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Figure 5. 

STDES-VRECTFD reference design - power board

The following figure shows the main sections of the power board.

Figure 6. 

STDES-VRECTFD power board sections

1.5.2

Power stage

1.5.2.1

Boost inductor

Boost inductors represent the energy storage elements that allow the PFC operation of the converter. This is
obtained by controlling the inductor current and using a proper conduction pattern in the power device section.

UM2975

Reference design description

UM2975

 - 

Rev 1

page 5/63

Summary of Contents for UM2975

Page 1: ...ance microcontroller provides the full control of the power factor PF the DC voltage and the auxiliary task to manage the protections and the soft start up procedure The high bandwidth continuous cond...

Page 2: ...ncy of the SiC MOSFETs 70 kHz and the multilevel structure allow an efficiency of almost 99 as well as the optimization of passive power components in terms of size and cost The high efficiency rectif...

Page 3: ...ngers and risks while operating this board even when it is not powered The qualified personnel must be familiar with the installation use and maintenance of power electrical systems During operation d...

Page 4: ...hree phase input voltage VAC 208 480 VACLL AC line frequency Hz 47 63 Hz Maximum output power POUTmax 15 7 kW VAC 230 VRMS IAC 21 VRMS VAC 110 VRMS IAC 21 VRMS Output voltage VDC 800 V Power factor PF...

Page 5: ...power board sections 1 5 2 Power stage 1 5 2 1 Boost inductor Boost inductors represent the energy storage elements that allow the PFC operation of the converter This is obtained by controlling the in...

Page 6: ...y and the rated DC AC operation voltages Table 3 Boost inductor parameters Parameter Symbol Value Unit DC voltage V0 800 V Switching frequency fsw 70 kHz Rated AC voltage VAC 230 VRMS Max ripple curre...

Page 7: ...d for each phase Figure 10 AC current sensing block diagram 1 5 2 3 2 AC voltage The three phase AC voltages are obtained using a two stage sensor circuit The first part represents an isolated op amp...

Page 8: ...rect value for the ADCs Figure 12 DC current sensing block diagram 1 5 2 3 4 DC voltage The DC voltages are obtained using two stage sensing The total DC bus voltage is split exploiting two voltage di...

Page 9: ...d The figure below shows the control board of the STDES VRECTFD reference design Figure 14 STDES VRECTFD reference design control board The following figure shows the main sections of the control boar...

Page 10: ...Figure 15 STDES VRECTFD control board sections Figure 16 STDES VRECTFD MCU pin assignment UM2975 Reference design description UM2975 Rev 1 page 10 63...

Page 11: ...d power factor Figure 17 PFC benefits 1 7 Converter operation The figure below shows the current paths of the Vienna topology To simplify the scheme we considered the single phase representation Figur...

Page 12: ...at 110 VAC RMS in a frequency between 47 and 63 Hz 2 2 How to connect the reference design To operate the reference design power converter properly consider the operating limits shown below Table 4 O...

Page 13: ...arity influences the DC load connection Figure 19 STDES VRECTFD connection Step 2 Connect an external fan to manage the thermal dissipation The auxiliary power supply can be externally provided 2 3 MC...

Page 14: ...ter to connect the platform to the PC Figure 20 ST LINK V2 and adapter Figure 21 ST LINK V2 connected to the control board Step 2 Select the main c file in the project Application User path UM2975 MCU...

Page 15: ...ARM debug procedure 2 3 1 Power supply section The power supply needs two different input voltages An embedded SMPS based on the VIPER26 family provides self powering from the DC link As shown in the...

Page 16: ...considered the SiC power MOSFETs The figure below shows this specific configuration Figure 25 Example of driver configuration 2 4 Preliminary test procedure 2 4 1 AC sensing To verify the proper opera...

Page 17: ...Figure 26 AC sensing section Figure 27 AC voltage sensing test procedure UM2975 Preliminary test procedure UM2975 Rev 1 page 17 63...

Page 18: ...edure 2 4 2 DC sensing To verify the proper operation of the DC sensing analyze the test points for voltages Figure 29 and currents Figure 30 Figure 29 DC voltage sensing test procedure UM2975 Prelimi...

Page 19: ...n line with the figure below A three phase sequence ABC is mandatory for the proper operation of the power converter Figure 31 AC connection and sequence 2 4 4 DC connection The figure below shows the...

Page 20: ...ge of the capacitor Then the burst operation boosts the output voltage The STDES VRECTFD reference design allows managing the complete startup procedure However a controlled step by step procedure is...

Page 21: ...T START N HW Error Y Y Achieved Enable Increase AC source VACrms_plug i e 10Vpk BLED IDLE N BLED WAIT Error N Achieved BLED IDLE Y Increase AC source VACrms_min i e 30Vpk N Y N BLED INIT Error Y N BLE...

Page 22: ...ck diagram Wait IDLE Power ON Idle ack STOP DPC_VAC_MIN DPC_TO_Set TO_IDLE TO_IDLE_Tick TO_OUT_OK Y Threshold Y N N Status_Plug_ACSource OK_Plug_ACSource 2 FSM Idle after TO_IDLE time elapses wait for...

Page 23: ...Complete 4 FSM_Start is related to the burst mode operation of the power converter During this procedure the PWM is activated The pulse sequence at a fixed duty cycle allows boosting the input voltag...

Page 24: ...ine manages a direct startup procedure The AC source takes the nominal voltage into consideration The inrush current limitation and the burst mode operation must be completed after the DC load connect...

Page 25: ...ady state error DC reference Use of a simple PI simple structure of the regulator Low bandwidth is allowed robust Best in transient first order behavior Effort frame transformation Digital version onl...

Page 26: ...Figure 42 Continuous conduction mode in current control Figure 43 Current decoupling control of the reference design converter model UM2975 Control strategy UM2975 Rev 1 page 26 63...

Page 27: ...control strategy The outer loop of the PFC operation is a voltage control Figure 45 Converter DC side model The figure below shows the closed loop representation of the above model UM2975 Control stra...

Page 28: ...p In converter control the PI regulators are usually used This kind of regulator gets the best results when using a DC reference term Figure 47 PLL internal regulator loop Figure 48 PLL in AC main vol...

Page 29: ...based on the STM32CubeG4 firmware package v1 3 0 Figure 49 STM32Cube ecosystem development flow An extensive range of generic and specific firmware modules is available to support the digital power co...

Page 30: ...rgy flow The figure below shows the algorithm schematic diagram of the implementation in the AC DC rectifier application Figure 51 AC DC rectifier application The figure below shows the basic represen...

Page 31: ...ns the application specific DEFINE that is the ADC gain factor PI regulator gain FSM configuration control reference value etc The DPC_Lib_conf header file contains the configuration parameters linked...

Page 32: ...5 Measurements 5 1 Startup procedure Figure 54 Startup procedure 5 2 PFC operation Figure 55 PFC operation UM2975 Measurements UM2975 Rev 1 page 32 63...

Page 33: ...9 3 0403 98 493 0 976 9 72 5 92 4 99 4 4 0919 4 0593 98 618 0 986 6 46 7 39 6 23 5 5 1078 5 0801 98 569 0 991 4 87 8 85 7 47 6 6 110 6 0877 98 491 0 994 4 57 10 27 8 67 7 7 096 7 0759 98 461 0 995 3 6...

Page 34: ...12 13 14 15 Power kW Figure 58 STDES VRECTFD efficiency plot 97 97 5 98 98 5 99 Eff 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Power kW Figure 59 STDES VRECTFD THDi plot 0 5 10 15 20 THDi 1 2 3 4 5 6 7 8 9 1...

Page 35: ...2H100A A C L7 TBD C239 15uF 35V C233 TBD JP61 Jp_pcb 1 2 C238 680uF 10V R261 51k 0 1 U34 VIPER26HD 8 COMP 16 DRAIN4 7 FB 5 VDD 1 GND1 15 DRAIN3 14 DRAIN2 13 DRAIN1 2 GND2 3 x C 4 x A 6 LIM 9 N C 1 10...

Page 36: ...P55 Con2 1 1 2 2 U30 LD29080DT50R VIN 1 VOUT 3 GND 2 C228 470nF 50V D66 LED RED A C JP56 Con2 1 1 2 2 Rled3 1k C218 10uF 50V TW10 CON1 1 U32 LD29080DT50R VIN 1 VOUT 3 GND 2 D56 LED RED A C C224 10uF 5...

Page 37: ...L4 506uH TP93 TestPoint_Ring C207 100nF 630V 1 2 D51 STPSC20H12WL A C C244 1nF 3kV 1 2 TP98 TestPoint_Ring TP92 TestPoint_Ring L_PFC L5 506uH R253 240k D52 STPSC20H12WL A C TP94 TestPoint_Ring C209 4...

Page 38: ...23 1uF 25V DC6 R12P22005D VIN 1 COM 6 VOUT 7 VIN 2 VOUT 5 JP27 Jp_pcb 1 2 TP64 TestPoint_Ring TP60 TestPoint_Ring JP43 Jp_pcb 1 2 JP26 Jp_pcb 1 2 R184 12 C164 N M C194 N M JP32 Jp_pcb 1 2 TP68 TestPoi...

Page 39: ...MHz 1 2 C102 N M TP50 TestPoint_Ring R153 1 6k C93 1nF 16V 0 F31 30Ohm 100MHz 1 2 C103 1uF 25V R164 0 TP53 TestPoint_Ring C94 N M C92 1uF 25V C104 100nF 16V U21 AMC1301DWVR VDD1 1 VINP 2 VINN 3 GND1 4...

Page 40: ...41 7 5k R131 0 C86 N M R138 9 1k C81 100nF 16V R133 0 R127 10k C84 N M TP46 TestPoint_Ring R135 N M TP47 TestPoint_Ring U13B TSV914IDT 5 6 7 R129 10k R137 10k C82 1uF 25V R136 24k 0 F24 30Ohm 100MHz 1...

Page 41: ...WM_10 VDD_3 3V VDD_5V VDD_12V GND_iso VDD_7V GND GND GND PWM_INP_Q1_AS PWM_INP_Q2_AS PWM_INP_Q3_AS FAN ZVD_C ZVD_B ZVD_A VlineC S VlineB S VlineA S Oout V_bus_up V_bus_down OinA_LEM OinB_LEM OinC_LEM...

Page 42: ...V C43 1uF 25V R95 0 R93 0 0 0 F10 30Ohm 100MHz 1 2 C62 1uF 25V R83 69 8k 0 1 R71 0 TP28 TestPoint_Ring R113 0 JP4 Jp_pcb 1 2 C54 100nF 16V JP3 Jp_pcb 1 2 R111 10k R72 0 R65 1M R96 10k R86 1M R107 13 3...

Page 43: ...5k C10 N M R24 N M 0 0 0 0 F7 30Ohm 100MHz 1 2 C11 N M R32 N M R45 0 0 F4 30Ohm 100MHz 1 2 R4 N M R48 0 U4B TSV912IDT 5 6 7 U5D TSV914IDT 12 13 14 TP14 TestPoint_Ring U5B TSV914IDT 5 6 7 R6 10k 0 0 0...

Page 44: ...6V 9B 9B 4 A2 1 F4 30Ohm 100MHz 15B 15B P1 Digital Power Connector LED_1 1 D7 RED 17A 17A 1 T_SWDIO PA5_DAC1_OUT2 19 PA13 SYS_JTMS SWDIO 49 TP3 TestPoint GND R56 1k USB2 microUSB USART_RX 5A 5A TC_LS...

Page 45: ...2 1 C240 SMD 0805 2012 Multilayer ceramic capacitor not mounted 3 2 C8 C14 100 nF SMD 0603 1608 16 V 10 Multilayer ceramic capacitors not mounted Wurth Elektronik 885012206046 4 5 C41 C55 C74 C93 C10...

Page 46: ...C137 C138 C141 C142 C145 C150 C153 C154 C157 C161 C166 C167 C170 C173 C174 C176 C181 C182 C188 C189 C195 C196 C198 C200 C201 C204 2 2 F SMD 1206 3216 50 V 5 Multilayer ceramic capacitors Any Any 12 1...

Page 47: ...apacitor Panasonic Electronic Components EEU EE2W150 26 1 C238 680 F Radial Can 50 V 5 Aluminium capacitor Panasonic Electronic Components EEU FR1C681L 27 1 C239 15 F Radial Can 50 V 5 Aluminium capac...

Page 48: ...x 9 8 mm x 12 5 mm DC DC converters Recom Power R12P22005D 41 49 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F37 F38 F39...

Page 49: ...L1 L2 L3 20 Inductors not mounted Pulse electronics PA0431LNL 53 3 L4 L5 L6 514 H Boost inductors Wurth Electronics Inc 750344313 54 1 L7 Inductor not mounted 55 6 L9 L10 L11 L12 L13 L14 22 H 130 mA 0...

Page 50: ...ny Any 64 31 R2 R8 R10 R20 R26 R28 R38 R44 R45 R56 R57 R58 R62 R71 R78 R79 R80 R84 R93 R100 R101 R102 R106 R115 R131 R140 R149 R163 R12 R30 R48 SMD Resistors Any Any 65 22 R4 R24 R42 R128 R191 R195 R1...

Page 51: ...1608 1 Resistors Any Any 78 6 R76 R98 R120 8 06k SMD 0603 1608 1 Resistors Any Any 79 5 R72 R94 R116 R150 R164 11 3 k SMD 0603 1608 1 Resistors Any Any 80 5 R75 R97 R119 R152 R167 3 74 k SMD 0603 1608...

Page 52: ...219 R233 R243 12 SMD 1210 3225 Resistors Any Any 96 6 R186 R188 R207 R217 R231 R241 100 SMD 0603 1608 Resistors Any Any 97 33 R9 R17 R35 R46 R53 R69 R72 R73 R91 R94 R95 R113 R116 R117 R133 R146 R149 R...

Page 53: ...TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 TP30 TP31 TP32 TP33 TP34 TP35 TP36 TP37 TP38 TP39 TP40 TP41 TP42 TP43 TP44 TP45...

Page 54: ...TGAP2SICS SO 8 Galvanically isolated 4 A single gate driver ST STGAP2SICS 116 4 U2 U4 U6 U9 TSV912IDT SO 8 Wide bandwidth 8 MHz rail to rail input output 5V CMOS Op Amps dual ST TSV912IDT 117 2 U30 U3...

Page 55: ...y 6 1 C18 470nF 50V CAPACITOR 805 Murata 7 1 C29 220pF 50V CAPACITOR 603 Any Any 8 1 C133 10 F 25V CAPACITOR 805 TDK 9 7 D2 D4 D5 D9 D12 D13 D15 GREEN LED SMD 0805 Any Any 10 2 D3 D10 SMAJ5 0A TR SMA...

Page 56: ...4 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP24 TP25 TP26 TP27 TestPoint TestPoint Any Any 26 1 USB2 microUSB connector MOLEX 47346 0001 27 5 U2 U5 U6 U9 U10 TSV912IDT SO 8 Wide bandwidth 8 MHz rail to...

Page 57: ...Revision history Table 10 Document revision history Date Revision Changes 18 Jan 2022 1 Initial release UM2975 UM2975 Rev 1 page 57 63...

Page 58: ...2 3 MCU programming and debugging 13 2 3 1 Power supply section 15 2 3 2 Driver section 16 2 4 Preliminary test procedure 16 2 4 1 AC sensing 16 2 4 2 DC sensing 18 2 4 3 AC connection 19 2 4 4 DC con...

Page 59: ...5 3 Step load 33 5 4 Power factor efficiency and THDi 33 6 Schematic diagrams 35 7 Bill of materials 45 Revision history 57 List of tables 60 List of figures 61 UM2975 Contents UM2975 Rev 1 page 59 63...

Page 60: ...tion condition limits 12 Table 5 Control strategy comparison 25 Table 6 STDES VRECTFD power factor efficiency and THDi 33 Table 7 STDES VRECTFD bill of materials 45 Table 8 Power board bill of materia...

Page 61: ...configuration 16 Figure 25 Example of driver configuration 16 Figure 26 AC sensing section 17 Figure 27 AC voltage sensing test procedure 17 Figure 28 AC grid current sensing test procedure 18 Figure...

Page 62: ...ES VRECTFD circuit schematic power board 4 of 11 38 Figure 64 STDES VRECTFD circuit schematic power board 5 of 11 38 Figure 65 STDES VRECTFD circuit schematic power board 6 of 11 39 Figure 66 STDES VR...

Page 63: ...ts and ST assumes no liability for application assistance or the design of Purchasers products No license express or implied to any intellectual property right is granted by ST herein Resale of ST pro...

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