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Stellaris LM3S818 AC Induction Motor

1. 433V 2 4 8 TDI Debug signals to J TAG board UL PAO UORx PAI UOTx PA2 SSICIk PA3 SSIFss 4 55 PAS SSITx PCO TCK SWCLK PCI TMS SWDIO PC2 TDI PC3 TDO SWO PCA PhA 5 PC6 PhB 7 4 ADCO ADCI ADC2 ADC3 ADC4 ADCS OSCO OSCI PBO PWM2 PWM_V_LO PBI PWM3 PB2 IDX PB3 FAULT PB4 CO 5 0 5 5 SWITCH IDX lt 18 5 ALL V LEDFAULT PB6 C0 PB7 PB7 TRST PDO PWMO INF PDI PWMI PD2 UIRx PD2 UIRx PD3 UITx PD4 CCPO PDS CCP2 PEO PWM4 PEI PWMS POT OSC PWM W LO PWM W HI C10 1UF 0 1UF 1UF 0 1UF 0 1UF 1UF ICL_OFF HDR 2X5 PFC Board Control Interface Link to ICL OFF when PFC option is not installed 15V 16 3 3 PAS SSITx PA2 SSICIK 5 6 PD2 UIRx PA3 SSIFss 7 PD3 UITx 4 55 9 7 Uncommited 1 0 Break out 220 n2 Power LED NX Green n 5 a 41 5 5 R6 220 LEDFAULT R7 220 lt PD2 UIRx R8 220 D5 v Green PD3 UITx R3 CAUTION Risk of Electric Shock Run Indicator LED NX Green Fault LED D4 Status LED 1 Status LED 2 Texas INSTRUMENTS Drawing Tile Ref
2. 14 RDIESpecifICatlOfis s etr e tre i eL e xi MER Le 15 seien edd ede de vedere ae dod eaten 15 ERN 15 GapabllitieS 5 tet nre tha 15 Chapter 2 Graphical User Interface 17 Main GUL eA E 17 File MOM E 20 Parameter Configuration 21 este Festes bra cette 21 eh Dr eerte e Hi i Srt alae ee i 22 Drive Gonfig ration csse ene et 23 DC Bus Configuration ecce nocet nce itor ttd dee Pe ner eive ae UB av vade tu de 24 Chapter 3 Hardware 27 System Descriptions exe sted RR ii erede in to ae ERE SONA EPA SERE 27 Block Diagram oia oii tan oem oe de b ea ed E 28 Funcional DescriptlOms te tte uet ue e M oet tee LET A 28 Microcontroller Schematic Pages 1 29 Output Power Stage Schematic Page 3 4 1 000 esee nnne eene nter 29 Isolated Control Interfaces Schematic Page 4
3. 0 1UF 400V C32 6 433V 09 R52 1 6 150 5 uS MS R40 vs our 2 ps 2 1 82 7 SUI Ca2 5 I J por_osc gt Mode Switch SWIN Speed Control 24 0 1UuF cs 2 1 GND C43 15045 ISOGND 557 0 1UF ISOGND R41 110 pest R42 ISO45V 10K pees R53 10K 1 6 47K ISOGND R47 2 5 Control Interface 1 MS 3 4 S gt 34 ROSNY P SWITCH IDX 5v O H IN A 2 50 ENCA IN B amp 4 sx 15045 5 ISQ45V 92 1 6 m R86 FANA174IS5X NL 4 7K GND G T 1 R48 2 5 j 1 AW Il 07100 EAR LAK ISOGND c3 S 4 L ENCA gt 10K 7T 33nF LL 15 USB MINI B RECEPTACLE S ISQ45V u12 FBI R44 ISO45V oco
4. 52 Current Stator Frequency 52 Current Rotor Frequency sssssssssssesseseeene nnns sens 52 52 DG Bus Voltage ft edt dedi i 52 Motor Phase U GUITent n a 53 Motor Phase Pereyra eer DET EVE Tate VY VERE TE TEE UD da dd 53 Motor Phase W Current an ut vu Per d ae eh ea uv bee n d e ne t 53 Motor GUrterib st t cere stie tai a bot b a Fev td atem bet bea v 53 Ambient TemperatUre ati ua e M debe e ER RM 53 Appendix B Schermialics nels eie a a sco Dude eee Por 55 Appendix PCB Component 63 Appendix D Bill of Materials 65 November 4 2009 5 November 4 2009 Stellaris amp Family Development Board User s Manual List of Tables Table 2 1 Description of GUI Main Window Controls enne nnne nnns 17 Table 2 2 Description of PWM Configuration eene nnns 21 Table 2 3 Description of Motor Configuration Controls 1 000 eere 22 Table 2 4 Description of Drive Configuration C
5. nennen enn 30 Power Supplies Schematic Page 5 31 Isolated JTAG Interface Schematic Page 6 ener 31 mE 31 Modulation Methods dite dine te i anuos 32 Other EUnctlons ode esi Det a Wie ite E dee E Qa Ae eeu ea eee eee de 32 Motor Control amp nennen 32 Parameter Rererence eoe sepe pios iti ieu aet ina OR 32 Implementation Considerations c iacit te tne co Ree P EE EHE e De vede Eo ce 33 Motor Sele Ct on ELEM 33 Bus CapacitOors 2r iic ea hited den ea ded ee aed re eodd 33 Heat SIMU 35 2 t cava dha Re a beate saine do e Fea 33 Power Line PRENG cc 33 Serial Protocol 33 Appendix A Parameters and Real Time Data Items esses enne nennen nnn nns 35 s eve 35 Parameter Descriptions Ta i d Ine d tede 37 November 4 2009 3 Informational Paramiel rs eoo ite tete tir e tbe ten 37 Firmware Versione uat redi era e PERRO 37 Motor Drive Status lin edit ves eoe id rave due ata tus ev ee 38 Motor Drive Fault Stats Io et itp cpi eco edite a eda dd e e ea ae 38 Motor Configuration Parameters
6. November 4 2009 67 Final Assembly Items N 7 7 7 7 Aeee S Es i O i o N 7 N 8 82 83 1 1 2 JP1 3 4 J8 3 4 84 44 C45 UN 8 46 Notes 68 18 Steel Bracket Aluminum base plate 5 25x6 75 4mm 91290A120 Cap Screw M3 x 16 socket head blk steel 90353A001 Machine screw M2 5 x 4 Pan Head Slotted Steel McMasterCarr 12504105 1290 111 1290A113 0591123 858 10 015 Line Filter Module with IEC socket 10A 115 230V Qualtek R30 6011102 Metric Spacers M3 x 11mm Brass 4 75mm O D 527C Fuse Cover insulating 222 Steel Clip C size SJ 5018 Rubber Feet Black Square Ep AME ewer Electro 1500uF 2096 200V 50x25mm Insulated Spade Terminal 0 25 16 14 31262104 Terminal Block Plug 4 pos 0 3 pitch black 31262102 Terminal Block Plug 2 pos 0 3 pitch black UJ Do not populate C17 FB1 R21 R28 R35 November 4 2009 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries reserve the right to make corrections modifications enhancements improvements and other changes to its products and services at any time and to discontinue any product or service without notice Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete All products are sold subject to Tl s terms and co
7. Q Brake High Low Side Motor A Gate Driver Q Fairchild High Low Side ESEN Motor E Gate Driver Smart Power Module Motor Sense Circuit Current Sense Circuit Current Sense Circuit Isense A Isense B Isense Variable frequency drives are often referred to as inverters because they convert DC to a variable frequency AC waveform The key components in this conversion are the microcontroller and the power switching stage but a lot of peripheral circuitry is needed to make a complete drive This section describes drive operation in detail 28 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Microcontroller Schematic Pages 1 2 At the core of the AC Induction Motor is a Stellaris LM3S818 microcontroller The LM3S818 contains a peripheral set that is optimized for three phase motor control including 6 high speed ADC channels a motor control PWM block and quadrature encoder inputs The RDK has three headers J6 J7 and J8 in close proximity to the microcontroller J7 has the JTAG port signals which are used for programming and debugging the microcontroller WARNING Risk of Electric Shock The microcontroller in the RDK is not referenced to ground it is at AC line potential Do not make direct connection to the JTAG header or any other microprocessor related circuit Read the Quicks
8. Use caution when using the on board controls to adjust motor speed etc High voltage circuits are in close proximity Never perform work on the control board motor or wiring while power is applied Always wear eye protection and use care when operating the motor In addition to safety risks other factors that may damage the control hardware the motor and its load include improper configuration wiring or software Minimize the risk of damage by following these guidelines Using the RDK The recommended steps for using the RDK are Follow the Quickstart Guide included in the kit The Quickstart guide will help you get the motor up and running in minutes It also contains important safety information that should be read before using the RDK November 4 2009 11 Stellaris amp AC Induction Motor Reference Design Kit Overview B Use the GUI software to evaluate and optimize motor performance The GUI gives real time access to over 30 operating parameters Parameters and data transfer between the control and PC over a USB cable Customize and integrate the hardware and software to suit an end application This User s Manual and the Software Reference Manual are two important references for completing your project Software can be programmed in the motor control board using either the RDK GUI software or using a JTAG debug interface available from leading development tools vendors Features W Advanced moto
9. DATA PHASE B CURRENT 1 256 of an ampere 0 to 65535 This real time data item provides the RMS current for the V phase of the motor See the Motor Phase U Current real time data item for the computation method Motor Phase W Current DATA PHASE C CURRENT 1 256 of an ampere 0 to 65535 This real time data item provides the RMS current for the W phase of the motor this will not be valid for a single phase motor since it does not have a W phase See the Motor Phase U Current real time data item for the computation method Motor Current DATA MOTOR CURRENT 1 256 of an ampere 0 to 65535 This real time data item provides the RMS current for the entire motor For a single phase motor this is the same as the U and V phase RMS currents the two are averaged For a three phase motor this is sqrt 3 times the RMS current through a single phase the three phase currents are averaged The motor under current and over current faults trigger based on the value of this real time data item Ambient Temperature DATA TEMPERATURE degrees Celsius 0 to 85 This real time data item provides the ambient temperature on the top of the microcontroller s package as inferred by measuring the microcontroller s junction temperature The over temperature fault triggers based on the value of this real time data item November 4 2009 53 Real Time Data Items Descriptions 54 November 4 2009 Schematics This section contains the
10. Figure 2 4 Drive Configuration Window KZ AIC Induction Motor Properties Configuration Motor Configuration Drive Configuration lal lt 2 m Frequency Hz Acceleration Hz sec 1 Starting 24 4 Maximum 2 340 0 Stopping 2 40 Motor Current Max Ambient Air Temp gt 2 Minimum 201 Temperature 85 5 Maximum 248 Injection Braking Closed Loop Controller Enable aj P coefficient 32768 Voltage 24 coefficient 128 Time gt 200 November 4 2009 23 Graphical User Interface Table 2 4 Description of Drive Configuration Controls 1 Frequency Minimum Sets the minimum motor frequency speed Maximum Sets the maximum motor frequency speed Use with minimum frequency to define the usable speed range 2 Motor Current Minimum Maximum Sets the limits for motor over and under current 3 Closed Loop Controller Coefficients In Closed Loop mode these parameters define the response characteristic of the PI controller Normally these parameters can be left at factory default settings 4 Acceleration Minimum Maximum Sets the acceleration and deceleration rates Reducing these values increases the time the motor takes to change speeds 5 Max Ambient Air Temp Temperature Trip point for over temperature tri
11. dete dea edad o Dia 44 Deceleration Rates teo diei 44 Target Drive Frequency e ducts ee xe 45 aseo de bal f e reed aped eR COBRE Re Ee denne 45 Dynamic Braking Configuration nennen nennen nnne nnns nen 45 iicet hr Pe Pert i te I LR Ee ha 45 Dynamic Brake Engage KENKERE 45 Dynamic Brake Disengage 46 Maximum Dynamic Braking 46 Dynamic Brake Cooling Time cde teet ate Rute dove de eese 46 DC Injection Braking Configuration 47 DC Injection Braking Enable dt eene sat e n oae aa 47 DC Injection Braking Voltage aiai steterit ns sistens 47 DC Injection Braking Time i aote tied dain bd xe ead 47 Closed Loop Configuration enne 47 Closed Loop Mode Enable 47 Frequency Controller P 48 Frequency Controller Coefficient esses 48 DG B
12. ie OMIT R49 ANS ISOGND PESES 1 82K ENCB R38 ISOGND 47 U6 1 1 1 1 2 VCCIO TXD 4 NCC uxp 15043 3 ISOGND 5 2 15 USBDM RTSn HD R50 USBDP CTSn EME von DTRn IK DSRn VCP lt p NC DCDn 4 54 RESETn Rin R39 21 osci CBUSO z CBUS1 15043 3 osco CBUS2 1S043 3V A 8083 3V30UT 2 CBUS4 ISOGND 26668 R45 al els 47K VCP TX ISOGND ISOGND ISOGND USB Virtual COM Port Circuits inside this box are isolated low voltage HIILIM 433V 59 C60 0 1UF CAUTION Risk of Electric Shock Texas INSTRUMENTS Drawing Tile ACIM Reference Design Page Title Isolated Control Interfaces Size Document Number Date Sheet 2 20 2007 4 of 6 A 6 6 230VAC 15 LINE INPUT Ji KI RVI r V430RA8 G5Q 1A4 DCI2 115VAC 15 LINE INPUT 12 MBR0520 m RV2 r 8 D13 DIO D15XB60 1 ELFH02410 ICL OFF 47K Q7 KST2222A AL 0 125 Mounting Hole BRAKE DC Link Stage HVDC 15V ee R62 D14 2 520 R59 Q2 KST2222A e Q4 R60 R61 eal ANY 100 01 2222 a ANY 100
13. rpm Displays the rotational speed of the stator field in revolutions per minute This field is not user editable In Open Loop mode this matches the target speed In Closed Loop mode the stator speed is higher than the target frequency as the PI control loop compensates for slip in the motor Rotor Displays the rotational speed of the rotor in revolutions per minute This field is not user editable In Open Loop mode this will be lower than the target speed due to slip in the motor In Closed Loop mode this matches the Target Speed 18 November 4 2009 Table 2 1 Stellaris amp AC Induction Motor RDK User s Manual Description of GUI Main Window Controls Continued 5 GUI Main Window Buttons Run button Starts the motor The motor runs using the current configuration until the Stop button is clicked or a fault condition is detected Stop button Stops the motor If the motor is running the motor decelerates to a stop Once the Stop button has been clicked the Run button must be clicked before the motor will operate again Configure button Opens the Parameter Configuration window The Parameter Configuration window is described in more detail in Parameter Configuration Window on page 21 6 Statistics Area DC Bus Voltage Indicates the average DC bus voltage As the RDK sends more power to the motor the ripple voltage increases and the DC bus voltage drops Motor Current
14. the delay between PWM on states is controlled by the PWM block inside the microcontroller and can be set in software The SPM operates from a 15 Vpc supply which is carefully capacitor decoupled to ensure reliable operation during switching To turn on the high side IGBTs the gate voltage must be driven higher than the collector This is achieved with the usual flying or bootstrap capacitor method Using Phase U as an example When the low side IGBT is ON diode D10 is forward biased and capacitors C21 and C24 charge to almost 15 V In turn this charge allows the high side IGBT to be turned on by the high side gate driver As the high side IGBT turns on its emitter voltage rises taking the negative terminal of the flying capacitor along with it The capacitor is sized to maintain high side supply voltage of at least 12 5 V during the ON state If the capacitor discharges below 11 3 V typ the SPM s under voltage lock out circuit activates to prevent the IGBT from moving outside its safe operating area SOA November 4 2009 29 Hardware Description Three 40 mQ resistive shunts provide 40 mV A current sensing The resultant voltage is fed to three different circuits see Table 3 1 Table 3 1 Current Monitoring Circuits SPM Current Trip Microcontroller Comparator Microcontroller ADC Short circuit or Software programmable Measurement of phase Trip Speed typ Function
15. 5200 page 40 integer scale factor 6200 7200 8300 9700 11500 13400 15200 17050 18900 20750 22550 24400 26250 28100 29900 31750 31750 31750 31750 PARAM MIN SPEED 1 10 of a Hertz 0 to 4000 600 page 40 PARAM MAX SPEED 1 10 of a Hertz 0 to 4000 3400 page 41 PARAM CURRENT 1 10 of an ampere 0 to 50 1 page 41 PARAM MAX CURRENT 1 10 of an ampere 0 to 50 48 page 41 November 4 2009 35 Parameters Table A 1 Parameter Configuration Summary Continued PWM Configuration Parameters PARAM PWM FREQUENCY choice 0 to 3 3 page 42 PARAM PWM DEAD TIME 20 nanoseconds 100 to 255 100 page 42 PARAM PWM UPDATE PWM periods 0 to 255 0 page 42 PARAM PWM MIN PULSE 1 10 of a 0 to 50 10 page 43 microsecond PARAM PRECHARGE TIME milliseconds 0 to 255 2 page 43 Motor Drive Configuration Parameters PARAM MODULATION choice 0 to 1 0 page 43 PARAM DIRECTION Boolean 0 to 1 0 page 44 PARAM ACCEL Hertz second 1 to 100 40 page 44 PARAM DECEL Hertz second 1 to 100 40 page 44 PARAM TARGET SPEED 1 10 of a Hertz 0 to 4000 varies page 45 PARAM CURRENT SPEED 1 10 of a Hertz 0 to 4000 0 page 45 Dynamic Braking Parameters PARAM USE DYNAM BRAKE Boolean 0 to 1 1 page 45 PARAM BRAKE ON VOLTAGE volts 1 to 400 360 page 45 PARAM BRAKE OFF VOLTAGE volts 1 to 400 350 page 46 PARAM MAX BRAKE TIME mi
16. Items Continued Motor Speed DATA STATOR SPEED 1 10 of a Hertz 0 to 4000 varies page 52 DATA ROTOR SPEED 1 10 of a Hertz 0 to 4000 varies page 52 Measurement DATA BUS VOLTAGE volts 0 to 400 varies page 52 DATA PHASE A CURRENT 1 256 of an ampere 0 to 65535 varies page 53 DATA PHASE B CURRENT 1 256 of an ampere 0 to 65535 varies page 53 DATA_PHASE_C_CURRENT 1 256 of an ampere 0 to 65535 varies page 53 DATA_MOTOR_CURRENT 1 256 of an ampere 0 to 65535 varies page 53 DATA_TEMPERATURE degrees Celsius 0 to 85 varies page 53 Real Time Data Items Descriptions This section describes the real time data items in detail The data items are grouped into two areas motor speed and measurement Drive Status Parameters Motor Drive Status DATA MOTOR STATUS enumeration n a This real time data item provides the current status of the motor drive This is the same data in the same format as the Motor Drive Status parameter Motor Drive Fault Status DATA FAULT STATUS flags n a This real time data item provides the current fault status of the motor drive This is the same data in the same format as the Motor Drive Fault Status parameter November 4 2009 51 Real Time Data ltems Descriptions Processor Usage DATA PROCESSOR USAGE 0 to 100 This real time data item provides the percentage of the processor being used Motor Speed Parameters Current Stator Frequency DA
17. PWM UPDATE PWM periods 0 to 255 0 This parameter specifies the number of PWM periods that occur between recomputations of the output waveforms The parameter value is the number of periods minus 1 for example a parameter value of 4 means that the waveform is recomputed every 5 PWM periods Smaller update rates mean more frequent recomputation of the output waveform This results in higher quality waveforms with less harmonic distortion at the cost of increased processor usage There is an indirection relationship between this parameter the PWM Frequency parameter and the Maximum Drive Frequency parameter The PWM Frequency combined with the Waveform Update Rate determines the Maximum Drive Frequency that can be produced by the motor drive without aliasing in the output waveforms The following equation must be true 42 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual PWM Frequency PWM UPDATE 1 gt PARAM MAX FREQUENCY 8 What this means is that there must be at least 8 computations of the waveform for every cycle of the output waveform that is the angle step at each computation should be gt 45 degrees This relation is not enforced by the firmware Minimum PWM Pulse Width PARAM PWM MIN PULSE 1 10 of a microsecond 0 to 50 10 This parameter provides the width of the smallest PWM pulse that will be generated by the motor drive If the motor drive attempts to produce a PWM pulse
18. Power The power module has detected a massive overcurrent condition or a supply voltage problem and has shut down This can be due to a problem with the motor wiring or the motor itself November 4 2009 19 Graphical User Interface Table 2 1 Description of GUI Main Window Controls Continued 8 Special Indicator Area COM Port Displays the COM port number and status If the indicator is shown in black and has a number shown for the COM port then the serial port is opened If the indicator is shown in red and shows Err then no COM port is opened The COM port selection dialog box can be opened by double clicking on the COM port indicator Target Displays the status of the target connection If the Target is shown in black and indicates ACIM then the program is communicating with the RDK via the USB serial port If the indicator is shown in red then there was a problem communicating with the target Communication with the target can be restarted by double clicking on the Target indicator File Menu The File menu can be used to help manage the parameters The following menu items are available Load Parameters from Flash The adjustable parameters that control the motor operation may be stored in flash memory in the RDK microcontroller This menu choice commands the target to copy the parameters that were found in flash into the active memory The parameters will only be loaded from flash
19. enne nnns 39 LE 39 39 Encoder Present i Stan tace ti 39 Number or Encoder Lines 3 et eet Pe 39 Vit Table Range Select iet ad ne utate e ue bt i e EE UII b P ce etta etd te 40 Vil Table ces E ETE CELA 40 Minimum Drive Frequerney s eee ete eet ee en pen 40 Maximum Drive Frequency 41 Minimum Motor Current peii aia p elie ea ie 41 Maximum Motor C rrent rimossi Fe doen n re de bed e db 41 PWM Configuration Parameters inne trennt 42 mA renum 42 PWM Dead Time eet d Red eel d dee dau de Dae dide edad ed ede a 42 Wavetorm Update Rates incerti Pi ide eden ette 42 Minimum PWM Pulse ete Mee inert adeb tenenda Fu Eae 43 High side Gate Driver Precharge 43 Motor Drive Configuration nennen 43 Modulation 43 Motor Ditve DIrectloh ear aeta e 44 Acceleration Rate Iudae eee E HERE edens Deer
20. if the motor is stopped If the parameters are loaded from flash then the values shown on the main and configuration windows will change to reflect the new parameter values Save Parameters to Flash Saves the adjustable motor parameters to the RDK microcontroller s flash memory The parameters are only saved when the motor is stopped If a valid set of parameters have been saved to flash those will be loaded whenever the target is powered or reset Load Parameters from File The adjustable motor parameters can be loaded from a file that was previously saved This menu choice will read the parameters from the file if available and send them to the target The parameters will only be loaded if the motor is stopped Save Parameters to File The adjustable motor parameters can be saved to a file Selecting this menu choice will cause all of the parameters to be read from the RDK board and stored to a file The parameters can only be stored to a file if the motor is stopped Update Firmware This menu choice can be used to load new firmware onto the RDK target board A file chooser dialog box will open to allow the user to select the firmware binary file to load to the target This menu choice can only be used if the motor is stopped Once a file is chosen the new firmware file will be sent to the RDK the RDK will update the flash with the new program and then restart NOTE To restore the default parameters that came with your kit from the F
21. it hits the motor s nominal operating frequency Figure 1 3 Linear V f Curve for a 340 Hz Motor Curve 125 LE Ion ied 100 120 140 160 180 200 220 240 260 280 300 320 340 350 380 100 Frequency Hz Range O 0 100 Hz November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual RDK Specifications This reference design meets the following specifications The RDK has been engineered to simplify scaling to other current or voltage requirements Electrical W Dual supply voltages plug selectable 230 Vac 15 1 phase 115 Vac 15 1 phase up to HP only Supply current 10 Arms Continuous output current 3 2 ARMS Electrical isolation 2500 Vams Mechanical PCB size 3 7 x 4 5 92 mm x 115 mm Overall size 5 25 x 6 75 x 1 3 134 mm x 172 mm x 34 mm Capabilities Frequency range 0 400 Hz in 0 1 Hz steps PWM frequency Selectable 8 12 5 16 and 20 kHz November 4 2009 15 Stellaris amp AC Induction Motor Reference Design Kit Overview 16 November 4 2009 Graphical User Interface This section describes the GUI interface in detail Main GUI Window Motor operation is controlled from the main window see Figure 2 1 The main window provides user controls for controlling the motor as well as several indicators to provide status of the motor operation Most parameters can only be modified when the motor is
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23. shoot through current trip current amplitude protection Amplifier Gain 11 Resolution n a 137 5 mV 10 bits Scale 40 mV A 0 15 V 40 mV A 0 15 V 1 bit 6 67 mA Trip Threshold typ 15 Amps Programmable In software reference lt 5 us lt 10 us Software dependent Isolated Control Interfaces Schematic Page 4 Page 4 of the schematics contains both high voltage and isolated circuitry Six opto isolators safely interface various control signals to the microprocessor The speed control potentiometer forms a simple variable frequency oscillator with U7 The microcontroller determines the potentiometer s position by measuring the frequency on PD5 CCP2 30 Three isolated digital inputs accommodate the Mode switch can also be used for encoder index pulse and two quadrature encoder signals The A input has a Schmitt trigger feature that supports the speed sensor signal from the ATB Selni motor included in the RDK This type of speed sensor is known as a tacho generator A small permanent magnet moves inside a coil of wire generates an AC voltage that is synchronized to the motor s speed The Schmitt trigger ensures the opto isolator is fed with a digital signal UARTO signals from the microcontroller get isolated by U8 and U13 Jumper JP1 routes the transmit and receive signals to either the USB device or to J4 the control interface terminal block RXD and TXD on J4 are CMOS level not RS232 level so may be directl
24. that is shorter than this value it will lengthen the PWM pulse to this value Small PWM pulses are removed since they do no useful work By the time the gate has turned on and is starting to let current flow it is turned off again by the short pulse In order to avoid switching that performs no useful work the pulse is lengthened Lengthening PWM pulses results in the introduction of harmonic distortion in the output waveforms High side Gate Driver Precharge Time PARAM_PRECHARGE_TIME milliseconds 0 to 255 2 This parameter specifies the amount of time to precharge the high side gate driver before starting to drive waveforms to the inverter bridge The high side gate drivers have a charge pump that generates the voltage required to drive the high side gates this charge pump only operates when there is switching on the corresponding low side gate The high side gate drivers are precharged by driving 50 duty cycle PWM signals to only the low side gate drivers for the specified time period Setting this value too low results in trying to drive PWM signal to the high side gate drivers before they can turn on the high side gates This results in PWM signals that do not make it to the motor This is a brief phenomenon and it is typically harmless to bypass the precharge step Setting this value too high simply results in an increased delay before the motor starts spinning Motor Drive Configuration Parameters Modulation Type PAR
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26. 09 9 10 November 4 2009 Stellaris amp AC Induction Motor Reference Design Kit Overview Reference Design Kits RDKs accelerate product development by providing ready to run hardware a typical motor and comprehensive documentation including hardware design files Designers without prior motor control experience can successfully implement a sophisticated motor control system using the AC Induction Motor RDK Safety Information WARNING Risk of Electric Shock The microcontroller in the RDK is not referenced to ground it is at AC line potential Do not make direct connection to the JTAG header or any other microcontroller related circuit Read the Quickstart Guide first for additional warnings This RDK operates from AC line voltage Improper use or application carries electric shock fire and other risks that may result in serious injury or death Please read and follow these safety notices This documentation and kit must only be used by people with training and experience in working with voltage potentials up to 230 V The control board has both high voltage potential and safety low voltage sections Do not connect high voltage potential circuits to safety low voltage circuits or to ground referenced equipment such as computers or test equipment W After power is removed high voltages remain until the bus capacitors discharge Wait at least one minute after removing power before working with high voltage circuitry
27. 0K 196 0805 Generic R43 R44 38 4 R10 R11 R12 Resistor 100 Ohm 596 0805 Generic R13 R14 R15 R60 R61 21 R70 R74 gi e R47 R48 R49 u7 sp 5 0805 R86 E R25 R26 R27 Resistor 5 6 Ohms 5 0805 3 44 R31 R32 R33 WSL2512RO400FEB_ Resistor 0 040 Ohms 1 1W 2512 LR2512 01 R040 F 45 R38 R45 R52 R53 10 Resistor 4 7K 5 0805 Generic R59 R83 R80 R85 R87 R88 R79 R82 R63 R64 R65 Resistor 221K 196 0805 Generic 666 Resistor 4 42K 1 0805 Generic 1 R67 R68 R81 uj gt R71 R72 5 5 5 Resistor 2 2K 596 0805 Generic Resistor 698 Ohms 196 0805 Generic 43F330E Resistor 330 Ohms 596 3W Silicone Ohmite 48 Resistor 5K 25W TO 220 Mount on Bottom Side Caddock of PCB R63 R64 665 3 MOV Resistor 33K 596 0805 Generic gt 2 3 5 6 7 8 9 4 H sec Eng USB UART Asynchronous Serial Data Transfer FTDI Chip SSOP28 Pb free IC RC Oscillator SOT23 5 Micrel U12 U13 U16 Single Low Voltage Low Power Rail to Rail Fairchi Output 3MHz Op Amp SOT 23 on Bottom Side of PCB KA431SAMFTF Adjustable Shunt Regulator 1 SOT23 Fairchi U17 U18 U19 U20 FOD2200S Optocoupler High Speed SMT EA 223 5 5 i NES 59 07 SW1 SW2 B3S 1000 Switch Momentary Tact SMT Omron o x ala a a 5 a d c E D 324
28. 535 varies This read only parameter provides the version number of the firmware Changing the value of this parameter in the source code makes it difficult for Texas Instruments support personnel to determine the firmware in use when trying to provide assistance this parameter should only be changed after careful consideration November 4 2009 37 Parameter Descriptions Motor Drive Status PARAM MOTOR STATUS enumeration n a 0 This parameter is a read only value that provides the current operating status of the motor drive The value will be one of the following 0 The motor drive is stopped 1 The motor drive is running 2 The motor drive is accelerating 3 The motor drive is decelerating Motor Drive Fault Status 38 PARAM FAULT STATUS flags n a 0 This parameter is a read only value that provides the current status of faults in the motor drive This value is a bit field with each bit indicating a different fault condition as follows 0 An emergency stop was requested 1 The DC bus voltage dropped too low The DC bus voltage rose too high The motor current dropped too low The motor current rose too high The smart power module indicated a fault The ambient temperature rose too high These fault conditions are sticky any fault condition that has occurred will be indicated A write of any value to this paramet
29. AM_MODULATION choice 0 to 1 0 This parameter selects the modulation type to be used to drive the motor A value of 0 indicates that sine wave modulation will be used and a value of 1 indicates that space vector modulation will November 4 2009 43 Parameter Descriptions be used Sine wave modulation is the only accepted modulation type when a single phase motor is being driven Sine wave modulation is easy to understand but only provides 86 6 utilization of the DC bus Space vector modulation is more complicated but provides 100 utilization of the DC bus Better utilization of the DC bus results in more output torque from the motor The value of this parameter can not be changed while the motor drive is running Motor Drive Direction PARAM DIRECTION Boolean 0 to 1 0 This parameter specifies the direction of rotation for the motor drive Since the motor drive has no knowledge of the connection of the windings to the drive it can not be said that one particular value means clockwise rotation and the other means counter clockwise rotation Changing the value of this parameter reverses the direction of rotation The value of this parameter can only be changed for three phase motors this parameter is forced to 0 for single phase motors Acceleration Rate PARAM ACCEL Hertz second 1 to 100 40 This parameter is the rate at which the output frequency increases when it is less than the target frequency When in Closed L
30. Bill of Materials BOM This section provides the BOM for the ACIM RDK November 4 2009 65 Texas I nstruments nc AC Induction Motor Control RDK Bill Of Materials Revision A 1 2 20 2007 C5 C7 C8 C22 C23 4 C0805C104J5RACTU Capacitor O0 1uF 0805 50V X7R 5 C30 C51 C54 C56 0 1 C24 C27 C28 C38 EEE FK1E100R Capacitor 10uF 25V Electro Low Z SMT Size B Panasonic C57 1 C41 C42 C43 C48 3 C52 C53 C58 101UR Capacitor 100uF 6 3V Electro Low Z SMT Size C C19 C20 C21 C25 C59 4 C4 C10 C26 C0805C105Z4VACTU Capacitor 1uF 16V Y5V 0805 C60 C31 C37 C40 C55 5 2 2 805 180 5 Capacitor 18pF 0805 NPO 50v 596 C9 C11 C12 C13 13 C0805C102K5RACTU 1000pF 0805 X7R 50V 10 Kemet C14 C15 C16 C18 C29 C33 C34 C35 C36 32652 4104 Capacitor 0 1uF Polypropylene Film 400V EPCOS C44a C44b 45 8730 Terminal Single pos open screw type C45b 1 210 Capacitor 1000pF Ceramic 1kV 7 5mm Mallory C46 C47 ECK ATS102ME Capacitor 1000pF Ceramic 250Vac 7 5mm Y2 X1 C39 C50 C0805C333K5RACTU 0 033uF 0805 X7R 50V 10 D1 D7 D11 D12 MBRO520L Diode Schottky 20V 500mA irchi D20 D2 D3 D5 D6 D19 LTST C171GKT LED 0805 SMT Green i LTST C171CKT LED 0805 SMT Red m D8 DY 010 D14 D15 016 017 018 RGF1M Diode Fast 1000V 1A Fairchild RS1505M Rectifier Bridge 15A 600V SIL Mou
31. In Open Loop mode the output frequency is set to the target frequency and the rotor spins at the frequency determined by its slip In Closed Loop mode the rotor frequency is monitored and the output frequency is set so that the rotor frequency matches the target frequency November 4 2009 47 Parameter Descriptions A parameter value of 1 enables Closed Loop mode Closed Loop mode is not possible and this parameter can not be set to 1 if there is not an encoder present on the rotor as indicated by the Encoder Present parameter When in Closed Loop mode the Frequency Controller P Coefficient and Frequency Controller 1 Coefficient are used to tune the PI controller that forms the feedback loop Frequency Controller P Coefficient PARAM SPEED P 16 16 fixed point 2 147 483 648 to 32768 signed integer 2 147 483 647 This parameter is the P coefficient of the PI controller used to adjust the frequency of the motor drive while in Closed Loop mode The P coefficient adjusts the output frequency based on the error in the most recently sampled rotor speed known as the proportional term In 16 16 fixed point notation 65536 corresponds to 1 0 that is the proportional term is equal to the error Larger values of the P coefficient result in a decrease in the rise time of the output in response to a step input an increase in the overshoot and a decrease in the steady state error Smaller values do the opposite For effective operation o
32. Indicates the AC root mean square rms motor current as measured by the RDK control board Processor Usage Indicates the microcontroller CPU load by percentage Useful for estimating the loading of different applications and motor control algorithms Temperature Indicates the ambient temperature near the microcontroller using the internal temperature sensor 7 Indicator Area Panic Indicates that control has received a request to immediately shut down without a controlled motor ramp down Motor Under Current Fault Indicates that the motor was drawing less current than the under current limit and the motor has been stopped This feature is MUC useful for detecting an open circuit in the motor Some motors have internal thermal cut outs that can be detected with the MUC indicator Motor Over Current Indicates that the motor was drawing more current than the over Fault MOC current limit and the motor has been stopped This may indicated a motor stall condition DC Over Voltage Indicates that the high voltage DC supply rail is too high This can Fault DCOV occur if the motor is slowed down too quickly DC Under Voltage Fault DCUV Indicates that the high voltage DC supply rail is too low This can occur if the AC line voltage is out of specification Over Temperature Fault TEMP The ambient air temperature near the microcontroller has exceeded the limit and the motor has been stopped
33. O 6 2 GND FOD22008 2X10 HDR SHRD ISOGND ISOGND STAG B 018 1 JTAG Debugger Header R75 2 ANY A 470 4 HDR2X4 GND Debug signals FOD22008 from main bd ISOGND 150 3 3 R74 4 019 220 Isolated Power LED vec R76 2 19 ANY 470 vs GND eom FOD22008 ISOGND U20 1 1 R77 2 470 3 150 5 15043 3 1 el FOD22008 ISOGND i e 1 gt isocxp HDR 2X2 D ISOLATED POWER FROM MAIN BD Circuits inside this box are isolated low voltage Circuits on this page are only required for development and debugging CAUTION Risk of Electric Shock Texas INSTRUMENTS Drawing Tite ACIM Reference Design Page Tite Isolated JTAG Interface Size Document Number Date 2 20 2007 I 6 62 November 4 2009 Component Locations This section shows the PCB component locations for the ACIM RDK November 4 2009 63 115V e 12 x QD Oo 2 mi oe 2 LECCE 07 K1 m D20 mamas Rom R6 O ve e rei R38 gy 1111 gt fo AE 2 ME LL PELLI e e 04 02 wa POWER 05 06 1 2 HANN HANN RRO FAULT V SCORE LINE
34. Stellaris amp AC Induction Motor Reference Design Kit User s Manual 4 TEXAS INSTRUMENTS RDK ACIM 03 Copyright 2007 2009 Texas Instruments Copyright Copyright 2007 2009 Texas Instruments Inc rights reserved Stellaris and StellarisWare are registered trademarks of Texas Instruments ARM and Thumb are registered trademarks and Cortex is a trademark of ARM Limited Other names and brands may be claimed as the property of others Texas Instruments 108 Wild Basin Suite 350 x Austin TX 78746 TEXAS Main 1 512 279 8800 Fax 1 512 279 8879 INSTRUMENTS http www luminarymicro com Cortex Intelligent Processors by u ARM 2 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Table of Contents Chapter 1 Stellaris amp AC Induction Motor Reference Design Kit 11 Safety Information siete et ehe eee o Da e be en ER Pe eser Paria aee 11 Using the RDK I 11 Lipf EET 12 Motor Technology det oo ete en e de eL EIE ei a oh P eet Rena 12 Introduction to AG Induction eed Do e retient fe Pod dee Epi 12 Induction Motor iem bee epe e say d a Een EE P a 13 Varable Speedi RT
35. TA STATOR SPEED 1 10 of a Hertz 0 to 4000 This real time data item provides the current frequency of the waveforms being driven to the inverter bridge Once driven to the motor this is the frequency of the magnetic field rotating through the stator of the motor Current Rotor Frequency DATA ROTOR SPEED 1 10 of a Hertz 0 to 4000 This real time data item provides the current frequency of the motor s rotor If an encoder is not present this will always be 0 The value of this real time data item will always be less than the value of the Current Stator Frequency real time data item due to the slip inherent in A C induction motors in fact the difference between the two is the slip frequency Measurement Parameters DC Bus Voltage DATA BUS VOLTAGE volts 0 to 400 This real time data item provides the DC bus voltage The DC bus under voltage and over voltage faults trigger based on the value of this real time data item and the dynamic braking and reduced deceleration controls operated based on this value as well 52 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Motor Phase U Current DATA PHASE A CURRENT 1 256 of an ampere 0 to 65535 This real time data item provides the RMS current for the U phase of the motor This is found by performing a peak detect across a full cycle of the drive waveform and dividing the peak value by sqrt 2 to find the RMS current Motor Phase V Current
36. a KST2907A 4 Braking Circuit IGBT FGD3N60LSD B 5 VSENSE 150 d 048 0 1UF Isolated 5V Supply 150 5 15043 3 1 2 S 4 1 gt ISOGND HDR 2X2 ISOLATI D16 11 10uH C52 100uF 6 3V ED POWER TO JTAG BD ISO45V C56 2 100uF 6 3 V Dal MMSZ5231B 51 D17 ISOGND 3 3V 10uH C53 CS8 100uF 6 3V gt lt 100uF 6 3V 16 U14 D18 TSDXOBM 1222 3 RGFIM c54 5 z gt 25V T 9 MMSZ5248B E 2 18V a 414 S EE16 VIE VA TRANS EE16 1W 4 Q b 1 2907 i a Flyback Converter 15V 60mA 3 3V 200mA 5V 65mA KST2222A 015 33nF R70 220 KA4318MF 45 TEXAS INSTRUMENTS Drawing Tite ACIM Reference Design Tie Power Supplies CAUTION Size Document Number Risk of Electric Shock Date 5505097 Sheet 5 gt 6 Rev 6 2 3 z 150 3 3 R78 116 IK 43 3V 1 6 4 SEA 7 sw2 Reset Switch SW PB 3 h HIILIM STOND ISO 5V 017 8 150 RESETn 7 ISO TDO 1 aa 79 470 IS
37. arameter specifies the DC bus voltage at which the braking resistor is enabled The braking resistor converts voltage on the DC bus into heat in an attempt to reduce the voltage level on the DC bus If this value is too low the braking resistor could be turned on all the time If it is too high the braking resistor may never be turned on or it may turn on immediately before an over voltage November 4 2009 45 Parameter Descriptions fault The value of this parameter must be greater than the value of the Dynamic Brake Disengage Voltage parameter though this is not enforced by the firmware Dynamic Brake Disengage Voltage PARAM BRAKE OFF VOLTAGE volts 1 to 400 350 This parameter specifies the DC bus voltage at which the braking resistor is disabled If this value is too low the braking resistor may never turn off once enabled if it is too high the braking resistor may not stay on for very long or it may cycle on and off very quickly The value of this parameter must be less than the value of the Dynamic Brake Engage Voltage parameter though this is not enforced by the firmware Maximum Dynamic Braking Time PARAM MAX BRAKE TIME milliseconds 0 to 60000 60000 This parameter specifies the maximum amount of accumulated time that the dynamic brake can be on Turning on the power resistor causes it to generate heat turning it off causes that heat to dissipate A counter increases when the power resistor is on and decrea
38. ate Rate 912 Table 2 2 Description of PWM Configuration Controls 1 PWM Parameters Frequency Sets the frequency of the PWM waveforms produced by the microcontroller Higher frequencies will produce less audible noise in the motor but result in higher processor usage Dead Time The amount of time between the activation of the high and low side Switches on a motor phase This is used to prevent a short circuit Pre Charge Time The amount of time to pre charge the high side gate drivers before starting the motor drive November 4 2009 21 Graphical User Interface Table 2 2 Description of PWM Configuration Controls Continued 2 Waveform Parameters Minimum Pulse The width of the smallest pulse positive or negative that should be Width produced by the motor drive This prevents pulses that are too short to perform any useful work but that still incur switching losses Update Rate The number of PWM periods between updates the output waveforms Updating the output waveform more frequently results in better quality waveforms and less harmonic distortion at the cost of higher processor usage Motor Configuration In the Parameter Configuration window click the Motor Configuration tab to display parameters for configuring the motor see Figure 2 3 Table 2 3 describes the controls in detail Figure 2 3 Motor Configuration Window AIC Inducti
39. chematic is only used during software development The isolated JTAG interface board can be unplugged from the main board when development is complete Four high speed opto isolators provide electrical isolation for TDI TMS and signals A lower speed isolator is sufficient for the reset circuit The reset switch is isolated but use caution as it is in close proximity to high voltages As opto isolators increase JTAG propagation delays it may be necessary to reduce the speed of some high speed JTAG debug interfaces when working with the RDK Software The software running on the Stellaris microcontroller is responsible for generating the waveforms that drive the motor The motor drive is capable of operation from 0 to 400 Hz with smooth November 4 2009 31 Hardware Description acceleration and deceleration from 1 to 100 Hz second Additionally it monitors the state of the motor drive and handles fault conditions The software is written entirely in C The RDK CD includes the full source code Modulation Methods The waveforms that drive the motor can be generated using either the sine wave modulation or space vector modulation technique Sine wave modulation is an easy to generate modulation technique but does not provide full utilization of the DC bus voltage it provides a peak voltage in the motor of roughly 86 of the DC bus voltage before distortion occurs Space vector modulation on the other hand allows full
40. e mains input to the board is disconnected or the mains power goes out Maximum DC Bus Voltage PARAM MAX BUS VOLTAGE volts 1 to 400 390 This parameter specifies the maximum DC bus voltage that should be present on the motor drive If the DC bus voltage goes above this value an over voltage fault will be triggered and the motor drive will immediately shut down Caution When the motor is being decelerated it acts like a generator increasing the DC bus voltage If the motor is decelerated too quickly the DC bus voltage will rise too high Left unhandled the elevated DC bus voltage could cause permanent damage to components on the motor drive board such as the DC bus capacitors which are rated for 400 volts DC Bus Voltage Compensation Enable PARAM USE BUS COMP Boolean 0 to 1 1 This parameter specifies whether DC bus voltage ripple compensation should be utilized a value of 1 enables ripple compensation and a value of 0 disables it Operation of the motor drive results in fluctuations on the DC bus voltage By measuring the DC bus voltage and providing instantaneous adjustments to the amplitude of the drive waveform the motor is presented with a voltage that is closer to the desired voltage since the bus ripple has been removed DC Bus Deceleration Voltage PARAM DECEL VOLTAGE volts 1 to 400 350 This parameter specifies the DC bus voltage at which the deceleration rate is reduced A slower deceleratio
41. er clears all fault conditions The motor drive will not operate while a fault condition is indicated in this parameter November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Motor Configuration Parameters Motor Type PARAM MOTOR TYPE choice 0 to 1 0 This parameter specifies whether a single phase or a three phase A C induction motor will be driven by the motor drive A value of 0 indicates that a three phase motor is being used and a value of 1 indicates that a single phase motor is being used The value of this parameter can be changed while the motor drive is stopped Number of Poles PARAM NUM POLES count 0 to 255 1 This parameter specifies the number of poles in the motor minus 1 since it not possible to have a zero pole motor This is for information purposes only it does not affect the behavior or operation of the motor drive The motor speed in rpm can be computed from this value with the equation RPM 120 PARAM CURRENT FREQUENCY NUMBER OF POLES 1 This information is obtained from the motor being used either from the name plate on the motor or from the data sheet for the motor Encoder Present This parameter indicates the presence of an encoder on the rotor shaft Closed Loop mode is not permitted if this parameter does not indicate the presence of an encoder A parameter value of 1 indicates that an encoder is present When an encoder is present the Number of Encoder L
42. erence Design Page Title MCU etc Size Document Number Date 2 20 2007 Sheet 6 6 bi ash VS w VB w R10 VCC wh PWM_W_HI gt WW 100 15V D9 IN wh ecu RIS en 26 MOTOR W 15 28 REM VS v 5 B n RI VCC 4 PWM V HI ANY n To Motor 100 45V IN v T D10 25 1 MOTOR V 2 5 Power Output 15 EIS REIN VS VB u ELFH04410 VCCQ 5 2 MOTOR U 100 m 9 I InF OMIT 8 osc 23 R31 0 040 FAULT 040 13 5 W LO 24 RIS 4 22 R32 gt WW 1 ANS 4 100 0 040 R14 C34 PWM U LO IN ul 100 shou cis 4 InF V m EN 5 510 60 ISENSE ALL 3 3V 3 3V 3 3V R21 R28 R35 OMIT OMIT U2 04 R 174155 NL R24 4174155 id 3 FANA174IS5X NL 1 82K LPHU 1 82K LPHV 1 82K 1 I PHW D7 c16 C36 ale 3V INF INF MBR0520 MBR0520 C30 MBR0520 e CAUTION 108 Risk of Electric Shock 25V 1UF TEXAS INSTRUMENTS R36 100K Drawing Tile Reference Design We Page Title Power Stage Size B Document Number Date 9 20 2007 sheet Za eof OMe 18
43. ergy from the motor as it brakes These settings control the braking levels and dynamic characteristics Max Time ms The maximum amount of time the dynamic brake can be applied before it is forced off to prevent overheating Cool Time ms The time at which the dynamic brake can be reapplied after reaching the Maximum time The brake is allowed to cool for the delta of Max Time and Cool Time On Voltage The dynamic brake is applied when the DC bus voltage exceeds this value Off Voltage Once applied the dynamic brake is disengaged when the DC bus voltage drops below this level November 4 2009 25 Graphical User Interface 26 November 4 2009 Hardware Description Key components in the reference design include a Stellaris LM3S818 microcontroller with an ARM Cortex M3 core and a Fairchild Semiconductor FSBS10CH60 Power Module Other complementary components round out the design by providing protection signal acquisition and power supply functions The entire circuit is built on a simple two layer printed circuit board design files are provided in the RDK CD System Description As is typical for AC powered motor controls the microcontroller interfaces directly to the power stage This scheme allows the microcontroller to directly measure current in the power module but it also requires that the microcontroller be at high voltage potential with respect to Earth ground One set of opto iso
44. f the PI controller the Frequency Controller Coefficient should also be set Frequency Controller Coefficient PARAM SPEED 1 16 16 fixed point 2 147 483 648 to 128 signed integer 2 147 483 647 This parameter is the coefficient of the PI controller used to adjust the frequency of the motor drive while in Closed Loop mode The I coefficient adjusts the output frequency based on the integral of all past errors in the sampled rotor speed known as the integral term In 16 16 fixed point notation 65536 corresponds to 1 0 that is the integral term is equal to the integrator value Larger values of the coefficient result in a decrease in the rise time of the output in response to a step input an increase in the overshoot and an elimination of the steady state error Smaller values do the opposite though the steady state error will always be eliminated by non zero coefficients For effective operation of the PI controller the Frequency Controller P Coefficient should also be set DC Bus Configuration Parameters Minimum DC Bus Voltage PARAM MIN BUS VOLTAGE volts 1 to 400 250 This parameter specifies the minimum DC bus voltage that should be present on the motor drive If the DC bus voltage drops below this value an under voltage fault will be triggered and the motor drive will immediately shut down 48 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual This will typically only occur when th
45. harge that accumulates in the shaft a motor that is not necessarily inverter duty may be suitable Regardless it is still important to address this with your motor supplier Bus Capacitors The bus capacitors C44 C45 are connected in series to achieve a 400 V rating and to enable the voltage doubler option For 230 V only operation a single capacitor would normally be used When electrolytic capacitors are used in a series configuration it is important that neither capacitor exceeds its individual voltage rating Because internal impedances can vary you should consider placing a power resistor in parallel with each capacitor to ensure voltage sharing especially during power up At least one manufacturer found that as long as capacitors were from the same batch voltage divider resistors were unnecessary and could be considered to have a negative effect on overall reliability Capacitors are typically the most expensive and shortest lived components in a motor control system therefore selecting the correct part is critical The ACIM RDK s design enables experimentation with different values sizes and temperature ratings Since heat directly affects capacitor life capacitor sizes with the greatest surface area are preferable Heat Sinking Underwriters Laboratories UL standards generally require that surfaces that could be touched by a user or service person must not exceed 70 C The RDK control aluminum baseplate may require addit
46. he frequency of the PWM signals used to drive the inverter bridge The PWM frequency can be 8 KHz parameter value 0 12 5 KHz parameter value 1 16 KHz parameter value 2 or 20 KHz parameter value 3 Higher PWM frequencies produce less audible noise in the motor windings though there may be little or no PWM frequency induced audible noise in the windings of high quality motors Higher PWM frequencies also cause higher processor usage due to an increased interrupt rate PWM Dead Time PARAM PWM DEAD TIME 20 nanoseconds 100 to 255 100 This parameter specifies the amount of time to delay between turning off one gate on a phase and turning on the other gate The dead time is required since the turn on and turn off times of the gates do not always match and the times for the high side and low side gates do not always match This time delay prevents shoot through current that would occur if both gates were on at the same time which is a short between the DC bus and ground While the dead time prevents damage to the motor and motor drive it also introduces harmonic distortion into the drive waveforms The dead time required by the smart power module on the RDK ACIM board is 2 uS this parameter can not be decreased It can be increased in order to evaluate the performance of the motor with a larger dead time before building a custom board with a different inverter that required a longer dead time Waveform Update Rate PARAM
47. ile menu select Load 20 Parameters from File and load the selni ini parameter file to the target Then select Save Parameters to Flash from the File menu to save the default parameters into flash memory November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Parameter Configuration Window The Parameter Configuration window is used to allow adjustment of certain system parameters The window contains four tabs PWM Configuration Motor Configuration Drive Configuration and DC Bus Configuration Open the Parameter Configuration window by clicking the Configure button on the main window and then clicking the tab you want to configure The left and right arrows to the right of the tabs can be used to scroll to the tabs that are not visible Change the parameters and click the OK button to send the new parameters to the target Click the Cancel button to discard any changes PWM Configuration In the Parameter Configuration window click the PWM Configuration tab to display parameters for configuring the PWM output see Figure 2 3 Table 2 3 describes the controls in detail Figure 2 2 PWM Configuration Window A C Induction Motor Properties c PWM Configuration Motor Configuration Drive Configuration 1 lt PWM Parameters 1 Fre j 20kHz Dead Time ns gt 2000 Pre Charge Time ms 2 2 2 Waveform Parameters Minimum Pulse Width us 2 1 0 a Upd
48. ines parameter indicates the number of lines in the encoder Number of Encoder Lines PARAM NUM LINES count 0 to 65535 7 This parameter specifies the number of lines in the encoder minus 1 since it is not possible to have a zero line encoder A line corresponds to a rising edge and a falling edge produced by the encoder This information is used to convert edges from the encoder into the rotor frequency November 4 2009 39 Parameter Descriptions V f Table V f Table Range Select PARAM VF RANGE choice 0 to 1 1 This parameter specifies the range of the V f table provided in the V f Table parameter A value of 0 specifies a V f table range of 0 Hz to 100 Hz and a value of 1 specifies a V f table range of 0 Hz to 400 Hz For 50 60 Hz motors a V f table range of 0 Hz to 100 Hz is the best choice and also allows the amplitude at 50 Hz to be specified which is not directly possible with the other range For high frequency motors such as 400 Hz aircraft motors a V f table range of 0 Hz to 400 Hz is the best choice PARAM VF TABLE 1 15 fixed point integer 0 to 37837 4200 5200 scale factor 6200 7200 8300 9700 11500 13400 15200 17050 18900 20750 22550 24400 26250 28100 29900 31750 31750 31750 31750 This table provides a mapping between the motor drive frequency and the amplitude that is voltage of the waveform produced by the motor drive By increasing the amplitude
49. ional heat sinking to keep it below this limit Securely mount the control to a larger aluminum heat sink using machine screws and thermal paste or sheet material Power Line Filtering The power entry filter used in the RDK is for evaluation and is not expected to meet compliance limits for conducted emissions Inverter based motor controls typically require a multi stage power line filter tailored to the end application Serial Protocol See the AC Induction Motor RDK Software Reference Manual for more information November 4 2009 33 Hardware Description 34 November 4 2009 APPENDIX Parameters and Real Time Data Items This section provides detailed information for parameters and real time data items see Real Time Data Items on page 50 Parameters Table A 1 provides a summary of all configuration parameters See Parameter Descriptions on page 37 for more information Table A 1 Parameter Configuration Summary Informational Parameters PARAM FIRMWARE VERSION number 0 to 65335 varies page 37 PARAM MOTOR STATUS enumeration n a 0 page 38 FAULT STATUS flags n a 0 page 38 Motor Configuration Parameters PARAM MOTOR TYPE choice 0 to 1 0 page 39 PARAM NUM POLES count 0 to 255 1 page 39 PARAM ENCODER PRESENT Boolean 0 to 1 1 page 39 PARAM NUM LINES count 0 to 65535 7 page 39 PARAM VF RANGE choice 0 to 1 1 page 40 PARAM VF TABLE 1 15 fixed point 0 to 37837 4200
50. lators provides electrical isolation for the serial and control signals A daughter board containing a second set of high speed opto isolators isolates the Stellaris microcontroller s JTAG port Once software development is complete the JTAG board can be removed to reduce power consumption A custom designed off line switching power supply often called a housekeeping supply generates three power supply rails one of which is isolated The RDK s line filter heat sink and DC bus capacitors are dependent on the end application and are easily customizable For operation above 0 25 HP it may be necessary to mount the RDK on an additional heat sink November 4 2009 27 Hardware Description Block Diagram Figure 3 1 Block Diagram AC IN 115 230Vac 50 60Hz AC Line Filter Tach Encoder TXD 5V Speed Pot Dir Mode Serial Position and speed input Control Inputs LM3S818 Stellaris Microcontroller M Electrical Isolation JTAG Functional Description CO Status LEDs In Rush Control e M I 5 BR E DC In 5 Zero Crossin DC Curren Gate Ctrl 2 Flyback Dynamic Power Supply DC Voltage Sense High Low Side Gate Driver
51. lliseconds 0 to 60000 60000 page 46 PARAM BRAKE COOL TIME milliseconds 0 to 60000 55000 page 46 DC Injection Braking Configuration Parameters PARAM USE DC BRAKE Boolean 0 to 1 1 page 47 PARAM DC BRAKE V volts 0 to 160 24 page 47 PARAM DC BRAKE TIME milliseconds 0 to 65535 200 page 47 Closed Loop Configuration Parameters PARAM CLOSED LOOP Boolean 0101 0 47 PARAM SPEED P 16 16 fixed point 2 147 483 648 to 32768 page 48 signed integer 2 147 483 647 PARAM SPEED 16 16 fixed point 2 147 483 648 to 128 page 48 signed integer 2 147 483 647 36 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Table A 1 Parameter Configuration Summary Continued DC Bus Configuration Parameters PARAM MIN BUS VOLTAGE volts 1 to 400 250 page 48 PARAM MAX BUS VOLTAGE volts 1 to 400 390 page 49 PARAM USE BUS COMP Boolean O to 1 1 page 49 PARAM DECEL VOLTAGE volts 1 to 400 350 page 49 Miscellaneous Configuration Parameters PARAM USE ONBOARD UI Boolean 0 to 1 1 page 50 PARAM MAX TEMPERATURE degrees Celsius 0 to 85 85 page 50 Parameter Descriptions This section describes parameter configuration in detail The parameters are grouped into the following areas Informational Motor PWM Motor drive Dynamic braking DC injection braking Closed Loop DC bus Miscellaneous Informational Parameters Firmware Version PARAM FIRMWARE VERSION number 0 to 65
52. n will result in a smaller increase in the DC bus voltage The deceleration rate is decreased proportional to the amount by which the DC bus voltage exceeds the value of this parameter with the deceleration reduced to Hz sec when the DC bus voltage is 64 V above this parameter Therefore this acts more aggressively as the DC bus voltage gets higher To avoid bouncing the DC bus voltage and therefore the deceleration rate a reduced deceleration rate is slowly increased by Hz every millisecond when the DC bus voltage is below the value of this parameter Setting the value of this parameter too low that is below the normal DC bus voltage will result in the motor decelerating slower than it could or should Setting the value of this parameter too high November 4 2009 49 Real Time Data Items will result in the ineffective control of the DC bus voltage Setting the value of this parameter at or above the value of the Maximum DC Bus Voltage parameter will effectively disable this feature Miscellaneous Parameters On board User Interface Enable PARAM USE ONBOARD UI Boolean 0 to 1 1 This parameter determines whether the on board user interface elements can be used to control the motor drive If the value of this parameter is 1 the on board user interface will control the motor drive if O they will not The motor drive can always be operated over the serial interface But the target frequency is constantly updated by the on b
53. nditions of sale supplied at the time of order acknowledgment TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with standard warranty Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty Except where mandated by government requirements testing of all parameters of each product is not necessarily performed TI assumes no liability for applications assistance or customer product design Customers are responsible for their products and applications using Tl components To minimize the risks associated with customer products and applications customers should provide adequate design and operating safeguards TI does not warrant or represent that any license either express or implied is granted under any TI patent right copyright mask work right or other TI intellectual property right relating to any combination machine or process in which TI products or services are used Information published by TI regarding third party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof Use of such information may require a license from a third party under the patents or other intellectual property of the third party or a license from TI under the patents or other intellectual property of TI Reproduction of TI information in TI data books or data sheets is
54. nt on Bottom Side of PCB 7 10 11 12 13 15 16 17 airchild MMSZ5231B Diode Zener 5 1V 500mW SOD 123 airchild 5ST 10 R Fuse 5x20mm 10A slow blow el Fuse 3517 Fuse Clip 5mm 15A ED555 7DS Terminal Block 7 pos LP 3 5mm black 54819 0572 Connector USB Mini B SMT 5pin PRPNO42PAEN RC Header 8 pos 2x4 2mm pitch 87831 1020 Header 10 pos 2x5 2mm pitch Molex 87831 0420 Header 4 pos 2x2 2mm pitch Molex Socket 4 pos 2x2 2mm pitch Mount on Bottom Molex Side of PCB 4 pos 2x4 2mm pitch Mount on Bottom Side of PCB horizontal horizontal N2520 6002RB Header 2x10 0 1 pitch shrouded black 31 1 G5Q 1A4 DC12 Relay SPNO 10A 12V 200mW coil Omron a 1 oj N N N N N N H Wl SS SS Of Bl ete PEE N 1 4 1 2 2 5 5 1 1 1 1 1 2 1 1 1 2 2 1 1 1 2 E pz wwszszass Zener 18v 500mW SOD 123 a par EA EE eed 66 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual L1 L2 L3 NLCV32T 100K PF Inductor 10uH 450mA 33 01 Q2 Q5 Q7 KST2222AMTF NPN Bipolar Transistor SOT 23 Fairchild Q3 Q6 KST2907AMTF PNP Bipolar Transistor SOT 23 Fairchild FGD3N60LSD IGBT N Channel 600V DPAK Fairchild 36 EVU TUAB16B54 Trimpot 16mm thumbwheel style SMT 50K ET 37 1 R2 R22 R29 11 Resistor 1
55. oard user interface when enabled making that parameter effectively uncontrollable from the serial interface when the on board user interface is enabled The on board user interface is disabled by the ACIM GUI upon startup and re enabled on exit Maximum Ambient Temperature PARAM MAX TEMPERATURE degrees Celsius 0 to 85 85 This parameter specifies the maximum ambient temperature that is allowed If the ambient temperature exceeds this value an over temperature fault will be triggered and the motor drive will immediately shut down The ambient temperature is an approximation of the ambient temperature on the top of the microcontroller s package which is relatively removed from the heat sink and the smart power module which generates a majority of the heat The junction temperature of the microcontroller is measured with the ADC and the on chip temperature sensor and used to approximate the ambient temperature as determined by lab characterization of the transfer function Real Time Data Items Table A 2 provides a summary of all real time data items See Real Time Data Items Descriptions on page 51 for more information Table A 2 Real Time Data Items Drive Status DATA MOTOR STATUS enumeration n a varies page 51 DATA FAULT STATUS flags n a varies page 51 DATA PROCESSOR USAGE 76 0 to 100 varies page 52 50 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Table A 2 Real Time Data
56. of the waveform as the frequency increases the torque produced by the motor is held approximately constant This table ranges from 0 Hz to either 100 Hz or 400 Hz based on the setting of the V F Range Select parameter The 0 100 range provides an amplitude value every 5 Hz and the 0 400 range provides a value every 20 Hz For the 0 100 range frequencies above 100 Hz are produced at the same amplitude as the 100 Hz entry of the table For any frequency an amplitude that is too high can cause the motor to rotate in an erratic fashion and an amplitude that is too low can cause the motor to fail to rotate Minimum Drive Frequency 40 PARAM MIN SPEED 1 10 of a Hertz 0 to 4000 600 This parameter specifies the minimum frequency at which the motor drive will operate When running the output frequency will not go below this frequency When stopping or reversing November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual direction this minimum frequency is ignored and the output frequency will slew all the way down to 0 The minimum drive frequency should never be set lower than the slowest drive frequency that will turn the motor setting this parameter lower will result in effort being expended for no gain the motor simply will not spin Maximum Drive Frequency PARAM MAX SPEED 1 10 of a Hertz 0 to 4000 3400 This parameter specifies the maximum frequency at which the motor drive will operate The output fre
57. on Motor Properties Configuration Motor Configuration Drive Configuration Ra r Motor Type Motor Parameters Number of Poles 2 2 Encoder Present 2 Single Phase Encoder Pulses 28 Curve 1255 Fre Oo Range 0 ADU Hz Table 2 3 Description of Motor Configuration Controls 1 Motor Type Three Phase Sets the motor type to three phase for motors such as the ATB Selni motor included in the kit Use this setting for the motor included in the ACIM RDK Single Phase Sets the single phase setting which creates a single phase output from the control board to U and V motor terminals 22 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Table 2 3 Description of Motor Configuration Controls Continued 2 Motor Configuration Number of Poles Used by the RDK to convert frequency Hz to rpm Encoder Present Check this box if an Encoder or Tach is present Encoder Pulses Number of pulses in each motor shaft rotation 3 V f Curve V f Range Sets the relationship between motor voltage and frequency A detailed explanation is provided later in this User s Guide Drive Configuration In the Parameter Configuration window click the Drive Configuration tab to display parameters for configuring the drive see Figure 2 4 Table 2 4 describes the controls in detail
58. ontrols sse eee 24 Table 2 5 Description of DC Bus Configuration Controls sse 25 Table 3 1 Current Monitoring nens nnne nnns nnne nen 30 Table 3 2 Control Interface Functions esses eene nennen einn instr nennen nennen 30 Table A 1 Parameter Configuration Summary esses 35 Table A 2 Real Time Data 50 November 4 2009 7 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual List of Figures Figure 151 AG Induction MOtOF rent redeat uvae d ed eot 13 Figure 1 2 Typical Blower Incorporating Single Phase PSC 14 Figure 1 3 Linear Curve for a 340 Hz 14 Figure 2 1 AC Induction Motor Main GUI enne nennen nnne 17 Figure 2 2 PWM Configuration 9 21 Figure 2 3 Motor Configuration 22 Figure 2 4 Drive Configuration 23 Figure 2 5 DC Bus Configuration Window sess nnne 25 Fig re 3 1 Diagram secsi 5 nuit p HER EUN 28 November 4 20
59. oop mode this is the maximum rate of acceleration that is allowed though lower acceleration rates can be utilized The rate of acceleration can also be viewed as the rate that slip is introduced into the motor drive Slip causes an increase in the current through the motor so setting the acceleration too high may result in the over current fault tripping due to excessive slip Deceleration Rate 44 PARAM DECEL Hertz second 1 to 100 40 This parameter is the rate at which the output frequency decreases when it is greater than the target frequency If the DC bus voltage exceeds the value of the DC Bus Deceleration Voltage parameter the value of this parameter will be temporarily scaled back to slow the rise in the DC bus voltage If the DC bus voltage is below the DC Bus Deceleration Voltage parameter and this parameter was previously scaled back it will be slewed back to the parameter value at a rate of 1 4 Hz sec every millisecond When in Closed Loop mode this is the maximum rate of deceleration that is allowed though lower deceleration rates can be utilized Setting this parameter value too high may result in DC bus voltage increases that can not be handled by deceleration rate scaling and dynamic braking In this case a DC bus over voltage fault will occur November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Target Drive Frequency PARAM TARGET SPEED 1 10 of a Hertz 0 to 4000 varies This parame
60. oth high level operation for example acceleration rate and low level operation for example modulation algorithm Because they are stored in flash rather than hard coded the parameters can be modified using a serial control protocol The RDK GUI program provides a visual method for monitoring and adjusting control parameters over the USB interface An introduction to the RDK GUI can be found in the Quickstart guide Parameter Reference See Appendix A Parameters and Real Time Data Items for detailed description of the RDK s parameters 32 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Implementation Considerations This section provides information on items to consider when implementing the ACIM RDK Motor Selection For new designs three phase motors rather than their single phase counterparts are recommended for use with the RDK This is due to three phase motors having higher torque better efficiency and wider speed range Premium motor models are often qualified by the manufacturer as inverter duty This implies that the manufacturer has taken measures in the motor design to reduce failures due to the high frequency switching inherent in a PWM based motor control Failure modes include insulation breakdown in the stator and bearing pitting At 230 V or less the negative effects of high speed switching are less of a concern In addition because the end application may provide a discharge path for any c
61. p 6 DC Injection Braking Enable Enables or disables DC injection braking Voltage Sets the DC voltage to the applied during DC injection braking Time Sets the length of time to apply DC injection braking DC Bus Configuration In the Parameter Configuration window click the DC Bus Configuration tab to display parameters for configuring the DC bus see Figure 2 5 Table 2 5 describes the controls in detail 24 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Figure 2 5 DC Bus Configuration Window AIC Induction Motor Properties t3 Motor Configuration Drive Configuration DC Bus Configuration r DC Bus Voltage V j Maximum gt 390 Dynamic Brake Enable Time ms 2 60000 Voltage 2 350 r Deceleration Voltage V Cool Time 2 55000 Voltage T 360 Off Voltage 350 Table 2 5 Description of DC Bus Configuration Controls 1 DC Bus Voltage V Minimum Sets the minimum DC bus voltage before a fault is signaled Maximum Sets the maximum DC bus voltage before a fault is signaled Deceleration Voltage V Voltage The DC bus voltage at which the deceleration rate is scaled back in an effort to control increases in the DC bus voltage Dynamic Brake Enable Turns dynamic braking on Dynamic braking actively dissipates en
62. quency will never exceed this frequency even if the target frequency matches the maximum frequency and Closed Loop mode is enabled slip in the motor requires that the drive frequency exceed the target frequency The maximum drive frequency should never be set higher than the maximum frequency that the motor can handle setting this parameter higher could result in permanent damage to the motor mechanical failure from excessive speed melted winding insulation from excessive heating and 0 Minimum Motor Current PARAM CURRENT 1 10 of an ampere 0 to 50 1 This parameter specifies the minimum RMS current that should be consumed by the motor while operating If the measured motor RMS current is less than this value an under current fault will be triggered and the motor drive will immediately shut down If this value is zero the minimum motor current check is disabled Maximum Motor Current PARAM MAX CURRENT 1 10 of an ampere 0 to 50 48 This parameter specifies the maximum RMS current that should be consumed by the motor while operating If the measured motor RMS current is greater than this value an over current fault will be triggered and the motor drive will immediately shut down If this value is zero the maximum motor current check is disabled November 4 2009 41 Parameter Descriptions PWM Configuration Parameters PWM Frequency PARAM PWM FREQUENCY choice 0 to 3 3 This parameter selects t
63. r control for three phase and single phase AC induction motors Flexible platform accelerates integration process W Easily change line filter bus capacitors and JTAG interface Compatible with all main control algorithms including space vector modulation and sine control W Split low side current sensing for accurate current sensing W Dynamic braking circuit Active in rush control circuit W Several isolated control input options including Integrated USB port Virtual COM port Windows GUI application for configuration control and monitoring Logic level serial port Speed potentiometer and mode switch Quadrature encoder tachometer input for speed and position monitoring Electrically isolated JTAG port for software debugging Bootloader for firmware upgrades over USB Integrated AC Line Filter Motor Technology Introduction to AC Induction Motors The ACIM RDK controls a class of motors known as Alternating Current AC induction motors AC induction motors are accurately described as the work horses of industry In addition AC induction motors are widely found throughout the home in applications such as heating and air conditioning systems ceiling fans and appliances 12 Inside the AC induction motor the applied AC voltage creates a sinusoidal current in the stator winding The stator does not move but its coil or coils are positioned to create a rotating electromagnetic field The AC induction mo
64. rd to make substitution easy Double check polarity when changing capacitors Capacitors are discussed further in the implementation section of this guide At power up the bus capacitors charge through R84 to eliminate in rush current The microcontroller monitors the HVDC voltage level and closes a relay K1 once the capacitors are almost fully charged This method is a more reliable and efficient method than using a NTC thermistor though a thermistor may be suitable in some applications The RDK also includes a dynamic braking circuit that also operates under software control If the HVpg bus exceeds a programmable level the braking circuit is activated to dump power from the HVpg bus until it returns to a safe level This condition typically occurs during motor deceleration where the rotor is turning faster than the stator field and regeneration occurs Due to the size cost and specificity of braking circuits the RDK design has a low power brake Even at 20 Watts the brake allows the RDK to drastically increase deceleration rates The house keeping power supply uses Fairchild s FSD200 Single chip SMPS device A custom transformer has taps for 43 3 V 15 V and 5 V so no linear voltage regulators are necessary low cost feedback circuit Q5 Q6 replaces the usual optoisolator Zener diodes on the unregulated rails are installed simply as a precaution during development Isolated JTAG Interface Schematic Page 6 This section of the s
65. s whether DC injection braking should be used a value of 1 enables DC injection braking and a value of 0 disables it DC injection braking is the application of DC voltage to an A C induction motor in order to make it stop quickly This is a form of electrical braking that does not involve any friction components such as a mechanical brake and therefore does not result in any wear Use DC injection braking with caution since applying DC voltage to a stopped A C induction motor will quickly increase the temperature in the motor windings possibly causing permanent damage DC Injection Braking Voltage PARAM DC BRAKE V volts 0 to 160 24 This parameter specifies the DC voltage to be applied to the motor when performing DC injection braking The higher the voltage applied the more braking and the more potentially damaging to the motor if left on for too long See the description of the DC Injection Braking Enable parameter for more details DC Injection Braking Time DC BRAKE TIME 0 to 65535 This parameter specifies the amount of time to perform DC injection braking Leaving DC injection braking on for too long could cause permanent damage to the motor See the description of the DC Injection Braking Enable parameter for more details Closed Loop Configuration Parameters Closed Loop Mode Enable PARAM CLOSED LOOP Boolean 0 to 1 0 This parameter selects between Open Loop and Closed Loop mode of the motor drive
66. schematics for the ACIM Motor Control Board Contents Page on page 56 Microcontroller on page 57 Power Stage on page 58 Isolated Control Interfaces on page 59 Power Supplies on page 60 Isolated JTAG Interface on page 61 November 4 2009 55 Table of Contents Page Description Table of Contents and Revision History AC Induction Motor Control RDK Revision History essen pne SSS Stellaris Microcontroller LED indicators 0 Jan 14 07 First Full Release for Rev 0 PCB 0 1 Feb 08 07 Add rework changes 1 pin swap Add Brake pull up 3 Power Module Stage Isolated Control Interfaces Power Supplies Isolated JTAG Interface Feb 20 07 Improve Reset circuit Add Tach Gen support Fix Release to Production CAUTION Risk of Electric Shock All circuits are high voltage unless otherwise noted 45 TEXAS INSTRUMENTS DC rail labels refer to voltage with respect to HVDC GND Di Title i H which is at AC line potential rawing 11 ACIM Reference Design Page Tite Contents Page Size Document Number Date 9 20 2007 Sheet 6 VCP_RX VCP TX LPHW 3 3V DI MBR0520 VSENSE TCK TMS TDI TDO RESETn PAS SSITx 22 6 00MHz CI c2 18
67. ses when it is off If the counter reaches the value of this parameter the power resistor is turned off regardless of the DC bus voltage to prevent overheating of the power resistor Once forced off the counter must decrease to the value of the Dynamic Brake Cooling Time parameter before it can be turned on again giving it time to cool down before being used again If the value of this parameter is too small the motor drive will not be able to make effective use of the power resistor to control the DC bus voltage If the value of this parameter is too large the power resistor may overheat resulting in permanent damage The value of this parameter must be larger than the value of the Dynamic Brake Cooling Time parameter though this is not enforced by the firmware Dynamic Brake Cooling Time 46 PARAM BRAKE COOL TIME milliseconds 0 to 60000 55000 This parameter specifies the value the dynamic brake counter must reach in order to re enable the power resistor if it has been forced off See the description of the Maximum Dynamic Braking Time parameter for details The value of this parameter must be less than the value of the Maximum Dynamic Braking Time parameter though this is not enforced by the firmware November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual DC Injection Braking Configuration Parameters DC Injection Braking Enable PARAM USE DC BRAKE Boolean 0 to 1 1 This parameter specifie
68. stopped and are not selectable while the motor is running Table 2 1 describes the controls in detail Figure 2 1 AC Induction Motor Main GUI Window AIC Induction Motor Drive File Modulation 6 Sine 1 Space Vector peration Closed Loop 2 Reverse Direction Voltage Comp Frequency Hz Target 32000 Stator 2000 Rotor 1988 Speed rpm Target 3112000 4 Stator 12000 Statistics DC Bus Voltage 308V Motor Curent 054 Processor Usage 47 Frequency Configure Rotor 11928 Temperature 8 USB UART 0 Target ACIM PANIC DCOY DCUV TEMP ITRIP Texas ATBSELIII INSTRUMENTS Technology in Motion Table 2 1 Description of GUI Main Window Controls oo 1 Modulation Area Sine Sets the modulation type to sine Space Vector Sets the modulation type to space vector November 4 2009 17 Graphical User Interface Table 2 1 Description of GUI Main Window Controls Continued 2 Operation Area Closed Loop mode Selects between Open Loop mode and Closed Loop mode This is only available for motors that have an encoder or tacho generator for feedback of the rotor speed motors without rotor speed feedback can only be run in Open Loop mode Reverse Direction Selects
69. t any damages arising out of the use of TI products in such safety critical applications TI products are neither designed nor intended for use in military aerospace applications or environments unless the TI products are specifically designated by TI as military grade or enhanced plastic Only products designated by TI as military grade meet military specifications Buyers acknowledge and agree that any such use of TI products which TI has not designated as military grade is solely at the Buyer s risk and that they are solely responsible for compliance with all legal and regulatory requirements in connection with such use TI products are neither designed nor intended for use in automotive applications or environments unless the specific products are designated by as compliant with ISO TS 16949 requirements Buyers acknowledge and agree that if they use any non designated products in automotive applications TI will not be responsible for any failure to meet such requirements Following are URLs where you can obtain information on other Texas Instruments products and application solutions Products Applications Amplifiers amplifier ti com Audio www ti com audio Data Converters dataconverter ti com Automotive www ti com automotive DLP Products www dlp com Broadband www ti com broadband DSP dsp ti com Digital Control www ti com digitalcontrol Clocks and Timers www ti com clocks Medical www ti com medical Interface interface
70. tart Guide first for additional warnings To allow safe development using JTAG the RDK includes an optical isolation board for JTAG signals This is described in detail in the Isolated JTAG Interface Schematic Page 6 on page 31 Header J8 contains signals for an external power factor correction PFC stage PFC uses an active switching stage to remove harmonics from the AC line current waveform The LM3S818 microcontroller can eliminate a conventional PFC control chip in this circuit block When PFC is not in use a jumper must be installed between J8 3 and J8 4 Unallocated GPIO signals from the microcontroller are routed to J6 This includes the SSI port which can be connected to a SPI EEPROM or similar device NOTE The GPIO signals are not isolated Finally page 1 of the schematic contains five LEDs These are also referenced to high voltage Output Power Stage Schematic Page 3 The most significant component on page 2 is the FSBS10CH60 Smart Power Module SPM from Fairchild Semiconductor This compact DIP style device contains six low loss IGBTs HVIC gate drivers and protection circuitry including under voltage lock out and short circuit protection The SPM has three negative DC terminals allowing independent monitoring of each phase current The microcontroller provides the SPM with three pairs of complementary PWM signals one pair for each phase A simple RC network on each digital PWM improves noise immunity Dead time
71. ter specifies the target frequency of the motor drive In Open Loop mode this is the output frequency of the motor drive In Closed Loop mode this is the frequency of the rotor Note that in Closed Loop mode the target frequency should not exceed the maximum drive frequency minus the motor slip frequency if it does then the motor drive will never be able to achieve the target rotor speed since the output frequency can never exceed the maximum drive frequency This parameter value must lie between the Minimum Drive Frequency and the Maximum Drive Frequency Current Drive Frequency PARAM CURRENT SPEED 1 10 of a Hertz 0 to 4000 0 This parameter is a read only value that provides the current output frequency of the motor drive This is the same value that is provided using the Current Stator Frequency real time data item Dynamic Braking Configuration Parameters Dynamic Braking Enable PARAM USE DYNAM BRAKE Boolean 0 to 1 1 This parameter specifies whether dynamic braking should be used a value of 1 enables dynamic braking and a value of 0 disables it Dynamic braking is the use of a power resistor to control the increase in the DC bus voltage caused by decelerating an A C induction motor By using dynamic braking the motor can be decelerated at a faster rate since the added DC bus voltage rise is counteracted by the power resistor Dynamic Brake Engage Voltage PARAM BRAKE ON VOLTAGE volts 1 to 400 360 This p
72. the direction of rotation This is not available for single phase motors Bus Voltage Comp Enables bus voltage compensation This improves the drive waveforms by reducing the voltage ripple seen by the motor Frequency Area Target Sets the frequency at which the motor runs In Open Loop mode this is the frequency applied to the motor In Closed Loop mode this setting is the rotor frequency that is the tach sensor allows the drive to compensate continuously for slip The desired frequency can be typed into the box If the motor is already running it will change frequency to match Stator Shows the rotational frequency of the stator field that is the field in the fixed part of the motor In Open Loop mode this matches the target frequency In Closed Loop mode the stator frequency is higher than the target frequency as the PI control loop compensates for slip in the motor Rotor Shows the rotational frequency of the rotor This field is not user editable In Open Loop mode this is lower than the target frequency due to slip in the motor In Closed Loop mode this matches the target frequency Speed rpm Area Target Speed rpm Displays the motor speed in revolutions per minute rpm There is a direct correlation between this value and the target frequency value In Open Loop mode this is the speed of the stator field In Closed Loop mode this is the actual shaft speed Stator Speed
73. tor contains no permanent magnets Instead the stator field induces a current in the rotor hence the term induction The current in the rotor creates its own electromagnetic field The coupling of the rotor and stator fields creates mechanical motion in the motor November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Figure 1 1 AC Induction Motor Rotor Motion Stator Current The speed of the motor is therefore primarily controlled by the frequency of the AC current in the stator and the also the number of poles intrinsic in the motor design This can be expressed as the following equation Synchronous Speed 120 Frequency Number of Poles As the rotor is loaded note that some inherent load is always present the motor must produce torque Torque requires that the rotor turns more slowly than the stator field The difference in speed is known as slip For example a typical motor with a synchronous speed of 3600 rpm may have a shaft speed of 3350 rpm at full load The motor included in the RDK is made by ATB Selni for laundry appliances The nameplate frequency range is 0 340 Hz and the motor has two poles so the synchronous speed range is 0 20400 rpm This motor is capable of very high speeds The RDK controls motor speed by varying the frequency of the current in the stator coil There are several different voltage modulation techniques but all are designed to result in sinusoidal stator current AC Ind
74. uction Motor Types There are numerous variations within the class of AC induction motors Possibly the most notable classification is the number of phases The ACIM RDK is a variable frequency motor control that can operate both single phase and three phase motors Three phase motors are most commonly used with variable frequency controls as they offer greater efficiency higher torque and wider speed range than their single phase counterparts There are many variations of single phase AC induction motors but only two types are candidates for variable frequency control Both permanent split capacitor PSC and shaded pole motors can be used with this RDK as they have no internal switching mechanism November 4 2009 13 Stellaris amp AC Induction Motor Reference Design Kit Overview Figure 1 2 Typical Blower Incorporating a Single Phase PSC Motor Variable Speed 14 Reducing voltage to increase slip is not an effective method of speed control as the torque drops considerably Varying frequency is far more effective but there are additional considerations As the frequency decreases the effective impedance of the motor decreases proportionately To maintain constant current and torque the RDK reduces voltage using a transfer function known as a V f curve The RDK allows this to be customized for a specific motor or application Figure 1 3 shows a linear V f curve for a 340 Hz motor Note that the voltage ramps with the frequency until
75. us Configuration Parameters 22 n orte ttr ea n ade i ep RE b eoo El 48 Minimum DC Bus 48 Maximum DCO Bus Voltage 49 DC Bus Voltage Compensation Enable nensi nennen 49 DC Bus Deceleration Voltage inns 49 Miscellaneous nennen nnn nnns 50 November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual On board User Interface Enable tete tte 50 Maximum Ambient 50 Real Time Data ap de e ATA 50 Real Time Data Items nennen nennen nnne 51 Drive Status Paramelers 5 rot dea ET c a qe a a pi s uv dea d a t ea ex da 51 Motor Drive Status eter M ert me 51 Motor Drive E de orit raso eva eva s Do Pv ode e dee 51 Processor Saggi Eee teet ie 52 Motor Speed 8
76. utilization of the DC bus voltage but is more complicated to compute For either modulation technique the rate at which new points on the waveform is computed can be adjusted allowing a trade off between processor usage and waveform quality a slower update rate will have lower processor usage but also a lower quality waveform Other Functions Monitoring of the DC bus voltage motor current power module fault signal and microcontroller ambient temperature is performed during the operation of the motor drive Several steps are taken to manage the DC bus voltage if the motor drive is decelerating and the DC bus voltage exceeds a parameter value due to regeneration the rate of deceleration is temporarily decreased If the DC bus voltage exceeds another parameter value a dynamic brake is applied to reduce the DC bus voltage There are several fault conditions that result in the motor drive being turned off as a safety measure DC bus voltage gets too high from excessive regeneration DC bus voltage gets too low usually from a loss of input power Motor current gets too high Motor current gets too low Power module signals a fault Microcontroller ambient temperature gets too high The fault condition must be manually cleared before the motor drive will operate again Motor Control Parameters The AC induction motor control software has an extensive set of parameters which it stores in on chip Flash memory The parameters define b
77. y connected to the UART of an external microcontroller Table 3 2 Control Interface Functions Terminal Label Function 1 5V Aux power out 40mA max 2 ENA Encoder Input A or Tach Input 3 ENB Encoder Input B 4 IDX Encoder Index Pulse normally used by Mode switch 5 RXD UART Receive data logic level 6 TXD UART Transmit data logic level November 4 2009 Stellaris amp AC Induction Motor RDK User s Manual Table 3 2 Control Interface Functions Continued 7 OV Common Ground for Isolated Control Interface In the factory default mode UART signals connect to the FT232RL USB device controller U6 which implements a Virtual COM Port An isolated 3 3V rail is obtained from the unregulated 5V rail by the FT232RK s internal regulator Power Supplies Schematic Page 5 The RDK can operate from either 115 Vac or 230 Vac In the case of 115 V operation the input diode bridge D13 is used in conjunction with the bus capacitors C44 and C45 to create a voltage doubler For 115V operation HVpc nom 115 Vx 2x 1 414 325 For 230V operation HVpc nom 230 V x 1 414 325 The RMS output voltage of the motor control varies from 0 to 230Vrms under software control Two 200V capacitors connected in series provide filtering on the DC bus Capacitor size and selection is an important parameter when designing motor controls so the RDK mounts the capacitors off boa

Stellaris LM3S818 AC Induction Motor

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