IEEE PEDS 2011, Singapore, 5 - 8 December 2011

A New 98% Soft-Switching Full-Bridge DC-DC

Converter based on Secondary-Side LC
Resonant Principle for PV Generation Systems
Daisuke Tsukiyama*, Yasuhiko Fukuda*, Shuji Miyake*,
Saad Mekhilef**, Soon-Kurl Kwon*** and Mutsuo Nakaoka***
* Dispersed Power System Division, Daihen Corporation, Osaka, Japan
** University of Malaya, Malaysia
*** Kyungnam University, Republic of Korea/Yamaguchi University, Yamaguchi, Japan
d-tsukiyama@daihen.co.jp

Abstract — This paper is mainly concerned with the

state-of-the-art feasible development of a novel prototype
high-efficiency phase-shift soft-switching pulse modulated
full-bridge DC-DC power converter with a high-
frequency power transformer, which is designed for
utility-grid tied photovoltaic (PV) power inverters. The
proposed high-frequency transformer (HFTR) link DC-
DC converter topology is based upon a new conceptual
secondary-side series resonant principle and its inherent
nature. All the active power switches in the HFTR
primary-side can achieve lossless capacitive snubber-
based ZVS with the aid of transformer parasitic
inductances. In addition to this, passive power switches
in its secondary-side can also perform ZVS and ZCS
transitions for input voltage and load variations.
In the first place, the operation principle of the newly-
proposed DC-DC converter and some remarkable
features are described in this paper on the basis of the
simulation analysis. In the second place, the 5 kW
experimental setup of the DC-DC converter treated here
is demonstrated and its experimental results are
illustrated from a practical point of view. Finally, some
comparative evaluations between simulation and
experimental data are actually discussed and considered Fig. 1. Overview of utility-grid tied photovoltaic (PV) system with high-
in this paper, together with its future works. frequency isolation and, circuit diagram of the new phase-shift
soft-switching pulse modulated full-bridge DC-DC converter,
Index Terms---DC-DC power converter, full bridge topology, high- which is based on the secondary-side series LC resonant principle.
frequency transformer link, secondary-side LC resonant principle,
primary-side ZVS, secondary-side ZCZVS, photovoltaic generation system
density and high performance solar converters have been
practically needed so far, which include high frequency
I. INTRODUCTION switching pulse modulated DC-DC converters and utility
In recent years, a variety of collaborated developments on interactive sinewave modulated inverters on the basis of
renewable, sustainable energy conversion devices digital control schemes.
technologies and advanced power electronics have been In particular, the front-end high-efficiency, high frequency
strongly required toward concrete realization of non-carbon switching boost DC-DC power converters such as non-
society from a global point of view. Of these relating to isolated and isolated circuit topologies have been considered
energy electronics, effective utilizations of the clean PV and discussed for solar power converters in order to improve
generating power and the energy with the aid of the latest their efficiency, power density and control performances
energy storage devices such as batteries and/or capacitors including noise issue. The authors have proposed several
have attracted special interest in the fields of power electronic circuit topologies of high- frequency switching DC-DC high-
distributed power supply systems applications and DC power converter circuits operating under the conditions of
feeding smart grid. Under such conditions mentioned above, soft commutation schemes for high power industrial
next generation developments of high-efficiency, high-power applications [1-2]. In addition, the authors have also

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978-1-4577-0001-9/11/$26.00 ©2011 IEEE 1112
developed utility-grid tied three-phase sinewave inverter
operating under the conditions of high efficiency control
strategy [3]. To further decrease the power consumption,
advanced high efficiency and high-power density soft-
switching DC-DC converter topology with high frequency
transformer link is proposed for a new issue on power
solution, which is based on its secondary-side LC resonant
circuit principle for the front-end solar converter in PV
generation systems.
Also, some previous researches about a variety of DC-DC
converter with high-frequency transformer are introduced to
improve their efficiency and power density [4-14]. It
includes series-resonant soft-switching DC-DC converter
with high-frequency transformer [13-14]. In these
researches, DC-DC converter utilizes the leakage inductance
of transformer for energy storing and/or soft commutation.
However, although it is useful for realizing soft switching
DC-DC converter, a large leakage inductance more than 2 μH
or presence of parasitic capacitance more than 1 μF have to
decrease magnetic coupling coefficient of the transformer.
This result leads to not only reducing the high-frequency
transformer efficiency but also increasing the surge voltage
applied to the high-frequency full bridge inverter circuit
which is introduced into this DC-DC converter with high-
frequency transformer. In addition to this, it is extremely
difficult that some series resonant DC-DC converters which
utilize the leakage inductance of transformer is adopted as
high voltage and high power applications above 1 kW, due to
the reduction of power transmission efficiency from primary-
side to secondary-side.
This paper presents an improved efficiency phase shift soft-
switching pulse modulated full-bridge DC-DC converter with
a high frequency transformer stage and front-end boost
converter cascade stage, which includes soft-switching full
bridge diode rectifier operating on the basis of the resonant
operating principle and inherent nature of the secondary-side
LC series resonant circuit. This new DC-DC power
converter suitable for solar converter can achieve not only
soft-switching transition based on ZVS in the primary-side,
but also ZVS and ZCS commutation for the full-bridge diode
rectifier in secondary-side. The operating principle of this
DC-DC converter in a periodic steady-state is described by
using switching mode equivalent circuits and simulation
analysis, along with its inherent remarkable features as
compared with conventional ones. The simulated operating
voltage and current waveforms are comparatively illustrated
in experimental ones. The actual efficiency vs. output
power characteristics and power loss analysis are
demonstrated from an experimental point of view. The
practical effectiveness of the proposed converter for PV
generation systems are confirmed and verified by means of 5
kW setup implementation and simulation analysis.
II. NEW SOFT-SWITCHING DC-DC CONVERTER
A. Circuit Description
Figure 1 shows a proposed high-frequency transformer link
phase-shift soft-switching pulse modulated full-bridge DC-
DC converter with the front-end boost converter cascade
stage which incorporates soft-switching full bridge rectifier
2
operating at the secondary-side LC resonant principle. The
LC resonant components are located across the output diode
rectifier. This high frequency isolated DC-DC converter
designed for PV generation systems can operate under ZVS
condition of the primary-side active switches S1 ～ S4 in H-
Bridge arms with the aid of lossless capacitor, leakage
inductor Ll and magnetizing inductance Lm of the two-
winding high-frequency transformer with ferrite core.
On the other hand, the passive switches in the secondary-
side full-bridge rectifier can also operate under a principle of
ZVS and ZCS transitions due to the secondary-side LC
resonant circuit property.
B. Principle of Converter Operation
Figure 2 illustrates the relevant voltage and current
operating waveforms during a complete switching period for
the gate driving pulse sequences. The switching operating
modes of the soft-switching full-bridge DC-DC converter
with a high frequency transformer are divided into 6
operations modes from mode 1 to mode 6 in accordance with
operational timing points from t0 to t6. As can be seen in Fig.
3, the operation principle is described with the equivalent
circuits corresponding to each operating mode.
●Mode 1 (t0～t1):
During an active state the corresponding set of the primary
switches and secondary rectifier diodes (S2, S3 and D2, D3)
conduct simultaneously so that the secondary voltage and
current have the same polarity. The output power is
delivered from the DC source to the load. Positive voltage
magnitude Vin is applied to the high-frequency transformer.
Both VS1 and VS4, the voltages across S1 and S4, respectively,
are also equal to the source voltage Vin.
●Mode 2 (t1～t2):
The turn-off signal is applied to S3 at time t1. After S3 is
turned off, VS1 begins to decrease gradually because the
capacitor paralleled with S1, previously charged to source
voltage Vin, is linearly discharging until zero level is reached.
At the same time, the capacitor paralleled with S3, previously
discharged to zero level, is linearly charging toward positive
voltage. Therefore, low-side switch S3 is able to be turned
off with ZVS due to current flowing into the capacitor
paralleled with S3. On the other hand, diode currents (iD2,
iD3) form sinusoidal wave approache to zero so that not only
D2 but also D3 can be easily turned off with extremely soft
recovery during this period.
●Mode 3 (t2～t3):
After the capacitor voltage VS1 reaches to zero, the diode
paralleled with S1 (DS1) starts to conduct and clamps voltage
on the high-side switch S1 at zero. And consequently, the
voltage across S3 is clamped at source voltage Vin. On the
other hand, the turn-off gate pulse signal is applied to S2 at
time t2. After S2 is turned off, VS4 begins to decrease
gradually because the capacitor paralleled with S4, previously
charged to source voltage Vin, is linearly discharging until zero
level is reached. At the same time, the capacitor paralleled
with S2, previously discharged to zero level, is linearly
charging toward positive voltage. Therefore, high-side
switch S2 is turned off with almost ZVS due to current flowing
into the capacitor paralleled with S3. Although all primary
switches (S1 ～ S4) are turned off, primary current is
1113
maintained

Fig. 2. Operating voltage and current waveforms of soft-switching high-

frequency link phase-shift full-bridge DC-DC converter based on the
secondary-side LC resonant principle.

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Mode 1 (t0 ≦t < t1 ) Mode 4 (t3 ≦t < t4 )

Mode 2 (t1 ≦t < t2 ) Mode 5 (t4 ≦t < t5 )

Mode 3 (t2 ≦t < t3 ) Mode 6 (t5 ≦t < t6 )

Fig. 3. Switching mode equivalent circuits of the phase-shift soft-switching full-bridge DC-
DC power converter with two winding high-frequency transformer link and soft-
switching full-bridge rectifier.

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maintained in the same direction during this state. C. Unique Features
●Mode 4 (t3～t4):
The specific advantageous points of the proposed DC-DC
Similarly to Mode 3, the diode DS4 begins to flow current
converter in Fig. 1 are as follows;
and clamps voltage on the bottom switch S4 at zero after the
capacitor voltage VS1 previously reaches to zero. On the
(1) Primary-side ZVS transition of all the active switches.
other hand, the current through the secondary-side diodes (D1
(2) Secondary-side ZVS and ZCS transition of all the
and D4) start to flow after VD1 and VD2 are equal to zero at the
passive switches.
same time when both VS2 and VS3, the voltage across S2 and S3,
(3) Minimum reverse recovery current switching loss at
respectively, reach to the source voltage Vin. At the time t4,
the diode full bridge stage.
primary current is still flow through diodes paralleled with S1
(4) Higher converter efficiency realization (98%, 380 V
and S4 (DS1 and DS4) while the turn-on signal is applied to S1.
DC output).
●Mode 5 (t4～t5):
(5) Flexible design of high voltage conversion ratio.
The current through the diodes of DS1 and DS4 decreases
(6) Ground leakage current protection from PV panel to
gradually toward zero as the secondary-side current of D1 and
power conversion circuit portion.
D4 increases. At the time t5, Both S1 and S4 are turned on
(7) Utilization of the high-efficiency transformer with less
with ZCS simultaneously.
●Mode 6 (t5～t6):
The sinusoidal resonant current flows through primary-
side active switches S1, S4 and the winding in primary-side of
high-frequency transformer. The current through M OSFET HF-
secondary-side diodes D1, D4 and the secondary-side winding Fu ll-bridge circuit Transformer
of the transformer also forms sinusoidal resonant wave as
well. The current through the primary-side is lagging
behind the voltage while the phase between the voltage and
current through the secondary-side is close to zero, because
the resonant capacitor is located between the transformer and
the full-bridge diode rectifier acts to form a leading current. Diode rectifier
This nature is effective to improve the converter efficiency.
In other words, there is no phase difference between the
voltage and the current in the secondary-side so that diodes
set in this side are able to be turned off without generating
reverse recovery current. In addition to this, all the diodes
paralleled with the primary-side active switches utilize the Series resonant
lagging current during free-wheeling states and can be turned in ductor and capacitor
off with zero reverse recovery current at time t5.

Fig. 4. Whole exterior appearance of boost converter-fed soft-switching

full-bridge high-frequency inverter link DC-DC converter with
(a)
S W 1 S W 3

S3 S1
1

soft-switching full bridge rectifier based on the secondary-side

0 . 8

0 . 6

0 . 4

S2 S4
0 . 2

series LC resonant principle.

S W 2 S W 4

(b) S2 S4
1

0 . 8

0 . 6

0 . 4

0 . 2

(C)
0 . 1 9 9 9 4 0 . 1 9 9 9 5 0 . 1 9 9 9 6 0 . 1 9 9 9 7 0 . 1 9 9 9 8 0 . 1 9 9 9 9
T i m e ( s )

ID1*20 V_D1

400

200 VD1 (V) iD1×20 (A)

0

(d) I_S1*20 V_S1

600
400
VS1 (V)
200
0
iS1×20 (A)
-200
(e) Itrans_pri

20

0
itr (A)
-20

(f) I_Lout*5 Vcap

150
100
50
iLout×5 (A)
0
-50
-100
Vcap (V)
0.19994 0.19995 0.19996 0.19997 0.19998 0.19999
Time (s)
Time (s)

Fig. 3. Simulated results of (a) gate driving signal S1 and S3, (b) gate
driving signal S2 and S4, (c) voltage and current of D1, (d) voltage
and current of S1, (e) resonant current of high-frequency
transformer and (f) inductor current and capacitor voltage of LC Fig. 5. Two winding high-frequency isolated power transformer is set
resonant circuit under the conditions of in 380 V and 5.5 kW. to the DC-DC high power converter.

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 leakage inductance and parasitic capacitance. transformer. The maximum decrease in efficiency of 0.3%
(8) High DC voltage step-up due to front-end boost was measured over 3 kW because of increasing actually
converter cascade topology. conduction losses.

Table 1. Design specifications and circuit parameters

III. CONVERTER SIMULATION

Real time-based computer simulations were carried out in Item Symbol Value Unit
PSIM version 9.0 to reveal the operation of this converter DC input voltage 380
Vin V
under constant load conditions. Figure 3 shows the (from boost converter) ～388
waveform of gate driving pulse signal (a) (b), the output DC output voltage Vout 380 V
rectifier (c), the MOSFET primary switch (d), transformer Maximum input power Pin 5.5 kW
secondary current (e) and voltage across the resonant Switching frequency fsw 30.6 kHz
capacitor connects series with the transformer secondary (VCr) Switching period Ts 16.33 μs
and the inductor current which composes output filter Phase shift time Tφ 0.95 μs
connected to load (iLout) (f) with 5 kW output specifications. Dead time Td 1.6 μs
As shown in Fig. 3 (c), diode D1 is turned off with ZVS and
Leakage inductance of
turned on with ZCS. In Fig. 3 (d), switch S1 is turned off Ll < 1.3 μH
high-frequency transformer
after iS1 reaches to zero due to the capacitor paralleled with it. Magnetizing inductance of
The current through the transformer forms sinusoidal wave Lm 640 μH
high-frequency transformer
due to series LC resonant circuit is depicted in Fig. 3 (e). Magnetic coupling coefficient of
Figure 3 (f) indicates the energy commutation between the k 0.998 -
high-frequency transformer
resonant capacitor (1/2CV2) and the resonant inductor (1/2Li2) Inductance of output filter
Lout 20 μH
which is connected to the output diode rectifier. (series resonant inductor)
Capacitance of capacitors CS1
5 nF
paralleled with transistors ～CS4
IV. EXPERIMENTAL RESULTS AND EVALUATIONS
Capacitance of Cin,
50 μF
A 380 V input DC-5 kW soft-switching phase-shift pulse input/output capacitors Cout
modulation full bridge DC-DC converter with soft-switching Capacitance of
Cr 0.88 μF
full bridge diode rectifier operating on the basis of the series resonant capasitor
secondary-side LC resonant topology was built and tested in Turn ratio of
N1 : N2 1:1 -
experiment. Figure 4 shows the whole appearance of the high-frequency transformer
proposed soft-switching full-bridge DC-DC converter based
on the secondary-side LC resonant principle for PV Item Symbol Product type
generation systems. The two-winding high-frequency Primary-side S1
FCA76N60N
transformer with ferrite core which is introduced in the DC- MOSFET switches ～S4
DC converter is shown in Fig. 5. The design specifications Secondary-side D1
RHRP3060
and circuit parameters of the converter are listed in Table 1. rectifier diodes ～D4
The measured voltage and current waveforms of this Core material of ferrite
-
prototype converter are illustrated in Fig. 6. Comparing Fig. high-frequency transformer (PQ107)
6 to Fig. 3 (c), it can be seen that these observed voltage and
current waveforms have good agreements with the simulated
ones.
The actual efficiency vs. output power characteristic is
illustrated in Fig. 7, under the conditions of constant output
voltage and some varying specifications. Observing Fig. 7, VG_S2 (10 V/Div)
the actual efficiency reaches maximum value of 98% around
the 3-4 kW output power ranges indicated by white-diamond
VS2 (250 V/Div)
marks. Over higher output power range, the efficiency
VD1
slightly decreases mainly because the total conduction loss of ID1
(100 V/Div) (5 A/Div)
the converter increases in accordance with the load current
increase. However, 97.8% efficiency can be still measured
at 5.2 kW outputs. The actual efficiency above 97% is
measured in the range of 1-5.2 kW outputs. Figure 7 also
depicts the efficiency in black-circle marks. In this
condition, terminals of these components are connected
directly to the measuring instruments by lengthening cables
for examining losses of each component which compose the Fig. 6. Experimental waveforms of gate-source voltage of S2 (VG_S2, 10
soft-switching DC-DC converter with high-frequency V/div), drain-source voltage of S2 (VS2, 250 V/div), diode D1
current (ID1, 5 A/div) and anode-cathode voltage (VD1, 100 V/div).

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 Efficiency (%) Loss (W)
Without wiring
99
for measurement 160 Rectifier + Output filter
98.5 Vin = 380 V
140 fsw = 30.6 kHz
98 27.0
120
Lout = 20 µH
97.5 21.0
97 HF-Transformer with
100 36.0
96.5 resonant capacitor
With wiring 12.9 31.0
96 80
for measurement
95.5 MOSFET switches 7.7
24.0
60
95 19.0
Vin = 380 V 3.2
94.5 40 3.2 15.3 73.0
81.0
fsw = 30.6 kHz 2.4
4.7 12.8
94 2.1
4.1
59.0

Lout = 20 µH 20 41.4
93.5 24.5 28.2 26.7 31.3

93 0

0 1 2 3 4 5 6 7 0.5 1.1 1.7 2.1 3.0 4.1 5.1 5.6

Output Power (kW) Output Power (kW)

Fig. 7. Measured actual efficiency of the trial-produced soft-switching Fig. 9. Power loss analysis about, full-bridge inverter circuit which is
full-bridge DC-DC power converter with secondary-side series consists of MOSFET primary switches, high-frequency
LC resonant rectifier as a function of the output power. transformer, and diode rectifier with output filter.

Loss (p. u.)

Efficiency (%) Rectifier + Output Filter Rectifier + Output filter
1
100
99.5 0.9
99 0.8
98.5
0.7
98
0.6
97.5
97 0.5
HF-Transformer with
96.5 0.4
resonant capacitor HF-Transformer with
96 Vin = 380 V
Vin = 380 V 0.3
95.5 MOSFET switches fsw = 30.6 kHz resonant capacitor
fsw = 30.6 kHz 0.2
95 Total system efficiency Lout = 20 µH MOSFET switches
94.5 Lout = 20 µH 0.1
94 0
0 1 2 3 4 5 6 7 0.5 1.1 1.7 2.1 3.0 4.1 5.1 5.6
Output Power (kW) Output Power (kW)

Fig. 8. Measured actual efficiencies versus output power characteristics
of, diode rectifier with output filter (black-circle marks), high-
frequency-transformer (white-triangle marks), MOSFET full-
bridge inverter circuit (black-square marks) and total efficiency of
the proposed converter with cables length consideration (white-
circle marks).
Fig. 10. Power loss analysis represented by p. u. of converter components
for, full-bridge inverter circuit adopts power MOSFETs as the
primary-side switches, high-frequency transformer, and diode
rectifier with output filter.

By connecting each input/output terminal of each power
circuit component composes the phase shift soft-switching
pulse modulated full-bridge DC-DC converter with a high
frequency transformer to the measuring instrument, input
and/or output power of each component can be measured
directly so that efficiencies and losses of these components
can also be investigated. Power efficiency of each
component was measured are shown in Fig. 8 as a function of
the output power. Total efficiency (white-circle marks) in
Fig. 8 is the same as black-circle marks in Fig. 7. As shown
in Fig. 8, all elements except full-bridge inverter which is
constructed by MOSFET reach to high efficiency of 99.5%
around 4 kW or more. Although the efficiency of the
rectifier with the filter (black-circle marks) is extremely high
in the area of 0.5-2 kW, it slightly decreases as output power
becomes larger than 3 kW. The efficiency of the full-bridge
inverter shows 98.6% maximum at 3 kW and appears to
maintain almost the same value even when output power is
more increased.
7
Power loss analysis about components of the converter was
investigated, the result of which is illustrated in Fig, 9. As
seen in Fig. 9, the sum of these losses is increased with
increasing output power. In the experimental condition of
Vin = 380 V, total loss of the soft-switching full-bridge DC-
DC converter with secondary-side resonant circuit is
increased from 30.7 W to 144 W (about 4.7 times growth)
with increasing output power from 0.5 kW to 5.5 kW (11
times growth). In the MOSFET full-bridge circuit part, the
loss is increased from 24.5 W to 81 W (3.3 times growth).
Similarly, 8.8 (from 4.1 W to 36 W) and 12.9 (from 2.1 W to
27 W) values as the growth rate of power loss are calculated
about the HF-transformer and the rectifier with the output
filter, respectively.
Figure 10 shows loss ratio of elements which compose the
converter. The primary-side MOSFET transistors which
construct the full-bridge circuit in the soft-switching DC-DC
converter account for 80% of a whole consumption in the
range of 1 kW or less and shows about 60% of that at 1.6 kW
1118
or more. This ratio still shows 56.3% at a full-load. These
results indicate that most of the total converter loss is
obviously due to the full-bridge circuit which consists of
MOSFET switches. The loss ratio of HF-transformer
decreases from about 30% to 25% with increasing output
power, in the range of 1.6 kW or more. On the contrary, the
loss ratio of the rectifier with the filter grows from 7.5% to
18.8% due to increasing conduction loss. Comparing Fig. 7
and Fig. 10, these results indicate that the effect of increasing
loss of the rectifier with the filter on efficiency degradation of
the converter becomes more significant as output power
increases.
V. CONCLUSION
In this paper, the latest high-efficiency phase-shift soft-
switching transition pulse modulation DC-DC power
converter with high-frequency transformer for PV generation
systems has been presented, which is based on the secondary-
side LC series resonant circuit principle.
The operation principle of this new DC-DC converter in a
steady state has been schematically described with the aid of
simulation analysis and confirmed in experiment. This new
conceptual high-frequency link is achieved by the high-
efficiency power conversion processing based on the
secondary-side LC resonant principle. The comparative key
operating waveforms between simulation and experimental
results have been discussed and evaluated in details. The
actual efficiency vs. output power characteristics have been
demonstrated and discussed in this paper.
Further considerations for this new conceptual soft-
switching DC-DC converter proposed have should be
discussed as the following topics;
(1) The soft-switching operating ranges for some circuit
parameters, lossless snubbing capacitors dead time
setting leakage and magnetizing inductance of high-
frequency transformer, and the secondary-side LC
resonant constants.
(2) SiC power MOSFETs and SiC-SBD Integration.
(3) Feasibility study of this DC-DC converter for utility-
grid tied PV generation systems.
(4) Multi-phase DC-DC converter system integration and
practical evaluation for Power Electronic Building
Block (PEBB).
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