TIDUFB1 December   2024

 

  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. 1System Description
    1. 1.1 Terminology
    2. 1.2 Key System Specifications
  8. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 Design Considerations
      1. 2.2.1 Control System Design Theory
        1. 2.2.1.1 PWM Modulation
        2. 2.2.1.2 Current Loop Model
        3. 2.2.1.3 DC Bus Regulation Loop
        4. 2.2.1.4 DC Voltage Balance Controller
    3. 2.3 Highlighted Products
      1. 2.3.1 TMS320F280013x
      2. 2.3.2 UCC5350
      3. 2.3.3 AMC1350
      4. 2.3.4 TMCS1123
      5. 2.3.5 UCC28750
      6. 2.3.6 LM25180
      7. 2.3.7 ISOTMP35
      8. 2.3.8 TLV76133
      9. 2.3.9 TLV9062
    4. 2.4 Hardware Design
      1. 2.4.1  Inductor Design
      2. 2.4.2  Bus Capacitor Selection
      3. 2.4.3  Input AC Voltage Sensing
      4. 2.4.4  Output DCBUS Voltage Sensing
      5. 2.4.5  Auxiliary Power Supply
      6. 2.4.6  Isolated Power Supply
      7. 2.4.7  Inductor Current Sensing
      8. 2.4.8  Gate Driver
      9. 2.4.9  Isolated Temperature Sensing
      10. 2.4.10 Overcurrent, Overvoltage Protection (CMPSS)
  9. 3Hardware, Software, Testing Requirements, and Test Results
    1. 3.1 Hardware Requirements
      1. 3.1.1 Getting Started Hardware
        1. 3.1.1.1 Board Overview
        2. 3.1.1.2 Test Equipment
    2. 3.2 Software Requirements
      1. 3.2.1 Getting Started GUI
        1. 3.2.1.1 Test Setup
        2. 3.2.1.2 Overview of a GUI Software
        3. 3.2.1.3 Procedures of Test With GUI
      2. 3.2.2 Getting Started Firmware
        1. 3.2.2.1 Opening the Project Inside Code Composer Studio™
        2. 3.2.2.2 Project Structure
        3. 3.2.2.3 Test Setup
        4. 3.2.2.4 Running Project
          1. 3.2.2.4.1 INCR_BUILD 1: Open Loop
            1. 3.2.2.4.1.1 Setting, Building, and Loading the Project
            2. 3.2.2.4.1.2 Setup Debug Environment Windows
            3. 3.2.2.4.1.3 Using Real-Time Emulation
            4. 3.2.2.4.1.4 Running Code (Build 1)
          2. 3.2.2.4.2 INCR_BUILD 2: Closed Current Loop
            1. 3.2.2.4.2.1 Running Code (Build 2)
            2. 3.2.2.4.2.2 Building and Loading the Project and Setting Up Debug
          3. 3.2.2.4.3 INCR_BUILD 3: Closed Voltage and Current Loop
            1. 3.2.2.4.3.1 Building and Loading the Project and Setting Up Debug
            2. 3.2.2.4.3.2 Running Code (Build 3)
          4. 3.2.2.4.4 INCR_BUILD 4: Closed Balance, Voltage, and Current Loop
            1. 3.2.2.4.4.1 Building and Loading the Project and Setting Up Debug
            2. 3.2.2.4.4.2 Running Code (Build 4)
    3. 3.3 Test Results
      1. 3.3.1  IGBT Gate Rising and Falling Time
      2. 3.3.2  Power On Sequence
      3. 3.3.3  PFC Started by GUI
      4. 3.3.4  Zero Crossing Under 380VAC, 9kW
      5. 3.3.5  Current Ripple Under 380VAC,10kW
      6. 3.3.6  10kW Load Test With Grid Power
      7. 3.3.7  9kW Load Test With AC Power Source
      8. 3.3.8  Power Analyzer Results
      9. 3.3.9  Thermal Performance
      10. 3.3.10 Voltage Short Interrupt Test
      11. 3.3.11 Efficiency, iTHD, and Power Factor Results
  10. 4Design and Documentation Support
    1. 4.1 Design Files
      1. 4.1.1 Schematics
      2. 4.1.2 Bill of Material (BOM)
    2. 4.2 Tools and Software
    3. 4.3 Documentation Support
    4. 4.4 Support Resources
    5. 4.5 Trademarks
  11. 5About the Author
Running Code (Build 4)
  1. Run project by clicking the TIDA-010257 button.
  2. Raise the AC input to 120VRMS VL-L and 208VRMS VL-L, 50/60Hz. Figure 3-30 shows a rectified current that is going to be drawn from the input.
    TIDA-010257 Build Level 4: Scope
                            Capture Ia and Va (120VRMS L-N) With PWM Tripped
    • CH1 (Blue): DCBUS output voltage
    • CH2 (Light blue): AC input phase A voltage
    • CH3 (Pink): IGBT gate voltage
    • CH4 (Green): AC Input phase A current
    Figure 3-30 Build Level 4: Scope Capture Ia and Va (120VRMS L-N) With PWM Tripped
  3. Bus voltage is set by the vBusRef variable, and is about 1.55V already, which corresponds to 650V for this design.
  4. Start the PFC action by writing a 1 to the clearTrip variable.
  5. The board now draws the sinusoidal current. Figure 3-31 shows the scope capture.
    TIDA-010257 Build Level 4: Scope
                            Capture Ia and Va (120VRMS L-N) With Full PFC
    • CH1 (Blue): DCBUS output voltage
    • CH2 (Light blue): AC input phase A voltage
    • CH3 (Pink): IGBT gate voltage
    • CH4 (Green): AC Input phase A current
    Figure 3-31 Build Level 4: Scope Capture Ia and Va (120VRMS L-N) With Full PFC
  6. Check the Expressions window shown in Figure 3-32. The DC bus voltages is also balanced, that is, the guiVbusPM and guiVbusMN variables are almost equal, which shows that the closed loop balance controller is working.
    TIDA-010257 Build Level 4:
                            Expressions Window With 120VAC and 650VDC Figure 3-32 Build Level 4: Expressions Window With 120VAC and 650VDC
  7. The balance loop open loop gain is controlled by the Gs_GainKp variable and can be adjusted in case the bandwidth is not enough. Though, for the balance loop, the bandwidth needs to be lower than the outer voltage loop and only 1Hz to 2Hz of bandwidth is sufficient.
  8. To bring the system to a safe stop bring the input AC voltage down to zero, observe the guiVBus variable comes down to zero as well.
  9. Fully halting the MCU when in real-time mode is a two-step process. First, halt the processor by using the Halt button on the toolbar (TIDA-010257 ) or by using Target > Halt. Then take the MCU out of real-time mode by clicking on the TIDA-010257 button. Finally reset the MCU by selecting the TIDA-010257 button.
  10. Close the CCS debug session by clicking on Terminate Debug Session (Target > Terminate all).
    TIDA-010257 .