and appropriately adjusting the zoom, waveforms like those in figure 22 will be displayed on the oscilloscope

    Shutdown:

    • Gradually reduce the load to zero
    • Disconnect the AC power supply
    • Enable the load to discharge the capacitors of the BUS
    DANGER: After performing the test and disconnecting the AC power supply, it is necessary to re-enable the load to discharge the output BUS capacitors. Furthermore, before touching connectors J20, J25 ensure with a multimeter that there is no residual charge on the DC BUS capacitors.
    Figure 22. Start-up waveforms of the PFC


DAB startup

This test is used to verify the DAB functionalities up to full load. By following the procedure outlined below, the converter executes the startup phase, bringing the DAB stage to nominal voltage conditions.

Subsequently, the load can be increased until the target conditions of the converter are reached.

Table 10. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP STM32CubeIDE
STDES-GAP2SICD x 4 FW: STSW-BCBIDIR
STDES-PFCBIDIRC x 1
Multichannel DC power supply
8 channel oscilloscope
ST-LINK/V2-ISOL + JTAG
Table 11. Hardware configurations
Hardware Status
AC input voltage Connected
DC load Connected
DC auxiliary power supply (12 V, 7 V) Connected
Table 12. Software configurations
Software Status
DPC_PWM_INIT PWM_Armed

Procedure to perform test

  1. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J19, J10) towards Vext to configure the external auxiliary power supply mode
  2. Connect the transformer according to the instruction in chapter 3
  3. Connect the DC-Source taking care of the correct polarity at the connector. Positive cable to J20, negative cable to J25
  4. Connect the DC-Load taking care of the correct polarity at the connector. Positive cable to J28, negative cable to J29, the load must be set to Constant Current mode (CC) and must be disabled
  5. Connect the fan cables to U11 respecting the correct polarity. Connect a 12 V power supply to the U10 and provide the power. Move selector J8 in position 1-2 (DCDC_FAN)
  6. Connect the four differential voltage probs: OUTA_DAB1- OUTB_DAB1 (TP94-TP95), OUTA_DAB2- OUTB_DAB2 (TP96-TP97) VBUS (TP92-TP84), VLOAD (TP126-TP127). Connect three hall-effect current probe on IBUS (cable connected to J59), ILOAD (cable connected to J20), IDAB1(cable connected to J28)
  7. Open the firmware: STSW_BCBIDIR_DAB inside the STSW-BCBIDIR, and verify that in the file project DPC_Application_Conf.h::

    /// DPC finite state machine DEFINE of STDES_DABBIDIR

    #define DPC_DAB_ADPPWM

    #define DPC_PC_State_Init FSM_Idle

    #define DPC_FSM_RUN_INIT Run_Idle

    #define DPC_FSM_STATE_INIT DPC_FSM_WAIT

    #define DPC_CTRL_INIT DAB_VOLTAGE_LOOP

    #define DPC_DAB_PWM_INIT PWM_Armed

    #define DPC_DAB_MODE_INIT HV2LV

    ///DC OUTPUT DEFINE of STDES-DCDC_DAB

    #define DPC_DAB_VDC_OUT 800

    #define DPC_DAB_IDC_OUT 5

    ///PROTECTION HV2LV

    #define DPC_DAB_VDCHV_OVP 850

    #define DPC_DAB_VDCHV_UV 650

    #define DPC_DAB_VDCHV_UVLO 30

    #define DPC_DAB_VDCHV_MIN 20

    #define DPC_DAB_IDCHV_OCP 5

    #define DPC_DAB_IDCLV_OCP 5

    #define DPC_DAB_VDCLV_OVP 900

  8. Connect the ST-LINK to the control board of the DAB (STDES-BCBIDIRC on connector P1) stage as is shown in Figure 16 and flash the code
  9. Enable DC power supply (800 VDC)

    Results

    After powering the board (800 VDC), setting a time base of 1 second, and appropriately adjusting the zoom, waveforms like those in figure 23 will be displayed on the oscilloscope

    Shutdown:
    • Gradually reduce the load to zero
    • Disconnect the DC power supply
    • Re-enable the load to discharge the capacitors of the output BUS
    • Discharge the DC BUS if there is a residual voltage, with a suitable discharge circuit
    DANGER: After performing the test and disconnecting the DC power supply, it is necessary to re-enable the load to discharge the output BUS capacitors. Furthermore, before touching connectors J20, J25, and J28, J29 ensure with a multimeter that there is no residual charge on the DC BUS capacitors.
    Figure 23. Startup waveforms of the DAB


Full-load test

This test is used to verify the design functionalities up to full load. By following the procedure outlined below, the converter executes the startup phase, bringing both stages to nominal voltage conditions. Subsequently, the load can be increased until the target conditions of the converter are reached.

Table 13. Hardware and software requirements
Hardware Software
STDES-BCBIDIRP STM32 CUBE IDE
STDES-GAP2SICD x7 FW: STSW-BCBIDIR
STDES-PFCBIDIRC x2
Multi-channel DC Power supply
8 channel oscilloscope
ST-linkV2 isol + JTAG
Table 14. Hardware configurations
Hardware Status
AC input voltage Connected
DC load Connected
DC auxiliary power supply (12 V, 7 V) Connected
Table 15. Software configurations
Software Status
DPC_PWM_INIT PWM_Armed

Procedure to perform test

  1. Connect the jumpers to enable MCU control of the relays (J39-J40-J41-J42 position 1-2, J35-J36-J37-J38 not connected). (Fig.6, first configuration)
  2. Connect the transformer according to the instruction in chapter 3
  3. Connect the low voltage auxiliary power supply (12 V, 7 V) respectively in U28 and U26 moving the selectors (J2, J3, J9, J10) towards Vext to configure the external auxiliary power supply mode
  4. Connect the AC power supply (J15 → PHA, J17 → PHB, J18 → PHC, J27 → N) without activation “output disabled”
  5. Connect the five differential voltage probes: OUTA_DAB1- OUTB_DAB1 (TP94-TP95), OUTA_DAB2-OUTB_DAB2 (TP96-TP97) VBUS (TP92-TP84), VLOAD (TP126-TP127) PHA-N (J15-J27). Connect two hall-effect current probe on ILOAD, IA and a Rogowski probe on IDAB1
  6. Connect the fan cables to U11 respecting the correct polarity. Connect a 12 V power supply to the U10 and provide the power. Move selector J8 in position 2-3 (PFC_FAN)
  7. Connect the DC-Load taking care of the correct polarity at the connector. Positive cable to J28, negative cable to J29, the load must be set to Constant Current mode (CC) and must be disabled
  8. Open the firmware: STSW_BCBIDIR_PFC inside the STSW-BCBIDIR, and verify that in the file project DPC_Application_Conf.h:

    ///DPC Finite State Machine DEFINE of STDES-BCBIDIR

    #define DPC_PC_State_Init FSM_Idle

    #define DPC_PWM_INIT PWM_Armed

    #define DPC_TTC_MODE_INIT AC2DC_PFC_OPERATION

    #define DPC_CTRL_INIT VOLTAGE_LOOP

    ///AC MAIN DEFINE of STDES-BCBIDIR

    #define DPC_TTC_VAC_EU

    ///AC MAIN Connection DEFINE of STDES-BCBIDIR

    #define DPC_AC_3W

    ///DC OUTPUT DEFINE of STDES-BCBIDIR

    #define DPC_PFC_VDC_OUT 800

    #define DPC_PFC_VDC_rampstart 760

    ///PROTECTION

    //AC-DC

    #define DPC_PFC_VAC_RMS_OVP 250

    #define DPC_PFC_VAC_RMS_UVLOP 10

    #define DPC_PFC_VAC_RMS_UVP 7

    #define DPC_PFC_IAC_OCP 27

    #define DPC_PFC_VDC_OVP 850

    #define DPC_PFC_IDC_OCP 17

  9. Connect the STLINK to the control board of the PFC (STDES-PFCBIDIRC on connector J1) stage as is shown in Figure 16 and flash the code
  10. Open the firmware: STSW_BCBIDIR_DAB inside the STSW-BCBIDIR, and verify that in the file project DPC_Application_Conf.h:

    /// DPC Finite State Machine DEFINE of STDES-DABBIDIR

    #define DPC_DAB_ADPPWM

    #define DPC_PC_State_Init FSM_Idle

    #define DPC_FSM_RUN_INIT Run_Idle

    #define DPC_FSM_STATE_INIT DPC_FSM_WAIT

    #define DPC_CTRL_INIT DAB_VOLTAGE_LOOP

    #define DPC_DAB_PWM_INIT PWM_Armed

    #define DPC_DAB_MODE_INIT HV2LV

    ///DC OUTPUT DEFINE of STDES-DCDC_DAB

    #define DPC_DAB_VDC_OUT 800

    #define DPC_DAB_IDC_OUT 6

    ///PROTECTION HV2LV

    #define DPC_DAB_VDCHV_OVP 850

    #define DPC_DAB_VDCHV_UV 650

    #define DPC_DAB_VDCHV_UVLO 30

    #define DPC_DAB_VDCHV_MIN 750

    #define DPC_DAB_IDCHV_OCP 17

    #define DPC_DAB_IDCLV_OCP 17

    #define DPC_DAB_VDCLV_OVP 850

  11. Connect the STLINK to the control board of the DAB (STDES-PFCBIDIRC on connector P1) stage as is shown in Figure 16 and flash the code
  12. Enable three-phase power supply (230 Vrms)

    After powering the board (230 Vrms), setting a proper time base, and appropriately adjusting the zoom, waveforms like those in Full power test–double conversion will be displayed on the oscilloscope

  13. Once the output voltage reaches the reference value (approximately 800 VDC), it will be possible to enable the load starting from 0 current up to full load
    Shutdown:
    • Gradually reduce the load to zero
    • Disconnect the AC power supply
    • Re-enable the load to discharge the capacitors of the output BUS
    • Discharge the DC BUS with a suitable discharge circuit
    DANGER: After performing the test and disconnecting the AC power supply, it is necessary to re-enable the load to discharge the output BUS capacitors. Furthermore, before touching connectors J20, J25, and J28, J29 ensure with a multimeter that there is no residual charge on the DC BUS capacitors
    Figure 24. Full power test–double conversion


Measurements/waveforms/test data

Waveform

Waveforms analysis at:

  • VIN = 230 Vrms
  • VOUT = 800 V
  • fSW (PFC) = 70 kHz
  • fSW (DC-DC) = 100 kHz
  • PF = 0.996
  • Voltage regulation operating mode
Figure 25. Steady-state operations


Channel labels:

C1 = IPRIM

C2 = VDAB1

C3 = VDAB2

C4 = IA

C5 = VA

C6 = IDC

C7 = VOUT

C8 = VBUS

As can be seen from the first plot in Figure 25 Steady-state operations, the phase voltage and the relative current are perfectly aligned due to the high power factor (0.996). It is also possible to observe, from plots 6 and 7 respectively, the voltages at the ends of the HFT and the primary current of the Dual Active Bridge.

Waveforms analysis at:

  • VIN = 230 Vrms
  • VOUT = 800 V
  • fSW (PFC) = 70 kHz
  • fSW (DC-DC) = 100 kHz
Figure 26. Soft start-up


Channel labels:

C1 = IPRIM

C2 = VDAB1

C3 = VDAB2

C4 = IA

C5 = VA

C6 = IDC

C7 = VOUT

C8 = VBUS

Figure 26 Soft start-up, shows the soft startup procedure implemented in the STDES-BCBIDIR. As can be seen from the fourth plot, the DC-BUS voltage (C8) is raised to the reference value following a controlled trend. After a configurable delay, the output voltage VOUT (C7) is raised to the reference value also in a controlled manner.

Efficiency characterizations at:

  • VIN = 230 Vrms
  • VOUT = 800 V
  • fSW (PFC) = 70 kHz
  • fSW (DC-DC) = 100 kHz
Figure 27. Overall Efficiency

image/svg+xml 86 88 90 92 94 96 98 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 Efficiency [%] Power [kW]

Schematic diagrams

Figure 28. STDES-BCBIDIR circuit schematic - Power board (1 of 18)

image/svg+xml GRID RELAY DRIVING SECTION INRUSH RELAY SECTION VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V VDD_12V RELAY_OUT_A V_line_A_IN_LEM V_line_B_IN_LEM V_line_C_IN_LEM RELAY_IN_B RELAY_OUT_B GPIO_RELAY RELAY_IN_C RELAY_OUT_C COIL_RELAY_GRID_C COIL_RELAY_GRID_B COIL_RELAY_GRID_N GPIO_GRID_RELAY_C GPIO_GRID_RELAY_B GPIO_GRID_RELAY_A GPIO_GRID_RELAY_N COIL_RELAY_GRID_A RELAY_IN_A RELAY_IN_B RELAY_IN_C RELAY_OUT_A RELAY_OUT_B RELAY_OUT_C RELAY_IN_A R21122 R197 150 R216 33k R205 4k R219 1k R217 1k R198 150 R20122 J41 Con3 1 2 3 J42 Con3 1 2 3 R200 150 D15 LED RED A C RE1 G7J-4A-P DC12 A1 A1_1 COIL_1 A1 A2 A2_1 COIL_2 A2 3 3 3_1 LA1 4 4 4_1 LA2 5 5 5_1 LB1 6 6 6_1 LB2 7 7 7_1 LC1 LC2 8_1 8 8 9 9 9_1 LN1 10_1 10 10 LN2 D14 LED RED A C Q4 STS6NF20V 1 4 6 2 3 5 8 7 J38 Con3 1 2 3 R218 1k R214 33k R215 1k Q6 STS6NF20V 1 4 6 2 3 5 8 7 Q5 STS6NF20V 1 4 6 2 3 5 8 7 R1994k R21022 R213 33k R207 4k J36 Con3 1 2 3 R20922 D11 LED RED A C D6LED RED A C D10 LED RED A C D5 J37 Con3 1 2 3 R206 4k Q2 STS6NF20V 1 4 6 2 3 5 8 7 R202 33k D12 LED RED A C Q3 STS6NF20V 1 4 6 2 3 5 8 7 J39 Con3 1 2 3 J35 Con3 1 2 3 R204 4k R212 33k R203 4k D9 LED RED A C D7 LED RED A C J40 Con3 1 2 3 R20822 D8 LED RED A C D13 LED RED A C

Figure 29. STDES-BCBIDIR circuit schematic - Power board (2 of 18)

image/svg+xml Auxiliary Power Supply POWER SECTION M1P45M12W2-1LA M1F45M12W2-1LA M1F45M12W2-1LA VDD_12V VDD_12V VDD_12V VDD_12V VDD_7V_INT VDD_12V_INT VDD_3.3V_DRIVER VDD_3.3V_DRIVER_DCDC VDD_3.3V_DRIVER_DCDC RELAY_IN_A RELAY_IN_B RELAY_IN_C BUS_N BUS_P_OUT BUS_N V_line_B V_line_C GATE_Q1 GATE_Q2 GATE_Q3 GATE_Q4 GATE_Q5 GATE_Q6 COIL_RELAY_GRID_B COIL_RELAY_GRID_C Neutral GND_ISO_Q6 GND_ISO_Q4 GND_ISO_Q2 GND_ISO_Q1 GND_ISO_Q3 GND_ISO_Q5 B C V_grid_A V_grid_B V_grid_C BUS_N BUS_P NTC_PFC COIL_RELAY_GRID_A COIL_RELAY_GRID_N V_grid_C Half BUS Neutral_ BUS_P BUS_LEM_DC2+ BUS_LEM_DC2- BUS_P2 BUS_N2 OUTA_DAB1 OUTB_DAB1 OUTA_DAB2 OUTB_DAB2 NTC_DCDC1 BUS_N2 BUS_N1 BUS_N1 BUS_N2 GND_ISO_D2 GND_ISO_D4 GND_ISO_D6 GND_ISO_D8 GATE_D2 GATE_D4 GATE_D6 GATE_D8 OUTA_DAB1 OUTB_DAB1_o OUTA_DAB2_o OUTB_DAB2 GND_ISO_D1 GND_ISO_D3 GND_ISO_D5 GND_ISO_D7 GATE_D1 GATE_D3 GATE_D5 GATE_D7 BUS_P1 BUS_P2 BUS_P1 BUS_P2 BUS_P1 BUS_N1 NTC_DCDC2 V_grid_A1 V_Filter_A V_grid_B1 V_Filter_B V_grid_C1 V_Filter_C Half BUS Neutral OUTB_DAB1_o OUTA_DAB2_o A V_line_A Neutral TP89 TP92 J15 74651195R L49 255u C161 470uF TP90 J24 74651195R J33 1 R195 240k C177 680nF J25 TP85 J30 1 C154 6.8uF J23 74651195R U63 N 1 N1 2 NC 3 NC_1 4 L3 5 L3_A 6 NC_2 7 NC_3 8 L2 9 L2_A 10 NC_4 11 NC_5 12 L1 13 L1_A 14 NTC2 15 NTC1 16 P 17 P1 18 G1 19 KS1 20 KS2 22 G2 21 G3 23 KS3 24 G4 25 KS4 26 G5 27 KS5 28 G6 29 KS6 30 NC_6 31 NC_7 32 R190 0.33 R196 240k U64 1 NC_1 2 NC_2 3 N1_1 4 N1_2 5 S2 6 G2 7 1_1 8 1_2 9 NC_3 S1 10 G1 11 NC_4 12 P1_1 13 P1_2 14 NC_5 15 NC_6 16 NC_7 17 18 NC_8 P2_1 19 P2_2 20 G3 22 NC_9 21 S3 23 NC_10 24 2_1 25 2_2 26 G4 27 S4 28 N2_1 29 30 N2_2 T1 31 T2 32 TP87 R194 240k C179 680nF L487.8 uH 1 2 J22 74651195R J26 TP88 L52 255u L53 7.8 uH 1 2 TP94 TP126 C158 25uF 1 2 3 4 TP93 J21 74651195R TP99 TP91 J27 74651195R D3 C160 10nF LS1 Relay 30A 1 4 3 5 2 TP86 C153 6.8uF LS4 Relay 30A 1 4 3 5 2 LS3 Relay 30A 1 4 3 5 2 LS2 Relay 30A 1 4 3 5 2 J17 74651195R TP84 TP97 L50 255u F130A D4 J20 C157 25uF 1 2 3 4 J32 1 C159 100nF R191 240k J19 C156 470uF R188 0.33 C162 470uF TP127 J29 C155 470uF TP98 J14 J18 74651195R TP95 C178 680nF C152 6.8uF L517.8 uH 1 2 R192 240k TP96 J16 F330A J31 1 J34 1 F230A R189 0.33 U62 1 NC_1 2 NC_2 3 N1_1 4 N1_2 5 S2 6 G2 7 1_1 8 1_2 9 NC_3 S1 10 G1 11 NC_4 12 P1_1 13 P1_2 14 NC_5 15 NC_6 16 NC_7 17 18 NC_8 P2_1 19 P2_2 20 G3 22 NC_9 21 S3 23 NC_10 24 2_1 25 2_2 26 G4 27 S4 28 N2_1 29 30 N2_2 T1 31 T2 32 R193 240k J28 Neutral_

Figure 30. STDES-BCBIDIR circuit schematic - Power board (3 of 18)

image/svg+xml LINE VOLTAGE SENSING 5V_MEAS_Line_AC VDD_5V VDD_BIAS_line_A GND_MEAS_Line_AC VDD_5V GND_MEAS_Line_AC GND_MEAS_Line_AC GND_MEAS_Line_AC 5V_MEAS_Line_AC VDD_5V VDD_BIAS_line_B GND_MEAS_Line_AC VDD_5V GND_MEAS_Line_AC GND_MEAS_Line_AC GND_MEAS_Line_AC 5V_MEAS_Line_AC VDD_5V GND_MEAS_Line_AC VDD_BIAS_line_C VDD_5V GND_MEAS_Line_AC GND_MEAS_Line_AC GND_MEAS_Line_AC VDD_5V VDD_BIAS_line_A VDD_5V VDD_BIAS_line_B VDD_5V VDD_BIAS_line_C V_line_A VlineA.S V_line_B VlineB.S V_line_C VlineC.S 0 L46 22Ohm@100MHz 1 2 0 L44 22Ohm@100MHz 1 2 R155 30k C146 100nF 25V TP76 TestPoint_Ring TP74 TestPoint_Ring R186 30k C133 100nF 25V C128 100nF 25V R150 1.27 M TP72 TestPoint_Ring R171 30k R174 8.25 k C142 100nF 25V R160 10 k R181 0 - + U58 TSV911IYLT 3 4 1 5 2 C134 1uF 25V R165 1k C150 100nF 25V C131 1uF 25V - + U60 TSV911IYLT 3 4 1 5 2 0 L4722Ohm@100MHz 1 2 C145 1uF 25V R167 10k TP69 TestPoint_Ring R182 10 k U59 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 C132 100nF 25V R161 8.25 k R187 8.25 k R173 10 k C144 100nF 25V R158 51.1 k C186 100pF/25V U76 TLVH431MIL3T A 3 K 2 REF 1 U56 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 R170 10 k R183 10k 0 L4522Ohm@100MHz 1 2 R179 1k R168 51.1 k R178 1.24 M R185 10 k C149 100nF 25V TP77 TestPoint_Ring TP71 TestPoint_Ring R157 10 k R152 8.25 k TP83 TestPoint_Ring TP70 TestPoint_Ring R1590 C139 1uF 25V C136 100nF 25V TP80 TestPoint_Ring R164 8.25 k - + U55 TSV911IYLT 3 4 1 5 2 R180 51.1 k R154 1.24 M R166 1.24 M R149 1.27 M 0 L4322Ohm@100MHz 1 2 TP82 TestPoint_Ring C185 100pF/25V 0 L42 22Ohm@100MHz 1 2 C141 1uF 25V TP78 TestPoint_Ring R163 1.27 M TP75 TestPoint_Ring TP73 TestPoint_Ring R169 0 C130 100nF 25V R176 1.27 M R175 1.27 M TP79 TestPoint_Ring U54 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 C138 100nF 25V R156 0 R151 1k R153 10k R1840 U74 TLVH431MIL3T A 3 K 2 REF 1 C147 1uF 25V R177 8.25 k R162 1.27 M TP81 TestPoint_Ring C137 1uF 25V C148 1uF 25V R1720 C184 100pF/25V C140 100nF 25V U75 TLVH431MIL3T A 3 K 2 REF 1 C129 1uF 25V

Figure 31. STDES-BCBIDIR circuit schematic - Power board (4 of 18)

image/svg+xml GRID VOLTAGE SENSING VDD_BIAS_grid_A GND_MEAS_Grid_AC 5V_MEAS_Grid_AC VDD_5V GND_MEAS_Grid_AC VDD_5V VDD_BIAS_grid_A 5V_MEAS_Grid_AC VDD_5V VDD_BIAS_grid_B VDD_5V GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC 5V_MEAS_Grid_AC VDD_5V VDD_BIAS_grid_C VDD_5V GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC GND_MEAS_Grid_AC VDD_5V VDD_5V VDD_BIAS_grid_B VDD_5V VDD_BIAS_grid_C V_grid_A VgridA.S V_grid_B VgridB.S V_grid_C VgridC.S R122 8.25 k - + U46 TSV911IYLT 3 4 1 5 2 R119 10 k C107 100nF 25V TP56 TestPoint_Ring R125 8.25 k R148 8.25 k U47 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 C118 1uF 25V C117 100nF 25V TP57 TestPoint_Ring C104 1uF 25V R110 1.27 M R131 10 k R144 10k L3922Ohm@100MHz 1 2 TP55 TestPoint_Ring C115 1uF 25V R139 1.24 M C126 1uF 25V R112 1k C106 1uF 25V C120 100nF 25V - + U48 TSV911IYLT 3 4 1 5 2 U45 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 C183 100pF/25V R123 1.27 M C114 100nF 25V U73 TLVH431MIL3T A 3 K 2 REF 1 R124 1.27 M R133 10 k TP67 TestPoint_Ring TP60 TestPoint_Ring TP62 TestPoint_Ring - + U51 TSV911IYLT 3 4 1 5 2 C125 100nF 25V R141 51.1 k R113 8.25 k L40 22Ohm@100MHz 1 2 R117 51.1 k TP58 TestPoint_Ring 00 00 L36 22Ohm@100MHz 1 2 R143 10 k R130 0 L38 22Ohm@100MHz 1 2 R146 10 k TP65 TestPoint_Ring R1200 R118 0 R147 30k C123 1uF 25V TP59 TestPoint_Ring C105 100nF 25V U50 AMC1350DWVR VDD1 1 VINP 2 VINN 3 GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 C124 100nF 25V C122 100nF 25V R134 30k R129 10k R114 10k R111 1.27 M R1320 R127 1k TP63 TestPoint_Ring C181 100pF/25V U71 TLVH431MIL3T A 3 K 2 REF 1 R115 1.24 M R142 0 TP66 TestPoint_Ring TP61 TestPoint_Ring R140 1k R135 8.25 k C108 100nF 25V R121 10 k U72 TLVH431MIL3T A 3 K 2 REF 1 R137 1.27 M R136 1.27 M R128 51.1 k R138 8.25 k L4122Ohm@100MHz 1 2 R126 1.24 M R1450 C110 1uF 25V R116 30k C112 100nF 25V TP54 TestPoint_Ring TP64 TestPoint_Ring C182 100pF/25V C116 100nF 25V C121 1uF 25V 0 0 L3722Ohm@100MHz 1 2 C109 100nF 25V C113 1uF 25V TP68 TestPoint_Ring 0 00 00 0

Figure 32. STDES-BCBIDIR circuit schematic - Power board (5 of 18)

image/svg+xml GRID CURRENT SENSING VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V I_GRID_A I_GRID_B I_GRID_C V_grid_A1 V_Filter_A V_grid_B1 V_Filter_B V_grid_C1 V_Filter_C U41 TL431ACL3T A 3 K 1 REF 2 L33 22Ohm@100MHz 1 2 R93 10 k C94 100nF 25V R97 1k TP48 TestPoint_Ring R92 N.M. - + U38 TSV911IYLT 3 4 1 5 2 R94 13.7 k R101 10 k TP51 TestPoint_Ring C103 N.M. LEM8 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 C93 1uF 25V R100 N.M. R90 0 C101 100nF 25V R87 N.M. JP5 Jp_pcb 1 2 U43 TL431ACL3T A 3 K 1 REF 2 00 L35 22Ohm@100MHz 1 2 C90 1uF 25V - + U40 TSV911IYLT 3 4 1 5 2 C99 100nF 25V TP43 TestPoint_Ring TP45 TestPoint_Ring R105 1k TP52 TestPoint_Ring R95 N.M. R88 4.12 k C97 1uF 25V R102 13.7 k R98 0 R109 10 k C95 1uF 25V R91 4.7 k TP47 TestPoint_Ring TP49 TestPoint_Ring R108 N.M. - + U42 TSV911IYLT 3 4 1 5 2 R96 4.12 k L30 22Ohm@100MHz 1 2 R99 4.7 k L32 22Ohm@100MHz 1 2 R103 N.M. U39 TL431ACL3T A 3 K 1 REF 2 TP42 TestPoint_Ring C102 1uF 25V C91 N.M. R106 0 C100 1uF 25V C92 100nF 25V JP6 Jp_pcb 1 2 LEM6 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 0 0 L31 22Ohm@100MHz 1 2 TP50 TestPoint_Ring C89 100nF 25V TP53 TestPoint_Ring R89 1k TP46 TestPoint_Ring TP44 TestPoint_Ring R104 4.12 k C98 N.M. 00 L34 22Ohm@100MHz 1 2 LEM7 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 JP4 Jp_pcb 1 2 R86 13.7 k C96 100nF 25V R107 4.7 k V_BIAS_currentGRID_A V_BIAS_currentGRID_A V_BIAS_currentGRID_B V_BIAS_currentGRID_B V_BIAS_currentGRID_C V_BIAS_currentGRID_C 0 00 0

Figure 33. STDES-BCBIDIR circuit schematic - Power board (6 of 18)

image/svg+xml DRIVER BOARD VDD_12V VDD_3.3V_DRIVER VDD_3.3V_DRIVER VDD_12V VDD_3.3V_DRIVER VDD_12V D_Q1 D_Q2 D_Q4 D_Q3 D_Q6 D_Q5 GND_ISO_Q1 GND_ISO_Q2 GATE_Q1 GATE_Q2 GND_ISO_Q4 GATE_Q4 GND_ISO_Q3 GATE_Q3 GND_ISO_Q6 GATE_Q6 GND_ISO_Q5 GATE_Q5 GND_ISO_Q1 GATE_Q1 GND_ISO_Q2 GATE_Q2 GND_ISO_Q3 GATE_Q3 GND_ISO_Q4 GATE_Q4 GND_ISO_Q5 GATE_Q5 GND_ISO_Q6 GATE_Q6 TP114 TP122 TP121 R255 47k R250 47k J13 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A TP124 J11 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A R254 47k TP117 R251 47k TP115 TP123 TP118 R253 47k TP125 TP120 J12 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A R252 47k TP119 TP116 PULLDOWN RESISTANCES

Figure 34. STDES-BCBIDIR circuit schematic - Power board (7 of 18)

image/svg+xml PFC DC VOLTAGE SENSING VDD_5V VDD_5V GND_MEAS_DC GND_MEAS_DC GND_MEAS_DC 5V_MEAS_DC GND_MEAS_DC BUS_P1 V_bus 0 0 L2922Ohm@100MHz 1 2 R82 10.5 k TP40 TestPoint_Ring - + U37 TSV911IYLT 3 4 1 5 2 TP38 TestPoint_Ring TP41 TestPoint_Ring U36 AMC1311QDWVRQ1 VDD1 1 VIN 2 3 SHTDN GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 0 0 L28 22Ohm@100MHz 1 2 TP39 TestPoint_Ring C84 1uF 25V R79 17.4 k R80 24 k C180 100pF/25V R830 R84 10.5 k R85 17.4 k C86 100nF 25V R76 3.9 M C85 100nF 25V R81 0 R78 2 M R77 5.6 M C83 100nF 25V C82 1uF 25V C87 1uF 25V

Figure 35. STDES-BCBIDIR circuit schematic - Power board (8 of 18)

image/svg+xml PFC DC CURRENT SENSING VDD_5V VDD_5V VDD_5V Idc_LEM BUS_P BUS_P_OUT C78 1uF 25V R73 1k U35 TL431ACL3T A 3 K 1 REF 2 C79 100nF 25V TP36 TestPoint_Ring 00 L26 22Ohm@100MHz 1 2 LEM5 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 R72 10 k TP37 TestPoint_Ring R71 4.7 k - + U34 TSV911IYLT 3 4 1 5 2 TP34 TestPoint_Ring TP35 TestPoint_Ring C77 100nF 25V C80 1uF 25V 00 00 L27 22Ohm@100MHz 1 2 C81 N.M. R74 0 R75 N.M. R70 4.12 k R68 13.7 k R67 0 R69 N.M. V_BIAS_currentDC V_BIAS_currentDC

Figure 36. STDES-BCBIDIR circuit schematic - Power board (9 of 18)

image/svg+xml ISO. DC/DC Power Supply for sensing PFC AUXILIARY POWER SUPPLY LED STATUS VDD_7V_INT VDD_7V VDD_7V_EXT VDD_3.3V_DRIVER VDD_3.3V VDD_5V VDD_12V_INT VDD_12V VDD_12V_EXT VDD_12V_INT VDD_12V VDD_12V_EXT VDD_7V_INT VDD_7V VDD_7V_EXT VDD_7V_EXT VDD_12V_EXT VDD_3.3V_DRIVER VDD_5V_STEP VDD_12V VDD_5V_STEP VDD_5V VDD_7V VDD_3.3V VDD_5V VDD_5V 5V_MEAS_Grid_AC GND_MEAS_GRID_AC GND_MEAS_Line_AC VDD_5V 5V_MEAS_DC VDD_5V 5V_MEAS_Line_AC GND_MEAS_lINE_AC GND_MEAS_DC GND_MEAS_DC Neutral_ BUS_N 00 00 L19 22Ohm@100MHz 1 2 C68 4.7uF 50V Rled11 4k Rled18 1k D_G13 LED_Green_0805 A C U30 LD29080DT50R VIN 1 VOUT 3 GND 4 C75470pF JP3 Jp_pcb 1 2 U29LD29150DT33R VIN 1 VOUT 3 GND 4 U33 5V_in/5V_out 1 +Vi 2 -Vi 7 +Vo 5 -Vo D_R3 LED_Red_0805 A C C69 4.7uF 50V U28 691213510002 1 1 2 2 L25 1uH D_G15 LED_Green_0805 A C C59 10uF Rled19 1k Rled14 1k D_G11 LED_Green_0805 A C JP2 Jp_pcb 1 2 C60 470nF/50V 00 L21 22Ohm@100MHz 1 2 C57 470nF/50V Rled12 4k J9 Dev3 1 2 3 L24 1uH C63 470nF/50V C54 470nF/50V U27 LD29080DT50R VIN 1 VOUT 3 GND 4 U26 691213510002 1 1 2 2 C71 4.7uF 50V D_G9 LED_Green_0805 A C D_G12 LED_Green_0805 A C D_R4 LED_Red_0805 A C C58 10uF L23 1uH C76470pF 0 L22 22Ohm@100MHz 1 2 U31 5V_in/5V_out 1 +Vi 2 -Vi 7 +Vo 5 -Vo C73 10uF 16V D_G14 LED_Green_0805 A C C65 4.7uF 50V C74470pF Rled15 2.2k C62 10uF C72 4.7uF 50V C67 10uF 16V 00 00 L20 22Ohm@100MHz 1 2 C56 10uF U32 5V_in/5V_out 1 +Vi 2 -Vi 7 +Vo 5 -Vo C61 470nF/50V Rled16 2.2k U25LD29150DT33R VIN 1 VOUT 3 GND 4 Rled13 4k C53 10uF D_G10 LED_Green_0805 A C C70 10uF 16V C64 10uF C55 470nF/50V C66 4.7uF 50V Rled17 2.2k J10 Dev3 1 2 3

Figure 37. STDES-BCBIDIR circuit schematic - Power board (10 of 18)

image/svg+xml AC CURRENT SENSING VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V VDD_5V V_line_A_IN_LEM V_line_A IlineB V_line_B_IN_LEM V_line_B IlineC V_line_C_IN_LEM V_line_C IlineA C38 100nF 25V R43 13.7 k R58 10 k U20 TL431ACL3T A 3 K 1 REF 2 C46 1uF 25V R48 4.7 k R64 4.7 k TP31 TestPoint_Ring L13 22Ohm@100MHz 1 2 R66 10 k TP27 TestPoint_Ring R52 N.M. TP32 TestPoint_Ring LEM3 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 R65 N.M. LEM2 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 R63 0 R62 1k R60 N.M. C43 100nF 25V C51 1uF 25V U24 TL431ACL3T A 3 K 1 REF 2 C48 100nF 25V R56 4.7 k L18 22Ohm@100MHz 1 2 R47 0 C44 1uF 25V R57 N.M. R45 4.12 k TP24 TestPoint_Ring C40 N.M. LEM4 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 C52 N.M. TP26 TestPoint_Ring U22 TL431ACL3T A 3 K 1 REF 2 C42 1uF 25V TP30 TestPoint_Ring L14 22Ohm@100MHz 1 2 C49 1uF 25V TP28 TestPoint_Ring C47 N.M. R53 4.12 k R59 13.7 k C39 1uF 25V L16 22Ohm@100MHz 1 2 R55 0 L15 22Ohm@100MHz 1 2 R46 1k L17 22Ohm@100MHz 1 2 - + U19 TSV911IYLT 3 4 1 5 2 TP23 TestPoint_Ring R51 13.7 k C41 100nF 25V TP29 TestPoint_Ring R49 N.M. R44 N.M. - + U23 TSV911IYLT 3 4 1 5 2 TP33 TestPoint_Ring R50 10 k C45 100nF 25V TP22 TestPoint_Ring TP25 TestPoint_Ring R54 1k - + U21 TSV911IYLT 3 4 1 5 2 C50 100nF 25V R61 4.12 k V_BIAS_currentAC_A V_BIAS_currentAC_B V_BIAS_currentAC_C V_BIAS_currentAC_A V_BIAS_currentAC_B V_BIAS_currentAC_C 0 0 0 0 0 0 0

Figure 38. STDES-BCBIDIR circuit schematic - Power board (11 of 18)

image/svg+xml FAN Supply FAN connection TEMEPRATURE SENSING VDD_5V_DCDC VDD_5V VDD_ref_NTC_PFC VDD_5V VDD_5V VDD_5V VDD_ref_NTC_DCDC1 VDD_5V VDD_5V VDD_ref_NTC_DCDC2 TEMP FAN TEMP FAN PFC_FAN DCDC_FAN NTC_PFC NTC_PFC_Temp NTC_DCDC1 NTC_DCDC1_Temp NTC_DCDC2 NTC_DCDC2_Temp TP20 TestPoint_Ring C31 100nF 25V C36 100nF 25V R39 1.4k TP15 TestPoint_Ring TP13 TestPoint_Ring Rled101k R41 1.5k TP19 TestPoint_Ring L10 22Ohm@100MHz 1 2 R26 1k - + U14 TSV911IYLT 3 4 1 5 2 R33 1.5k C34 100nF 25V R37 1k TP16 TestPoint_Ring C35 1uF 25V U11 1 1 2 2 R30 1.4k C29 100nF 25V R27 10k R20470 R36 475 C37 1uF 25V R40 30k U79 TLVH431MIL3T A 3 K 2 REF 1 R23 33k R32 30k R38 10k - + U13 TSV911IYLT 3 4 1 5 2 R24 10k R25 1k TP12 TestPoint_Ring D_G8 LED_Green_0805 A C R42 475 U12 STLM20W87F NC 1 GND 2 VOUT 3 VCC 4 GND1 5 L12 22Ohm@100MHz 1 2 TP18 TestPoint_Ring C32 1uF 25V U10 1 1 2 2 L11 22Ohm@100MHz 1 2 - + U17 TSV911IYLT 3 4 1 5 2 U78 TLVH431MIL3T A 3 K 2 REF 1 J8 Dev3 1 2 3 TP14 TestPoint_Ring R35 1.5k R34 475 C33 100nF 25V U77 TLVH431MIL3T A 3 K 2 REF 1 Q1 STS6NF20V 8 3 4 5 6 7 2 1 TP21 TestPoint_Ring R29 1.4k R2222 C30 100nF 25V TP17 TestPoint_Ring R21 5.1k R31 30k R28 10k VDD_ref_NTC_PFC VDD_ref_NTC_DCDC1 VDD_ref_NTC_DCDC2 0 0 0 0 0

Figure 39. STDES-BCBIDIR circuit schematic - Power board (12 of 18)

image/svg+xml DC DC VOLTAGE SENSING 5V_MEAS_DC2_DCDC VDD_5V_DCDC VDD_5V_DCDC GND_MEAS_DC2 GND_MEAS_DC2 GND_MEAS_DC2 GND_MEAS_DC2 BUS_P2 V_bus_DC2 R10 3.9 M R12 2 M R1917.4 k U8 AMC1311QDWVRQ1 VDD1 1 VIN 2 3 SHTDN GND1 4 GND2 5 VOUTN 6 VOUTP 7 VDD2 8 R170 C27 1uF 25V C22 1uF 25V C28 100pF/25V R18 10.5 k R16 10.5 k C25 100nF 25V TP9 TestPoint_Ring R15 0 0 0 L922Ohm@100MHz 1 2 C24 1uF 25V R14 24 k R13 17.4 k C23 100nF 25V R11 5.6 M TP11 TestPoint_Ring C26 100nF 25V TP8 TestPoint_Ring 0 0 L8 22Ohm@100MHz 1 2 - + U9 TSV911IYLT 3 4 1 5 2 TP10 TestPoint_Ring

Figure 40. STDES-BCBIDIR circuit schematic - Power board (13 of 18)

image/svg+xml DRIVER BOARD VDD_12V_DCDC VDD_3.3V_DRIVER_DCDC VDD_3.3V_DRIVER_DCDC VDD_12V_DCDC VDD_3.3V_DRIVER_DCDC VDD_3.3V_DRIVER_DCDC VDD_12V_DCDC VDD_12V_DCDC D_D1 D_D2 GND_ISO_D1 GATE_D1 GND_ISO_D2 GATE_D2 D_D3 D_D4 GND_ISO_D3 GATE_D3 GND_ISO_D4 GATE_D4 D_D5 D_D6 D_D7 D_D8 GND_ISO_D5 GATE_D5 GND_ISO_D6 GATE_D6 GND_ISO_D7 GATE_D7 GND_ISO_D8 GATE_D8 GND_ISO_D3 GATE_D3 GND_ISO_D1 GATE_D1 GND_ISO_D4 GATE_D4 GND_ISO_D2 GATE_D2 GND_ISO_D5 GATE_D5 GND_ISO_D7 GATE_D7 GND_ISO_D6 GATE_D6 GND_ISO_D8 GATE_D8 J44 Testpoint 1 R261 47k J53 Testpoint 1 J5 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A R263 47k J48 Testpoint 1 J55 Testpoint 1 J4 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A J45 Testpoint 1 J58 Testpoint 1 J51 Testpoint 1 R260 47k J49 Testpoint 1 R262 47k R259 47k J54 Testpoint 1 R257 47k J43 Testpoint 1 J56 Testpoint 1 J46 Testpoint 1 J47 Testpoint 1 R258 47k J7 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A J52 Testpoint 1 J6 DaughterBoard 1 3.3V 2 12V 3 GND 4 GND1 5 D_Q2 6 D_Q1 7 GND ISO Q2 8 GND ISO Q2_A 9 GATE Q2 10 GATE Q2_A 11 GND ISO Q1 12 GND ISO Q1_A GATE Q1 13 14 GATE Q1_A R256 47k J50 Testpoint 1 J57 Testpoint 1 PULLDOWN RESISTANCES

Figure 41. STDES-BCBIDIR circuit schematic - Power board (14 of 18)

image/svg+xml DCDC CURRENT SENSING VDD_5V_DCDC VDD_5V_DCDC VDD_5V_DCDC Idc2_LEM BUS_LEM_DC2+ BUS_LEM_DC2- R9 N.M. C20 1uF 25V R2 13.7 k R5 1k C18 1uF 25V R1 0 R4 4.12 k TP7 TestPoint_Ring R8 10 k 00 00 L6 22Ohm@100MHz 1 2 TP4 TestPoint_Ring C21 N.M. TP6 TestPoint_Ring C17 100nF 25V 0 0 L7 22Ohm@100MHz 1 2 R7 4.7 k LEM1 CASR 15-NP IN-1 1 IN-2 2 IN-3 3 OUT-1 4 OUT-2 5 OUT-3 6 Ref 7 OUT 8 0 9 5V 10 TP5 TestPoint_Ring - + U6 TSV911IYLT 3 4 1 5 2 C19 100nF 25V U7 TL431ACL3T A 3 K 1 REF 2 R6 0 R3 N.M. V_BIAS_currentDC2 V_BIAS_currentDC2

Figure 42. STDES-BCBIDIR circuit schematic - Power board (15 of 18)

image/svg+xml LED STATUS VDD_5V_DCDC VDD_7V_DCDC VDD_3.3V_DCDC VDD_5V_DCDC VDD_7V_DCDC VDD_7V_EXT VDD_7V_DCDC VDD_7V_EXT VDD_12V_DCDC VDD_12V_EXT VDD_12V_DCDC VDD_12V_EXT VDD_3.3V_DRIVER_DCDC VDD_7V_INT VDD_12V_INT VDD_12V_INT VDD_7V_INT VDD_5V_STEP_DCDC VDD_3.3V_DRIVER_DCDC VDD_12V_DCDC VDD_5V_STEP_DCDC VDD_3.3V_DCDC VDD_5V_DCDC VDD_5V_DCDC 5V_MEAS_DC2_DCDC GND_MEAS_DC2 GND_MEAS_DC2 BUS_N2 Rled4 1k U2LD29150DT33R VIN 1 VOUT 3 GND 4 C14 4.7uF 50V L2 22Ohm@100MHz 1 2 J2 Dev3 1 2 3 Rled8 1k C4 10uF 00 00 L4 22Ohm@100MHz 1 2 C8 470nF/50V Rled3 4k U3 LD29080DT50R VIN 1 VOUT 3 GND 4 Rled5 2.2k J3 Dev3 1 2 3 D_G2 LED_Green_0805 A C C5 10uF 00 00 L1 22Ohm@100MHz 1 2 U4LD29150DT33R VIN 1 VOUT 3 GND 4 D_G3 LED_Green_0805 A C C15 10uF 16V C16470pF C10 10uF D_R1 LED_Red_0805 A C Rled1 4k D_G4 LED_Green_0805 A C U1 LD29080DT50R VIN 1 VOUT 3 GND 4 C3 470nF/50V Rled2 4k C9 470nF/50V C11 470nF/50V Rled6 2.2k U5 5V_in/5V_out 1 +Vi 2 -Vi 7 +Vo 5 -Vo C13 4.7uF 50V Rled7 2.2k D_G1 LED_Green_0805 A C C1 470nF/50V JP1 Jp_pcb 1 2 C2 10uF D_G5 LED_Green_0805 A C D_R2 LED_Red_0805 A C C6 470nF/50V D_G7 LED_Green_0805 A C Rled9 1k C7 10uF C12 10uF 00 00 L3 22Ohm@100MHz 1 2 L5 1uH D_G6 LED_Green_0805 A C DCDC AUXILIARY POWER SUPPLY 0 0

Figure 43. STDES-BCBIDIR circuit schematic - Power board (16 of 18)

image/svg+xml EXTERNAL CONNECTORS V_bus V_bus_DC1 VDD_5V GND GND VDD_5V_DCDC VDD_3.3V_DCDC VDD_3.3V GPIO_GRID_RELAY_A D_Q2 D_Q1 D_Q4 PFC_FAN GPIO_GRID_RELAY_N GPIO_GRID_RELAY_B GPIO_RELAY V_bus Idc_LEM IlineC IlineB GPIO_GRID_RELAY_C IlineA VlineC.S VlineB.S VlineA.S VgridC.S VgridB.S VgridA.S D_D2 D_D8 D_D1 D_D7 D_D4 D_D3 D_D6 D_D5 DCDC_FAN Idc2_LEM TEMP V_bus_DC1 V_bus_DC2 NTC_PFC_Temp NTC_DCDC1_Temp NTC_DCDC2_Temp D_Q3 D_Q6 D_Q5 I_GRID_A I_GRID_B I_GRID_C Io_trafoA VF_trafoA Io_trafoB VF_trafoB Idc_LEM HV_Discharge J1 PFC Digital Power Connector 1B 1B 2A 2A 2B 2B 3B 3B 4A 4A 4B 4B 5A 5A 5B 5B 6A 6A 6B 6B 7B 7B 8A 8A 8B 8B 9A 9A 9B 9B 10A 10A 10B 10B 11A 11A 11B 11B 12A 12A 12B 12B 13A 13A 13B 13B 14A 14A 14B 14B 15A 15A 15B 15B 16A 16A 16B 16B 17A 17A 17B 17B 18A 18A 18B 18B 19A 19A 19B 19B 20A 20A 20B 20B 21A 21A 21B 21B 22A 22A 22B 22B 23A 23A 23B 23B 24A 24A 24B 24B 25A 25A 25B 25B 7A 7A 1A 1A 26B 26B 29B 29B 27B 27B 28B 28B 30B 30B 26A 26A 27A 27A 28A 28A 29A 29A 30A 30A 32A 32A 31B 31B 32B 32B 31A 31A 3A 3A P1 DCDC Digital Power Connector 1B 1B 2A 2A 2B 2B 3B 3B 4A 4A 4B 4B 5A 5A 5B 5B 6A 6A 6B 6B 7B 7B 8A 8A 8B 8B 9A 9A 9B 9B 10A 10A 10B 10B 11A 11A 11B 11B 12A 12A 12B 12B 13A 13A 13B 13B 14A 14A 14B 14B 15A 15A 15B 15B 16A 16A 16B 16B 17A 17A 17B 17B 18A 18A 18B 18B 19A 19A 19B 19B 20A 20A 20B 20B 21A 21A 21B 21B 22A 22A 22B 22B 23A 23A 23B 23B 24A 24A 24B 24B 25A 25A 25B 25B 7A 7A 1A 1A 26B 26B 29B 29B 27B 27B 28B 28B 30B 30B 26A 26A 27A 27A 28A 28A 29A 29A 30A 30A 32A 32A 31B 31B 32B 32B 31A 31A 3A 3A

Figure 44. STDES-BCBIDIR circuit schematic - Power board (17 of 18)

image/svg+xml TRANSFORMER CURRENT SENSING VDD_5V VDD_5V VDD_5V VDD_5V VDD_BIAS_TrafoA VDD_5V VDD_5V VDD_BIAS_TrafoB VDD_5V VDD_5V OUTB_DAB1 OUTB_DAB1_o OUTA_DAB2_o OUTA_DAB2 VF_trafoA VF_trafoB Io_trafoA Io_trafoB R242 1.05 k R238 1k R233 9.09 k TP105 TestPoint_Ring 0 L57 22Ohm@100MHz 1 2 R237 14 k TP112 TestPoint_Ring JP9 Jp_pcb 1 2 R240 30k C171 100nF 25V R246 14 k R239 10k R247 9.09 k TP110 TestPoint_Ring IC1 MCA1101-50-5 IP+_1 1 IP+_2 2 IP+_3 3 IP+_4 4 IP-_1 5 IP-_2 6 IP-_3 7 IP-_4 8 VOC 16 GND_3 15 GND_2 14 VREF 13 VOUT 12 GND_1 11 VCC 10 FAULTB 9 C168 100nF 25V TP108 TestPoint_Ring 0 L56 22Ohm@100MHz 1 2 TP113 TestPoint_Ring C175 100nF 25V C173 100nF 25V R245 10k U81 TLVH431MIL3T A 3 K 2 REF 1 R235 11.7 k U80 TLVH431MIL3T A 3 K 2 REF 1 0 0 L58 22Ohm@100MHz 1 2 - + U67 TSV911IYLT 3 4 1 5 2 JP8 Jp_pcb 1 2 IC2 MCA1101-50-5 IP+_1 1 IP+_2 2 IP+_3 3 IP+_4 4 IP-_1 5 IP-_2 6 IP-_3 7 IP-_4 8 VOC 16 GND_3 15 GND_2 14 VREF 13 VOUT 12 GND_1 11 VCC 10 FAULTB 9 R236 34 k R243 1k - + U69 TSV911IYLT 3 4 1 5 2 0 L59 22Ohm@100MHz 1 2 C172 1uF 25V R228 3.3 k TP109 TestPoint_Ring TP111 TestPoint_Ring R249 11.7 k R248 30k C169 1uF 25V TP107 TestPoint_Ring C176 1uF 25V R230 1.05 k R244 34 k C174 1uF 25V R241 3.3 k VDD_BIAS_TrafoA VDD_BIAS_TrafoB

Figure 45. STDES-BCBIDIR circuit schematic (18 of 18) - Power board

image/svg+xml TW18 CON1 1 TW2 CON1 1 TW7 CON1 1 TW11 CON1 1 H21tdex6015 TW16 CON1 1 TW5 CON1 1 TW9 CON1 1 TW14 CON1 1 TW3 CON1 1 H22tdex6015 TW8 CON1 1 TW12 CON1 1 TW17 CON1 1 TW1 CON1 1 TW6 CON1 1 TW10 CON1 1 TW15 CON1 1 H20tdex6015 TW4 CON1 1 TW13 CON1 1

Figure 46. STDES-BCBIDIR circuit schematic - Control board
image/svg+xml UART TTL (3,3V) ESDALC6V1-1M2 VDD = 1.71 V to 3.6 V pag6 AN5093 UART TTL (3,3V) I2C TTL (3,3V) +3.3V_iso USART_TX USART_RX CAN_TX CAN_RX SMBus_SCL SMBus_SMBA SMBus_SDA FAULT_1 GPIO_1/COMP_3_OUT/GP_PWM_1/EEV_4 GPIO_3/COMP_1_OUT/FAULT_2 GPIO_9/EEV_3 A_VDD VDD_3.3V VDD_3.3V VDD_3.3V VDD_3.3V_INT VDD_5V_INT GND_iso GND GND AGND AGND AGND AGND AGND AGND VDD_3.3V AGND AGND AGND VDD_3.3V AVDD_3.3V AVDD_3.3V VDD_5V_USB VDD_5V VDD_5V_USB VDD_5V_EXT VDD_5V_INT VDD_3.3V_REG VDD_5V VDD_3.3V_INT VDD_3.3V VDD_3.3V_REG VDD_3.3V AGND AGND VDD_3.3V AGND AGND AGND AGND AGND AGND AGND AGND AGND AVDD_3.3V AVDD_3.3V VDD_3.3V VDD_3.3V VDD_3.3V AGND AGND AGND VDD_3.3V FAN RLY_C RLY_B RLY_A Vgrid_C Vgrid_B Vgrid_A Iout V_bus_up V_bus_down IinA IinB IinC TEMP IinA IinB IinC INRUSH_RELAY INRUSH_RELAY Vgrid_B_uC VgridC.S VgridB.S VgridA.S Vgrid_C_uC Vgrid_A_uC TP32 TestPoint C11 100nF/16V D9 GREEN TP36 TestPoint C10 100nF/16V C19 100pF/50V C36 2.2nF/50V C22 2.2nF/50V C9 1uF/25V TP1TestPoint TP24 TestPoint R291k R5 10k TP28TestPoint R30 1k TP37 TestPoint R11 10k D6 GREEN D8 SMAJ5.0A-TR 1 2 TP40 TestPoint R19 10k C31 2.2nF/50V TP10 TestPoint C25 100pF/50V C3 100nF/16V C13 100nF/16V + C16 10uF 1 2 R2810k C28 100pF/50V TP7 TestPoint C2 100nF/16V TP18 TestPoint C24 100pF/50V C23 100pF/50V TP25 TestPoint C27 2.2nF/50V R271k C39 2.2nF/50V R31 1k TP31 TestPoint D7 GREEN C21 2.2nF/50V S2 FSM4JSMA 1 4 2 3 C35 100pF/50V TP13TestPoint TP27TestPoint CN1 Jtag_SWD_Adapter VDD 1 SWDIO 2 SWCLK 4 GND 9 RST 10 R21 10k TP12 TestPoint R2 10k TP22 TestPoint R10 0 C7 100pF/50V TP2TestPoint C17 100pF/50V C37 2.2nF/50V J3 UART2 1 2 3 4 TP29 TestPoint C8 2.2nF/50V R17 10k R13 0 TP41 TestPoint R9 0 C30 2.2nF/50V TP30TestPoint TP34TestPoint C34 100nF/16V J2 UART1 1 2 3 4 C20 100pF/50V TP5 TestPoint R241k TP38 TestPoint TP20TestPoint USB1 microUSB V 1 D- 2 D+ 3 GND 5 D 4 M1 6 M2 7 M3 8 M4 9 C15 470nF/50V D4 GREEN TP17 TestPoint C26 100pF/50V R8 10k JP2 STRIP_2X3 1 3 5 2 4 6 C18 100pF/50V R15 0 TP23 TestPoint R12 10k R23 1k D3 SMAJ5.0A-TR 1 2 R7 1k R14 0 TP21TestPoint U3 ESDAL 1 2 3 C33 100pF/50V C40 100pF/50V J1 PLUG 64 PIN 90 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 TP9 TestPoint C5 100pF/50V TP16 TestPoint D2 GREEN 1 of 2 STM32G474RET3 U1B 12 PA0 13 PA1 14 PA2 17 PA3 18 PA4 19 PA5 20 PA6 21 PA7 42 PA8 43 PA9 44 PA10 45 PA11 46 PA12 49 PA13 50 PA14 51 PA15 24 PB0 25 PB1 26 PB2 56 PB3 57 PB4 58 PB5 59 PB6 60 PB7 61 PB8-BOOT0 62 PB9 30 PB10 33 PB11 34 PB12 35 PB13 36 PB14 37 PB15 8 PC0 9 PC1 10 PC2 11 PC3 22 PC4 23 PC5 38 PC6 39 PC7 40 PC8 41 PC9 52 PC10 53 PC11 54 PC12 2 PC13 3 PC14-OSC32_IN 4 PC15-OSC32_OUT 55 PD2 5 PF0-OSC_IN 6 PF1-OSC_OUT 7 PG10-NRST C38 2.2nF/50V TP33 TestPoint TP8TestPoint TP6 TestPoint TP19 TestPoint R6 10k U2LDL1117S33R VIN 3 VOUT 2 GND 1 2 of 2 U1A STM32G474RET3 15 VSS1 27 VSSA 28 VREF+ 1 VBAT 29 VDDA 31 VSS2 16 VDD1 32 VDD2 48 VDD3 47 VSS3 63 VSS4 64 VDD4 D5 GREEN R18 0 JP1 3JP_pcb C41 2.2nF/50V TP3 TestPoint S1 FSM4JSMA 1 4 2 3 R20 10k R1 10k L1 WE-CBF TP15 TestPoint C4 100pF/50V C43 100nF/16V D10 GREEN TP14 TestPoint J4 i2C 1 2 3 4 R4 1k C29 100pF/50V R331k TP11 TestPoint R3 10k R22 10k R25 0 LED1 SMTL4-SBC 1 1 2 2 3 3 4 4 R26 10k TP4 TestPoint TP39 TestPoint JP3 3JP_pcb C6 100pF/50V R321k C1 2.2nF/50V TP35 TestPoint R16 10k C42 100nF/16V TP26TestPoint C12 100nF/16V C14 2.2nF/50V D1 GREEN C32 1uF/25V RLY_A RLY_B RLY_C FAN TA_HS HRTIM1_CHA1 TA_LS TA_AS TB_HS TB_LS TB_AS TC_HS TC_LS TA_DS TB_DS TC_DS TA_AS TA_DS TA_HS TB_LS TC_DS TB_AS TB_HS TC_AS TC_HS USR_BTN TEMP Iout_uC Iout IB+_uC IA+_uC V_bus_up_uC V_bus_down_uC V_bus_down V_bus_up IC+_uC USART2_TX USART2_RX T_NRST T_NRST T_SWDIO T_SWCLK T_NRST T_SWCLK T_SWDIO VgridA.S VgridA.S_uC VgridB.S VgridB.S_uC VgridC.S VgridC.S_uC TA_LS TB_DS TC_LS LED_1 LED_2 IC+_uC Iout_uC V_bus_up_uC V_bus_down_uC VgridC.S_uC TEMP_uC IA+_uC IB+_uC VgridA.S_uC VgridB.S_uC T_SWDIO USART2_RX T_SWCLK USART2_TX T_NRST i2C_SDA i2C_SCL USR_BTN FAN DAC1 DAC2 DAC3 RLY_B RLY_C RLY_A HRTIM1_CHC1 HRTIM1_CHC2 HRTIM1_CHD1 HRTIM1_CHD2 HRTIM1_CHF2 HRTIM1_CHF1 HRTIM1_CHF1 HRTIM1_CHE1 HRTIM1_CHE2 HRTIM1_CHA1 HRTIM1_CHA2 HRTIM1_CHB1 HRTIM1_CHB2 HRTIM1_CHB1 HRTIM1_CHB2 HRTIM1_CHA2 HRTIM1_CHC2 TC_AS HRTIM1_CHC1 HRTIM1_CHD2 HRTIM1_CHD1 HRTIM1_CHE2 HRTIM1_CHE1 HRTIM1_CHF2 LED_2 LED_1 STATUS_LED USART3_TX USART3_RX USART3_TX USART3_RX DAC1 DAC2 DAC3 TEMP_uC i2C_SCL i2C_SDA Vgrid_A Vgrid_A_uC Vgrid_B Vgrid_B_uC Vgrid_C Vgrid_C_uC STATUS_LED DigProb2 DigProb1
Figure 47. STDES-BCBIDIR circuit schematic - Driver board

image/svg+xml VDD_12V VL_Q1 VH_Q1 VDD_3.3V_DRIVER VL_Q2 VH_Q2 VDD_12V VDD_3.3V_DRIVER VDD_3.3V_DRIVER VDD_3.3V_DRIVER VDD_3.3V_DRIVER VDD_12V D_Q1 GATE_Q1 GATE_Q2 GND_ISO_Q1 GND_ISO_Q2 D_Q2 SD BRAKE iLOCK SD BRAKE iLOCK GND_ISO_Q1 GND_ISO_Q2 D_Q2 GATE_Q1 GATE_Q2 D_Q1 R18022 R175 47k N.M. 0 L51 22Ohm@100MHz 1 2 R184 47k N.M. J20 1 2 C253 2.2 uF C385 22 uF J19 1 2 C240 100 nF D28 TZMB20-GS08 A C 0 0 F1 22Ohm@100MHz 1 2 C251 0.1uF U53 STGAP2SiCD NC1 1 NC2 2 NC3 3 NC4 4 8 INB 7 INA 6 VDD 5 NC5 13 GND NC6 12 16 NC9 14 NC7 BRAKE 10 iLOCK 11 SD 9 15 NC8 17 NC10 18 NC11 NC12 19 VH_B 20 NC13 21 GON_B 22 GOFF_B 23 GNDISO_B 24 CLAMP_B 25 VH_A 30 GON_A 31 GOFF_A 32 CLAMP_A 33 GNDISO_A1 34 GNDISO_A2 35 NC14 36 C238 22 uF R178 N.MN.M. C246 1 nF J17 SOLDER JUMPER3 1 2 3 C248 220pF D25 TZMB20-GS08 A C J23 1 2 C245 100 nF TP67 TestPoint_Ring R182 R C234 220pF C244 2.2 uF C384 22 uF c2322.2uF/25V J22 1 2 C252 1 uF R1724.7 R173 R C257 CAP NP R17122 C229 2.2 uF C243 CAP NP DC9 R12P22005D VIN+ 1 COM 6 +VOUT 7 VIN- 2 -VOUT 5 TP69 TestPoint_Ring C231 1 nF C239 2.2 uF c233470nF/50V R177100 C230 100 nF J21 1 2 J18 SOLDER JUMPER3 1 2 3 D26 TZMC5V1-GS08 A C R169 N.MN.M. TP72 TestPoint_Ring L50 IND 1 2 J25 1 2 C250 1 nF c247470nF/50V c2492.2uF/25V TP70 TestPoint_Ring C241 1 nF TP68 TestPoint_Ring R168100 TP71 TestPoint_Ring C255 1 nF L49 IND 1 2 C228 22 uF J24 1 2 D29 TZMC5V1-GS08 A C DC10 R12P22005D VIN+ 1 COM 6 +VOUT 7 VIN- 2 -VOUT 5 R1814.7 C254 100 nF J16 SOLDER JUMPER3 1 2 3 VH_Q1 GND_ISO_Q1 VL_Q1 VH_Q2 GND_ISO_Q2 VL_Q2

Bill of materials

Table 16. STDES-BCBIDIR bill of materials
Item Q.ty Ref. Part / Value Description Manufacturer Order code
1 1 - STDES-BCBIDIR Main power board ST Not available for separate sale
2 2 - STDES-PFCBIDIR Control board ST Not available for separate sale
3 2 - STDES-GAP2SICD Driver board ST Not available for separate sale
Table 17. STDES-BCBIDIR - main power board
Item Q.ty Ref. Part / Value Description Manufacturer Order code
1 12 C1 C3 C6 C8 C9 C11 C54 C55 C57 C60 C61 C63 470nF/50V Condensatore ceramico multistrato (MLCC) WURTH 470nF, ±10%, 50 V c.c., SMD Wurth Electronics Inc. 885012207102
2 12 C2 C4 C5 C7 C10 C12 C53 C56 C58 C59 C62 C64 10uF Aluminum Electrolytic Capacitors Wurth Electronics Inc. 865250643009
3 8 C13 C14 C65 C66 C68 C69 C71 C72 4.7uF 50V CAPACITOR CERAMIC SMD 1210 Wurth Electronics Inc. 885012209048
4 4 C15 C67 C70 C73 10uF 16V CAPACITOR CERAMIC SMD 1210 Wurth Electronics Inc. 885012109009
5 4 C16 C74 C75 C76 470pF CAPACITOR CERAMIC SMD 2211 Murata GA352QR7GF471KW01L
6 56 C17 C19 C23 C25 C26 C29 C30 C31 C33 C34 C36 C38 C41 C43 C45 C48 C50 C77 C79 C83 C85 C86 C89 C92 C94 C96 C99 C101 C105 C107 C108 C109 C112 C114 C116 C117 C120 C122 C124 C125 C128 C130 C132 C133 C136 C138 C140 C142 C144 C146 C149 C150 C168 C171 C173 C175 100nF 25V CAPACITOR CERAMIC SMD 0603 Wurth Electronics Inc. 885012206071R
7 47 C18 C20 C22 C24 C27 C32 C35 C37 C39 C42 C44 C46 C49 C51 C78 C80 C82 C84 C87 C90 C93 C95 C97 C100 C102 C104 C106 C110 C113 C115 C118 C121 C123 C126 C129 C131 C134 C137 C139 C141 C145 C147 C148 C169 C172 C174 C176 1uF 25V CAPACITOR CERAMIC SMD 0603 Wurth Electronics Inc. 885012206076
8 8 C21 C40 C47 C52 C81 C91 C98 C103 N.M. CAPACITOR CERAMIC SMD 0603 ANY ANY
9 8 C28 C180 C181 C182 C183 C184 C185 C186 100pF/25V Condensatore ceramico multistrato (MLCC) 100pF, ±5%, 25V cc, SMD ANY
10 3 C152 C153 C154 6.8uF X2-Safety Class Capacitor; MKP - Metallized Polypropylene Wurth Electronics Inc. 890324028008
11 4 C155 C156 C161 C162 470uF Aluminium Electrolytic Capacitors Wurth Electronics Inc. 861141486024
12 2 C157 C158 25uF WCAP-FTDB DC-Link Capacitor,32.5mm,25uF Wurth Electronics Inc. 890494428004CS
13 1 C159 100nF MKT-Metallized polyester Wurth Electronics Inc. 890493425009CS
14 1 C160 10nF MKT-Metallized polyester Wurth Electronics Inc. 890493422002CS
15 3 C177 C178 C179 680nF WCAP-FTBE Film Capacitors,C2,PITCH:15,LxWxH:18x8.5x15 890283425008CS
16 5 D1 D2 D3 D4 D5 STPS360AFY DIODE SCHOTTKY 60V 3A SOD128 STMicroelectronics STPS360AFY
17 10 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 LED RED LED RED CLEAR 1206 SMD Wurth Electronics Inc. 150120RS75000
18 15 D_G1 D_G2 D_G3 D_G4 D_G5 D_G6 D_G7 D_G8 D_G9 D_G10 D_G11 D_G12 D_G13 D_G14 D_G15 LED_Green_0805 Wurth Electronics Inc. 150080GS75000
19 4 D_R1 D_R2 D_R3 D_R4 LED_Red_0805 Wurth Electronics Inc. 150080RS75000
20 3 F1 F2 F3 30A Industrial & Electrical Fuses 30A 250VAC Midget Littelfuse 0BLN030.T
21 3 H20 H21 H22 tdex6015 t high-performance extruded fan heat sink Thermo Electric Devices TDEX6015/TH12G
22 2 IC1 IC2 MCA1101-50-5 Board Mount Current Sensors High Accuracy +/-50A Current Sensor, 3.3V, Fixed gain, 1.5MHz 3dB BW, OCD, Galvanic Isolation. UL/IEC/EN60950-1 and UL1577 certified. SOIC-16
23 2 J1 P1 Digital Power Connector Connector Erni 284166 32X2 female ERNI 284166
24 5 J2 J3 J8 J9 J10 Dev3 SWITCH SLIDE SPDT 500MA 12V Wurth Electronics Inc. 450301014042
25 4 J4 J5 J6 J7 DaughterBoard Each DaughterBoard consists of 7 connectors of the indicated part number Preci-Dip 801-87-002-10-001101
26 3 J11 J12 J13 DaughterBoard Each DaughterBoard consists of 7 connectors of the indicated part number Mill-Max Mfg Corp. 834-43-002-10-001000
27 16 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J29 74651195R Screw erminal with External Thread Wurth Electronics Inc. 74651195R
28 5 J30 J31 J32 J33 J34 9324-0-15-15-23-27-04-0 Circuit Board Hardware - PCB RECPT. GOLD/NICKEL .106 IN. PRESSFIT Mill-Max Mfg Corp. 9324-0-15-15-23-27-04-0
29 8 J35 J36 J37 J38 J39 J40 J41 J42 Con3 SIL VERTICAL PC TAIL PIN HEADER Harwin Inc. M20-9990345
30 28 J43 J44 J45 J46 J47 J48 J49 J50 J51 J52 J53 J54 J55 J56 J57 J58 TP114 TP115 TP116 TP117 TP118 TP119 TP120 TP121 TP122 TP123 TP124 TP125 Testpoint PC TEST POINT NATURAL Harwin Inc. S2751-46R
31 8 JP1 JP2 JP3 JP4 JP5 JP6 JP8 JP9 Jp_pcb ANY
32 47 L1 L2 L3 L4 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L26 L27 L28 L29 L30 L31 L32 L33 L34 L35 L36 L37 L38 L39 L40 L41 L42 L43 L44 L45 L46 L47 L56 L57 L58 L59 22Ohm@100MHz Wurth Electronics Inc. 742792021
33 4 L5 L23 L24 L25 1uH SMT Power Inductor Wurth Electronics Inc. 7447730
34 3 L48 L51 L53 7.8 uH Power Inductor 7.8 uH 20.5A Wurth Electronics Inc. 750344312
35 3 L49 L50 L52 255u Power Inductor 255uH 23 A Wurth Electronics Inc. 760801101
36 8 LEM1 LEM2 LEM3 LEM4 LEM5 LEM6 LEM7 LEM8 CASR 15-NP SENSOR CURRENT HALL 15A AC/DC LEM USA Inc. CASR 15-NP
37 4 LS1 LS2 LS3 LS4 Relay 30A General Purpose Relays Industrial Relays (General Purpose) TE Connectivity / P&B T9AV5L12-12
38 6 Q1 Q2 Q3 Q4 Q5 Q6 STS6NF20V, SO-8 MOSFET N-CH 20V 6A 8SOIC ST STS6NF20V
39 10 R1 R6 R47 R55 R63 R67 R74 R90 R98 R106 0 CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
40 8 R2 R43 R51 R59 R68 R86 R94 R102 13.7 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
41 8 R3 R44 R52 R60 R69 R87 R95 R103 N.M. N.M. N.M. N.M.
42 8 R4 R45 R53 R61 R70 R88 R96 R104 4.12 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
43 19 R5 R25 R26 R37 R46 R54 R62 R73 R89 R97 R105 R112 R127 R140 R151 R165 R179 R238 R243 1k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
44 8 R7 R48 R56 R64 R71 R91 R99 R107 4.7 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
45 20 R8 R50 R58 R66 R72 R93 R101 R109 R119 R121 R131 R133 R143 R146 R157 R160 R170 R173 R182 R185 10 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
46 8 R9 R49 R57 R65 R75 R92 R100 R108 N.M. CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
47 1 R10 3.9 M CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
48 1 R11 5.6 M CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
49 1 R12 2 M CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
50 1 R13 17.4 k CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
51 1 R14 24 k CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
52 2 R15 R17 0 CHIP RESISTOR SMD 0.1% 1/4W 0603 ANY
53 2 R16 R18 10.5 k CHIP RESISTOR SMD 0.1% 1/4W 0603 ANY
54 1 R19 17.4 k CHIP RESISTOR SMD 0.1% 1/4W 0603 ANY
55 1 R20 470 Resistore per montaggio superficiale a film spesso Vishay 470O ±1%, 0,1W, 0603, serie CRCW ANY
56 1 R21 5.1k Resistore per montaggio superficiale a film spesso Panasonic 5,1kO ±1%, 0,25W, 0603, serie ERJPA3 ANY
57 1 R22 22 Resistore per montaggio superficiale a film spesso Vishay 22O ±1%, 0,25W, 1206, serie CRCW ANY
58 1 R23 33k Resistore per montaggio superficiale a film spesso Vishay 33kO ±1%, 0,1W, 0603, serie CRCW ANY
59 1 R24 10k Resistore SMD Bourns 10kO ±1%, 0,1W, 0603, serie CR0603-FX ANY
60 11 R27 R28 R38 R114 R129 R144 R153 R167 R183 R239 R245 10k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
61 3 R29 R30 R39 1.4k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
62 11 R31 R32 R40 R116 R134 R147 R155 R171 R186 R240 R248 30k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
63 3 R33 R35 R41 1.5k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
64 3 R34 R36 R42 475 CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
65 1 R76 3.9 M CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
66 1 R77 5.6 M CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
67 1 R78 2 M CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
68 2 R79 R85 17.4 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
69 1 R80 24 k CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
70 14 R81 R83 R118 R120 R130 R132 R142 R145 R156 R159 R169 R172 R181 R184 0 CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
71 2 R82 R84 10.5 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
72 6 R110 R111 R123 R124 R136 R137 1.27 M CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
73 12 R113 R122 R125 R135 R138 R148 R152 R161 R164 R174 R177 R187 8.25 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
74 3 R115 R126 R139 1.24 M CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
75 3 R117 R128 R141 51.1 k CHIP RESISTOR SMD 0.1% 1/10W 1206 ANY
76 6 R149 R150 R162 R163 R175 R176 1.27 M CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
77 3 R154 R166 R178 1.24 M CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
78 3 R158 R168 R180 51.1 k CHIP RESISTOR SMD 0.1% 1/4W 1206 ANY
79 3 R188 R189 R190 0.33 RES 0.33 OHM 5W 5% RADIAL TE Connectivity Passive Product SQMW5R33J
80 6 R191 R192 R193 R194 R195 R196 240k Resistenza fissa per montaggio superficiale di precisione a film spesso Panasonic 240kO ±1%, 0,25W, 1206, serie ERJ ANY
81 3 R197 R198 R200 150 Wirewound Resistors - Through Hole 150 Ohms 5W 300PPM TE Connectivity SQMW5150RJ
82 12 R199 R203 R204 R205 R206 R207 RLED1 RLED2 RLED3 RLED11 RLED12 RLED13 4k Resistore per montaggio superficiale a film spesso TE Connectivity 1kO ±1%, 0,1W, 0603, serie CRG0603 ANY ANY
83 5 R201 R208 R209 R210 R211 22 CHIP RESISTOR SMD 1% 1/10W 0603 ANY
84 5 R202 R212 R213 R214 R216 33k CHIP RESISTOR SMD 1% 1/10W 0603 ANY
85 11 R215 R217 R218 R219 RLED4 RLED8 RLED9 RLED10 RLED14 RLED18 RLED19 1k Resistore per montaggio superficiale a film spesso TE Connectivity 1kO ±1%, 0,1W, 0603, serie CRG0603 ANY ANY
86 2 R228 R241 3.3 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
87 2 R230 R242 1.05 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
88 2 R233 R247 9.09 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
89 2 R235 R249 11.7 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
90 2 R236 R244 34 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
91 2 R237 R246 14 k CHIP RESISTOR SMD 0.1% 1/10W 0603 ANY
92 14 R250 R251 R252 R253 R254 R255 R256 R257 R258 R259 R260 R261 R262 R263 47k CHIP RESISTOR SMD 1% 1/8W 0805 ANY
93 1 RE1 G7J-4A-P DC12 ANY G7J-4A-P DC12
94 6 RLED5 RLED6 RLED7 RLED15 RLED16 RLED17 2.2k Resistore per montaggio superficiale a film spesso TE Connectivity 1kO ±1%, 0,1W, 0603, serie CRG0603 ANY ANY
95 88 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 TP30 TP31 TP32 TP33 TP34 TP35 TP36 TP37 TP38 TP39 TP40 TP41 TP42 TP43 TP44 TP45 TP46 TP47 TP48 TP49 TP50 TP51 TP52 TP53 TP54 TP55 TP56 TP57 TP58 TP59 TP60 TP61 TP62 TP63 TP64 TP65 TP66 TP67 TP68 TP69 TP70 TP71 TP72 TP73 TP74 TP75 TP76 TP77 TP78 TP79 TP80 TP81 TP82 TP83 TP105 TP107 TP108 TP109 TP110 TP111 TP112 TP113 TestPoint_Ring Polo terminale RS Pro, diam. foro 1mm, Bronzo fosforoso ANY ANY
96 18 TP84 TP85 TP86 TP87 TP88 TP89 TP90 TP91 TP92 TP93 TP94 TP95 TP96 TP97 TP98 TP99 TP126 TP127 TEST POINT PC TEST POINT NATURAL Harwin Inc. S1751-46R
97 18 TW1 TW2 TW3 TW4 TW5 TW6 TW7 TW8 TW9 TW10 TW11 TW12 TW13 TW14 TW15 TW16 TW17 TW18 CON1 Standoffs & Spacers WA-SBRIE M3x60mm Wurth Electronics Inc. 971600324
98 4 U1 U3 U27 U30 LD29080DT50R, DPAK IC REG LINEAR 5V 800MA DPAK ST LD29080DT50R
99 4 U2 U4 U25 U29 LD29150DT33R, DPAK Regolatori di tensione LDO 1.5A VLD 400mV 3.3V Fixed ST LD29150DT33R
100 4 U5 U31 U32 U33 5V_in/5V_out Modulo di alimentazione c.c.-c.c. DCH010505SN7, Modulo SIP, 4-Pin Wurth Electronics Inc. 1779205141
101 21 U6 U9 U13 U14 U17 U19 U21 U23 U34 U37 U38 U40 U42 U46 U48 U51 U55 U58 U60 U67 U69 TSV911IYLT, SOT23-5L IC OPAMP GP 8MHZ RRO SOT23-5 ST TSV911IYLT
102 8 U7 U20 U22 U24 U35 U39 U41 U43 TL431ACL3T, SOT23 IC VREF SHUNT ADJ SOT23-3 ST TL431ACL3T
103 2 U8 U36 AMC1311QDWVRQ1 IC ISOLATION 8SOIC Texas Instruments AMC1311QDWVRQ1
104 4 U10 U11 U26 U28 691213510002 Fixed Terminal Blocks WR-TBL 5.08mm THT 2Pin 14A 300V 20mOhm Wurth Electronics Inc. 691213510002
105 1 U12 STLM20W87F, SOT323-5L SENS TEMP ANLG VOLT SOT-323-5 ST STLM20W87F
106 6 U45 U47 U50 U54 U56 U59 AMC1350DWVR Amplificatore Di isolamento 1 Circuito 8-SOIC TexasInstrument AMC1350DWVR
107 2 U62 U64 M1F45M12W2-1LA, ACEPACK DMT-32 Power module fourpack topology 45 m? typ. SiC Power MOSFET with NTC ST M1F45M12W2-1LA
108 1 U63 M1P45M12W2-1LA Power module sixpack topology 27.5 m? typ. SiC Power MOSFET with NTC ST M1P45M12W2-1LA
109 11 U71 U72 U73 U74 U75 U76 U77 U78 U79 U80 U81 TLVH431MIL3T, SOT23 IC VREF SHUNT ADJ SOT23-3 STMicroelectronics TLVH431AIL3T
Table 18. STDES-PFCBIDIR - control board
Item Q.ty Ref. Part / Value Description Manufacturer Order code
1 13 C1 C8 C14 C21 C22 C27 C30 C31 C36 C37 C38 C39 C41 2.2nF/50V Wurth Elektronik, 0603 (1608M) 2.2nF Multilayer Ceramic Capacitor MLCC 50V dc ±10% , SMD 885012206085 Wurth Elektronik 885012206085
2 9 C2 C3 C10 C11 C12 C13 C34 C42 C43 100nF/16V Wurth Elektronik, 0603 (1608M) 100nF Multilayer Ceramic Capacitor MLCC 16V dc ±10% , SMD 885012206046 Wurth Elektronik 885012206046
3 16 C4 C5 C6 C7 C18 C19 C20 C23 C24 C25 C26 C28 C29 C33 C35 C40 100pF/50V Wurth Elektronik, 0603 (1608M) MLCC 885012006057 Wurth Elektronik 885012006057
4 2 C9 C32 1uF/25V Wurth Elektronik, 0603 (1608M) 1µF Multilayer Ceramic Capacitor MLCC 25V dc ±10% , SMD 885012206076 Wurth Elektronik 885012206076
5 1 C15 470nF/50V Wurth Elektronik, 0805 (2012M) 470nF Multilayer Ceramic Capacitor MLCC 50V dc, SMD 885012207102 Wurth Elektronik 885012207102
6 1 C16 10uF Wurth Elektronik 10µF Electrolytic Capacitor 16V dc, Surface Mount - 865230340001 Wurth Elektronik 865230340001
7 1 C17 100pF/50V Wurth Elektronik, 0603 (1608M) MLCC 885012006057 Wurth Elektronik 885012006057
8 1 CN1 Jtag_SWD_Adapter Samtec, FTSH, 10 Way, 2 Row, Straight Pin Header Samtec FTSH-105-01-F-D-K
9 8 D1 D2 D4 D5 D6 D7 D9 D10 GREEN 3.2 V Green LED 2012 (0805) SMD, Wurth Elektronik WL-SMCW 150080GS75000 Wurth Elektronik 150080GS75000
10 2 D3 D8 SMAJ5.0A-TR, SMA STMicroelectronics SMAJ5.0A-TR, Uni-Directional TVS Diode, 400W, 2-Pin DO-214AC ST SMAJ5.0A-TR
11 1 J1 PLUG 64 PIN 90 Connector Erni 90° 384241 32X2 male ERNI 384241
12 1 J2 UART1 Wurth Elektronik, WR-PHD, 6130, 4 Way, 1 Row, Straight Pin Header Wurth Elektronik 61300411121
13 1 J3 UART2 Wurth Elektronik, WR-PHD, 6130, 4 Way, 1 Row, Straight Pin Header Wurth Elektronik 61300411121
14 1 J4 i2C Wurth Elektronik, WR-PHD, 6130, 4 Way, 1 Row, Straight Pin Header Wurth Elektronik 61300411121
15 2 JP1 JP3 3JP_pcb N.M. N.M.
16 1 JP2 STRIP_2X3 N.M. N.M.
17 1 L1 WE-CBF Wurth Elektronik Ferrite Bead (EMI Suppression), 1.6 x 0.8 x 0.8mm (0603 (1608M)), 120O impedance at 100 MHz Wurth Elektronik 74279262
18 1 LED1 PLCC4_3P2X2P8 LED Bivar, Verde, rosso, SMD, 2,4 V, 2 Led, PLCC 4 Bivar SMTL4-SBC
19 16 R1 R2 R3 R5 R6 R8 R11 R12 R16 R17 R19 R20 R21 R22 R26 R28 10k Bourns 10kO, 0603 (1608M) Thick Film SMD Resistor ±1% 0.1W - CR0603-FX-1002ELF ANY ANY
20 10 R4 R7 R23 R24 R27 R29 R30 R31 R32 R33 1k TE Connectivity 1kO, 0603 Thick Film SMD Resistor ±1% 0.1W - CRG0603F1K0 ANY ANY
21 7 R9 R10 R13 R14 R15 R18 R25 0 TE Connectivity 0O, 0603 (1608M) Thick Film SMD Resistor ±0% 0.1W - CRG0603ZR ANY ANY
22 2 S1 S2 FSM4JSMA Black Button Tactile Switch, Single Pole Single Throw (SPST) 50 mA @ 24 V dc 1.4mm Surface Mount TE Connectivity ALCOSWITCH Switches FSM4JSMA
23 41 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 TP30 TP31 TP32 TP33 TP34 TP35 TP36 TP37 TP38 TP39 TP40 TP41 TestPoint RS PRO 1mm Black Terminal Post ANY ANY
24 1 U1 STM32G474RET3, LQFP 64 10x10x1.4 mm Arm® Cortex®-M4 32b MCU+FPU, 512KB Flash, 150 MHz, 128KB SRAM ST STM32G474RET3
25 1 U2 LDL1117S33R, SOT-223 STMicroelectronics LDL1117S33R, 1 Low Dropout Voltage, Voltage Regulator 1.2A, 3.3 V 4-Pin, SOT-223 ST LDL1117S33R
26 1 U3 ESDAL, SOT23-3L STMicroelectronics ESDA6V1L, Dual-Element Uni-Directional TVS Diode, 300W, 3-Pin SOT-23 ST ESDA6V1L
27 1 USB1 microUSB Molex Right Angle, SMT, Socket Type Micro-B 2.0 USB Connector MOLEX 47346-0001
Table 19. STDES-GAP2SICD - driver board
Item Q.ty Ref. Part / Value Description Manufacturer Order code
1 4 C228 C238 C384 C385 22 uF CAPACITOR CERAMIC SMD 0805
2 4 C229 C239 C244 C253 2.2 uF CAPACITOR CERAMIC SMD 0805
3 4 C230 C240 C245 C254 100 nF CAPACITOR CERAMIC SMD 0603
4 4 C231 C241 C246 C255 1 nF CAPACITOR CERAMIC SMD 0603
5 2 C234 C248 220pF CAPACITOR CERAMIC SMD 0603 Würth Elektronik 885012206079
6 2 C243 C257 CAP NP ANY
7 1 C250 1 nF CAP CER 1 nF 25V 0603 Würth Elektronik 885012006044
8 1 C251 0.1uF CAP CER 0.1UF 50V X7R 0603 Würth Elektronik 885012206095
9 1 C252 1 uF CAP CER 1UF 6.3V X5R 0603 Yageo CC0603KRX5R5BB105
10 2 D25 D28 TZMB20-GS08 DIODE ZENER 20V 500MW SOD80 Vishay Semiconductor Diodes Division TZMB20-GS08
11 2 D26 D29 TZMC5V1-GS08 DIODE ZENER 5.1V 500MW SOD80 Vishay Semiconductor Diodes Division TZMC5V1-GS08
12 2 DC9 DC10 R12P22005D CONV DC/DC 2W 12VIN +20/-5VOUT T Recom Power R12P22005D
13 2 F1 L51 22Ohm@100MHz Würth Elektronik 742792021
14 3 J16 J17 J18 SOLDER JUMPER3 TIN DROP JUMPER 0603 3pin
15 7 J19 J20 J21 J22 J23 J24 J25 CONN_002P_000C_1 802-10-002-20-001000
16 2 L49 L50 IND Fixed Inductor 22uH SMD 0805 Taiyo Yuden LBC2012T220M
17 2 R168 R177 100 CHIP RESISTOR SMD 1% 1/10W 0603
18 2 R169 R178 N.M CHIP RESISTOR SMD 1% 1/10W 0603
19 2 R171 R180 22 CHIP RESISTOR SMD 5% 1/4W 1206 any
20 2 R172 R181 4.7 CHIP RESISTOR SMD 5% 1/4W 1206 any
21 2 R173 R182 R
22 2 R175 R184 47k CHIP RESISTOR SMD 1% 1/8W 0805
23 6 TP67 TP68 TP69 TP70 TP71 TP72 TestPoint_Ring Polo terminale RS Pro, diam. foro 1mm, Bronzo fosforoso ANY ANY
24 1 U53 STGAP2SiCD, SSOP 32 LEAD 300 MIL PKG .0315 P STGAP2SiCD ST STGAP2SiCD
25 2 C232 C249 2.2uF/25V Condensatore ceramico multistrato (MLCC) WE 2,2µF, ±10%, 25 V c.c., SMD Würth Elektronik 885012108019
26 2 C233 C247 470nF/50V Condensatore ceramico multistrato (MLCC) 470nF, ±10%, 50 V c.c., SMD Würth Elektronik 885012207102

Reference design warnings, restrictions and disclaimer

Important: The reference design is not a complete product. It is intended exclusively for evaluation in laboratory/development environments by technically qualified electronics experts who are familiar with the dangers and application risks associated with handling electrical/mechanical components, systems and subsystems.
DANGER: Exceeding the specified reference design ratings (including but not limited to input and output voltage, current, power, and environmental ranges) may cause property damage, personal injury or death. If there are questions concerning these ratings, contact an STMicroelectronics field representative prior to connecting interface electronics, including input power and intended loads. Any loads applied outside of the specified output range may result in unintended and/or inaccurate operation and/or possible permanent damage to the reference design and/or interface electronics. During normal operation, some circuit components may reach very high temperatures. These components include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors which can be identified in the reference design schematic diagrams.

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List of tables

Table 1. Main characteristics

Table 2. Hardware and software requirements

Table 3. Hardware and software requirements

Table 4. Hardware and software configurations

Table 5. Hardware and software requirements

Table 6. Hardware configurations

Table 7. Software configurations

Table 8. Hardware and software requirements

Table 9. Hardware and software requirements

Table 10. Hardware and software requirements

Table 11. Hardware configurations

Table 12. Software configurations

Table 13. Hardware and software requirements

Table 14. Hardware configurations

Table 15. Software configurations

Table 16. STDES-BCBIDIR bill of materials

Table 17. STDES-BCBIDIR - main power board

Table 18. STDES-PFCBIDIR - control board

Table 19. STDES-GAP2SICD - driver board

Table 20. Document revision history

List of figures

Figure 1. STDES-BCBIDIR reference design

Figure 2. HFT - 2446.0001 AQ magnetic cable labeling

Figure 3. HFT - 2446.0001 AQ magnetic connection to the board

Figure 4. Typical test bench

Figure 5. Grid relays management

Figure 6. Grid relay jumper configuration

Figure 7. Grid relay check

Figure 8. PFC section - Grid voltage sensing

Figure 9. PFC section - Grid current sensing

Figure 10. PFC section - Line voltage sensing

Figure 11. PFC section - Line current sensing

Figure 12. DC-DC section - DC voltage sensing

Figure 13. DC-DC section - DC current sensing

Figure 14. Measurement of the mains voltage and reading of the corresponding sensor

Figure 15. Measurement of the BUS voltage and reading of the corresponding sensor

Figure 16. ST-LINK/V2 connected to the control board

Figure 17. PLL test waveforms

Figure 18. PLL test environment and procedure

Figure 19. Testing procedure of gate to source voltages

Figure 20. Gate to source voltage PFC stage

Figure 21. Gate to source voltage DC-DC stage

Figure 22. Start-up waveforms of the PFC

Figure 23. Startup waveforms of the DAB

Figure 24. Full power test–double conversion

Figure 25. Steady-state operations

Figure 26. Soft start-up

Figure 27. Overall Efficiency

Figure 28. STDES-BCBIDIR circuit schematic - Power board (1 of 18)

Figure 29. STDES-BCBIDIR circuit schematic - Power board (2 of 18)

Figure 30. STDES-BCBIDIR circuit schematic - Power board (3 of 18)

Figure 31. STDES-BCBIDIR circuit schematic - Power board (4 of 18)

Figure 32. STDES-BCBIDIR circuit schematic - Power board (5 of 18)

Figure 33. STDES-BCBIDIR circuit schematic - Power board (6 of 18)

Figure 34. STDES-BCBIDIR circuit schematic - Power board (7 of 18)

Figure 35. STDES-BCBIDIR circuit schematic - Power board (8 of 18)

Figure 36. STDES-BCBIDIR circuit schematic - Power board (9 of 18)

Figure 37. STDES-BCBIDIR circuit schematic - Power board (10 of 18)

Figure 38. STDES-BCBIDIR circuit schematic - Power board (11 of 18)

Figure 39. STDES-BCBIDIR circuit schematic - Power board (12 of 18)

Figure 40. STDES-BCBIDIR circuit schematic - Power board (13 of 18)

Figure 41. STDES-BCBIDIR circuit schematic - Power board (14 of 18)

Figure 42. STDES-BCBIDIR circuit schematic - Power board (15 of 18)

Figure 43. STDES-BCBIDIR circuit schematic - Power board (16 of 18)

Figure 44. STDES-BCBIDIR circuit schematic - Power board (17 of 18)

Figure 45. STDES-BCBIDIR circuit schematic (18 of 18) - Power board

Figure 46. STDES-BCBIDIR circuit schematic - Control board

Figure 47. STDES-BCBIDIR circuit schematic - Driver board

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