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Semiconductor Application Note
Order AN1918/D (Motorola Order Number) Rev. 6/01
Freescale Semiconductor, Inc.
Indirect Power Factor Correction 3-Phase Motor Control with V/Hz Speed Open Loop Application Using DSP56F80x
Design Indirect Power Factor Correction
Contents
Introduction Application Benefit Motorola Advantages Features System Design Concepts. Hardware Implementation
System Outline High Voltage Hardware Set.
Software Implementation
Files Drivers Library Function Appconfig.h File Control Integration 5.4.1 Resources 5.4.2 Modification 5.4.3 Initialization 5.4.4 Control Enable 5.4.5 Control Disable Input Current Harmonics Contents.
Introduction Application Benefit
This Application Note describes design Indirect Power Factor Correction (Indirect PFC) 3-phase Motor V/Hz Speed Open Loop application. based Motorola's 56F80X digital signal processor (DSP) which dedicated motor control applications. Most practical electronic power supplies consist conventional single-phase full-bridge rectifier filter stages. well-known, this type circuit draws high current levels from power line produces high level harmonics. This harmonic distortion power factor (PF) reduce maximum power available from power lines reduce efficiency electrical supply networks. European Normative 61000-3-2 defines limits harmonic content input current power line supplied equipment. meet these requirements, designs require active power factor correction (PFC) input. emulates ideal ohmic load electronically controlling input current drawn from line. There many specific available market task. Those approach require additional electronic components, increasing system cost complexity. other hand, there implement control
Master Memory Usage
Motorola, Inc., 2001
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Indirect Power Factor Correction
References
Motorola Advantage Features
through addition main control tasks like motor control, etc. digital replaces number reduces system cost. Another benefit software implementation easy modification without changing hardware.
Motorola Advantage Features
members Motorola DSP56F80x family well suited digital motor control, combining DSP's calculation capability with MCU's controller features 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 RAM. typical member family, DSP56F805, provides following peripheral blocks:
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Pulse Width Modulator modules (PWMA PWMB), each with outputs, three Current Status inputs, four Fault inputs, fault tolerant design with deadtime insertion, supports both Center- Edge- aligned modes Twelve-bit Analog Digital Convertors (ADCs), supporting simultaneous conversions with dual 4-pin multiplexed inputs; synchronized modules Quadrature Decoders (Quad Dec0 Quad Dec1), each with four inputs, additional Quad Timers dedicated General Purpose Quad Timers totalling pins: Timer with pins Timer with pins Module with 2-pin ports used transmit receive Serial Communication Interfaces (SCI0 SCI1), each with pins, four additional GPIO lines Serial Peripheral Interface (SPI), with configurable 4-pin port, four additional GPIO lines Computer Operating Properly (COP) timer dedicated external interrupt pins Fourteen dedicated General Purpose (GPIO) pins, multiplexed GPIO pins External reset hardware reset JTAG/On-Chip Emulation (OnCE) Software-programmable, Phase Lock Loop-based frequency synthesizer core clock Memory configuration 32252 16-bit words Program Flash 16-bit words Program 16-bit words Data 16-bit words Data Flash 16-bit words Boot Flash
Other than fast Analog-to-Digital converter 16-bit Quadrature Timers, most interesting peripheral from motor control point view Pulse Width Modulation (PWM) module. configuration permits efficient control motors.
Indirect Power Factor Correction
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System Design Concepts
following features: Three complementary signal pairs, independent signals Complementary channel operation Deadtime insertion Separate bottom pulse width correction current status inputs software Separate bottom polarity control Edge-aligned center-aligned signals 15-bits resolution Half-cycle reload capability Integral reload rates from Individual software-controlled output Programmable fault protection Polarity control 20-mA current sink capability pins Write-protectable registers
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Motor control utilizes block complementary mode, which configures output pair complimentary channels.
System Design Concepts
Motor Control Targeted DSP56F803/805EVM platforms Running 3-phase AC/BLDC Motor Control Development Platform single line voltage 360V Control technique incorporates V/Hz speed open loop bi-directional rotation motoring regenerating mode Overvoltage, Undervoltage, Overcurrent, Temperature Fault protection Master Manual Interface Power Stage Identification Control Input power supply voltage 115-230V Input power supply frequency 50/60 Nominal output voltage 360V 10%. Nominal output power 180W Input current harmonic content will comply with standard 1000-3-2
system basic characteristics both Digital Power Factor Correction 3-phase motor V/Hz Open Loop applications described below:
Indirect Power Factor Correction
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System Design Concepts
system designed integrate control with real motor control application. base 3-phase Motor V/Hz Speed Open Loop application. runs main control algorithm. generates 3-phase output signal motor according user's input. also controls power factor correction hardware that provides power supply motor.
DC-Bus
~115-230V 50/60Hz
3-ph
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pulse wide modulator
Temperature, Current Voltage sensors
Zero crossing detection
Pulse wide modulation
Inhibit output
Temperature, voltage fault processing
Input frequency measurement. Milestone generation. Base frequency Reference voltage calculation
Generator with Dead Time DC-Bus Ripple Cancel
Speed set-up
Speed Command Processing
Regulator V/Hz Speed Processing
DSP56F80X
Figure 3-1. System Concept system integrates independent parts that keep their features. First 3-phase motor drive with V/Hz Speed Open Loop algorithm; second Power Factor Correction (PFC) algorithm (see Figure 3-1). runs main control algorithm. According user interface input feedback signals, generates 3-phase output signals motor inverter. provides power Motor inverter. main advantage power factor correction system reduction electrical noise. This will possible input current waveform sine-like. hardware does directly control inverter switch. modifies reference voltage only, which makes possible simple 3-point sine approximation input current waveform. enough comply with standard simplifies control software complexity. second feature stable output voltage. circit boost voltage converter, output voltage cannot less than rectified input voltage.
Indirect Power Factor Correction
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Hardware Implementation
Hardware Implementation
System Outline
hardware designed drive 3-phase AC/BLDC motor. This application notes describes uses with -phase motor. application Motorola motor control DSPs using Board: DSP56F803 DSP56F805
designed software capable only High Voltage Hardware described below. setup shown Figure 4-1, described also documents Targeting_DSP56803_Platform, Targeting_DSP56805_Platform according targeted DSP/EVM. Those documents also describe jumper settings.
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High Voltage Hardware
system configuration shown Figure 4-1. system parts supplied documented according following references: Controller Board DSP56F805: supplied DSP56805EVM described Evaluation Module Hardware User's Manual Controller Board DSP56F803: supplied DSP56803EVM described Evaluation Module Hardware User's Manual AC/BLDC High Voltage Power Stage supplied with Optoisolation Board ECOPTHIVACBLDC described MEMC3BLDCPSUM/D Phase Brushless High Voltage Power Stage Optoisolation Board supplied with AC/BLDC High Voltage Power Stage ECOPTHIVACBLDC supplied alone ECOPT optoisolation board described MEMCOBUM/D Optoisolation Board User's Manual Warning: strongly recommended optoisolation (optocouplers optoisolation amplifiers) during development time avoid damage development equipment. Motor-Brake AM40V SG40N supplied ECMTRHIVAC Notes: Information above mentioned boards documents found
Indirect Power Factor Correction
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Hardware Implementation
+12VDC flat ribbon cable, gray JP1.1 JP1.2
J11.1 J11.2
AC/BLDC High Voltage Power Stage J13.1 J13.2 J13.3
ECOPT JP201
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Black White
flat ribbon cable, gray
ECOPTHIVACBLDC
Motor-Brake
AM40V SG40N
Hall sensor encoder 00126A ECMTRHIVAC
Incremental encoder Baumer Electric
16.05A
1024-12-5
used application
used application
Figure 4-1. High Voltage System Configuration system parts supplied documented according following references: Controller Board DSP56F805: supplied DSP56805EVM described DSP56F805EVMUM/D Evaluation Module Hardware User's Manual Controller Board DSP56F803: supplied DSP56803EVM described DSP56F803EVMUM/D Evaluation Module Hardware User's Manual AC/BLDC High Voltage Power Stage
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White Black
Optoisolation Board
Controller Board
Software Implementation
supplied with Optoisolation Board ECOPTHIVACBLDC described MEMC3BLDCPSUM/D Phase Brushless High Voltage Power Stage Optoisolation Board supplied with AC/BLDC High Voltage Power Stage ECOPTHIVACBLDC supplied alone ECOPT optoisolation board described MEMCOBUM/D Optoisolation Board User's Manual Warning: strongly recommended optoisolation (optocouplers optoisolation amplifiers) during development time avoid damage development equipment. Notes: Information above mentioned boards documents found
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Software Implementation
Motorola Embedded collection APIs, libraries, services, rules guidelines. This software infrastructure designed DSP5680x software developers create high-level, efficient, portable code. This chapter describes minor changes needed basic 3-phase motor V/Hz Open Loop application that necessary integrate control.
Files
application composed following files: \3ph_AC_VHz_OpenLoop_PFC.c (main program) (PFC control program) (PFC control header file) \3ph_AC_VHz_OpenLoop_PFC.mcp (application project file) (application configuration source file FLASH) (application configuration header file FLASH) (linker command file FLASH) (configuration file FLASH) (application configuration source file external RAM) (application configuration header file external RAM)
Indirect Power Factor Correction
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Software Implementation
(linker command file external RAM)
Where means type target (DSP56F803 DSP56F805 EVM). These files located SDK. additional files, dpfc.c dpfc.h, added basic 3-phase motor Open Loop application.
Drivers Library Function
Each peripheral accessible through driver. detailed description drivers, document Embedded (Software Development Kit) Targeting Motorola DSP5680X Platform.
Appconfig.h File
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purpose appconfig.h file provide mechanism overriding default configuration settings, which defined config.h file. following lines should included appconfig.h file functionality:
#define #define #define #define INCLUDE_USER_TIMER_D_0 INCLUDE_USER_TIMER_D_1 INCLUDE_USER_TIMER_D_2 INCLUDE_USER_TIMER_C_0
difference inhibit output, which connected general purpose input/output (GPIO) timer dedicated DSP56F803/805 EVM. DSP56F803, line that defines channel timer module will excluded from appconfig.h. interrupt priority level will additionally defined appconfig.h file. Because input current waveform generation time critical process, timer interrupt will have highest interrupt priority (level this example; level reserved interrupt):
#define GPR_INT_PRIORITY_32
Control Integration
5.4.1 Resources
control uses some peripherals cannot share resources with motor control application (excluding channel DC-bus voltage measurement). following resources allocated control: Quadrature timer module channel Quadrature timer module channel Quadrature timer module channel Quadrature timer module channel (for DSP56F805 only) GPIO port (for DSP56F803 only)
These lines dpfc.c support hardware connection differences between variants 56F80x family.
Indirect Power Factor Correction
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Software Implementation Uncomment following lines #define DSP56F803EVM #define DSP56F805EVM
5.4.2 Modification
following line placed into main program provides access control functions:
#include "dpfc.h"
5.4.3 Initialization
Initialization peripherals will contain additional parts. following line will included after motor control initialization function call:
PFC_Init(); peripherals initialization
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control software must aware DC-bus voltage value. Usually motor control application uses this value calculations requires different sample rate measurement. case control used, main program should provide continuous measurement DC-bus voltage sample rate less then twice input voltage frequency. This assures proper operation when control possible means passing DC-bus voltage value control following line conversion complete callback:
PFC_SetUOut(u_dc_bus); Pass DC-bus voltage value
5.4.4 Control Enable
possible enable control time after PFC_Init() function call. Before control enabled, application will able measure DC-bus voltage. enable control, following line:
PFC_Enable(); control enable
control operates from interrupts. possible disable global interrupts when control
5.4.5 Control Disable
There reasons disabling control motor control application. first reason power saving when output load zero, second reasonose fault protection. motor control application performs shutdown after error detection, following line:
PFC_Disable();
control disable
Input Current Harmonics Contents
result power factor correction, spectrum input current will contain components with lowest amplitudes than same spectrum without PFC. harmonics contents both applications (with without PFC) were measured output power about 120W shown Figure 5-1.
Indirect Power Factor Correction
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Master
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harmonic
P=124W
ithout P=124W
Figure 5-1. Input Current Harmonics Contents (RMS)
Master
Master designed provide debugging, diagnostic demonstration tool development algorithms applications. consists components running parts running target device. Master application part Motorola Embedded selectively installed during installation. enable Master operation target board application, following lines must added appconfig.h file:
#define SCI_DRIVER #define INCLUDE_PCMASTER
These lines automatically include driver install necessary services running Master. detailed Master description provided Master User Manual. stored directory
Memory Usage
Table shows much memory needed execute 3-phase induction V/Hz Open Loop application. part memory still available other tasks.
Indirect Power Factor Correction
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References
Table 7-1. FLASH Memory Usage SDK2.3
Memory Words) Program FLASH Data
Available DSP56F803 DSP56F805
Used Application Stack 12614 1541+ stack
Used Application without Master, SCI, ident. 8437 1173 stack
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References
Design 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 Evaluation Module Hardware User's Manual, DSP56F803EVMUM/D, Motorola Evaluation Module Hardware User's Manual, DSP56F805EVMUM/D, Motorola Motorola DSP56F8XX Software Development Optoisolation Board User's Manual, MEMCOBUM/D Phase Brushless High Voltage Power Stage, MEMC3BLDCPSUM/D, Motorola 3-Phase Motor Control with V/Hz Speed Open Loop Using DSP56F80x, Motorola, AN1911/D page: http://e-www.motorola.com/motor
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OnCE registered trademark Motorola, Inc.
Motorola reserves right make changes without further notice products herein. Motorola makes warranty, representation guarantee regarding suitability products particular purpose, does Motorola assume liability arising application product circuit, specifically disclaims liability, including without limitation consequential incidental damages. "Typical" parameters which provided Motorola data sheets and/or specifications vary different applications actual performance vary over time. operating parameters, including "Typicals" must validated each customer application customer's technical experts. Motorola does convey license under patent rights rights others. Motorola products designed, intended, authorized components systems intended surgical implant into body, other applications intended support sustain life, other application which failure Motorola product could create situation where personal injury death occur. Should Buyer purchase Motorola products such unintended unauthorized application, Buyer shall indemnify hold Motorola officers, employees, subsidiaries, affiliates, distributors harmless against claims, costs, damages, expenses, reasonable attorney fees arising directly indirectly, claim personal injury death associated with such unintended unauthorized use, even such claim alleges that Motorola negligent regarding design manufacture part. Motorola registered trademarks Motorola, Inc. Motorola, Inc. Equal Opportunity/Affirmative Action Employer.
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AN1918/D
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