Infineon XC164 Series Installation and operating instructions

Microc o ntr o ll e r s

XC164

Main Control for 5KVA

Single-Phase On-Line UPS

Reference esign with

XC164CM

A p p l i c a t i o n N o t e , V 1 . 0 , M a r 2 0 0 7

AP16098

Edition 2007-03-19

Published by

Infineon Technologies AG

81726 ünchen, Germany

©Infineon Technologies AG 2007.

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IN THIS APPLICATION NOTE.

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AP16098

UPS ain Control

Application Note 3 V1.0, 2007-03

AP16098

Revision History: 2007-03 V1.0

Previous Version: none

Page Subjects (major changes since last revision)

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AP16098

UPS ain Control

Table of Contents Page

Application Note 4 V1.0, 2007-03

1 Introduction…………………………………………….................................................5

2 System Overview…………………………………...…………………………………….6

2.1 Power Flow…………….….………………………………………………………………..6

2.2 Specifications.………………………………………………………………………………7

3 ain Control Principle…...………………………………………………………………9

4 XC164CS Implementation for ain Control…...……………………………………11

4.1 XC164CM Introduction…….....................................................................................11

4.2 Pin Configuration.………..………….......................................................................12

4.3 Initialization Settings…….……………......................................................................13

4.3.1 CAPCOM6……………….………………...................................................................13

4.3.2 A C...…………………….………………...................................................................14

4.3.3 CAPCOM2...…………….………………...................................................................14

4.3.4 I/O Ports..……………….………………...................................................................14

4.3.5 ASC0…….……………….………………...................................................................14

4.4 Some Programming Considerations........................................................................15

4.5 States iagram and Flow Chart.….........................................................................16

5 Experiment Results……………………………........................................................18

6 Conclusions………..…………………………………………………………………….20

AP16098

UPS ain Control

Introduction

Application Note 5 V1.0, 2007-03

1 Introduction

The implementation of main control for a 5KVA single-phase on-line UPS (Uninterrupted

Power Supply) reference design using an Infineon 16-bit microcontroller XC164CM is

described in this application note.

The basic theory and system control flow of this UPS reference design is briefly

introduced in Section 2. Section 3 gives the detailed explanation of the main control

principle. In Section 4, XC164CM implementation for main control is illustrated from AvE

configurations to code programming together with flow charts. Then some related

waveforms measured by oscilloscope and experiment result figures are shown in Section

5. Some conclusion comments are drawn at the end of this article.

AP16098

UPS ain Control

System Overview

Application Note 6 V1.0, 2007-03

2 System Overview

2.1 Power Flow

The 5KVA single-phase UPS reference design offers an integrated uninterrupted power

supply solution with Infineon microcontrollers (Figure 1). Its main control process including

PWM signals generation, output voltage feedback control, system faults and errors

managing, charger module control, modules synchronization is all handled by the control

board based on Infineon 16-bit microcontroller XC164CM. The information display with

LC and keyboard operations are implemented by the monitoring board based on Infineon

8-bit microcontrollers XC866 (Figure 1).

Figure 1 UPS System Block iagram

The system block diagram of this UPS reference design is shown in Figure 2.

Figure 2 UPS System Block iagram

AP16098

UPS ain Control

System Overview

Application Note 7 V1.0, 2007-03

To eliminate the common noise, the input power is first filtered by an EMI filter which is

connected to tow fuses. Afterwards the power flows into the passive power factor

correction circuit in order to ensure the input current shape quality.

After reduction of voltage by an autotransformer, the input line voltage is rectified into C

voltage. The C-bus voltage is then filtered and regulated by capacitors with a resistor in

series which can restrain the inrush current. A relay is placed in parallel with the resistor

and it will be closed to shorten this resistor when the C-bus voltage reaches a certain

value.

The battery module is connected with the C-bus capacitors through a diode. If input line

power blackout happens, the battery module will be switched to offer power to the inverter

in order to keep the power uninterrupted.

The full-bridge inverter is utilized, whose output voltage is boosted by an isolating

transformer and then filtered by the circuit consisting of inductor and capacitors. The

leakage inductance of the transformer is adopted to filter out the high frequency and

difference voltage. The output voltage of the inverter also provides power to the battery

charger circuit. In “line” mode the charger circuit will receive the command to run from the

control board, but in “bat” mode it always remains off.

A TRIAC is connected with the bypass relay via a switch. When overload or other fault

occurs, the system will automatically switch to bypass mode so that the whole system as

well as the load has got protection.

Figure 3 illustrates the topology utilized in this UPS reference design.

Figure 3 UPS Topology

AP16098

UPS ain Control

System Overview

Application Note 8 V1.0, 2007-03

2.2 ain Specifications

The main technical specifications of this UPS reference design are listed in Table 1.

Table 1 UPS Reference esign Main Specifications

Items Specifications Notes

Nominal

Voltage AC 220V

Phase Single-Phase with Ground

Input

Voltage Input Voltage

Range AC 187V~253V

Input

Frequency

Nominal

Frequency 50Hz/60Hz Auto-detection

Input

Efficiency 87% At rated load

VA/Watt 5000VA/4000W

Nominal

Voltage AC 220V Sine Wave

Voltage

Regulation ±2%

TH 0.55%

Normal mode

with rated

linear load

Output

Power

ynamic

Performance ynamic Performance Classification 1

Refer

IEC62040-

3/GB7620.3

Output

Frequency

Input Synchronization within

±5%

Output

Frequency Range Free Running ±0.1Hz

Overload 120% 60 seconds,

150% 10 seconds

Output

Overload

Capacity Battery 192V 7AH VRLA

Bypass Bypass Switch Mechanical with Static Aux.

AP16098

UPS ain Control

ain Control Principle

Application Note 9 V1.0, 2007-03

3 ain Control Principle

As introduced in the system overview section, an Infineon 16-bit microcontroller

XC164CM is designed as the kernel of the main control circuit for the whole UPS system.

The main control functions executed by the microcontroller are briefly illustrated in Figure 4.

Figure 4 Main Control Functions Overview

To obtain output which can be filtered into sine voltage, the full-bridge inverter should be

driven by 4-channel signals with positive and negative cycles which can be originally

generated by the microcontroller. These PWM signals from the microcontrollers are first

isolated by optocouplers and then input to a flyback converter whose output can directly

drive the inverter bridge.

Fault or error status associated with inverter is monitored and processed by the

microcontroller. Once receiving fatal fault signals such as short circuit of the inverter or

over temperature of IGBTs, the microcontroller will immediately close off all PWM output

and generate disable signal to terminate the inverter operation. Therefore the protection

function for inverter against severe damage is realized. After faults or errors have been

released, all PWM signals will be resent out to run the inverter again for maintaining

normal operation.

There are many physical parameters to be sampled by the Analog- igital converter of

the microcontroller and further calculated during main control process. These parameters

include line voltage, C-bus voltage, primary current of output transformer, output voltage,

output current, battery voltage, IGBT temperature.

The charger module is enabled or disabled by the signal generated from the

microcontroller depending on different states. In line mode it is launched into working so as

to ensure full capacity of the battery voltage and is ceased to be inactive under the battery

mode.

AP16098

UPS ain Control

ain Control Principle

Application Note 10 V1.0, 2007-03

The microcontroller is also in charge of the synchronization control of all modules of this

UPS system as well as the inverter feedback control. The line voltage zero-crossing signal

is captured by the microcontroller to synchronize the input voltage/phase with the output

voltage/phase. The ON/OFF control signals for C-bus relay and bypass relay along with

TRIAC control signal are both produced by the microcontroller.

The display control board is designed based on an Infineon 8-bit microcontroller XC866

which needs to communicate with the microcontroller on the main control board for data

transfer and receiving. Two necessary signals Rx and Tx are offered by the

microcontroller to be connected with XC866 for implementing display of states, operation

and errors information.

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