PSOC™ Control MCU: PCCM buck converter multi-phase

This code example demonstrates a multi-phase buck converter in peak current control mode (PCCM) with the PSOC™ Control C3M5 Complete System Dual Buck Evaluation Kit. This code example uses the Power Conversion Configurator (PCC) tool and power conversion middleware for implementation.

View this README on GitHub.

Provide feedback on this code example.

Requirements

ModusToolbox™ v3.5 or later
Board support package (BSP) minimum required version: 1.0.3
Programming language: C
Associated parts: All PSOC™ Control C3 MCUs
ModusToolbox™ Industrial MCU Pack: v2.1 or later

Supported toolchains (make variable 'TOOLCHAIN')

GNU Arm® Embedded Compiler v11.3.1 (GCC_ARM) – Default value of TOOLCHAIN
Arm® Compiler v6.22 (ARM)
IAR C/C++ Compiler v9.50.2 (IAR)

Supported kits (make variable 'TARGET')

PSOC™ Control C3M5 Digital Power Control Card (KIT_PSC3M5_CC1) – Default value of TARGET
PSOC™ Control C3M5 Complete System Dual Buck Evaluation Kit (KIT_PSC3M5_DP1)

Hardware setup

This code example is intended to be used with the PSOC™ Control C3M5 Digital Power Control Card. The control card can be used with an interface board or a dual buck system board with two buck converter power stages on it. The combination with the dual buck system board is called "PSOC™ Control C3M5 Complete System Dual Buck Evaluation Kit".

This code example demonstrates the operation of the two converters available on the board in PCCM.

Follow these steps to set up the hardware to use this code example (See Figure 1):

Insert the PSOC™ Control C3M5 Digital Power Control Card to the dual buck evaluation board
Connect the Type-C cable provided with the kit between the control card and the PC
Connect the 24 V wall adapter provided with the kit to the connector J1 on the dual buck evaluation board and power socket

Figure 1. PSOC™ Control C3M5 Complete System Dual Buck Evaluation Kit
Connect the jumper (J14) to configure the board in multi-phase topology
To measure the output voltage, connect an oscilloscope or multimeter to the output terminals of buck converter (TP23) or (TP27)
The dual buck evaluation board comes with onboard load. To use the onboard load, ensure that the jumpers J5 and J6 (for channel 1), and J8 and J9 (for channel 2) are mounted on dual buck evaluation board

To evaluate different signals, the test points (TP) are provided on the dual buck evaluation board. For PWM signals:

TP5 and TP7 for buck 1
TP14 and TP16 for buck 2

See the kit user guide for more information.

Software setup

See the ModusToolbox™ tools package installation guide for information about installing and configuring the tools package.

Install a terminal emulator if you do not have one. Instructions in this document use Tera Term
Install ModusToolbox™ Industrial MCU Pack from Infineon Developer Center to use the Power Conversion Configurator (PCC) tool

Using the code example

Create the project

The ModusToolbox™ tools package provides the Project Creator as both a GUI tool and a command line tool.

Use Project Creator GUI

Open the Project Creator GUI tool

There are several ways to do this, including launching it from the dashboard or from inside the Eclipse IDE. For more details, see the Project Creator user guide (locally available at {ModusToolbox™ install directory}/tools_{version}/project-creator/docs/project-creator.pdf)
On the Choose Board Support Package (BSP) page, select a kit supported by this code example. See Supported kits

Note: To use this code example for a kit not listed here, you may need to update the source files. If the kit does not have the required resources, the application may not work
On the Select Application page:

a. Select the Applications(s) Root Path and the Target IDE

Note: Depending on how you open the Project Creator tool, these fields may be pre-selected for you

b. Select this code example from the list by enabling its check box

Note: You can narrow the list of displayed examples by typing in the filter box

c. (Optional) Change the suggested New Application Name and New BSP Name

d. Click Create to complete the application creation process

Use Project Creator CLI

The 'project-creator-cli' tool can be used to create applications from a CLI terminal or from within batch files or shell scripts. This tool is available in the {ModusToolbox™ install directory}/tools_{version}/project-creator/ directory.

Use a CLI terminal to invoke the 'project-creator-cli' tool. On Windows, use the command-line 'modus-shell' program provided in the ModusToolbox™ installation instead of a standard Windows command-line application. This shell provides access to all ModusToolbox™ tools. You can access it by typing "modus-shell" in the search box in the Windows menu. In Linux and macOS, you can use any terminal application.

The following example clones the "PCCM buck converter multi-phase" application with the desired name "PccmMultiPhaseBuck" configured for the KIT_PSC3M5_CC1 BSP into the specified working directory, C:/mtb_projects:

project-creator-cli --board-id KIT_PSC3M5_CC1 --app-id mtb-example-ce241298-pccm-buck-multi-phase --user-app-name PccmMultiPhaseBuck --target-dir "C:/mtb_projects"

The 'project-creator-cli' tool has the following arguments:

Argument	Description	Required/optional
`--board-id`	Defined in the field of the BSP manifest	Required
`--app-id`	Defined in the field of the CE manifest	Required
`--target-dir`	Specify the directory in which the application is to be created if you prefer not to use the default current working directory	Optional
`--user-app-name`	Specify the name of the application if you prefer to have a name other than the example's default name	Optional

Note: The project-creator-cli tool uses the git clone and make getlibs commands to fetch the repository and import the required libraries. For details, see the "Project creator tools" section of the ModusToolbox™ tools package user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mtb_user_guide.pdf).

Open the project

After the project has been created, you can open it in your preferred development environment.

Eclipse IDE

If you opened the Project Creator tool from the included Eclipse IDE, the project will open in Eclipse automatically.

For more details, see the Eclipse IDE for ModusToolbox™ user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mt_ide_user_guide.pdf).

Visual Studio (VS) Code

Launch VS Code manually, and then open the generated {project-name}.code-workspace file located in the project directory.

For more details, see the Visual Studio Code for ModusToolbox™ user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mt_vscode_user_guide.pdf).

Arm® Keil® µVision®

Double-click the generated {project-name}.cprj file to launch the Keil® µVision® IDE.

For more details, see the Arm® Keil® µVision® for ModusToolbox™ user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mt_uvision_user_guide.pdf).

IAR Embedded Workbench

Open IAR Embedded Workbench manually, and create a new project. Then select the generated {project-name}.ipcf file located in the project directory.

For more details, see the IAR Embedded Workbench for ModusToolbox™ user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mt_iar_user_guide.pdf).

Command line

If you prefer to use the CLI, open the appropriate terminal, and navigate to the project directory. On Windows, use the command-line 'modus-shell' program; on Linux and macOS, you can use any terminal application. From there, you can run various make commands.

For more details, see the ModusToolbox™ tools package user guide (locally available at {ModusToolbox™ install directory}/docs_{version}/mtb_user_guide.pdf).

Operation

Set up the hardware as explained in the Hardware setup section
Start the terminal emulator program and open the COM port emulated for the control card
Configure the COM port with the following settings:

Speed: 115200, Data bits: 8 bits, Parity: None, Stop bits: 1, Flow control: None
Build and download the project to the hardware
Press the reset button on the control card. The terminal displays the messages as shown in Figure 2. Verify that the STATUS LED on the control card is blinking

Figure 2. Terminal output on program startup
Press the USER_BTN on the dual buck evaluation board to start the regulation of output voltage in the buck converter. The ACT_LED(D5) on the dual buck evaluation board will start glowing
To test the converters using variable load, keep the SPDT switches SW4 and SW5 in variable mode and rotate the potentiometers R42 and R61 to vary the load current
Measure the output voltage from both converters with TP23 (buck 1) and TP27 (buck 2) using an oscilloscope or a multimeter. It should show 5 V DC in both cases
To test the transient load, keep the SPDT switches in the transient mode and switch the converter to the transient test mode by pressing the user button. When the transient test is running, the ACT LED (D5) will blink

Figure 3. Switch and load details
Press the button again to stop the pulses for transient testing and output voltage regulation in the buck converter. ACT_LED(D5) will also turn off
Press the button again to repeat the sequence from Step 6

Note: Do not switch from the transient load to variable load using SPDT switches when the converter is running, as it will cause the converter to generate a fault signal. Only change it when the converter is in the OFF state

To evaluate different signals, the test points (TP) are provided on the dual buck evaluation board. For example, for PWM signals:

TP5 and TP7 for buck 1
TP14 and TP16 for buck 2

See the kit user guide for more information.

Debugging

You can debug the example to step through the code.

In Eclipse IDE

Use the <Application Name> Debug (JLink) configuration in the Quick Panel. For details, see the "Program and debug" section in the Eclipse IDE for ModusToolbox™ user guide.

In other IDEs

Follow the instructions in your preferred IDE.

PCC tool and middleware

The Power Conversion Configurator (PCC) tool is a software-ready solution that demonstrates application-oriented power converters and makes the firmware ready to users. The aim of the tool is to save design/R&D time of the user and provide an ecosystem to quickly develop power conversion solutions. It is an intuitive tool that allows the firmware generation needed for control systems in the context of power converters with just a few mouse clicks.

The tool currently supports buck converter designing in various configurations, including single-instance, multi-instance, and multi-phase (interleaved) topologies, operating in both voltage control mode (VCM) and peak current control mode (PCCM). The tool also supports the control loop divider feature which enables the use of high PWM frequencies. It generates coefficients for 2p2z and 3p3z compensators based on the converter parameters.

The power conversion middleware provides a library of compensators using different power converter topologies; it also provides personalities to work with the Device Configurator and PCC tool. By using the power conversion middleware personalities, the Device Configurator and PCC tool generate customized firmware, ensuring a seamless and efficient design process.

The power conversion middleware and the PCC tool work together. In this code example, the middleware is added to the project and the configuration is updated with the PCC tool and Device Configurator to work as a PCCM multi-phase buck converter.

Figure 4 shows the image of complete PCC tool.

Figure 4. PCC tool

Note: See the PCC tool and middleware documentation for more information.

Design and implementation

This code example is intended to be used with the PSOC™ Control C3M5 Complete System Dual Buck Evaluation Kit. Two synchronous buck converters are available on the dual buck evaluation board provided with the kit. The buck converters on the dual buck evaluation board can be used in multiple configurations, such as single-phase, multi-phase, and multi-instance. This code example demonstrates the multi-phase configuration.

This code example converts a DC 24 V input provided to the dual buck evaluation board from the wall adapter to a stable DC 5 V output. Two instances of the PWM available with the chip drives the gates for the two buck converters. Another instance of the PWM is used for transient load testing at a frequency of 1 Hz (on time - 30% and off time - 70%). The ADCs and the comparator and slope generator (CSG) available with the high-performance programmable analog subsystem (HPPASS) are used in the feedback path. Two instances of DMA available and selectable through PCC tool per buck converter are used to transfer the data without CPU intervention. One DMA instance is used for transferring the data from ADC result register to output voltage variable in SRAM and another instance is used to transfer the output of the 2P2Z filter (next peak reference) to the DAC A buffer register. DMA usage is selectable through the PCC tool.

During peak current control, the output voltage is regulated by two essential loops:

A digital voltage control loop executed at a defined control frequency which updates the peak current reference
An analog current control loop based on DAC and comparator is provided in the analog peripheral of the PSOC™ Control C3M5 device

A 2P2Z compensator implemented in the firmware controls the outer voltage loop. It calculates the initial and final values for the slope generator in the CSG in all PWM cycles based on the measured output voltage and writes the results to the CSG registers. To achieve this, the PWM triggers an ADC conversion every PWM cycle. The ADC conversion complete signal triggers a DMA data transfer and generate a DMA transfer complete interrupt. The compensator runs within the interrupt service routine (ISR). As this implementation is multi-instance, one ADC groups is used for reading the output voltage from interleaved converters. ADC groups is triggered by the respective buck 1 PWMs on their terminal count.

The inner current loop is controlled by the CSG available with HPPASS. The inductor current captured through a current transformer is fed directly to the comparator of the CSG as one input. The comparator compares it with the reference generated by the internal DAC and modulates the PWM.

The cycle-by-cycle current loop provides a good response for fast load transients. However, this becomes unstable with a duty cycle of over 50 percent. To avoid this, slope compensation is added to maintain an average current waveform and avoid instability. To enable slope compensation, the CSG can generate the slope from the initial and final values calculated by the compensator.

Three LEDs (STATUS LED, ACT LED, and FAULT LED) and a user button are available on the kit. Out of the three LEDs, ACT LED and FAULT LED are on the dual buck evaluation board while the STATUS LED is on the control card.

The user button can be used to switch the converter between different states. Behavior of the converter and the LED status are shown in Figure 8 of the Firmware states section.

The dual buck evaluation board integrates two onboard transient and variable load circuits, providing individual load control for each buck circuit. A single pole double throw (SPDT) switch, SW4 for buck 1 and SW5 for buck 2, provides easy selection between transient and variable load circuits, enabling flexible load management.

To perform the transient load test, it is required to keep the SPDT switch in transient mode and the same for the variable load test. The transient load circuit enables seamless load switching between 0.2 A and 1.8 A. Control for this circuit is managed by a 3.3 V PWM waveform from the PSOC™ C3M5 controller.

The variable load circuit supports load variation from 0.2 A to 1 A, controlled by potentiometers R42 for buck 1 and R61 for buck 2. The load can be increased by rotating the potentiometer clockwise and decreased by rotating it anti-clockwise.

Figure 5 shows the block diagram of PCCM with a multi-phase converter.

Figure 5. Block diagram - PCCM multi-phase

One of the most prominent features of PSOC™ Control C3M5 devices is the comprehensive interconnectivity matrix within on-chip peripherals. The HPPASS and TCPWM modules are highly interconnected; the conversion can be run completely in the background. The start of the conversion is triggered when the terminal count of the TCPWM counter occurs. Once the conversion result is available, a DMA transfer complete interrupt service request is activated, and the outer voltage loop function is executed in software (2P2Z compensator) within the ISR.

Figure 6 shows the PCCM timing diagram.

Figure 6. PCCM timing scheme

During the ON time of the PWM, the inductor current rises. When this current reaches the peak current reference level, the PWM ON time period is terminated by a trigger from the CSG. The output voltage is sampled periodically; any difference with the reference voltage is compensated for and supplied as the peak current reference.

Frequency response:

Figure 7 shows the frequency response captured from bode analyzer with these parameters.

The red line indicates the amplitude response
The blue line indicates the phase response

Figure 7. Frequency response

Features of the CE

Input voltage: 24 V
Output voltage: 5 V
Switching frequency: 300 kHz
Control loop frequency: 300 kHz (control loop divider = 1)
Crossover frequency: 5 kHz
Phase margin: 50 degrees
Pure time delay: 2
Control loop execution time : 590 ns
DMA based data transfer
Control loop divider
Hardware-based protection (ADC limit detection)
Scheduled ADC group

The PCC tool has the option to enable callbacks functions. You can provide the name of the callback functions in the Device Configurator and PCC tool. As these functions are being called from the ISR, the functions must be defined as static inline functions to achieve optimal performance. The Device Configurator even gives you the option to name the header file. When the code is generated, it will include the header file in the generated files and add calls to the user functions from the ISR. These callback functions can be used for implementing features, such as overvoltage or overcurrent protection.

In this code example, using a callback functions called as buck1_fault_callback and buck1_scheduled_adc_callback.

Note: See the AN23829 - Synchronous buck converter with PSOC™ Control C3 MCU for detailed information.

Protection and soft start implementation

Protection mechanisms are implemented to avoid the system operating beyond a limit. Input voltage, output voltage, output current, and temperature are checked, ensuring the system is not damaged by operating beyond the values it could run.

Currently, the following values are set as the range:

Input voltage lower limit: 12 V
Input voltage upper limit: 42 V
Output voltage lower limit: 4 V
Output voltage upper limit: 6 V
Output current upper limit: 3 A
Board temperature upper limit: 75 degrees Celsius

The protection logic is implemented in two ways, hardware and software-based. For output voltage, ADC limit detection-based hardware protection is implemented. For input voltage, output current, and temperature scheduled ADC-based software protection is implemented. The protection logic runs within a callback function from the ISR, which is triggered by software/firmware every 100 Hz. The moving average of the input voltage, output current, and temperature is calculated. If any one of the values go out of the predefined range, a fault condition is triggered and the PWM is terminated. The FAULT LED glows to indicate the fault condition.

In addition to the protection implementation, soft start is implemented to ensure that the output voltage ramps up gradually from zero on startup. An additional timer is used to implement this feature; it runs at 100 Hz and triggers interrupts at the terminal count. The soft start logic is implemented inside this ISR by gradually increasing the output reference value for the compensator. After the completion of soft start, the timer is kept enabled; to provide firmware trigger to the scheduled ADC group.

Firmware states

During startup, the firmware initializes the peripherals and configures the interrupt, and then waits for button interrupts. When it is pressed, the state machine switches between different states and turning ON and OFF of the converter, transient test pulses, LED, and more will take place. See Figure 8 for more details.

Figure 8. State machine

As Figure 8 shows, the four states are implemented. During startup, the state machine is in the "Idle" state. When the button is pressed, it switches between the different states as shown in Figure 8. When a fault is detected by the firmware, it immediately switches to the "Fault" state and disables the converter and transient testing pulses. The converter can be restarted by pressing the user button again.

Resources and settings

Table 2. Application resources

Resource	Alias/object	Purpose
TCPWM[0] Group[0] Counter[0], P4.4, P4.5	PWM_BUCK_1, PWM_B1_L, PWM_B1_C	PWM driving the gates of buck converter 1
TCPWM[0] Group[0] Counter[1], P4.6, P4.7	PWM_BUCK_2, PWM_B2_L, PWM_B2_C	PWM driving the gates of buck converter 2
TCPWM[0] Group[1] Counter[0], P6.0, P6.1	PWM_LOAD, LOAD_1, LOAD_2	PWM for transient load testing
TCPWM[0] Group[1] Counter[1]	BUCK1_BLANK_PULSE	PWM for internal blanking pulse generation for buck converter 1
TCPWM[0] Group[1] Counter[2]	BUCK2_BLANK_PULSE	PWM for internal blanking pulse generation for buck converter 2
TCPWM[0] Group[2] Counter[0]	SOFT_START_COUNTER	Timer for soft start
TCPWM[0] Group[2] Counter[1], P9.5	STATUS_LED	PWM for blinking status LED
TCPWM[0] Group[2] Counter[2], P2.3	ACT_LED	PWM for blinking transient LED
ADC Sampler 0, AN_A0	BUCK1_VOUT	Output feedback voltage from buck converter 1
ADC Sampler 5, AN_A5	BUCK2_VOUT	Output feedback voltage from buck converter 2
ADC Sampler 6, AN_A6	BUCK1_IOUT	Inductor current from buck converter 1
ADC Sampler 7, AN_A7	VIN	Input voltage
ADC Muxed Sampler 0, AN_B4	BUCK2_IOUT	Inductor current from buck converter 2
ADC Muxed Sampler 1, AN_B5	BUCK1_TEMP	Board temperature from buck converter 1
ADC Muxed Sampler 3, P8.0	BUCK2_TEMP	Board temperature from buck converter 2
CSG Slice 1, AN_A1	IND_CURRENT_BUCK1	Converter 1 high side switch current
CSG Slice 3, AN_A3	IND_CURRENT_BUCK2	Converter 2 high side switch current
DMA DW0, channel 0	DMA_BUCK1_MOD	Data transfer from output of 2P2Z compensator to DAC A buffer register for buck converter
DMA DW0, channel 1	DMA_BUCK1_PROT	Data transfer from ADC result register to output voltage variable for buck converter
P3.0	FAULT_LED	Indication for fault detection
P3.1	ACT_LED	Indication for converter running and transient testing status
P9.5	STATUS_LED	Indication for code running status
P9.4	USER_BUTTON	Button for switching between different states
SCB3	DEBUG_UART	UART HAL object used by retarget-I/O for the debug UART port

Related resources

Resources	Links
Application notes	AN238329 – Getting started with PSOC™ Control C3 MCU on ModusToolbox™ software AN239714 – KIT_PSC3M5_DP1 Dual Buck Evaluation Board user guide AN239961 – Synchronous buck converter with PSOC™ Control C3 MCU
Code examples	Using ModusToolbox™ on GitHub
Device documentation	PSOC™ Control C3 MCU datasheet PSOC™ Control C3 technical reference manuals
Development kits	Select your kits from the Evaluation board finder
Libraries on GitHub	mtb-pdl-cat1 – Peripheral Driver Library (PDL) mtb-hal-psc3 – Hardware Abstraction Layer (HAL) library retarget-io – Utility library to retarget STDIO messages to a UART port
Middleware on GitHub	mtb-pwrconv – ModusToolbox™ power conversion middleware
Tools	ModusToolbox™ – ModusToolbox™ software is a collection of easy-to-use libraries and tools enabling rapid development with Infineon MCUs for applications ranging from wireless and cloud-connected systems, edge AI/ML, embedded sense and control, to wired USB connectivity using PSOC™ Industrial/IoT MCUs, AIROC™ Wi-Fi and Bluetooth® connectivity devices, XMC™ Industrial MCUs, and EZ-USB™/EZ-PD™ wired connectivity controllers. ModusToolbox™ incorporates a comprehensive set of BSPs, HAL, libraries, configuration tools, and provides support for industry-standard IDEs to fast-track your embedded application development

Other resources

Infineon provides a wealth of data at www.infineon.com to help you select the right device, and quickly and effectively integrate it into your design.

Document history

Document title: CE241298 – PSOC™ Control MCU: PCCM buck converter multi-phase

Version	Description of change
1.0.0	New code example

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