1. Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. TM Single Phase On-Line UPS Demo Using MC9S12E128

2. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 2 Based on the topology the UPSes are classified to the three basic categories (IEC 62040-3):  Passive Standby (Off-line)  Line-interactive  Double Conversion (On-Line) UPS Classification

3. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 3 Advantages: - Very low cost - High efficiency - Compact size Advantages: - Very low cost - High efficiency - Compact size Disadvantages: - Limited protection - Not sinusoidal output - Uses battery during brownouts - Short drop-out during transition on battery Disadvantages: - Limited protection - Not sinusoidal output - Uses battery during brownouts - Short drop-out during transition on battery MCU: - MC68HC908x MCU: - MC68HC908x Basic UPS Topology - Off-line UPS

4. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 4 Advantages: - Medium cost - High efficiency - Better voltage conditioning Advantages: - Medium cost - High efficiency - Better voltage conditioning Disadvantages: - Still limited protection - Short drop-out during transition on battery Disadvantages: - Still limited protection - Short drop-out during transition on battery MCU: - MC68HC908x - MC68HC908MRx MCU: - MC68HC908x - MC68HC908MRx Basic UPS Topology - Line-Interactive UPS

5. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 5 Advantages: - Excellent voltage conditioning - Full protection Advantages: - Excellent voltage conditioning - Full protection Disadvantages: - High cost - Low efficiency Disadvantages: - High cost - Low efficiency Possible MCU: - HCS12E128 - DSP56F80x - DSP56F80xx -DSP56F83xx Possible MCU: - HCS12E128 - DSP56F80x - DSP56F80xx -DSP56F83xx Basic UPS Topology - On-Line UPS

6. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 6 Single Phase On-Line UPS Demo Using MC9S12E128

7. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 7 Single Phase On-Line UPS Demo Using MC9S12E128 Demo Features  Single Phase On-line Topology  750 VA Output Power  115/230 V Input Line  Controlled by MC9S12E128  Single LED User Interface >4 Status LEDs >6 LEDs Bar Graph >2 Buttons  Graphical User Interface on PC  Ready for GUI Display  Demo suitcase

8. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 8 Single Phase On-Line UPS Demo Using MC9S12E128 Demo Concept  Four PCBs >UPS Power Stage >Input Filter >User Interface >MC9S12E128 Control Board  Demo case

9. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 9 Concept Schematic Battery Charger FlyBack DC-DC Converter Controlled by TOP249Y (Power Integration, Inc.) Max. Output Power: 60W 3 – State Charging Algorithm (Bulk charge, Absorption, Float) controlled by MCU Battery Charger FlyBack DC-DC Converter Controlled by TOP249Y (Power Integration, Inc.) Max. Output Power: 60W 3 – State Charging Algorithm (Bulk charge, Absorption, Float) controlled by MCU PFC Average Current Mode PFC Directly controlled by MCU PFC Average Current Mode PFC Directly controlled by MCU Input Rectifier Voltage Doubler Input Rectifier Voltage Doubler Output Inverter True Sinusoidal Output Directly controlled by MCU Output Inverter True Sinusoidal Output Directly controlled by MCU DC-DC Step Up Converter Push - Pull Converter Directly Controlled by MCU Max. Output Power: 560W DC-DC Step Up Converter Push - Pull Converter Directly Controlled by MCU Max. Output Power: 560W Whole UPS controlled by one MC9S12E128 only Single Phase On-Line UPS Demo Using MC9S12E128

10. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 10 Single Phase On-Line UPS Demo Using MC9S12E128 MC9S12E128 Features  16-bit HCS12 CPU, 50 MHz core clock  128K bytes of Flash EEPROM, 8K bytes of RAM  3 x SCI, 1 x SPI, 1 x IIC  3 x 4-channel 16-bit timer modules (TIM)  6-channel 15-bit Pulse Modulator with Fault protection module (PMF)  6-channel 8-bit Pulse Width Modulator (PWM)  16-channel 10-bit analog-to-digital converter (ADC)  2 x 1-channel 8-bit digital-to-analog converter (DAC)  Up to 16 pins available as Keypad Wake-Up inputs  2 x additional external asynchronous interrupts  Up to 74 I/O port pins and 18 input only pins for 112 pin package  Up to 42 I/O port pins and 18 input only pins for 80 pin package

11. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 11 Battery Charger  Fly-Back Topology Converter  Dedicated circuit used (TOP249)  Output parameters >Output voltage: 29.4 or 27.4 V (set by MCU) >Output current: max. 1.8 A >Current limitation: 0 – 1.8 A (set by MCU)  Charge algorithm >3 state (bulk charge, absorption, float)  MCU Interface >2 analog inputs (battery voltage and battery current) >1 analog output (PWM + filter, current limitation) >1 digital output (output voltage 29.4 or 27.4 V) Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation

12. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 12 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Battery Charger Schematic

13. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 13 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Battery Charging Algorithm  3 Step Charging: Bulk, Absorption, Float

14. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 14 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation DC/DC Step Up Converter  Converts the battery voltage (24 V) to DC bus voltage (+/- 390V)  Push-Pull Topology  50 kHz switching frequency  Fully controlled by MCU  Output parameters >Output Voltage: +/- 390 V >Output Current: 0.8 A  MCU interface >2 analog inputs (+/- DC bus voltage) >2 PWM outputs (PWM for transistors)

15. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 15 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation DC/DC Step Up Converter Schematic

16. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 16 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Input Rectifier + Power Factor Correction (PFC)  Voltage doubler rectifier  PFC using bidirectional switch (one transistor only)  Control technique >Average Current Mode Control by MCU >40 kHz switching frequency >Current control loop 50  s >Voltage control loop 1 ms  Output parameters >Output power: 750 W >DC Bus voltage: +/- 390 V  MCU Interface >4x analog input (2x DC bus voltage, 1x input current, 1x input voltage) >1x PWM output (PFC transistor) >1x Input Capture (Zero crossing)

17. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 17 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Input Rectifier + PFC Controller Schematic

18. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 18 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Output Inverter  Half bridge topology  20 kHz switching frequency  Control technique >Fully controlled by MCU >PID controller + voltage feed forward + current feedback >50  s control loop  Output parameters >Output Voltage: 110 - 240 V >Output current: 3.3 A  MCU Interface >4 analog input (2x DC bus voltage, 1x output current, 1x output voltage) >2 PWM outputs (inverter transistors)

19. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 19 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation Output Inverter Schematic

20. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 20 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation MC9S12E128 Control Board  MC9S12E128 16-bit +5V Microcontroller operating at 25MHz  8.00MHz crystal oscillator for MCU frequency generation  Background Debug Mode (BDM) interface connector  2x Optically isolated RS-232 interface  Communication Header (SPI, SCI1, IIC)  PWM and Timer Header >Pulse Width Modulation, PWM, or Timer2, TIM2 Timer1, TIM1  ADC and DAC Header >Analog-to-Digital Converter, ADC >Digital-to-Analog Converter, DAC Expansion Header for 16-bit Multiplexed Wide Bus  On-board power regulation from an external 12V DC supplied power input

21. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 21 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation MC9S12E128 Control Board - continue  Light Emitting Diode (LED) power indicator  One on-board real-time user debugging LEDs  Six on-board PWM monitoring LEDs  Six on-board PMF monitoring LEDs  Four on-board PMF Fault monitoring LEDs  UNI-3 Motor interface  Over-Voltage sensing  Over-Current sensing  Comparators for automatic current profiling  Encoder/Hall-Effect interface  Manual RESET push-button  General purpose and interrupt toggle switch  2x General purpose and interrupt push-button

22. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 22 Single Phase On-Line UPS Demo Using MC9S12E128 - HW Implementation MC9S12E128 Control Board – Block Diagram

23. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 23 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Software Structure  5x periodical interrupts (2x 50  s, 1x 1 ms, 1x 10 ms, 1x 50ms)  3x event interrupts (PMF faults, LVI, SCI)  Background loop  Written in C language  Some critical algorithms written in assembler (sine wave generation, PID controllers, arithmetic functions)

24. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 24 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Software Structure - continue

25. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 25 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Software Structure - continue

26. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 26 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Battery Charger Execution period: 50 ms

27. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 27 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation DC/DC Step Up Converter Execution period: 1 ms

28. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 28 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Power Factor Correction Execution period: 1 ms Execution period: 50  s

29. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 29 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Output Inverter Execution period: 1 ms Execution period: 50  s

30. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 30 Single Phase On-Line UPS Demo Using MC9S12E128 - SW Implementation Application State Machine

31. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 31 Single Phase On-Line UPS Demo Using MC9S12E128 - Software Measurements UPS Software Measurements  Code Length >FLASH memory: 10087 bytes >RAM memory: 3014 bytes (include stack 512 bytes)  MCU load: 77.5 % (without PCMaster serial communication) >PMF Reload 15.8  s(period 50  s) >ATD Complete19.4  s(period 50  s) >TIM0 ch4 IC7.8  s(period 8.3 ms) >TIM0 ch5 OC69  s(period 1 ms) >TIM0 ch6 OC43.4  s(period 50 ms)

32. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 32 Single Phase On-Line UPS Demo Using MC9S12E128 - Software Measurements UPS Software Measurements - continues PMF Reload ATD Complete TIM0 ch5 OC TIM0 ch6 OC

33. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 33 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Load defined by IEC 62040-1  Linear load (525 W) >R = 100   Non-linear load (750 VA) >R = 160  >Rs = 2.8  >C = 780  F

34. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 34 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Overall efficiency – linear load

35. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 35 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Overall efficiency – non-linear load

36. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 36 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output frequency - synchronized

37. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 37 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output frequency – free running

38. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 38 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Voltage THD – without load

39. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 39 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Voltage THD – with linear load

40. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 40 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Voltage THD – with non-linear load

41. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 41 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Voltage THD – with non-linear load

42. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 42 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Voltage THD – with non-linear load

43. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 43 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Input Power Factor

44. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 44 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Output Power Factor (linear load)

45. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 45 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Load Step 20 % -> 100 %

46. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 46 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Load Step 20 % -> 100 %

47. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 47 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Load Step 100 % -> 20 %

48. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 48 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Measurements Load Step 100 % -> 20 %

49. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 49 Single Phase On-Line UPS Demo Using MC9S12E128 - Performance Summary TopologyOn-line (double conversion) Input Voltage80 – 270V Input frequency45 – 65 Hz Output power750 VA (at nominal line voltage) THD1 % linear, 5 non-linear load Efficiency 90 % Power factor> 0.95 Transfer time0 s Battery2 x 12V, 7.2 Ah GUI2 x buttons, 10x LEDs Remote controlFrom PC by PC Master Communication2x RS232

50. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 50 Single Phase On-Line UPS Demo Using MC9S12E128 - Developments tools FreeMaster  Real time monitor  Read and write any variable in application  Display the variables in physical quantities  Scope  Recorder  Control page in HTML code

51. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 51 Single Phase On-Line UPS Demo Using MC9S12E128 - Developments tools Scope or recorder Variables window

52. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 52 Single Phase On-Line UPS Demo Using MC9S12E128 - Developments tools Control page

53. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 53 Reference Design Deliverables  Design documentation (source and PDF)  Targeting documentation (source and PDF)  Application note  Presentation Material  All source code and related material for written software  PCB layout gerber files (source and PDF)  Schematic files (source and PDF)  BOM (source and PDF) Single Phase On-Line UPS Demo Using MC9S12E128 - Deliverables

54. TM Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2005. Slide 54 TM