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

1.2 Key System Specifications

Table 1-1 details the three-phase Vienna rectifier key power specifications.

Table 1-1 Key System Specifications
PARAMETERSPECIFICATION
Input voltage (VIN)
  • AC 208VRMS VL-L or 120VRMS L-N , 60Hz
    or
  • AC 380VRMS VL-L or 220VRMS L-N , 50Hz
Input current (IIN)
  • 16A RMS maximum
Output voltage (VOUT)
  • 650V DC bus nominal
Output current (IOUT)
  • Absolute RMS maximum 16A, pulse maximum 29A
Power rating
  • 10kW at three-phase 380VRMS
Current THD
  • < 1.5% at 10kW load
  • < 5% under 2.5kW load
EfficiencyPeak 98%
Primary filter inductor355µH under 31A bias current
Output capacitance940µF
PWM switching frequency40kHz
TIDA-010257
WARNING:

TI intends this reference design to be operated in a lab environment only and does not consider the board to be a finished product for general consumer use.

TI Intends this reference design to be used only by qualified engineers and technicians familiar with risks associated with handling high-voltage electrical and mechanical components, systems, and subsystems.

There are accessible high voltages present on the board. The board operates at voltages and currents that can cause shock, fire, or injury if not properly handled or applied. Use the equipment with necessary caution and appropriate safeguards to avoid injuring yourself or damaging property.

TIDA-010257
TIDA-010257
TIDA-010257
CAUTION:

Do not leave reference design powered when unattended.

High voltage! There are accessible high voltages present on the board. Electric shock is possible. The board operates at voltages and currents that can cause shock, fire, or injury if not properly handled. Use the equipment with necessary caution and appropriate safeguards to avoid injuring yourself or damaging property. For safety, use of isolated test equipment with overvoltage and overcurrent protection is highly recommended.

TI considers it the user's responsibility to confirm that the voltages and isolation requirements are identified and understood before energizing the board or simulation. When energized, do not touch the reference design or components connected to the reference design.

Hot surface! Contact may cause burns. Do not touch!

Some components can reach high temperatures >55°C when the board is powered on. The user must not touch the board at any point during operation or immediately after operating, as high temperatures can be present.