ST UM2975 User Manual
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ST UM2975 User Manual

ST UM2975 User Manual

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UM2975
User manual
How to use the 15 kW three-level three-phase Vienna rectifier with digital control
for power factor correction
Introduction
The
STDES-VRECTFD
reference design represents a complete solution for high-power, three-phase active front end (AFE)
rectifier applications based on the three-level Vienna topology.
This reference design topology is mostly used for DC fast charging applications related to industrial and electric vehicles.
It features full digital control. The embedded
STM32G474RET3
mixed-signal high-performance 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 conduction mode (CCM) current regulation allows the maximum power quality in terms of total
harmonic distortion (THD) and power factor (PF).
Figure 1.
DC charging station
UM2975 - Rev 1 - January 2022
www.st.com
For further information contact your local STMicroelectronics sales office.

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  • Page 1: Figure 1. Dc Charging Station

    The high-bandwidth continuous conduction mode (CCM) current regulation allows the maximum power quality in terms of total harmonic distortion (THD) and power factor (PF). Figure 1. DC charging station UM2975 - Rev 1 - January 2022 www.st.com For further information contact your local STMicroelectronics sales office.

  • Page 2: Figure 2. Stdes-Vrectfd Reference Design - Power Board

    The high efficiency rectifier is designed for several end applications such as electric vehicle (EV), industrial battery chargers, and industrial equipment, which requires a very high PF and low THD. STDES-VRECTFD is a fully assembled kit developed for performance evaluation only, not available for sale. UM2975 - Rev 1 page 2/63...

  • Page 3: Getting Started

    Nominal rate for AC voltage: 400 V at 50 Hz – Maximum power: 15 kW – Power factor: >0.99 – Inrush current control and soft start-up – THD lower than 5% at nominal operation UM2975 - Rev 1 page 3/63...

  • Page 4: Main Characteristics

    Min. Typ. Max. Unit HVDC overvoltage protection DCovp HVCAP overvoltage protection CAPovp AC overcurrent protection ACovp Reference design description 1.5.1 Power board The figure below shows the power board of the STDES-VRECTFD reference design. UM2975 - Rev 1 page 4/63...

  • Page 5: Power Stage

    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 - Rev 1 page 5/63...

  • Page 6: Table 3. Boost Inductor Parameters

    Unit DC voltage Switching frequency Rated AC voltage Δ Max. ripple current iLppmax Boost inductance 470-6 1.5.2.2 Passive current limiter NTC Figure 7. Three and four-wire connections Figure 8. Focus on the STDES-VRECTFD NTC UM2975 - Rev 1 page 6/63...

  • Page 7: Figure 9. Stdes-Vrectfd Ntc Specifications

    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 measuring an AC voltage referenced by a virtual or grid neutral point. The circuit is replicated for each phase. UM2975 - Rev 1 page 7/63...

  • Page 8: Figure 11. Ac Voltage Sensing Block Diagram

    The DC voltages are obtained using two-stage sensing. The total DC bus voltage is split exploiting two voltage dividers. Both voltages are needed to obtain the monitoring of each capacitor to avoid overvoltage, offering independent DC voltages for the control. UM2975 - Rev 1 page 8/63...

  • Page 9: Control Board

    1.5.3 Control board 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 board. UM2975 - Rev 1 page 9/63...

  • Page 10: Figure 15. Stdes-Vrectfd Control Board Sections

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

  • Page 11: Power Factor Correction (Pfc) Benefits

    Figure 17. PFC benefits Converter operation The figure below shows the current paths of the Vienna topology. To simplify the scheme, we considered the single phase representation. Figure 18. Switching paths of the Vienna topology UM2975 - Rev 1 page 11/63...

  • Page 12: How To Use The Stdes-Vrectfd Reference Design

    To operate the reference design power converter properly, consider the operating limits shown below. Table 4. Operation condition limits Description Value Unit Three-phase input voltage range 208-400 Line frequency range 47-63 Maximum output power at 230 V Voltage limit of the bulk capacitors UM2975 - Rev 1 page 12/63...

  • Page 13: Mcu Programming And Debugging

    Step 2. Connect an external fan to manage the thermal dissipation. The auxiliary power supply can be externally provided. MCU programming and debugging You can program and debug the microcontroller unit (MCU) through different tools. UM2975 - Rev 1 page 13/63...

  • Page 14: Figure 20. St-Link/V2 And Adapter

    20- to 10-pin JTAG adapter 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 - Rev 1...

  • Page 15: 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 figure below, you can select either an internal or external supply voltage. Specific LEDs allow identifying the selected configuration. UM2975 - Rev 1 page 15/63...

  • Page 16: Driver Section

    Figure 25. Example of driver configuration Preliminary test procedure 2.4.1 AC sensing To verify the proper operation of the AC sensing (Figure 26), analyze the test points for voltages (Figure 27) and currents (Figure 28). UM2975 - Rev 1 page 16/63...

  • Page 17: Figure 26. Ac Sensing Section

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

  • Page 18: Dc Sensing

    AC grid current sensing test procedure 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 - Rev 1 page 18/63...

  • Page 19: Ac Connection

    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 output DC connection. Ensure to apply the correct polarity. UM2975 - Rev 1 page 19/63...

  • Page 20: Startup Procedure

    However, a controlled step-by-step procedure is available. It is useful during the preliminary test or after hardware/sw modification. Figure 33. Startup procedure 2.5.1 Controlled startup procedure The AC power supply is slowly increased to verify the procedure step step-by-step as shown below. UM2975 - Rev 1 page 20/63...

  • Page 21: Figure 34. Connection And Power-On Procedure

    1. Turn Off (AC) BLED “INIT” Error START 2. Turn Off (PS) Error/Fault 3. Disconnect Load This procedure takes the ICL NTCs into consideration. Figure 35. STDES- VRECTFD ICL NTCs The procedure consists of the following steps. UM2975 - Rev 1 page 21/63...

  • Page 22: Figure 36. Fsm_Wait Block Diagram

    After checking the load current, a new timeout is set (TO_INIT) to prevent PLL instability. FSM moves to FSM_Init. Figure 37. FSM_Idle block diagram TO_IDLE DPC_VAC_PK_UV DPC_NO_LOAD_CURR +- DPC_NO_LOAD_DELTA_CURR % Overcome Expired Not Overcome Init ack DPC_TO_Check Status_Source Status_Load Idle ack IDLE INIT TO_OUT_TOOK OK_SOURCE NO_LOAD STOP UM2975 - Rev 1 page 22/63...

  • Page 23: Figure 38. Fsm_Init Block Diagram

    Figure 40. FSM_Run block diagram True False - Run ack Status_Source==OK_SOURCE && DPC_FLT_Faulterror_Check() Status_Load PLL_Status==PLL_SYNC True False BURST Error Error STOP UM2975 - Rev 1 page 23/63...

  • Page 24: Direct Startup Procedure

    The finite state machine 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 connection. UM2975 - Rev 1 page 24/63...

  • Page 25: Control

    Cascaded control Voltage Controller Controller ωL Space αβ Vector αβ Outer Loop MODULATOR ωL Controller ‘’Decoupling’’ Inner Loop θ Vabc 3-Phases 3.1.1 Current control strategy A continuous conduction mode controls the reference design current. UM2975 - Rev 1 page 25/63...

  • Page 26: Figure 42. Continuous Conduction Mode In Current Control

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

  • Page 27: Voltage Control Strategy

    Figure 44. 3.1.2 Voltage 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 - Rev 1 page 27/63...

  • Page 28: Phase Locked Loop

    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 voltage UM2975 - Rev 1 page 28/63...

  • Page 29: Software Implementation

    MCU peripheral and the DPC application configuration. On the basis of this information, an STM32CubeMX project, properly configured and initialized, is provided. Then, the needed DPC module is included and configured. UM2975 - Rev 1 page 29/63...

  • Page 30: Configuration Files

    This allows managing the energy flow in terms of AC current. Figure 52. Simplified execution task of the control in AC-DC Configuration files STDES-VRECTFD power converter configuration is based on two main configuration files. UM2975 - Rev 1 page 30/63...

  • Page 31: Figure 53. Stdes-Vrectfd Configuration Files

    The “DPC_application_conf” header file contains 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 to the MCU peripheral configuration. UM2975 - Rev 1 page 31/63...

  • Page 32: Measurements

    UM2975 Measurements Measurements Startup procedure Figure 54. Startup procedure PFC operation Figure 55. PFC operation UM2975 - Rev 1 page 32/63...

  • Page 33: Step Load

    10.94 11.186 11.1719 97.99 0.998 2.42 17.76 14.96 12.27 12.26 97.86 0.999 2.31 19.29 16.2 13.30 13.29 97.74 0.999 1.99 20.74 17.39 14.31 14.29 97.59 0.999 2.01 22.26 18.66 15.357 15.345 97.49 0.999 2.01 UM2975 - Rev 1 page 33/63...

  • Page 34: Figure 57. Stdes-Vrectfd Power Factor Plot

    STDES-VRECTFD efficiency plot 98.5 97.5 9 10 11 12 13 14 15 Power [kW] Figure 59. STDES-VRECTFD THDi plot 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Power [kW] UM2975 - Rev 1 page 34/63...

  • Page 35: Schematic Diagrams

    Schematic diagrams Figure 60. STDES-VRECTFD circuit schematic - power board (1 of 11) JP60 CENTRO_BUS Jp_pcb R261 51k 0.1% C230 TRANSFORMER FLAT COMPACT 3,3nF/200V VDD_12V_INT R262 51k 0.1% STPS2H100A C232 C231 + C233 + C234 560uF 16V STTH1L06A BUS_N VDD_7V_INT C235 C236 STPS2L60A...

  • Page 36: Figure 61. Stdes-Vrectfd Circuit Schematic - Power Board (2 Of 11)

    Figure 61. STDES-VRECTFD circuit schematic - power board (2 of 11) Dev3 VDD_5V VDD_7V_INT VDD_3.3V LD29080S33R VDD_7V VOUT VDD_5V VOUT 30Ohm@100MHz C218 30Ohm@100MHz VDD_7V_EXT Rled1 C219 JP55 Rled2 C221 C220 Rled3 470nF/50V 10uF/50V LD29080DT50R 470nF/50V 10uF/50V C222 C223 Rled4 Con2 LED RED 470nF/50V 10uF/50V...

  • Page 37: Figure 62. Stdes-Vrectfd Circuit Schematic - Power Board (3 Of 11)

    Figure 62. STDES-VRECTFD circuit schematic - power board (3 of 11) TP90 TestPoint_Ring BUS_P STPSC20H12WL STPSC20H12WL STPSC20H12WL R252 TestPoint_Ring TestPoint_Ring 240k C207 TP91 TP92 GND_ISO_Q1 100nF 630V SCTW35N65G2V SCTW35N65G2V R253 + C208 + C209 V_line_A 240k 470uF 500V L_PFC 506uH 470uF 500V C210 100nF 630V...

  • Page 38: Figure 63. Stdes-Vrectfd Circuit Schematic - Power Board (4 Of 11)

    Figure 63. STDES-VRECTFD circuit schematic - power board (4 of 11) JP14 JP13 TP61 TP60 Jp_pcb Tes tPoint_Ring Jp_pcb Tes tPoint_Ring VH_Q1_R VH_Q1_L 2STF1360 2STF1360 R181 30Ohm @100MHz VDD_DRIVER R180 30Ohm @100MHz VDD_DRIVER C123 C127 C245 C125 C243 C124 1uF/25V 100nF/16V C128 100nF/16V...

  • Page 39: Figure 65. Stdes-Vrectfd Circuit Schematic - Power Board (6 Of 11)

    Figure 65. STDES-VRECTFD circuit schematic - power board (6 of 11) BUS_P 5V_MEAS_DC VDD_5V VDD_5V TP49 R142 TestPoint_Ring TP50 30Ohm@100MHz 30Ohm@100MHz TestPoint_Ring 30Ohm@100MHz R143 GND_MEAS_DC 1uF/25V 100nF/16V 4.7u/25V 100nF/16V TP51 1uF/25V 100nF/16V R144 R145 16.9k TestPoint_Ring GND_MEAS_DC VDD1 VDD2 U14A R147 R146 VINP...

  • Page 40: Figure 66. Stdes-Vrectfd Circuit Schematic - Power Board (7 Of 11)

    Figure 66. STDES-VRECTFD circuit schematic - power board (7 of 11) VDD_5V VDD_5V 30Ohm@100MHz TestPoint_Ring 30Ohm@100MHz LEM4 1uF/25V 100nF/16V TP44 R127 TP45 LTSR 15-NP R128 N.M. TestPoint_Ring U13A U13B R130 R131 U13C R129 R132 1uF/25V 100nF/16V R133 9.1k TSV914IDT Oout R134 TSV914IDT R135...

  • Page 41: Figure 67. Stdes-Vrectfd Circuit Schematic - Power Board (8 Of 11)

    Figure 67. STDES-VRECTFD circuit schematic - power board (8 of 11) +3.3V VDD_3.3V VDD_5V +3.3V_iso VDD_12V NULL_1 USART_TX USART_RX NULL_1 NULL_2 GND_iso NULL_2 VDD_7V CAN_TX CAN_RX SMBus_SCL SMBus_SMBA SMBus_SDA PWM_INP_Q1_AS PWM_1 +3.3V PWM_INP_Q2_AS PWM_5 FAULT_1 GPIO_1/COMP_3_OUT/GP_PWM_1/EEV_4 PWM_INP_Q3_AS PWM_9 PWM_1 PWM_2 PWM_3 PWM_4 PWM_INP_Q1_DS...

  • Page 42: Figure 69. Stdes-Vrectfd Circuit Schematic - Power Board (10 Of 11)

    Figure 69. STDES-VRECTFD circuit schematic - power board (10 of 11) VDD_5V TP22 30Ohm@100MHz TestPoint_Ring TP23 VDD_5V TestPoint_Ring 100nF/16V 1uF/25V TP24 27k 0,1% TestPoint_Ring V_line_A VDD_BIAS_A ZVD_A TSV912IDT 36k 0.1% VDD_5V 69.8k 0.1% TP25 TSV912IDT N.M. 5V_MEAS_AC TSV914IDT TestPoint_Ring 13.3k 0.1% N.M.

  • Page 43: Figure 70. Stdes-Vrectfd Circuit Schematic - Power Board (11 Of 11)

    Figure 70. STDES-VRECTFD circuit schematic - power board (11 of 11) VDD_5V TestPoint_Ring R1 7.5k VDD_5V VDD_5V VDD_A2.5V TestPoint_Ring TSV914IDT 7.5k 30Ohm@100MHz N.M. 100nF/16V 30Ohm@100MHz 1uF/25V VDD_5V VDD_A2.5V LEM1 1uF/25V TestPoint_Ring 100nF/16V TestPoint_Ring LTSR 15-NP 100nF/16V TestPoint_Ring N.M. 30Ohm@100MHz TestPoint_Ring 1uF/25V 100nF/16V TSV914IDT...

  • Page 44: Figure 71. Stdes-Vrectfd Circuit Schematic - Control Board

    Figure 71. STDES-VRECTFD circuit schematic - control board TP25 TestPoint VDD_3.3V IA+_uC OinA_LEM R210k 100nF/16V VDD = 1.71 V to 3.6 V pag6 AN5093 VlineA.S_uC VlineA.S te_fsm4jsma AGND R12810k C137 VDD_3.3V_INT IB+_uC 100nF/16V USR_BTN OinB_LEM 3JP_pcb AGND TestPoint R410k TestPoint TestPoint TestPoint 100nF/16V...

  • Page 45: Bill Of Materials

    C81, C83, C85, C88, C90, C91, C96, C98, C99, C104, C105, C125, C127, C152, C160, C180, C186 Multilayer 1 µF, SMD 0603 ceramic Wurth (1608), 440 885012206076 capacitor (not Elektronik , ±20 % mounted) UM2975 - Rev 1 page 45/63...
  • Page 46 0603 (1608), ceramic 885012206079 Elektronik C187, C192 500 V, ±20 % capacitors C146, C147, C171, C177, 470 nF, SMD Multilayer C199, C205, 0805(2012), 1K ceramic C219, C220, , ±10 % capacitors C223, C225, C226, C228 UM2975 - Rev 1 page 46/63...
  • Page 47 D55, D56, D57, 20 A Inc. D58, D59, D60, D66, D67 D7, D8, D12, TZMB20-GS08, Vishay D14, D21, D23, DO-213AC, Zener diodes Semiconductor TZMB20-GS08 D24, D29, D35, MINI-MELF, Diodes Division D37, D38, D43 SOD-80, 100 V UM2975 - Rev 1 page 47/63...
  • Page 48 Connector ERNI 284166 32X2 connector Male DIN 41612 Adapter digital P2 X 2 through hole 90 power ERNI 384241 degree connector Con3_32A, 3P Fixed terminal Phoenix J3, J10 9.52 mm 1714984 blocks Contact 90DEG UM2975 - Rev 1 page 48/63...
  • Page 49 LEM3, LEM4 0.126" Diam., 6 sensors leads Sullins CON40A, 2X20, 2XP3 Connector Connector PPPC202LJBN-RC pitch 2.54 mm Solution PROBE1, PROBE2, PROBE3, PROBE4, PROBE5, PROBE6, Jumpers (not PROBE8, Current_ProbE mounted) PROBE9, PROBE10, PROBE11, PROBE12, PROBE13, PROBE14 UM2975 - Rev 1 page 49/63...
  • Page 50 R23, R25, R31, R34, R40, R41, R43, R49, R52, 10 k, SMD R74, R96, 0603(1608), Resistors R118, R125, ±0.1 % R127, R129, R134, R137, R151, R18, R36, R54, R67, R89, R111 R15, R33, R51 Resistors UM2975 - Rev 1 page 50/63...
  • Page 51 33 k, SMD 0603 R126 Resistors (1608), ± 0.1 % 24 k, SMD 0603 R130, R136 Resistors (1608), ±0.1 % 9.1 k, SMD R132, R138 Resistors 0603(1608) 30 k, SMD R135 N.M. Resistors 0603(1608), %, UM2975 - Rev 1 page 51/63...
  • Page 52 240 k, SMD R254, R255, Resistors 1206 (3216) R256, R257 750, SMD 0805 R258, R259 Resistors (2012) 750, SMD 1206 R260 Resistor (3216) 51k, SMD 1206 R261, R262 Resistors (3216) 10, SMD R263 Resistor 0603(1608), %, UM2975 - Rev 1 page 52/63...
  • Page 53 TP70, TP71, TP72, TP73, TP74, TP75, TP76, TP77, TP78, TP79, TP80, TP81, TP82, TP83, TP84, TP85, TP86, TP87, TP88, TP89, TP90, TP91, TP92, TP93, TP94, TP95, TP96, TP97, TP98, TP99, TP100, TP101, TP102, TP103, TP104 UM2975 - Rev 1 page 53/63...
  • Page 54 482-8515 M3X6mm TW6, TW7, Brass Hex TW8, TW9, M3X40, Brass Standoff Male/ Wurth TW10, TW11, 971100354 Hex Standoff Female, 40mm, Elektronik TW12, TW13, M3 x M3 TW14, TW15 Hex Nut, M3 Hex nut 483-0502 UM2975 - Rev 1 page 54/63...

  • Page 55: Table 9. Control Board Bill Of Materials

    CONNECTOR, CON4 strip4_100m_v LED1 OSRAM LSG T676 WE-CBF FERRITE, 603 74279262 64 male Connector ERNI 533406 R2, R4, R5, R8, R10, R13, R16, R19, R23, R30, RESISTOR, 603 R35, R44, R125, R128, R129, R130 UM2975 - Rev 1 page 55/63...
  • Page 56 Mainstream Arm Cortex-M4 MCU 170 MHz with STM32G474RE 512 Kbytes of STM32G474RET3 T3, LQFP64 Flash memory, Math Accelerator, HR Timer, High Analog level integration ESDA6V1L, Dual Transil array ESDA6V1L SOT23-3L for ESD protection UM2975 - Rev 1 page 56/63...

  • Page 57: Revision History

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

  • Page 58: Table Of Contents

    PFC operation ..............32 UM2975 - Rev 1...
  • Page 59 List of figures................61 UM2975 - Rev 1...

  • Page 60: List Of Tables

    Document revision history ............. 57 UM2975 - Rev 1...

  • Page 61: List Of Figures

    ST-LINK/V2 connected to the control board ........
  • Page 62 STDES-VRECTFD circuit schematic - control board ......... 44 UM2975 - Rev 1...
  • Page 63 ST’s terms and conditions of sale in place at the time of order acknowledgement. Purchasers are solely responsible for the choice, selection, and use of ST products and ST assumes no liability for application assistance or the design of Purchasers’...

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