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Air-Conditioner Reference Design
2
Where We Fit?
Air Conditioner Indoor Unit
Air Conditioner Outdoor Unit and HVAC
3
Air Conditioner
Market Trends
⚫ Inverter based air conditioner
⚫ Variable speed drive enables continuous temperature
regulation and are more efficient compared to fixed
speed operation
⚫ BLDC compressor for higher energy efficiency
⚫ Proven solution for 1KW to 2KW PFC, sensor
less Field Oriented Control (FOC) & torque
compensation
⚫ Compact form factor
⚫ Cost optimized turnkey solution
4
Aircon Reference Design
Features
⚫ Implements PFC, compressor motor control and fan motor control
Benefits
⚫ Targets higher Energy Efficiency Ratings (EER)
⚫ Single chip solution for cost optimization
⚫ Separates application and PFC code development from dual motor
control code using the two cores in dsPIC33CH DSC
Design Code Separately and Integrate Seamlessly
⚫ Total input power of up to 1.8KW
⚫ 4 temperature sensors connection
⚫ Communication with indoor unit
⚫ Optional support for ACIM and
BLDC motor with built-in drive
5
Block Diagram
Bridge
Rectifier
Interleaved
PFC
3 Phase
IPM
3 Phase
Discreet
IGBT
Power
Stage
EMI
Filter
Gate
DriverMCP14E4
230VAC
EEPROMAT24C512C
Over Current &
Voltage Protection
MCP6541/2
7×Current &
voltage Sense
MCP6V92
VDC
3.3V
Aux
Power
15V
LDOMCP1826
12VVDC
Relay RelayField
Communication
Indoor
UnitValve/ACIM
Control
3×
Temp Sense
Ambient
Condenser
Discharge
Suction
Condenser Fan
Compressor
Driver
Stepper
Motor
Electronic
Expansion
Valve Microchip Components
2×
6
Specification
SectionsDesigned
power (W)
Tested
power (W)
Input voltage140V to 280V,
50/ 60 Hz
140V to 240V,
60 Hz
PFC input 1800 1600#
PFC output 1620 1520
Compressor drive input 1490 1350*
Compressor drive output 1341 1300
Fan drive input 130 130**
Fan drive output 117 117**
* Back calculated based on PFC efficiency and input power drawn
** Based on Input power – no results on power analyzer
# Based on maximum load availability
7
Air-Conditioner Reference Design Board
8
Test Setup
9
Test Setup
S.No. Item Make and Part Number
1 Air conditioner unit Supplied by customer
2 Controlled power supply Chroma 61604
3 Power analyzer Hioki PW6001
4 Oscilloscope Keysight MSOX3054T
5 Current probe Keysight 1147B
6 Air conditioner reference board Microchip reference design
10
PFC Section
⚫ Implemented in master core of
dsPIC33CH128MP508
⚫ Active interleaved PFC
⚫ Efficiency > 93%
⚫ THD < 5% above 50% load
⚫ Power factor > 0.95 above 50% load
⚫ Switching frequency 64 kHz
⚫ IGBT and diode from ROHM
⚫ Gate driver from Microchip
Bridge
RectifierInterleaved
PFC
EMI
Filter
Gate
DriverMCP14E4
230VAC
11
PFC Test Results – Diff
Diode, IGBT Combination
* Tested with resistive load
12
Compressor Section
Compressor Motor
⚫ Supports PMSM or IPMSM
⚫ dsPIC33CH128MP208 slave
core for motor control
⚫ Up to 1.4KW inverter stage
⚫ 4 to 20kHz switching frequency
Sensorless
FOCVariable
Speed
Control
Field
Weakening
Stall Detection
Torque
CompensationImplemented
Motor Control
Algorithms
Interleaved
PFC
3 Phase
IPM
Gate
DriverMCP14E4
Over Current &
Voltage Protection
MCP6541/2
7×Current &
voltage Sense
MCP6V92
VDC
3×
Compressor
PLL EstimatorMTPA for
IPMSM
13
Test Results – with PFC &
Compressor Motor
* Board efficiency: PFC input and drive output
14
Outdoor Unit Fan Section
Fan Motor
⚫ Supports PMSM or IPMSM
⚫ dsPIC33CH128MP slave
core for motor control
⚫ 150W power stage
⚫ 20kHz switching frequency
Interleaved
PFC
3 Phase
Discreet
IGBT
Power
Stage
Gate
DriverMCP14E4
Over Current &
Voltage Protection
MCP6541/2
7×Current &
voltage Sense
MCP6V92
VDC
3×
Fan
Sensorless
FOCVariable
Speed
Control Stall Detection
w/ Recovery
Wind-MillingImplemented
Motor Control
Algorithms PLL EstimatorMTPA for
IPMSM
15
dsPIC33 DSC Roadmap
70 MIPS 3V/5V
Fe
atu
res
/Mem
ory
dsPIC33EP512MC
32 - 512KB Flash
4 - 48KB RAMOp-Amps, CAN
3V, Functional Safety28/36/44/64 pins
100 MIPS Single/Dual Core
dsPIC33EV256GM
32 - 256KB ECC Flash
4 - 16KB RAM
Op-Amps, CAN, SENT
5V, Functional Safety
28/44/64 pins
dsPIC33CH128MP
64 - 128KB ECC Flash
20KB RAM
Dual Core, Dual Motor
DACs, PGAs, CAN-FD
28/36/48/64/80 pins
dsPIC33CH512MP
256 - 512KB ECC Flash
48 - 72KB RAM BIST
Dual Core, Dual Motor
DACs, PGAs, 2xCAN-FD
48/64/80 pin
dsPIC33CK256MP
32 - 256KB ECC Flash
8 - 24KB RAM
Single Core, DACs
Op-Amps, CAN-FD
28/36/48/64/80 pins
dsPIC33CK64MP
32 - 64KB Flash, ECC
8KB RAM
Single Core, DACs
Op-Amps, SENT
28/36/48 pins
Ideal DSCs for
Aircon Design
16
dsPIC33CH Block Diagram
Peripheral Tigger Gen (1)
SMPS/MC PWM (4 Ch.)
ADC (1x 12-bit, 16 Ch.)
Analog Comparator (1)
I2C (2)
CAN-FD
UART (2)
SPI (2)
SENT (2)
Timers
Capture/Comp/
PWM (8)
Configurable
Logic Cell
MEMORY BUS
PE
RIP
HE
RA
L B
US
MASTER
Core
dsPIC33C
90 MIPS
5 Reg Set 5 ACC Set
SMPS/MC PWM (8 Ch.)
ADC (3x 12-bit, 18 Ch.)
Analog Comparator (3)
PGA (3)
I2C (1)
SPI
UART
Configurable
Logic Cell
Capture/Comp/
PWM (4)
Timers
MEMORY BUS
PE
RIP
HE
RA
L B
US
SLAVE
Core
dsPIC33C
100 MIPS
5 ACC Set5 Reg Set
128 KB
ECC Flash
16 KB
Data RAMDMA (6)
24 KB
ECC PRAM
4 KB
Data RAMDMA (2)
Mailboxes
FIFO
FIFO
WDT & DMT WDT
17
Target Markets
Air Conditioner
Refrigerator
Washing Machine Dish Washer
PFC Power Supplies
18
Enabling Aircon Customers
⚫ Schematics, BoM and PCB design files
⚫ Firmware implementation for PFC and dual motor control
⚫ User’s guide and application note
⚫ Demo boards are available on loan to qualified customers
⚫ Refence design webpage: www.microchip.com/aircon
Complete solution for Air-Conditioner Outdoor Unit
http://www.microchip.com/aircon
19
Summary
SLAVE
Core
dsPIC33CH
100 MIPS
MASTER
Core
dsPIC33CH
90 MIPS
Power Factor
Correction Fan Compressor
IPC
A solution that reduces three devices to one
⚫ Air Conditioner Reference Design based on
Dual Core dsPIC33CH DSCs
⚫ Platform for developing high voltage power
systems (1.8KW) with PFC for white goods
⚫ Integrates PFC and dual motor
control into a single chip for
cost effectiveness
⚫ Implements sophisticated
motor control algorithms for
high efficiency