3-Phase Switched Reluctance High
Contents
1. deg goa 001 E E uwoq inus zy 95495 29 3928 m iH esues viv 01 1 cory SO09V191VJH c 0 dui usiszszsww WH 020 gorn 0 20rd 09 300 52112 1 oni I ssa 91 8v 2 2 LS SHEN tora ds 2 09N0LgOS ou LEE T E SA zl x ab SV 4 ou 0 x Aci 0 4 8 5 r 2400 19 5 ________ HEISSAN asi 05 400 torn 1090 2 T 021 510915 9 Lory lord 2090 4 wv 1 SO09V191V3H oeNoigos 19 L 504 god MOTOROLA 3 Phase Switched Reluctance High Voltage Power Stage Design Considerations For More Information On This Product Go to www freescale com User s Manual 46 Freescale Semiconductor Inc Design Considerations Phase Outputs At the input pull down resistors R403 and R404 set a logic low in the absence of a signal Open input pull down is important since it is desirable to keep the power transistors off in case of either a broken connection or absence of power on the control board The drive signal is buf2. 56 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA List of Figures 7 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc List of Figures User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 8 List of Figures MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage List of Tables Table Title Page 2 1 CharactenslieS decer PEE AED PC 21 2 2 VIE oos Ep EE dr EGG DPI ERO ERES 22 42 22 ida 23 3 1 Connector J14 Signal 28 4 1 Power Substrate Paris List cosas uu rre EE Rx 40 4 2 Printed Circuit Board Parts List rr ER DR REOR ERR 40 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA List of Tables 9 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc List Tables User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 10 List of Tables MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Po
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5. O 15 Section 2 Operational Description ZA bolo os hens 19 B2 Mee Lege PO eee 19 2 3 21 2 4 X Modification for 1 2 and 3 4 Horsepower 22 2 3 gt 23 Section 3 Pin Descriptions 3 1 LOU 25 3 2 25 33 Signal Descriptions boss 26 3 3 1 40 Pin Ribbon Connector J14 26 2 2 2 Power Connectors 1 2222552 425545 4 4 4 54224 26 3 3 3 External Brake Connectors 712 ccs assess eek ses 26 3 3 4 Motor Output Connector 113 30 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Table of Contents 5 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Table of Contents Section 4 Schematics and Parts List 4 1 5 0 doh eh ee 31 4 2 Mechanical Characteristics 4 666406 en E EX ORE E RYE 31 4 3 DONA DE E doa oO Rabe dc CR 32 4 4 Voc 40 Section 5 Design Considerations 5 1 deo 45 5 2 do X 45 23 PET 45 5 4 Bus Voltage and Current Feedback 48 55 Cycl by Cycle Current 14 48 5 6 Temperature 2254242592900 EAR iti 51 51 Phase 52 5 8 12212 EPI SERA A
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7. 5 3 Cycle by Cycle Current Limiting User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 50 Design Considerations MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations Temperature Sensing 5 6 Temperature Sensing Cycle by cycle current limiting keeps average bus current within safe limits Current limiting by itself however does not necessarily ensure that a power stage is operating within safe thermal limits For thermal protection the circuit in Figure 5 4 is used It consists of four diodes connected in series a bias resistor and a noise suppression capacitor The four diodes have a combined temperature coefficient of 8 8 mV C The resulting signal Temp sense is fed back to an A D input where software can be used to set safe operating limits Due to unit to unit variations in diode forward voltage it is highly desirable to calibrate this signal To do so a value for Temp sense is read at a known temperature and then stored in non volatile memory The measured value rather than the nominal value is then used as a reference point for further readings 13 3V o R302 2 2 1 014 013 4 14 BAV99LT1 BAV99LT1 4 sense PIN 26 CONNECTOR J 14 6301 100 nF V GNDA Figure 5 4 Temperature Sensing 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design C
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10. Design Considerations 51 Contents 5 2 LOI oos cosa ee 45 2 4 Phase Lus quos e pap Cede EHE 45 54 Bus Volum and Current Feedback 48 5 5 Cycle by Cycle 48 5 6 Temperate RAT 51 dud Pass Sues ide Cue et ps atq eee eee ewes 32 5 8 casu EL Pe IDEAE 54 5 9 Power Factor LORD iod n n 55 5 2 Overview From a systems point of view the HV SR power stage fits into an architecture that is designed for software development In addition to the hardware that is needed to run a motor a variety of feedback signals that facilitate control algorithm development and a PFC circuit are provided Circuit descriptions for the HV SR power stage appear in this subsection 5 3 Phase Outputs The output stage is configured as a dual output per phase 3 phase bridge with IGBT output transistors It is simplified considerably by high voltage integrated gate drivers that have a cycle by cycle current limit feature A schematic that shows one phase is illustrated in Figure 5 1 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design Considerations 45 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations 1 6 4
11. J1 20 Pin Female Header Fisher Elektronik BL 2 20Z 2 J3 J10 6 Pin Female Header Fisher Elektronik BL 1 6Z 1 J4 6 Pin Female Header Fisher Elektronik BL 1 6Z 3 J5 J6 J7 10 Pin Female Header Fisher Elektronik BL 1 10Z 2 J9 J8 4 Pin Female Header Fisher Elektronik BL 1 4Z 2 J11 J12 2 Pole Terminal Block Weidmuller LP 7 62 2 90 1 J13 3 Pole Terminal Block Weidmuller LP 7 62 3 90 see note 1 014 40 Pin Connector Fischer Elektronik ASLG40G male 1 11201 4 9mH 2 3A Thompson Television Compon SMT4 ref G6982 01 1 R1 Inrush Limiter Rhopoint Components 56190 Dale CRCW1206 102J 1 R104 270 Dale CRCWO0805 271J 1 R105 820 Dale CRCWO0805 821J 2 R106 R109 2 21k 1 Any available 1 108 56 Any available Dale CRCW1206 270J 1 114 1 0k Dale CRCWO0805 102J 1 R115 330 Dale CRCWO0805 331J 1 R201 3 92 1 Any available User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 42 Schematics and Parts List For More Information On This Product Go to www freescale com MOTOROLA Freescale Semiconductor Inc Schematics and Parts List Parts Lists Table 4 2 Printed Circuit Board Parts List Sheet 4 of 5 Qty Reference Description Part 4 Manufacturer R208 R211 R213 R215 R223 R312 18 ES E id 10k Dale CRCWO805 103J R414 R801 R802 R803 R804 R805 2 R202 R214 3 3k Dale CRCW0805 332
12. Looking toward the top of Figure 5 7 Q8 L201 D12 and the bus capacitors form a boost power supply The configuration allows current to be drawn from the ac line when line voltage is lower than the dc bus voltage Pulse width modulation is controlled by software and augmented by the analog circuitry in the lower half of Figure 5 7 Voltage feedback is provided by the bus voltage sensing circuit in Figure 5 2 A zero cross feedback signal z c is also used z c is produced by the circuit shown in Figure 5 8 In this circuit R219 R220 and R221 provide a relatively high impedance connection to the rectified line voltage and form an 11 1 voltage divider with R222 D203 clamps the divided down voltage to approximately 15 7 volts Comparator U203B then compares this signal to an 11 8 volt reference Approximately 40 mV of hysteresis and a small reduction to the reference voltage are added by R216 The result is a logic high at output PFC_z_c when the comparator s input voltage falls below 11 72 volts This output remains high until 11 76 volts is reached on the next cycle 15V D 15V D 45V D O R216 270k D203 R217 SM 1N4148 2 7k C211 1nF R220 R221 __ ze 33k D8 10 5085 010 33k 33k R223 R222 10k 10k GNDA GNDA 10 5085 R5 0 075 1 Sense PFC1 Sense PFC2 Figure 5 8 PFC Zero Crossing Feedback 3 Phase Switched Reluctance High Voltage Power S
13. Switched Reluctance High Voltage Power Stage Schematics and Parts List 39 For More Information On This Product MOTOROLA Go to www freescale com 4 4 Parts Lists Freescale Semiconductor Inc Schematics and Parts List The HV SR power stage s parts content is described in Table 4 1 for the power substrate and in Table 4 2 for the printed circuit board Table 4 1 Power Substrate Parts List Qty Reference Description Manufacturer Part D1 D2 D3 E 6 8A 600V Ultrafast Rectifier International Rectifier HFAO8TB60S D4 D5 D6 4 D7 D8 D9 D10 10A 800V Rectifier International Rectifier 10ETSO8S 2 D11 D12 8A 600V Ultrafast Rectifier International Rectifier 8 605 2 D14 D13 Dual Diode Temp Sensing On Semiconductor BAV99LT1 2 J1 J2 SM CON MCRD SR 500 male Fisher Elektronik SL 11 SMD 104 20Z 2 3 10 SM CON MCRD SR 500 male Fisher Elektronik SL 10 SMD 104 6Z 1 J4 SM CON MCRD SR 500 C male Fisher Elektronik SL 10 SMD 104 6Z 3 45 46 J7 SM CON MCRD SR 500 D male Fisher Elektronik SL 10 SMD 104 10Z 2 8 9 SM CON MCRD SR 500 E male Fisher Elektronik SL 10 SMD 104 4Z Q1 Q2 Q3 Q4 j 7 Q5 Q6 Q7 10A 600V IGBT Infineon SGB10N60 1 Q8 8A 500V MOSFET On Semiconductor MTB8N50E Table 4 2 Printed Circuit Board Parts List Sheet 1 of 5 Qty Reference Description Part Manuf
14. dc supply to provide input power The connection is made on connector J11 Bias voltages are developed by internal power supplies One power input is all that is required Operation from an ac power line is significantly more hazardous than operation from a line isolated and current limited dc power supply An isolation transformer should be used when operating from an ac power line 5 6 Setup the optoisolation and control boards The HV SR power stage is shipped with power factor correction PFC disabled If power factor correction is desired it is necessary to remove and re solder power jumper JP201 from the no PFC position to the PFC position This jumper is found on the left side of the top board between the dc bus capacitor and PFC inductor Circuit connections are illustrated in Figure 1 4 For first time setups operation without power factor correction is recommended Apply power first to the optoisolator and then to the power stage The green power on LED in the upper right hand corner lights and both fans run when power is present The optoisolation board powers the control board The optoisolation board is not fully powered until power is applied to the power stage Hazardous voltages are present Please re read all of the warnings in 1 4 Warnings carefully 3 Phase Switched Reluctance High Voltage Power Stage 16 Introduction and Setup MOTOROLA For More Information On This Product Go to www freescal
15. of this cable goes to the optoisolation board s 40 pin output connector 2 Connect motor leads to output connector J13 located along the back edge of the top board Phase A phase B and phase C are labeled Ph A Ph B and Ph C There are two connections for each phase to accommodate the independent phase coil configuration that is used in switched reluctance motors Standoffs Control Power Stage Ribbon Standoffs Optoisolator High Voltage Motor Supply Figure 1 3 Setup 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 15 For More Information On This Product Go to www freescale com CAUTION NOTE WARNING User s Manual Freescale Semiconductor Inc Introduction Setup 3 Connect earth ground to the earth ground terminals on the top board and on the heat sink The top board s ground terminal is located in the front left hand corner and is marked with a ground symbol The heat sink has a screw on its front edge that is also marked with a ground symbol Connect an isolated line current limited dc power supply to connector J11 located on the front edge of the top board The input voltage range is 140 Vdc to 230 Vdc Current limit should be set for less than 4 amps The dc supply s polarity does not matter Either a 110 volt or 220 volt ac line that is coupled through an isolation transformer may be used in place of a
16. 075 196 sense A R304 10k 196 U302B DCB Cap Neg MC33502D R305 75 1 323 390 V ref 483 A 1 65V re R324 C307 C306 Tage mts 100nF 3 3uF 10V U304 R325 LM285M 33 2k 1 SZ GNDA GNDA GNDA Figure 5 5 Phase A Current Sensing 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design Considerations 53 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations 5 8 Brake User s Manual A brake circuit is included to dissipate re generative motor energy during periods of active deceleration or rapid reversal Under these conditions motor back EMF adds to the dc bus voltage Without a means to dissipate excess energy an overvoltage condition could easily occur The circuit shown in Figure 5 6 connects R6 RO across the dc bus to dissipate energy Q7 is turned on by software when the bus voltage sensing circuit in Figure 5 2 indicates that bus voltage could exceed safe levels On board power resistors 6 9 will safely dissipate up to 50 watts continuously or up to 100 watts for 15 seconds Additional power dissipation capability can be added externally via brake connector J12 Figure 5 6 Brake 3 Phase Switched Reluctance High Voltage Power Stage 54 Design Considerations MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations Power Fa
17. 6 Temp sense Temp sense is an analog sense signal that measures power module temperature 27 No connection 28 Shielding Pin 28 is connected to a shield wire in the ribbon cable and analog ground on the board 29 Brake control Brake control is the gate drive signal for the brake IGBT Serial Con is an identification signal that lets the controller know which power 30 Serial Con 2 stage is present 31 PWM PFC PWM is a digital signal that controls the power factor correction circuit s Switch 32 PFC inhibit PFC inhibit is a digital signal that is used to enable or disable the power factor correction circuit 33 zc 2 cis a digital signal and its edges represent power line voltage 0 crossing events 34 No connection 35 No connection 36 No connection 37 Shielding Pin 37 is connected to a shield wire in the ribbon cable and analog ground on the board 38 No connection 39 No connection 40 No connection 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Pin Descriptions 29 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Pin Descriptions 3 3 4 Motor Output Connector J13 Power outputs to the motor are located on connector J13 Phase outputs are labeled Ph A Ph B and Ph C Pin assignments are Pin 1 Ph A Pin 1 supplies power to motor Phase A It is connected to bottom switch output signal Phase AB Either of the two ph
18. 8 V Analog output range Vout 0 3 3 V Bus current sense voltage ISense 563 mV A Bus voltage sense voltage VBus 8 09 mV V Peak output current lpk 2 7 Brake resistor dissipation continuous 50 W Brake resistor dissipation 15 sec pk 100 Total power dissipation Piss 85 W 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Operational Description 21 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Operational Description 2 4 Modification for 1 2 and 3 4 Horsepower The HV SR power stage can be modified to drive either 1 2 or 3 4 horsepower motors To change maximum output power these steps apply 1 Remove power and wait until the power on LED is off 2 If PFC jumper 2 is in the PFC position remove and resolder it into the no PFC position 3 Make the resistor value changes shown in Table 2 2 These resistors set current amplifier gains For 1 2 and 3 4 horsepower motors lower gains allow for higher measured currents and higher overcurrent trip points Table 2 2 Resistor Value User s Manual Resistors 1 4 HP 1 2 HP 3 4 HP 180 W 370 W 550 W 8303 R305 8307 8314 R315 8318 R319 8322 75 62 56 8301 8304 8311 8313 R316 R317 8320 R321 10 kQ 15 16 ko 4 Configure identification coding jumper JP801 with the setti
19. 8184 2 81 1813 0813 0 SONILLAS LINVAAG a 080 v S 3 L ASt 2 XOL Ok 9084 7084 2088 2088 390 A 9 3nOL O Ast AS 2080 1080 GOW ASt ast 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List For More Information On This Product 38 Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List Schematics Ajddng 9219 T Y 3 1 4 008 49001 991 999 xot AP S s 210 ella Rs 9019H4S F p 39001 210 12 E LIH sity 01 dvSeANL O E 1g 1 a a E g nano 3001 LI 44001 df 1219 EE
20. 93D335X 010A2 3 402 C406 C410 4 7uF 16V Sprague 293D475X 016B2 C403 C404 C407 6 C408 C411 C412 470nF 50V Vitramon VJ1206U474MXAA _ 3 413 C414 C415 8 2 Vitramon VJ0805A8R2DXA 1 D1 Disk Varistor EPCOS SOIV S 10K250 1 10100 Transient Suppressor On Semiconductor P6SMB200AT3 1 10101 6A 60V Shottky On Semiconductor MBRD660CT 4 Dite D401 D408 Ultrafast On Semiconductor MURS160T3 4 Dio D104 0105 4 4 00V Schottky On Semiconductor MBRS1100T3 1 10107 12 On Semiconductor MMSZ5242BT1 1 0108 5 1V Zener On Semiconductor MMSZ5231BT1 4 5 D110 D111 Schottky On Semiconductor MBRO530T1 1 D113 Green LED Kingbright L 934GT 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List For More Information On This Product Go to www freescale com 41 Freescale Semiconductor Inc Schematics and Parts List Table 4 2 Printed Circuit Board Parts List Sheet 3 of 5 Qty Reference Description Part Manufacturer D201 D202 D403 8 D405 D407 D410 22V Zener On Semiconductor MMSZ5251BT1 0412 D415 1 D203 SMD 1N4148 FairChild 1N4148LL 34 6 ps Dar SUEDE 1A 30V Schottky On Semiconductor MBRS130LT3 1 F1 Fuse Holder MULTICOMP MCHTE15M 1 JP201 Power Jumper Wire D 1 5mm L 12mm 1 JP801 4X2 Jumper Pads 2 J2
21. Freescale Semiconductor Inc MEMC3PSRHVPSUM D Motorola Embedded Motion Control 3 Phase Switched Reluctance High Voltage Power Stage User s Manual Mj MOTOROLA Freescale Semiconductor Inc Important Notice to Users While every effort has been made to ensure the accuracy of all information in this document Motorola assumes no liability to any party for any loss or damage caused by errors or omissions or by statements of any kind in this document its updates supplements or special editions whether such errors are omissions or statements resulting from negligence accident or any other cause Motorola further assumes no liability arising out of the application or use of any information product or system described herein nor any liability for incidental or consequential damages arising from the use of this document Motorola disclaims all warranties regarding the information contained herein whether expressed implied or statutory including implied warranties of merchantability or fitness for a particular purpose Motorola makes no representation that the interconnection of products in the manner described herein will not infringe on existing or future patent rights nor do the descriptions contained herein imply the granting or license to make use or sell equipment constructed in accordance with this description Trademarks This document includes these trademarks Motorola and the Motorola logo are registered tradem
22. Go to www freescale com Freescale Semiconductor Inc Design Considerations Cycle by Cycle Current Limiting Bus Voltage Sensing DCB Cap pos V sense DCB half 15 274 1 274k 196 4 87 1 274k 196 R228 R224 R225 R226 R227 6 81k 196 R229 255 1 V sense DCB 3 24V DC Bus 400V 6 81k 196 GNDA R315 75k 196 DC Bus Current Sensing Lsense DCB R316 10k 196 sense DCB1 sense DCB2 sense DCB 1 65V 1 65V Imax R317 10 1 R323 390 33V A 1 65V ref 3 3V R324 GNDA 100k 1 C307 C306 100nF 3 3uF 10V U304 R325 LM285M 33 2k 1 GNDA GNDA GNDA Figure 5 2 Bus Feedback 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design Considerations 49 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations T 5 gt gt 11 6 12 5 PWMATop gt 13 4 PWM A Bottom gt 15 1 gt gt Bottom Out 1821125 C413 8 2pF 45V D B BT 7 op Out 6 5 PWM B Bottom 2 1 1 gt gt B Bottom Out 21125 45V D R306 680k C414 8 2pF 15V D ed 4 45V D R308 R309 1 2k 1 2k 03038 sense DCB 7 C303 100 680pF LM393D 8 gt gt C Out GNDA 6 7 3 3 8310 PWM C Bottom gt 5 470 1 gt gt C Bottom Out IR2112S C415 8 2pF GNDA 45V D Figure
23. J 1 R203 68 1 1 Any available 2 R204 R413 100 Dale CRCW0805 101J 1 R206 100k Dale CRCW0805 104J 1 R207 12 1 1 Any available 1 R210 33 Dale CRCW0805 330J 1 R212 681 196 Any available 1 R216 270k Dale CRCW0805 274J 1 R217 2 7k Dale CRCW0805 272J 1 R218 4 7k Dale CRCW0805 472J 1 R219 33k Dale CRCW0805 333J 2 R220 R221 33k Dale CRCW0805 333J 1 R222 10k Dale CRCW0805 103J 3 R224 R225 R227 274k 1 Any available 1 226 4 87k 1 Any available 2 R228 R230 6 81k 196 Any available 1 R229 255 196 Any available R209 R301 R304 9 R311 8313 R316 10 1 Dale CRCW0805 103F R317 R320 R321 1 R302 2 21 1 Any available 1 R205 1k 196 Dale CRCW0805 102F R303 R305 R307 8 R314 R315 R318 75k 1 Dale CRCW0805 753F 8319 R322 1 R306 680k Dale CRCW0805 684J 2 R308 8309 1 2k Dale CRCW0805 122J 1 R310 470_ Dale CRCW0805 471J 1 R323 390_ Dale CRCW0805 391 J 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List For More Information On This Product Go to www freescale com 43 Freescale Semiconductor Inc Schematics and Parts List Table 4 2 Printed Circuit Board Parts List Sheet 5 of 5 Qty Reference Description Part Manufacturer 1 R324 100 1 Dale CRCW0805 104F 1 R825 33 2k 196 A
24. N sng oa EE sod deg goa ino sna User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Schematics and Parts List 35 For More Information On This Product MOTOROLA Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List 34001 lt 060 91 961 61 azosesow AS9 AGILE god ___ AASL dese inus 4089 9054 esues duie PALS 5054 V AE esues 10001 LOED 2 esues Bulsuas pue 1uaJun ainbi4 91 92 5084 Bulsuas uang aseud 1 401 LOCH 2089 n 9224 voen AOWANE E 3u001 9060 4060 V AS9 L 066 5254 9205659 bris gen 91 0 2168 99 1 ASS L 20 esues 2804 esues oesus s E 10 esues __ goa esuss SIO OZEY 91 01 916H 91 82 8164 Bulsuas uan sng 3u001 059 60 91 464 2 a 91 01 ELEH prouseiui AS9 L ASS L Ex fused L E 18 esues 1 OV At Et n 7oL40L goq
25. R316 The output voltage is shifted up by 1 65 V to accommodate both positive and negative current swings 3000 mV voltage drop across the sense resistor corresponds to a measured current range of 2 93 amps In addition to providing an A D input this signal is also used for cycle by cycle current limiting A discussion of cycle by cycle current limiting follows in 5 5 Cycle by Cycle Current Limiting 5 5 Cycle by Cycle Current Limiting User s Manual Cycle by cycle current limiting is provided by the circuitry illustrated in Figure 5 3 Bus current feedback signal I sense DCB is filtered with R308 and C303 to remove spikes and then compared to 3 15 volt reference in U303B The open collector output of U303B is pulled up by R414 Additional filtering is provided by C413 C414 and C415 The resulting signal is fed into the IR2112 gate driver s shutdown input on all three phases Therefore when bus current exceeds 2 69 amps all six output transistors are switched off The IR2112 s shutdown input is buffered by RS latches for both top and bottom gate drives Once a shutdown signal is received the latches hold the gate drive off for each output transistor until that transistor s gate drive signal is switched low and then is turned on again Hence current limiting occurs on a cycle by cycle basis 3 Phase Switched Reluctance High Voltage Power Stage 48 Design Considerations MOTOROLA For More Information On This Product
26. REE EC d Jd MR EE RU 54 2 9 Power Factor Correctie ERRARE AR RR EAS 55 User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 6 Table of Contents MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage List of Figures Figure Title Page 1 1 Systems 12 1 2 3 Phase Switched Reluctance High Voltage Power Stage 13 DX rrr 15 14 PPE ec IE EDO ERE aca Gd edo acea d a da 17 i 20 3 1 40 Pin Ribbon Connector T4 UA 24 4 1 3 Phase High Voltage Power Stage Overview 33 __ 34 c gt 2555554556535 9 569548 35 4 4 Current and Temperature Feedback 36 4 5 Power Factor Correction and Brake Gage Drive EE 45 Identification Black S PS 38 da aH E 39 Jl dh 46 Met oe 49 23 Cyde by Cycle Current 50 S4 Temperature alocosssbheckussREk3i RE se ER aad 51 53 53 54 7 wes 55 25 PRC Zero Crossing Feedback
27. They are e Power input connector e 712 Brake connector e J13 Motor output connector e 4 40 pin ribbon cable connector Pin descriptions for each of these connectors are identified in this subsection Pin assignments for the 40 pin ribbon connector J14 are shown in Figure 3 1 In this figure a schematic representation appears on the left and a physical layout of the connector appears on the right The physical view assumes that the board is oriented such that its title is read from left to right Signal descriptions are provided in Table 3 1 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Pin Descriptions 25 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Pin Descriptions 3 3 Signal Descriptions This subsection describes the signals 3 3 1 40 Pin Ribbon Connector J14 Signal inputs are grouped together on a 40 pin ribbon cable connector J14 located on the right side of the board Pin assignments are shown in Figure 3 1 Signal descriptions are listed in Table 3 1 3 3 2 Power Connectors J11 The power input connector labeled J11 is located on the front edge of the board It will accept dc voltages from 140 to 230 volts or an isolated ac line input from 100 to 240 volts In either case the power source should be capable of supplying at least 200 watts 3 3 3 External Brake Connectors J12 An optional external brake r
28. Z 240 AOS JU0 v SZLLZHI go ero 24429 po ou x 500 T 1 viwa xE on ag k ou LEE 10 eounos E S 2 Tite aie go 30001 19192675 CA 7 i 6062 OF m cm AOS JU0Zy 021 EL09LSHNW Tes 0 _ Aor WreoLSvvZWa 10 emo n 1 0L 0L ELT106LSH8IN y nodi gory 0 8g 1928 WreorevvZWa 119192925 021 arorn ee 1290 9074 09 400 ero 2079 Fs X SSA gt ASZ Jnt d 2 un LS 8 6 L10 LSH8W 60v Zeon xe 2 om as 7 i xH ou SE 18 j 8 S 2 B EH 01 mur I 8 6 30001 119192675 2 4002 zorn 5070 9 5 021 ELO9LSHNW 1079 A9L JnL v 9009 015 18 eio 4 NORD 2 E OL avast umoqinus copy 8v eoios 3928 Ta WreorSlVPLWQ dul 119192978 021 gron 09 62 sora 09 440 av ero voro p 9 x Ast _____ Asz 4nes de 21 499 SSN T T ELT0ELSU8IN so FT x ou as 4 xH on LEE anog 4 8 S 2 t ae SM 25 8 y 5 on A 4400 6
29. acturer C1 C2 C105 C109 C110 C112 C114 C116 C123 19 C126 C127 C203 100nF 25V Vitramon VJ0805U104MXXA _ C301 C304 C305 C307 C401 C405 C409 1 C100 10pF 500V Vishay Sprague Typ 5GAQ10 Serie 562C C101 C102 C103 220uF 10V AVX TPSE227K010R0100 C104 C128 C801 10uF 6 3V Sprague 293D106X 6R3B2 C107 C108 C111 8 C113 C129 C416 33uF 25V AVX TPSE336K025R0200 C417 C418 User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 40 Schematics and Parts List MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List Parts Lists Table 4 2 Printed Circuit Board Parts List Sheet 2 of 5 Qty Reference Description Part 4 Manufacturer 1 C117 47uF 16V Any available 1 C122 100uF 16V AVX TPSE107K016R0100 C204 C206 C302 5 C425 C802 10nF Vitramon VJ0805U103MXXA _ 1 124 100pF 500V Vishay Sprague Typ 5GAT10 Serie 562C 1 C125 1nFAkV muRata 0 0505 10241 1 C201 6 8nF Vitramon VJ0805A682JXA _ 1 202 10uF 35V Sprague 293D106X 035D2 2 C207 C205 22nF Vitramon VJ0805A223JXA _ 1 208 22nF 630VDC WIMA MKP10 1 C209 470uF 400V Philips Components 15746471 C211 C212 C419 8 C420 C421 C422 1nF Vitramon VJ0805A102JXA _ C423 C424 2 C213 C214 10nF 3000V Thomson 5ST410MCMCA 1 C303 680pF Vitramon VJ0805A681JXA 1 306 3 3uF 10V Sprague 2
30. ards and an optoisolation board it provides a software development platform that allows algorithms to be written and tested without the need to design and build a power stage It supports a wide variety of algorithms for controlling switched reluctance motors Input connections are made via 40 pin ribbon cable connector J14 Pin assignments for the input connector are shown in Figure 3 1 40 Pin Ribbon Connector J14 Power connections to the motor are made on output connector J13 Phase A phase B and phase C are labeled Ph A Ph B Ph C on the board Power requirements are met with a single external 140 volt to 230 volt dc power supply or an ac line voltage Either input is supplied through connector J11 Current measuring circuitry is set up for 2 93 amps full scale Both bus and phase leg currents are measured A cycle by cycle overcurrent trip point is set at 2 69 amps 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Operational Description 19 For More Information On This Product Go to www freescale com User s Manual Freescale Semiconductor Inc Operational Description The HV SR power stage has both a printed circuit board and a power substrate The printed circuit board contains IGBT gate drive circuits analog signal conditioning low voltage power supplies power factor control circuitry and some of the large passive power components This board also has a MC68HC705JJ7 microcontrol
31. arks of Motorola Inc Motorola Inc is an Equal Opportunity Affirmative Action Employer 9 Motorola Inc 2000 Rights Reserved User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 2 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage List of Sections Section 1 Introduction and Setup 11 Section 2 Operational Description 19 Section 3 Pin Descriptions 25 Section 4 Schematics and Parts List 31 Section 5 Design Considerations 45 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA List of Sections For More Information On This Product Go to www freescale com 3 Freescale Semiconductor Inc List of Sections User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 4 List of Sections MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Table of Contents Section 1 Introduction and Setup 1 1 ee er E ERA 11 1 2 11 13 P EORR RC CEDE RR HER 13 00 Pr 14 1 5 Pe P
32. ase A motor leads may be connected here Pin 2 Ph A Pin 2 supplies power to motor Phase A It is connected to top switch output signal Phase_AT Either of the two phase A motor leads may be connected here e Pin 3 Ph B Pin 3 supplies power to motor Phase B It is connected to bottom switch output signal Phase_BB Either of the two phase B motor leads may be connected here e Pin 4 Ph B Pin 4 supplies power to motor Phase B It is connected to top switch output signal Phase_BT Either of the two phase B motor leads may be connected here e Pin 5 Ph C Pin 5 supplies power to motor Phase C It is connected to bottom switch output signal Phase CB Either of the two phase C motor leads may be connected here e Pin6 Ph C Pin 6 supplies power to motor Phase It is connected to top switch output signal Phase CT Either of the two phase C motor leads may be connected here User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 30 Pin Descriptions MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Section 4 Schematics and Parts List 4 1 Contents 4 2 Mechanical Characteristics caes cus e bade ee ips ak 31 4 3 SOUS RIS as coa Qi 32 4 4 oa tarea 40 4 2 Mechanical Characteristics Mechanically the HV SR power s
33. authorized application Buyer shall indemnify and hold Motorola and its officers employees subsidiaries affiliates and distributors harmless against all claims costs damages and expenses and reasonable attorney fees arising out of directly or indirectly any claim of personal injury or death associated with such unintended or unauthorized use even if such claim alleges that Motorola was negligent regarding the design or manufacture of the part Motorola and are registered trademarks of Motorola Inc Motorola Inc is an Equal Opportunity Affirmative Action Employer How to reach us USA EUROPE Locations Not Listed Motorola Literature Distribution P O Box 5405 Denver Colorado 80217 1 303 675 2140 or 1 800 441 2447 JAPAN Motorola Japan Ltd SPS Technical Information Center 3 20 1 Minami Azabu Minato ku Tokyo 106 8573 Japan 81 3 3440 3569 ASIA PACIFIC Motorola Semiconductors H K Ltd Silicon Harbour Centre 2 Dai King Street Tai Po Industrial Estate Tai Po N T Hong Kong 852 26668334 Technical Information Center 1 800 521 6274 HOME PAGE http www motorola com semiconductors Motorola Inc 2000 Mj MEMC3PSRHVPSUM D For More Information On This Product Go to www freescale com
34. ctor Correction 5 9 Power Factor Correction A power factor correction PFC circuit is included to facilitate development of software that includes PFC control features The objective of the PFC hardware and software are to draw sinusoidal current from the ac line in an attempt to approach as closely as possible a unity power factor Without PFC current is drawn from the ac line at the peak of the sine wave when the ac line voltage exceeds the dc bus voltage PFC circuitry is illustrated in Figure 5 7 no PFC o JP201 ET D12 Go OPN 4 9mH 2 3A D7 D8 PFC HFAOBTB60S 10ETSO8S 10 5085 C213 10nF 3000V AC IN L1 gt MTB8N50E C208 C209 Earth GND AC IN 12 arth_G 22nF 630VDC 470uF 400V D9 D10 C214 10 5085 10ETSO8S 10nF 3000V D202 R5 bes MMSZ5251BT1 0 075 1 Sense Sense PFC2 R203 1 68 1 1 415V A R205 R206 100k 1k 1 22nF C201 R207 C205 amp 8nF 12 1 1 R201 R209 LM393D 19 10k 1 3 92k 1 U203A GNDA enable R215 10k Figure 5 7 PFC Circuitry 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design Considerations 55 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations D7 10ETS08S AC IN L1 AC IN L2 D9 10 08 User s Manual R219
35. d 13 GND Digital and power ground redundant connection 14 5V digital Digital 5 volt power supply 15 5 digital Digital 5 volt power supply redundant connection 16 3 3V analog Analog 3 3 volt power supply 17 GNDA Analog power supply ground 18 GNDA Analog power supply ground redundant connection 19 15V_A Analog 15 volt power supply 20 15V A Analog 15 volt power supply 21 V sense DCB V sense DCB is an analog sense signal that measures dc bus voltage It is scaled at 8 09 mV per volt of dc bus voltage 22 sense DCB sense DCB is an analog sense signal that measures dc bus current It is scaled at 0 563 V per amp of dc bus current User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 28 Pin Descriptions MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Pin Descriptions Signal Descriptions Table 3 1 Connector J14 Signal Descriptions Continued NS Signal Name Description sense A is an analog sense signal that measures current in phase A It is scaled 23 sense A at 0 563 V per amp of dc bus current sense B is an analog sense signal that measures current in phase B It is scaled 24 sense B at 0 563 V per amp of dc bus current sense C is an analog sense signal that measures current in phase C It is scaled 25 sense C at 0 563 V per amp of dc bus current 2
36. d 0 6129 1027 qui uondo 24d ALZ 4 4128 87 FENES BuissoJ12 01927 ast 1 5 X022 9128 ASL ge leu ele 202 1 lt s LL8LSZSZSWIN BALI 9185 ce toza A 001 1 aye gt ote ano AL aul gt oL 1 189 i GVOOLOHAPZON 1 1 veozn vino LT vul 2 4 666 1 40 ALIZEE odd 4 Fz L 5 T 6024 1029 i ON grozn LS auz vioen LL8LSZSZSIWIN zozn 2080 ONS 9185 24 520 1029 934 4001 1020 8029 9020 duzz VONO A X00 9028 S0zH E qu NS WASL V ASIE ASE Jn01 V ASI 2029 301 1 1 89 9715170 0zH avast esues Odd OON ASH User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Schematics and Parts List 37 For More Information On This Product MOTOROLA Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List xoo g 9 14 4 9 4 9 98184 S 7 2
37. e com Freescale Semiconductor Inc Introduction and Setup Setup Guide L201 PFC O DCB PFC 2 _ JP201 4 9 2 DCB 1 Cc DCB Cap pos C206 C209 C210 22nF 630VDC 4TOuF 400V 470uF 4D0V Earth GND Optional DCB Cap neg Figure 1 4 PFC Jumper 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 17 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Introduction Setup User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 18 Introduction and Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 2 1 Contents 2 2 Description Section 2 Operational Description DECOM Loa eee RES 19 23 Ve d e dd 21 24 Modification for 1 2 and 3 4 Horsepower 22 22 Fuse MNT Pc 23 Motorola s embedded motion control series high voltage HV switched reluctance SR power stage is a 180 watt 1 4 horsepower 3 phase power stage that will operate off of dc input voltages from 140 volts to 230 volts and ac line voltages from 100 volts to 240 volts In combination with one of Motorola s Embedded Motion Control Series control bo
38. e fuse with one of the selections shown in Table 2 4 Set the controller s speed control input to 0 RPM 2 3 4 Replace the protective case 5 6 Apply power and resume operation Table 2 4 Fuse Ratings Motor RMS Fuse Fuse Horesnowar Input Current Current Rating Voltage Rating Amps Amps Volts 1 4 2 3 2 5 250 Fast blow 1 2 4 8 6 3 250 Fast blow 3 4 7 1 8 250 Fast blow 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA For More Information On This Product Operational Description Go to www freescale com 23 Freescale Semiconductor Inc Operational Description User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 24 Operational Description MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Section 3 Pin Descriptions 3 1 Contents 3 2 o eco 25 3 3 DOSES 26 331 40 Pin Ribbon Connector J14 26 222 Power Connectors JIl 26 3 3 3 External Brake Connectors 12 26 3 3 4 Motor Output Connector 713 30 3 2 Introduction There are four connectors on the top board for making input and output connections
39. esistor can be connected to external brake connector J12 labeled Ext Brake The external resistor allows power dissipation to be increased beyond the 50 watts that brake resistors R6 R9 provide User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 26 Pin Descriptions MOTOROLA For More Information On This Product Go to www freescale com Ju Freescale Semiconductor Inc Pin Descriptions Signal Descriptions 01 e Shielding 7 3 Shielding m BT 15 6 Shielding Shielding PWM_BB 8 Shielding PWM 19 Shielding CB 11 GND GND PS 0 13 5V_D 5v 0 15 43 3V A PFC inhibit 17 GNDA PECSRWM 45 A 19 15V A Serial Con V sense DCB 21 sense DCB Brake control sense A 123 sense B Shielding sense 25 Temp sense Shielding Temp sense Brake control 29 Serial Con sense C PFC 31 PFC inhibit sense B 2 c 33 sense 2 sense DCB ieldi ie Shielding 37 15V A 415V AER PHYSICAL VIEW GNDA 43 3V 45V A 45V A GND GND PWM CB Shielding PWM_CT 9 Shielding 8 PWM_BB 7 Shielding 6 5 Shielding 4 PWM AB 3 Shielding 2 AT 1 SCHEMATIC VIEW Figure 3 1 40 Pin Ribbon Connector J14 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Pin Descriptions 27 For More Information On This Product Go to www freescale co
40. esues 91 384 2068 9205559 azoen S0 H 91 01 POEH esues 8 95195 QNO V A V Ae et 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List For More Information On This Product 36 Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List Schematics pue 101284 G p WX X OGAOE9 3Uc2 6020 8029 4 Deu QV0019HAFZOW 95 11879 uen 2 Avc m esues oDeyoA sng 9 1 992 er eem 4 000 400 Sigo 91 189 ALAY 1 9 2 SL yeu goq esues sod dej goa vano Yano 40984 9224 9204 teza 4 as Gumes ou 24d oad geoen o HUl6 7 D E E amp 890 cee 92 Odd AML LL hee
41. fered by U404A and U404B This part has a minimum logic 1 input voltage of 2 0 volts and maximum logic 0 input voltage of 0 8 volts which allows for inputs from either 3 3 volt or 5 volt logic Gate drive is supplied by an International Rectifier IR2112 Under voltage lockout and cycle by cycle current limiting are also provided by the IR2112 Under voltage lockout is set nominally at 8 4 volts Current limiting is discussed further in 5 5 Cycle by Cycle Current Limiting One of the more important design decisions in a motor drive is selection of gate drive impedance for the output transistors In Figure 5 1 resistor R402 diode D404 and the IR2112 s nominal 500 mA current sinking capability determine gate drive impedance for the lower half bridge transistor A similar network is used on the upper half bridge These networks set turn on gate drive impedance at approximately 120 ohms and turn off gate drive to approximately 500 mA These values produce transition times of approximately 200 ns Transition times of this length represent a carefully weighed compromise between power dissipation and noise generation Generally speaking transition times longer than 250 ns tend to get power hungry at non audible PWM rates and transition times under 50 ns create di dt s so large that proper operation is difficult to achieve The HV SR power stage is designed with switching times at the higher end of this range to minimize noise Anti parallel diode
42. imizes the possibility of electrical shock Operation in lab setups that have grounded tables and or chairs should be avoided Wearing safety glasses avoiding ties and jewelry using shields and operation by personnel trained in high voltage lab techniques are advisable Power transistors the PFC coil and motor can reach temperatures hot enough to cause burns When powering down due to storage in the bus capacitors dangerous voltages are present until the power on LED is off 3 Phase Switched Reluctance High Voltage Power Stage 14 Introduction and Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc 1 5 Setup Guide Freescale Semiconductor Inc Introduction and Setup Setup Guide Setup and connections are very straightforward The HV SR power stage connects to an embedded motion control optoisolation board via a 40 pin ribbon cable and can be powered either by a 140 volt to 230 volt dc power supply or with line voltage For both safety reasons and ease of making measurements it is strongly recommended that a dc supply is used unless power factor correction is specifically being investigated The power supply should be current limited to under 4 amps Figure 1 3 depicts a completed setup A step by step setup procedure is described as 1 Plug one end of the 40 pin ribbon cable that comes with the optoisolator kit into input connector J14 The other end
43. in connector J14 are shown in Figure 3 1 e A pin by pin description of input and output signals is contained in 3 3 Signal Descriptions For those interested in the reference design aspects of the board s circuitry a description is provided in Section 5 Design Considerations 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 13 For More Information On This Product Go to www freescale com User s Manual NOTE Freescale Semiconductor Inc Introduction Setup 1 4 Warnings This development tool set operates in an environment that includes dangerous voltages and rotating machinery To facilitate safe operation b 4 input power for the HV AC power stage should come from a DC laboratory power supply unless HIGH power factor correction is specifically being VOLT AGE investigated An isolation transformer should be used when operating off an ac power line If an isolation transformer is not used power stage grounds and oscilloscope grounds are at different potentials unless the oscilloscope is floating Because the probe grounds it is subjected to dangerous voltages in the case of floated oscilloscope The user should be aware that Before moving scope probes making connections etc it is generally advisable to power down the motor supply When high voltage is applied using only one hand for operating the test setup min
44. ler used for board configuration and identification of the power electronics that need to dissipate heat mounted on the power substrate This substrate includes the power IGBTs brake resistors current sensing resistors a power factor correction MOSFET and temperature sensing diodes Figure 2 1 shows a block diagram HV POWER INPUT 4 SWITCH MODE POWER SUPPLY SIGNALS PFC CONTROL DC BUS BRAKE 3 PHASE IGBT TO FROM CONTROL 7 DRIVERS GATE POWER MODULE N BOARD PHASE CURRENT N PHASE VOLTAGE BOARD ID BLOCK BUS CURRENT MONITOR a Figure 2 1 Block Diagram TO 3 PHASE SR MOTOR 3 Phase Switched Reluctance High Voltage Power Stage 20 Operational Description For More Information On This Product Go to www freescale com MOTOROLA Freescale Semiconductor Inc Operational Description Electrical Characteristics 2 3 Electrical Characteristics The electrical characteristics in Table 2 1 apply to operation at 25 C with a 160 Vdc supply voltage Table 2 1 Electrical Characteristics Characteristic Symbol Min Typ Max Units DC input voltage Vdc 140 160 230 V AC input voltage Vac 100 208 240 V Quiescent current loc 70 mA Min logic 1 input voltage 2 0 V Max logic 0 input voltage Vi 0
45. m Freescale Semiconductor Inc Pin Descriptions Table 3 1 Connector J14 Signal Descriptions Signal Name Description No PWM AT is the gate drive signal for the top half bridge of phase A A logic high 1 PWM AT turns phase top switch on 2 Shielding Pin 2 is connected to a shield wire in the ribbon cable and ground on the board PWM is the gate drive signal for the bottom half bridge of phase A A logic high 3 PWM AB turns phase A s bottom switch on 4 Shielding Pin 4 is connected to a shield wire in the ribbon cable and ground on the board PWM BT is the gate drive signal for the top half bridge of phase B A logic high 5 PWM BT turns phase B s top switch on 6 Shielding Pin 6 is connected to a shield wire in the ribbon cable and ground on the board _ is the gate drive signal for the bottom half bridge of phase B A logic high 7 PWM BB turns phase B s bottom switch on 8 Shielding Pin 8 is connected to a shield wire in the ribbon cable and ground on the board PWM CT is the gate drive signal for the top half bridge of phase C A logic high 9 PWM CT turns phase C s top switch on 10 Shielding Pin 10 is connected to a shield wire in the ribbon cable and ground on the board PWM_CB is the gate drive signal for the bottom half bridge of phase C A logic high 11 PWM CB turns phase C s bottom switch on 12 GND Digital and power groun
46. n board power supply is shown in Figure 4 7 Unless otherwise specified resistors are 1 8 watt have a 5 tolerance and have values shown in ohms Interrupted lines coded with the same letters are electrically connected Parts lists for the power substrate and printed circuit board appear in Table 4 1 and Table 4 2 3 Phase Switched Reluctance High Voltage Power Stage 32 Schematics and Parts List MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Schematics and Parts List Schematics HH 9seud e 2 esues duie esues esues duie esues 795195 2 v sues GAS
47. ngs that are indicated in Table 2 3 This procedure allows software to interpret the new analog values correctly Table 2 3 JP801 Settings Position 1 4 HP 1 2 HP 3 4 HP 180 W 370 W 550 W 1 2 Open Short Open 3 4 Open Open Short 5 6 Open Open Open 7 8 Open Open Open 5 For 3 4 horsepower motors it is also necessary to add an additional 470 uF 400 volt bus capacitor To install the capacitor it is first necessary to remove PFC inductor L201 Mounting holes for the additional capacitor are located within L201 s footprint Note that it is essential to orient the capacitor such that polarity is correct Positive and negative connections are indicated by and silk screened labels on the board In addition the pad for the capacitor s positive lead is square and the pad for its negative lead is round 3 Phase Switched Reluctance High Voltage Power Stage 22 Operational Description For More Information On This Product Go to www freescale com MOTOROLA Freescale Semiconductor Inc Operational Description Fuse Replacement Once these changes have been made configuration for either 1 2 or 3 4 horsepower is complete 2 5 Fuse Replacement A fast blow fuse is located on the front right hand corner of the top board If this fuse has to be replaced these steps apply 1 Remove power and wait until the power on LED is off Remove the fuse s protective case Replace th
48. ny available 6 Boe Bs CRCW0805 121J 1 T100 SMPS Transformer Tronic Praha s r o TRONIC 99 060 09 1 T101 SMPS Transformer Tronic Praha s r o TRONIC 00 003 73 2 U100 U104 Optocoupler Infineon SFH6106 2 1 U101 Voltage Reference On Semiconductor TL431BCD 1 0102 SMPS Controller Power Integration TOP202YAI 1 0103 SMPS Controller Power Integration TNY254P 2 0108 0106 15V Voltage Regulator Semiconductor MC78L15ACD 1 0107 15V Voltage Regulator On Semiconductor MC79L15ACD 1 0110 3 3V Voltage Regulator On Semiconductor MC78PC33NTR 1 U201 Quad NAND Gate On Semiconductor MC74VHCTOOAD 1 U202 Gate Driver On Semiconductor MC33152D 2 U203 U303 Dual Comparator On Semiconductor LM393D 2 U301 0302 Rail to Rail Op Amp On Semiconductor MC33502D 1 0304 Voltage Reference National Semiconductor LM285M 3 0401 0402 0403 Gate Driver International Rectifier 21125 1 0404 Fairchild DM74ALS1034M 1 U801 Programmed MCU Motorola MC68HC708JJ7CDW 1 X801 4MHz Resonator muRata CSTCC4 00MG DN 1 Sticker gt HIGH VOLTAGE 0 R107 NOT POPULATED 0 C115 C210 NOT POPULATED User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 44 Schematics and Parts List MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc User s Manual 3 Phase Switched Reluctance High Voltage Power Stage Section 5
49. onsiderations 51 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations 5 7 Phase Current Sensing User s Manual Sampling resistors provide phase current information for all three phases These resistors sample current in the lower phase legs which in a switched reluctance output directly measures phase current The circuitry for phase A is shown in Figure 5 5 Referencing the sampling resistors to the negative motor rail makes the measurement circuitry straightforward and inexpensive Current is sampled by resistor R1 and amplified by differential amplifier U302B This circuit provides a voltage output suitable for use with A D inputs An MC33502 is again used for the differential amplifier With R301 R304 and R303 R305 the gain is given by R303 R301 The output voltage is shifted up by 1 65 V to accommodate both positive and negative current swings A 300 mV voltage drop across the shunt resistor corresponds to a measured current range of 2 93 amps 3 Phase Switched Reluctance High Voltage Power Stage 52 Design Considerations MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations Phase Current Sensing DCB Cap Pos Q1 SGB10N60 D2 HFA16TA60CS Phase_AT Phase AB Q2 SGB10N60 HFA16TA60CS R303 75k 196 R301 10 1 R1 0
50. s e 3 bridge inverter 6 IGBT s e Individual phase and dc bus current sensing shunts with Kelvin connections Power stage temperature sensing diodes e IGBT gate drivers Current and temperature signal conditioning e Board identification processor MC68HC705JJ7 Low voltage on board power supplies e Cooling fans ZA is DSP EVM BOARD i P EMULATOR CONTROL BOARD WORKSTATION BOARD POWER STAGE BOARD POWER STAGE OPTOISOLATION HIGH VOLTAGE E HIGH VOLTAGE MOTOR MOTOR NES MICROCONTROLLER b 56800 DSP Figure 1 1 Systems Configurations User s Manual 3 Phase Switched Reluctance High Voltage Power Stage 12 Introduction and Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Introduction and Setup About this Manual Figure 1 2 3 Phase Switched Reluctance High Voltage Power Stage 1 3 About this Manual Key items can be found in the following locations in this manual e Setup instructions are found in 1 5 Setup Guide e Schematics are found in Section 4 Schematics and Parts List Pin assignments for 40 p
51. softness is also a first order design consideration If the anti parallel diodes in an off line motor drive are allowed to snap the resulting di dt s can cause noise management problems that are difficult to solve In general it is desirable to have peak to zero di dt approximately equal the applied di dt that is used to turn the anti parallel diodes off The HFA16TA60CS soft recovery rectifiers that are used in this design are targeted at this kind of reverse recovery characteristic 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Design Considerations 47 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Design Considerations 5 4 Bus Voltage and Current Feedback Feedback signals proportional to bus voltage and bus current are provided by the circuitry shown in Figure 5 2 Bus voltage is scaled down by a voltage divider consisting of R224 R230 The values are chosen such that a 400 volt maximum bus voltage corresponds to 3 24 volts at output V sense DCB An additional output V sense DCB half 15 provides a reference that is used in Zero crossing detection Bus current is sampled by resistor R4 in Figure 4 3 3 Phase Output and amplified by the circuit in Figure 5 2 This circuit provides a voltage output suitable for sampling with A D inputs An MC33502 is used for the differential amplifier With R315 R319 and R316 R317 the gain is given by R315
52. tage 56 Design Considerations MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Motorola reserves the right to make changes without further notice to any products herein Motorola makes no warranty representation or guarantee regarding the suitability of its products for any particular purpose nor does Motorola assume any liability arising out of the application or use of any product or circuit and specifically disclaims any and all liability including without limitation consequential or incidental damages Typical parameters which may be provided in Motorola data sheets and or specifications can and do vary in different applications and actual performance may vary over time All operating parameters including Typicals must be validated for each customer application by customer s technical experts Motorola does not convey any license under its patent rights nor the rights of others Motorola products are not designed intended or authorized for use as components in systems intended for surgical implant into the body or other applications intended to support or sustain life or for any other application in which the failure of the Motorola product could create a Situation where personal injury or death may occur Should Buyer purchase or use Motorola products for any such unintended or un
53. tage consists of an FR 4 circuit board a 3 2 mm aluminum circuit board two fans a fan bracket a heat sink inter board connectors and standoffs Construction is depicted in Figure 1 2 3 Phase Switched Reluctance High Voltage Power Stage The aluminum circuit board fans and heat sink provide the thermal capability surface mounted power components The FR 4 board contains control circuitry and through hole mounted power components The two boards plug together via 10 vertical connectors to in effect form a discrete power module Four holes on the top board are spaced to allow mounting standoffs such that a control board can be placed on top of the power stage This configuration allows mounting control and power functions in one compact mechanical assembly 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List 31 For More Information On This Product Go to www freescale com 4 3 Schematics User s Manual Freescale Semiconductor Inc Schematics and Parts List A set of schematics for the HV SR power stage appears in Figure 4 1 through Figure 4 7 An overview appears in Figure 4 1 Output transistor gate drive is shown in Figure 4 2 The 3 phase output stage appears in Figure 4 3 Current and temperature feedback circuits are shown in Figure 4 4 Power factor correction and brake gate drives are shown in Figure 4 5 The identification block is shown in Figure 4 6 The o
54. wer Stage 1 1 Contents 1 2 Introduction Section 1 Introduction and Setup 1 2 oo EP PER 11 ia PN s Mammal eM Pm 13 TT 14 I3 Me AIG 15 Motorola s 3 phase switched reluctance high voltage power stage HV SR power stage is a 115 230 volt 180 watt 1 4 horsepower off line power stage that is an integral part of Motorola s embedded motion control series of development tools The HV SR power stage is supplied in kit number ECPWRHIVSR In combination with one of the Embedded Motion Control series control boards and an Embedded Motion Control series optoisolation board it provides a ready made software development platform for fractional horsepower off line switched reluctance motors Feedback signals are provided that allow control with a wide variety of algorithms In addition the HV SR power stage includes an active power factor correction PFC circuit that facilitates development of power factor correction algorithms An illustration of the systems architecture is shown in Figure 1 1 A line drawing appears in Figure 1 2 3 Phase Switched Reluctance High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 11 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Introduction Setup Features of the HV SR power stage are e phase bridge rectifier e Power factor switch and diode e dc bus brake IGBT and brake resistor
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