3 phase motor control high voltage inverter module
Contents
1. 044 4355111 http www necel com Santa Clara CA 95050 2554 U S A Tel 408 5886000 http www am necel com Europe NEC Electronics Europe GmbH Arcadiastrasse 10 40472 D sseldorf Germany Tel 0211 65030 http www eu necel com United Kingdom Branch Cygnus House Sunrise Parkway Linford Wood Milton Keynes MK14 6NP U K Tel 01908 691133 Succursale Francaise 9 rue Paul Dautier B P 52 78142 Velizy Villacoublay C dex France Tel 01 30675800 Sucursal en Espa a Juan Esplandiu 15 28007 Madrid Spain Tel 091 5042787 Tyskland Filial Taby Centrum Entrance S 7th floor 18322 T by Sweden Tel 08 6387200 Filiale Italiana Via Fabio Filzi 25 A 20124 Milano Italy Tel 02 667541 Branch The Netherlands Steijgerweg 6 5616 HS Eindhoven The Netherlands Tel 040 2654010 User s Manual U17811EE2V0UMOO Asia amp Oceania NEC Electronics China Co Ltd 7th Floor Quantum Plaza No 27 ZhiChunLu Haidian District Beijing 100083 P R China Tel 010 82351155 http www cn necel com NEC Electronics Shanghai Ltd Room 2511 2512 Bank of China Tower 200 Yincheng Road Central Pudong New Area Shanghai 200120 P R China Tel 021 58885400 http www cn necel com NEC Electronics Hong Kong Ltd 12 F Cityplaza 4 12 Taikoo Wan Road Hong Kong Tel 2886 9318 http www hk necel com NEC Electronics Taiwan Ltd 7F No 363 Fu Shing North Road Taipei Taiwan R O C Tel2. 0 0000e eee eee 22 Chapter6 Power Supplies 0 00 000 ccc cccecc cece eee ee 23 6 1 IO ose E NR 23 6 2 Mains Input sta en a A eel 23 6 2 1 Mains Selection Options oooocooccccccccncc ees 24 Chapter 7 User Connections 0 000 00 0c ccc eeece eee 26 7 1 Motor Terminal Connections 0 0000 eect eee 27 7 2 Motor Selection e eda ii ae ee a he a Dake BARS LE EA Se a 28 7 2 1 INDUCTION Motol iaa ae en a a ANE aa sens 29 7 2 2 Brushless DG Motot si as cr rl a ee a a e yal der aoe 29 Chapter 8 Appendices 00 000 c ccc cece ccc eee eee teen ees 30 8 User s Manual U17811EE2V0UMOO Chapter 1 Introduction 1 1 This document details the operation interfaces and cautions for the 3 Inverter Starter Kit Module supporting NEC Electronics range of Motor Control ASSPs The module is designed to support 30 Brushless DC 30 PMAC and 30 AC Induction motor types Warnings This high voltage starter kit Inverter unit operates in an environment that includes dangerous voltages and rotating machinery Care should be taken when using the unit especially if the unit is removed from the case When switching off the mains supply stored energy will remain in the high voltage capacitors It is necessary to wait at least 50 seconds after disconnecting the mains supply before disconnecting any of the attached equipment i e The Motor or Control Boards or before opening the ca
3. Inverter unit forms part of the overall Motor Control starter kit products which consist of 3 component parts see figure 1 1 A Motor control ASSP microcontroller board 2 A user interface and I O board 3 A3 high voltage Inverter Module including Power supplies and Opto lsolation The boards are designed in such a way that they maybe used individually or as a kit Please note that the high voltage unit will only available separately The other component parts can be purchased separately VEIAN 30 Motor Control Starter Kit Inverter Module Connection to the Microcontroller and I O boards is via the 40 way interface connector shown on the side of the case All interfaces mains power input motor connections and selectable options provided ensure that the user is protected from the high voltage areas The unit is not intended for use without the case Equipment Ratings The unit is designed to operate over the following electrical and environmental conditions User s Manual U17811EE2V0UMOO 41 Chapter 2 Definitions Table 2 1 Mains Input Ratings Specification Rating Input voltage 100 VAC to 240 VAC Input current 3A Mains Frequency 50 60 Hz Mains connection Appliance inlet Type IEC320 Table 2 2 Output Ratings Specification Rating Output voltage 130 Vdc to 350 Vdc Output power 300 600 W max Table 2 3 Protection Le
4. Isolation Transformer please be aware that the Power Stage grounds and external ground i e oscilloscope Control Board etc will be at different potentials Note that if an un earthed oscilloscope is used the probe ground references and the case can be subject to dangerous voltages Before moving scope probes making connections etc it is generally advisable to power down the high voltage supply and ensure that it is fully discharged Care should be taken with Jewellery and other loose items and the use of a protective shield is advisable Operation in lab setups that have grounded tables and or chairs should be avoided The power cord plug must be easily accessible at any time so that it can be disconnected immediately in case of danger If the circuit board has been removed from the case ensure that the cables are reconnected to the correct connectors when it is re assembled Note The Inverter units is not intended for use without the case All applications should utilise the Over Current and Thermal Protection capabilities to protect the IGBT module and motor Ensure that all connections and settings to the unit are correct before operation to avoid possible damage to the components and or the motor Ensure that the correct settings are used for the appropriate Motor rating see section Equipment Ratings User s Manual U17811EE2V0UMOO Chapter 2 Definitions 2 1 Figure 2 1 2 2 Overview The high voltage
5. LIN1 Logic Input Low Side Gate Driver Phase 1 19 LIN2 Logic Input Low Side Gate Driver Phase 2 20 LIN3 Logic Input Low Side Gate Driver Phase 3 21 T ltrip Temperature Monitor and Shut down Pin 22 VCC 15V Main Supply 23 VSS Negative Main Supply Note The PWM drive input from the Microcontroller 1 O board should be set to Active Low All 6 channels of the PWM timer should be used i e HiU LoU HiV LoV HiW LoW The circuit schematic for the IGBT module is as shown in Appendix B User s Manual U17811EE2V0UMOO 15 Chapter 4 IGBT Module 16 4 1 2 Figure 4 1 IGBT Module Thermal Characteristics As can be seen in figure 3 below the IGBT module provides an internal over temperature monitor which can be combined with a hardware shutdown function The module may need to be shutdown for either of the following reasons 1 Over temperature 2 Over current detection Current detection and monitoring is described later in this document The use of the TSENSE ITRIP pin can be used to protect the IGBT module for both over temperature or over current events Vee 22 4 HA IR21365 Internal NTC Connection Diagram Temperature Sensing and Measurement The temperature output TSENSE ITRIP from the IGBT module shown in Figure 4 1 is provided to the user interface as an isolated analogue signal TEMP ST1 pin 9 in the range OV to 3 3V The isolation circuit provides a unity ga
6. due to noise etc the device may malfunction Take care to prevent chattering noise from entering the device when the input level is fixed and also in the transition period when the input level passes through the area between VIL MAX and VIH MIN 2 HANDLING OF UNUSED INPUT PINS Unconnected CMOS device inputs can result in malfunction If an input pin is unconnected it is possible that an internal input level may be generated due to noise etc causing malfunction CMOS devices behave differently than Bipolar or NMOS devices Input levels of CMOS devices must be fixed high or low by using pull up or pull down circuitry Each unused pin should be connected to VDD or GND via a resistor if there is a possibility that it will be an output pin All handling related to unused pins must be judged separately for each device and according to related specifications governing the device 3 PRECAUTION AGAINST ESD A strong electric field when exposed to a MOS device can cause destruction of the gate oxide and ultimately degrade the device operation Steps must be taken to stop generation of static electricity as much as possible and to quickly dissipate it should it occur Environmental control must be adequate When it is dry a humidifier should be used It is recommended to avoid using insulators that easily build up static electricity Semiconductor devices must be stored and transported in an anti static container static shielding bag or c
7. phase High Voltage monitor 350 VP NOaAPR Ww 5 2 1 Functional Description Current Measurement The current measurement circuits provide an analogue shunt measurement for each phase together with a total current measurement function The individual current measurement circuits operate over a range of OA to 3A per phase which is converted to an output voltage in the range of OV to 5V full scale This provides an output conversion ratio of 600mA V The total current measurement circuit provides an input range of OA to 3A providing an output range of OV to 5V full scale 1 50 4 00 500m4 20 2 00m 4 00m 6 00m 8 00m Ti 10 0m 12 0m 14 0m 16 0m 18 0m 20 0m ime Figure 5 3 Current Measurement Transfer Function The total current measurement is also converted into a digital output ITRIP to provide a hardware shutdown signal for the 6 PWM outputs from the Microcontroller The polarity of the ITRIP signal is 1 OV Normal Operation 2 5V Over current i e Shutdown condition 3A User s Manual U17811EE2V0UMOO Opto Isolation Chapter 5 Note 5 2 2 5 2 3 Automatic shut down of the IGBT module is provided by ensuring that Jumper W5 is connected Default manufacture setting This is a latching function so that once triggered i e Shutdown the mains power to the unit must be switched off and allowed to discharge Once fully discharged the mains power can be r
8. stages CMPU_IS BEMF U Signal CMPV IS BEMF V conditioning T ___ a _ _ circuits lt ap BEMF W Am AN Prototype area Figure 3 1 Inverter Module block diagram User s Manual U17811EE2V0UMOO 13 Chapter 4 IGBT Module The 30 IGBT module provides all of the six transistor drive for the Motor together with the integrated high side driver and protection functions The IGBT module used on the is supplied by International Rectifier part number IRAMS10UP60A Features Integrated Gate Drivers and Bootstrap Diodes Temperature Monitor Temperature and Over current shutdown Fully Isolated Package Low VCE on Non Punch Through IGBT Technology Under voltage lockout for all channels Matched propagation delay for all channels Low side IGBT emitter pins for current control Schmitt triggered input logic Cross conduction prevention logic Lower di dt gate driver for better noise immunity 4 1 Specifications A summary of the specifications of the IGBT module is as follows For full specifications and recommended use of the IGBT module specifications please refer to manufacturer s data sheet and the Inverter module reference schematics 4 1 1 IGBT Driver Maximum Operating Conditions Table 4 1 Maximum IGBT Module Operating Conditions Symbol Definition Min Max Units Vh High Side Floating Supply Voltage Vs 12 Vs 20 V Vs High Side Supply Offset Voltag
9. 02 27192377 NEC Electronics Singapore Pte Ltd 238A Thomson Road 12 08 Novena Square Singapore 307684 Tel 6253 8311 http www sg necel com NEC Electronics Korea Ltd 11F Samik Lavied or Bldg 720 2 Yeoksam Dong Kangnam Ku Seoul 135 080 Korea Tel 02 558 3737 http www kr necel com Readers Purpose Organization Legend Note Caution Numeric Notation Prefixes Preface This manual is intended for users who want to understand the functions of the 3 Phase Inverter Starter Kit Module supporting NEC Electronics range of Motor Control ASSPs This manual presents the hardware manual of the 3 Phase Inverter Starter Kit Module supporting NEC Electronics range of Motor Control ASSPs This system specification describes the following sections Inverter module IGBT module Opto isolation Power supplies User connections Symbols and notation are used as follows Weight in data notation Left is high order column right is low order column Active low notation xxx pin or signal name is over scored or xxx slash before signal name Memory map address High order at high stage and low order at low stage Note Caution Additional remark or tip Item deserving extra attention Binary xxxx or xxxB Decimal xxxx Hexadecimal xxxxH or Ox xxxx representing powers of 2 address space memory capacity User s Manual U17811EE2V0UMOO K kilo 210 1024 M mega 220 10242 1
10. 048 576 G giga 230 10243 1 073 741 824 Table of Contents Chapter 1 Introduction 000 00 c ccc ccc cece eee ees 9 1 1 WarninGS ieta aare a A Ed Aig eo da Gea ean Coweta cere a 9 1 2 Precautions 4 3203 E A A Peek Gia ee RE BARS BOE Bete RR Dea a dd 10 Chapter 2 Definitions oooooooooccccccccccccccccccnccccnnooo 11 2 1 OVEIVICW A Stee Rita Eee and 11 2 2 Equipment Ratings oara ae ac ttt oe nein We a aa ae eo 11 Chapter 3 Inverter Module 000 00 cece cece eee ee 13 Chapter 4 IGBT Module 00 00 00 00 ccc cece ccc eee ee 14 4 1 Specifications v oA a a eae otek Meee ae a ena aie Oe A a ee 14 4 1 1 IGBT Driver Maximum Operating Conditions 0 cece eee eee 14 4 1 2 IGBT Module Thermal Characteristics oocoocooccocconcnccn eee 16 4 1 3 Module ShutdoOwntncs ceo corista sat ve oe erat eek erie callie eee at 17 Chapter 5 Opto Isolation oooooccccccccccccccccccncooo 18 5 1 Isolation Block Diagram oscura rta Aa wanes 19 5 2 Analogue Isolation Circuit Description ocoococcccccncco 19 5 2 1 Functional Description Current Measurement 2 0200e eee eee ees 20 5 2 2 Functional Description Zero Crossing Detection 0 0 eee eee eee 21 5 2 3 Functional Description Inverter Motor Terminal Voltages ooooo oo 21 5 2 4 Functional Description IGBT Temperature Sensor
11. 6 1 Mains Power Input The AC mains input provides a switched filtered and fused supply to the board Please ensure that if it is necessary to replace either of the two fuses that they are replaced with the same type and rating T6 3A 250V In order to select the correct mains input voltage a switch S1 is provided on the side of the case as shown in Figure 6 2 Warning Ensure that the mains selection switch S1 is set to the correct setting before 24 6 2 1 connecting and switching on the unit An incorrect setting of this switch could cause damage to the unit See section below and Table 6 1 below for the correct settings Mains Selection Options The module is designed to provide the maximum motor voltage from either a 100V 110V or 240V mains supply The power supply includes an AC voltage doubler circuit so it is important that the correct AC voltage setting is used when operating the units outside of Europe or when using lower rated motors that require a lower AC supply voltage The location of the switch is a shown in Figure 6 2 below User s Manual U17811EE2V0UMOO Power Supplies Chapter 6 AC Mains Input Selection Switch S1 Figure 6 2 AC Mains Input Selection If a motor is used that that requires a lower voltage i e 150Vdc 110Vac then the Inverter board should be set for 240V mains input no doubling via the switch S1 If necessary an external step down transformer should be used to provide th
12. HE MPW_IS OV_CURR_TR 2 gt _TRIP Analogue Isolation Stage BPIS I BYOA MOT V_DCLIN ANI6_V_DCLINK IU ANIO_IU IV ANI1_IV IW ANI2_IW TMP ANI7_TMP ISHUNT ANI5_ISHUNT Analogue Isolation stage example Input HV Output LV a Vons Vcc Hi Volts Digital Signal In Lo V oN Analogue Signal out HV Ov Lo Volts 0 5v Ov Lo Volts Ov Hi Volts cc Lo Volts Analogue Signal out Lo V 0 5v v Lo Volts The Opto isolation for the digital I O signals provide a Non Inverting signal conversion Analogue Isolation Circuit Description The following section describes the functions and operation of the analogue isolation circuitry providing feedback and monitoring functions to the microcontroller control system The functions provided by the analogue isolation circuits are as follows 1 Three zero crossing detection comparator circuits for BLDC Sensor less control User s Manual U17811EE2V0UMOO 19 Chapter 5 Opto Isolation 4 505 4 004 3 50 4 3 004 1 2 50 2 An isolated over current input to the control system Digital Input to the control system This function can also be used for automatic hardware over current shutdown of the IGBT module Current measurement of each phase Total current monitor combined with item 2 above IGBT module Temperature sensor output Voltage monitor for each
13. NEC User s Manual 3 Phase Motor Control High Voltage Inverter Module Document No U17811EE2V0UMOO Date published October 2007 NEC Electronics 2007 Printed in Germany Legal Notes The information in this document is current as of August 2007 The information is subject to change without notice For actual design in refer to the latest publications of NEC Electronics data sheets or data books etc for the most up to date specifications of NEC Electronics products Not all products and or types are available in every country Please check with an NEC Electronics sales representative for availability and additional information No part of this document may be copied or reproduced in any form or by any means without the prior written consent of NEC Electronics NEC Electronics assumes no responsibility for any errors that may appear in this document NEC Electronics does not assume any liability for infringement of patents copyrights or other intellectual property rights of third parties by or arising from the use of NEC Electronics products listed in this document or any other liability arising from the use of such products No license express implied or otherwise is granted under any patents copyrights or other intellectual property rights of NEC Electronics or others Descriptions of circuits software and other related information in this document are provided for illustrative purposes in semiconductor produ
14. O 28 CMPU GND 2 O O 130 5v GND 31 O O 32 TEMP GND 33 O O 34 I SHUNT GND 35 O O 36 IW V_DCLINK 37 O 33 IV TRIP 39 O O j401U Figure 7 2 Control Interface Signal Allocation ST1 7 1 Motor Terminal Connections The connections to the Motor are provided via connector located on the Inverter unit as shown below The connector provides full mechanical isolation from the high motor voltages User s Manual U17811EE2V0UMOO 27 Chapter 7 User Connections 28 Figure 7 3 Table 7 1 7 2 Note C Electronics Europe GmbH Motor Terminal Connections Motor Terminal Interface MOTOR VU CONNECTION 3 230VAC ur POWER 200W 115V INPUT 690W 230V INPUT Earth Connections The connections to the motor are as shown in Table 7 1 below Motor Terminal Connections Pin Number Function Pin 1 Phase Voltage W Vw Pin 2 Phase Voltage V Vv Pin 3 Phase Voltage U Vu Motor Selection Detailed below are the two reference 30 motors that were used to develop application examples for the Inverter module The motors are not included with the Inverter unit but can be supplied by the appropriate manufacturer or distributor as required The user is able to use an alternative motor which may be more suited to their end application No changes need to be made on the Inverter unit from the default Factory settings in order to use the example motors and associated software If al
15. ct operation and application examples The incorporation of these circuits software and information in the design of a customer s equipment shall be done under the full responsibility of the customer NEC Electronics assumes no responsibility for any losses incurred by customers or third parties arising from the use of these circuits software and information e While NEC Electronics endeavors to enhance the quality reliability and safety of NEC Electronics products customers agree and acknowledge that the possibility of defects thereof cannot be eliminated entirely To minimize risks of damage to property or injury including death to persons arising from defects in NEC Electronics products customers must incorporate sufficient safety measures in their design such as redundancy fire containment and anti failure features NEC Electronics products are classified into the following three quality grades Standard Special and Specific e The Specific quality grade applies only to NEC Electronics products developed based on a customer designated quality assurance program for a specific application The recommended applications of an NEC Electronics product depend on its quality grade as indicated below Customers must check the quality grade of each NEC Electronics product before using it in a particular application Standard Computers office equipment communications equipment test and measurement equipment audio and v
16. ding to related specifications governing the device 6 INPUT OF SIGNAL DURING POWER OFF STATE Do not input signals or an I O pull up power supply while the device is not powered The current injection that results from input of such a signal or I O pull up power supply may cause malfunction and the abnormal current that passes in the device at this time may cause degradation of internal elements Input of signals during the power off state must be judged separately for each device and according to related specifications governing the device User s Manual U17811EE2V0UMOO America NEC Electronics America Inc 2880 Scott Blvd Regional Information Some information contained in this document may vary from country to country Before using any NEC product in your application please contact theNEC office in your country to obtain a list of authorized representatives anddistributors They will verify Device availability Ordering information Product release schedule Availability of related technical literature Development environment specifications for example specifications for third party tools and components host computers power plugs AC supply voltages and so forth Network requirements In addition trademarks registered trademarks export restrictions and otherlegal issues may also vary from country to country NEC Electronics Corporation 1753 Shimonumabe Nakahara ku Kawasaki Kanagawa 211 8668 Japan Tel
17. e applied to the unit Assuming that the cause of the fault condition has been fixed It is advisable to stop the operation of the Microcontroller ASSP during this operation The hardware PWM shutdown input of the micro controller needs to be set for Ve edge triggering or active high level The signals are provided on the 40 way interface connector ST1 are as shown below Signal Pin Number Comments 1 IW ST1 pin 36 Phase W current Analogue Output 2 IV ST1 pin 38 Phase V current Analogue Output 3 IU ST1 pin 40 Phase U current Analogue Output 4 ISHUNT ST1 pin 34 Total current Analogue Output 5 ITRIP ST1 pin 39 Over current Digital Output Functional Description Zero Crossing Detection The zero crossing detection circuits consist of comparator circuits with input signal conditioning and filtering components The design of these circuits is to provide a zero crossing detection of the motor BEMF signals The schematic diagrams of these functions are included in Appendix C The output of the isolated signals provides a logic level drive Ov 5V for the control system These signals are provided on the interface connector as shown below Signal Pin Number Comments CMPW STi pin 24 Phase W Zero Crossing 2 CMPV ST1 pin 26 Phase V Zero Crossing 3 CMPU ST1 pin 28 Phase U Zero Crossing _ Functional Description Inverter Motor Terminal Voltages The isolation circuits for the three Motor Phase voltag
18. e appropriate mains input supply Other valid input combinations are available for the selection of AC Mains voltage and rectified DC motor voltage The table below shows the possible options for AC mains input and rectified DC voltage Table 6 1 AC Mains and DC Motor Voltage Valid Switch Combinations AC Mains Input Section Voltage Voltage 100V 110V 200V 283V 100V 240V 100V 142V 110V 110V 220V 311V 110V 240V 110V 156V 240V 240V 240V 340V 240V 110v Not Allowed Not Allowed Caution The only option for 240V AC mains input is with the Switch S1 set to 240V Any other setting will damage the unit User s Manual U17811EE2V0UMOO 25 26 Chapter 7 User Connections The main connection between the Inverter unit and the Microcontroller IO board or user control board is as shown in Figure 7 1 below Control Interface Connector ST1 Figure 7 1 Control Interface The signal connection between the Inverter module and the microcontroller IO board is as shown in Figure 7 2 below User s Manual U17811EE2V0UMOO User Connections Chapter 7 40 way Male Header Spare Analogue O P1 O O 2 V W Spare Digital O P 3 O O 4 V V Gnd Spare Digital IP 5 O O 6 v u GND 7 O O ls 15v GND 9 O O 10 LO W GND 11 O O 12LO V GND 13 O O 14 LO U GND 15 O O 16 HI W GND 17 O O 18 HEV GND 19 O O 20 HIU GND 2 O O 22 TRIP GND 23 O O 24 CMPW GND 235 O O 26 CMPV GND 27 O
19. e 450 V Vdd Low Side Logic Fixed Supply Voltage 12 20 V Virip T ltrip input voltage Vss Vss 5 V Vin Logic Input Voltage Lin Hin Vss Vss 5 V 14 User s Manual U17811EE2V0UMOO IGBT Module Chapter 4 Typical IGBT Driver Switching Characteristics Voo Ves Veas 15V l 1A Vp 9V Ta 25 C Table 4 2 Typical IGBT Module Switching Conditions Symbol Definition VAIRE Units Typ Ton Input to Output turn On delay time 470 nS Toff Input to Output turn off delay time 615 nS Dt Dead time 300 nS ltrip T lirip turn off delay time 750 nS T Post lip to turn off clear time 9 mS Table 4 3 IGBT Module Pin Connections Pin Name Description 1 VB3 High Side Floating Supply Voltage 3 2 W VS3 Output 3 High Side Floating Supply Offset Voltage 3 na None 4 VB2 High Side Floating Supply Voltage 2 5 V VS2 Output 2 High Side Floating Supply Offset Voltage 6 na None 7 VB1 High Side Floating Supply Voltage 1 8 U VS1 Output 1 High Side Floating Supply Offset Voltage 9 na None 10 V Positive Bus Input Voltage 11 na None 12 LE1 Low Side Emitter Connection Phase 1 13 LE2 Low Side Emitter Connection Phase 2 14 LE3 Low Side Emitter Connection Phase 3 15 HINA Logic Input High Side Gate Driver Phase 1 16 HIN2 Logic Input High Side Gate Driver Phase 2 17 HIN3 Logic Input High Side Gate Driver Phase 3 18
20. es provide input signal conditioning and conversion from the high voltage PWM inverter voltage to that of an analogue output This also includes an output indicating the High Voltage inverter supply level These signals in the range of 1 Input Voltage Range OV to 375V 2 Isolated Output Voltage Range OV to 5V This provides a conversion ratio of 75V V The schematic diagrams for these circuits are included in Appendix C These signals are provided on the interface connector as shown below Signal Pin Number Comments 1 V W ST1 pin 2 Phase W Terminal Voltage 2 V V ST1 pin 4 Phase V Terminal Voltage User s Manual U17811EE2V0UMOO 21 Chapter 5 Opto Isolation 22 5 2 4 3 V U ST1 pin 6 Phase U Terminal Voltage 4 V_DCLINK STi pin 37 Inverter Supply Voltage 350VP Functional Description IGBT Temperature Sensor The output from the IGBT module is converted into an analogue voltage with unity gain levels The output level is in the range of OV to 3 3V The maximum operating level is 3 3V This provides an approximate conversion of 36 30C per Volt See Figure 4 2 Signal Pin Number Comments 1 TEMP ST1 pin 32 IGBT Temperature Voltage User s Manual U17811EE2V0UMOO Chapter 6 6 1 Note 6 2 Power Supplies Overview The power supply is designed to provide the unregulated DC supply for the IGBT and motor as well as regulated DC supplies for the isolated side of the inverter unit The regulated su
21. in stage so that the temperature can effectively be monitored directly from the IGBT module See the graph of Figure 4 2 This enables the control system to monitor this parameter to ensure that the IGBT module does not overheat User s Manual U17811EE2V0UMOO IGBT Module Chapter 4 Figure 4 2 Maximum Nominal Minimum V sense V 0 20 40 60 80 100 120 140 Thermistor Temperature C Internal NTC Thermistor Characteristics Please note that the Analogue reference voltages of the A D converter on the microcontroller ASSP boards are set to Vdd 5V So the maximum threshold of the analogue input TEMP is 66 of the analogue reference voltage i e 3 3V 5V To change the ADC reference voltage please refer to the Microcontroller ASSP board circuit schematics Module Shutdown The module can be shut down by the control system either with the hardware shutdown signal TRIP ST1 pin 19 or stopping the PWM drive signals to the IGBT module by software Ideally both methods should be used The Inverter unit employs an automatic over current temperature detection circuit which is designed shutdown the IGBT module automatically Please note that this function is designed as latching circuit so once tripped i e shutdown it will remain unit the main power to the unit is switched off and the high voltage capacitors discharged The automatic IGBT shutdown function is enabled as the default manufact
22. isual equipment home electronic appliances machine tools personal electronic equipment and industrial robots Special Transportation equipment automobiles trains ships etc traffic control systems anti disaster systems anti crime User s Manual U17811EE2V0UMOO systems safety equipment and medical equipment not specifically designed for life support Specific Aircraft aerospace equipment submersible repeaters nuclear reactor control systems life support systems and medical equipment for life support etc The quality grade of NEC Electronics products is Standard unless otherwise expressly specified in NEC Electronics data sheets or data books etc If customers wish to use NEC Electronics products in applications not intended by NEC Electronics they must contact an NEC Electronics sales representative in advance to determine NEC Electronics willingness to support a given application Note 1 NEC Electronics as used in this statement means NEC Electronics Corporation and also includes its majority owned subsidiaries 2 NEC Electronics products means any product developed or manufactured by or for NEC Electronics as defined above User s Manual U17811EE2V0UMOO 3 Notes for CMOS Devices 1 VOLTAGE APPLICATION WAVEFORM AT INPUT PIN Waveform distortion due to input noise or a reflected wave may cause malfunction If the input of the CMOS device stays in the area between VIL MAX and VIH MIN
23. on uses the three Hall sensors mounted in the motor providing speed and position feedback for the Microcontroller The Sensorless application uses the same control software design but uses the three zero crossing comparators instead of the Hall sensors to provide as the speed and position feedback to the Microcontroller An outline of the motor parameters are described below Oriental 30 BLDC Motor 4 pole 75 Watt Part Number FBLM575W A 150V Maximum Rated Speed 4 000 RPM 3 x Integrated Hall Sensors 2 pulses per revolution sensor Ou Gore User s Manual U17811EE2V0UMOO 29 30 Chapter 8 Appendices This document contains file attachments Use the Attachments tab to see them User s Manual U17811EE2V0UMOO
24. onductive material All test and measurement tools including work benches and floors should be grounded The operator should be grounded using a wrist strap Semiconductor devices must not be touched with bare hands Similar precautions need to be taken for PW boards with mounted semiconductor devices 4 STATUS BEFORE INITIALIZATION Power on does not necessarily define the initial status of a MOS device Immediately after the power source is turned ON devices with reset functions have not yet been initialized Hence power on does not guarantee output pin levels I O settings or contents of registers A device is not initialized until the reset signal is received A reset operation must be executed immediately after power on for devices with reset functions 5 POWER ON OFF SEQUENCE In the case of a device that uses different power supplies for the internal operation and external interface as a rule switch on the external power supply after switching on the internal power supply When switching the power supply off as a rule switch off the external power supply and then the internal power supply Use of the reverse power on off sequences may result in the application of an overvoltage to the internal elements of the device causing malfunction and degradation of internal elements due to the passage of an abnormal current The correct power on off sequence must be User s Manual U17811EE2V0UMOO judged separately for each device and accor
25. pplies provide power for the Opto isolation circuits and the low voltage supply for the IGBT module 15V Supplies available on the module are 1 Regulated 5V and 15V DC 330mA Total 2 Unregulated 350V DC 3A Total The on board power supplies only provide power to the un isolated i e high voltage side of the unit An external 5V DC supply is needed to supply power to the isolated side This can be supplied directly from the Microcontroller I O boards or the users target control system via the interface connector ST1 The unit is able to support 100V 110V and 240V mains input voltages while designed to supply the maximum motor voltage The Inverter unit employs a voltage doubler circuit so it is important that the correct mains supply setting is selected using switch S1 to avoid damage to the Inverter and possibly the motor The circuit schematic for the Power supply is as shown in Appendix A The 5V DC supply is derived from the 15V supply thus the maximum power supply current indicated above is a combined total Mains Input The power input is designed to be connected using a standard Mains cable to the IEC320 switched appliance inlet as shown in Figure 6 1 below User s Manual U17811EE2V0UMOO 23 Chapter 6 Power Supplies T6 3A 250V INPUT RATINGS 11SVAC 230 VAC 3A 50 60 HZ CHECK VOLTAGE SELECTOR FOR CORRECT RANGE SAME TYPE ANU RATINGS Fused AC Mains Input Connector and On Off Switch Figure
26. se Switching on the module without ensuring that the high voltage supplies have fully discharged and that the drive signal are in the OFF state is liable to cause damage to the unit Bias resistors are provided to ensure correct polarity of these signals if the unit is inadvertently switched on without any control boards connected Ensure that the input voltage selector is set for the correct AC Mains voltage range Incorrect setting of the switch for the mains supply used will cause damage to the unit For continued protection against risk of fire only replace fuses with the same type and rating T6 3A 250V Repairs may only be attempted by authorised personnel Repairs performed inappropriately and changes or modifications not explicitly allowed by the equipment s manufacturer may cause damage to the unit and severe danger to the user The Power Module and the motor can reach temperatures hot enough to cause burns Care should be taken to avoid touching the motor or removing the case after prolonged operation User s Manual U17811EE2V0UMOO Chapter 1 Introduction 10 1 2 Precautions A The following precautions should be taken and used in conjunction with the following sections of this document The intended use of this inverter module is as test and measuring equipment for use in electronic development offices or laboratories and used by appropriate professionals When operating from an AC Mains supply without an
27. ternate 30 motors are used the demonstration software available will need to be adapted to the new motor parameters User s Manual U17811EE2V0UMOO User Connections Chapter 7 7 2 1 7 2 2 Induction Motor A Reference 3 Induction motor was used with the Inverter module to provide an example application using Space Vector Modulation The Speed feedback is provided by an external Incremental Encoder added to the Rotor spindle in order to show the capability of the appropriate microcontrollers Please note that the example application software is liable to change as more Motor control microcontrollers are developed An outline of the reference motor parameters are described below 1 ABB 30 2 pole General Purpose Squirrel Cage Induction Motor 2 Motor Type M2VA56A Product Code 3GVA051 001 ASA 3 400V 50Hz 4 Maximum Rated Speed 4 000 RPM The incremental encoder used with the ABB reference motor is 1 Hohner Automation Incremental Encoder type 0710 13DR 0256 2 256 Pulses per Revolution The encoder was used primarily to provide speed indication of the motor It can however be used in conjunction with an appropriate timer on the Microcontroller as a full incremental encoder function i e both direction and speed measurement Brushless DC Motor Areference 30 Brushless DC motor was used with the Inverter module to provide an example Sensored and Sensorless demonstration application The sensored applicati
28. uring condition It can be disabled by removing Jumper W5 User s Manual U17811EE2V0UMOO 17 18 Chapter 5 Opto Isolation Figure 5 1 Overview Isolation is provided for all digital and Analogue signals between the low voltage Microcontroller I O boards and the high voltage power electronics for the motor Bu 00000 o35 gt z CES oo oo oo oo oo oo oo oo oo oo oo oo Il AA 000000000000000 000000000000 000000000000 00000000 0009 A 5 Analogue Digital isolation isolation areas area Opto lsolation The PCB layout in Figure 5 1 above is shown removed from the case for illustration purposes only Operation of the unit should always be with the PCB mounted inside the case The circuit schematics for the Analogue and Digital isolation are shown in Appendices B and C The isolation scheme is as shown in Figure 5 2 below User s Manual U17811EE2V0UMOO Opto Isolation Chapter 5 5 1 e High Voltage Sie gt Digital Isolation stage example Input LV Output HV Vcc Hi Volts Digital Signal out HV Ov Hi Volts Figure 5 2 Analogue and Digital Opto isolation Stages 5 2 Isolation Block Diagrams Digital Isolation stage x 6 HINU HI_U HINV LO_U HINW HI_V LINU LO_V LINV HI_W LINW LO_W Digital Isolation stage Input LV ITRIP Output lt TRIP HV Digital Isolation stage CMPU CMPU_IS CMPV H CMPV_IS CMPW
29. vels Specification Rating Protection Class 1 Transient voltage Category 2 Pollution degree Level 2 Table 2 4 Operating Conditions Specification Rating Operating temperature range 5 C to 35 C Storage temperature range 40 to 70 C Operating relative humidity 20 to 80 Storage relative humidity 5 to 85 12 User s Manual U17811EE2V0UMOO Chapter 3 Inverter Module The high voltage Inverter unit contains the following sections 1 The High Voltage 30 IGBT Bridge Module 2 All the necessary Power Supplies 3 Opto isolation for the logic drive and logic level sensor signals 4 Opto isolation for the analogue sensor signals This unit includes all of the necessary power supplies and inverter circuitry for controlling a 3 motor It provides all necessary current and voltage measurement circuits and signal conditioning circuits required for motor control The module rectifies 100V to 220V AC mains voltage to the high voltage unregulated DC supply for the Inverter bridge module The 5V and 15V regulated DC supplies for the control and interface circuits are generated from the unregulated DC supply The inverter bridge uses an integrated 6 transistor IGBT module which includes high side drivers and protection circuitry 220v 115v AC 40 way IDC Header To 3 phase 12v _ poor 5v AS Dy seek se 3 i Inverter 6 Digital PWM signals i Module Opto isolation Analogue outputs
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