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3-Phase ac BLDC High-Voltage Power Stage
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1. RU 25 34 Pineby Pin Descriptions 25 3 2 1 Power 25 2252 Motor Ouipal Connector 113 e t 26 3 2 3 External Brake Connector 112 542 5222 nr th ER Ren 26 3 2 4 Ribbon Connector J14 27 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Table of Contents 5 5 User s Manual 41 42 4 3 4 4 5 2 Ia 5 4 53 5 6 du 5 8 2 9 2 10 Section 4 Schematics and Parts List Mechanical Seheniall68 Section 5 Design Considerations COMMS aus Tr ar reet dw ao d 3 Phase BLDC High Voltage Power Stage 6 Table of Contents MOTOROLA User s Manual 3 Phase High Voltage Power Stage List of Figures Figure Title Page 1 1 Systems 255455542 HERI RE E C ERA 13 1 2 3 Phase BLDC High Voltage Power 14 17 49 OE 18 TERES TRE AFERCEU REPE NUES TRE EM 20 3 1 ain Ribbon Connector 21 4 1 3 Phase BLDC High Voltage Power Stage Overview
2. 15V_A 0530 1 0530 1 15 D 127 100nF FAN GREENLED 45V D C801 C802 45V D 45V D 10uF 6 3V 10nF U801 MC68HC705JJ7DW MOD R802 R803 804 R805 10k 10k 10k 10k VCC 4 Identification PA5 10k Coding bit 4 45V D O PB7 5 42 4 4 3 PBA TCMP 3 4 20 Ree PETANI PB1 AN1 Coding bit Coding bit O 5V_D DEFAULT SETTINGS 0 PTBO 1 2 2 3 PTB3 GND 4 PTB4 5 5 6 PTA6 GND 7 7 Figure 4 8 Identification Block Schematics and Parts List 4 4 Parts Lists The HV ac 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 Designators Qty Description Manufacturer Part Number D7 D8 D9 4 10 00 V rectifier International _ 5085 D10 Rectifier 011 012 2 8 600 V ultrafast rectifier International 013 014 2 Dual diode temp sensing BAV99LT1 Semiconductor Fisher J1 J2 2 SM CON MCRD SR 500 A male SL 11 SMD 104 20Z Elektronik Fisher 3 J10 2 SM CON MCRD SR 500 male SL 10 SMD 104 62 Elektronik J4 J5 6 7 4 SM CON MCRD SR 500 C male dil SL 10 SMD 104
3. 1 JUMPER DCB L C23 p 10nF 3000 V Earth GND T cin 246209 co S 470 pF 400 V 470 pF 400 V OPTIONAL ca 10 nF 3000 V Capneg e Figure 1 4 PFC Jumper User s Manual 3 Phase ac BLDC High Voltage Power Stage 18 Introduction and Setup MOTOROLA User s Manual 3 Phase High Voltage Power Stage 2 1 Contents 2 2 Description Section 2 Operational Description En gt 19 2 3 21 24 Modification for One Half Three Fourths Horsepower 22 23 Fise 23 Motorola s embedded motion control series high voltage ac power stage is a 180 watt one fourth horsepower 3 phase power stage that will operate off of dc input voltages from 140 to 230 volts and ac line voltages from 100 to 240 volts In combination with one of the embedded motion control series control boards 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 both ac induction and brushless dc BLDC motors Input connections are made via 40 pin ribbon cable connector J14 Pin assignments for the input connector are shown in Figu
4. 32 vectes ER ERES DES 33 amp 34 44 Current and Temperature 22 43 Back EMF Signals 36 4 6 Power Factor Correction and Brake Gate Drives 37 et Ne 38 AP Identification Block 29 gt 49 21 5 3 Cycle by Cycle Current 1 53 354 Tempersure Sensing 2 ethos 5 4h es hese 8 54 DO _ 5 2 45 Phase A Current Sensing 56 5525995 OE Ad 9e ees e dos 58 C eas 59 39 Zero Crossing Feedback 60 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA List of Figures 7 List of Figures User s Manual 3 Phase ac BLDC High Voltage Power Stage 8 List of Figures MOTOROLA User s Manual 3 Phase High Voltage Power Stage List of Tables Table Title Page 2 1 e RE s 21 000000041 22 2 JPU SED senya n 22 23 3 1 Connector J13 Signal Descriptions 26 3 2 Connector J14 Signal Descriptions 28 4 1 Power Subs
5. Figure 4 6 Power Factor Correction amp Brake Gate Drives Power pos pos Power neg e lt 3 3 ___ D O 15V D 5 O 45V A 5V A O 15V A GNDA GNDA GND Petras ____ 4FAN ___ R106 2 21k 1 R109 2 21k 1 Power_pos 110 27 113 27 123 100nF 124 100pF 500V FB 65 200 1 100 10pF 500V D102 0109 MBR0530T1 U110 MC78PC33NTR Vin Vout a z C104 MMSZ5231BT1 MURS160T3 R102 1 0k 3 0100 ak SFH6106 eiii 33uF 25V GND R108 Drain 0102 6 8 Control TL431BCD 6117 Sourc 47uF 16V D106 T101 SM Trafo_EFD15 12PN MPRSTI00T8 f 11 C122 100uF 16V D107 MMSZ5242BT1 U104 SFH6106 C125 1nF 1kV Figure 4 7 Power Supply Ground Connection 1 1 _____ 8 220uF 10V 220 7 0106 MC78L15ACD VIN VOUT SM Trafo EFD20 12PIN 25 33 1OuF 6 3V 0110 wBRo530T1 15 67 100nF GNDA 5 112 Vin Gnd Vin Vout 100nF 100nF MC79L15ACD TOP202YAI
6. 0406 MBRS130LT3 Gate BT 405 120 0407 MMSZ5251BT1 _ Source MBRS130LT3 Gate_BB D410 MMSZ5251BT1 Source_BB MBRS130LT3 Gate_CT R409 120 D412 MMSZ5251BT1 0414 4 MBRS130LT3 1 Gate vss COM 33uF 25V 45V D n c LO z 1921125 470nF 50V C419 C420 4048 inF inF DM74ALS1034M 8414 10 8413 413 8 2 Shut Down 1 100 04046 DM74ALS1034M D408 4 7uF 16V Pur m MBRS130LT3 BT gt 5 6 C405 U402 M 18 nic L 12 VDD vs 13 HIN 44 SD n c n 33uF 25V PWM BB gt 8 8 12 VSS LO 1821125 470nF 50V C421 U404D inF DM74ALS1034M C414 8 2pF e o 9V D 0411 U404E DM74ALS1034M 5V_D ei um 4 7uF 16V C411 MBRS130LT3 PWM_CT C409 1403 470 50 415V_D x24 nie 8 VB VDD vs L 1 1 SN we H 44 C418 LIN PWM vss 2 33uF 25V n c LO C412 IR21128 470nF 50V 1nF 415V D 45V D GND 424 1nF 45V D U404F DM74ALS1034M 10nF C425 Figure 4 2 C415 8 2pF ot5V_D Gate Drive R410 D415 120 MMSZ5251BT1 Source CB DCB 1 gt DCB Cap Pos D12 DCB 2 8 605 Q1 Q3 Q5 R8
7. 16 Introduction and Setup MOTOROLA Introduction and Setup Setup Guide 5 Setup the optoisolation and control boards 6 Optional PFC The HV ac power stage is shipped with power factor correction PFC disabled If power factor correction is desired it is necessary to remove and resolder 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 7 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 Note that the optoisolation board powers the control board and that the optoisolation board is not fully powered until power is applied to the power stage CAUTION Hazardous voltages are present Re read all of 1 4 Warnings carefully i STANDOFFS 555 4 2 CONTROL BOARD 4 42 Vd SS B SS POWER STAGE lt OPTOISOLATOR RIBBON CABLE lt 5 3 dt OU e 112 v v v 75 STANDOFFS HIGH VOLTAGE MOTOR SUPPLY Figure 1 3 Setup 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 17 Introduction and Setup PFC UD 1 DCB 2
8. R203 1 68 1 1 Any available R204 R413 2 1000 Dale CRCW20805 101J R206 1 100 Dale CRCW0805 104J R207 1 12 1 1 Any available R210 1 930 Dale CRCWO0805 330J R212 1 681 0 1 Any available R216 1 12700 Dale CRCW0805 274J R217 1 2 7kQ Dale CRCW0805 272J 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List 43 Schematics and Parts List Table 4 2 Printed Circuit Board Parts List Sheet 4 of 5 Designators Qty Description Manufacturer Part Number R218 1 4 7kQ Dale CRCW0805 472J R219 1 38 Dale CRCW0805 333J R220 R221 2 33kQ CRCW0805 333J R222 1 10kQ Dale CRCW0805 103J Brio 2 905 6 274 1 Any available R226 1 4 87 1 Any available 5 6 81 Any available R229 1 255 1 Any available R209 R301 R304 R31 1 8313 R316 R317 R320 9 10 196 Dale CRCWO0805 103F R321 R302 1 2 21 1 Any available R205 1 1 196 Dale CRCWO0805 102F ies is ient oo 8 75 1 Dale CRCWO805 753F R306 1 680 CRCW0805 684J R308 R309 2 1 2 CRCW0805 122J R310 1 2200 CRCW20805 221J R323 1 3900 CRCW20805 391 J R324 1 100 kQ 1 Dale CRCW0805 104F 8325 1 33 2 1 Any available ie ie MM EN 8629 Dale CRCWO805 121J R501 R509 R517 3 1324 1 Any available R504 R512 R520 3 245 19 Any available R506 R514
9. R522 3 0 Any available R507 R515 R523 3 21 0kQ 1 Any available T100 1 SMPS transformer Praha TRONIC 99 060 09 User s Manual 3 Phase ac BLDC High Voltage Power Stage 44 Schematics and Parts List MOTOROLA Schematics and Parts List Parts Lists Table 4 2 Printed Circuit Board Parts List Sheet 5 of 5 3 Phase ac BLDC High Voltage Power Stage Designators Qty Description Manufacturer Part Number T101 1 SMPS transformer Praha TRONIC 00 003 73 U100 U104 2 Optocoupler Infineon SFH6106 2 ON U101 1 Voltage reference TL431BCD Semiconductor U102 1 SMPS controller Power 202 Integration U103 1 SMPS controller TNY254P Integration ON U108 U106 2 15 V 1 A regulator MC78L15ACD Semiconductor ON U107 1 15 V 0 1 A regulator MC79L15ACD Semiconductor ON U110 1 3 3 V 15 A regulator MC78PC33NTR Semiconductor U201 1 Quad 2 input NAND gate MC74VHCTOOAD Semiconductor 0202 1 Dual gate driver MC33152D Semiconductor ON U203 U303 2 Dual comparator LM393D Semiconductor U301 U302 2 Dual op am MC33502D pamp Semiconductor U304 1 Voltage reference National LM285M Semiconductor U401 U402 U403 3 Dual gate driver International 521125 Rectifier U404 1 Hex non inverting driver Fairchild DM74ALS1034M ON U501 1 Quad comparator LM339D Semiconductor U801 1 Microcontroller Motorola MC68HC708JJ7CDW X801 1
10. f 15v_D 3 3V_A 3 3V_A e G DA Xr T Processing sense DCB2 sense DCB1 GNDA GND sense A2 sense 1 sense sense B2 sense B1 sense C2 Shut Down Open C Temp sense sense sense B sense A sense DCB Temp sense 1 Temp sense 2 Source BT Gate BT Gate AT Source AT Phase C M CQ cO 5 2 o HV Drivers 415V D 45V D lt Temp sense 2 GNDA Figure 4 1 3 Phase AC BLDC High Voltage Power Stage Overview 45V D GND BEMF sense C BEMF sense B BEMF sense A Sheilding Zero cross C Zero cross B Zero cross A z c PFC enable PFC PWM Serial Con Brake control Shielding Temp sense I sense C I sense B I sense A I sense DCB V sense DCB PWM CB Shielding PWM CT Shielding PWM BB Shielding PWM BT Shielding PWM AB Shielding PWM AT AT gt U404A DM74ALS1034M D402 45V D C402 D401 4 7uF 16V C403 MBRS130LT3 C401 U401 M ot 15V_D 100nF 9 uc HO 8 VB 6 VDD VS 5 HIN n c x SD n c Ee d LIN VCC C423 MBRS130LT3 Gate_AT R401 120 D403 MMSZ5251BT1 Source_AT 130LT3 Gate_AB D405 120 MMSZ5251BT1 1 Source
11. 4 MHz resonator muRata CSTCC4 00MG User s Manual MOTOROLA Schematics and Parts List 45 Schematics and Parts List User s Manual 3 Phase ac BLDC High Voltage Power Stage 46 Schematics and Parts List MOTOROLA User s Manual 3 Phase High Voltage Power Stage 5 1 Contents 5 2 Overview Section 5 Design Considerations 34 4 1 0 47 22 48 54 Bus Voltage and Current Feedback 50 3 5 Cycle by vole LIMINE 52 36 54 M EMF 224 2 ob ie Eo ra a 55 5 8 Phase Current SO 56 5 9 57 3 10 Power Factor Correct ia edat oy CHE h ss nEri 58 From a systems point of view the HV ac 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 ac power stage appear in 5 3 3 Phase H Bridge through 5 10 Power Factor Correction One phase leg of the 3 phase H bridge is looked at in 5 3 3 Phase H Bridge Bus voltage and bus current feedback are discussed in 5 4 Bus Voltage and Current Feedback Cycle by cycle current limiting
12. 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 6 Shielding Pin 6 is connected to a shield wire in the ribbon cable and ground on the board PWM BB 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 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 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 ground 13 GND Digital and power ground redundant connection 14 5 digital Digital 5 volt power supply 15 5V digital Digital 5 volt power supply redundant connection 16 3 3V analog Analog 3 3 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 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 sense DCB is an analog
13. 6Z Elektronik Fisher J8 J9 2 SM CON MCRD SR 500 male SL 10 SMD 104 4Z Elektronik Q1 Q2 Q3 O4 05 Q6 6 10 A 600 V co packaged IGBT Infineon SKB10N60 Q7 1 10 A 600 V IGBT Infineon SGB10N60 ON Q8 1 8 A 500 V MOSFET MTB8N50E Semiconductor R1 R2 R3 R4 R5 5 0 075 1 Isabellenhutte PMA A R075 1 aT 4 2500 Caddock 725 250 5 0 R9 Electronics 1 Power substrate CUBE 46615770 User s Manual 3 Phase ac BLDC High Voltage Power Stage 40 Schematics and Parts List MOTOROLA Schematics and Parts List Parts Lists Table 4 2 Printed Circuit Board Parts List Sheet 1 of 5 3 Phase ac BLDC High Voltage Power Stage Designators Qty Description Manufacturer Part Number C1 C2 C105 C109 C110 C112 C114 C116 C123 C126 C127 C203 C301 19 100 nF 25 V Vitramon VJ0805U104MXXA C304 C305 C307 C401 C405 C409 C100 1 10 pF 500 V Vishay Sprague Typ 5GAQ10 Serie 562C C101 C102 C103 3 220 AVX TPSE227K010R0100 104 128 801 3 10 uF 6 3 V Sprague 293D106X 6R3B2 5129 cde tn z ca 5 8 33 uF 25 V TPSE336K025R0200 C117 1 47 uF 16 V Any available C122 1 100 uF 16 V AVX TPSE107K016R0100 S 5 cons tee Se Leona V Vitramon VJO805U103MXXA C124 3 100 pF 500 V Vishay Sprague Typ 5GAT10 Serie 562C C125 1 1 nF 1 kV muRata 0 0505 10271 201 1 6 8 Vitramon VJ0805A682JXA C202 1 10 uF 35 2
14. 7 Back EMF Signals Back EMF and zero crossing signals are included to support sensorless algorithms for brushless dc motors and dead time distortion correction for ac induction motors Referring to Figure 5 5 which shows circuitry for phase A the raw phase voltage is scaled down by a voltage divider consisting of 501 R502 R504 R507 and R508 One output from this divider produces back EMF sense voltage BEMF sense A Resistor values are chosen such that a 400 volt maximum phase voltage corresponds to a 3 24 volt maximum A D input A Zero crossing signal is obtained by comparing motor phase voltage with one half the motor bus voltage Comparator U501C performs this function producing zero crossing signal Zero cross A Phase A R501 324 1 R502 274 1 R504 215 10 8506 0 ko AW R507 71 kQ 1 U501C Zero cross A C501 LM339D BEMF sense A T 10 pF 3 24 V Q Phase 400 V GNDA R50 6 81 1 GNDA V sense DCB half 15 _ C505 T 22 GNDA Figure 5 5 Phase A Back EMF 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Design Considerations 55 Design Considerations 5 8 Phase Current Sensing Lower half bridge sampling resistors provide phase current information for all three phases Since these resistors sample current in the lower phase legs they do not directly measure phase current However given phase voltages for all three phases phase current ca
15. AB Shielding BEMF sense A PWM BT Shielding Shielding PWM BB Shielding Zero cross C PWM CT Shielding Zero cross B PWM CB GND Zero cross A GND PS zc 45 D inhibit GNDA GNDA PFC PWM 15V_A 19 15V_A Serial_Con V sense 21 sense DCB Brake control sense 123 sense B Shielding sense 25 Temp sense Shielding Temp sense Brake control Serial Con sense C 0 31 PFC inhibit sense B c 133 Zero cross sense A Zero cross 1 35 Zero cross C sense DCB Shielding 137 BEMF sense A V sense DCB BEMF sense 0 39 BEMF sense 15V A 415V A PHYSICAL VIEW GNDA GNDA 33V 5V_D GND GND PWM CB Shielding CT 9 Shielding 8 PWM BB 7 Shielding 6 BT 5 Shielding 4 PWM AB 3 Shielding 2 SCHEMATIC VIEW AT 1 Conan Figure 3 1 40 Pin Ribbon Connector J14 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Pin Descriptions 27 Pin Descriptions Table 3 2 Connector J14 Signal Descriptions NS Signal Name Description PWM is the gate drive signal for the top half bridge of phase 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 AB is the gate drive signal for the bottom half bridge of phase A A logic high 3 PWM AB turns phase bottom switch on
16. SKB10N60 SKB10N60 SKB10N60 1 oETSOBS d ETS 25 Pan 250 5 Gate 5 D11 Phase gt Phase B Phase 9 R R7 de 08 605 250 02 Q4 Q6 AC IN L1 gt MTB8N50E Q8 SKB10N60 SKB10N60 SKB10N60 IN 12 gt i Brake Res Gate gt gt 2 2 Source 5 9 Source gt Source gt Source 09 010 10ETSO8S 10ETSO8S SGB10N60 Lsense 0 Lsense R2 S Gate Brake 0 075 1 0 075 196 0 075 196 RS sense 2 99758 _ 2 0 075 1 4 _ 2 0 075 1 d B 9 9 DCB Cap Neg 9 g Y Sense Sense PFC2 Sense DCB1 Sense DCB2 BAV99LT1 BAV99LT1 Temp sense2 o Oo e a m v a 2 20 25 8 N of Sa 3i 8 amp oso Bod E lt od 1 o 1 lt m a 2 m m 2559359 S g 2 3 8 8 lt lt mq o 6 E 2205 m E i g E oq SM CON MCRD SR 500 A male SM CON MCRD SR 500 male sense C1 sense C2 Source CB Gate CB J8 SM CON MCRD SR 500 A male sense B2 sense B1 Gate BB Source BB lt lt J9 J3 SM CON
17. Temp sense 1 R306 680k 15V_D U303B Shut_Down_Open C 7 LM393D GND 315 75k 1 C303 680pF 3 3V_A O R310 R312 GNDA 470 10k GNDA DC Bus Current Sensing R316 10k 196 Lsense_DCB1 2 sense DCB2 3 317 10k 196 R319 75 1 Current amp Temperature Feedback sense DCB 1 U302A 1 65V 1 65V Imax MC33502D O 3 3 o 100nF GNDA 501 Phase 400 324k 1 R502 274k 1 R504 215 1 8506 8507 0 21 0 1 501 sense A 10pF 3 24V Phase A 400V R508 6 81k 1 GNDA R509 NZ Phase GNDA 400V max 324k 1 R510 374k 1 R512 215k 196 8514 R515 0 21 0k 196 C502 10pF BEMF sense 3 24 Phase 400V R516 6 81k 1 GNDA R517 Phase GNDA 400V max 324 1 R519 374k 1 R520 215 1 8522 8523 0 21 0 1 504 10pF sene V sense DCB half 15 3 24 Phase C 400V R524 6 60 Vbus 400V 6 81k 1 GNDA GNDA GNDA C505 22pF 45V D 505 9 8 E lt Zero cross U501C LM339D 415V D Q C503 45V D Q 10nF R513 10 5 2 lt Zero cross B U501A LM339D 45V D ND 506 10nF 45V D 521 l lt Zero cross C U501B LM339D Figure 4 5 Back EMF Signals 415V D 1 0 15 D 5 0 o 5V_D GND GNDA G
18. correct Positive and negative connections are indicated by plus and minus 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 6 Oncethese changes have been made configuration for either one half or three fourths 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 follow these steps 1 Remove power and wait until the power on LED is off 2 Remove the fuse s protective case 3 Replace the fuse with one of the selections shown in Table 2 4 Table 2 4 Fuse Ratings Fuse Fuse Motor RMS Input Current Voltage Current Fuse Type Horsepower Amps Rating Rating Amps Volts 1 l4 180W 2 3 2 5 250 Fast blow 1 l2 370W 4 8 6 3 250 Fast blow 9i 550 W 7 1 8 250 Fast blow 4 Replace the protective case 5 Setthe controller s speed control input to zero RPM 6 Apply power and resume operation 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Operational Description 23 Operational Description User s Manual 3 Phase ac BLDC High Voltage Power Stage 24 Operational Description MOTOROLA User s Manual 3 Phase BLDC High Voltage Power Stage Section 3 Pin Descriptions 3 1 Contents 22 Publ Descriptions sche os ons b
19. of 2 69 amps 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 7 connects 6 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 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Design Considerations 57 Design Considerations 45V D o C20 10 uF 35 V 1 011 08 605 C203 100 nF GND U202 6 18 lt 2 gt 7 Brake control R204 Q7 4 InB OutB 5 Niky SGB10N60 100 Q mos QRL GND D201 10 i 3 MC33152D MMSZ5251BT1 GND GND GND GND Figure 5 7 Brake 5 10 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 is to draw sinusoidal current from the ac line in an attempt t
20. 25 C415 82 pF 55V D C BOTTOM OUT IR 21125 Figure 5 3 Cycle by Cycle Current Limiting 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Design Considerations 53 Design Considerations 5 6 Temperature Sensing User s Manual 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 nonvolatile memory The measured value rather than the nominal value is then used as a reference point for further readings 433V R302 2 2 1 D13 014 e a lt lt BAV99LTI BAV99LTI eo Temp_sense PIN 26 CONNECTOR J 14 ve Figure 5 4 Temperature Sensing 3 Phase ac BLDC High Voltage Power Stage 54 Design Considerations MOTOROLA Design Considerations Back EMF Signals 5
21. 411 D414 6 1 A 30 V Schottky Semidond ctor MBRS130LT3 F1 1 Fuse holder MULTICOMP MCHTE15M JP201 1 Power jumper JP801 1 4X2 jumper pads J2 J1 2 20 connector BL 2 207 Elektronik Fisher J3 J10 2 6 pin connector Elektronik BL 1 62 J4 J5 J6 J7 4 6 connector BL 167 Elektronik Fisher J9 J8 2 4 pin connector Elektronik BL 142 11 12 2 Weidmuller LP 7 62 2 90 User s Manual 3 Phase ac BLDC High Voltage Power Stage 42 Schematics and Parts List MOTOROLA Schematics and Parts List Parts Lists Table 4 2 Printed Circuit Board Parts List Sheet 3 of 5 Designators Qty Description Manufacturer Part Number J13 1 Terminal block Weidmuller LP 7 62 3 90 J14 1 40 pin connector ASLG40G Thompson L201 1 4 9 mH 2 3 A Television SMTA ref G6982 Components R1 1 Inrush limiter 50190 R100 R101 R102 R103 4 1 0kQ Dale CRCW1206 102J R104 1 2700 CRCW0805 271J R105 1 8200 Dale CRCW0805 821J R106 R109 2 2 21kQ 1 Any available R108 1 560 Any available R110 R111 R112 R113 4 270 CRCW1206 270J R114 1 1 0 CRCW0805 102J R115 1 3300 CRCWO0805 331J R201 1 3 92 1 Any available R202 214 2 3 3kQ Dale CRCWO0805 332J R208 R211 R213 R215 R223 R312 R403 R404 i ius 21 10ka Dale CRCWO805 103J R801 R802 R803 R804 R805
22. 930106 _03502_ 205 207 2 22 nF Vitramon VJ0805A223JXA C208 1 22 nF 630 Vdc WIMA MKP10 C209 1 470 uF 400 V C Ono lt 15746471 4 22 22 2 8 1 Vitramon VJ0805A102JXA C213 C214 2 10 nF 3000 V Thomson 5ST410MCMCA C303 1 680 pF Vitramon VJ0805A681JXA C306 1 3 3 uF 10 V Sprague 2930335 _010 2_ 402 406 410 3 47 uF 16 V Sprague 293D475X_016B2_ aa eae 0407 OS 6 470 50 Vitramon VJ1206U474MXAA _ C413 C414 C415 3 8 2 pF Vitramon VJ0O805A8R2DXA C505 1 22 pF Vitramon VJ0805A220DXA _ User s Manual MOTOROLA Schematics and Parts List 41 Schematics and Parts List Table 4 2 Printed Circuit Board Parts List Sheet 2 of 5 Designators Qty Description Manufacturer Part Number D1 1 V14E250 EPCOS SOIV S 10K250 0100 1 Transient suppressor P6SMB200AT3 Semiconductor ON D101 1 6 A 60 V Schottky MBRD660CT Semiconductor D102 D401 D408 D413 4 1 A 600 V ultrafast MURS160T3 Semiconductor D103 D104 D105 D106 4 1 A 100 V Schottky ON MBRS1100T3 Semiconductor ON D107 1 12 V 5 W zener MMSZ5242BT1 Semiconductor ON D108 1 5 1 V 5 W zener MMSZ5231BT1 Semiconductor D109 D110 D111 D112 4 0 5 A 30 V Schottky ON 0530 1 Semiconductor D113 1 Green LED Kingbright L 934GT D201 D202 D403 D405 ON D407 D410 D412 D415 iE Semiconductor 525251 1 D203 1 1N4148 Fairchild 1N4148LL 34 0402 0404 0406 0409 D
23. Affirmative Action Employer Motorola Inc 2000 Rights Reserved User s Manual 3 Phase ac BLDC High Voltage Power Stage 2 MOTOROLA User s Manual 3 Phase High Voltage Power Stage 3 Phase ac BLDC 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 47 User s Manual MOTOROLA List of Sections 3 List of Sections User s Manual 3 Phase ac BLDC High Voltage Power Stage 4 List of Sections MOTOROLA User s Manual 3 Phase BLDC High Voltage Power Stage Table of Contents Section 1 Introduction and Setup 11 11 1 2 lu pono o M 11 13 PODES xad b XR VS HER dE REM ees 13 quie ages 15 a EM crm 16 Section 2 Operational Description 2 1 19 2 4 lb 40 CPU 19 23 Elccirical ua a3 aues esae ROCA ORE RS 21 24 Modification for One Half and Three Fourths Horsepower 22 2 9 fuss BODIE eeu 23 Section 3 Pin Descriptions COONS
24. CERES R6 ERES 25 3 2 1 Power Connector JU ER 25 Motor Qutput Connector 26 3 2 3 External Brake Connector 26 3 2 4 40 Pin Ribbon Connector 114 27 3 2 Pin by Pin Descriptions Inputs and outputs are located on four connectors Pin descriptions for each of these connectors are included in this section 3 2 1 Power Input Connector 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 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Pin Descriptions 25 Pin Descriptions 3 2 2 Motor Output Connector J13 Power outputs to the motor are located on connector J11 Phase outputs are labeled Ph_A Ph_B and Ph_C Pin assignments are described in Table 3 1 Table 3 1 Connector J13 Signal Descriptions Pin No Signal Name Description Ph_A supplies power to motor phase A On an induction motor any one of the three phase windings can be connected here For brushless dc motors it is important to connect the wire color coded for phase A into the connector terminal labeled Ph_A and so on for phase B and phase C Ph_B supplies power to motor phase B On an i
25. 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 Ph B and Ph C For an ac induction motor it does not matter which lead goes to which phase For BLDC motors it is important to get the wire color coded for phase A into the connector terminal labeled Ph A and so on for phase B and phase C 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 screw its front edge that is also marked with a ground symbol Connect a line isolated current limited dc power supply to connector J11 located on the front edge of the top board The input voltage range is 140 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 dc supply to provide input power The connection is made on connector J11 Bias voltages are developed by internal power supplies Only one power input is required Operation off 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 off an ac power line 3 Phase ac BLDC High Voltage Power Stage
26. M GATE db AC CONTROL DRIVERS MOTOR PHASE CURRENT PHASE VOLTAGE BUS CURRENT BUS VOLTAGE MONITOR ZERO CROSS BACK EMF SENSE Figure 2 1 Block Diagram 3 Phase ac BLDC High Voltage Power Stage 20 Operational Description MOTOROLA 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 power 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 Max logic 0 input voltage Vi 0 8 Input resistance Rin 10 Analog output range Vout 0 3 3 V Bus current sense voltage ISense 563 Bus voltage sense voltage VBus 8 09 mV V Peak output current IpK 2 8 A Brake resistor dissipation Pak E _ 50 continuous dissipation Pipes __ 100 Total power dissipation Pdiss 85 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Operational Description 21 Operational Description 2 4 Modification for One Half and Three Fourths Horsepower The HV ac power stage can be modified for operation at either one half or three fourths horsepower To change maximum output power follow these steps 1 Remove power and wait
27. MCRD_SR_500_B male SM CON MCRD_SR_500_E male YOO J4 SM CON MCRD_SR_500_C male sense A2 sense A1 Sense DCB1 Gate AB Source AB Sense DCB2 lt lt lt QN CO x 10 CO J10 SM CON MCRD SR 500 B male J5 SM CON MCRD SR 500 C male Figure 4 3 3 Phase H Bridge J SM CON MCR 6 D SR 500 C male 7 SM CON MCRD SR 500 C male 415V D 415V D 43V 43 3V A C302 GNDA 10nF Phase Current nsin GND EXE R303 75k 196 R301 10k 1 sense A1 sense A 2 sense 1 65V 1 65V Imax R304 10k 1 03028 8305 MC33502D 75k 1 H 5 R307 75k 196 R311 10k 1 _ 1 sense B sense B2 1 65V 1 65V Imax R313 10 1 U301A R314 MC33502D 75k 1 43 3V_A 4 gt C304 100nF GNDA R318 75k 196 R320 10k 1 sense C1 5 Lsense C sense C2 1 65V 1 65V Imax R321 10k 196 R322 U301B 75 1 MC33502D R323 390 33 A 1 65V ref al R324 C307 C306 100k 1 100nF 3 3uF 10V 5 LM285M R325 U304 33 2k 1 GNDA bi ETA Figure 4 4 45V D U303A LM393D GNDA b GND Over current Detection R308 1 2k sense DCB Temp sense 2 Temperature Sensing R309 1 2k 43 3V A R302 2 21k 1 Temp_sense C301 100nF
28. MEMC3PBLDCPSUM D Motorola Embedded Motion Control 3 Phase ac BLDC High Voltage Power Stage User s Manual 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 trademarks of Motorola Inc Motorola Inc is an Equal Opportunity
29. NDA U501D LM339D _ 1 ___ 45V D 5V_D 15V_D C204 R203 15V_D 5v D 10nF 68 19 15V ___ 15V 3 5 D 206 100k y m GNDA __ T PFC Switch C203 gate 201 100nF GND zi R207 202 MMSZ5251BT1 1 8 8201 R209 PFC_Source PFC_PWM 2 3 92k 1 10 1 Tg MC74VHCTOOAD R212 MC74VHCTOOAD GND MC74VHCTOOAD R211 a fo 10k lt _ Brake 3 3k D201 GNDA Brake Switch MMSZ5251BT1 Brake control GND a PFC enable R202 C212 GND 10k 1nF R215 10k 15V D 415V D E 216 270k GND 9 Detection Deus SM 1N4148 R217 211 2 7k PF ion Optio 1201 ref 11 811 3 R219 R220 R221 ref h 11 86 lt 2 2 LM393D 2 201 4 9 2 33k 33k 33k U203B DCB PFC 1 PFC Jumper R222 R223 Loos 10k 10k no PFC Bus Voltage Feedback Cappos 7 V sense DCB halt 15 GNDA GNDA 274k 196 274 1 4 87 1 274k 196 R228 R224 R225 R226 R227 6 81k 1 C213 10nF 3000V 8229 5208 209 255 1 Earth RS 22nF 630VDC 470uF 400V 1 V sense C214 3 235 Vbus 400V 8230 OnF 3000
30. at this kind of reverse recovery characteristic 3 Phase ac BLDC High Voltage Power Stage 48 Design Considerations MOTOROLA gt AB gt 419 1nF Shut Down R40 10k ND 0420 1nF R404 10k U404A DM74ALS1034M U404B DM74ALS1034M DCB Cap Pos D402 MBRS130LT3 45V D C402 D401 R401 4 7uF 16V C403 MBRS130LT3 120 D403 C401 0401 470 50 lt MMSZ5251BT1 100nF 3 zi m 8 T 11 VB 6 13 VDD VS 5 13 74 tz SD 5 0404 MBRS130LT3 LIN L4 53 33uF 25V _16 C404 ND 1821125 470nF 50V R402 D405 ND 120 MMSZ5251BT1 5V_D R414 sense 10k sense A1 sense 2 R413 C413 8 2pF 45V D 100 Figure 5 1 Phase A Output Sense Q1 SKB10N60 Q2 SKB10N60 R1 0 075 1 Design Considerations 5 4 Bus Voltage and Current Feedback User s Manual 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 used in zero crossing detection Bus current is sampled by resistor R4 in Figure 4 3 and amplified by the circuit in Figure 5 2 Thi
31. e electrically connected 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Schematics and Parts List 31 C1 C2 FAN 100nF 100nF Earth Ground J15 PFC DC BUS BRAKE 4 2 6 Identification 45V D 415V GND 15 9 9 sv 7 2 LETS ac z 525 LA xe 2a psz OZ 60465 Ou 41010 lo ac 9m ats 25 oa T een al o e 8 a 5 22 5 8 8 59 5o 55 gt o m Eath GND 99 ra 15 A 3 3 9 15 V sense DCB half 15 GND ana I Iz lt BEMF sense C _ _____ 40 5962 sense 39 38 37 Zero cros 36 35 34 o o 9 32 31 BSc 30 J8 CON E J9 CON E J2 CON A J7 CON C CON C J6 CON C J5 CON C POWER MODULE Identification 414 Motor Terminals J13 Phase A Phase B Source CB Gate CB Source BB Gate CT Source CT 01 V14E250 R1 SG 190 21 FA 2 5A 250V Fast Blow dip 88 Input 15V_D O
32. e feedback is provided by the bus voltage sensing circuit in Figure 5 2 A zero crossing feedback signal 7 is also used and is produced by the circuit in Figure 5 9 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Design Considerations 59 Design Considerations R219 33 KQ User s Manual R220 33 KQ D7 10ETS085 AC IN 5 e NO PFC E 0 Cap pos 2 IE L201 JUMPER DCB 2 49 mH 2 3A 08 10575085 09 10575085 45V D R221 33 ko D10 10 75085 Sense 45V D 45V D R216 270 45V D PFC zc LM393D U203B R222 R223 47 10 GND Figure 5 9 Zero Crossing Feedback In this circuit connection to R222 D203c 219 R220 and R221 provide a relatively high impedance the rectified line voltage and form a 32 1 voltage divider with lamps the divided down voltage to approximately 15 7 volts Comparator U203B then compares this signal to a 11 8 volt reference Approximatel y fifty millivolts of hysteresis is added by R216 The result is a logic high at output z c when the comparator s input voltage falls below 11 79 volts This output remains high until 10 84 volts is reached on the next cycle 3 Phase ac BLDC High Voltage Power Stage 60 Des
33. ey 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 M 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 Customer Focus Center 1 800 521 6274 JAPAN Motorola Japan Ltd SPS Technical Information Center 3 20 1 Minami Azabu Minato ku Tokyo 106 8573 Japan 81 3 3440 8573 ASIA PACIFIC Motorola Semiconductors Ltd Silicon Harbour Centre 2 Dai King Street Tai Po Industrial Estate Tai Po N T Hong Kong 852 26668334 HOME PAGE hitp motorola com semiconductors Motorola Inc 2000 MEMC3PBLDCPSUM D
34. ically the high voltage HV power stage 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 ac BLDC High Voltage Power Stage The aluminum circuit board fans and heat sink provide thermal capability for 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 A set of schematics for the HV ac power stage appears in Figure 4 1 through Figure 4 8 An overview of the board appears in Figure 4 1 H bridge gate drive is shown in Figure 4 2 The 3 phase H bridge appears in Figure 4 3 Current and temperature feedback circuits are shown in Figure 4 4 Back EMF feedback circuitry appears in Figure 4 5 Power factor correction and brake gate drives are shown in Figure 4 6 An on board power supply appears in Figure 4 7 and finally the identification block is shown in Figure 4 8 Unless otherwise specified resistors are 1 8 watt have 5 tolerance and have values shown in ohms Interrupted lines coded with the same letters ar
35. ign Considerations MOTOROLA 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 unauthorized 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 attorn
36. imiting 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 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 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 ac power stage is designed with switching times at the higher end of this range to minimize noise Anti parallel diode 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 itis 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 SKB10N60 IGBT s that are used in this design are targeted
37. is highlighted in 5 5 Cycle by Cycle Current Limiting Temperature sensing is discussed in 5 6 Temperature Sensing Back EMF signals appear in 5 7 Back EMF Signals Phase current sensing is discussed in 5 8 Phase Current Sensing The brake is highlighted in 5 9 Brake and finally power factor correction is discussed in 5 10 Power Factor Correction 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Design Considerations 47 Design Considerations 5 3 3 H Bridge User s Manual The output stage is configured as a 3 phase H 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 At the input pulldown resistors R403 and R404 set a logic low in the absence of a signal Open input pulldown 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 buffered by U404A and U404B This part has a minimum logic 1 input voltage of 2 0 volts and a maximum logic 0 input voltage of 0 8 volts which allows for inputs from either 3 3 or 5 volt logic Gate drive is supplied by an international rectifier IR2112 Undervoltage lockout and cycle by cycle current limiting are also provided by the IR2112 Undervoltage lockout is set nominally at 8 4 volts Current l
38. l Its edges represent power line voltage zero crossing events 34 Zero cross A Zero cross is a digital signal used for sensing phase A back EMF zero crossing events 35 Zero cross B Zero cross B is a digital signal used for sensing phase B back EMF zero crossing events 36 Zero cross C Zero cross C is a digital signal used for sensing phase C back EMF zero crossing events 37 Shielding Pin 37 is connected to a shield wire in the ribbon cable and analog ground on the board 38 BEMF sense A BEMF sense Ais an analog sense signal that measures phase A back EMF It is scaled at 8 09 mV per volt of dc bus voltage 39 sense B BEMF sense 15 an analog sense signal that measures phase back It is scaled at 8 09 mV per volt of dc bus voltage 40 sense C BEMF sense Ais an analog sense signal that measures phase C back EMF It is 3 Phase ac BLDC High Voltage Power Stage scaled at 8 09 mV per volt of dc bus voltage User s Manual MOTOROLA Pin Descriptions 29 Pin Descriptions User s Manual 3 Phase ac BLDC High Voltage Power Stage 30 Pin Descriptions MOTOROLA User s Manual 3 Phase High Voltage Power Stage 4 1 Contents Section 4 Schematics and Parts List 4 2 Mechanical 1 31 4 3 Ole CS prse qu 31 4 4 40 4 2 Mechanical Characteristics 4 3 Schematics Mechan
39. n be constructed mathematically from the lower phase leg values This information can be used in vector control algorithms for ac induction motors The measurement circuitry for one phase is shown in Figure 5 6 DCB Cap 1 01 Gate SKB10N60 Phase A _______e 22 Gate SKB10N60 Source 351 9 1 S R301 10 1 6 R1 0 075 Q 1 sense A U302B DU R304 10 1 MC33502D Sense DCB2 lt R305 75 1 8323 390 1 65 Vref 3 3V_A o e C307 306 R324 100 nF T 3 3 uF 10 V 100 0 1 LM285M U304 Vv R325 GNDA 33 1 GNDA Figure 5 6 Phase A Current Sensing User s Manual 3 Phase ac BLDC High Voltage Power Stage 56 Design Considerations MOTOROLA 5 9 Design Considerations Brake 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 sampling with A D inputs An MC33502 is again used for the differential amplifier With R301 R302 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
40. nduction motor any one of the three phase windings can be connected here For brushless dc motors it is important to connect the wire color coded for phase B into the connector terminal labeled Ph_B and so on for phase A and phase C Ph_C supplies power to motor phase C On an induction motor any one of the three phase windings can be connected here For brushless dc motors it is important to connect the wire color coded for phase C into the connector terminal labeled Ph_C and so on for phase A and phase B 3 2 3 External Brake Connector J12 An optional external brake resistor can be connected to external brake connector J12 labeled Ext Brake The external resistor allows power dissipation to increase beyond 50 watts that brake resistors R6 R9 provide User s Manual 3 Phase ac BLDC High Voltage Power Stage 26 Pin Descriptions MOTOROLA Pin Descriptions Pin by Pin Descriptions 3 2 4 40 Pin Ribbon Connector J14 Signal inputs are grouped together on 40 pin ribbon cable connector J14 located on the right side of the board Pin assignments 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 listed in Table 3 2 14 BEMF sense PWM AT Shielding BEMF sense B PWM
41. o 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 8 User s Manual 3 Phase ac BLDC High Voltage Power Stage 58 Design Considerations MOTOROLA Design Considerations Power Factor Correction NO PFC 20 2 _ 201 PFCJUMPER 0 D12 gt 4 9 2 3 08 605 Lg 07 08 T 3000 V 10 5085 10 5085 5 08 AC IN 11 C208 209 36210 22nF 25470 25470 122 Earth GND 630 400V 400 V OPTIONAL 09 010 10 75085 ne R5 0 075 196 Sense PFC1 lt lt Sense PFC2 4 sense 1 68 1 Q 1 C201 l 207 eus 6 8 nF PET AE U201A T 3 R201 R209 3 92kQ 100 MC7AVHCTOOAD 1 1 R212 R211 MCTAVHCTOOAD wic74VHCTOOAD 10 33 A GND GND PFC enable R215 10 GND Figure 5 8 PFC Circuitry Looking toward the top of Figure 5 8 Q8 L201 D12 and the bus capacitors form a boost power supply This 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 8 Voltag
42. p minimizes the possibility of electrical shock Operation in lab setups that have grounded tables and or chairs should be avoided e Wearing safety glasses avoiding ties and jewelry using shields and operation by personnel trained in high voltage lab techniques are also advisable e Power transistors the coil and the 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 ac BLDC High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 15 Introduction Setup 1 5 Setup Guide WARNING User s Manual Setup and connections for the HV ac power stage are straightforward The power stage connects to an embedded motion control optoisolation board via a 40 pin ribbon cable and can be powered either by a 140 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 step by step setup procedure is 1 Plug one end of the 40 pin ribbon cable that comes with optoisolator kit into input connector J14 The other end of this cable goes to the optoisolation board s 40 pin output connector
43. ration of the systems architecture is shown in Figure 1 1 A line drawing appears in Figure 1 2 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 11 Introduction Setup The HV ac power stage s features are e 1 bridge rectifier e Power factor switch and diode e dc bus brake IGBT and brake resistors e 3 phase bridge inverter 6 IGBT s e Individual phase and dc bus current sensing shunts with Kelvin connections e Power stage temperature sensing diodes e IGBT gate drivers e Current and temperature signal conditioning e 3 phase back EMF voltage sensing and zero cross detection circuitry e Board identification processor MC68HC705JJ7 e Low voltage on board power supplies e Cooling fans User s Manual 3 Phase ac BLDC High Voltage Power Stage 12 Introduction and Setup MOTOROLA Introduction and Setup About this Manual EMULATOR CONTROL BOARD OPTOISOLATION BOARD DSP EVM BOARD OPTOISOLATION BOARD HIGH VOLTAGE POWER STAGE HIGH VOLTAGE POWER STAGE a MICROCONTROLLER b 56800 DSP Figure 1 1 Systems Configurations 1 3 About this Manual Key items can be found in the following locations in this manual Setup instructions are found 1 5 Setup Guide e Schema
44. re 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 and Ph C on the board Power requirements are met with a single external 140 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 ac BLDC High Voltage Power Stage User s Manual MOTOROLA Operational Description 19 Operational Description User s Manual The high voltage ac 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 an MC68HC705JJ7 microcontroller that is used for configuration and identification of the power electronics which 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 SWITCH MODE POWER SUPPLY PFC CONTROL dc BUS BRAKE 3 PHASE IGBT POWER MODULE SIGNALS TO FRO
45. s circuit provides a voltage output suitable for sampling with A D analog to digital inputs An MC33502 is used for the differential amplifier With R315 R319 and R316 R317 the gain is given by A R315 R316 The output voltage is shifted up by 1 65 V to accommodate both positive and negative current swings 300 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 also is used for cycle by cycle current limiting A discussion of cycle by cycle current limiting follows in 5 3 3 Phase H Bridge 3 Phase ac BLDC High Voltage Power Stage 50 Design Considerations MOTOROLA V sense DCB half 15 6 60V DC Bus 400V 274 1 274 1 4 87k 196 274 1 R224 R225 R226 R227 R228 6 81k 1 DC Bus Voltage Sensing V_sense_DCB 3 24V DC Bus 400V R230 6 81k 1 GNDA R315 75 1 DC Bus Current Sensing sense DCB R316 10k 196 sense DCB1 I sense DCB sense DCB2 U302A R317 10k 196 MC33502D 3 3 A R323 390 1 65V ref C305 3 3 100nF R324 GNDA C307 C306 100 1 100nF 3 3uF 10V LM285M R325 U304 33 2k 196 GNDA VA GNDA Figure 5 2 Bus Feedback Design Considerations 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 c
46. sense signal that measures dc bus current It is scaled 22 sense DCB at 0 563 volts per amp of dc bus current User s Manual 3 Phase ac BLDC High Voltage Power Stage 28 Pin Descriptions MOTOROLA Pin Descriptions Pin by Pin Descriptions Table 3 2 Connector J14 Signal Descriptions Continued Ho Signal Name Description sense is an analog sense signal that measures current in phase A It is scaled 23 sense A at 0 563 volts per amp of dc bus current sense is an analog sense signal that measures current in phase B It is scaled 24 sense B at 0 563 volts 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 volts per amp of dc bus current 26 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 stage is present 31 is a digital signal that controls the power factor correction circuit s switch 42 inhibit inhibit is a digital output used to enable or disable the power factor correction circuit 33 zc PFC z cis a digital signa
47. tics are found in Section 4 Schematics and Parts List Pin assignments are shown in Figure 3 1 40 Pin Ribbon Connector J14 and a pin by pin description is contained in 3 2 Pin by Pin 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 ac BLDC High Voltage Power Stage User s Manual MOTOROLA Introduction and Setup 13 Figure 1 2 3 Phase BLDC High Voltage Power Stage Introduction and Setup Warnings 1 4 Warnings This development tool set operates in an environment that includes dangerous voltages and rotating machinery To facilitate safe operation input power for the HV ac power stage should come from a current limited dc laboratory power supply unless power factor correction is specifically being 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 Note that probe grounds and therefore the case of a floated oscilloscope are subjected to dangerous voltages user should be aware that Before moving scope probes making connections etc it is generally advisable to power down the high voltage supply Whenhigh voltage is applied using only one hand for operating the test setu
48. trate Parts List 40 42 Printed Circuit Board Parts 1 8 41 3 Phase ac BLDC High Voltage Power Stage User s Manual MOTOROLA List of Tables 9 List of Tables User s Manual 3 Phase ac BLDC High Voltage Power Stage 10 List of Tables MOTOROLA User s Manual 3 Phase High Voltage Power Stage 1 1 Contents 1 2 Introduction Section 1 Introduction and Setup 1 2 s cool si 6 0 544 ee ASS E 11 1 3 5 552424255544 d d 19 odere kit 15 1 5 Ee 16 Motorola s 3 Phase high voltage brushless dc BLDC power stage HV power stage is a 115 230 volt 180 watt one fourth horsepower off line power stage that is an integral part of Motorola s embedded motion control series of development tools It is supplied in kit number ECPWRHiV ACBLDC 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 motors Feedback signals are provided that allow 3 phase ac induction and BLDC motors to be controlled with a wide variety of algorithms In addition the HV ac power stage includes an active power factor correction PFC circuit that facilitates development of PFC algorithms An illust
49. until the power on LED is off 2 If PFC jumper JP201 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 one half and three fourths horsepower lower gains allow for higher measured currents and higher overcurrent trip points Table 2 2 Resistor Values 14 HP 1 HP 3j HP Resistors 180 W 370 W 550 W 8303 R305 R307 R314 R315 R318 R319 R322 75 62 56 8301 8304 R311 R313 R316 R317 R320 R321 10 15 16 4 Configure identification coding jumper JP801 with the settings indicated in Table 2 3 This proceedure allows software to interpret the new analog values correctly Table 2 3 JP801 Settings User s Manual Position 1 44 HP 1 HP 3 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 3 Phase ac BLDC High Voltage Power Stage 22 Operational Description MOTOROLA Operational Description Fuse Replacement 5 For 550 watts three fourths horsepower it is also necessary to add an addional 470 1 400 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
50. urrent feedback signal I sense DCB is filtered with R308 and C303 to remove spikes and then compared to a 3 15 volt reference with 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 bot tom 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 ac BLDC High Voltage Power Stage 52 Design Considerations MOTOROLA Design Considerations Cycle by Cycle Current Limiting 9 3 lt OUT 10 x NIC H i vob VS PWM A TOP K 434 PWM A BOTTOM KHH LIN lt A BOTTOM OUT IR21125 C413 82 pF 5V_D C414 82 pF 9v D 0402 B TOP lt PWM BOTTOM 45V D R306 680 8308 R309 R414 sense DCB 1 2kQ 1 2kQ 10 kQ Ws R413 C303 33V _ 100 Q 680 pF R310 LM393D 000 gR 4 10 GNDA GND GNDA C TOP 4 HO VB VS N C N C COM LO H B TOP OUT IR 211
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