AN1918 Application Note
Contents
1. s input The DSP also controls the power factor correction hardware that provides the power supply for the motor DC Bus 115 230V 50 60Hz Temperature Current amp Voltage sensors r Zero crossing Pulse wide Inhibit detection modulation output Input Base frequency frequency nl Reference Temperature voltage and fault processing PWM Generator with Dead Time measurement voltage Milestone i calculation DC Bus generation Ripple Cancel Speed set up Speed Command PI V Hz Processing Regulator Speed Processing DSP56F80X De a ee ey ed ee es ee ee es Figure 3 1 System Concept The system integrates two independent parts that keep all their own features First is a 3 phase AC motor drive with V Hz Speed Open Loop algorithm the second is a Power Factor Correction PFC algorithm see Figure 3 1 The DSP runs the main control algorithm According to the user interface input and feedback signals it generates 3 phase PWM output signals for the motor inverter The PFC provides the power for the Motor inverter The main advantage of the power factor correction system is the reduction of electrical noise This will be possible if the input current waveform is sine like The hardware does not directly control the PFC inverter switch It modifies the PFC reference voltage only which makes possible simple a 3 point sine appr2. phase AC induction V Hz Open Loop application A part of the DSP memory is still available for other tasks 10 Indirect Power Factor Correction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc References Table 7 1 RAM and FLASH Memory Usage for SDK2 3 and CW 4 0 Memory Available Used Used in 16 bit Words DSP56F803 Application Stack Application without DSP56F805 PC Master SCI ident Program FLASH 32K 12614 8437 Data RAM 2K 1541 352 stack 1173 352 stack 8 References Design of Indirect Power Factor Correction Using DSP56F80x Motorola AN1919 D DSP56F800 16 bit Digital Signal Processor Family Manual DSP56F800FM D Motorola DSP56F80x 16 bit Digital Signal Processor User s Manual DSP56F801 7UM D Motorola DSP Evaluation Module Hardware User s Manual DSP56F803EVMUM D Motorola DSP Evaluation Module Hardware User s Manual DSP56F805EVMUM D Motorola Motorola DSP56F8XX Software Development Kit Optoisolation Board User s Manual MEMCOBUM D Phase Brushless DC High Voltage Power Stage MEMC3BLDCPSUM D Motorola 3 Phase AC Motor Control with V Hz Speed Open Loop Using DSP56F80x Motorola AN1911 D Web page http e www motorola com motor MOTOROLA Indirect Power Factor Correction 11 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc OnCE is a registered trademark of Motorola Inc
3. Freescale Semiconductor Inc MOTOROLA Order by AN1918 D Semiconductor Application Note Motorola Order Number E Rev 0 6 01 Indirect Power Factor Contents Correction for 3 Phase AC tneduction ot Application Benefit 1 Motor Control with V Hz Deiat nse EEE Speed Open Loop Features 0 cccsseseeccceeeeceeeeee 2 Appl icati on U si n g 3 System Design Concepts 3 D S P D 6 F 8 0x ee a eee 2 i 4 2 High Voltage Hardware Set 5 Design of Indirect Power Factor Correction 5 Software Implementation 7 Sadi HUES ios coos cet E E hese tebeet 7 5 2 Drivers and Library Function 8 5 3 Appconfig h File eee 8 5 4 PFC Control Integration 8 1 e e e DAT RESOULCES x secssesecvscssvenses eaesaeseese 8 Introduction of Application 5 4 2 Modification ccc 8 5 4 3 Initialization oe 9 B enefit 5 4 4 PFC Control Enable 9 5 4 5 PFC Control Disable 9 This Application Note describes the design of a Indirect Power Factor Correction Indirect PFC for 3 phase AC 5 5 Input Current Harmonics Contents 9 Motor V Hz Speed Open Loop application It is based on 6 PC Master esesesssssssssssssssssseseeeeee 10 Motorola s 56F80X digital signal processor DSP which is dedicated for motor control applications 7 Memory Usage eesssssssessesseeeeeeee 10 Most practical electronic power supplies consist of a 8 Referentes siisii reisse 11 con
4. Motorola reserves the right to make changes without further notice to any products herein Motorola makes no warranty representation or guarantee regarding the suitability of its products for any particular purpose nor does Motorola assume any liability arising out of the application or use of any product or circuit and specifically disclaims any and all liability including without limitation consequential or incidental damages Typical parameters which may be provided in Motorola data sheets and or specifications can and do vary in different applications and actual performance may vary over time All operating parameters including Typicals must be validated for each customer application by customer s technical experts Motorola does not convey any license under its patent rights nor the rights of others Motorola products are not designed intended or authorized for use as components in systems intended for surgical implant into the body or other applications intended to support or sustain life or for any other application in which the failure of the Motorola product could create a situation where personal injury or death may occur Should Buyer purchase or use Motorola products for any such unintended or unauthorized application Buyer shall indemnify and hold Motorola and its officers employees subsidiaries affiliates and distributors harmless against all claims costs damages and expenses and reasonable attorney fees arising out of d
5. are must be aware of the DC bus voltage value Usually a motor control application uses this value in own calculations and requires different sample rate for measurement In the case of PFC control used the main program should provide continuous measurement of DC bus voltage at a sample rate not less then twice the input voltage frequency This assures proper operation when PFC control is on One of the possible means of passing the DC bus voltage value to the PFC control is to put the following line in ADC conversion complete callback PFC_SetUOut u_dc_bus Pass DC bus voltage value 5 4 4 PFC Control Enable It is possible to enable PFC control at any time after the PF C_Init function call Before PFC control is enabled the application will be able to measure DC bus voltage To enable PFC control add the following line PFC_Enable PFC control enable PFC control operates from interrupts So it is not possible to disable global interrupts when PFC control is on 5 4 5 PFC Control Disable There are two reasons for disabling PFC control in a motor control application The first reason is power saving when the output load is zero and the second reasonose is fault protection If motor control application performs a shutdown after error detection add the following line PFC_Disable PFC control disable 5 5 Input Current Harmonics Contents As a result of power factor correction the spectrum of the input curr
6. chapter describes the minor changes needed for the basic 3 phase AC motor V Hz Open Loop application that are necessary to integrate PFC control 5 1 Files The application is composed of the following files dsp5680Xevm nos applications 3ph_AC_VHz_OpenLoop_PFC Bph_AC_VHz_OpenLoop_PFC c main program dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PFC dpfc c PFC control program dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PFC dpfc h PFC control header file dsp5680Xevm nos applications 3ph_AC_VHz_OpenLoop_PFC 3ph_AC_VHz_OpenLoop_PFC mcp application project file dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PF C configflash appconfig c application configuration source file for FLASH dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PF C configflash appconfig h application configuration header file for FLASH dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PF C configflash linker cmd linker command file for FLASH dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PF C configflash flash cfg configuration file for FLASH dsp5680Xevm nos applications 3 ph_AC_VHz_OpenLoop_PF C configextram appconfig c application configuration source file for external RAM dsp5680Xevm nos applications 3ph_AC_VHz_OpenLoop_PFC configextram appconfig h application configuration header file for external RAM MOTOROLA Indirect Power Factor Correction 7 For More Information On Thi
7. d external interrupt pins Fourteen dedicated General Purpose I O GPIO pins 18 multiplexed GPIO pins External reset pin for hardware reset JTAG On Chip Emulation OnCE Software programmable Phase Lock Loop based frequency synthesizer for the DSP core clock Memory configuration 32252 x 16 bit words of Program Flash 512 x 16 bit words of Program RAM 2K x 16 bit words of Data RAM 4K x 16 bit words of Data Flash 2K x 16 bit words of Boot Flash Other than the fast Analog to Digital converter and 16 bit Quadrature Timers the most interesting peripheral from a motor control point of view is the Pulse Width Modulation PWM module Its configuration permits efficient control of AC motors Indirect Power Factor Correction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc System Design Concepts The PWM has the following features Three complementary PWM signal pairs or six independent PWM signals Complementary channel operation Deadtime insertion Separate top and bottom pulse width correction via current status inputs or software Separate top and bottom polarity control Edge aligned or center aligned PWM signals 15 bits of resolution Half cycle reload capability Integral reload rates from one to 16 Individual software controlled PWM output Programmable fault protection Polarity control 20 mA current sink capability on PWM pins Write protectab
8. ent will contain components with lowest amplitudes than the same spectrum without PFC The harmonics contents of both applications with and without PFC were measured for output power about 120W and are shown in Figure 5 1 MOTOROLA Indirect Power Factor Correction 9 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc PC Master al Noon Tana 0 0 m e m harmonic 5 11 17 23 29 35 41 47 m w ith PFC P 124W g without PFC P 124W Figure 5 1 Input Current Harmonics Contents RMS 6 PC Master PC Master was designed to provide the debugging diagnostic and demonstration tool for the development of algorithms and applications It consists of components running on a PC and parts running on the target DSP device The PC Master application is part of the Motorola Embedded SDK and may be selectively installed during SDK installation To enable the PC Master operation on the target board application the following lines must be added to the appconfig h file define SCI_DRIVER define INCLUDE _PCMASTER These two lines automatically include the SCI driver and install all necessary services for running PC Master The detailed PC Master description is provided by the PC Master User Manual It is stored in the SDK directory sdk pc_master dsp_gui_um dsp_gui_um pdf 7 Memory Usage Table 7 1 shows how much memory is needed to execute the 3
9. generation is a time critical process one timer interrupt will have the highest interrupt priority level 3 for this example level 2 is reserved for ADC interrupt define GPR_INT_PRIORITY_32 3 5 4 PFC Control Integration 5 4 1 Resources PFC control uses some DSP peripherals and cannot share resources with the motor control application excluding the ADC channel for DC bus voltage measurement The following resources are allocated to PFC control e Quadrature timer module D channel 0 e Quadrature timer module D channel 1 e Quadrature timer module D channel 2 e Quadrature timer module C channel 0 for DSP56F805 only e GPIO port E pin 4 for DSP56F803 only These two lines in dpfc c support PFC hardware connection differences between variants of the 56F80x family 8 Indirect Power Factor Correction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Implementation Uncomment one of the following lines define DSP56F803EVM define DSP56F805EVM 5 4 2 Modification The following line placed into the main program provides access to the PFC control API functions include dpfc h 5 4 3 Initialization Initialization of DSP peripherals will contain two additional parts The following line will be included after the motor control initialization function call PFC_Init PFC peripherals initialization The PFC control softw
10. hout changing the hardware 2 Motorola DSP Advantage and Features The members of the Motorola DSP56F80x family are well suited for digital motor control combining the DSP s calculation capability with an MCU s controller features on a single chip These DSPs offer many peripherals including Pulse Width Modulation PWM unit Analog to Digital Converter ADC Timers communication peripherals SCI SPI CAN on board Flash and RAM The typical member of the family the DSP56F805 provides the following peripheral blocks Two Pulse Width Modulator modules PWMA amp PWMB each with six PWM outputs three Current Status inputs and four Fault inputs fault tolerant design with deadtime insertion supports both Center and Edge aligned modes Twelve bit Analog to Digital Convertors ADCs supporting two simultaneous conversions with dual 4 pin multiplexed inputs ADC can be synchronized by PWM modules Two Quadrature Decoders Quad Dec0 amp Quad Dec1 each with four inputs or two additional Quad Timers A amp B Two dedicated General Purpose Quad Timers totalling 6 pins Timer C with 2 pins and Timer D with 4 pins CAN 2 0 A B Module with 2 pin ports used to transmit and receive Two Serial Communication Interfaces SCIO amp SCI1 each with two pins or four additional GPIO lines Serial Peripheral Interface SPI with configurable 4 pin port or four additional GPIO lines Computer Operating Properly COP timer Two dedicate
11. irectly or indirectly any claim of personal injury or death associated with such unintended or unauthorized use even if such claim alleges that Motorola was negligent regarding the design or manufacture of the part Motorola and are registered trademarks of Motorola Inc Motorola Inc is an Equal Opportunity Affirmative Action Employer How to reach us USA EUROPE Locations Not Listed Motorola Literature Distribution P O Box 5405 Denver Colorado 80217 1 303 675 2140 or 1 800 441 2447 JAPAN Motorola Japan Ltd SPS Technical Information Center 3 20 1 Minami Azabu Minato ku Tokyo 106 8573 Japan 81 3 3440 3569 ASIA PACIFIC Motorola Semiconductors H K Ltd Silicon Harbour Centre 2 Dai King Street Tai Po Industrial Estate Tao Po N T Hong Kong 852 26668334 Technical Information Center 1 800 521 6274 HOME PAGE http motorola com semiconductors dsp MOTOROLA HOME PAGE hittp motorola com semiconductors OM MOTOROLA Mes AN1918 D For More Information On This Product Go to www freescale com
12. le registers The AC Motor control utilizes the PWM block set in the complementary PWM mode which configures the PWM output as a pair of complimentary channels Bi System Design Concepts The system has all of the basic characteristics of both Digital Power Factor Correction and 3 phase AC motor V Hz Open Loop applications described below Motor Control Targeted for DSP56F803 805EVM platforms Running on 3 phase AC BLDC Motor Control Development Platform at single line voltage 360V DC 10 Control technique incorporates V Hz speed open loop bi directional rotation motoring and regenerating mode Overvoltage Undervoltage Overcurrent and Temperature Fault protection PC Master and Manual Interface Power Stage Identification PFC Control Input power supply voltage 115 230V AC Input power supply frequency 50 60 Hz Nominal output voltage 360V DC 10 Nominal output power 180W Input current harmonic content will comply with standard IEC 1000 3 2 MOTOROLA Indirect Power Factor Correction 3 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc System Design Concepts The system is designed to integrate PFC control with a real motor control application The base is the 3 phase AC Motor V Hz Speed Open Loop application The DSP runs the main control algorithm It generates a 3 phase PWM output signal for the motor according to the user
13. ng references e Ul Controller Board for DSP56F805 supplied as DSP56805EVM described in DSP56F805EVMUM D DSP Evaluation Module Hardware User s Manual e or U1 Controller Board for DSP56F803 supplied as DSP56803EVM described in DSP56F803EVMUM D DSP Evaluation Module Hardware User s Manual e U2 3 ph AC BLDC High Voltage Power Stage 6 Indirect Power Factor Correction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Implementation Warning supplied in kit with Optoisolation Board as ECOPTHIVACBLDC described in MEMC3BLDCPSUMDID 3 Phase Brushless DC High Voltage Power Stage U3 Optoisolation Board supplied with 3 ph AC BLDC High Voltage Power Stage as ECOPTHIVACBLDC or supplied alone as ECOPT optoisolation board described in MEMCOBUM D Optoisolation Board User s Manual It is strongly recommended to use optoisolation optocouplers and optoisolation amplifiers during the development time to avoid any damage to the development equipment Notes Information of all above mentioned boards and documents can be found on http mot sps com motor devtools index html 5 Software Implementation The Motorola Embedded SDK is a collection of APIs libraries services rules and guidelines This software infrastructure is designed to let DSP5680x software developers create high level efficient portable code This
14. oximation of the input current waveform It is enough to comply with IEC standard and simplifies control software complexity The second PFC feature is the stable output voltage The PFC circit is a boost voltage converter so output voltage cannot be less than rectified input voltage 4 Indirect Power Factor Correction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware Implementation 4 Hardware Implementation 4 1 System Outline The hardware is designed to drive the 3 phase AC BLDC motor This application notes describes PFC uses with a 3 phase AC motor The application can run on Motorola motor control DSPs using the DSP EVM Board e DSP56F803 e DSPS56F805 The designed software is capable to run only on High Voltage Hardware Set described below The HW setup is shown in Figure 4 1 but it is described also in the documents Targeting_DSP56803_Platform and Targeting DSP56805_Platform according to targeted DSP EVM Those documents also describe EVM jumper settings 4 2 High Voltage Hardware Set The system configuration is shown in Figure 4 1 All the system parts are supplied and documented according the following references e Ul Controller Board for DSP56F805 supplied as DSP56805EVM described in DSP Evaluation Module Hardware User s Manual e or U1 Controller Board for DSP56F803 supplied as DSP56803EVM described in DSP Evaluation Mod
15. s Product Go to www freescale com Freescale Semiconductor Inc Software Implementation e dsp5680Xevm nos applications 3ph_AC_VHz_OpenLoop_PFC configextram Ninker cmd linker command file for external RAM Where X means type of target DSP DSP56F803 EVM or DSP56F805 EVM These files are located in the SDK Two additional files dpfc c and dpfc h are added to the basic 3 phase AC motor VHz Open Loop application 5 2 Drivers and Library Function Each peripheral is accessible through driver For a detailed description of drivers see the document Embedded SDK Software Development Kit Targeting Motorola DSP5680X Platform 5 3 Appconfig h File The purpose of the appconfig h file is to provide a mechanism for overriding default configuration settings which are defined in the config h file The following lines should be included in appconfig h file to use PFC functionality define INCLUDE_USER_TIMER_D_0O 0 define INCLUDE_USER_TIMER_D_1 0 define INCLUDE_USER_TIMER_D_2 0 define INCLUDE_USER_TIMER_C_0O 0 The difference is in the PFC inhibit output which is connected to general purpose input output GPIO pin or to a timer dedicated pin for DSP56F803 805 EVM For DSP56F803 the line that defines channel 0 of timer module C will be excluded from appconfig h One interrupt priority level will be additionally defined in the appconfig h file Because input current waveform
16. ule Hardware User s Manual e U2 3ph AC BLDC High Voltage Power Stage supplied in kit with Optoisolation Board as ECOPTHIVACBLDC described in MEMC3BLDCPSUMID 3 Phase Brushless DC High Voltage Power Stage e U3 Optoisolation Board supplied with 3 ph AC BLDC High Voltage Power Stage as ECOPTHIVACBLDC or supplied alone as ECOPT optoisolation board described in MEMCOBUM D Optoisolation Board User s Manual Warning It is strongly recommended to use optoisolation optocouplers and optoisolation amplifiers during the development time to avoid any damage to the development equipment e MBI Motor Brake AM40V SG40N supplied as ECMTRHIVAC Notes Information on all above mentioned boards and documents can be found on http mot sps com motor devtools index html MOTOROLA Indirect Power Factor Correction 5 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware Implementation 12VDC GND U3 40w flat ribbon cable gray 3ph AC BLDC High Voltage Power Stage Controller Optoisolation 40w flat ribbon cable gray ECMTRHIVAC Hall sensor encoder 00126A Incremental encoder Baumer Electric BHK 16 05A 1024 12 5 Not used in application Not used in application Figure 4 1 High Voltage HW System Configuration All the system parts are supplied and documented according the followi
17. ventional single phase full bridge rectifier and filter stages As is well known this type of circuit draws high current levels from the power line and produces a high level of harmonics This harmonic distortion and low power factor PF reduce the maximum power available from the power lines and reduce the efficiency of the electrical supply networks The European Normative EN 61000 3 2 defines the limits of the harmonic content of the input current for the power line supplied equipment To meet these requirements new designs require the use of an active power factor correction PFC at the input The PFC emulates the ideal ohmic load by electronically controlling input current drawn from the line Cc 2 6b pe p je a O 49 LL a 0 z O ai S 6b O There are many specific ICs available on the market to do the PFC task Those approach require additional electronic components increasing the system cost and complexity On the other hand there is a way to implement PFC control Motorola Inc 2001 Meat For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Motorola DSP Advantage and Features through the DSP in addition to the main control tasks like motor control etc The use of a digital PFC replaces a number of ICs and reduces the system cost Another benefit of the software implementation is easy modification wit
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