UM2979 User manual How to use the STDES-PFCBIDIR reference design Introduction STDES-PFCBIDIR reference design represents a complete solution for high-power, three-phase active front end (AFE) rectifier applications based on the three-level T-Type topology. This reference design topology is mostly used for DC fast charging applications related to industrial and electric vehicles.
UM2979 Figure 2. STDES-PFCBIDIR reference design - power board Fully assembled board developed for performance evaluation only, not available for sale Figure 3. STDES-PFCBIDIR reference design - control board Fully assembled board developed for performance evaluation only, not available for sale The high switching frequency 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.
During operation, do not touch the board as some of its components could reach a very high temperature. Block diagram Figure 4. STDES-PFCBIDIR block diagram Features • 3-phase, 3-level bidirectional AC-DC power converter: –...
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-PFCBIDIR reference design. UM2979 - Rev 1 page 4/70...
UM2979 Reference design description 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 - Rev 1 page 5/70...
UM2979 Reference design description 1.5.2 Power stage 1.5.2.1 Boost inductor Boost inductors are part of the LCL-R AC side filter. They allow obtaining the converter PFC operation by controlling the inductor current using a proper conduction pattern in the power device section. Continuous conduction mode (CCM) performs the PFC operation of this reference design.
UM2979 Reference design description Figure 9. STDES-PFCBIDIR NTC specifications Figure 10. Active relays 1.5.2.3 Sensing 1.5.2.3.1 AC current An isolated sensor measures the AC input current. It represents the boost inductor current to be controlled for the proper operation of the PFC behavior of the power converter.
UM2979 Reference design description Figure 11. 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 that allows measuring 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.
UM2979 Reference design description 1.5.2.3.3 DC current An isolated sensor measures the DC output current. Hall sensors are taken into consideration. A conditioning circuit allows obtaining the correct value for the ADCs. Figure 13. DC current sensing block diagram 1.5.2.3.4 DC voltage The DC voltages are obtained using two-stage sensing.
1.5.3 Control board 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 board. UM2979 - Rev 1 page 10/70...
UM2979 Power factor correction (PFC) benefits Power factor correction (PFC) benefits The figure below highlights the PFC benefits in terms of rest factor and power factor. Figure 18. 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.
UM2979 How to use the STDES-PFCBIDIR reference design How to use the STDES-PFCBIDIR reference design System setup To use the STDES-PFCBIDIR, you need: • a programmable AC emulator or a programmable AC source; • a DC electronic load; • a power analyzer;...
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 main.c file in the project/Application/User path. UM2979 - Rev 1...
Click on the [Run] button to start the code execution. Figure 24. IAR EWARM debug procedure Board configuration STDES-PFCBIDIR is a customizable reference design. You 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 for the power supply.
Open Open 2.4.3 Relay section 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 converter, we considered four relays. Three of them are for the three-line connection and one is for the neutral.
UM2979 Preliminary test procedure Figure 27. Example of relay configuration Preliminary 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 UM2979 - Rev 1 page 17/70...
UM2979 Preliminary test procedure Figure 29. AC voltage sensing test procedure Figure 30. AC grid voltage sensing test procedure UM2979 - Rev 1 page 18/70...
UM2979 Preliminary test procedure Figure 31. AC grid current sensing test procedure 2.5.2 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 - Rev 1 page 19/70...
DC voltage sensing test procedure (2 of 2) 2.5.3 AC connection Connect the STDES-PFCBIDIR AC main 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...
Figure 35. DC side load connection 2.5.5 Relay section STDES-PFCBIDIR reference design uses two groups of relays to manage the AC side connection and ICL. Step 1. To verify the functionality, configure the power board as shown below. Figure 36.
UM2979 Startup procedure Figure 37. Typical startup procedure 2.6.1 Controlled startup procedure The AC power supply is slowly increased to verify the procedure step-by-step as shown below. Figure 38. Connection and power-on procedure BLED “WAIT” START BLED Enable | Increase AC source Start “START”...
UM2979 Startup procedure Figure 39. STDES-PFCBIDIR relays The procedure consists of the following steps. FSM Wait: PWM signals are in IDLE state, configured in low state, to force all the MOSFETs in off state. The AC main voltage is already under monitoring. This state is maintained until AC main reaches a lower AC voltage threshold (OK_Plug_ACSource), that is 30 V .
UM2979 Startup procedure FSM Idle: after TO_IDLE time elapses, wait for the AC mains to reach the uvAC value (OK_SOURCE). After checking the load current, a new timeout is set (TO_INIT) to prevent PLL instability. FSM moves to FSM_Init. All relays are maintained in the off state. Figure 41.
UM2979 Startup procedure 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 voltage and increasing the DC output voltage at a reference voltage. The state machine then moves to FSM_Run state. Figure 43.
UM2979 Control Control The voltage-oriented control allows controlling the PFC behavior of the converter in the dq-axis synchronous reference frame. Table 6. Control strategy comparison Reference frame Pros Cons • Poor in transient • Simple implementation with PI • Phase shifting (lag) •...
UM2979 Control strategy Figure 46. Continuous conduction mode in current control Figure 47. Current decoupling control of the reference design converter model UM2979 - Rev 1 page 27/70...
UM2979 Control strategy Figure 48. 3.1.2 Voltage 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 - Rev 1 page 28/70...
UM2979 Phase locked loop Figure 50. Voltage control diagram 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 51. PLL internal regulator loop Figure 52.
UM2979 Software implementation Software implementation STM32G474RET3 MCU controls the STDES-PFCBIDIR. The firmware package is based on the STM32Cube ecosystem. Starting from the STM32CubeMX, all the peripherals and pins used are activated and configured according to the basic project. The application firmware is supported and tested using STM32CubeIDE, IAR, and Keil development environments.
STM32CubeProgrammer. At the end of this operation, the DPC application is tested and debugged through STM32CubeMonitor. The digital power converter firmware is then released, if compliant, and the DPC is adapted. STDES-PFCBIDIR reference design power converter allows managing the two-direction energy flow. The figure below shows the algorithm schematic diagram of the implementation in the AC-DC rectifier application and DC-AC inverter application.
STDES-PFCBIDIR power converter configuration is based on two main 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 reference value, etc.). “DPC_Lib_conf.h” contains the configuration parameters linked to the MCU peripherals configuration.
UM2979 Measurements Measurements PFC operation The figure below shows a steady state condition 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.
UM2979 Efficiency Efficiency Figure 62. Efficiency The figure below shows the current THD measurements. Test conditions are V = 230 Vrms, V = 800 V. According to the specification, THD is lower than 5% starting from 10% of the full load. Figure 63.
Con2 CENTRO_BUS Con3_32A TP51 1-1393210-4 TestPoint_Ring Neutral COIL_RELAY_GRID_N STPS1L30A VDD_12V Figure 75. STDES-PFCBIDIR schematic diagram - power board: active inrush current and AC grid connection management VDD_12V VDD_12V VDD_12V R354 R355 R356 LED RED VDD_12V LED RED LED RED VDD_12V...
UM2979 Bill of materials Bill of materials Table 7. STDES-PFCBIDIR bill of materials Item Q.ty Ref. Part/value Description Manufacturer Order code Table 8. STDES-PFCBIDIR control Control board ST Not available for separate sale board Table 9. STDES-PFCBIDIR power Power board...
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UM2979 Bill of materials Item Q.ty Ref. Value Description Manufacturer Order code D3,D1 Uni-directional SMAJ5.0A-TR, SMA, 400 W SMAJ5.0A-TR TVS Diode, RED, SMD 0805, 2.4 V Red LED Wurth 150080RS75000 F1,F2, F3,F4, 22 Ohm@100 MHz, 6 A Ferrite beads Wurth 742792021 Solder jumper JP1,JP...
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UM2979 Bill of materials Item Q.ty Ref. Value Description Manufacturer Order code R17,R 39,R45 ,R46,R Thick film SMD 50,R51 1 k, 603, 0.1 W, ±1% resistors ,R53,R 56,R13 1,R133 R23,R 30,R35 ,R126, Thick film SMD 0, 603, 0.1 W, ±1% R127, resistors R134,...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code JP2, JP3, JP4, JP6, JP18, JP20, JP21, JP24, JP43, Solder jumper JP44, JP51, 3JP_pcb selector (not JP52, JP72, mounted) JP75, JP76, JP82 N.M (NOT Assembly) Fixed Terminal Phoenix Con2 Blocks GMKDS...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code DIN 41612 Connectors 64P Digital Power 2.54MM VERT FML ERNI 284166 32X2 Connector TYPE B 4MM SLDR Phoenix Contact MKDS 5/3-9.5, 3 Phoenix J3, J4 Con3_32A 1714984 Way PCB Terminal Contact...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code Q5, Q6, Q7, Silicon Carbide Q8, Q9, Q10, 650V, 45A HIP247 (not SCTW35N65G2V N.M (NOT mounted) Assembly) Q14, Q15, Q16, Q17, Q18, Q19, NPN Transistor, 3- 60V, 3A 2STF1360 Q20, Q21, Q22,...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code R221, R232, R235, R236, R237, R238, R240, R255, R256, R266, R270, R271, R275, R276, R278, R281, R286, R288, R289 N.M (NOT Assembly) R2, R5, R6, R7, R10, R13, R14, R15, R18, R21, R22, R23,...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code (not mounted), N.M. 0603 8.06k, 0.1W, Thin Film SMD R46, R68, R90 ±0.1% Resistor, 0603 (not mounted), R67, R89 N.M. 0603 470Ω, 0.1W, Thick Film SMD ±1% Resistor, 0603 Thick Film SMD...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code R128, R133, Thick Film SMD 0, ±1% R142, R146 Resistor, 0603 R129, R134, 10.5k, 0.063W, Thin Film SMD R143, R147 ±0.1% Resistor, 0603 R130, R135, 1.6k, 0.063W, Metal Film SMD R141, R148 ±0.1%...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code 750Ω, 0.25W, Thick Film SMD R345, R346 ±1% Resistor, 1206 51k, 0.25W, Thin Film SMD R347, R348 ±0.1% Resistor, 1206 10Ω, 0.1W, Thin Film SMD R349 ±0.1% Resistor, 0603 27k, 0.1W,...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code TP82, TP83, TP84, TP85, TP86, TP87, TP88, TP89, TP90, TP91, TP92, TP93, TP94, TP95, TP96, TP97, TP98, TP99, TP100, TP101, TP102, TP103, TP104, TP105, TP106, TP107, TP108, TP109, TP110, TP111, TP112, TP113,...
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UM2979 Bill of materials Item Q.ty Ref. Part / Value Description Manufacturer Order code U6, U9, U12, IC OPAMP Texas U17, U18, U20, ISOLATION 1 CIRC AMC1301DWVR Instruments U36, U38, U40 8SOIC, SOIC-8 1-Channel DC-DC Power Supply Texas U13, U22 Module 4-Pin, DCH010505SN7 Instruments...
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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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