Single Phase On-Line UPS Demo Using MC9S12E128

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

Single Phase On-Line UPS DemoUsing MC9S12E128

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.

Slide 2

• 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)

UPS Classification


Slide 3

DC

AC~ =

+ -

DC

AC~=

LIN E FILTER

BATTERYCHAR GE R

BATTERY

INVE RTE R

SW ITCH

Norm al operationBackup operation

Advantages:- Very low cost- High efficiency- Compact size

Advantages:- Very low cost- High efficiency- Compact size

Disadvantages:- Limited protection- Not sinusoidal output- Uses battery during brownouts- Short drop-out during

transition on battery

Disadvantages:- Limited protection- Not sinusoidal output- Uses battery during brownouts- Short drop-out during

transition on battery

MCU:- MC68HC908x

MCU:- MC68HC908x

Basic UPS Topology - Off-line UPS


Slide 4

DC

AC~ =

+ -

DC

AC~=

BATTERYCHARGER

BATTERY

INVERTER

SWITCH

BYPASS

Normal operationBackup operation

LINE FILTER AVR

Advantages:- Medium cost- High efficiency- Better voltage conditioning

Advantages:- Medium cost- High efficiency- Better voltage conditioning

Disadvantages:- Still limited protection- Short drop-out during transition on battery

Disadvantages:- Still limited protection- Short drop-out during transition on battery

MCU:- MC68HC908x- MC68HC908MRx

MCU:- MC68HC908x- MC68HC908MRx

Basic UPS Topology - Line-Interactive UPS


Slide 5

+ -

RE CTIF IER

BATTERYCHAR GE R

BATTERY

DC-DCCO NV ERTER

BY PAS S

DC=

DC=

DC=

DC=

DC

AC~=

INVE RTE R

Norm al operationBackup operation

Advantages:- Excellent voltage conditioning- Full protection

Advantages:- Excellent voltage conditioning- Full protection

Disadvantages:- High cost- Low efficiency

Disadvantages:- High cost- Low efficiency

Possible MCU:- HCS12E128- DSP56F80x- DSP56F80xx-DSP56F83xx

Possible MCU:- HCS12E128- DSP56F80x- DSP56F80xx-DSP56F83xx

Basic UPS Topology - On-Line UPS


Slide 6

Single Phase On-Line UPS Demo Using MC9S12E128



Slide 7


• 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 8


• Demo Concept

Four PCBs>UPS Power Stage>Input Filter>User Interface>MC9S12E128

Control BoardDemo case


Slide 9

• Concept Schematic

GND

L1D1

D5

- +

D2KBU8J

Q2

IN

IN

Charger(FlybackConverter)

PFC

Q5

Q3

+ C1

Filter

Q1

BT1

GND

D6

+C2 D4

D9

GND

OUT

DC-DC Converter

D7

DC-AC

Q4

GND

D8

OUT

T1

D3

L2

L3

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

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

PFC•Average Current Mode PFC•Directly controlled by MCU

PFC•Average Current Mode PFC•Directly controlled by MCU

Input Rectifier•Voltage Doubler

Input Rectifier•Voltage Doubler

Output Inverter•True Sinusoidal Output•Directly controlled by MCU

Output Inverter•True Sinusoidal Output•Directly controlled by MCU

DC-DC Step Up Converter•Push - Pull Converter•Directly Controlled by MCU•Max. Output Power: 560W

DC-DC Step Up Converter•Push - Pull Converter•Directly Controlled by MCU•Max. Output Power: 560W

Whole UPS controlled by one MC9S12E128 onlyWhole UPS controlled by one MC9S12E128 only



Slide 10


• MC9S12E128 Features

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 11

• 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)

Single Phase On-Line UPS Demo Using MC9S12E128- HW Implementation


Slide 12


• Battery Charger Schematic

N

IBAT_CONTROL

-VBAT

D

G

SQ301MMBF0201NLT1

GNDA

HV_BAT_LEVEL

IBAT

VBAT

C31410n

R331100

GND

GND_CH

GND_CH

GND_CH

GND

L301

47uH

Q300

BC847

T300

TR02/MC145

1

7

6

13

5

9

L300

47uH

+

C306

100u/50

U302TL431ACD

61

8

29.4V @ Q4 ON27.4V @ Q4 OFF

5.05V @ 39V

R320

1k

C309470nF

4.875V @ 2.34A

+VBAT

R3263k9

sense

sense

R3000.1

+

- U301BLM358D

5

67

+

C302220uF/450V

TP300Vbat

R3021M

R31733K

R3191k6

R3211k6

D305BYV26C

R322220

IBAT1

IBAT2

IBAT1

D301BYW29E-200

IBAT2

C308

100nF

+

C304

220uF/50V

D304

1N4148 C303

100nF

ISO300SFH615A-2 1

23

4

R3136.8

+ C30747uF/10V

R308470

GND

R31133k D300

1N4148

L

R3157.5k

+

C305

220uF/50V

R30439k

R3105K6

+

-U301ALM358D

3

21

84

R318

100k

+5V_A

R307620

R30168k

C301

4.7nF

R3061M

GND

D303P6KE200

C310

470nF

R3231k

C311

470nF

R3241k

CONTROL

LC

XF

U300

TOP249Y 4

7 2

5 3

1

-+

D302B250R

LINE_OK

R30324k

R3051k8

R3092k4

R312200

C315100n

GND

R314

100

GND_TR

C300

100nF

R316220

R32533K


Slide 13


• Battery Charging Algorithm

3 Step Charging: Bulk, Absorption, Float


Slide 14


• DC/DC Step Up Converter

Converts the battery voltage (24 V) to DC bus voltage

(+/- 390V)Push-Pull Topology50 kHz switching frequencyFully controlled by MCUOutput 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 15


• DC/DC Step Up Converter Schematic

OutBInB

GND

InA

NC NC

OutA

VCCU500 MC33152D

2

3

5

6

7

81

4

GND_BAT

OutB InB

GND

InA

NCNC

OutA

VCCU501 MC33152D

2

3

5

6

7

8 1

4

-VBATD502

FFPF05U120STU

D505

FFPF05U120STU

D500FFPF05U120STU

D504

FFPF05U120STU

D

G

S

Q501NTD45N60

D

G

S

Q500NTD45N60

C5081n

12

R503100R/1W

1 2

+15V

GND_BAT

L500330u

GND_BAT

D

G

S

Q503NTD45N60

D

G

S

Q502NTD45N60

R504100R/1W

12

C511100n

C500100n

+

C50947uF

1 2 +

C51047uF

1 2

GND_BAT

+C512

680u/50V

12

+C513

680u/50V

12

GND_BATGND_BAT

GND_BAT

GND_BAT

GND_BAT

GND_BAT

T500TR03/MC145

1 4 6

10 13

15

918

+Bat

+C502

680u/50V

12

+C503

680u/50V

12

C5071n1

2

+C504

680u/50V

12

D503

MUR180

D501

MUR180

+15V

C50122n/400V

1 2

+C505

680u/50V1

2

C50622n/400V

1 2

PWM4PWM5

R505

10

1 2

R506

10

1 2

R500

10

1 2

R507

10

1 2

+OUT

-OUT

R50810k

12

R50910k

12

R5011k/5W1 2

R5021k/5W1 2

+VBAT

TP501PWM_4 TP502

PWM_5

DCB_NEG

DCB_POS

L501

650u/1A

L502

650u/1A

L503330u

GND

GND_BATGND_BAT


Slide 16


• 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 s>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 17


• Input Rectifier + PFC Controller Schematic

+ C608330uF/450V

Q608

HGTG10N120BND

Q605

HGTG10N120BNDC603

MKP10/22nF/630VDC

C607

MKP10/22nF/630VDC

L505

2.5mH

- +

D606KBPC606

Q606IRG4IBC20W

GATE_PFC

GND

D604

RHRP8120

D608

RHRP8120

+C602

330uF/450V

9 7

1 2

CT11:100

GND_BOT

GND_TOP

GATE_BOT

GATE_TOP

GND_PFC

DCB_POS

DCB_NEG

DCB_POS

DCB_NEG

I_IN1 I_IN2


Slide 18


• Output Inverter

Half bridge topology 20 kHz switching frequency Control technique

>Fully controlled by MCU>PID controller + voltage feed forward + current

feedback>50 s 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 19


• Output Inverter Schematic

+ C608330uF/450V

Q608

HGTG10N120BND

Q605

HGTG10N120BNDC603

MKP10/22nF/630VDC

C607

MKP10/22nF/630VDC

C605

3.3uF/400V

L506

6mH

I_OUT1I_OUT2

8 5

1 2 3 4

CT2

CS2106

D604

RHRP8120

D608

RHRP8120

+C602

330uF/450V

GND_BOT

GND_TOP

GATE_BOT

GATE_TOP

DCB_POS

DCB_NEG

GND

DCB_POS

DCB_NEG

V_OUT


Slide 20


• MC9S12E128 Control Board

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 21


• MC9S12E128 Control Board - continue

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 22


• MC9S12E128 Control Board – Block Diagram

MC9S12E128

UNI3 ExpansionConnector

Digital Expansion

Headers

BDMConnector

EncoderConnector

2 x RS232 Interface

3.3V AnalogReference

5V AnalogPower Supply

5V DigitalPower Supply

8MHzCrystal User, Fault and

& PWM's LEDs

ADCPMFPorts

BKGD

SCI0SCI2

PWMPMF

User's Interface

Port E

TIM0

AnalogExpansion

Headers

ADCDAC

HeaderRing

All Pins

SCI1SPI

TIM1

Port APort B


Slide 23

Single Phase On-Line UPS Demo Using MC9S12E128- SW Implementation

• Software Structure

5x periodical interrupts (2x 50 s, 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 24


• Software Structure - continue


Slide 25


• Software Structure - continue


Slide 26


• Battery Charger

Execution period: 50 ms


Slide 27


• DC/DC Step Up Converter

Execution period: 1 ms


Slide 28


• Power Factor Correction

Execution period: 1 msExecution period: 50 s


Slide 29


• Output Inverter

Execution period: 1 msExecution period: 50 s


Slide 30


• Application State Machine


Slide 31

Single Phase On-Line UPS Demo Using MC9S12E128- Software Measurements

• UPS Software Measurements

Code Length>FLASH memory: 10087 bytes>RAM memory: 3014 bytes (include stack 512 bytes)

MCU load: 77.5 % (without PCMaster serial

communication)>PMF Reload 15.8 s (period 50 s)>ATD Complete 19.4 s (period 50 s)>TIM0 ch4 IC 7.8 s (period 8.3 ms)>TIM0 ch5 OC 69 s (period 1 ms)>TIM0 ch6 OC 43.4 s (period 50 ms)


Slide 32

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 33

Single Phase On-Line UPS Demo Using MC9S12E128- Performance Measurements

• Load defined by IEC 62040-1

Linear load (525 W)>R = 100

Non-linear load (750 VA)>R = 160

>Rs = 2.8

>C = 780 F

D1

D2

D3

D4

+C1937 uF

P1160

Rs

2.8


Slide 34


• Overall efficiency – linear load


Slide 35


• Overall efficiency – non-linear load


Slide 36


• Output frequency - synchronized


Slide 37


• Output frequency – free running


Slide 38


• Output Voltage THD – without load


Slide 39


• Output Voltage THD – with linear load


Slide 40


• Output Voltage THD – with non-linear load


Slide 41




Slide 42




Slide 43


• Input Power Factor


Slide 44


• Output Power Factor (linear load)


Slide 45


• Load Step 20 % -> 100 %


Slide 46


• Load Step 20 % -> 100 %


Slide 47


• Load Step 100 % -> 20 %


Slide 48


• Load Step 100 % -> 20 %


Slide 49

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 0 s

Battery 2 x 12V, 7.2 Ah

GUI 2 x buttons, 10x LEDs

Remote control From PC by PC Master

Communication 2x RS232


Slide 50

Single Phase On-Line UPS Demo Using MC9S12E128- Developments tools

• FreeMasterReal time monitorRead and write any variable in applicationDisplay the variables in physical quantitiesScopeRecorderControl page in HTML code


Slide 51


Scope or recorder

Variables window


Slide 52


Control page


Slide 53

• Reference Design Deliverables

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)

Single Phase On-Line UPS Demo Using MC9S12E128- Deliverables


Slide 54

TM

Documents

Single Phase On-Line UPS Demo Using MC9S12E128