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Figure 5.

STDES-PFCBIDIR reference design - power board

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

Figure 6.

STDES-PFCBIDIR power board sections

UM2979

Reference design description

UM2979

Rev 1

page 5/70

Содержание STDES-PFCBIDIR

Страница 1: ...RET3 mixed signal high performance microcontroller provides the full control of the power factor PF the DC voltage and the auxiliary task to manage the grid connection and the soft startup procedure T...

Страница 2: ...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 bidirectional...

Страница 3: ...d even when it is not powered The qualified personnel must be familiar with the installation use and maintenance of power electrical systems During operation do not touch the board as some of its comp...

Страница 4: ...Unit Comments Three phase input voltage VAC 208 400 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...

Страница 5: ...TDES PFCBIDIR reference design power board The following figure shows the main sections of the power board Figure 6 STDES PFCBIDIR power board sections UM2979 Reference design description UM2979 Rev 1...

Страница 6: ...The inductance value is related to several parameters the current ripple the available converter voltage levels the switching frequency and the rated DC AC operation voltages Table 3 Boost inductor p...

Страница 7: ...to be controlled for the proper operation of the PFC behavior of the power converter The output voltage of the Hall effect transducer is not in scale and contains a DC component of 2 5 V with respect...

Страница 8: ...the HV through a voltage divider with an isolation barrier Isol Op AMP output is limited in volts and is scaled with a second stage of op amps with a proper gain and bias This circuit allows measurin...

Страница 9: ...s Figure 13 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 dividers Both voltages a...

Страница 10: ...The figure below shows the control board of the STDES PFCBIDIR reference design Figure 15 STDES PFCBIDIR reference design control board The following figure shows the main sections of the control boa...

Страница 11: ...Figure 16 STDES PFCBIDIR control board sections Figure 17 STDES PFCBIDIR MCU pin assignment UM2979 Reference design description UM2979 Rev 1 page 11 70...

Страница 12: ...d power factor Figure 18 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...

Страница 13: ...on limits Description Value Unit Three phase input voltage range 208 400 VAC Line frequency range 47 63 Hz Maximum output power at 230 VAC 15 kW Voltage limit of the bulk capacitors 500 V Step 1 Conne...

Страница 14: ...tools Step 1 Use ST LINK V2 and a 20 to 10 pin JTAG adapter to connect the platform to the PC Figure 21 ST LINK V2 and adapter Figure 22 ST LINK V2 connected to the control board Step 2 Select the mai...

Страница 15: ...can customize the power supply the driving section the grid relays the inrush current limiter and the DC current sensing technique 2 4 1 Power supply section Two different input voltages are required...

Страница 16: ...ed Closed Open Open 2 4 3 Relay section The STDES PFCBIDIR allows managing the power in both directions AC DC rectifier mode a DC AC inverter mode To customize the AC side connection with the power co...

Страница 17: ...ary test procedure 2 5 1 AC sensing To verify the proper operation of the AC sensing analyze some test points for voltages and currents as shown in the figures below Figure 28 AC sensing section UM297...

Страница 18: ...Figure 29 AC voltage sensing test procedure Figure 30 AC grid voltage sensing test procedure UM2979 Preliminary test procedure UM2979 Rev 1 page 18 70...

Страница 19: ...2 DC sensing To verify the proper operation of the DC sensing analyze the test points for voltages and currents as shown in the figures below Figure 32 DC voltage sensing test procedure 1 of 2 UM2979...

Страница 20: ...as shown below A correct ABC sequence is mandatory for the proper operation of the power converter Figure 34 AC main connection and sequence 2 5 4 DC connection The figure below shows the output DC c...

Страница 21: ...multimeter according to the configuration three phase and neutral 2 6 Startup procedure After connection and debugging initialization you can perform the startup procedure An embedded finite state ma...

Страница 22: ...es No Power No Power Check No Load E Load disabled N Y Power On 12V 7V Power Supply PS BLED WAIT START N HW Error Y Y Achieved Enable Increase AC source VACrms_plug i e 10Vpk BLED IDLE N BLED WAIT Err...

Страница 23: ...n voltage is already under monitoring This state is maintained until AC main reaches a lower AC voltage threshold OK_Plug_ACSource that is 30 VAC After that an internal timeout TO_IDLE is activated to...

Страница 24: ...tage is correct the status source is equal to OK_SOURCE The bulk capacitors are at low voltage and the inrush current must be limited For this reason during this state the inrush relays are considered...

Страница 25: ...eted without any issue FSM_Start manages the PFC operation of the power converter The burst operation still maintains the DC voltage If a DC load occurs the PFC modulation and the control loop are act...

Страница 26: ...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...

Страница 27: ...Figure 46 Continuous conduction mode in current control Figure 47 Current decoupling control of the reference design converter model UM2979 Control strategy UM2979 Rev 1 page 27 70...

Страница 28: ...control strategy The outer loop of the PFC operation is a voltage control Figure 49 Converter DC side model The figure below shows the closed loop representation of the above model UM2979 Control stra...

Страница 29: ...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 51 PLL internal regulator loop Figure 52 PLL in AC main vol...

Страница 30: ...ed through the IDE or STM32CubeProgrammer To monitor and control the application you can use a GUI based on STM32CubeMonitor The firmware described in this documentation development is based on the ST...

Страница 31: ...er firmware is then released if compliant and the DPC is adapted The STDES PFCBIDIR reference design power converter allows managing the two direction energy flow The figure below shows the algorithm...

Страница 32: ...configuration files Figure 57 STDES PFCBIDIR configuration files DPC_application_conf h contains the application specific DEFINE that is the ADC gain factor PI regulator gain FSM configuration control...

Страница 33: ...ion test considering 800 V DC voltage and 220 Vrms AC voltage with 15 kW DC load constant current This test represents the PFC operation with the DC voltage regulation active Figure 58 PFC operation 5...

Страница 34: ...5 3 UVP AC Figure 60 UVP AC 5 4 Power factor Figure 61 Power factor UM2979 UVP AC UM2979 Rev 1 page 34 70...

Страница 35: ...THD The figure below shows the current THD measurements Test conditions are VAC 230 Vrms VDC 800 V According to the specification THD is lower than 5 starting from 10 of the full load Figure 63 THD UM...

Страница 36: ...B 10A 10A 10B 10B 11A 11A 11B 11B 12A 12A 12B 12B 13A 13A 13B 13B 14A 14A 14B 14B 15A 15A 15B 15B 16A 16A 16B 16B 17A 17A 17B 17B 18A 18A 18B 18B 19A 19A 19B 19B 20A 20A 20B 20B 21A 21A 21B 21B 22A 22...

Страница 37: ...30Ohm 100MHz TP8 TestPoint_Ring TestPoint_Ring 3 V V TP3 TestPoint_Ring R9 N M OUT 3 2 R5 10k 0 1 OinA 3 R20 0 F2 30Ohm 100MHz IN 2 V_line_A VDD_5V R17 N M TestPoint_Ring 1 0 R13 10k 0 1 5 R7 10k 0 1...

Страница 38: ...8 1uF 25V TP19 TestPoint_Ring F18 30Ohm 100MHz 11 C24 1uF 25V R51 36k 0 1 C36 N M VOUTN TP27 TestPoint_Ring 2 8 TP23 TestPoint_Ring VDD2 12 C51 100nF 16V U11B TSV914IDT 7 TP33 TestPoint_Ring 13 TP21 T...

Страница 39: ...100MHz J17 Dev3 VDD_7V C A R345 750 A TW10 CON1 VDD_5V 1 VDD_7V Rled8 1k C 1 VIN U43 LD29080DT50R VDD_3 3V_DRIVER VDD_5V_DRIVER JP97 3JP_pcb GND1 Rled7 1k TW8 CON1 3 C344 470nF 50V 1 2 C341 470nF 50V...

Страница 40: ...ridA S PWM_INP_Q3_R 17B PWM_INP_Q2_R OinB 26A PWM_INP_Q3_DOWN 13A 27A 18B 3B 9A VDD_5V FAN FAULT_1 16A GND 22A 27B 7A 18A 27A 30A 7A 23A CAN_RX 18B 22B 8A 31B 24A 19A GPIO_9 EEV_3 5A SMBus_SDA 12B 12B...

Страница 41: ...LTSR 15 NP JP7 Jp_pcb C88 100nF 16V 8 U15A TSV912IDT VDD2 R109 0 Oout_LEM 4 6 2 VDD_5V IN 1 TP54 TestPoint_Ring SHUNT_DC F25 30Ohm 100MHz R117 2k TP63 TestPoint_Ring Oout_SHUNT TP61 TestPoint_Ring R12...

Страница 42: ...VOUTN GND_MEAS_DC 7 R132 0 GND_MEAS_CURR_DC C112 100nF 16V R143 10 5k 0 1 VDD_5V 2 VOUTP C117 1uF 25V JP9 Jp_pcb U21B TSV912IDT R125 1M U20 AMC1301DWVR 4 GND_MEAS_DC GND2 C104 1uF 25V F31 30Ohm 100MH...

Страница 43: ...60 C161 2 2uF 50V R152 1k 2 C162 470nF 50V 2 VIN R164 0 C137 100nF 25V C154 1nF 50V A JP11 Jp_pcb 1 R194 1k 1 DC1 R12P22005D 7 GND_ISO_Q1 A 1 VH 1 GNDISO TP97 TestPoint_Ring R169 0 D15 TZMB20 GS08 A 2...

Страница 44: ...1 R337 0 VOUTP 4 TP153 TestPoint_Ring R323 11 3k 0 1 C322 N M U36 AMC1301DWVR R343 NM TP164 TestPoint_Ring VDD2 3 8 F61 30Ohm 100MHz TP151 TestPoint_Ring R326 NM GND_MEAS_AC 2 9 V_grid_A 2 12 TP165 T...

Страница 45: ...3 22uH 3 2 GND_ISO_Q1_DOWN 1 Neutral JP5 Con2 GATE1_L 1 BUS_LEM Q4 SCTW40N120G2V C 2 1 1 V_line_C 2 2 L6 506uH GATE3_UP TP50 TestPoint_Ring SHUNT_DC GND_ISO_Q2_UP B32926C3106M 1 K1 1 1393210 4 L5 3 22...

Страница 46: ...AN 2 8 R96 33k 1 5 3 2 VCC R93 5 1k GND1 U14 STLM20W87F 1 5 TP38 TestPoint_Ring R925 6k R95 10k C J1 Con2 7 R94 1 2 NC VDD_5V TP39 TestPoint_Ring VDD_12V TP37 TestPoint_Ring VOUT GND D1 LED RED 4 3 C6...

Страница 47: ...C62 C65 C 66 C13 4 100 nF 603 16 V 10 Multilayer ceramic capacitors Wurth 885012206046 3 7 C2 C2 7 C35 C47 C 50 C58 C64 1 F 603 25 V Multilayer ceramic capacitors Wurth 885012206076 4 17 C11 C 12 C13...

Страница 48: ...w straight pin header Wurth 61300411121 16 2 J2 J3 CON4 strip4_100m_v 4 way 1 row straight pin header Wurth 61300411121 17 1 LED1 SMTL4 SBC 2 V SMD LED BIVAR SMTL4 SBC 18 1 L1 WE CBF 603 500 m A 25 Fe...

Страница 49: ...TP18 TP19 TP20 TP21 TP22 TP24 TP25 TP26 TP27 TestPoint Test terminals ANY ANY 26 1 USB2 microUSB Micro USB connector receptacle MOLEX 47346 0001 27 5 U2 U5 U6 U9 U10 TSV912IDT SO 8 Wide bandwidth 8 M...

Страница 50: ...111 C112 C114 C122 C125 C131 C141 C182 C187 C198 C203 C242 c246 C255 C266 C302 C304 C306 C307 C308 C309 C313 C315 C317 C318 C319 C320 C324 C326 C328 C329 C330 C331 100nF 16V 10 Multilayer ceramic capa...

Страница 51: ...nents MAL215759471E3 12 1 C73 100nF 3kV 5 Polypropylene Capacitor KEMET R474N310050A1K 13 1 C74 1nF 3kV 5 Polypropylene Capacitor KEMET PHE450XB4100JB04R1 7 14 3 C80 C81 C82 10 F 305V 20 Polypropylene...

Страница 52: ...C160 c169 c173 C191 C195 C207 C209 C218 C220 C224 C233 C250 C257 C260 C270 C276 C285 C288 C297 100nF 25V 5 Multilayer ceramic capacitor SMD 1206 ANY ANY 22 12 C149 C150 C151 C152 C192 C200 C212 C215 C...

Страница 53: ...hole ANY ANY 34 1 C357 220pF 100V 5 Multilayer ceramic capacitor SMD 0805 ANY ANY 35 12 DC1 DC2 DC3 DC4 DC5 DC6 DC7 DC8 DC9 DC10 DC11 DC12 Vin 10 8 13 2V dc Vout 5V dc 20 2W Isolated DC DC Converter T...

Страница 54: ...A Silicon Junction Diode 2 Pin DO 214AC ST STPS1150A 43 1 D93 100V 2A Silicon Junction Diode 2 Pin DO 214AC ST STPS2H100A 44 1 D94 60V 2A Silicon Junction Diode 2 Pin DO 214AC ST STPS2L60A 45 70 F1 F2...

Страница 55: ...P36 JP37 JP38 JP39 JP40 JP41 JP42 JP45 JP46 JP47 JP48 JP49 JP50 JP53 JP54 JP55 JP56 JP57 JP58 JP59 JP60 JP61 JP62 JP63 JP64 JP65 JP66 JP67 JP68 JP69 JP70 JP71 JP73 JP74 JP77 JP78 JP79 JP80 JP81 JP83 J...

Страница 56: ...SPST NO 1 Form A 15VDC Coil Through Hole TE Connectivity Potter Brumfield Relays T9AS1D12 15 60 4 LEM1 LEM2 LEM3 LEM4 LTSR 15 NP 0 48A nom LEM LTSR Series Closed Loop Current Sensor LTSR 25 NP LEM USA...

Страница 57: ...2mm 20A Inrush Current Limiters KINK INRSH CURR LIMITER Ametherm SL32 5R020 B 72 3 RT4 RT5 RT6 150 6W 0 1 Thin Film SMD Resistor 2512 6432M Vishay PCAN2512E1500BST3 73 60 Rled1 Rled2 Rled3 Rled4 Rled5...

Страница 58: ...ANY ANY 80 15 R26 R27 R28 R32 R41 R48 R49 R50 R54 R63 R70 R71 R72 R76 R85 0 0 1W 1 Thick Film SMD Resistor 0603 ANY ANY 81 3 R29 R51 R73 36k 0 1W 0 1 Thin Film SMD Resistor 0603 ANY ANY 82 9 R30 R34...

Страница 59: ...Resistor ANY ANY 101 1 R108 3 4k 0 1W 0 1 Metal Film SMD Resistor 0603 ANY ANY 102 1 R110 18k 0 1W 0 1 Thin Film SMD Resistor 0603 ANY ANY 103 1 R111 12k 0 1W 0 1 Thin Film SMD Resistor 0603 ANY ANY 1...

Страница 60: ...268 R269 R273 R279 R284 0 0 5W 0 Thick Film SMD Resistor ANY ANY 118 12 R168 R175 R177 R180 R213 R217 R231 R234 R258 R260 R274 R285 22 0 5W 1 Thick Film SMD Resistor ANY ANY 119 12 R188 R189 R192 R193...

Страница 61: ...0 1W 1 Thick Film SMD Resistor 0603 ANY ANY 135 1 R368 1k 0 1W 1 Thick Film SMD Resistor 0603 ANY ANY 136 4 R370 R371 R372 R373 22 0 25W 1 Thick Film SMD Resistor 0603 ANY ANY 137 2 SHUNT1 SHUNT2 25m...

Страница 62: ...TP145 TP146 TP147 TP148 TP149 TP150 TP151 TP152 TP153 TP154 TP155 TP156 TP157 TP158 TP159 TP160 TP161 TP162 TP163 TP164 TP165 TP166 TP167 TP168 139 4 TP37 TP38 TP39 TP40 TestPoint_Ring RS PRO 1mm Bla...

Страница 63: ...ensor Analogue 5 Pin SOT 323 SOT323 5L ST STLM20W87F 147 12 U23 U24 U25 U26 U27 U28 U29 U30 U31 U32 U33 U34 4A DGTL ISO single Gate Drive ST STGAP2SM 148 2 U41 U43 800mA LDO Voltage Regulators Fixed A...

Страница 64: ...Revision history Table 10 Document revision history Date Revision Changes 28 Feb 2022 1 Initial release UM2979 UM2979 Rev 1 page 64 70...

Страница 65: ...MCU programming and debugging 14 2 4 Board configuration 15 2 4 1 Power supply section 15 2 4 2 Driver section 16 2 4 3 Relay section 16 2 5 Preliminary test procedure 17 2 5 1 AC sensing 17 2 5 2 DC...

Страница 66: ...tion 33 5 2 Step load 33 5 3 UVP AC 34 5 4 Power factor 34 5 5 Efficiency 35 5 6 THD 35 6 Schematic diagrams 36 7 Bill of materials 47 Revision history 64 List of tables 67 List of figures 68 UM2979 C...

Страница 67: ...Operation condition limits 13 Table 5 Example of driving section configuration 16 Table 6 Control strategy comparison 26 Table 7 STDES PFCBIDIR bill of materials 47 Table 8 STDES PFCBIDIR control boar...

Страница 68: ...ample of power supply configuration 16 Figure 26 Example of driver configuration 16 Figure 27 Example of relay configuration 17 Figure 28 AC sensing section 17 Figure 29 AC voltage sensing test proced...

Страница 69: ...DES PFCBIDIR schematic diagram power board aux power DC DC 39 Figure 68 STDES PFCBIDIR schematic diagram power board aux power VIPER 40 Figure 69 STDES PFCBIDIR schematic diagram power board connector...

Страница 70: ...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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