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.
All Rights Reserved.
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AP16098
UPS ain Control
Application Note 3 V1.0, 2007-03
AP16098
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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

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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

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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.
SW

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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.

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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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UPS ain Control
XC164CS Implementation of ain Control
Application Note 11 V1.0, 2007-03
4 XC164CS Implementation of ain Control
4.1 XC164C Introduction
XC164CM is a member of the enhanced 16-bit microcontroller family XC166 which
offers impressive SP performance and advanced interrupt handling combined with a
powerful integrated peripheral set and high performance, reliable on-chip Flash memory.
The resource of Infineon 16-bit microcontroller XC164CM utilized in this UPS reference
design is illustrated in Figure 5 (the modules encircled by magenta rectangles).
Figure 5 XC164CM Overview ( AvE Interface)
“CAPCOM6”: The CAPCOM6 unit is made up of a Timer T12 block with 3
capture/compare channels and a Timer T13 block with 1 compare channel. The T12
channels can independently generate PWM signals or accept capture triggers, or they can
jointly generate control signal patterns to drive AC-motors or inverters. Its block diagram is
shown on Figure 6.
“A C”: Four conversion modes are supported: Fixed Channel Single Conversion mode,
Fixed Channel Continuous Conversion mode, Auto Scan Single Conversion mode, Auto
Scan Continuous Conversion mode. 8-bit or 10-bit resolution is alternative. MA (PEC)
support is available for result transfer to memory.
“CAPCOM2”: Two 16-bit timers (T7/T8) with reload registers provide 2 independent
time bases for each capture/compare register array which contain 16 dual purpose
capture/compare registers, each of which may be individually allocated to either timer T7
or T8 respectively and programmed for capture or compare operation. Figure 7 gives out
its block diagram.
“Port”: Up to 47 general I/O pins are available in XC164CM. All port lines are
individually bit-addressable and all I/O lines are independently programmable for input or
output. The driver strength, open drain modes and input thresholds for dedicated ports are
all programmable.

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UPS ain Control
XC164CS Implementation of ain Control
Application Note 12 V1.0, 2007-03
“ASC0”: It supports full-duplex asynchronous communication and half-duplex
synchronous communication. The highlighted features include Loopback capability,
autobaud detection unit for asynchronous operating modes, 8-stage FIFO with 9-Bit FIFO
data width, etc.
Figure 6 CAPCOM6 Block iagram
Figure 7 CAPCOM2 Block iagram

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UPS ain Control
XC164CS Implementation of ain Control
Application Note 13 V1.0, 2007-03
4.2 Pin Configuration
Table 2 indicates the configuration for all the XC164CM pins utilized in this UPS
reference design.
Table 2 XC164CM Pins Configuration
Functions Pin Name Pin Number Direction odules
CC60 49
COUT60 50
CC61 51
PW drive signals for inverter
COUT61 52
Out CAPCOM6
Primary current AN0 9
IGBT temperature AN1 10
Output current AN2 11
DC-bus voltage AN3 12
Output voltage AN4 13
Line voltage AN5 14
Battery voltage AN10 15
In A C
Line voltage zero-crossing signal CC22 56 In CAPCOM2
TRIAC control P1H.0 1 In
Bypass relay control P1L.4 53 Out
DC-bus relay control P1L.5 54 Out
Changer control P3.8 35 Out
Short-circuit signal P9.1 44 In
Disable inverter signal P9.2 45 Out
I/O Ports
UART communication with XC866 for
display control TX 0 37 Out ASC0
4.3 Initialization Settings
4.3.1 CAPCO 6
The CAPCOM6 initialization for PWM signal generation to drive the full-bridge inverter is
summarized as follows (according to display order in AvE):
“Module Clock”: Enable module.
“Pin Control”: Use pin CC60, CC61, COUT60, COUT61 as output. Pin CC62 is not
used.
“T12”: fcpu/1 (Resolution: 0.025us), Center-aligned mode, T12 period 50us (carried
frequency 20KHz), Enable interrupt for T12 period match (generating interrupt
per carrier cycle), ead-time 1.2us.
“T13”: No initialization is required for it isn’t used here.
“Multi Ch.”: isable multi-channel mode.
“Channels”: Compare and capture modes should be disabled for channel 2. Channel
0,1 should be individually configured as (x=0,1): Compare Mode 3 (Use
pins CC6x/COUT6x as output); Enable T12 modulation for CC6x; The
compare output CC6x drives passive level while CC6xST is “1”; The
compare output COUT6x drives passive level while CC6xST is “0”; The
passive level of CC6x and COUT6x output are all “0”; Enable dead time
generation.

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XC164CS Implementation of ain Control
Application Note 14 V1.0, 2007-03
“Trap/INT”: o not use pin #CTRAP as input. In “Interrupt Configuration” Enable T12
interrupt/node I2.
“Interrupts”: CCU6 I2 INT -> Level 14, Group 2.
“Functions”: In “Initialization Function” select “CCU6_vInit”; In “Function Library (Part
1)” select “CCU6_vStartTmr”, “CCU6_vStopTmr”, “CCU6_vResetTmr”,
“CCU6_vEnableShadowTransfer”.
4.3.2 ADC
The A C initialization for sampling physical parameters is summarized as (according to
display order in AvE):
“Module Clock”: Enable module.
“Control”: Select “Enhanced Mode”. In “Enhanced Mode” select “Fixed channel single
conversion”; 10-bit resolution; In “Analog Channel Input Selection” select
“Analog channel 2”; Conversion basic clock is fcpu/1 (tbc=25ns); Sample
time is tbc*8=200ns.
“Port Control”: isconnect all digital input stages from port P5.
“Functions”: In “Initialization Function” select “A C_vInit”; In “Function Library (Part
1)” select “A C_vStartConv”, “A C_uwReadConv”.
4.3.3 CAPCO 2
The CAPCOM2 initialization for capturing line voltage zero-crossing signal is
summarized as (according to display order in AvE):
“Module Clock”: Enable module.
“Control”: The content of the port register is changed by the CAPCOM2 unit.
“Timer7/8”: Timer 7 Input Selection as “Module Clock / 32 (Resolution: 0.8us)”
“Channels”: In “Configure channel 22” select “Capture on positive transition at pin
CC22IO (P1L.7)”; CC22 allocated to timer T7; Enable
Capture/Compare interrupt (IE).
“Interrupts”: CC2 ch22 INT -> Level 14, Group 0.
“Functions”: In “Initialization Function” select “CC2_vInit”; In “Function Library (Part
1)” Select “CC2_vStartTmr”, “CC2_vStopTmr”, “CC2_vClearTmr”.
4.3.4 I/O Ports
The “Port” module in AvE is configured as:
P1H.0 as general IO, In; P1L.4/P1L.5 as general IO, Out;
P3.8 as general IO, Out, Open drain;
P9.0 as general IO, In; P9.1 as general IO, Out.

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UPS ain Control
XC164CS Implementation of ain Control
Application Note 15 V1.0, 2007-03
4.3.5 ASC0
The ASC0 initialization for communicating with XC866 on the display board is
summarized as below (according to display order in AvE):
“Module Clock”: Enable module.
“Pin Selection”: Full-duplex asynchronous operating modes; Use pin Tx A0 (P3.10);
Use pin Rx A0 (P3.11).
“Control ”: 8-bit data (asynchronous); One stop bit; Enable receiver (REN).
“Baud Rate”: Additionally reduce serial clock to 2; Enable baud rate generator;
Required baud rate 9.6k.
“Functions”: In “Initialization Function” select “ASC0_vInit”.
4.4 Some Programming Considerations
In CCU6 T12 period-match interrupt service routine, the output current and voltage,
primary current, line voltage, battery voltage and IGBT temperature are all sampled. Here
the dual-loop control strategy is utilized so the primary current and output voltage are both
involved to control the inverter. Figure 8 shows the block diagram of this control scheme.
R
LS
LRCS
RCS
++
+
2
1
1
+
RCS
R
Figure 8 ual-loop Control Block iagram
It can be calculated that the proportion coefficient ki of the current loop is 1.4. The
equation for compensation link of the voltage loop can be described as
1003.0
30
8.2)( + += s syCL (E-1)
The difference equation can be derived that
)1(9835.0)1(506.2)(0848.3)(
−
⋅
+
−
⋅
−
⋅
=
kykekeky (E-2)
where )(ky is the output value of the compensation and )(ke is the error value.
The width of the SPWM signal which drives the inverter can be calculated by







+×= 15.0 softstart
cm
gK
U
U
PW (E-3)
where softstart K is the modulation coefficient. To avoid inrush current at start-up, soft starting
operation is required. The value of m is increased to get better performance for soft
starting.
The RMS value of the output voltage is also calculated to modify the reference sine
table to meet the voltage regulation specification. The maximum amplitude of the output

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UPS ain Control
XC164CS Implementation of ain Control
Application Note 16 V1.0, 2007-03
voltage 3112220 ≈× (volts) can be normalized with a number 30967. So after being
attenuated by sampling circuit and knocked off by the C offset, the A convertion result
of the output voltage should be multiplied by 16.004 for normalization. The output value of
the voltage loop is also normalized to be limited between 48000 and –48000. Suppose that
the maximum positive value of the primary current is 130A and the attenuation coefficient
is 011.02000/22
=
, then the original A conversion result is 11715/4096011.0130
=
×
×
.
Therefore all the A conversion results of the primary current should be multiplied by
411171/48000
=
for normalization in order to be limited within the output range of voltage
loop.
The value of the
°
90 point of modulated sine wave is also detected in the T12 period-
match interrupt service routine. If short-circuit fault occurs on the output of the inverter, the
value of this point will be lower than the set value 400, which represents 68 volts of the
output voltage.
The zero-crossing point of the line voltage is calculated and detected to trigger the
CAPCOM2 external interrupt. In order to save operation time, the average value of the line
voltage is calculated instead of RMS. The relationship between the average value and the
RMS value is (for 50Hz):
11.1
)502sin(311
02.0220
02.0
0
=
⋅×
×
∫dtt
Urms
π
(E-4)
In this interrupt service routine, when lock signal is available, If the measured phase of
reference is less than
°
180 , the pointer for the reference sine table will be increased with 1
point. If it is larger than
°
180 , this pointer will be decreased with 1 point.

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UPS ain Control
XC164CS Implementation of ain Control
Application Note 17 V1.0, 2007-03
4.5 States Diagram and Flow Chart
Figure 9 States iagram for Main Control
Figure 9 illustrates the state diagram for main control. The flowchart for T12 period-
match interrupt service routine is shown in Figure 10.

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XC164CS Implementation of ain Control
Application Note 18 V1.0, 2007-03
Start
T12 Period-Match Interrupt
Service Routine
Enable Shadow
Transfer
C-Bus is short-circuit?
Over Primary Current?
No
No
A/ Conversion for
Output Voltage
Output is short-circuit?
No
Calculate Output
Voltage RMS
Synchronize the
Line Frequency
PI Regulating for
Output Voltage
A/ Conversion for
Primary Current
Yes
Soft Start
Yes
isable Inverter
Yes
Calculate
Current Loop
Calculate SPWM
uty Cycle
Calculate
Line Voltage
Calculate
Output Current
150% Overload?
120% Overload?
Calculate
Battery Voltage
No
No
A/ Conversion for
IGBT Temperature
Overload
temperature?
Communication is
available?
End
No
No
Yes
Yes
Set OT Flag
Set COM Flag
Yes
Yes
10s Start
60s Start
Figure 10 Flow Chart for CCU6 T12 Period-Match Interrupt Service Routine

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UPS ain Control
Experiment Results
Application Note 19 V1.0, 2007-03
5 Experiment Results
Figure 11 shows the measured filtered output voltage waveforms with feedback under
no-load and rated resistant load conditions respectively.
(a) Without Load (b) With Rated Resistant Load
Figure 11 Measured Output Voltage Waveforms
Figure 12(a) records the output transient response waveform with full resistant load
taken ON under line mode without connecting any battery. The waveform for dynamic
performance under battery mode is shown in Figure 12(b).
(a) Line Mode (No Battery) (b) Battery Mode
Figure 12 Output Transient Response
Figure 13 illustrates the short-circuit protection action, where channel 1 is for output
current and channel 4 is for output voltage.
The phase difference between the output voltage and the line voltage is shown in Figure
14, where channel 1 is for the output and channel 4 is for the line power. The time interval
between two zero-crossing points is 95us.
Figure 15 displays the bypass relay and TRIAC actions under overload condition, in
which channel A is for output voltage and channel C is for bypass current.

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UPS ain Control
Experiment Results
Application Note 20 V1.0, 2007-03
Figure 13 Short-Circuit Protection
Figure 14 Synchronization
Figure 15 Overload Protection and Bypass Control