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
3.2.2.4.1.4 Running Code (Build 1)
  1. Run the project by clicking the TIDA-010257 button.
  2. In the watch view, periodically check if the guiVbus (VIENNA_guiVbus_Volts in the Expression window) variable is updating. If there is no change in the value, then make sure the real-time mode is enabled, and the hardware is set up correctly. Do not proceed further unless the update is verified.
    Note: As no power is applied right now, this value is close to zero.
  3. Slowly increase the input AC voltage from 0VRMS to 80VRMS L-N.
  4. Verify the voltage sensing: Make sure guiVbus, guiVbusPM, and guiVbusMN display the correct values. For the 80VRMS L-N, guiVbus is close to 190V, the graph function can show the waveform, as shown in Figure 3-10. The guiVbusPM and guiVbusMN variables are both close to 85V. The code runs a sine analyzer module, which computes the RMS value of the voltage and current. Figure 3-11 shows that the guiVrms1, guiVrms2 and guiVrms3 values are close to the input value, that is, 80VRMS. This verifies the voltage sensing of the board.
    TIDA-010257 Build Level 1: Graph Showing Measured Output VoltagesFigure 3-10 Build Level 1: Graph Showing Measured Output Voltages
    TIDA-010257 Build Level 1: Graph Showing Measured Input VoltagesFigure 3-11 Build Level 1: Graph Showing Measured Input Voltages
  5. Verifying the current sensing: Notice the guiVrms1, guiVrms2, and guiVrms3 variables, for the given test condition these values are close to 0.5A. Additionally, the graphs must be seen to verify the current measurement. Figure 3-12 shows the currents on a graph.
    TIDA-010257 Build Level 1: Graph Showing Measured CurrentsFigure 3-12 Build Level 1: Graph Showing Measured Currents
  6. Figure 3-13 shows the scope capture of the input voltage and current.
    TIDA-010257 Build Level 1: Scope Capture Ia and Va (80VRMS 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 3-13 Build Level 1: Scope Capture Ia and Va (80VRMS L-N) With PWM Tripped
  7. Verify the PWM action, first reduce the input voltage to zero and wait for all the voltages to go down to zero.
  8. Set the dutyPU_DC variable to 0.5 in the expressions view.
  9. Clear the PWM trip by writing a 1 to clearTrip.
  10. Slowly increase the input voltage and keep watching the input current. The duty cycle imparts a boost action. For example, when VAC is 80VRMS without switching enabled, the guiVbus is about 190V; with switching, the guiVbus rises up to 380V. Thus, guiVbusPM and guiVbusMN are both higher than the input voltage maximum.
  11. Below are the test conditions described in this build, the guiVbus variable rises to about 380V and guiVbusPM and guiVbusMN are close to 190V each, and the current is close to 1.1ARMS when the input voltage reaches 80VRMS L-N. The Expressions view appears as shown in step Figure 3-14. Make sure all the variables are accurate, that is, guiVrms1, guiVrms2, guiVrms3, guiIrms1, guiIrms2, guiIrms3, guiPF1, guiPF2, and guiPF3. If any variable is not accurate (as shown in Figure 3-14), this means there is a hardware issue with the sensing circuit.
    TIDA-010257 Build Level 1: Expressions View With Power MeasurementFigure 3-14 Build Level 1: Expressions View With Power Measurement
  12. Figure 3-15 shows the scope capture.
    TIDA-010257 Build Level 1: Scope Capture Ia and Va (80VRMS L-N) With Duty Cycle 0.5
    • 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 3-15 Build Level 1: Scope Capture Ia and Va (80VRMS L-N) With Duty Cycle 0.5
  13. This check verifies at a basic level the PWM driver and connection of the hardware.
  14. Reduce the input voltage to zero, and watch for the bus voltages to reduce down to zero.
  15. This completes the check for this build, the following items are verified on successful completion of this build:
    1. Sensing of voltages and currents and scaling to be correct
    2. Interrupt generation and execution of the build 1 code in the controlISR and tenkHzISR() variables
    3. PWM driver and switching
    If any issue is observed, carefully inspection the hardware to eliminate any build issues, and so forth.
  16. The controller can now be halted, and the debug connection terminated.
  17. 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 icon. Finally, reset the MCU by clicking on the TIDA-010257 button.
  18. Close the CCS debug session by clicking on Terminate Debug Session (Target > Terminate all).
    TIDA-010257