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1. o xd 4 2 3 E ow ZH Zn gu x Dm e e B o J9 m JB T laia a Ld 0v a pase vA 7 we J2 s ia n ps _ o E B 3 C Figure 6 PINT Design with Power Line Filter for 3 Amp load PINT Example 2 incorporates a power line filter MOV suppressors a NTC thermistor for in rush control and DC bus capacitors Power Line Filtering A power line filter is the main method for emmisions control By controlling conducted emmisions the filter is also successful in controlling radiated emissions from the power supply cable Line filters usually consists of a common mode inductor two X capacitors across the line and two Y capacitors line to Earth Most power line filters follow this format and information on filter design and component selection is widely available Probably the most important consideration is selecting a common mode inductor with sufficient current rating to avoid saturation Because of the input rectifier the power factor of an inverter is much less than the motor itself As a rule of thumb the filter should be sized for 2X the motor current This rating applies to other components affected by current such as the fuse and power conductors Selecting the basic components for a filter design is straightforward However measuring it s effectiveness is not Anacon recommends using a test lab and or filter design service for fine tuning a design2. 3 Wire must have approved insulation for AC line voltage Section The Reference Design Kit Howtoasartleadladwutethe PDB3 RdaexeDesgi Kit The components in the Reference Design Kit can be assembled into a complete working drive to allow evaluation of motor performance under variable speed The Configuration Kit DD3CFG allows a Windows PC to take the place of a COIN board Control Interface Refer to Configuration Kit documentation for instructions on software installation and operation STEP 1 Mount PDB3 on Heatsink Remove the blue backing from the thermal interface material included in the hardware kit Apply the interface material to PDB3 s aluminum mounting plate Next remove the clear backing from the exposed side of the thermal interface material Position PDB3 on heatsink with the power connections in the center of the heatsink Secure with the short 8 32 screws and washers STEP 2 Mount PINT on Heatsink and Connect PINT Use 3 plated spacers and the long 8 32 screws to mount the PINT board on the heatsink Six flying wires from the PINT connect to the power connections on PDB3 OV DC AC AC MI M2 BLACK RED BROWN BLUE WHITE YELLOW Finally connect the 3 way wire harness to J7 The two pin connector from the harness connects to J3 or J4 on the PINT board This wiring provides a speed control potentiometer and supplies power to the in rush control relay on the PINT Figure 4 Photo of Ful
3. If the DC bus is higher than its typical value the modulation is scaled down If the DC bus is lower than typical then modulation is increased An external microprocessor can read the DC bus voltage using the Q06 command calculate the error and adjust the output voltage using the O command The error calculation must take into account the effect of flat topping for all modulation values over 100 28 For example with 100Vac supply voltage For Int Mod less than 100 Vout rms Int Mod 96 0 972 4 17 34 For Int Mod greater than 100 Vout rms Int Mod 0 33 71 4 If the AC Supply is say 10 low Comp 100 90 1 11 For Int Mod less than 100 Vout rms Int Mod 0 972 1 11 17 34 For Int Mod greater than 100 Vout rms Int Mod 0 33 1 11 714 Configuration Memory The operation of PDB3 is controlled by parameters stored in EEPROM Serial commands are used to read and write the parameters The EEPROM parameters and their locations are given in the following table 00 EE Programmed DE 0x55 EE programmed indicator 01 EE Input Select DE 1 30 PWM 1 0 5V input 2 Serial 02 EE_Max_Freq DE 130 365 Hz 03 EE Min Freq DE 30 315 Hz 04 EE Accel DE 10 10 Hz sec 05 EE Decet DE 5 35 Hz sec 06 EE Boost Time DE 5 35 Sec 07 Boost Freq DE 100 50 Hz 08 EE_Start_Mod DE 64 350 96 09 End Mod DE 128 100 96 EE Knob Off DE 12 33 12 255 0 25V OB EE Knob
4. This is especially true if a regulatory standard must be met ie EN standards for European Union Bus Capacitors Bus capacitor selection is important in determining the performance and reliability of the system They are one of the few components that has a definite wear out characteristic The capacitor voltage should be selected according to the highest DC bus voltage 1 414 x Vline For 115Vac 10 200V capacitors are normally used The capacitor value determines its ripple rating and internal impedance These factors in turn influence the stability of PDB3 s output waveform under load and the temperature and life of the capacitor Cornell Dublier has a capacitor life calculator applet on their website www cornell dubillier com In Rush Control When power is applied the DC bus capacitors must charge to hundreds of volts before the drive can start This will create a current in rush capable of damaging the input rectifier or blowing fuses if not controlled An in rush control circuit adds impedance while the bus capacitors charge before assuming a low impedance state when PDB3 runs The peak current should be kept below 25 Amps 20 NTC thermistors are an economical solution where the line current is less than 10 Amps Keystone Thermometrics is a good source for additional information and parts The PINT included with the Design Accelerator Kit uses a relay in parallel with a PTC thermistor When powe
5. Current Measurement 33 Overview Introduction Introduction to PDB3 Design Manual Single phase Induction motors are everywhere but until Anacon Systems created the DigiDrive family control options were limited to poorly performing Triac based controls Anacon s drive technology synthesizes a true sine wave through the motor The result is variable speed with better efficiency quieter operation greater range and longer life Anacon s Power Drive Block HI PDB3 allows Original Equipment Manufacturers to take advantage of this technology within their own products PDB3 is a compact module containing proprietary circuits and sophisticated firmware Creating a customized drive solution requires adding just a few external components The PDB3 Design Guide contains detailed information on every aspect of designing with PDB3 including numerous tips to assist with product development PDB3 Design Accelerator Kit This Manual is supplied with the PDB3 Design Accelerator Kit Before proceeding check that all listed items are included and take a moment to familiarize yourself with each PDB3 Design Guide This document x1 PDB3 Module Part No B1182 x2 Power Interface Board PINT Part No B1201 x1 PDB3 Configuration Kit Part No DD3CFG x1 o DashDrive 2 0 for Windows 95 98 Me 2000 and XP D D O UD o Configuration Adaptor with Cables o Instruction Manual Power Line Filters CAUTION o Corcom
6. On DE 20 38 20 255 or 0 4V OC EE_Serial_Timeout DE 10 10 seconds OD EE Default Freq DE 191 1596 191 255 about 52Hz w Default values OE EE VF Curve Select DE 2 360Hz Weak Fan only used by DashDrive 15 EE Current Limit LSBDE Oxff Current Limit of the drive 16 EE_Current_Limit_MSB DE Oxff 17 EE_VBus_High_LSB DE OxFF Max DC Bus voltage for the drive 18 EE_VBus_High_MSB DE OxFF 19 EE_VBus_Low_LSB DE OxFF Min DC Bus voltage for the drive 1A EE_VBus_High_MSB 1B EE_Baudrate DE 0x07 sbaud rate 9600 baud Monitor Values starting at location 20h 20 EE_Num_Starts_LSB DE 21 EE_Num_Starts_MSB DE 22EE Run Time LSB DE 23 EE Run Time ISB DE 24 EE Run Time MSB DE xdrive start counter Drive run time in minutes E 29 VF Curve starting at location 40h 17 values in table This one is the Weak Fan 40 EE VF Curve DE 6 8 17 28 41 55 77 102 146 146 146 146 146 146 146 146 146 Programmable Baud Rates A parameter in EEPROM allows changing the AS1101 baud rate to any standard baud rate from 1200 to 115 2k baud The table below gives the baud rates the EEPROM value to set the baud rate and the 5 command used to change the baud rate The Baud Rate parameter is at location 27 1B hex in EEPROM Baud Rate EEPROM Value EEPROM Command 1152k 0 SIBOOES 76 8k 1 S1B01E4 57 6k 2 S1B02E3 38 4k 3 S1
7. Usngthe PDB35 srid amatin jo antrd bya host ystan Overview The PDB3 s serial interface is used for both configuration and control In most cases the configuration is factory programmed using a PC running DashDrive However there are situations where the COIN microprocessor may need to make changes The same communications protocol is used for both configuration and control Simple ASCII characters pass command and data information so a Terminal program such as Hyper Terminal part of Windows can be used for testing PDB3 applies all commands and configuration changes immediately with the exception of a baud rate change The new baud rate setting will be applied the next time power is cycled assuming JP1 is set to USR Using a Terminal Configure HyperTerminal or other terminal program to match PD B3 s communications settings The default configuration is 9600 baud no parity 8 data bits and 1 stop bit 9600 n 8 1 Enter the commands as shown below followed by a carriage return Enter If the command is recognized by PDB3 it will send the appropriate response followed by ok If the command is not understood the command it received followed by will be echoed If the command is understood but there is a problem with the data sent with the command i e checksum error then the response will be NOT ok 24 Commands V Request firmware version V Version 01 00 ok U Request an Update record fr
8. status information Configuration PDB3 s internal Eeprom stores a table of configuration information for parameters such as frequency range acceleration and alarm limits The configuration can be edited using Anacon s DashDrive Configuration Kit included in the PDB3 Design Kit and a Windows PC or by the COIN directly if the COIN is microprocessor based The configuration commands are covered in Section 6 Before reading Section 6 Install DashDrive 2 0 and familiarize yourself with the configuration options DashDrive can configure and monitor most but not all PDB3 parameters e g Some control signal modes Block Diagram l sig EN 99i SR L 810 Thermal Shutdown Nut z P Input Rectifier p Pas 218 N 3 zio n SN 1 y ES 18V D N A KCN vA N A on M Bus Voltage Sense Power Inverter Stage Isolated Interface N TxD b Nee 1 RxDi Opto Anacon Microcontroller Isolation bs D 1 m i SX fos PDI M SN i Motor Current Sense S TN PC CX m2 J SY Me Non Isolated Interface e OP 15v 5v J OV REF ST J FLT J X por Nu uA NEF NEUES 0 Figure 3 PDB3 Block Dia
9. that the capacitors have discharged by measuring the DC bus voltage between and DC terminals with a meter STEP 5 Evaluate Connect the Configuration Adaptor to J12 on the PDB3 Use the supplied straight through serial cable to connect the Configuration Adaptor s 9 pin connector to a PC serial port Install DashDrive 2 0 or susequent version following the instructions in the DashDrive 2 0 User Manual Connect a motor to the drive output and apply power establish a connection to PD B3 Depending on the speed input control setting either the speed pot or DashDrive will control the motor speed The default settings will provide a good starting point for determining optimal configuration As a minimum we suggest configuring the following parameters in this order 1 Maximum Frequency 2 Minimum Frequency 3 Acceleration Deceleration 4 Volts Hertz Curve 5 Boost STEP 6 Filter Evaluation Two filter samples have been provided with the Design Accelerator Kit Metal can filters like these are a good starting point for filter evaluation In the final PINT design the filter can be implemented using descrete capacitors and inductors The 10VK3 Filter from Corcom provides modest control of conducted emissions The ED F1121 US Filter available from Anacon meets EN50081 2 and EN50081 1 when applied correctly to a PDB3 design Figure 5 Reference Design with ED F1121 US Filter Installed Section Power Interface Desig
10. 10VK3 RFI Filter x1 o Anacon ED F1121 US 10 Amp EN Filter x1 Q Heatsink Q Thermal Interface Material Q Insulated Speed Control Potentiometer with 3 way harness Hardware Kit x1 Also required but not included Q Line fuse or circuit breaker 10 Amp Q Power cable Before Proceeding Power electronics involves inherent risks both to equipment and personnel This manual assumes that the design engineer has experience with high voltage electronics Incorrect use of the PDB3 can be hazardous to development staff as well as the end user of the equipment Throughout the manual notes draw attention to safety related information This is not a complete list so the designer must research and understand electrical and mechanical issues specific to the end product yess Section The Ins and Outs of single Phase Motor Control Saneimpatant infamtin mmia sdatimand patim Motors that run directly from single phase power can be grouped into two main categories those that use brushes and those that don t Within those classifications are even more variations Brushed Motors Brushed motors can be built with magnets DC Brushed motor or without Universal motor In either case PDB3 is not a suitable control for these types of motors The speed of a brushed motor is proportional to voltage so a chopper circuit is usually the control of choice Induction Motors Single Phase motors without brushes are generally r
11. 2 D5 E60 72 72 05 0A 15 21 2C 49 5F 72 72 72 72 72 72 1D E70 72 72 72 05 06 OD 16 20 2B 3C 50 72 72 72 72 72 6B OK S The S command stores a value at a particular EEPROM location The format of the command is Saavvcc This command says at EEPROM location aa store value cc is an 8 bit checksum The checksum is computed so that the 8 bit sum of aa vv cc is always 0 All values must be in HEX and zero padded so that there are always 6 characters after the S command The HEX numbers A F must be entered in upper case If the firmware agrees that the checksum is correct and successfully programs the value it will respond with an ok prompt If the checksum is not correct it will respond with NOT ok The following command programs location 30 hex with 55 hex 30557B ok Reads a value from the EEPROM The format of the command is Raacc where aa is the EEPROM location of the value and cc is an 8 bit checksum The checksum is computed so that the 8 bit sum of aa cc is always 0 All values must be in HEX and zero padded so that there are always 4 characters after the R command The drive will respond with the value in the format of the S command as shown above Continuing with the example above for the S command if you then entered the following R command R30D0 30557B ok F Sets the frequency of the drive The format of the command is Fxx where xx is the desired speed in Hertz Two d
12. 232 Line Driver optional Sensor Signal Conditioning optional Control connectors Because PDB3 is highly integrated a complete drive can be built by adding a single capacitor for the PINT and a potentiometer for a COIN In practice most applications will require some of the additional circuits listed above The PINT and COIN circuits can often be implemented on a single circuit board In some cases the COIN will be a board that is already present in a system A typical example being a microprocessor based front panel circuit board Section Inside PDB3 InamatiavavPDB3S Feature and Funds Overview PDB3 is a small drive module for Single Phase Induction motors Only a few external electronic components and a heatsink are needed for a complete drive solution PDB3 is available in 4 0 Amp B1181 and 6 5 Amp B1182 current ratings and both can be used with line voltages from 100Vac to 277Vac see Electrical Specifications Pg36 for use above 240Vac All PD B3 circuits except J12 are at high voltage when power is applied Care should be taken when connecting external circuits and test Non isolated control o Isolated Jumpers DC Bus AC Input Control Terminals Terminal po Terminals Figure 2 PDB3 Interfaces PDB3 can be controlled with either analog or digital control signals The two way signals adjust the drive output frequency as well as return
13. B03E2 28 8k 4 S1B04E1 19 2k 5 S1B05E0 14 4k 6 51 06 9600 7 SIBO7DE 4800 8 SIBOSDD 2400 9 SIBO9DC 1200 10 SIBOADB PDO Functions The PDO output is open collector so the COIN should supply a pull up resistor in the to 100k range if the output is used Fault Code Output The PDO signal can output the status of the FAULT led The might be used to drive an LED on the front panel to show fault codes from the drive Under Voltage Output Signal In this mode PDO is normally high impedance i e Pulled to 5V Any time the DC bus voltage is below the programmed level the open collector output will be activated 30 When Vbus is GREATER than ALARM then PDO output is high impedance can be pulled high When Vbus is LESS than or equal to UV ALARM then PDO output is low UV ALARM is a 16 bit value at Eeprom locations 12hex LSB and 13hex MSB If the value is 0000 hex this feature is turned off Default For example to set UV ALARM to 130Vdc 0150 hex x 0 38467 then send the following commands 512509 ok S1301EC Ok The new limit will be active immediately and the micro will update the PDO output status every 100ms PDI Functions Enable Input PDI can be configured to act as a digital control input When the signal is LOW the drive is disabled Isolated PWM Speed Control PDI can also act as an isolated 100Hz PWM speed input where 0 is OFF and 100 is full speed Enablin
14. Engineering Documents for Safety and EMC documents www global ihs com 39 TEST EQUIPMENT John Fluke Manufacturing www fluke com Fluke 41B Power Harmonics Meter 40 Appendix FAQ FrqueantlyA skal Quetins Q What versions of DashDrive can be used with PDB3 A DashDrive 2 0 and subsequent releases can be used with PDB3 Q What is the best instrument for measuring the output voltage and current A We recommend a Fluke 41B Power Harmonics Analyzer This instrument does a great job of filtering the PWM waveform and can make many useful measurements including frequency power and distortion Q Can you please send me the schematic diagrams for PDB3 A No The PDB3 hardware is proprietary to Anacon Systems Q Does the PDB3 serial protocol support multi drop communications A No The protocol supports point to pomt communication only Q How can I get assistance with my PINT and COIN design A Anacon can provide design engineering consultation and services for an hourly or fixed fee My company s control needs go beyond PDBS3 s capabilities What are my options A Anacon has building blocks an advanced library of application design and experienced design staff We develop motor control solutions quickly and affordably Call Toll free 1 888 456 3398 for a proposal 41 Appendix Glossary AC Input Voltage The AC line voltage expressed in RMS volts AC Output Voltage Motor Voltag
15. SYSTEMS PDB3 Design Guide ANACON SYSTEMS INC DESIGN AND APPLICATION CENTER 9433 BEE CAVE ROAD BLDG 1 SUITE 140 AUSTIN TX 78733 TEL 512 263 8668 FAX 512 263 8060 AMACOM SV Arras Design Guide DashDrive Cet um me Vm aee cerne De USER INSTRUCTIONS PDB3 Design Guide Revision 1 1 Copyright 2002 Anacon Systems Inc DashDrive and DigiDrive are trademarks of Anacon Systems Inc Windows is a trademark of Microsoft Corporation Table of Contents Introduction 4 Mechanical and Thermal 34 PDB3 Design Accelerator Kit 4 EMC and Safety Compliance 35 Before Proceeding 5 Safety 35 The Ins and Outs of Single Phase EMC 36 Motor Control 6 PDB3 Electrical Specification 37 Brushed Motors 6 PDBS Dimensions 38 Induction Motors 6 Resources 39 How Anacon Single Phase Drives Work 7 FAQ 41 System Architecture 8 Glossary 42 Inside PDB3 10 Overview 10 Configuration 11 Block Diagram 11 Jumpers 12 LED Status Indication 12 Fault Detection and Indication 12 Connections 13 The Reference Design Kit 15 Power Interface Design 18 Considerations 18 Example 1 18 Example 2 19 Control Interface Design 22 Considerations 22 Serial PWM or Analog Control 22 Example 1 23 Configuration and Communication24 Overview 24 Using a Terminal 24 Commands 25 Protocol 27 Output Voltage 27 Bus Voltage Compensation 28 Configuration Memory 29 PDO Functions 30 PDI Functions 31 Making Measurements 32 DC Bus Measurement 32 AC Motor
16. as series of flashes followed by a pause Faults can only occur when the drive output is running Disabling the drive output using serial commands the Enable input or the 0 5V speed input will clear faults The appropriate method will depend on which control source is selected in the Eeprom configuration Fault Code Description Default Setting Can be disabled 2 Fast Current Trip Short Circuit Enabled No 3 Over Current Disabled for now Yes 4 Heatsink Over Temperature 95 5 DC Bus Voltage too High Disabled Yes 6 DC Bus Voltage too Low Disabled Yes Connections PDB3 has three sets of connections 1 J1 6 High voltage Power connect to PINT Jl J2 are AC Input Terminals J3 J4 are Motor Output Terminals J5 J6 are DC Bus Capacitor Terminals 2 J7 Non lsolated Control connect to COIN 3 J12 Isolated Control connect to COIN Normally only J7 or J12 is used J12 being fully isolated is the preferred COIN connection however it is a digital only interface Both control connectors have DC supply outputs available for powering external COIN circuits Refer to Electrical Specifications for voltage and current capabilities CONTROL SIGNALS ISOLATED Terminal Label Description Comment L AC Input J2 N AC Input J3 MI Motor Output 1 J4 M2 Motor Output 2 J5 DC DC Bus Capacitor DC Bus voltage is Vline 1 414 J6 OV DC Bus Capac
17. e lg ees Be a ea er eC ee ap Sele ee es ee SS Whe ue o e sae ear a i i i 1 T 150 ia i LW7 amp LUSACZ 42 1 11 1 1 R41 gt 2 s an Are C bil oiv e n our H e 5 IS045N 12K 2 Teu e ND uB a 02 M 1 HLI 1 our TJ nur v il 7 Jn Na to no i 5G GND BO Ww AUT u Lr nd PIE 6F B28 K 160427 3 ae 5G GND ET H RA2 VREF RAI gt HRA e1 rao H RS 3 Joa i 45V us a 10K R44 02 RA7 OSECI R20 7 Jer ess m e osco Lo BORSo I0 GND pe C Ro slyss wo gt 7 Y n i Ji VL az LI 2 i 5K sv o mx RBI Rx roe To 5 pro z 2 TX RES _ R22 ga i 3 1 rga H2 10K HABIT a 1 R21 a e 7 S K 5 T7025 Jy ute H 5 WF 3 E fr oe 11 _ I 1 a Pol AND PDO CONNECTIONS ARE DPTIONAL caer 32V HB 112 4 H 4 1 7 7 PDO rt PDO Al 412 7 6 1 um J b C cow 11 Cem 1K Bm 180 GND M MCN Mater cR RAE Dac eae E NA TEN PUBS ISULATED CDNTRUL PORT Figure 7 Interfacing PDB3 to a host Microcontroller TYPICAL HUST MICRO GIRCLIT 23 Section Configuration and Communication
18. e The actual output waveform of the drive is a high frequency PWM The AC Output voltage is the RMS representation of this voltage COIN The Control Interface circuit connects PDB3 to a control source It can be a simple speed control potentiometer or a more complex analog and or digital circuit DC Bus Voltage The voltage across the bus capacitors measured in DC volts With no load the ripple voltage on the bus will be very low As the load current increases the ripple will also increase Modulation Intemal Modulation This can be expressed either as a normal percentage value or as a hexadecimal equivalent 100 modulation is 7F hexadecimal Modulation Extemal Modulation To avoid a confusing level of detail most Anacon documentation including DashDrive refer to 100 modulation as being full output voltage ie 115Vac in gt 115Vac out This is easier to understand but quite different from the internal modulation percentage 42 PDB3 Power Drive Block 3 is a compact single phase drive module incorporating Anacon s proprietary technology It requires only a few external components to create a complete drive for PSC and Induction motors PINT The Power Interface board contains DC bus capacitors and any addition components needed to interface PDB3 to the AC line and motor load V F Curve The V F curve is an internal table that determines the internal modulation value for a given frequency The tabl
19. e can be modified to change the AC output voltage for a given frequency Using the O serial command over rides the V F curve and sets the modulation directly 43 44
20. eferred to as induction motors or squirrel cage motors Again within this classification are several variations that have different starting methods torque characteristics etc The most important feature when considering using an Anacon drive is whether the induction motor contains a switching mechanism or not Motors that can be used with PDB3 and Anacon DigiDrive Permanent Split Capacitor PSC Shaded Pole Motors that are not recommended for use with PDB3 or DigiDrive Split Phase Capacitor Start Capacitor Start Capacitor Run These motors all incorporate a switching device usually a centrifugal switch that creates problems for variable speed control in three ways Firstly transient voltages occur when the switch activates causing a fault condition on PDB3 Secondly the starting current is typically much higher than with PSC motors resulting in levels higher than PDB3 s 150 short term current rating Finally the switch reverts to the start mode when the speed drops below about 6596 which greatly limits the useable speed range Overall PSC motors are the best choice for use with Anacon drives They are widely used readily available and give good overall performance In pump and direct drive fan and blower applications speed control from 20 to 110 is typical with PSC motors How Anacon Single Phase Drives Work The fundamental operation of PDB3 is very similar to a Three Phase Variable Frequency Dri
21. ernal microprocessor The information also provides more insights on how to accurately adjust output voltage by converting from volts to modulation and back Bus Voltage Compensation The output voltage is proportional to the 8 bit modulation value The modulation value comes from either the internal V F curve or from a serial O command from an external controller The actual output voltage is a fraction of the DC Bus voltage 0 modulation equates to zero volts AC Output voltage 100 internal modulation is the point at which the peak value of the AC output voltage equals the DC bus voltage Because of inherent losses in the system the 100 internal modulation point will result in an AC RMS output voltage that is less than the AC RMS input voltage The PDB3 does not work internally with decimal percentages 0 100 Instead it uses 0 79 hex to represent the same scale Sending a modulation value of 7F hex using the O command gives 100 modulation To achieve an RMS AC output voltage that is equal to the AC input voltage the drive flat tops the output waveform This increases the RMS voltage by adding third harmonics Full AC output voltage requires an internal modulation of around 113 113 is stored in the V F curve as AA hex In practice the DC bus voltage varies slightly with load current and with AC Input voltage Voltage compensation can be used to correct the AC output voltage against variations in DC bus voltage
22. g PWM speed control disables serial speed control Note that the PWM speed input is a completely separate function from the PWMing used to generate the motor waveform 31 Section Making Measurements Howtosclemasuranst radng fran PDB3 intovdts anps dc DC Bus Measurement PDB3 senses the DC bus voltage with a 10 bit ADC Firmware filters out line frequency ripple and uses the value to set Under Voltage and Over Voltage limits The COIN can use the DC bus reading to calculate AC line voltage and make minor adjustments to operating points etc The real DC bus voltage is approximately equal to the line input voltage x 1 414 2 0V This calculation can be used to estimate the AC line voltage The error will increase when the motor is running due to sagging on the DC bus PDB3 makes the DC bus value available as a 16 bit number using the Q06 serial command Refer to Serial Commands documentation for additional details Span 412 Vdc Span approx line voltage 290 Vrms ADC Resolution 10 bit 0 4034 Vdc ADC Resolution line voltage 0 283 Vrms Typical error at 25degC 2 0 Vdc Worst case error at 25degC 4 9328 Vdc Worst case error at 50degC 5 9645 Vdc Worst case error at 70degC 6 7899 Vdc Drift after 1 year 0 1808 Vdc Drift after 10 years 1 8075 Vdc Note Error limits assume no motor load 32 AC Motor Current Measurement PDB3 estimates the motor current based on
23. gram CAUTION Jumpers Option Jumper JP1 selects whether to use the factory default configuration DEF or customized user USR configuration The position of JP1 is checked by PDB3 each time power is applied If JP1 is in the DEF position PDB3 writes the factory default configuration into Eeprom overwriting whatever parameters were in there previously The saved parameter information is retained when JP1 is in the USR position Jumper JP2 selects which V F Curve is used when JP1 is in the DEF position Its status 15 ignored at other times JP1 and JP2 are at high voltage when power is applied To move the jumper first remove power and wait for the DC bus to discharge The configuration changes will be retained as the jumpers are only read once when power is applied If the Eeprom gets corrupted some values may go out of range This can prevent PDB3 from starting To correct this set JP2 DEF and cycle power Then move JP2 to USER and reconfigure the drive LED Status Indication Description Color Function Status Green Pulses at 1 5Hz when output is off and no fault conditions exist Full on when drive output is on Power Green Indicates available AC Power Fault Red Pulses fault code when drive detects a fault condition see table below Full off when no fault condition is present Fault Detection and Indication PDB35 fault codes follow the same format as DigiDrive The code is displayed
24. igits must be entered FOO will cause the drive to stop The drive must be in the serial input mode for this command to work F60 ok Sets the operating point of the drive The format is Offmmcc when ff is the frequency in 0 5Hz increments mm is the modulation and cc is a checksum The value of cc is such that ff mm cc 0 The operating point command allows operation at points that are not on the V F curve Refer to information later in this section for an explanation on how to calculate modulation The example below sets the output to 50Hz 90 modulation O648C10 ok 26 Q Queries operating parameters from the drive The format of the Q command is where xx 00 16bit PWM 01 16 bit 0 5V 02 16 bit Set Speed 03 16 bit Actual Speed 04 16 bit Modulation 05 16 bit State Flags 06 16 bit Voltage 07 16 bit Current 08 Motor Phase Angle The response to the query command is a 4 digit 16 bit hexadecimal number with MSB first Section 7 Making Measurements explains how to scale this into a real number Protocol The commands can all be sent in simple ASCII format The only other protocol consideration is handshaking control Multiple command sequences and Queries can be in succession by performing a simple check The COIN controller should always wait for the ok response before sending the next command If your control waits for the character then no additional dela
25. itor Notes 1 power connections are 0 110 x 0 032 spade terminals 2 Use AMP Part 2 520273 or equivalent fully insulated quick connector on connecting wires 3 Wire gauge should be sized for line current 1 5 x motor current CONTROL SIGNALS ISOLATED Terminal Label Description Comment J12 1 18V 18Vdc Output Can be used to power external circuits J12 2 TxD Serial Data Out Open drain output J12 3 RxD Serial Data Input LED Cathode J12 4 PDO Programmable Digital Output Refer to section 6 for functions J12 5 PDI Programmable Digital Input Refer to section 6 for functions J12 6 COM Common for Isolated Signals Notes 1 J12 is 6 way 0 1 polarized header AMP Part 640456 6 2 Mating connector is AMP Tyco Part 770602 6 terminal 770666 1 CONTROL SIGNALS NON ISOLATED Terminal Label Description Comment J7 1 FLT Fault Digital Output J7 2 STATUS Status Digital Output J7 3 CTRL Control Digital Input PWM Enable J7 4 REF 0 5V Speed Sensor Feedback Not Implemented Future Use J7 5 OV Common for Non Isolated Signals J7 6 SPD 0 5V Speed Input Signal J7 7 5V 5Vdc Output at 5mA Connect to speed potentiometer J7 8 15V 18Vdc Output at 10mA Can be used to power external circuits Notes 1 J7 is 8 way 0 1 polarized header AMP Tyco Part 640456 8 2 Mating connector is AMP Tyco Part 770602 8 terminal 770666 1
26. ly Assembled Reference Design STEP 3 Apply Power Verify that the drive powers up correctly before connecting the Configuration Cable Note Although 115V or 230V power can be applied directly it is better to use a current limited supply for the initial power up test A DC lab supply set to 100V DC is sufficient to start PDB3 s SMPS Set the current limit to 100mA Standby supply current will be 50mA or less PDB3 runs perfectly from a DC supply so this technique can be used at any stage of development if a suitable supply is available Remember to multiply the nominal AC rms voltage by 1 414 to find the exact DC equivalent Alternatively an AC lab supply or a variac can be used If using a variac slowly advance the supply voltage while monitoring the supply current with a meter When the supply reaches about 70Vac 100Vdc the PDB3 s LEDs will light The Power LED will remain lit and the Status LED will flash slowly indicating a standby condition STEP 4 Remove Power If the LEDs are lit and the supply current is within specification remove the power and wait for the DC bus capacitors to discharge before proceeding The DC bus capacitors can hold high voltages for extended periods if no current is drawn from them PDB3 s power supply acts to discharge the capacitors in less than 30 seconds If PDB3 is not connected or it is otherwise non functional the bus capacitors may not discharge In all situations use caution and verify
27. n Howtodagia Powr Intafxebaadtoawtea sngephasedive Depending on the application and end market PINT designs can range from very simple to quite complex Designing a PINT is really a series of design decisions and does not normally involve low level design effort In almost all cases the PINT will be a Through hole technology circuit board Considerations The following checklist covers the most common items to consider in a PINT design Form Factor Voltage Current Line Filtering Output Filtering In Rush Control Transient Suppression Connectors Harmonic Current Control D O 0 Oc O O 0 O O D0 Protection Example 1 The PINT supplied in the PDB Design Kit is an example of a typical design Its features can be summarized using the checklist proposed above Item Requirement Implementation Form Factor Custom to fit enclosure PCB outline Voltage Up to 230Vac 400V Bus Capacitors Current 6 5 Amps 4x 220uF Capacitors Line Filtering External Filter Module None Output Filtering Not required None In Rush Control Suitable for 6 5Amps PTC Relay Transient Suppression MOV MOV to Earth Connectors Easy Field installation Barrier Terminal Block Harmonic Current Control Not required None Protection External Fuse None Considerations for Design Kit PINT Example 2 p
28. necessary Specifically designed series inductors are an economical solution for currents up to 4 Amps Higher currents may require active power factor correction With active PFC the PFC stage feeds the DC bus directly eliminating the rectifier stage Suseptibility PDB3 has an internal MOV for controlling line to line transients Additional devices may be required in the PINT design PDB3 has only minimal protection on control inputs The COIN may require filters and suppressors for ESD and other transients PDB3 incorporates a watchdog timer so it will recover after a disturbance that causes interruption in firmware execution 36 PDB3 Electrical opecification Appendix Parameter Typical Min Max Units Note AC INPUT Supply Voltage 115 85 300 Vrms Operation over 240V requires special conformal coating contact factory Startup Supply 70 60 80 Vrms Line Voltage required for PD B3 Voltage power supply to start Drop Out Supply 30 Vrms Low Line Voltage before PD B3 Voltage power supply enters shut down Standby Current 42 mA With 115V supply Standby Power 1 0 0 9 12 Watts Supply Frequency 50 60 DC 400 Hz MOTOR OUTPUT Output Voltage 0 300 Vrms Output Frequency 1 128 Hz Output Current 4 0 Amps Continuous rating for B1181 Model Output Current 6 Amps 30 second rating for B1181 Model Output Current 6 5 Amps Continuous rating for B1182 M
29. odel Output Current 9 5 Amps 30 second rating for B1182 Model ISOLATED CONTROL PORT Isolation Voltage 3 000 Vac 100 Production Tested Creapage 6 5 mm Meets UL CSA and IEC requirements for reinforced isolation DC Voltage 16 5 18 0 18 5 Vdc Fully isolated and available for Output external circuits DC Supply 80 mA Fully isolated and available for Current external circuits Thermal Base plate 90 2G Temperature Thermal Shutdown 95 we 37 Appendix PDB3 Dimensions sse Ec 0 11 POWER CONNECTIONS x2 TOYLNOOD aa1viosi CONTROL Aluminum Base Plate 3 90 PDB3 Elevations Dimensions in inches 38 GENERAL INFORMATION COMPONENTS COMPLIANCE INFORMATION Appendix Resources Sanehdpfl websites and publianans rdataltomaa digi Anacon Systems Inc www anaconsystems com Cornell Dubilier Capacitors www cornell dubillier com Panasonic Electolytic Capacitors X Y Capacitors www panasonic com industrial components Evox Rifa X Y Capacitors www evox rifa com Renco Electronics Common Mode Toroids www rencousa com Bergquist Company Thermal Management www bergquistcompany com Underwriters Laboratories www ul com UL508c Power Conversion Equipment Canadian Standards Authority CSA www csa ca 22 2 No 14 Global
30. om PD B3 with current parameters U 00 02 00 00 00 00 11 00 00 00 ED ok There are 10 data values and a checksum The data values are 1 PWM Input 0 255 0 100 2 A D Input 0 255 0 100 3 Serial Command Input 0 255 0 100 4 Calculated Setpoint Val 2 Freq 2 5 Actual Setpoint Val 2 Freq 2 6 Modulation Index 128 100 7 State Flag Status Byte Stop Bit 0 b Run Bit 1 c Boost Bit 2 d Boost On Bit 3 e ENABLED Bit 4 f TEMP ALARM Bit 5 g SERIAL TIMEOUT Bit 6 h Unused Bit 7 8 Bus Voltage 9 Current 10 Checksum The U command only returns 8 bit parameters Use the Q command for greater resolution where applicable E Send back the contents of the entire EEPROM 128 locations This block is printed in 8 lines with 16 values plus a checksum for each line Each line begins with a header that is Exx where the E indicates these are EEPROM values the xx is the hex address of the first value of the line E E00 55 83 21 64 32 32 6E 00 05 05 00 01 05 02 A6 E10 0D 19 00 00 00 00 00 DC 6E FF 00 00 00 00 00 00 91 m E30 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 E40 05 10 1E 2C 48 56 64 72 72 72 72 72 72 72 72 D5 zi N o m 1 Oo D o o o o o o o o o o o o o o o Ww o o o o o o 00 Se NEUSS 25 E50 72 05 10 1E 2 3A 48 56 64 72 72 72 72 72 72 7
31. r is applied the relay is open and the DC bus charges through the thermistor a resistor could be used When the DC bus is charged the internal 15V power supply closes the relay which shorts out the PTC The advantage of this method over a NTC thermistor solution is lower temperature and better in rush control at higher operating currents 21 Section Control Interface Design Howtodsgia COIN bardtoantrd COIN designs are much more application specific than PINT designs The simplest control interface consists of nothing more than a potentiometer for varying speed If more than a simple interface function is required the COIN usually incorporates a microcontroller Considerations The following checklist covers the most common items to consider in a COIN design Serial PWM or Analog control Isolated or Non Isolated User Interface Sensor Signal Conditioning Fault Diagnostics D D O D O O Power Source In many applications an existing microprocessor or signal conditioning circuit can be used for the COIN function Serial PWM or Analog Control Three methods are available for controlling output speed frequency Serial control is the most flexible as it allows bi directional exchange of information It does imply that the COIN is microprocessor based Serial communications is asynchronous and can be implemented with just two control lines The PWM input option uses a 100Hz pulse width modulated signal
32. reylatay sandacds The regulatory requirements for a motor control are determined by the application and the market Expert advise is needed to determine what standards must met Safety PDB3 is designed to UL508c and is available as a recognized component This standard is representative of other international standards Within UL508c are many sub classifications that depend on environment and application Additional components terminals and heatsinking will be needed to meet specific requirements Some useful information and recommendations for safety compliance Temperature Safety standards apply maximum operating temperature limits for components It s not difficult to exceed these especially at elevated operating temperatures so allow plenty of margin Components such as the NTC Termistor for In rush current control are designed to get very hot Make the component leads as long as possible to keep the heat away the PCB Using large copper areas on the PCB also helps Heatsink temperature is normally limited to 70 C if it can be touched by the end user Isolation Any metal surfaces or circuits that can be touched when the circuit is powered have special isolation requirements To address this PDB3 has isolation and 6 5mm creapage distances on J12 the isolated control connector Extreme applications may require addition optoisolation Classification A mis classification can add a lot of unecessary work and expense A good e
33. s stored as a table in PDB3 PDB3 has a default V F curve Because motor characteristics vary it is often desirable to modify the V F curve to suit an application For example reducing voltage at a given frequency can improve efficiency and eliminate a mechanical resonance point Conversely too little voltage creates high slip and low torque Anacon Systems DashDrive for Windows provides a graphical interface for making curve changes and assessing motor performance in real time System Architecture To simplify drive system customization Anacon has partitioned a drive solution into three blocks PDB3 connects between the Power Interface PINT block and the Control Interface COIN block dad POWER PDB3 CONTROL INTERFACE Power Drive INTERFACE 4 PINT Block COIN Motor Out Figure 1 System Block Diagram PDB3 contains highly integrated electronics including power devices and Anacon s proprietary microcontroller It is a complete drive minus voltage and interface specific components Adding PINT and COIN blocks customizes the drive system to suit the application PDB3 Circuits Anacon Microcontroller ow Voltage DC Power Supply Power Devices Optoisolators Sense and control circuits Typical PINT Circuits DC Bus Capacitors Power Line Filter optional Fuse and protection circuits Terminals Typical COIN Circuits Host Microcontroller optional RS
34. the positive DC bus current The scale factor to convert bits to amps therefore varies with the power factor of the load Typically 1 bit represents l0mA of RMS motor current To maximize accuracy for an application the scale factor can be recalculated from measurement data The COIN can use the scale factors to calculate the actual amps PDB3 does not have an internal scaling capability Accuracy is approx 10 once calibrated for an application Averaging several readings from PD B3 can further improve accuracy Irms Q07 result 0 01 33 WESS Section Mechanical and Thermal Howtomant andhatsnk PDBS Even with an efficiency over 95 PD B3 needs to dissipate a lot of energy when operating at full load A good thermal management solution not only cools PDB3 but also keeps heat away from other drive components to improve system life and reliability PDB3 s heatsinking surface is electrically isolated so no additional insulation barrier is needed Thermal paste or a material such as SIL Pad made by Bergquist should be applied between PDB3 and the heatsink according to the manufacturer s specifications No special torque down procedure is required but the mounting surface must be flat and even PBD3 s base plate temperature must be kept below 90 C If PDB3 is not adequately heatsinked an internal thermal cut out will activate 34 Section EMC and Safety Compliance a dagingfa CE UL FCC ad dhr
35. to control speed over the Fmin 096 to Fmax 10096 range The PWM input uses a single control line 22 CDN MERA ANA CONNECTIONS Example 1 which is internally isolated and suitable for long distance signaling A PWM signal can be generated either by a microprocessor or by an analog circuit Connecting PDB3 to an external microprocessor is simplified by the internal opto isolators on PDB3 In this example PDB3 has been interfaced to a PIC16F628 microcontroller from Microchip The COIN circuit is powered from PDB3 s 18V output through a 5 regulator A pull up resistor R3 is required on the TxD output The PIC micro s UART is configured to 4800 baud though faster data rates could be used if the distances are short and resistor R3 is increased When considering remote communications keep in mind that the CMOS logic levels are not buffered and do not offer the noise immunity of RS232 or RS485 422 level signals PDI Programmable Digital Input and PDO Programmable Digital Output lines are shown connecting to the micro These connections are normally not required as all information is available through serial communications In some cases PDI and PDO can be configured to reduce communications by directly signaling conditions such as Start Stop and Under Voltag
36. ve The speed of an induction motor is a function of frequency slip and the number of poles in the motor Speed Frequency 120 No of Poles Slip Where Speed is in RPM Frequency is in Hertz Poles is number of motor poles 2 4 6 or 8 and Slip is also in RPM Triac controls and other voltage controls vary the motor speed by reducing voltage to increase slip Because Anacon drives vary frequency slip remains almost constant over a wide speed range resulting in control that is more precise and efficient To vary frequency the 50 60Hz AC supply is first rectified then filtered by DC Bus capacitors Next a PWM controlled power stage switches at 18kHz to synthesize a sine wave output When viewed with an oscilloscope the voltage across the motor appears as a periodic sequence of fast DC pulses Because a motor is essentially an inductor the motor sees only the low variable frequency i e 10 60Hz This is visible in the current waveform through the motor which is a clean sine wave The motor windings filter the PWM voltage across the motor capacitor so the capacitor is unaffected by variable frequency control An important concept in variable frequency control is the Volts per Hertz curve or VF curve When the frequency controlling a motor is reduced its impedance is also reduced To keep the current constant at or below Full Load Amp FLA rating the RMS voltage to the motor must reduced The ratio of Volts per Hertz i
37. xample is the relaxed requirements for Devices having Limited Ratings in 35 ULS08c This classification is not immediately obvious to someone unfamiliar with the specification Wamings A warning label can simplify a design For example PD B3 does not have internal overspeed control This can be addressed by a warning statement in the nameplate Another example is that a warning regarding the time for the DC bus to safely discharge eliminates the need for an automatic discharge circuit EMC A complete discussion of EMC is well beyond the scope of this manual We are able to make some suggestions and highlight pitfalls Emmisions Meeting emissions standards is a challenge for any electrical device and even more so for an inverter like PDB3 As always the best approach is to keep all conductors as short as possible In particular mount PDB3 as close to the motor as possible Using shielded cable designed for AC power will also help if it is applied correctly Emmisions from a drive using PD B3 is dominated by noise caused by PWM switching transitions The Anacon microprocessor and the 18kHz carrier frequency are not significant noise sources Cunent Harmonics Restrictions on the line current waveshape are now in effect for most classes of products in the European Union EN61000 3 2 and Australia Other countries are working on similar controls If harmonics compliance is required additional PINT circuitry may be
38. y is needed The ok response indicates that the command is being actioned and that a new command may be sent but it may not be complete For example the O command may still be ramping to the new frequency If a new O command is sent it will over ride the previous command With this method several commands per second are possible with 9600 baud Output Voltage The amplitude of the output waveform is determined by the modulation value expressed in percent This value comes from the V F curve the boost profile or an O serial command For example a modulation percentage of 113 sets the AC output voltage the same as the AC line input PD B3 requires a converted number to make internal math easier To set the V F curve directly or to use the O command to set modulation convert the value as follows Mod Value Modulation Percent 1 28 25 27 Therefore 113 becomes AA hex Modulation 96 Mod Value Output Voltage 60 66 hex 70Vrms 82 82 hex 90Vrms 113 AA hex 100Vrms Table showing output voltage vs modulation assuming an AC supply of 100V PDB3 and other Anacon products use open loop control of the output voltage That is the drive is not able to monitor its own output voltage This is due to the complex PWM waveform The alternate approach is to monitor and compensate for the DC bus voltage The following paragraphs describe how to implement DC Bus Voltage Compensation using an ext
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