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3-Phase
Switched Reluctance
High-Voltage
Power Stage
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A G R E E M E N T
Motorola Embedded Motion Control
N O N - D I S C L O S U R E
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R E Q U I R E D
MEMC3PSRHVPSUM/D
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Important Notice to Users
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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 / Affirmative Action Employer.
© Motorola, Inc., 2000; All Rights Reserved
User’s Manual
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Sections
Section 1. Introduction and Setup . . . . . . . . . . . . . . . . . . 11
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Section 2. Operational Description . . . . . . . . . . . . . . . . . 19
Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . 25
Section 4. Schematics and Parts List . . . . . . . . . . . . . . . 31
Section 5. Design Considerations . . . . . . . . . . . . . . . . . . 45
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List of Sections
User’s Manual
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Table of Contents
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Section 1. Introduction and Setup
1.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5
Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2. Operational Description
2.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4
Modification for 1/2 and 3/4 Horsepower . . . . . . . . . . . . . . . . . . . . . 22
2.5
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 3. Pin Descriptions
3.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3
Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1
40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2
Power Connectors J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.3
External Brake Connectors J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.4
Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Table of Contents
Section 4. Schematics and Parts List
4.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2
Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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Section 5. Design Considerations
User’s Manual
6
5.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3
Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4
Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5
Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6
Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7
Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9
Power Factor Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Figures
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Figure
Title
1-1
1-2
1-3
1-4
Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-Phase Switched Reluctance High-Voltage Power Stage . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PFC Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-1
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-1
40-Pin Ribbon Connector J14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-1
4-2
4-3
4-4
4-5
4-6
4-7
3-Phase HR High-Voltage Power Stage Overview . . . . . . . . . . . . . . 33
Gate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-Phase Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Current and Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Factor Correction and Brake Gage Drive . . . . . . . . . . . . . . . . 37
Identification Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bus Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Phase A Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PFC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PFC Zero Crossing Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3-Phase Switched Reluctance High-Voltage Power Stage
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List of Figures
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List of Figures
User’s Manual
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3-Phase Switched Reluctance High-Voltage Power Stage
List of Figures
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Tables
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Table
Title
2-1
2-2
2-3
2-4
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Resistor Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
JP801 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-1
Connector J14 Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-1
4-2
Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Printed Circuit Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-Phase Switched Reluctance High-Voltage Power Stage
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List of Tables
User’s Manual
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3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 1. Introduction and Setup
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1.1 Contents
1.2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5
Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Introduction
Motorola’s 3-phase, switched reluctance high-voltage power stage (HV SR
power stage) is a 115/230 volt, 180 watt (1/4 horsepower), off-line power stage
that is an integral part of Motorola’s embedded motion control series of
development tools. The HV SR power stage is supplied in kit number
ECPWRHiVSR.
In combination with one of the Embedded Motion Control series control boards
and an Embedded Motion Control series optoisolation board, it provides a ready
made software development platform for fractional horsepower off-line
switched reluctance motors. Feedback signals are provided that allow control
with a wide variety of algorithms. In addition, the HV SR power stage includes
an active power factor correction (PFC) circuit that facilitates development of
power factor correction algorithms.
An illustration of the systems architecture is shown in Figure 1-1. A line
drawing appears in Figure 1-2.
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Introduction and Setup
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Introduction and Setup
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Features of the HV SR power stage are:
•
1-phase bridge rectifier
•
Power factor switch and diode
•
dc-bus brake IGBT and brake resistors
•
3-phase bridge inverter (6-IGBT’s)
•
Individual phase and dc bus current sensing shunts with Kelvin
connections
•
Power stage temperature sensing diodes
•
IGBT gate drivers
•
Current and temperature signal conditioning
•
Board identification processor (MC68HC705JJ7)
•
Low voltage on-board power supplies
•
Cooling fans
EMULATOR
CONTROL BOARD
DSP EVM BOARD
WORKSTATION
WORKSTATION
OPTOISOLATION
BOARD
HIGH-VOLTAGE
POWER STAGE
HIGH-VOLTAGE
POWER STAGE
OPTOISOLATION
BOARD
MOTOR
a) MICROCONTROLLER
MOTOR
b) 56800 DSP
Figure 1-1. Systems’ Configurations
User’s Manual
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3-Phase Switched Reluctance High-Voltage Power Stage
Introduction and Setup
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Introduction and Setup
About this Manual
Figure 1-2. 3-Phase Switched Reluctance
High-Voltage Power Stage
1.3 About this Manual
Key items can be found in the following locations in this manual:
•
Setup instructions are found in 1.5 Setup Guide.
•
Schematics are found in Section 4. Schematics and Parts List.
•
Pin assignments for 40-pin connector J14 are shown in Figure 3-1.
•
A pin-by-pin description of input and output signals is contained in
3.3 Signal Descriptions.
•
For those interested in the reference design aspects of the board’s
circuitry, a description is provided in Section 5. Design Considerations.
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Introduction and Setup
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 DC laboratory power supply, unless
power factor correction is specifically being
investigated.
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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:
Because the probe grounds, it is subjected to dangerous voltages in the case of
a floated oscilloscope.
The user should be aware that:
User’s Manual
14
•
Before moving scope probes, making connections, etc., it is generally
advisable to power down the motor supply.
•
When high voltage is applied, using only one hand for operating the test
setup minimizes the possibility of electrical shock.
•
Operation in lab setups that have grounded tables and/or chairs should be
avoided.
•
Wearing safety glasses, avoiding ties and jewelry, using shields, and
operation by personnel trained in high voltage lab techniques are
advisable.
•
Power transistors, the PFC coil, and motor can reach temperatures hot
enough to cause burns.
•
When powering down; due to storage in the bus capacitors, dangerous
voltages are present until the power-on LED is off.
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Introduction and Setup
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Introduction and Setup
Setup Guide
1.5 Setup Guide
Setup and connections are very straightforward. The HV SR power stage
connects to an embedded motion control optoisolation board via a 40-pin ribbon
cable and can be powered either by a 140-volt to 230-volt dc power supply or
with line voltage. For both safety reasons and ease of making measurements, it
is strongly recommended that a dc supply is used, unless power factor
correction is specifically being investigated. The power supply should be
current limited to under 4 amps. Figure 1-3 depicts a completed setup.
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A step-by-step setup procedure is described as:
1. Plug one end of the 40-pin ribbon cable that comes with the optoisolator
kit into input connector J14. The other end of this cable goes to the
optoisolation board’s 40-pin output connector.
2. Connect motor leads to output connector J13 located along the back edge
of the top board. Phase A, phase B, and phase C are labeled Ph. A, Ph. B,
and Ph. C. There are two connections for each phase, to accommodate
the independent phase coil configuration that is used in switched
reluctance motors.
Mo t orola
Dav e’s
Co n tro l
Cen t er
M
Standoffs
Standoffs
- +
- +
- +
Ph
A
Ph
B
Ph
C
1
+12 VDC
+12
Vdc
40 Pin
Control
Board
40 Pin
Ribbon
Ribbon
4040Pin
Pin
Ribbon
Ribbon
Power Stage
Standoffs
Standoffs
Optoisolator
HighVoltage
Voltage
High
Motor Supply
Motor Supply
Figure 1-3. Setup
Figure 1-3. Setup
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Introduction and Setup
3. Connect earth ground to the earth ground terminals on the top board and
on the heat sink. The top board’s ground terminal is located in the front
left-hand corner, and is marked with a ground symbol. The heat sink has
a screw on its front edge that is also marked with a ground symbol.
4. Connect an isolated line, current limited dc power supply to connector
J11 located on the front edge of the top board. The input voltage range is
140 Vdc to 230 Vdc. Current limit should be set for less than 4 amps.
The dc supply’s polarity does not matter.
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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. One power input is all that is required.
CAUTION:
Operation from an ac power line is significantly more hazardous than operation
from a line isolated and current limited dc power supply.
An isolation transformer should be used when operating from an ac power line.
5. Setup the optoisolation and control boards.
6. The HV SR power stage is shipped with power factor correction (PFC)
disabled. If power factor correction is desired, it is necessary to remove
and re-solder power jumper JP201 from the no PFC position to the PFC
position. This jumper is found on the left side of the top board, between
the dc bus capacitor and PFC inductor. Circuit connections are illustrated
in Figure 1-4. For first time setups, operation without power factor
correction is recommended.
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:
WARNING:
User’s Manual
16
The optoisolation board powers the control board. The optoisolation board is
not fully powered until power is applied to the power stage.
Hazardous voltages are present. Please re-read all of the warnings in
1.4 Warnings carefully.
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Introduction and Setup
Setup Guide
Figure 1-4. PFC Jumper
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Introduction and Setup
User’s Manual
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Introduction and Setup
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 2. Operational Description
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2.1 Contents
2.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4
Modification for 1/2 and 3/4 Horsepower . . . . . . . . . . . . . . . . . . . . . 22
2.5
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Description
Motorola’s embedded motion control series high-voltage (HV) switched
reluctance (SR) power stage is a 180 watt (1/4 horsepower), 3-phase power
stage that will operate off of dc input voltages from 140 volts to 230 volts and
ac line voltages from 100 volts to 240 volts. In combination with one of
Motorola’s Embedded Motion Control Series control 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 controlling switched
reluctance motors.
Input connections are made via 40-pin ribbon cable connector J14. Pin
assignments for the input connector are shown in Figure 3-1. 40-Pin Ribbon
Connector J14. Power connections to the motor are made on output connector
J13. Phase A, phase B, and phase C are labeled Ph. A, Ph. B, Ph. C on the board.
Power requirements are met with a single external 140-volt to 230-volt dc
power supply or an ac line voltage. Either input is supplied through connector
J11. Current measuring circuitry is set up for 2.93 amps full scale. Both bus and
phase leg currents are measured. A cycle-by-cycle overcurrent trip point is set
at 2.69 amps.
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Operational Description
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The HV SR power stage has both a printed circuit board and a power substrate.
The printed circuit board contains IGBT gate drive circuits, analog signal
conditioning, low-voltage power supplies, power factor control circuitry, and
some of the large passive power components. This board also has a
MC68HC705JJ7 microcontroller used for board configuration and
identification. All of the power electronics that need to dissipate heat are
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/FROM
CONTROL
BOARD
GATE
DRIVERS
TO 3-PHASE
SR MOTOR
PHASE CURRENT
PHASE VOLTAGE
BUS CURRENT
MONITOR
BOARD
ID BLOCK
Figure 2-1. Block Diagram
User’s Manual
20
3-Phase Switched Reluctance High-Voltage Power Stage
Operational Description
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Operational Description
Electrical Characteristics
2.3 Electrical Characteristics
The electrical characteristics in Table 2-1 apply to operation at 25°C with a
160-Vdc supply voltage.
Table 2-1. Electrical Characteristics
Freescale Semiconductor, Inc...
Characteristic
Symbol
Min
Typ
Max
Units
DC input voltage
Vdc
140
160
230
V
AC input voltage
Vac
100
208
240
V
Quiescent current
ICC
—
70
—
mA
Min logic 1 input voltage
VIH
2.0
—
—
V
Max logic 0 input voltage
VIL
—
—
0.8
V
VOut
0
—
3.3
V
Bus current sense voltage
ISense
—
563
—
mV/A
Bus voltage sense voltage
VBus
—
8.09
—
mV/V
Peak output current
IPK
—
—
2.7
A
Brake resistor dissipation (continuous)
PBK
—
—
50
W
Brake resistor dissipation (15 sec pk)
PBK(Pk)
—
—
100
W
Pdiss
—
—
85
W
Analog output range
Total power dissipation
3-Phase Switched Reluctance High-Voltage Power Stage
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Freescale Semiconductor, Inc.
Operational Description
2.4 Modification for 1/2 and 3/4 Horsepower
The HV SR power stage can be modified to drive either 1/2 or 3/4 horsepower
motors. To change maximum output power these steps apply:
1. Remove power and wait until the power-on LED is off.
2. If PFC jumper JP201 is in the PFC position, remove and resolder it into
the no PFC position.
Freescale Semiconductor, Inc...
3. Make the resistor value changes shown in Table 2-2. These resistors set
current amplifier gains. For 1/2 and 3/4 horsepower motors, lower gains
allow for higher measured currents, and higher overcurrent trip points.
Table 2-2. Resistor Value
Resistors
1/4 HP
(180 W)
1/2 HP
(370 W)
3/4 HP
(550 W)
R303, R305, R307, R314,
R315, R318, R319, R322
75 kΩ
62 kΩ
56 kΩ
R301, R304, R311, R313,
R316, R317, R320, R321
10 kΩ
15 kΩ
16 kΩ
4. Configure identification coding jumper JP801 with the settings that are
indicated in Table 2-3. This procedure allows software to interpret the
new analog values correctly.
Table 2-3. JP801 Settings
Position
1/4 HP
(180 W)
1/2 HP
(370 W)
3/4 HP
(550 W)
1-2
Open
Short
Open
3-4
Open
Open
Short
5-6
Open
Open
Open
7-8
Open
Open
Open
5. For 3/4 horsepower motors it is also necessary to add an additional
470-µF/400-volt bus capacitor. To install the capacitor, it is first
necessary to remove PFC inductor L201. Mounting holes for the
additional capacitor are located within L201’s footprint. Note that it is
essential to orient the capacitor such that polarity is correct. Positive and
negative connections are indicated by + and – silk screened labels on the
board. In addition, the pad for the capacitor’s positive lead is square, and
the pad for its negative lead is round.
User’s Manual
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3-Phase Switched Reluctance High-Voltage Power Stage
Operational Description
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Operational Description
Fuse Replacement
Once these changes have been made, configuration for either 1/2 or 3/4
horsepower is complete.
2.5 Fuse Replacement
A fast-blow fuse is located on the front right-hand corner of the top board. If
this fuse has to be replaced these steps apply:
Freescale Semiconductor, Inc...
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.
4. Replace the protective case.
5. Set the controller’s speed control input to 0 RPM.
6. Apply power and resume operation.
Table 2-4. Fuse Ratings
Motor
Horsepower
RMS
Input Current
(Amps)
Fuse
Current Rating
(Amps)
Fuse
Voltage Rating
(Volts)
Fuse
Type
1/4
2.3
2.5
250
Fast blow
1/2
4.8
6.3
250
Fast blow
3/4
7.1
8
250
Fast blow
3-Phase Switched Reluctance High-Voltage Power Stage
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Operational Description
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User’s Manual
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Operational Description
User’s Manual
24
3-Phase Switched Reluctance High-Voltage Power Stage
Operational Description
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Freescale Semiconductor, Inc.
User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 3. Pin Descriptions
3.1 Contents
Freescale Semiconductor, Inc...
3.2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3
Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1
40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2
Power Connectors J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.3
External Brake Connectors J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.4
Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Introduction
There are four connectors on the top board for making input and output
connections. They are:
•
J11 — Power input connector
•
J12 — Brake connector
•
J13 — Motor output connector
•
J14 — 40-pin ribbon cable connector
Pin descriptions for each of these connectors are identified in this subsection.
Pin assignments for the 40-pin ribbon connector, J14, are shown in Figure 3-1.
In this figure, a schematic representation appears on the left, and a physical
layout of the connector appears on the right. The physical view assumes that
the board is oriented such that its title is read from left to right. Signal
descriptions are provided in Table 3-1.
3-Phase Switched Reluctance High-Voltage Power Stage
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Pin Descriptions
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User’s Manual
25
Freescale Semiconductor, Inc.
Pin Descriptions
3.3 Signal Descriptions
This subsection describes the signals.
3.3.1 40-Pin Ribbon Connector J14
Freescale Semiconductor, Inc...
Signal inputs are grouped together on a 40-pin ribbon cable connector, J14,
located on the right side of the board. Pin assignments are shown in Figure 3-1.
Signal descriptions are listed in Table 3-1.
3.3.2 Power Connectors J11
The power input connector, labeled J11, is located on the front edge of the
board. It will accept dc voltages from 140 to 230 volts, or an isolated ac line
input from 100 to 240 volts. In either case, the power source should be capable
of supplying at least 200 watts.
3.3.3 External Brake Connectors J12
An optional external brake resistor can be connected to external brake connector
J12, labeled Ext. Brake. The external resistor allows power dissipation to be
increased beyond the 50 watts that brake resistors R6–R9 provide.
User’s Manual
26
3-Phase Switched Reluctance High-Voltage Power Stage
Pin Descriptions
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Pin Descriptions
Signal Descriptions
J14
Shielding
Freescale Semiconductor, Inc...
PFC_z_c
PFC_inhibit
PFC_PWM
Serial_Con
Brake_control
Shielding
Temp_sense
I_sense_C
I_sense_B
I_sense_A
I_sense_DCB
V_sense_DCB
–15V_A
+15V_A
GNDA
GNDA
+3.3V_A
+5V_A
+5V_A
GND
GND
PWM_CB
Shielding
PWM_CT
Shielding
PWM_BB
Shielding
PWM_BT
Shielding
PWM_AB
Shielding
PWM_AT
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
PWM_AT
PWM_AB
PWM_BT
PWM_BB
PWM_CT
PWM_CB
GND_PS
+5V_D
GNDA
+15_A
V_sense_DCB
I_sense_A
I_sense_C
Brake_control
PFC_PWM
PFC_z_c
Shielding
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
Shielding
Shielding
Shielding
Shielding
Shielding
GND
+5V_D
+3.3V_A
GNDA
–15V_A
I_sense_DCB
I_sense_B
Temp_sense
Shielding
Serial_Con
PFC_inhibit
PHYSICAL VIEW
SCHEMATIC VIEW
Figure 3-1. 40-Pin Ribbon Connector J14
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Pin Descriptions
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Freescale Semiconductor, Inc.
Pin Descriptions
Table 3-1. Connector J14 Signal Descriptions
Signal Name
1
PWM_AT
PWM_AT is the gate drive signal for the top half-bridge of phase A. A logic high
turns phase A’s top switch on.
2
Shielding
Pin 2 is connected to a shield wire in the ribbon cable and ground on the board.
3
PWM_AB
PWM_AB is the gate drive signal for the bottom half-bridge of phase A. A logic high
turns phase A’s bottom switch on.
4
Shielding
Pin 4 is connected to a shield wire in the ribbon cable and ground on the board.
5
PWM_BT
PWM_BT is the gate drive signal for the top half-bridge of phase B. A logic high
turns phase B’s top switch on.
6
Shielding
Pin 6 is connected to a shield wire in the ribbon cable and ground on the board.
7
PWM_BB
PWM_BB is the gate drive signal for the bottom half-bridge of phase B. A logic high
turns phase B’s bottom switch on.
8
Shielding
Pin 8 is connected to a shield wire in the ribbon cable and ground on the board.
9
PWM_CT
PWM_CT is the gate drive signal for the top half-bridge of phase C. A logic high
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.
11
PWM_CB
PWM_CB is the gate drive signal for the bottom half-bridge of phase C. A logic high
turns phase C’s bottom switch on.
12
GND
Digital and power ground
13
GND
Digital and power ground, redundant connection
14
+5V digital
Digital +5-volt power supply
15
+5V digital
Digital +5-volt power supply, redundant connection
16
+3.3V analog
17
GNDA
Analog power supply ground
18
GNDA
Analog power supply ground, redundant connection
19
+15V_A
Analog +15-volt power supply
20
–15V_A
Analog –15-volt power supply
21
V_sense_DCB
V_sense_DCB is an analog sense signal that measures dc bus voltage. It is scaled
at 8.09 mV per volt of dc bus voltage.
22
I_sense_DCB
I_sense_DCB is an analog sense signal that measures dc bus current. It is scaled
at 0.563 V per amp of dc bus current.
Freescale Semiconductor, Inc...
Pin
No.
User’s Manual
28
Description
Analog +3.3-volt power supply
3-Phase Switched Reluctance High-Voltage Power Stage
Pin Descriptions
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Pin Descriptions
Signal Descriptions
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Table 3-1. Connector J14 Signal Descriptions (Continued)
Pin
No.
Signal Name
Description
23
I_sense_A
I_sense_A is an analog sense signal that measures current in phase A. It is scaled
at 0.563 V per amp of dc bus current.
24
I_sense_B
I_sense_B is an analog sense signal that measures current in phase B. It is scaled
at 0.563 V per amp of dc bus current.
25
I_sense_C
I_sense_C is an analog sense signal that measures current in phase C. It is scaled
at 0.563 V per amp of dc bus current.
26
Temp_sense
Temp_sense is an analog sense signal that measures power module temperature.
27
No connection
Pin 28 is connected to a shield wire in the ribbon cable and analog ground on the
board.
28
Shielding
29
Brake_control
30
Serial_Con
Serial_Con is an identification signal that lets the controller know which power
stage is present.
31
PFC_PWM
PFC_PWM is a digital signal that controls the power factor correction circuit’s
switch.
32
PFC_inhibit
PFC_inhibit is a digital signal that is used to enable or disable the power factor
correction circuit.
33
PFC_z_c
Brake_control is the gate drive signal for the brake IGBT.
PFC_z_c is a digital signal and its edges represent power line voltage 0 crossing
events.
34
No connection
35
No connection
36
No connection
37
Shielding
Pin 37 is connected to a shield wire in the ribbon cable and analog ground on the
board.
38
No connection
39
No connection
40
No connection
3-Phase Switched Reluctance High-Voltage Power Stage
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Pin Descriptions
3.3.4 Motor Output Connector J13
Freescale Semiconductor, Inc...
Power outputs to the motor are located on connector J13. Phase outputs are
labeled Ph. A, Ph. B, and Ph. C. Pin assignments are:
User’s Manual
30
•
Pin 1: Ph. A — Pin 1 supplies power to motor Phase A. It is connected
to bottom switch output signal Phase_AB. Either of the two phase A
motor leads may be connected here.
•
Pin 2: Ph. A — Pin 2 supplies power to motor Phase A. It is connected
to top switch output signal Phase_AT. Either of the two phase A motor
leads may be connected here.
•
Pin 3: Ph. B — Pin 3 supplies power to motor Phase B. It is connected to
bottom switch output signal Phase_BB. Either of the two phase B motor
leads may be connected here.
•
Pin 4: Ph. B — Pin 4 supplies power to motor Phase B. It is connected to
top switch output signal Phase_BT. Either of the two phase B motor
leads may be connected here.
•
Pin 5: Ph. C — Pin 5 supplies power to motor Phase C. It is connected to
bottom switch output signal Phase_CB. Either of the two phase C motor
leads may be connected here.
•
Pin 6: Ph. C — Pin 6 supplies power to motor Phase C. It is connected to
top switch output signal Phase_CT. Either of the two phase C motor
leads may be connected here.
3-Phase Switched Reluctance High-Voltage Power Stage
Pin Descriptions
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 4. Schematics and Parts List
Freescale Semiconductor, Inc...
4.1 Contents
4.2
Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Mechanical Characteristics
Mechanically, the HV SR 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
Switched Reluctance High-Voltage Power Stage. The aluminum circuit
board, fans, and heat sink provide the thermal capability surface mounted power
components. The FR-4 board contains control circuitry and through-hole
mounted power components. The two boards plug together via 10 vertical
connectors to, in effect, form a discrete power module.
Four holes on the top board are spaced to allow mounting standoffs such that a
control board can be placed on top of the power stage. This configuration allows
mounting control and power functions in one compact mechanical assembly.
3-Phase Switched Reluctance High-Voltage Power Stage
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Schematics and Parts List
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Schematics and Parts List
4.3 Schematics
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A set of schematics for the HV SR power stage appears in Figure 4-1 through
Figure 4-7.
•
An overview appears in Figure 4-1.
•
Output transistor gate drive is shown in Figure 4-2.
•
The 3-phase output stage appears in Figure 4-3.
•
Current and temperature feedback circuits are shown in Figure 4-4.
•
Power factor correction and brake gate drives are shown in Figure 4-5.
•
The identification block is shown in Figure 4-6.
•
The on-board power supply is shown in Figure 4-7.
Unless otherwise specified, resistors are 1/8 watt, have a ±5% tolerance, and
have values shown in ohms. Interrupted lines coded with the same letters are
electrically connected. Parts lists for the power substrate and printed circuit
board appear in Table 4-1 and Table 4-2.
User’s Manual
32
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
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FAN 2
J11
F1
2.5A/250V
Fast-Blow
R1
R/ivar SG-190
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
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i
Line
Input
D1
V14E250
Earth
Ground
J15
1
J10
CON/B
J1
CON/A
GND
+3.3V_A
+3.3V_A
GND
GNDA
+15V_D
GNDA
Earth_GND
Temp_sense_2
+15V_D
GNDA
I_sense_DCB2
I_sense_DCB1
100nF
J9
CON/E
+15V_A
+15V_D
+5V_D
J8
CON/E
J3
CON/B
J5
CON/D
GNDA
GND
J4
CON/C
Temp_sense_2
Source_CB
Gate_CB
Source_BB
Gate_BB
Source_AB
Gate_AB
DCB_Cap_pos
J6
CON/D
J2
CON/A
GNDA
+15V_D
-15V_A
+15V_A
+3.3V_A
+15V_D
+5V_D
+5V_D
6
J7
CON/D
GND
+FAN
-FAN
POWER
MODULE
GND
GNDA
HV_Drivers
PWM_CB
PWM_CT
PWM_BB
PWM_BT
PWM_AB
PWM_AT
GNDA
J13
1
2
3
4
5
6
Phase_AB
Phase_AT
Phase_BB
Phase_BT
Phase_CB
Phase_CT
Motor
Terminals
J12
1
2
Brake
GND
Figure 4-1. 3-Phase HR High-Voltage Power Stage Overview
I_T_Processing
Temp_sense_1
Temp_sense_2
Shut_Down_Open C.
Temp_sense
I_sense_C
I_sense_B
I_sense_A
I_sense_DCB
1
2
3
4
5
6
I_sense_A2
I_sense_A1
C2
DCB_PFC_1
DCB_PFC_2
1
2
3
4
I_sense_B2
I_sense_B1
GND
GNDA
4
5
6
FAN 2
1
PFC_DC_BUS_BRAKE
20
19
18
17
PFC_gate
PFC_Source
1
2
3
4
I_sense_C2
I_sense_C1
+5V_D
Power_pos
100nF
PFC_z_c
PFC_enable
PFC_PWM
Brake_control
12
11
10
9
V_sense_DCB_5
V_sense_DCB_half_15
4
3
2
1
+5V_D
+15V_D
+15V_A
PFC_I_sense_1
1
2
3
4
5
6
1
2
3
Brake_gate
1
6
+3.3V_A
C1
Shut_Down
8
9
10
DCB_Cap_neg
1
2
3
Gate_CT
Source_CT
-FAN
Gate_BT
Source_BT
1
2
3
4
+15V_D
SMPS
9
10
11
12
8
9
10
+5V_D
+15V_D
Power_neg
+FAN
GND
+15V_A
-15V_A
6
17
18
19
20
1
2
3
Gate_AT
Source_AT
-FAN
+FAN
8
9
10
MOTOROLA
2
1
Freescale Semiconductor, Inc...
+3.3V_A
+5V_D
GND
GNDA
GNDA
GND
+5V_D
-15V_A
+15V_A
Identification
Identification
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J14
GND
PWM_CB
Shielding
PWM_CT
Shielding
PWM_BB
Shielding
PWM_BT
Shielding
PWM_AB
Shielding
PWM_AT
Temp_sense
I_sense_C
I_sense_B
I_sense_A
I_sense_DCB
V_sense_DCB
PFC_z_c
PFC_inhibit
PFC_PWM
Serial_Con
Brake_control
Sheilding
Sheilding
+5V_D
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Schematics and Parts List
Schematics
User’s Manual
33
User’s Manual
34
Schematics and Parts List
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GND
+5V_D
+15V_D
PWM_CB
PWM_CT
PWM_BB
PWM_BT
PWM_AB
PWM_AT
C423
1nF
C421
1nF
C419
1nF
GND
VCC
R412
10k
GND
R411
10k
+15V_D
R408
10k
GND
R407
10k
R404
10k
GND
R403
10k
+5V_D
C424
1nF
C422
1nF
8
9
12
13
GND
10nF
C425
U404F
DM74ALS1034M
10
11
U404E
DM74ALS1034M
U404D
DM74ALS1034M
6
5
U404C
DM74ALS1034M
U404B
DM74ALS1034M
4
3
VCC
C420
1nF
2
1
U404A
DM74ALS1034M
Shut_Down
GND
+
IR2112S
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
U401
IR2112S
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
U402
IR2112S
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
U403
C415 8.2pF
9
10
11
12
13
14
15
16
C414 8.2pF
9
10
11
12
13
14
15
16
C413 8.2pF
9
10
11
12
13
14
15
16
HO
VB
VS
n/c
n/c
VCC
COM
LO
HO
VB
VS
n/c
n/c
VCC
COM
LO
+5V_D
HO
VB
VS
n/c
n/c
VCC
COM
LO
+5V_D
+5V_D
Figure 4-2. Gate Drive
GND
+
C410
4.7uF/16V
+5V_D
C409
100nF
100
R413
GND
+
C406
4.7uF/16V
+5V_D
C405
100nF
R414
10k
+5V_D
C401
100nF
C402
4.7uF/16V
+5V_D
C412
470nF/50V
8
7
6
5
4
3
2
1
+
C416
33uF/25V
C417
33uF/25V
GND
+
C418
33uF/25V
D413
MURS160T3
GND
C411
470nF/50V
C408
470nF/50V
8
7
6
5
4
3
2
1
GND
+
D408
C407
MURS160T3
470nF/50V
C404
470nF/50V
8
7
6
5
4
3
2
1
D401
C403
MURS160T3
470nF/50V
Freescale Semiconductor, Inc...
+15V_D
+15V_D
+15V_D
D414
D411
D409
D406
D404
D402
R410
120
R409
120
R406
120
R405
120
R402
120
R401
120
Gate_AT
Gate_AB
Source_AT
Gate_BT
Source_AB
Gate_BB
Source_BT
Gate_CT
Source_BB
Gate_CB
Source_CT
Source_CB
D415
MMSZ5251BT1
MBRS130LT3
D412
MMSZ5251BT1
MBRS130LT3
D410
MMSZ5251BT1
MBRS130LT3
D407
MMSZ5251BT1
MBRS130LT3
D405
MMSZ5251BT1
MBRS130LT3
D403
MMSZ5251BT1
MBRS130LT3
Freescale Semiconductor, Inc.
Schematics and Parts List
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
D9
10ETS08S
R5
0.075 1%
D10
10ETS08S
Source_PFC
Gate_PFC
I_Sense_PFC1
D14
BAV99LT1
D13
BAV99LT1
J1
SM/CON/MCRD_SR_500_A - male
sense
AC_IN_L2
Q8
I_Sense_PFC2
MTB8N50E
DC_BUS_IN
AC_IN_L1
DC_BUS_OUT
1
2
3
4
AC_IN_L1
9
10
11
12
R6
250
R9
250
Temp_sense2
Temp_sense1
J2
SM/CON/MCRD_SR_500_A - male
R4
0.075 1%
I_Sense_DCB1
I_Sense_DCB2
R1
0.075 1%
Gate_BT
R2
0.075 1%
Gate_CT
Q5
SGB10N60
I_sense_C2
I_sense_C1
Gate_CB
Source_CB
sense
sense
D5
HFA16TA60CS
Phase_CT
Phase_CB
J4
SM/CON/MCRD_SR_500_C - male
sense
sense
Q4
SGB10N60
D4
HFA16TA60CS
J6
SM/CON/MCRD_SR_500_D - male
I_sense_B2
I_sense_B1
Gate_BB
Source_BB
Figure 4-3. 3-Phase Output
Q3
SGB10N60
D3
HFA16TA60CS
Phase_BT
Phase_BB
J10
SM/CON/MCRD_SR_500_B - male
sense
sense
Q2
SGB10N60
D2
HFA16TA60CS
J9
SM/CON/MCRD_SR_500_E - male
I_sense_A2
I_sense_A1
Gate_AB
Source_AB
J3
SM/CON/MCRD_SR_500_B - male
Q1
SGB10N60
D1
HFA16TA60CS
Phase_AT
Phase_AB
Gate_AT
D11
HFA08TB60S
Q7
SGB10N60
R8
250
R7
250
J8
SM/CON/MCRD_SR_500_E - male
DCB_Cap_Neg
Gate_Brake
Brake_Res
DCB_Cap_Neg
sense
AC_IN_L2
17
18
19
20
DCB_Cap_Pos
1
2
3
4
sense
HFA08TB60S
Gate_CB
Source_CB
I_sense_C2
I_sense_C1
9
10
11
12
sense
Gate_PFC
Source_PFC
Temp_sense2
I_Sense_PFC2
1
2
3
4
17
18
19
20
I_Sense_PFC1
Temp_sense1
D8
10ETS08S
Gate_BB
Source_BB
I_sense_B2
I_sense_B1
1
2
3
4
5
6
I_Sense_DCB2
I_Sense_DCB1
Gate_AB
Source_AB
I_sense_A2
I_sense_A1
D7
10ETS08S
Phase_BB
1
2
3
DC_BUS_IN
R3
0.075 1%
Q6
SGB10N60
D6
HFA16TA60CS
J5
SM/CON/MCRD_SR_500_D - male
J7
SM/CON/MCRD_SR_500_D - male
Phase_BT
DCB_Cap_Pos
Gate_BT
6
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
1
2
3
4
Brake_Res
8
9
10
1
2
3
4
5
6
Gate_Brake
1
Phase_AB
1
2
3
D12
Gate_AT
DC_BUS_OUT
Phase_AT
4
5
6
Phase_CB
1
2
3
Gate_CT
6
Phase_CT
8
9
10
MOTOROLA
6
3-Phase Switched Reluctance High-Voltage Power Stage
8
9
10
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
Schematics and Parts List
Schematics
User’s Manual
35
C307
100nF
+3.3V_A
GNDA
I_sense_C2
I_sense_C1
I_sense_B2
I_sense_B1
I_sense_A2
I_sense_A1
GND
GNDA
+
C306
3.3uF/10V
GNDA
5
R325
33.2k-1%
3
2
1
I_sense_C
(1.65V +/- 1.65V @ +/- Imax)
U301B
MC33502D
7
I_sense_B
-
+
C303
680pF
I_sense_DCB2
Over-curent
threshold =
3.15V
R310
470
R317 10k-1%
R316 10k-1%
DC Bus Current
Sensing
GNDA
+3.3V_A
6
5
-
+
GND
3
2
1
GNDA
C305
100nF
+3.3V_A
U302A
MC33502D
GNDA
I_sense_DCB
I_sense_DCB
Shut_Down_Open C.
Temp_sense
(1.65V +/- 1.65V @ +/- Imax)
LM393D
7
U303B
+15V_D
C301
100nF
R315 75k-1%
R319
75k-1%
GNDA
R312
10k
R309
1.2k
Temp_sense_1
2.21k-1%
R302
+3.3V_A
R306 680k
Temperature
Sensing
Temp_sense_2
Overcurrent
Detection
LM393D
1
U303A
R308
1.2k
GND
I_sense_DCB1
I_sense_DCB
GNDA
2
3
+15V_D
Figure 4-4. Current and Temperature Feedback
R322
75k-1%
5
6
R318 75k-1%
GNDA
C304
100nF
+3.3V_A
U301A
MC33502D
GNDA
I_sense_A
(1.65V +/- 1.65V @ +/- Imax)
U302B
MC33502D
7
R307 75k-1%
5
6
R303 75k-1%
Phase Current
Sensing
R314
75k-1%
R305
75k-1%
R324
100k-1%
GNDA
1.65V ref
R321 10k-1%
R320 10k-1%
R313 10k-1%
R311 10k-1%
R304 10k-1%
R301 10k-1%
GND
U304
LM285M
R323 390
GND
GNDA
C302
10nF
+15V_D
8
4
+3.3V_A
8
+15V_D
8
4
8
+
-
+3.3V_A
8
+
-
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
4
4
+
-
+
36
-
User’s Manual
4
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
Schematics and Parts List
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
DCB_Cap_neg
Earth_GND
DCB_Cap_pos
DCB_PFC_1
PFC_enable
PFC_PWM
GND
2
1
GND
3
C204
10nF
3
1
JP201
PFC Jumper
3.92k-1%
R201
6.8nF
C201
C208
22nF/630VDC
C214
10nF/3000V
R224
274k-1%
C207
22nF
C205
R212
681-1%
-
+
GND
5
LM393D
U203A
R226
4.87k-1%
R227
274k-1%
33k
R219
R228
6.81k-1%
R230
6.81k-1%
GNDA
9
+15V_D
33k
R221
C211
1nF
V_sense_DCB_half_15
33k
R220
Zero Crossing
Detection
GND
C212
1nF
Brake Gate Drive
R202
3.3k
8
GNDA
R222
10k
GND
GNDA
R223
10k
ref_l = 11.72V
ref_h = 11.76V
R217
2.7k
5
7
8
6
5
-
+
GND
100
GND
LM393D
U203B
7
Brake_gate
PFC_Source
U201D
R218
4.7k
11
PFC_z_c
D201
MMSZ5251BT1
+5V_D
GND
GND
PFC_gate
D202
MMSZ5251BT1
MC74VHCT00AD
13
12
R213
10k
R204
33
R210
+15V_D
R216 270k
OutB
OutA
NC
C203
100nF GND
GND
+15V_D
MC33152D
4 InB
C202
10uF/35V
VCC
+15V_D
U202
NC
2 InA
1
D203
SM/1N4148
GND
MC74VHCT00AD R211
10k
10
V_sense_DCB
(3.24V @ DC-Bus = 400V)
R229
255-1%
6
U201C
PFC Gate Drive
MC74VHCT00AD
U201B
Brake_control
4
R208
10k
+5V_D
1
GND
C206
10nF
DCB_PFC_2
2
3
+15V_D
R206 100k
Bus Voltage
Sensing
274k-1%
R225
GNDA
4.9mH/2.3A
L201
10k-1%
R209
R207
12.1k-1%
22nF
1k-1%
R205
+15V_A
R203
68.1-1%
Figure 4-5. Power Factor Correction and Brake Gage Drive
C209
470uF/400V
+
no PFC
(default setting)
2
PFC
PFC Option:
MC74VHCT00AD
U201A
GND
C213
10nF/3000V
R215
10k
GND
R214
3.3k
GND
GNDA
+15V_A
+15V_A
GNDA
+15V_D
+15V_D
PFC_I_sense_1
+
+5V_D
VCC
8
4
6
3
+5V_D
8
MOTOROLA
4
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
Schematics and Parts List
Schematics
User’s Manual
37
User’s Manual
38
GND
+5V_D
Identification
GND
+5V_D
+5V_D
GND
C801 +
10uF/6.3V
GND
4MHz
X801
R801
+5V_D
20
14
15
16
17
11
12
13
18
PB0
IRQ
RESET
OSC2
OSC1
PA2
PA1
PA0
GND
7
6
5
4
3
2
1
10
9
8
3
2
1
Coding bit #
R802 R803
10k
10k
Figure 4-6. Identification Block
GND
+5V_D
19
+5V_D
PB7
PB6
PB5
PB4/TCMP
PB3/TCAP
PB2/AN2
PB1/AN1
U801
PA3
PA4
PA5
VCC
MC68HC705JJ7DW_MOD
Coding bit #
0
10k
C802
10nF
R804 R805
10k
10k
SM/JUMPER4x2
7
5
3
1
JP801
8
6
4
2
Coding bit #
7
6
5
4
GND
DEFAULT SETTINGS:
0 - PTB0 = H
1 - PTB1 = H
2 - PTB2 = L
3 - PTB3 = H
4 - PTB4 = H
5 - PTB5 = H
6 - PTA6 = H
7 - PTA7 = H
+5V_D
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
Schematics and Parts List
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
MOTOROLA
+15V_A
-15V_A
+15V_A
-15V_A
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
GND
R113
27
2
1
R109
2.21k/1%
R106
2.21k/1%
R110
27
C124
100pF/500V
-FAN
-FAN
Power_pos
+FAN
GND
+FAN
GND
GND
C123
100nF
+15V_D
+15V_D
GNDA
+5V_D
+5V_D
GNDA
+3.3V_A
+3.3V_A
Power_neg
Power_pos
S
6
S
S
3
7
U103
TNY254P
8
EN
S
Drain
R112
27
S
8
100nF
C116
820
R105
R104
270
1
R111
27
BP
FB
7
6
Power_pos
1
2
4
5
R102
1.0k
4
3
3
4
1
2
2
S
D
C122
100uF/16V
C
3
GND
R114
1.0k
D107
MMSZ5242BT1
+
D106
MBRS1100T3
1
MBRS1100T3
C111
33uF/25V
GND
+
D103
MURS160T3
D102
D100
P6SMB200AT3
-FAN
+FAN
U102
TOP202YAI
GND
GREEN LED
+
+5V_D
+17V_D
GND
C126
100nF
+
+
+17V_D
GNDA C112
100nF
8
VIN VOUT
2 3
6 7
1
1
GND
C127
100nF
+15V_D
-15V_A
C114
100nF
GNDA
+15V_A
GNDA
10uF/6.3V
+ C104
C110
100nF
MBR0530T1
U107
MC79L15ACD
Vin Gnd
Vin
Vin Vout
Vin
D112
7
6
3
2
5
VIN VOUT
2 3
6 7
1
MBR0530T1
-CE
+3.3V_A
MBR0530T1
U110
MC78PC33NTR
5
Vin Vout
U106
MC78L15ACD
MBR0530T1
8
U108
MC78L15ACD
D111
C129
33uF/25V
+
C109
100nF
3
1
D109
C105
100nF
D110
GC101
Ground_Connection
+
C128
10uF/6.3V
D108
MMSZ5231BT1
33uF/25V
+
C107 C108
C113
33uF/25V
GND
MBRS1100T3
D105
+
33uF/25V
MBRS1100T3
D104
+
FB
C102 C103
GND
220uF/10V 220uF/10V
C101
220uF/10V
D113
R115
330
3
4
D101
MBRD660CT
1
+5V_D
SM/Trafo_EFD20/12PIN
7
8
5
6
9
10
4
3
12
11
T100
2
1
Figure 4-7. Power Supply
C125 1nF/1kV
U104
SFH6106
7
6
9
4
8
10
3
5
11
2
GND
47uF/16V
+ C117
R108
56
R103
1.0k
C100
10pF/500V
T101
SM/Trafo_EFD15/12PIN
1
12
U101
TL431BCD
U100
SFH6106
R101
1.0k
R100
1.0k
Power_pos
3
2
GND
MOTOROLA
2
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
Schematics and Parts List
Schematics
User’s Manual
39
Freescale Semiconductor, Inc.
Schematics and Parts List
4.4 Parts Lists
The HV SR power stage’s parts content is described in Table 4-1 for the power
substrate and in Table 4-2 for the printed circuit board.
Table 4-1. Power Substrate Parts List
Freescale Semiconductor, Inc...
Qty
Reference
Description
Manufacturer
Part #
6
D1, D2, D3,
D4, D5, D6
8A/600V Ultrafast Rectifier
International Rectifier
HFA08TB60S
4
D7, D8, D9, D10
10A/800V Rectifier
International Rectifier
10ETS08S
2
D11, D12
8A/600V Ultrafast Rectifier
International Rectifier
HFA08TB60S
2
D14, D13
Dual Diode – Temp Sensing
On Semiconductor
BAV99LT1
2
J1, J2
SM/CON/MCRD_SR_500_A — male
Fisher Elektronik
SL 11 SMD 104 20Z
2
J3, J10
SM/CON/MCRD_SR_500_B — male
Fisher Elektronik
SL 10 SMD 104 6Z
1
J4
SM/CON/MCRD_SR_500_C — male
Fisher Elektronik
SL 10 SMD 104 6Z
3
J5, J6, J7
SM/CON/MCRD_SR_500_D — male
Fisher Elektronik
SL 10 SMD 104 10Z
2
J8, J9
SM/CON/MCRD_SR_500_E — male
Fisher Elektronik
SL 10 SMD 104 4Z
7
Q1, Q2, Q3, Q4,
Q5, Q6, Q7
10A/600V IGBT
Infineon
SGB10N60
1
Q8
8A/500V MOSFET
On Semiconductor
MTB8N50E
Table 4-2. Printed Circuit Board Parts List (Sheet 1 of 5)
Qty
Reference
Description
Part #
Manufacturer
C1, C2, C105,
C109, C110, C112,
C114, C116, C123,
19 C126, C127, C203, 100nF/25V
C301, C304, C305,
C307, C401, C405,
C409
Vitramon
VJ0805U104MXXA_
1
C100
Vishay Sprague
Typ:5GAQ10, Serie: 562C
3
C101, C102, C103 220uF/10V
AVX
TPSE227K010R0100
3
C104, C128, C801 10uF/6.3V
Sprague
293D106X_6R3B2_
8
C107, C108, C111,
C113, C129, C416, 33uF/25V
C417, C418
AVX
TPSE336K025R0200
User’s Manual
40
10pF/500V
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
MOTOROLA
Freescale Semiconductor, Inc.
Schematics and Parts List
Parts Lists
Table 4-2. Printed Circuit Board Parts List (Sheet 2 of 5)
Freescale Semiconductor, Inc...
Qty
Reference
Description
Part #
Manufacturer
1
C117
47uF/16V
Any available
1
C122
100uF/16V
AVX
TPSE107K016R0100
5
C204, C206, C302,
10nF
C425, C802
Vitramon
VJ0805U103MXXA_
1
C124
100pF/500V
Vishay Sprague
Typ:5GAT10, Serie: 562C
1
C125
1nF/1kV
muRata
DE0505E102Z1K
1
C201
6.8nF
Vitramon
VJ0805A682JXA_
1
C202
10uF/35V
Sprague
293D106X_035D2_
2
C207, C205
22nF
Vitramon
VJ0805A223JXA_
1
C208
22nF/630VDC
WIMA
MKP10
1
C209
470uF/400V
Philips Components
15746471
8
C211, C212, C419,
C420, C421, C422, 1nF
C423, C424
Vitramon
VJ0805A102JXA_
2
C213, C214
10nF/ 3000V
Thomson
5ST410MCMCA
1
C303
680pF
Vitramon
VJ0805A681JXA_
1
C306
3.3uF/10V
Sprague
293D335X_010A2_
3
C402, C406, C410 4.7uF/16V
Sprague
293D475X_016B2_
6
C403, C404, C407,
470nF/50V
C408, C411, C412
Vitramon
VJ1206U474MXAA_
3
C413, C414, C415 8.2pF
Vitramon
VJ0805A8R2DXA_
1
D1
Disk Varistor
EPCOS
SOIV-S-10K250
1
D100
Transient Suppressor
On Semiconductor
P6SMB200AT3
1
D101
6A/60V Shottky
On Semiconductor
MBRD660CT
4
D102, D401, D408,
1A/600V Ultrafast
D413
On Semiconductor
MURS160T3
4
D103, D104, D105,
1A/100V Schottky
D106
On Semiconductor
MBRS1100T3
1
D107
12V Zener
On Semiconductor
MMSZ5242BT1
1
D108
5.1V Zener
On Semiconductor
MMSZ5231BT1
4
D109, D110, D111,
.0.5A/30V Schottky
D112
On Semiconductor
MBR0530T1
1
D113
Kingbright
L-934GT
Green LED
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Schematics and Parts List
For More Information On This Product,
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User’s Manual
41
Freescale Semiconductor, Inc.
Schematics and Parts List
Table 4-2. Printed Circuit Board Parts List (Sheet 3 of 5)
Freescale Semiconductor, Inc...
Qty
Reference
Description
Part #
Manufacturer
8
D201, D202, D403,
D405, D407, D410, 22V Zener
D412, D415
On Semiconductor
MMSZ5251BT1
1
D203
FairChild
1N4148LL-34
6
D402, D404, D406,
1A/30V Schottky
D409, D411, D414
On Semiconductor
MBRS130LT3
1
F1
Fuse Holder
MULTICOMP
MCHTE15M
1
JP201
Power Jumper
—
Wire, D = 1.5mm, L = 12mm
1
JP801
4X2 Jumper Pads
—
—
2
J2, J1
20 Pin Female Header
Fisher Elektronik
BL 2 20Z
2
J3, J10
6 Pin Female Header
Fisher Elektronik
BL 1 6Z
1
J4
6 Pin Female Header
Fisher Elektronik
BL 1 6Z
3
J5, J6, J7
10 Pin Female Header
Fisher Elektronik
BL 1 10Z
2
J9, J8
4 Pin Female Header
Fisher Elektronik
BL 1 4Z
2
J11, J12
2 Pole Terminal Block
Weidmuller
LP 7.62/2/90
1
J13
3 Pole Terminal Block
Weidmuller
LP 7.62/3/90 — see note!
1
J14
40 Pin Connector —
male
Fischer Elektronik
ASLG40G
1
L201
4.9mH/2.3A
Thompson Television Compon. SMT4 ref G6982-01
1
R1
Inrush Limiter
Rhopoint Components
SG190
4
R100, R101, R102,
1.0k
R103
Dale
CRCW1206-102J
1
R104
270_
Dale
CRCW0805-271J
1
R105
820_
Dale
CRCW0805-821J
2
R106, R109
2.21k–1%
Any available
—
1
R108
56_
Any available
—
4
R110, R111, R112,
27_
R113
Dale
CRCW1206-270J
1
R114
1.0k
Dale
CRCW0805-102J
1
R115
330_
Dale
CRCW0805-331J
1
R201
3.92k–1%
Any available
User’s Manual
42
SMD/1N4148
—
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
Go to: www.freescale.com
MOTOROLA
Freescale Semiconductor, Inc.
Schematics and Parts List
Parts Lists
Table 4-2. Printed Circuit Board Parts List (Sheet 4 of 5)
Freescale Semiconductor, Inc...
Qty
Reference
Description
Part #
Manufacturer
R208, R211, R213,
R215, R223, R312,
R403, R404, R407,
10k
18
R408, R411, R412,
R414, R801, R802,
R803, R804, R805
Dale
CRCW0805-103J
2
R202, R214
3.3k
Dale
CRCW0805-332J
1
R203
68.1–1%
Any available
2
R204, R413
100_
Dale
CRCW0805-101J
1
R206
100k
Dale
CRCW0805-104J
1
R207
12.1k–1%
Any available
1
R210
33_
Dale
1
R212
681_–1%
Any available
1
R216
270k
Dale
CRCW0805-274J
1
R217
2.7k
Dale
CRCW0805-272J
1
R218
4.7k
Dale
CRCW0805-472J
1
R219
33k
Dale
CRCW0805-333J
2
R220, R221
33k
Dale
CRCW0805-333J
1
R222
10k
Dale
CRCW0805-103J
3
R224, R225, R227 274k–1%
Any available
—
1
R226
4.87k–1%
Any available
—
2
R228, R230
6.81k–1%
Any available
—
1
R229
255_–1%
Any available
—
9
R209, R301, R304,
R311, R313, R316, 10k–1%
R317, R320, R321
Dale
1
R302
2.21k–1%
Any available
1
R205
1k–1%
Dale
CRCW0805-102F
8
R303, R305, R307,
R314, R315, R318, 75k–1%
R319, R322
Dale
CRCW0805-753F
1
R306
680k
Dale
CRCW0805-684J
2
R308, R309
1.2k
Dale
CRCW0805-122J
1
R310
470_
Dale
CRCW0805-471J
1
R323
390_
Dale
CRCW0805-391J
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Schematics and Parts List
For More Information On This Product,
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CRCW0805-330J
CRCW0805-103F
User’s Manual
43
Freescale Semiconductor, Inc.
Schematics and Parts List
Table 4-2. Printed Circuit Board Parts List (Sheet 5 of 5)
Freescale Semiconductor, Inc...
Qty
Reference
Description
Part #
Manufacturer
1
R324
100k–1%
Dale
1
R325
33.2k–1%
Any available
6
R401, R402, R405,
120_
R406, R409, R410
Dale
CRCW0805-121J
1
T100
SMPS Transformer
Tronic Praha s.r.o
TRONIC 99 060 09
1
T101
SMPS Transformer
Tronic Praha s.r.o
TRONIC 00 003 73
2
U100, U104
Optocoupler
Infineon
SFH6106-2
1
U101
Voltage Reference
On Semiconductor
TL431BCD
1
U102
SMPS Controller
Power Integration
TOP202YAI
1
U103
SMPS Controller
Power Integration
TNY254P
2
U108, U106
15V Voltage Regulator
On Semiconductor
MC78L15ACD
1
U107
–15V Voltage Regulator
On Semiconductor
MC79L15ACD
1
U110
3.3V Voltage Regulator
On Semiconductor
MC78PC33NTR
1
U201
Quad NAND Gate
On Semiconductor
MC74VHCT00AD
1
U202
Gate Driver
On Semiconductor
MC33152D
2
U203, U303
Dual Comparator
On Semiconductor
LM393D
2
U301, U302
Rail-to-Rail Op Amp
On Semiconductor
MC33502D
1
U304
Voltage Reference
National Semiconductor
LM285M
3
U401, U402, U403 Gate Driver
International Rectifier
IR2112S
1
U404
Fairchild
DM74ALS1034M
1
U801
Motorola
MC68HC708JJ7CDW
1
X801
muRata
CSTCC4.00MG
1
Hex Driver
Programmed MCU
4MHz Resonator
—
CRCW0805-104F
—
—
Sticker
0
R107
NOT POPULATED
—
—
0
C115, C210
NOT POPULATED
—
—
User’s Manual
44
3-Phase Switched Reluctance High-Voltage Power Stage
Schematics and Parts List
For More Information On This Product,
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MOTOROLA
Freescale Semiconductor, Inc.
User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 5. Design Considerations
Freescale Semiconductor, Inc...
5.1 Contents
5.2
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3
Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4
Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5
Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6
Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7
Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9
Power Factor Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Overview
From a systems point of view, the HV SR power stage fits into an architecture
that is designed for software development. In addition to the hardware that is
needed to run a motor, a variety of feedback signals that facilitate control
algorithm development and a PFC circuit are provided.
Circuit descriptions for the HV SR power stage appear in this subsection.
5.3 Phase Outputs
The output stage is configured as a dual output per phase, 3-phase, bridge with
IGBT output transistors. It is simplified considerably by high-voltage integrated
gate drivers that have a cycle-by-cycle current limit feature. A schematic that
shows one phase is illustrated in Figure 5-1.
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
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User’s Manual
45
User’s Manual
46
Shut_Down
PWM_AB
PWM_AT
C419
1nF
R404
10k
GND
R403
10k
C420
1nF
4
3
U404B
DM74ALS1034M
2
1
U404A
DM74ALS1034M
R414
10k
Design Considerations
For More Information On This Product,
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100
R413
GND
+
IR2112S
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
U401
C413 8.2pF
9
10
11
12
13
14
15
16
+5V_D
HO
VB
VS
n/c
n/c
VCC
COM
LO
C404
470nF/50V
8
7
6
5
4
3
2
1
GND
+
C416
33uF/25V
D401
C403
MURS160T3
470nF/50V
Figure 5-1. Phase A Output
+5V_D
C401
100nF
C402
4.7uF/16V
+5V_D
D404
Q1
SGB10N60
DCB_Cap_Neg
I_sense_A2
I_sense_A1
sense
sense
D1
HFA16TA60CS
D405
MMSZ5251BT1
MBRS130LT3
D403
MMSZ5251BT1
MBRS130LT3
R401
120
R402
120
+15V_D
D402
DCB_Cap_Pos
Freescale Semiconductor, Inc...
R1
0.075 1%
Q2
SGB10N60
D2
HFA16TA60CS
Phase_AB
Phase_AT
Freescale Semiconductor, Inc.
Design Considerations
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Freescale Semiconductor, Inc.
Design Considerations
Phase Outputs
Freescale Semiconductor, Inc...
At the input, pull down resistors, R403 and R404, set a logic low in the absence
of a signal. Open input pull down is important, since it is desirable to keep the
power transistors off in case of either a broken connection or absence of power
on the control board. The drive signal is buffered by U404A and U404B. This
part has a minimum logic 1 input voltage of 2.0 volts and maximum logic 0
input voltage of 0.8 volts, which allows for inputs from either 3.3-volt or 5-volt
logic. Gate drive is supplied by an International Rectifier IR2112.
Under-voltage lockout and cycle-by-cycle current limiting are also provided by
the IR2112. Under-voltage lockout is set nominally at 8.4 volts. Current
limiting is discussed further in 5.5 Cycle-by-Cycle Current Limiting.
One of the more important design decisions in a motor drive is selection of gate
drive impedance for the output transistors. In Figure 5-1, resistor R402, diode
D404, and the IR2112’s nominal 500-mA current sinking capability determine
gate drive impedance for the lower half-bridge transistor. A similar network is
used on the upper half-bridge. These networks set turn-on gate drive
impedance at approximately 120 ohms, and turn-off gate drive to approximately
500 mA. These values produce transition times of approximately 200 ns.
Transition times of this length represent a carefully weighed compromise
between power dissipation and noise generation. Generally speaking, transition
times longer than 250 ns tend to get power hungry at non-audible PWM rates;
and transition times under 50 ns create di/dt’s so large that proper operation is
difficult to achieve. The HV SR power stage is designed with switching times
at the higher end of this range to minimize noise.
Anti-parallel diode softness is also a first order design consideration. If the
anti-parallel diodes in an off-line motor drive are allowed to snap, the resulting
di/dt’s can cause noise management problems that are difficult to solve. In
general, it is desirable to have peak to zero di/dt approximately equal the applied
di/dt that is used to turn the anti-parallel diodes off. The HFA16TA60CS soft
recovery rectifiers that are used in this design are targeted at this kind of reverse
recovery characteristic.
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
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User’s Manual
47
Freescale Semiconductor, Inc.
Design Considerations
5.4 Bus Voltage and Current Feedback
Freescale Semiconductor, Inc...
Feedback signals proportional to bus voltage and bus current are provided by
the circuitry shown in Figure 5-2. Bus voltage is scaled down by a voltage
divider consisting of R224–R230. The values are chosen such that a 400-volt
maximum bus voltage corresponds to 3.24 volts at output V_sense_DCB. An
additional output, V_sense_DCB_half_15 provides a reference that is used in
zero crossing detection.
Bus current is sampled by resistor R4 in Figure 4-3. 3-Phase Output and
amplified by the circuit in Figure 5-2. This circuit provides a voltage output
suitable for sampling with A/D inputs. An MC33502 is used for the differential
amplifier. With R315 = R319 and R316 = R317, the gain is given by:
A = R315/R316
The output voltage is shifted up by 1.65 V to accommodate both positive and
negative current swings. A ±3000 mV voltage drop across the sense resistor
corresponds to a measured current range of ±2.93 amps. In addition to
providing an A/D input, this signal is also used for cycle-by-cycle current
limiting. A discussion of cycle-by-cycle current limiting follows in
5.5 Cycle-by-Cycle Current Limiting.
5.5 Cycle-by-Cycle Current Limiting
Cycle-by-cycle current limiting is provided by the circuitry illustrated in
Figure 5-3. Bus current feedback signal I_sense_DCB is filtered with R308 and
C303 to remove spikes, and then compared to a 3.15-volt reference in U303B.
The open-collector output of U303B is pulled up by R414. Additional filtering
is provided by C413, C414, and C415. The resulting signal is fed into the
IR2112 gate driver’s shutdown input on all three phases. Therefore, when bus
current exceeds 2.69 amps, all six output transistors are switched off.
The IR2112’s shutdown input is buffered by RS latches for both top and bottom
gate drives. Once a shutdown signal is received, the latches hold the gate drive
off for each output transistor, until that transistor’s gate drive signal is switched
low, and then is turned on again. Hence, current limiting occurs on a
cycle-by-cycle basis.
User’s Manual
48
3-Phase Switched Reluctance High-Voltage Power Stage
Design Considerations
For More Information On This Product,
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MOTOROLA
Freescale Semiconductor, Inc.
Design Considerations
Cycle-by-Cycle Current Limiting
Bus Voltage
Sensing
DCB_Cap_pos
V_sense_DCB_half_15
274k-1%
R224
274k-1%
R225
4.87k-1%
R226
R228
6.81k-1%
274k-1%
R227
V_sense_DCB
(3.24V @ DC-Bus = 400V)
R230
6.81k-1%
GNDA
R315 75k-1%
DC Bus Current
Sensing
4
I_sense_DCB
2
I_sense_DCB1
3
I_sense_DCB2
GNDA
1
+
R316 10k-1%
8
R317 10k-1%
U302A
MC33502D
R319
75k-1%
R323 390
C305
100nF
R324
100k-1%
8
+
C307
100nF
+3.3V_A
1.65V ref
+3.3V_A
C306
3.3uF/10V
I_sense_DCB
(1.65V +/- 1.65V @ +/- Imax)
GNDA
5
U304
LM285M
R325
33.2k-1%
4
Freescale Semiconductor, Inc...
R229
255-1%
GNDA
GNDA
GNDA
Figure 5-2. Bus Feedback
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
For More Information On This Product,
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User’s Manual
49
Freescale Semiconductor, Inc.
Design Considerations
U401
PWM A Top
PWM A Bottom
9
10
11
12
13
14
15
16
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
HO
VB
VS
n/c
n/c
VCC
COM
LO
8
7
6
5
4
3
2
1
A Top Out
A Bottom Out
IR2112S
C413 8.2pF
Freescale Semiconductor, Inc...
+5V_D
U402
PWM B Top
PWM B Bottom
9
10
11
12
13
14
15
16
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
HO
VB
VS
n/c
n/c
VCC
COM
LO
8
7
6
5
4
3
2
1
B Top Out
B Bottom Out
IR2112S
+5V_D
R306
680k
C414 8.2pF
+15V_D
R309
1.2k
8
R308
1.2k
5
I_sense_DCB
+
6
+5V_D
U303B
R413
7
-
C303
680pF
R414
10k
100
U403
4
LM393D
GNDA
GND
PWM C Top
+3.3V_A
PWM C Bottom
R310
470
R312
10k
9
10
11
12
13
14
15
16
n/c
n/c
VDD
HIN
SD
LIN
VSS
n/c
HO
VB
VS
n/c
n/c
VCC
COM
LO
8
7
6
5
4
3
2
1
C Top Out
C Bottom Out
IR2112S
C415 8.2pF
+5V_D
GNDA
Figure 5-3. Cycle-by-Cycle Current Limiting
User’s Manual
50
3-Phase Switched Reluctance High-Voltage Power Stage
Design Considerations
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MOTOROLA
Freescale Semiconductor, Inc.
Design Considerations
Temperature Sensing
5.6 Temperature Sensing
Cycle-by-cycle current limiting keeps average bus current within safe limits.
Current limiting by itself, however, does not necessarily ensure that a power
stage is operating within safe thermal limits. For thermal protection, the circuit
in Figure 5-4 is used. It consists of four diodes connected in series, a bias
resistor, and a noise suppression capacitor. The four diodes have a combined
temperature coefficient of –8.8 mV/°C. The resulting signal, Temp_sense, is fed
back to an A/D input where software can be used to set safe operating limits.
Freescale Semiconductor, Inc...
Due to unit-to-unit variations in diode forward voltage, it is highly desirable to
calibrate this signal. To do so, a value for Temp_sense is read at a known
temperature and then stored in non-volatile memory. The measured value,
rather than the nominal value, is then used as a reference point for further
readings.
+3.3V_A
R302
2.2 kΩ –1%
D14
BAV99LT1
D13
BAV99LT1
Temp_sense
PIN 26, CONNECTOR J14
C301
100 nF
GNDA
Figure 5-4. Temperature Sensing
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
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User’s Manual
51
Freescale Semiconductor, Inc.
Design Considerations
5.7 Phase Current Sensing
Sampling resistors provide phase current information for all three phases. These
resistors sample current in the lower phase legs which in a switched reluctance
output directly measures phase current. The circuitry for phase A is shown in
Figure 5-5.
Freescale Semiconductor, Inc...
Referencing the sampling resistors to the negative motor rail makes the
measurement circuitry straightforward and inexpensive. Current is sampled by
resistor R1, and amplified by differential amplifier U302B. This circuit
provides a voltage output suitable for use with A/D inputs. An MC33502 is
again used for the differential amplifier. With R301 = R304 and R303 = R305,
the gain is given by:
A = R303/R301
The output voltage is shifted up by 1.65 V to accommodate both positive and
negative current swings. A ±300-mV voltage drop across the shunt resistor
corresponds to a measured current range of ±2.93 amps.
User’s Manual
52
3-Phase Switched Reluctance High-Voltage Power Stage
Design Considerations
For More Information On This Product,
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Freescale Semiconductor, Inc.
Design Considerations
Phase Current Sensing
DCB_Cap_Pos
Q1
SGB10N60
D2
HFA16TA60CS
Gate_AT
Phase_AT
Q2
SGB10N60
Gate_AB
D1
HFA16TA60CS
R303 75k-1%
R301 10k-1%
sense
sense
5
7
I_sense_A
+
6
R1
0.075 1%
-
R304 10k-1%
U302B
MC33502D
DCB_Cap_Neg
R305
75k-1%
R323 390
1.65V ref
+
C307
100nF
R324
100k-1%
8
+3.3V_A
C306
3.3uF/10V
5
U304
LM285M
R325
33.2k-1%
4
Freescale Semiconductor, Inc...
Phase_AB
GNDA
GNDA
GNDA
Figure 5-5. Phase A Current Sensing
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
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User’s Manual
53
Freescale Semiconductor, Inc.
Design Considerations
5.8 Brake
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.
Freescale Semiconductor, Inc...
The circuit shown in Figure 5-6 connects R6–R9 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 R6–R9 will safely dissipate up to 50 watts continuously or up to
100 watts for 15 seconds. Additional power dissipation capability can be added
externally via brake connector J12.
Figure 5-6. Brake
User’s Manual
54
3-Phase Switched Reluctance High-Voltage Power Stage
Design Considerations
For More Information On This Product,
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Freescale Semiconductor, Inc.
Design Considerations
Power Factor Correction
5.9 Power Factor Correction
no PFC
3
JP201
2
L201
PFC Jumper
1
D7
10ETS08S
D8
10ETS08S
D12
4.9mH/2.3A
PFC
HFA08TB60S
C213
10nF/3000V
AC_IN_L1
+
Q8
MTB8N50E
AC_IN_L2
C208
22nF/630VDC
Earth_GND
D10
10ETS08S
C214
10nF/3000V
R213
10k
sense
R5
0.075 1%
I_Sense_PFC1
C209
470uF/400V
D202
MMSZ5251BT1
GND
I_Sense_PFC2
+15V_D
6
D9
10ETS08S
sense
U202
1 NC
NC
8
2 InA
OutA
7
4 InB
OutB
5
VCC
R210
33
R203
PFC_I_sense_1
68.1-1%
+15V_A
R206 100k
R205
+5V_D
1k-1%
+15V_D
R207
12.1k-1%
U201A
1
3
2
PFC_PWM
MC74VHCT00AD
R214
3.3k
R201
R209
3.92k-1%
10k-1%
GND
R208
10k
MC33152D
C205
C207
22nF
GND
8
6.8nF
C206
10nF
3
22nF
C201
GND
3
+
2
4
Freescale Semiconductor, Inc...
A power factor correction (PFC) circuit is included to facilitate development of
software that includes PFC control features. The objective of the PFC hardware
and software are to draw sinusoidal current from the ac line in an attempt to
approach as closely as possible a unity power factor. Without PFC, current is
drawn from the ac line at the peak of the sine wave, when the ac line voltage
exceeds the dc bus voltage. PFC circuitry is illustrated in Figure 5-7.
R212
681-1%
1
U201B
4
U201C
6
LM393D
U203A
9
5
8
10
MC74VHCT00AD
MC74VHCT00AD
GND
R211
10k
GNDA
GND
PFC_enable
GND
R215
10k
GND
Figure 5-7. PFC Circuitry
3-Phase Switched Reluctance High-Voltage Power Stage
MOTOROLA
Design Considerations
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User’s Manual
55
Freescale Semiconductor, Inc.
Design Considerations
Looking toward the top of Figure 5-7, Q8, L201, D12, and the bus capacitors
form a boost power supply. The configuration allows current to be drawn from
the ac line, when line voltage is lower than the dc bus voltage. Pulse width
modulation is controlled by software, and augmented by the analog circuitry in
the lower half of Figure 5-7. Voltage feedback is provided by the bus voltage
sensing circuit in Figure 5-2. A zero cross feedback signal, PFC_z_c, is also
used. PFC_z_c is produced by the circuit shown in Figure 5-8.
Freescale Semiconductor, Inc...
In this circuit, R219, R220, and R221 provide a relatively high impedance
connection to the rectified line voltage, and form an 11:1 voltage divider with
R222. D203 clamps the divided down voltage to approximately 15.7 volts.
Comparator U203B then compares this signal to an 11.8-volt reference.
Approximately 40 mV of hysteresis and a small reduction to the reference
voltage are added by R216. The result is a logic high at output PFC_z_c when
the comparator’s input voltage falls below 11.72 volts. This output remains high
until 11.76 volts is reached on the next cycle.
+15V_D
+5V_D
+15V_D
R216
270k
+15V_D
D203
SM/1N4148
R217
2.7k
R218
4.7k
R220
33k
R221
33k
5
+
6
-
33k
R222
10k
R223
10k
7
PFC_z_c
LM393D
U203B
4
R219
8
C211
1nF
GND
D7
10ETS08S
D8
10ETS08S
GNDA
GNDA
AC_IN_L1
AC_IN_L2
D9
10ETS08S
D10
10ETS08S
sense
I_Sense_PFC1
sense
R5
0.075 1%
GND
I_Sense_PFC2
Figure 5-8. PFC Zero Crossing Feedback
User’s Manual
56
3-Phase Switched Reluctance High-Voltage Power Stage
Design Considerations
For More Information On This Product,
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MOTOROLA
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
Freescale Semiconductor, Inc...
Freescale Semiconductor, Inc.
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