Transcript Single Phase On-Line UPS Demo Using MC9S12E128

Single Phase On-Line UPS Demo
Using MC9S12E128
TM
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
UPS Classification
• Based on the topology the UPSes are classified to the three basic
categories (IEC 62040-3):
 Passive Standby (Off-line)
 Line-interactive
 Double Conversion (On-Line)
Slide 2
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Basic UPS Topology - Off-line UPS
Advantages:
- Very low cost
- High efficiency
- Compact size
LINE FILTER
BATTERY
CHARGER
AC
~
Disadvantages:
- Limited protection
- Not sinusoidal output
- Uses battery during
brownouts
- Short drop-out during
transition on battery
AC
=
DC
=
DC
~
INVERTER
+
-
BATTERY
Slide 3
TM
SWITCH
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MCU:
Normal operation
- MC68HC908x
Backup
operation
Basic UPS Topology - Line-Interactive UPS
BYPASS
Advantages:
- Medium cost
- High efficiency
- Better voltage
conditioning
AVR
LINE FILTER
BATTERY
CHARGER
AC
AC
~
Disadvantages:
- Still limited protection
- Short drop-out during
transition on battery
=
DC
=
DC
~
INVERTER
+
-
BATTERY
Slide 4
TM
SWITCH
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MCU:
- MC68HC908x
Normal operation
Backup operation
- MC68HC908MRx
Basic UPS Topology - On-Line UPS
BYPASS
Advantages:
- Excellent voltage
conditioning
- Full protection
INVERTER
RECTIFIER
DC
=
~
AC
DC
=
Disadvantages:
- High cost
- Low efficiency
DC
=
=
DC
BATTERY
CHARGER
DC-DC
CONVERTER
+
-
BATTERY
Slide 5
TM
=
DC
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Possible MCU:
- HCS12E128
- DSP56F80x
Normal operation
Backup operation
- DSP56F80xx
-DSP56F83xx
Single Phase On-Line UPS Demo Using MC9S12E128
Single Phase On-Line UPS Demo
Using MC9S12E128
Slide 6
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Single Phase On-Line UPS Demo Using MC9S12E128
• Demo Features





Single Phase On-line Topology
750 VA Output Power
115/230 V Input Line
Controlled by MC9S12E128
Single LED User Interface
> 4 Status LEDs
> 6 LEDs Bar Graph
> 2 Buttons
 Graphical User Interface on PC
 Ready for GUI Display
 Demo suitcase
Slide 7
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Single Phase On-Line UPS Demo Using MC9S12E128
• Demo Concept
 Four PCBs
>UPS Power Stage
>Input Filter
>User Interface
>MC9S12E128
Control Board
 Demo case
Slide 8
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Single Phase On-Line UPS Demo Using MC9S12E128
• Concept Schematic
DC-AC
PFC
L1
D1
D2
K BU8J
IN
-
Q1
+
+
Q2
D3
C1
Input Rectifier
•Voltage Doubler
IN
C2
+
D4
Q3
G ND
PFC
•Average Current Mode PFC
•Directly controlled by MCU
O UT
D5
Filter
O UT
DC-DC Converter
D6
Battery Charger
•FlyBack DC-DC Converter
•Controlled by TOP249Y (Power Integration, Inc.)
•Max. Output Power: 60W
•3 – State Charging Algorithm (Bulk charge,
Absorption, Float) controlled by MCU
D7
L2
Q4
DC-DC Step Up Converter
•Push - Pull Converter
•Directly Controlled by MCU
•Max. Output Power: 560W
T1
G ND
Q5
D8
Charger
(Flybac k
Converter)
L3
D9
B T1
G ND
G ND
Whole UPS controlled by one MC9S12E128 only
Slide 9
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Output Inverter
•True Sinusoidal Output
•Directly controlled by MCU
Single Phase On-Line UPS Demo Using MC9S12E128
• MC9S12E128 Features



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
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
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
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
16-bit HCS12 CPU, 50 MHz core clock
128K bytes of Flash EEPROM, 8K bytes of RAM
3 x SCI, 1 x SPI, 1 x IIC
3 x 4-channel 16-bit timer modules (TIM)
6-channel 15-bit Pulse Modulator with Fault protection module
(PMF)
6-channel 8-bit Pulse Width Modulator (PWM)
16-channel 10-bit analog-to-digital converter (ADC)
2 x 1-channel 8-bit digital-to-analog converter (DAC)
Up to 16 pins available as Keypad Wake-Up inputs
2 x additional external asynchronous interrupts
Up to 74 I/O port pins and 18 input only pins for 112 pin package
Up to 42 I/O port pins and 18 input only pins for 80 pin package
Slide 10
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Battery Charger
 Fly-Back Topology Converter
 Dedicated circuit used (TOP249)
 Output parameters
>Output voltage: 29.4 or 27.4 V (set by MCU)
>Output current: max. 1.8 A
>Current limitation: 0 – 1.8 A (set by MCU)
 Charge algorithm
>3 state (bulk charge, absorption, float)
 MCU Interface
>2 analog inputs (battery voltage and battery current)
>1 analog output (PWM + filter, current limitation)
>1 digital output (output voltage 29.4 or 27.4 V)
Slide 11
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Battery Charger Schematic
C302
220uF/450V
C301
+
L
4.7nF
TP300
Vbat
D301
BYW29E-200
D303
P6KE200
T300
1
L300
13
+
D302
B250R
LINE_O K
R301
68k
R302
1M
+VBAT
R303
24k
9
D304
R304
39k
-
7
1N4148
6
D305
BYV26C
N
R306
1M
C303
5
TR02/MC145
29.4V @ Q4 ON
27.4V @ Q4 OFF
47uH
220uF/50V
100nF
220uF/50V
100u/50
+
+
C304
R305
1k8
+
R307
620
C306
C305
R309
2k4
5.05V @ 39V
VBAT
D
R311
33k
7
G
G ND_TR
2
L301
R312
200
F
4
C
ISO 300
SFH615A-2
1
4
X
G ND_CH
-VBAT
1
IBAT1
R313
6.8
5 3
sense
CONTROL
G ND
IBAT2
G NDA
3
2
R314
HV_BAT_LEVEL
100
R315
7.5k
+ C307
47uF/10V
R308
470
R331
100
R316
220
R317
33K
+5V_A
100nF
C300
R321
1k6
R318
100nF
Q 300
3
+
2
-
100k
1
8
BC847
U301A
LM358D
1k
R322
220
G ND_CH
1
8
R320
4
5
LM358D
U301B
7
+
6
IBAT2
-
IBAT1
C308
6
C309
470nF
R319
1k6
U302
TL431ACD
G ND
C314
10n
R323
1k
G ND_CH
R324
1k
IBAT_CONTRO L
R325
33K
R326
3k9
C311
C310
470nF
470nF
G ND
4.875V @ 2. 34A
IBAT
G ND
G ND
Slide 12
TM
C315
100n
Q 301 S
MMBF0201NLT1
47uH
L
TO P249Y
R300
0.1
sense
U300
D300
1N4148
R310
5K6
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Battery Charging Algorithm
 3 Step Charging: Bulk, Absorption, Float
Slide 13
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• DC/DC Step Up Converter
 Converts the battery voltage (24 V) to DC bus voltage
(+/- 390V)
 Push-Pull Topology
 50 kHz switching frequency
 Fully controlled by MCU
 Output parameters
>Output Voltage: +/- 390 V
>Output Current: 0.8 A
 MCU interface
>2 analog inputs (+/- DC bus voltage)
>2 PWM outputs (PWM for transistors)
Slide 14
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• DC/DC Step Up Converter Schematic
L501
680u/50V 680u/50V
MUR180
1
1
1
1
2
2
2
2
680u/50V
FFPF05U120STU
D500
680u/50V
FFPF05U120STU
D502
2
R502
1 1k/5W
2
MUR180
G ND_BAT
1
D504
D505
2
C506
22n/400V
L502
+O UT
FFPF05U120STU
13
18
+15V
10
15
+15V
T500
TR03/MC145
L503
330u
G ND_BAT
MC33152D
VCC
NC
2 InA
O utA
7
1
PWM4
R505
2
10
O utB
4 InB
R508
10k
5
1
R506
Q 502 Q 503
NTD45N60 NTD45N60
D
D
G
G
S
G
S
G1
S
2
R500
U501
8 NC
MC33152D
VCC
NC
1
2
7 O utA
InA
2
2
5 O utB
InB
4
TP502
PWM_5
10
S
PWM5
1
R507
R509
10k
10
10
3
G ND
3
G ND
2
G ND_BAT
G ND_BAT
G ND_BAT
8
2
100n
C500
G ND_BAT
Q 501 Q 500
NTD45N60 NTD45N60
D
D
TP501
PWM_4
1
C507
1n
6
U500
1 NC
1
1
1
100n
C511
47uF
C510
C508
1n
1
2
G ND_BAT
2
2
+
2
R503
100R/1W
1
1
100R/1W
R504
2
L500
330u
4 6
9
1
47uF
C509
1
DCB_POS
650u/1A
G ND
FFPF05U120STU
D503
2
680u/50V
R501
1 1k/5W
+
-VBAT
2
2
C502 + C503 + C504 + C505 + C512 + C513 +
DCB_NEG
C501
22n/400V
2
6
1
1
+VBAT
+Bat
680u/50V
-O UT
650u/1A
D501
1
G ND_BAT
G ND_BAT
G ND_BAT
G ND_BAT
Slide 15
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G ND_BAT
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Input Rectifier + Power Factor Correction (PFC)
 Voltage doubler rectifier
 PFC using bidirectional switch (one transistor only)
 Control technique
> Average Current Mode Control by MCU
> 40 kHz switching frequency
> Current control loop 50 ms
> Voltage control loop 1 ms
 Output parameters
> Output power: 750 W
> DC Bus voltage: +/- 390 V
 MCU Interface
> 4x analog input (2x DC bus voltage, 1x input current, 1x input voltage)
> 1x PWM output (PFC transistor)
> 1x Input Capture (Zero crossing)
Slide 16
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Input Rectifier + PFC Controller Schematic
7
I_IN2
9
I_IN1
CT1
1:100
DCB_POS
DCB_POS
D604
2
1
L505
2.5mH
RHRP8120
D606
KBPC606
-
+
Q 605
C602
+
C603
Q 606
IRG 4IBC20W
MKP10/22nF/630VDC
330uF/450V
G ATE_TO P
HG TG10N120BND
G ND_TO P
G ATE_PFC
G ND_PFC
G ND
Q 608
C607
+
MKP10/22nF/630VDC
G ATE_BO T
C608
330uF/450V
G ND_BO T
D608
RHRP8120
DCB_NEG
DCB_NEG
Slide 17
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HG TG10N120BND
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Output Inverter
 Half bridge topology
 20 kHz switching frequency
 Control technique
> Fully controlled by MCU
> PID controller + voltage feed forward + current
feedback
> 50 ms control loop
 Output parameters
> Output Voltage: 110 - 240 V
> Output current: 3.3 A
 MCU Interface
> 4 analog input (2x DC bus voltage, 1x output current,
1x output voltage)
> 2 PWM outputs (inverter transistors)
Slide 18
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• Output Inverter Schematic
DCB_POS
DCB_POS
D604
RHRP8120
Q 605
C602
+
C603
MKP10/22nF/630VDC
330uF/450V
G ATE_TO P
HG TG10N120BND
V_OUT
L506
G ND_TO P
6mH
C605
3
4
1
2
3.3uF/400V
CT2
G ND
I_OUT2
Q 608
C607
+
MKP10/22nF/630VDC
G ATE_BO T
C608
330uF/450V
HG TG10N120BND
G ND_BO T
D608
RHRP8120
DCB_NEG
DCB_NEG
Slide 19
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5
8
CS2106
I_OUT1
Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• MC9S12E128 Control Board
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
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

MC9S12E128 16-bit +5V Microcontroller operating at 25MHz
8.00MHz crystal oscillator for MCU frequency generation
Background Debug Mode (BDM) interface connector
2x Optically isolated RS-232 interface
Communication Header (SPI, SCI1, IIC)
PWM and Timer Header
> Pulse Width Modulation, PWM, or Timer2, TIM2 Timer1, TIM1
 ADC and DAC Header
> Analog-to-Digital Converter, ADC
> Digital-to-Analog Converter, DAC Expansion Header for 16-bit
Multiplexed Wide Bus
 On-board power regulation from an external 12V DC supplied
power input
Slide 20
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• MC9S12E128 Control Board - continue
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

Light Emitting Diode (LED) power indicator
One on-board real-time user debugging LEDs
Six on-board PWM monitoring LEDs
Six on-board PMF monitoring LEDs
Four on-board PMF Fault monitoring LEDs
UNI-3 Motor interface
Over-Voltage sensing
Over-Current sensing
Comparators for automatic current profiling
Encoder/Hall-Effect interface
Manual RESET push-button
General purpose and interrupt toggle switch
2x General purpose and interrupt push-button
Slide 21
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Single Phase On-Line UPS Demo Using MC9S12E128
- HW Implementation
• MC9S12E128 Control Board – Block Diagram
MC9S12E128
BDM
Connector
BKGD
8MHz
Crystal
ADC
PMF
Ports
UNI3 Expansion
Connector
PWM
PMF
TIM1
SCI1
SPI
Port A
Port B
Digital
Expansion
Headers
3.3V Analog
Reference
ADC
DAC
Analog
Expansion
Headers
5V Analog
Power Supply
TIM0
Encoder
Connector
2 x RS232
Interface
SCI0
SCI2
All Pins
Port E
User, Fault and
& PWM's LEDs
5V Digital
Power Supply
Header
Ring
User's Interface
Slide 22
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Software Structure
 5x periodical interrupts (2x 50 ms, 1x 1 ms, 1x 10 ms,
1x 50ms)
 3x event interrupts (PMF faults, LVI, SCI)
 Background loop
 Written in C language
 Some critical algorithms written in assembler (sine
wave generation, PID controllers, arithmetic functions)
Slide 23
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Software Structure - continue
Slide 24
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Software Structure - continue
Slide 25
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Battery Charger
Execution period: 50 ms
Slide 26
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or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• DC/DC Step Up Converter
Execution period: 1 ms
Slide 27
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Power Factor Correction
Execution period: 1 ms
Execution period: 50 ms
Slide 28
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Output Inverter
Execution period: 1 ms
Execution period: 50 ms
Slide 29
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Single Phase On-Line UPS Demo Using MC9S12E128
- SW Implementation
• Application State Machine
Slide 30
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Single Phase On-Line UPS Demo Using MC9S12E128
- Software Measurements
• UPS Software Measurements
 Code Length
>FLASH memory:
>RAM memory:
10087 bytes
3014 bytes (include stack 512 bytes)
 MCU load: 77.5 % (without PCMaster serial
communication)
>PMF Reload
>ATD Complete
>TIM0 ch4 IC
>TIM0 ch5 OC
>TIM0 ch6 OC
15.8 ms
19.4 ms
7.8 ms
69 ms
43.4 ms
(period 50 ms)
(period 50 ms)
(period 8.3 ms)
(period 1 ms)
(period 50 ms)
Slide 31
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Single Phase On-Line UPS Demo Using MC9S12E128
- Software Measurements
• UPS Software Measurements - continues
PMF Reload
ATD Complete
TIM0 ch5 OC
TIM0 ch6 OC
Slide 32
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Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Load defined by IEC 62040-1
 Linear load (525 W)
>R = 100 W
 Non-linear load (750 VA)
>R = 160 W
D1
>Rs = 2.8 W
Rs
2.8
>C = 780 mF
+
D2
Slide 33
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D4
C1
937 uF
P1
160
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Overall efficiency – linear load
Slide 34
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Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Overall efficiency – non-linear load
Slide 35
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Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output frequency - synchronized
Slide 36
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output frequency – free running
Slide 37
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Voltage THD – without load
Slide 38
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Voltage THD – with linear load
Slide 39
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Voltage THD – with non-linear load
Slide 40
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Voltage THD – with non-linear load
Slide 41
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Voltage THD – with non-linear load
Slide 42
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Input Power Factor
Slide 43
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Output Power Factor (linear load)
Slide 44
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Load Step 20 % -> 100 %
Slide 45
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Load Step 20 % -> 100 %
Slide 46
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Load Step 100 % -> 20 %
Slide 47
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Measurements
• Load Step 100 % -> 20 %
Slide 48
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Performance Summary
Topology
On-line (double conversion)
Input Voltage
80 – 270V
Input frequency
45 – 65 Hz
Output power
750 VA (at nominal line voltage)
THD
1 % linear , 5 non-linear load
Efficiency
90 %
Power factor
> 0.95
Transfer time
0s
Battery
2 x 12V, 7.2 Ah
GUI
2 x buttons, 10x LEDs
Remote control
From PC by PC Master
Communication
2x RS232
Slide 49
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Developments tools
• FreeMaster
 Real time monitor
 Read and write any variable in application
 Display the variables in physical quantities
 Scope
 Recorder
 Control page in HTML code
Slide 50
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Developments tools
Scope or recorder
Variables window
Slide 51
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Developments tools
Control page
Slide 52
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
Single Phase On-Line UPS Demo Using MC9S12E128
- Deliverables
• Reference Design Deliverables
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






Design documentation (source and PDF)
Targeting documentation (source and PDF)
Application note
Presentation Material
All source code and related material for written software
PCB layout gerber files (source and PDF)
Schematic files (source and PDF)
BOM (source and PDF)
Slide 53
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.
TM
Slide 54
TM
Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product
or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005.