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Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved. Class ID: DevCon 2012 Power Factor Correction – Why and How?

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Presentation on theme: "Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved. Class ID: DevCon 2012 Power Factor Correction – Why and How?"— Presentation transcript:

1 Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved. Class ID: DevCon 2012 Power Factor Correction – Why and How? John Pocs, Applications Engineering Manager 7C03I

2 © 2012 Renesas Electronics America Inc. All rights reserved.2 John Pocs Sr. Application Engineering Manager Application focus: motor control Support Renesas MCUs, Rx, V850, RL78 20+ years embedded system development, application and industrial experience 16 yrs with Renesas Electronics/ NEC Electronics – Hardware, firmware, development tools, applications 8 yrs with Electronics Detection Systems – Life safety, security systems and CCTV 5 yrs with Anina (Romania) Power Generation Plant – Power generator, plant automation, power inverters Knowledge in 8/16/32-bit MCUs MSEE – San Francisco State University Diploma Engineer in Industrial Electronics from Polytechnic Institute Iasi - Romania

3 © 2012 Renesas Electronics America Inc. All rights reserved.3 Renesas Technology & Solution Portfolio

4 © 2012 Renesas Electronics America Inc. All rights reserved.4 Microcontroller and Microprocessor Line-up Wide Format LCDs  Industrial & Automotive, 130nm  350µA/MHz, 1µA standby 44 DMIPS, True Low Power Embedded Security, ASSP 165 DMIPS, FPU, DSC 1200 DMIPS, Performance 1200 DMIPS, Superscalar 500 DMIPS, Low Power 165 DMIPS, FPU, DSC 25 DMIPS, Low Power 10 DMIPS, Capacitive Touch  Industrial & Automotive, 150nm  190µA/MHz, 0.3µA standby  Industrial, 90nm  242µA/MHz, 0.2µA standby  Automotive & Industrial, 90nm  600µA/MHz, 1.5µA standby  Automotive & Industrial, 65nm  600µA/MHz, 1.5µA standby  Automotive, 40nm  500µA/MHz, 35µA deep standby  Industrial, 40nm  242µA/MHz, 0.2µA standby  Industrial, 90nm  1mA/MHz, 100µA standby  Industrial & Automotive, 130nm  144µA/MHz, 0.2µA standby 2010 2013 32-bit 8/16-bit

5 © 2012 Renesas Electronics America Inc. All rights reserved.5 Enabling the Smart Society Energy efficiency is key to a Smart Society Power quality is key to efficient energy management

6 © 2012 Renesas Electronics America Inc. All rights reserved.6 Agenda Market drivers for Power Factor Correction What is Power Factor and why do we need to correct it? Definition of Power Factor (PF) What causes PF degradation Impacts of bad PF on power distribution and billings How do we correct bad Power Factor? Basic PFC topologies Renesas PFC Solutions Analog and Digital Solutions Implementation with Renesas MCU and Analog & Power devices Summary

7 © 2012 Renesas Electronics America Inc. All rights reserved.7 PFC Market Drivers

8 © 2012 Renesas Electronics America Inc. All rights reserved.8 What Drives the PFC Market? Some energy is delivered but not used due to bad PF Consumers Some consumers are charged for energy they don’t use Power utilities Need to cover consumers who are not charged for bad PF Need to compensate by over-sizing: – Distribution lines, Transformers, Energy production Harmonics can disrupt other consumers Government regulations

9 © 2012 Renesas Electronics America Inc. All rights reserved.9 Real Power:P = 400 W (Watts) Apparent Power : S = 120V x 5.1A = 612 VA (Volt Ampere) Power Factor: What is Power Factor? ~ A A A P AC Motor WattmeterAmmeter 120V 60Hz 5.1 A400W PF = 400/612 = 0.653

10 © 2012 Renesas Electronics America Inc. All rights reserved.10 What is Power Factor? Where did the power go? AC current AC voltage φ Displacement Range: 0 – 1 Q(VAR): Reactive Power DPF = 1 when Q = 0 P (W) Q (VAR) S (VA) φ S’ Inductive Load

11 © 2012 Renesas Electronics America Inc. All rights reserved.11 What is Power Factor? Total Harmonic Distortion (THD) Non-linear loads distort original AC current Total Power Factor Combination of Displacement Power Factor (DPF) and Distortion Power Factor (THD) AC current AC voltage φ Displacement Distortion I 1 : RMS value of AC current fundamental I n: RMS value of AC current nth harmonic

12 © 2012 Renesas Electronics America Inc. All rights reserved.12 What causes PF degradation? Inductive loads store reactive power and cause current lag Non-linear loads with switching elements distort the original AC current and introduce harmonics Total Power Factor Bad PF:

13 © 2012 Renesas Electronics America Inc. All rights reserved.13 Question 1 What causes PF degradation? A.Resistive loads B.Inductive loads C.Capacitive loads D.Non-linear loads E.B, C, D F.None of the above

14 © 2012 Renesas Electronics America Inc. All rights reserved.14 Why Power Factor < 1 is bad? Reactive energy is not used to produce real power Utilities need to compensate by over sizing: Distribution lines Transformers Energy production Harmonic distortion can disrupt other consumers

15 © 2012 Renesas Electronics America Inc. All rights reserved.15 Power Factor Correction

16 © 2012 Renesas Electronics America Inc. All rights reserved.16 Power Factor Correction PFC makes the load look like a resistor! Need to control current to match the shape and phase of the voltage AC current AC voltage φ Displacement AC current AC voltage

17 © 2012 Renesas Electronics America Inc. All rights reserved.17 Power Factor Correction Methodologies Passive PFC Passive components to compensate for reactive energy loss Active PFC Active components to drive solid state switches with PWM signals in combination with passive reactive components such as inductors + -

18 © 2012 Renesas Electronics America Inc. All rights reserved.18 Passive PFC Control harmonic current using filter Expensive large high-current inductor No automatic adjustment for wider AC input power DC output varies with AC input voltage Passive Power Factor Correction

19 © 2012 Renesas Electronics America Inc. All rights reserved.19 Active PFC Input current is controlled to follow the shape and phase of input AC voltage Transistor Q is switched ON/OFF at a PWM rate Most common configuration – Boost converter Efficiency is affected by Q switching losses and diode recovery Active Power Factor Correction Q

20 © 2012 Renesas Electronics America Inc. All rights reserved.20 Active PFC Topologies Critical Conduction Mode (CRM) Q switched on when inductor current reaches zero Inductor ripple current - High Low power applications No recovery loss through diode Q Rectified, unfiltered AC voltage Average AC current Inductor ripple current

21 © 2012 Renesas Electronics America Inc. All rights reserved.21 Active PFC Topologies Continuous Conduction Mode (CCM) Q switched on before the inductor current reaches zero Inductor ripple current – Low High power applications Recovery loss through the diode Rectified, unfiltered AC voltage Average AC current Inductor ripple current Q

22 © 2012 Renesas Electronics America Inc. All rights reserved.22 Implementation Example of Active CRM PFC CMP+ (Zero current detection) TMX00 (PFC output) PFC-ON pulse width Rectified, unfiltered AC voltage PFC-off pulse width Average AC current CMP+ TMX00 ANI0 Interlock Zero current detection Internal Vref T1 DC BUS Critical Conduction Mode (CRM) PFC Boost Converter MCU Timer A/D

23 © 2012 Renesas Electronics America Inc. All rights reserved.23 Two channel interleaved Single channel Active PFC Topologies D1 Q1 ~ 120V AC C PFC Cb L1 D1 Q1 ~ 120V AC C PFC Cb L1 D2 L2 Q2 Reduced current ripple Q1 I L1 Q1 I L1 Q2 I L2 I L1+ I L2

24 © 2012 Renesas Electronics America Inc. All rights reserved.24 Effect of High-frequency Switching Harmonics and inductor current ripple can disrupt other consumers Regulation standards apply – IEC61000-2-2 Higher ripple current will require better filters with multiple stages Q ~ 120V AC L L CC

25 © 2012 Renesas Electronics America Inc. All rights reserved.25 Advantages of Interleaving Reduced current ripple Size and number of input filters can be reduced Size of inductors, capacitor, switching devices can be reduced Overall efficiency is increased

26 © 2012 Renesas Electronics America Inc. All rights reserved.26 Interleaved PFC Versus Single Channel Single channel Inductor ripple current affects size of: – Inductor, Bulk Capacitor and input EMI filter High current through IGBT/MOSFET cause conduction losses Two channel interleaved Two sets of smaller and less expensive components: – Inductor, Diode, Capacitor and IGBT/MOSFET 180° out of phase switching – Inductor ripple currents cancel out each other – Further reduction in bulk capacitor size and EMI filter Better efficiency due to reduced conduction losses Multiple interleaving can further reduce the size of components

27 © 2012 Renesas Electronics America Inc. All rights reserved.27 Interleaved PFC versus Single Channel ItemSingle Channel2-Ch Interleaved Ripple currentLargeSmall Inductor1 large2 small (less $) Transistor1 large2 small (less $) Diode1 large (SiC?)2 small (less $) Bulk capacitorLargeSmall EMI filterLargeSmall EfficiencyGoodBetter CCM topology for large power application (>300W)       

28 © 2012 Renesas Electronics America Inc. All rights reserved.28 Typical Application - Motor Control and PFC MCU 90 – 264 VAC Gate Driver PWM Current, voltage, temperature, OC-detection PWM Fast Recovery Diode ( SiC ) L C PFC Control IC AC voltage, DC voltage current 3 Phase Inverter stage D T 3 Phase Motor Speed, Position

29 © 2012 Renesas Electronics America Inc. All rights reserved.29 Digital PFC for Motor Control Inverter MCU 90 – 264 VAC Gate Driver PWM Current, voltage, temperature, OC-detection PWM Fast Recovery Diode ( SiC ) L C AC voltage, DC voltage current 3 Phase Inverter stage D T 3 Phase Motor Speed, Position

30 © 2012 Renesas Electronics America Inc. All rights reserved.30 Renesas PFC Solutions Renesas offers a variety of analog and digital devices to support PFC Analog: PFC Controller ICs Single channel and interleaved CCM and CRM topologies Internal MOSFET/IGBT driver Digital: MCUs with integrated peripherals High performance CPU with FPU and 10ns flash access Internal PGAs and Comparators High-speed ADC with multiple S&H Fast over-current protection by hardware Fast interrupt response

31 © 2012 Renesas Electronics America Inc. All rights reserved.31 Analog PFC Solutions

32 © 2012 Renesas Electronics America Inc. All rights reserved.32 PFC Controllers – CCM (Continuous Conduction Mode) – CRM (Critical Conduction Mode) PFC Boost Switch – Super Junction MOSFETs for high frequency (> 50 kHz), up to 2.5 kW – High Speed, Low Vceon, IGBTs for lower frequency (< 40 kHz) and above 2.5 kW PFC Boost Diode (SiC) Support and Collateral Datasheet Evaluation Boards Technical Support Renesas Offers Complete Analog PFC Solutions

33 © 2012 Renesas Electronics America Inc. All rights reserved.33 ModePart #FeaturesApplications CCM InterleavedR2A20114 R2A20104 Small current ripple Average SW noise More complex circuit Server Air conditioner Induction heating SingleR2A20115 Large current ripple Large SW noise Simple circuit Plasma TV PC Office automation CRM InterleavedR2A20132 R2A20118A R2A20117 R2A20112 Small current ripple Average SW noise More complex circuit Air conditioner Plasma TV PC Office automation SingleR2A20113 Large current ripple Large SW noise Simple circuit LCD monitor AC adaptor LCD projector Renesas Analog PFC Controller Solutions

34 © 2012 Renesas Electronics America Inc. All rights reserved.34 Current transformers CCM Interleaved PFC Controllers 2A20114/20104 Phase drop control input Internal / external clock can be used 20104 can use current transformer

35 © 2012 Renesas Electronics America Inc. All rights reserved.35 CRM Interleaved PFC Controllers 2A20132 Phase drop control input OTC – prevents increase of switching frequency at light loads —Increased efficiency at light loads Protection circuits: Brownout, ZCD pin opening

36 © 2012 Renesas Electronics America Inc. All rights reserved.36 CCM Interleaved PFC Controllers Protection features ZCD open/short OCP timer latch RAMP charge current Brownout Soft start Gate drivability VFB 1.5% R2A20118/117/112

37 © 2012 Renesas Electronics America Inc. All rights reserved.37 Digital PFC Solutions

38 © 2012 Renesas Electronics America Inc. All rights reserved.38 PFC Control Functions PFC Controller 85 – 264VAC 400V DC Inductor ripple current Gate PWM OC/OV Detection VREF PFC Hardware VAC VDC PF > 0.9

39 © 2012 Renesas Electronics America Inc. All rights reserved.39 PFC Control Functions – Input/Output Control functionInputOutput Output voltageFeedback voltageConstant DC bus voltage AC voltage rangeAC voltageAdjust to 85-264VAC Inductor current IGBT current AC voltage Inductor current amplitude Synchronize with AC voltage phase Hardware protection Over-current Over-voltage Under-voltage Disable IGBT gate signals

40 © 2012 Renesas Electronics America Inc. All rights reserved.40 Digital PFC for Motor Control Inverter Rx62T MCU 90 – 264 VAC Gate Driver PWM Current, voltage, temperature, OC-detection PWM Fast Recovery Diode ( SiC ) L C AC voltage, DC voltage current 3 Phase Inverter stage D T 3 Phase Motor Speed, Position

41 © 2012 Renesas Electronics America Inc. All rights reserved.41 Interleaved PFC Reference Design PFC CH1 Rx62T MCU board PFC CH2 Auxiliary power DC/DC converter SIC Diodes 395V 3.8A output 85-264 VAC input

42 © 2012 Renesas Electronics America Inc. All rights reserved.42 Complete PFC Solution from Renesas RX62T/100pin R5F562TAADFP IGBT: RJH60F4DPK Diode: RJS6005TDPP-EJ (target) IGBT: RJH60F4DPK

43 © 2012 Renesas Electronics America Inc. All rights reserved.43 System Specification 1MCU R5F562TAADFP (RX62T) (Flash: 256kB, RAM: 32kB, CLK: 100MHz, VCC: 5V ) 2Circuit systemContinuous Conduction Mode / 2-phase interleaved 3Switching deviceIGBT (RJH60F4DPK: 600V/50A) 4Input voltageAC 85 to 264 V 5Output voltageDC 395 V 6Maximum output current3.8 A 7Maximum output power1.5 kW 8PWM frequency35 kHz / 1 phase x 2 9Efficiency> 96 % 10Power factor> 0.96

44 © 2012 Renesas Electronics America Inc. All rights reserved.44 PFC Controller System Block Diagram ProtectionSWHW

45 © 2012 Renesas Electronics America Inc. All rights reserved.45 CS1 GD1 GD2 Controller Implementation Control loops: Two-stage IIR filter CC1 CC2 VC CS2 VAC VFB CS1,2 - Current sensing Ch1,2 VAC - AC Input voltage VFB - DC Output voltage CC1,2 - Current controller 1,2 VC - Voltage controller

46 © 2012 Renesas Electronics America Inc. All rights reserved.46 Program Flow Conversion start by GPT Conversion complete interrupt Voltage reference calculation Voltage IIR filter controller Current IIR filter controller GPT PWM duty update ADC conversion interrupt 12-Bit ADC ADC to voltage calculation Voltage controller Current controller PWM update Main Interrupt 10-Bit ADC VAC CS FB

47 © 2012 Renesas Electronics America Inc. All rights reserved.47 Signal name MCU Peripheral Pin NameI/O Resolutio n Functions GD1GPT0GTIOC0A-AOUT20nsPWM for IGBT1 gate GD2GPT1GTIOC1A-AOUT20nsPWM for IGBT1 gate VFB12-Bit ADC0AN000IN12bitOutput DC voltage sensing CS212-Bit ADC0AN001IN12bitIGBT1 current sensing CS212-Bit ADC0AN002IN12bitIGBT2 current sensing VAC10-Bit ADCAN2IN10bitInput AC voltage sensing RX62T MCU Resources Used

48 © 2012 Renesas Electronics America Inc. All rights reserved.48 RX62T Peripherals used for PFC 16-Bit CMT 4 channel Multi purpose timer Flash up to 256KB Data Flash 8KB (30k times E/W) RAM 16KB RX CPU (100 MHz) FPU Multiplier, Divider, Multiply, Accumulate Ch 3&4 3-ph PWM Ch 1&2 2 Encoder Inputs Ch 0 Hall / BEMF Input Ch 5 Dead-time compensation Ch 6&7 3-ph PWM 16-Bit MTU3 12bit ADC 4-ch x 2 3 PGA 3 Comp x 2 10bit ADC 12-ch 16-bit PWM Timer GPT0 16-bit PWM Timer GPT1 16-bit PWM Timer GPT2 16-bit PWM Timer GPT3 390VDC ~ CS1 CS2 VFB VAC GPT RX 62T GD1 GD2

49 © 2012 Renesas Electronics America Inc. All rights reserved.49 Gate Drive, Synchronized ADC sampling GD1 GD2 VFB CS1 CS2

50 © 2012 Renesas Electronics America Inc. All rights reserved.50 * 1. Protection by external hardware * 2. Protection by internal hardware by POE function * 1* 2 Overvoltage Protection by Hardware - Example of PFC and DC/DC converter

51 © 2012 Renesas Electronics America Inc. All rights reserved.51 AN000/AN101 AN001/AN101 AN002/AN102 ADC unit 0 Data Register 0 Data Register 1 Data Register 2 Data Register 3 S/H Three S&H for sensing currents and voltage for interleaved PFC. PGA (Programmable Gain Amp) with selectable gain 1 usec conversion time per channel at AVCC0=AVCC=4.0 to 5.5V. AN003/AN103 Feedback Signal Measurement by 12-Bit ADC PGA S/H Multiplexer ADC VFBPF_IN VCSPF1_IN VCSPF2_IN VAC_IN

52 © 2012 Renesas Electronics America Inc. All rights reserved.52 Implementation with General Purpose Timers 4-Channels, 16-Bit counters, 100 MHz count clock Phase shifted operation – 180° for interleaved PFC Triangular wave with center aligned PWM ADC conversion start trigger by timer GTIOC0A-A/B POE3 CPU interrupt for POE AD trigger CPU Interrupt GTCCRA0 GPT0.GTCNT ON GTIOC0A-A ON OFF ON OFF ON OFF GPT1.GTCNT 1. GTPR0,1:PWM frequency ( 35kHz) 2. GTCCRA0,1:PWM duty GTIOC1A-A GTCCRA1 GPT0 GTIOC0B-A/B GTIOC1A-A/B AD trigger CPU Interrupt GPT1 GTIOC1B-A/B GTIOC2A-A/B AD trigger CPU Interrupt GPT2 GTIOC2B-A/B GTIOC3A AD trigger CPU Interrupt GPT3 GTIOC3B Output protect

53 © 2012 Renesas Electronics America Inc. All rights reserved.53 Example of PFC Control Trigger by GPT0 GTIOC0A output PFC gate drive GTADTRA ADC Trigger ADC conversion start ADC conversion end PFC control startPFC control end ADC conversion end interrupt ∆t Register write aaaa bbbb cccc dddd eeee ffff GPT0.GTCNT Counter value bbbbffffdddd hhhh GTP0.GTPR PFC Cycle hhhh ddddffff Buffer transfer at crestBuffer transfer at throughBuffer transfer at crest Time GTP0.GTCCRC PFC Duty Cycle

54 © 2012 Renesas Electronics America Inc. All rights reserved.54 CPU BW for Interleaved PFC: 32% @35KHz GD1 PFC control timing 28us 9us(32%)Control loop processing: 4.5us

55 © 2012 Renesas Electronics America Inc. All rights reserved.55 Input AC voltage Input AC current Inductor current Output voltage ripple AC Current Waveforms @1.5KW – 100V AC input 1.5KW @ 100V AC Input

56 © 2012 Renesas Electronics America Inc. All rights reserved.56 Each GPT channel can generate HR-PWM for two outputs independently Minimum resolution is 1/32 of normal resolution: 312.5psec @100MHz 390.0psec @80MHz GTCNT Comparator GTCCRF GTCCRBGTCCRA Controller GTDVU GTPR GTCCRD GTCCREGTCCRC GTPBR Output control GTADTRA GTADTBRA GTADTRB Output protect External Trigger. PWM1 PWM2 POEx AD trigger CPU interrupts CPU Interrupt GTADTBRB GTADTDBRA GTADTDBRB GTPDBR Input control GTDBU GTDVD GTDBD Comparator input Highresolution risingfalling GTTCRA GTDLYRA GTDLYFA GTIOCA GTTCRA 15 0 Upper 16bitLower 5bit + GTDLYRA + GTDLYFA 0 4 GTDLYRA Rx62G High Resolution PWM Timer

57 © 2012 Renesas Electronics America Inc. All rights reserved.57 Question 2 What PFC method is used in the Renesas digital reference design? A.Single-channel PFC in Critical Conduction Mode (CRM) B. Single-channel PFC in Continuous Conduction Mode (CCM) C. Dual-channel interleaved in Continuous Conduction Mode (CCM) D. None of the above

58 © 2012 Renesas Electronics America Inc. All rights reserved.58 Summary Market drivers for Power Factor Correction What is Power Factor and why do we need to correct it? Definition of Power Factor (PF) What causes PF degradation Impacts of bad PF on power distribution and billings How do we correct bad Power Factor? Basic PFC topologies Renesas PFC Solutions Analog and Digital Solutions Implementation with Renesas MCU and Analog & Power devices

59 © 2012 Renesas Electronics America Inc. All rights reserved.59 Questions? Questions?

60 © 2012 Renesas Electronics America Inc. All rights reserved.60 Enabling the Smart Society Energy efficiency is key to a Smart Society Power quality is key to efficient energy management

61 © 2012 Renesas Electronics America Inc. All rights reserved.61 Please utilize the ‘Guidebook’ application to leave feedback or Ask me for the paper feedback form for you to use… Please Provide Your Feedback…

62 Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved.


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