TIDUD61E October   2020  – April 2021

 

  1.   Description
  2.   Resources
  3.   Features
  4.   Applications
  5.   5
  6. 1System Description
    1. 1.1 Key System Specifications
  7. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 Design Considerations
      1. 2.2.1 Input AC Voltage Sensing
      2. 2.2.2 Bus Voltage Sensing
      3. 2.2.3 AC Current Sensing
      4. 2.2.4 Sense Filter
      5. 2.2.5 Protection (CMPSS)
    3. 2.3 Highlighted Products
      1. 2.3.1 C2000™ MCU F28004x
      2. 2.3.2 LMG3410R070
      3. 2.3.3 UCC27714
    4. 2.4 System Design Theory
      1. 2.4.1 PWM
      2. 2.4.2 Current Loop Model (PFC and Inverter mode)
      3. 2.4.3 DC Bus Regulation Loop (for PFC mode only)
      4. 2.4.4 Soft Start Around Zero Crossing for Eliminate or Reduce Current Spike
      5. 2.4.5 AC Drop Test
  8. 3Hardware, Software, Testing Requirements, and Test Results
    1. 3.1 Required Hardware and Software
      1. 3.1.1 Hardware
        1. 3.1.1.1 Base Board Settings
        2. 3.1.1.2 Control Card Settings
      2. 3.1.2 Software
        1. 3.1.2.1 Opening Project Inside CCS
        2. 3.1.2.2 Project Structure
        3. 3.1.2.3 Using CLA on C2000 MCU to Alleviate CPU Burden
        4. 3.1.2.4 CPU and CLA Utilization and Memory Allocation
        5. 3.1.2.5 Running the Project
          1. 3.1.2.5.1 Lab 1: Open Loop, DC (PFC Mode)
            1. 3.1.2.5.1.1 Setting Software Options for LAB 1
            2. 3.1.2.5.1.2 Building and Loading Project
            3. 3.1.2.5.1.3 Setup Debug Environment Windows
            4. 3.1.2.5.1.4 Using Real-Time Emulation
            5. 3.1.2.5.1.5 Running Code
          2. 3.1.2.5.2 Lab 2: Closed Current Loop DC (PFC)
            1. 3.1.2.5.2.1 Setting Software Options for Lab 2
            2. 3.1.2.5.2.2 Designing Current Loop Compensator
            3. 3.1.2.5.2.3 Building and Loading Project and Setting up Debug
            4. 3.1.2.5.2.4 Running Code
          3. 3.1.2.5.3 Lab 3: Closed Current Loop, AC (PFC)
            1. 3.1.2.5.3.1 Setting Software Options for Lab 3
            2. 3.1.2.5.3.2 Building and Loading Project and Setting up Debug
            3. 3.1.2.5.3.3 Running Code
          4. 3.1.2.5.4 Lab 4: Closed Voltage and Current Loop (PFC)
            1. 3.1.2.5.4.1 Setting Software Options for Lab 4
            2. 3.1.2.5.4.2 Designing Voltage Loop Compensator
            3. 3.1.2.5.4.3 Building and Loading Project and Setting up Debug
            4. 3.1.2.5.4.4 Running Code
          5. 3.1.2.5.5 Lab 5: Open loop, DC (Inverter)
            1. 3.1.2.5.5.1 Setting Software Options for Lab 5
            2. 3.1.2.5.5.2 Building and Loading Project
            3. 3.1.2.5.5.3 Setup Debug Environment Windows
            4. 3.1.2.5.5.4 Running Code
          6. 3.1.2.5.6 Lab 6: Open loop, AC (Inverter)
            1. 3.1.2.5.6.1 Setting Software Options for Lab 6
            2. 3.1.2.5.6.2 Building and Loading Project and Setting up Debug
            3. 3.1.2.5.6.3 Running Code
          7. 3.1.2.5.7 Lab 7: Closed Current Loop, DC (Inverter with resistive load)
            1. 3.1.2.5.7.1 Setting Software Options for Lab 7
            2. 3.1.2.5.7.2 Designing Current Loop Compensator
            3. 3.1.2.5.7.3 Building and Loading Project and Setting up Debug
            4. 3.1.2.5.7.4 Running Code
          8. 3.1.2.5.8 Lab 8: Closed Current Loop, AC (Inverter with resistive load)
            1. 3.1.2.5.8.1 Setting Software Options for Lab 8
            2. 3.1.2.5.8.2 Building and Loading Project and Setting up Debug
            3. 3.1.2.5.8.3 Running Code
          9. 3.1.2.5.9 Lab 9: Closed Current Loop (Grid Connected Inverter)
            1. 3.1.2.5.9.1 Setting Software Options for Lab 9
            2. 3.1.2.5.9.2 Building and Loading Project and Setting up Debug
            3. 3.1.2.5.9.3 Running Code: Emulated Grid-tied Condition (Verification purpose only)
            4. 3.1.2.5.9.4 Running Code: Grid-tied Condition
        6. 3.1.2.6 Running Code on CLA
        7. 3.1.2.7 Advanced Options
          1. 3.1.2.7.1 Input Cap Compensation for PF Improvement Under Light Load
          2. 3.1.2.7.2 83
          3. 3.1.2.7.3 Adaptive Dead Time for Efficiency Improvements
          4. 3.1.2.7.4 Phase Shedding for Efficiency Improvements
          5. 3.1.2.7.5 Non-Linear Voltage Loop for Transient Reduction
          6. 3.1.2.7.6 Software Phase Locked Loop Methods: SOGI - FLL
    2. 3.2 Testing and Results
      1. 3.2.1 Test Results at Input 120 Vrms, 60 Hz, Output 380-V DC
        1. 3.2.1.1 Startup
        2. 3.2.1.2 Steady State Condition
        3. 3.2.1.3 Transient Test With Step Load Change
          1. 3.2.1.3.1 0% to 50% Load Step Change
          2. 3.2.1.3.2 50% to 100% Load Step Change
          3. 3.2.1.3.3 100% to 50% Load Step Change
          4. 3.2.1.3.4 50% to 100% Load Step Change
      2. 3.2.2 Test Results at Input 230 Vrms, 50 Hz, Output 380 V DC
        1. 3.2.2.1 Startup
        2. 3.2.2.2 Steady State Condition
        3. 3.2.2.3 Transient Test With Step Load Change
          1. 3.2.2.3.1 33% to 100% Load Step Change
          2. 3.2.2.3.2 100% to 33% Load Step Change
      3. 3.2.3 Test Results Graphs
  9. 4Design Files
    1. 4.1 Schematics
    2. 4.2 Bill of Materials
    3. 4.3 PCB Layout Recommendations
      1. 4.3.1 Layout Prints
    4. 4.4 Altium Project
    5. 4.5 Gerber Files
    6. 4.6 Assembly Drawings
  10. 5Software Files
  11. 6Related Documentation
    1. 6.1 Trademarks
  12. 7About the Author
  13. 8Revision History

3.2.1.2 Steady State Condition

Steady state current waveforms are shown in Figure 3-65, Figure 3-66, and Figure 3-67 at different load conditions. Phase shedding is disabled for these readings.

GUID-CF050ED3-2C8D-40C9-B396-9DEABE2275B8-low.gifFigure 3-65 Steady State 120-Vac IN, 380-V DC OUT 300W, iTHD 5.5%
GUID-4EF80C86-A7B9-4783-8FC1-0351C7CC4080-low.gifFigure 3-66 Steady State 120-Vac IN, 380-V DC OUT 880W, iTHD 2.15%
GUID-9C963378-4D06-48B9-A405-09150207712D-low.gifFigure 3-67 Steady State 120-Vac IN, 380-V DC OUT, 1.674-KW, iTHD 1.75%

Table 3-3 lists the detailed test results of this design under varying load conditions with 120-Vac input and 380-V DC output. For this data, phase shedding is disabled, adaptive dead time is enabled, 100 ns is chosen as the fixed dead time for the hard-switched edge, and the soft switching edge dead time varies between 20 ns and 200 ns.

Table 3-3 Detailed Test Results with 120-Vac IN, 380-V DC OUT, and Different Power Levels
Vin (V RMS)Vout (V)Pin (W)Iout (A)Pout (W)EFFICIENCY %iTHD%PF% RATED LOADTHETA OFFSETGI KP
120.05382.02154.270.375143.4792.9810.540.99279.0-0.0140.35
119.86382.01301.300.750286.3695.145.500.997417.9-0.010.35
119.49382.01444.401.120427.7696.304.160.998726.7-0.010.35
119.42382.03579.101.469561.4096.942.890.995035.1-0.010.35
119.16382.02721.301.837701.8097.302.420.999543.9-0.010.35
119.02382.05863.002.202841.5097.522.150.999552.600.35
118.78381.961007.202.573983.3097.641.920.999561.500.35
118.63382.081152.002.9441125.3097.691.820.999570.300.35
118.40382.081298.403.3191268.2097.701.720.999479.300.35
118.25382.081442.003.6851408.3097.691.870.999188.000.3
118.03382.081593.804.0711555.5097.651.800.999197.200.3
117.98382.051716.404.4491674.8097.611.750.9991104.700.3