AN1590/D AN1590 HC16Y1 HC08MP16 HC05MC4 HCPL0453 HP4504 MPIC2112 1N4148 MUR160 - Datasheet Archive

 

AN1590/D Freescale Semiconductor AN1590 HIGH VOLTAGE MEDIUM POWER BOARD FOR THREE PHASE MOTORS Freescale Semiconductor, Inc. By

 

Order this document by AN1590/D AN1590/D Freescale Semiconductor AN1590 AN1590 HIGH VOLTAGE MEDIUM POWER BOARD FOR THREE PHASE MOTORS Freescale Semiconductor, Inc. By Ivan Skalka, Leos Chalupa, Radim Visinka Industrial System Application Laboratory Freescale, Roznov pod Radhostem, Czech Republic 1 INTRODUCTION This application note discusses one member of the Motor Control Kit, developed by Freescale. Freescale offers a wide variety of microcontrollers, analog ICs and power devices which leads to many possible types of control and power boards suitable for different applications. The Motor Control Kit takes advantage of this portfolio by allowing the optimum combination of boards to be selected, based on customer requirements. This application note describes and explains how to use the High Voltage (HV) Power Board with Isolated Gate Transistors such as MOS or IGBT (Isolated Gate Bipolar Transistor) of up to a maximum of 400 V DC-Bus voltage and a maximum of 5A DC-Bus current. The power board is very suitable for driving three phase AC induction motors, three phase synchronous motors, three phase Brushless DC (BLDC) motors or Switch Reluctance (SR) motors with power ratings up to 600 W Stepper Motor Power Board 1 Phase Power Board Microcontroller Board - HC16Y1 HC16Y1 LV Power Board HV Power Board with HPM Microcontroller Board - HC08MP16 HC08MP16 Microcontroller board - HC05MC4 HC05MC4 HV Power Board with discrete IGBTs 1 1 J1 J1 UNI-2 J2 J2 Figure 1-1. Members of the Motor Control Kit © Freescale Semiconductor, Inc., 2004. All rights reserved. Ó AN1590/D AN1590/D For More Information On This Product, Go to: www.freescale.com MOTOROLA LTD., 1997. All trademarks are recognized. Freescale Semiconductor, Inc. 2 FEATURES The High Voltage Power Board with discrete IGBTs has been developed as a member of the Motor Control Kit. This means that the power board must meet some common requirements and the most important is the interface between control and power boards. The block diagram of the power board is shown in Figure 2-1. High Voltage Power Board Power devices TO220+Diode Opto isolation Interface Drivers OR To motor COPACK Customer circuit area OR or SENSING: DC Bus Voltage + DC Bus Current SENSING: Phase A,B,C Voltage Opto Opto Extra PCB Board Opto Freescale Semiconductor, Inc. To micro board Figure 2-1. Block diagram of the High Voltage Power Board Features included are: · interface which meets the UNI-2 specification · opto isolation · · · · · · · · 2.1 input gates (buffers or inverters) for PWM signals support for multiple package options of power switches DC-Bus current sensing DC-Bus voltage sensing phase A,B, and C voltage sensing resistor dividers for high voltage lines sensing measurement points for all important signals variable configuration UNI-2 Interface Connector The connection to the all boards necessary for the whole system (microcontroller board, extra PCB boards) is provided through one common interface - UNI-2 (connector J1). The definition of the interface covers several possibilities in order to keep compatibility with the present power boards actually available. The base is an area with 40 holes which allows placement of several different connectors. Refer to Figure 2-2. for a description of each pin and its functionality. For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Freescale Semiconductor, Inc. For more details refer to the UNI-2 specification. Present interface UNI-1 2 connectors 1 New interface UNI-2 1 2 +5 V Atop +5 V Abot GND Btop GND Bbot GND GND GND New interface UNI-2 2 connectors 1 connector 2 1 2 Ctrl1 +5 V Ctrl1 +5 V Ctrl2 +5 V Ctrl2 GND Ctrl3 GND Ctrl3 GND Ctrl4 GND Ctrl4 Ctop GND Ctrl5 GND Ctrl5 Cbot GND Ctrl6 GND Ctrl6 GND GND GND GND GND +5 V J1 J1 Reserved Reserved Reserved Reserved Reserved Reserved Freescale Semiconductor, Inc. Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved1 Reserved Reserved Reserved J1 -5 V Fault -5 V Fault -5 V Fault -15 V1 +15 V -15 V +15 V -15 V +15 V GND Phase A GND Sense1 GND Sense1 GND Phase B GND Sense2 GND Sense2 GND Phase C GND Sense3 GND Sense3 GND Reserved GND Reserved GND Reserved GND Reserved GND Reserved GND Reserved GND Vtemp GND Vtemp GND Vtemp Vbus GND Analog Vbus GND Analog Vbus GND Analog Isense GND Analog Isense GND Analog Isense GND Analog 14+16 pins Some analog signals 0 - 2.5 V J2 J2 14+20 pins All analog signals 0-5V Figure 2-2. 40 pins All analog signals 0-5V Interface connector Signals Ctrl1 - Ctrl6 and Sense1 - Sense3 are defined for the three phase power board as follows: Ctrl1- PWM signal for the top transistor in phase A (Atop) Ctrl2 - PWM signal for the bottom transistor in phase A (Abot) Ctrl3 - PWM signal for the top transistor in phase B (Btop) Ctrl4 - PWM signal for the bottom transistor in phase B (Bbot) Ctrl5 - PWM signal for the top transistor in phase C (Ctop) Ctrl6 - PWM signal for the bottom transistor in phase C (Cbot) Sense1 - It can be either an analog signal which represents voltage or current of phase A, or a digital signal. In analog form +5 V represents a maximal value of the sensed quantity. Sense2 - It can be either an analog signal which represents voltage or current of phase B, or a digital signal. In analog form +5 V represents a maximal value of the sensed quantity. Sense3 - It can be either an analog signal which represents voltage or current of phase C, or a digital signal. In analog form +5 V represents a maximal value of the sensed quantity. It would be ideal to define ground signals to exclusively occupy one side of the connector and to allow an easier PCB layout, but compatibility with UNI-1 excludes this possibility. There are ground lines between all signals in the interface cable to avoid distortion of signals. The definition of the interface includes some spare pins which are available for the user. There are 2 spare pins in the two connector (14 + 20 pins) solution and 8 spare pins in the one connector (40 pins) solution. AN1590 AN1590 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. 2.2 Opto-isolation When the power stage is supplied directly from the line, an opto isolation has to be used to fulfil the safety requirements. The high speed Motorola's opto-isolator HCPL0453 HCPL0453 (surface mount package) is a suitable device for this application. It is ideally suited for applications requiring fast propagation delay times in industrially noisy environments and includes an internal Faraday shield on the detector, which gives the device the high level noise immunity. The layout of the HV Power Board is done strictly with through-holes. This enables easy replacement of damaged parts when a new application is developed. Because of this reason, the compatible device - HP4504 HP4504 is used. When an opto-isolator is not used it is necessary to connect together pin 3 and 6 of U2 through U7. 2.3 Driver for Isolated Gate Transistor Freescale Semiconductor, Inc. In order to provide a convenient and cost effective gate drive solution, one member of Motorola's MPIC family was chosen as the control IC. The system design using the MPIC2112 MPIC2112 is simple and requires only a few external components. The high voltage driver IC's are designed to directly drive the gates of power MOS devices. They provide the level shifting that is required to drive high side bridge circuits commonly used in motor drives and other power applications. They are capable of withstanding floating supply offset voltages up to 600 volts. The shut-down input of the MPIC2112 MPIC2112 can be used to switch off all IGBT's by a shut-down signal. All outputs of the MPIC2112 MPIC2112 will turn off when the SD input goes high and the outputs will remain off, even after the SD input returns to low, until the next rising edge of the respective inputs. This will happen when the fault signal from the microcontroller (pin 22 of J1) goes high. +15V isol 8 9 10 11 12 13 14 U8 N.C. VDD HIN SD LIN VSS N.C. HO 7 VB 6 VS 5 4 N.C. VCC 3 COM 2 LO 1 MPIC2112 MPIC2112 R1 C1 1R0 220nF D14 1N4148 1N4148 22R R2 22R D7 MUR160 MUR160 MUR160 MUR160 C2 220nF D10 R3 R4 22R D15 1N4148 1N4148 Figure 2-3. R52 MGP20N60 MGP20N60 DZ1 22V Q1 22R MGP20N60 MGP20N60 R53 22R DZ2 22V Q2 D1 MSR860 MSR860 D2 MSR860 MSR860 Example of Power Stage Solution Figure 2-3. shows a solution for driving Isolated Gate Transistors. Resistors R2,R4 (R6, R8, R10, R12) limit the switching speed and of course also the turn-off time. Increasing the value of the series gate resistors causes the amplitude of the negative spike decreases, while the turn-off time is a linear function of the series gate resistance. Experimental results show that R3 (R7, R11) suppresses the negative spikes on pin VS of the top transistor more effectively than R2. R3 (R7, R11) also has less effect on the turn-off time. Resistors R52,R53 (R54, R55, R56, R57) and diodes D14,D15 (D16, D17, D18, D19) set different turn-off and turn-on times when such a function is required. The diode D10 (D11, D12) is another method of suppressing the negative spike on pin VS. The most important parameter of the diode is the turn-on time. In this case resistor R3 (R7, R11) limits the current through the diode. Freescale allows and guarantees operation of the MPIC drivers up to a maximum of -5 V on pin VS (pin 5). For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Freescale Semiconductor, Inc. 2.4 Power Devices The HV Power Board supports multiple package options for the power switches (TO220,TO247 and TO264). This also makes possible to mount discrete TMOS transistors or IGBTs with discrete fly-back diodes or a copack (IGBT with build-in diode) devices only. The following table summarises all combinations. Device vs. package type Discrete power switch TO220 No No No TO247* TO264* Discrete diode TO220 No No No No No Copack IGBT No TO220 TO247 TO264 No No Freescale Semiconductor, Inc. * only for T-MOS where its internal diode can be used instead of the discrete one Table 2-1. Figure 2-3. shows one possible configuration of the power stage. Freescale MGP20N60 MGP20N60 IGBTS and MSR860 MSR860 diodes are used with the following characteristics: MGP20N60 MGP20N60 Collector-Emitter voltage 600 Vdc MSR860 MSR860 Reverse voltage 600 V Collector current - continuous Rectified forward current 20 A 8A An emitter of the high side transistor and a collector of the low side transistor are disconnected to make possible the measurement of the leg current through every Isolated Gate Transistor. Before using this board each point pair: PH1-PH2, PH3-PH4, PH5-PH6 must be connected. The PCB layout is also designed for an easy mounting of the heatsink because the power switches are all in-line. 2.5 Sensing 2.5.1 DC-Bus Voltage Sensing The DC-Bus voltage is one of the feedback signals. An on-board resistor divider (R15-R18 R15-R18) and over voltage suppressor is provided (D13). The customer circuit area can be used for needed buffering, filtering and amplifying. Figure 2-4. shows an example: R15 1M DC voltage max. 400 V R16 1M R17 1M R18 2k Isolation amplifier VCC Amplifier 150pF VCC D13 1N4004 1N4004 max. 200 mV 10k +15V +5V 5V6 10nF 1 2 3 4 8 7 6 5 HCPL7800 HCPL7800 100nF 2k2 3 2 2k2 150pF 10k 8 4 -15V AN1590 AN1590 1 MC34082 MC34082 Customer circuit area Figure 2-4. A DC-Bus Voltage Sensing For More Information On This Product, Go to: www.freescale.com Vout cca 5 V Freescale Semiconductor, Inc. 2.5.2 Phase A,B,C Voltage Sensing 2.5.3 DC-Bus Current Sensing The resistor dividers of the phase output lines (R40-R51 R40-R51) give the possibility to sense the phase voltages. These can provide the feedback for the sensorless drive, the dead time compensation or other feedback techniques. The buffering, filtering and amplifying circuit can be similar as that for DC-Bus voltage sensing. The current sense resistor is placed in series with the Isolated Gate Transistor's emitters. The current sense resistor can be grounded in two different ways (See 3.3 Jumpers JP1 and JP2 - Ground Reference.). This is useful for different methods of sensing current, with or without relationship to the HV DC bus voltage sensing. Figure 2-5. shows an example: Isolation amplifier Low pass filter Freescale Semiconductor, Inc. 2n2 IGBTs Rsense R13 +15 VG 56k 56k 2n2 8 3 2 1 4 max. 200 mV -15 VG MC34082 MC34082 Customer circuit area 2.6 A VCC VCC 1N4004 1N4004 5V6 10nF 1 1k0 2 Figure 2-5. 3 4 Amplifier 150pF 10k +15 V +5 V 8 7 6 5 HCPL7800 HCPL7800 100nF 2k2 2k2 150pF 5 6 8 B 7 MC34082 MC34082 Vout cca 5 V 10k 4 -15 V DC-Bus Current Sensing Customer Circuit Area The customer circuit area enables one to customise the HV Power Board functions (such as buffering, filtering, amplifying, limiting and limit detection of the sensed signals). The over(under)-voltage and the over-current detection can be designed on the board using this possibility. All feedback signals as well as all power supply voltages are available close to the customer circuit area. The isolation gap in the customer circuit area provides the possibility to place very easy an opto isolation device for feedback signals. If an extra PCB board is used to handle the feedback signals (see Figure 2-1.), then it can be mounted onto the HV Power Board above the customer circuit area. See Figure A-1. Schematic. 2.7 Power Supply Power can be connected to the power board through J1 and/or J2 and/or J3. J1 is an interface connector (refer to Figure 2-1 for specifications). All important power supply lines are included in the interface connector and this configuration allows all boards to be supplied from one board which simplifies the system. Connector J2 is dedicated for the power side and J3 for the microcontroller side when optoisolators are used. There are also voltage regulators placed on-board: U11 (+5 V) for the power side and U12 (+5 V) for the microcontroller side. For power supply considerations, it should be taken into account whether opto-isolators are used and how many voltages (+5 V, +15V,.) are needed on the microcontroller side and on the power side. Then the right case can be chosen and the minimal number of power supplies reached. For example. The necessary voltages for a power board with opto-isolators and HV DC bus voltage sensing (HCPL7800 HCPL7800 and MC34082 MC34082 see Figure 2-4.) are: Power side +15 V (through J2) - VCC is created on the board by U11. Microcontroller side +15 V (through J3) - VCC is created on the board by U12. -15 V (through J3) The voltages +5 V, +15 V, -15 V are also available for the microcontroller and other board through J1. For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Freescale Semiconductor, Inc. 3 CONFIGURATION 3.1 Jumper JP4 - PWM Signals The Jumper JP4 selects between pull-up or pull-down configurations. The logic integrated circuit (IC U1) is inserted between the microcontroller's outputs and the optoisolator's inputs, because of the following reasons: 1. Creates the possibility to invert easy the drive signals (PWM) for the IGBT. 3. Creates the capability to drive the IGBT drivers when no opto-isolation is used. 2. Freescale Semiconductor, Inc. 4. Creates the capability to drive the opto-couplers with logic input levels. Creates an easy transition from an isolated application to a non-isolated version of an application during development. The explanation is the following. Not every microcontroller is able to sink 15 mA in a logical low level. Therefore the integrated circuit U1 has been included to provide extra current to drive the other devices. When a non-isolated application is being developed, the first step is the implementation of an isolated version with compatible functions and signals. The opto-couplers invert the signal, thus an additional IC can compensate this function and creates an easy transition from isolated to non-isolated version. In Figure 3-1 the schematic diagram for different types of Isolated Gate Transistor's drive signals is shown. 1 VCC JP4 1 VCC from connector J1 10k JP4 10k 1 A +5V 2 74LS05 74LS05 A 2 1 74LS07 74LS07 Figure 3-1. VCC OFF 330 1 2 3 4 8 7 6 5 HP4504 HP4504 2k2 100nF to MPIC2112 MPIC2112 IGBT ON Adjusting the Signal for Isolated Gate Transistor When the logic gates are not used, it is necessary to connect together pins 1-2, 3-4, 5-6, 8-9, 10-11, 12-13 of U1. NOTE Jumper JP4 and resistor network RN1 ensure the turn off level of the Isolated Gate Transistors when the connector J1 is disconnected. WARNING If the jumper JP4 is not set correctly, then all the power switches could be turned on during power turn on or off. If this happen when the DC-Bus capacitor is already charged, then it will cause the short circuit and may damage of the HV Power Board. AN1590 AN1590 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. 3.2 Jumpers JP3 and JP5 - Fault Signal The shut down inputs (pin 11- SD) of the IGBT drivers (MPIC2112 MPIC2112) can be connected either to ground or to opto-coupler's (U13) output (fault signal) using jumper JP3. Jumper JP5 gives the possibility to ground the fault signal on the microcontroller side, if required. WARNING Freescale Semiconductor, Inc. If the power supply voltage fails on the "Micro side" and an application is using the opto-couplers, then all opto-couplers' outputs are in high state. It means that all PWM signals are ON (See Figure A-1. Schematic.) and HV Power Board will be damaged. To prevent such case, the shut-down inputs must be connected to U13 opto-coupler's output. The value of resistor R32 secures that the output of the opto-coupler U13 will be set high faster than the other opto-couplers' outputs. Thus the shut down circuit of the IGBT driver is excited before all input (PWM) signals are ON. 3.3 Jumpers JP1 and JP2 - Ground Reference Different motor control applications require the ground potential to be referenced differently (before or after current sensing resistor R13). The jumpers JP1 and JP2 allow to select the ground reference for the whole application accordingly (see Figure A-1. Schematic). 3.4 Soldering Bridge SB1 - Isolated or Non-isolated Configuration When the HV Power Board is used in non-isolated (the "Micro side" is not isolated from "Power side") configuration, then the soldering bridge SB1 must be established. Solder thick wire here if no isolation is used Figure 3-2. 3.5 Soldering Bridge Additional PCBs The mechanical design of the HV Power Board offers two different connection possibilities for additional boards through the UNI-2 interface. The Figure A-3. shows the possible configuration. Some boards can be mounted on top of the customer circuit area or they can be put next the Power Board PCB. All boards can share the necessary signals via connectors of the UNI-2 interface. Thus a variable and flexible system is achieved. For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Freescale Semiconductor, Inc. 4 DRIVER FOR ISOLATED GATE TRANSISTORS AND RELIABILITY CONSIDERATIONS Since high current switching at high speed is not done without some difficulties, there are some subtle aspects which must be taken into account when designing such circuits. The PCB layout is probably more important than the schematic. Optimization of the layout requires one to minimize the stray inductances which severely affect the behaviour of the board. Stray inductances in the main current path can store a significant amount of energy and, at turn-off of the switching device, the following problems may occur: 1. 2. High voltage spikes Additional power dissipation in the switching devices due to absorbed inductive energy Noise generation Negative spikes on pin 5 of MPIC2112 MPIC2112 Freescale Semiconductor, Inc. 3. 4. The noise can disturb the control circuit or cause misfire of the switching devices. An excessive negative voltage spike can damage the control IC (latch-up). A typical half-bridge circuit, that employs two Isolated Gate Transistors and an MPIC2112 MPIC2112, is shown in Figure 4-1. The critical stray inductances, which affect the behaviour of the circuit, are located in the high current path. Ld1 and Ls2 are due to the wiring inductance between the Isolated Gate Transistors and the decoupling capacitor. Therefore in Figure A-1. there is a decoupling electrolytic capacitor, C8 and/or C9, located very close to the Isolated Gate Transistors and the capacitor C7 is split into two parts C7a and C7b to decrease the influence of the stray inductances Ld1 and Ls2. MPIC2112 MPIC2112 Ld1 HO Q1 Ls1 + Lload Rload Ld2 LO Figure 4-1. 5 + Q2 HV1 HV2 Ls2 Half Bridge with Stray Inductance PCB LAYOUT FOR HIGH SPEED AND HIGH CURRENT LINES The PCB for the power board has been designed as a double-sided board. For PCB layout design it is strictly recommended not to use an common autorouter. Big problems usually occur when an autorouter is allowed to place high speed, high current lines without guidance for this kind of circuit. A few general rules are listed below, that can minimize the difficulties in PCB layouts: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. AN1590 AN1590 High current switching lines as short and as wide as possible Minimize the stray inductances Avoid loops Minimize the area of the remaining high current loops Locate proper high frequency decoupling close to the Isolated Gate Transistors A "three-to-one rule": the trace width should not be less than 1/3 of its length Minimize length of lines between MPIC and Isolated Gate Transistor, Isolation gap (opto isolation) Isolation gaps between high voltage lines If Isolated Gate Transistors in case TO220 are used, then the middle pin of the transistor must be bent out of line for good isolation between soldering pads (VDE regulation on isolation distance). For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. 6 STARTING ACTIVITIES Before using this power board for three phase motors, perform the following steps: 1. Consider polarization of signal for opto-isolators. 3. Consider how many power supplies are needed for the control board and the power board including HV DC bus voltages. 2. 4. 5. Freescale Semiconductor, Inc. 6. 7. 8. 9. Consider opto isolation. When the opto-isolators are omitted, then connect the solder bridge between the ground on the power side and the ground on microcontroller side (located close to the interface connector J1). Choose the jumper JP1 or JP2 to select ground reference for the application. Connect the points PH1-PH2, PH3-PH4, PH5-PH6 with wires which are only as long as necessary for leg current measurement. Set the jumpers JP3, JP4, JP5 when the shutdown signal for MPIC2112 MPIC2112 drivers is required. Wire the connector J4 (only if needed) from points PH1, PH3, PH5. Use the customer circuit area to create the desired circuit for feedback signals. Connect the control signals via connector J1 (UNI-2 interface) 10. Turn ON all auxiliary power supplies (such as +5V, ±15V .). The DC-Bus power supply is still turned OFF. 11. Check all signals, especially the IGBT gate signals. Check the switching sequence without motor and the DC-Bus voltage if possible. 12. Connect the DC_Bus power supply and set 0V. 13. Finally, slowly increase the DC-Bus voltage up to the required value and check the DC-Bus current continuously. 14. Connect the motor and run it (check the DC-Bus current continuously). 7 SAFETY CONSIDERATIONS WARNING When working with opto-isolators do not touch the board or any of its components outside the isolation barrier When working with opto-isolators and the HV DC bus is powered directly from the line, do not connect any computer, scope or development system outside the isolation barrier. In this case is necessary to use an isolation transformer. When working without opto-isolators, do not connect any computer, scope or development system when the HV DC bus is powered directly from the line. In this case it is necessary to use an isolation transformer. For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Freescale Semiconductor, Inc. APPENDIX A A.1 List of Measurement's Points The board provides a number of useful measurement points. Freescale Semiconductor, Inc. MP1 MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP9 MP10 MP11 MP12 MP13 MP14 MP15 MP16 MP17 MP18 MP19 MP20 MP21 MP22 MP23 MP24 MP25 MP26 MP27 MP28 MP29 MP30 MP31 MP32 AN1590 AN1590 Gate of Q1 - Atop Gate of Q2 - Abot Phase A Gate of Q3 - Btop Gate of Q4 - Bbot Phase B Gate of Q5 - Ctop Gate of Q6 - Cbot Phase C Shunt DC Bus DC Bus + DC Bus sensing Fault signal (shut-down signal) Atop from microcontroller Abot from microcontroller Btop from microcontroller Bbot from microcontroller Ctop from microcontroller Cbot from microcontroller GND Isol. +5 V Isol. -15 V Isol. +15 V Isol. GND +5 V +15 V -15 V Phase A voltage (divided down-to 0-15V) Phase B voltage (divided down-to 0-15V) Phase C voltage (divided down-to 0-15V) Ground Reference - Isolated For More Information On This Product, Go to: www.freescale.com For More Information On This Product, Go to: www.freescale.com GNDF 4 3 2 1 J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 3 2 1 J2 J1 C20 C30 C22 100nF 2 1 C25 1 MP22 C19 1 MP23 1 R28 R29 1 GNDF 1 MP20 SB1 1 BF4 2k2 BF3 1 +15V isol C16 100nF 2k2 C15 100nF 2k2 C14 100nF 2k2 C13 100nF 2k2 C12 100nF 2k2 C11 100nF -15V isol R31 R24 R23 R22 2k2 C10 100nF R21 R20 R19 VCC isol -15V isol Solder bridge. GND Junction when optoisolation is not used. min dist. 5mm GNDS Customer Circuit Area 1 BF5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 Power side 1 BF6 HP4504 HP4504 U13 HP4504 HP4504 U7 HP4504 HP4504 U6 HP4504 HP4504 U5 HP4504 HP4504 U4 HP4504 HP4504 U3 HP4504 HP4504 U2 Customer Circuit Area BF7 1 VCC 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Micro side BF8 +15V isol BF9 620 R32 330 R30 MP19 1 330 1 MP18 330 MP17 1 330 MP16 MP24 1 1 330 R26 330 R25 1 VCC BF10 VCC R27 1 MP15 10uF/50V C24 10uF/50V Analog GND GNDS 1 1 GNDS 100nF C17 VCC Across supply voltage pins of 74LS07 74LS07 MP28 100nF C18 1 MP21 OUT GD 8 10 12 2 4 100nF GNDS 2 GD OUT 7805 1 MP27 74LS07 74LS07 74LS07 74LS07 U1D 74LS07 74LS07 U1E 74LS07 74LS07 U1F 74LS07 74LS07 U1A 1 6 JP4 74LS07 74LS07 U1B U1C GNDS 78L05 78L05 IN U12 1 100nF 3 U11 3 IN 100nF C23 10uF/50V C21 100nF 1000uF/35V Analog GND 9 11 13 1 3 5 MP26 GNDS C28 GNDS 1 MP25 1000uF/35V C29 C27 10uF/50V C26 GC1 100nF JP5 9 8 7 6 5 4 3 2 1 VCC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CON15 CON15 J6 BF2 1 1 VCC isol DC_Bus C B A I2 I1 VCC isol GNDP -15V isol +15V isol BF1 1 Analog GND isol GNDP VCC isol 1 JP3 MP14 VCC isol 1 MP13 DC_Bus 8 9 10 11 12 13 14 C31 100nF 8 9 10 11 12 13 14 8 9 10 11 12 13 14 1M5 HO VB VS N.C. VCC COM LO HO VB VS N.C. VCC COM LO HO VB VS N.C. VCC COM LO GNDP 1 1M5 1 MP7 MP5 1 1 MP4 MP2 1 MP8 R16 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 Analog GND isol R18 75k R17 D13 1N4004 1N4004 VCC isol MPIC2112 MPIC2112 N.C. VDD HIN SD LIN VSS N.C. U10 MPIC2112 MPIC2112 N.C. VDD HIN SD LIN VSS N.C. U9 MPIC2112 MPIC2112 N.C. VDD HIN SD LIN VSS N.C. U8 1 MP1 1M5 R15 2 1 J5 C6 220nF C5 220nF C4 220nF C3 220nF C2 220nF C1 220nF D12 D9 MUR160 MUR160 1R0 R9 D11 D8 MUR160 MUR160 1R0 R5 D10 MUR160 MUR160 1R0 R1 R4 R8 22R C9 1 100uF/400V 1 22R R52 MP12 22R R57 22R 22R R56 22R R55 22R 22R R54 22R R53 22R MP11 R12 22R 1N4148 1N4148 D19 MUR160 MUR160 1N4148 1N4148 R10 D18 1N4148 1N4148 D17 MUR160 MUR160 1N4148 1N4148 R6 D16 1N4148 1N4148 D15 22R 1N4148 1N4148 R2 D14 D7 MUR160 MUR160 +15V isol C8 I1 I2 DZ6 22V JP1 MGP20N60 MGP20N60 DZ5 22V MGP20N60 MGP20N60 DZ4 22V MGP20N60 MGP20N60 DZ3 22V MGP20N60 MGP20N60 DZ2 22V MGP20N60 MGP20N60 100uF/400V 22R R11 22R R7 22R R3 DZ1 22V MGP20N60 MGP20N60 GNDP JP2 1 D6 MUR860 MUR860 1 MP9 D5 MUR860 MUR860 D4 MUR860 MUR860 1 MP6 D3 MUR860 MUR860 D2 MUR860 MUR860 1 MP3 D1 MUR860 MUR860 Analog GND isol GC2 R13 RM Q6 Q5 Q4 Q3 Q2 Q1 MP32 1 1 MP10 1 PH6 1 PH5 4n7 C7b 1 PH4 1 PH3 4n7 C7a PH2 1 PH1 GNDP GNDP GNDP A B C R51 150k 1 MP31 R50 1M 1M5 R49 R48 1M5 R47 150k 1 MP30 R46 1M R45 1M5 R44 1M5 R43 150k 1 MP29 R42 1M5 R41 1M5 1M5 R40 1 2 3 J4 A.2 8*10k RN1 Freescale Semiconductor, Inc. Freescale Semiconductor, Inc. HV Power Board PCB Figure A-1. Schematic AN1590 AN1590 Freescale Semiconductor, Inc. Connector for motor Power supply connector - isol. Point for measurement Co-pack Freescale Semiconductor, Inc. or IGBT+Diode Customer circuit area microcontroller side Wire connection Interface connector Area for heatsink Isolation barrier Customer circuit area power side Soldering bridge Ileg Signals for customer circuit area Power supply connector Current probe DC Bus Figure A-2. PCB Layout AN1590 AN1590 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. Freescale Semiconductor, Inc. Table A-1. List of components Component Reference U1 U2,3,4,5,6,7,13 U8,9,10 U11 U12 Q1,2,3,4,5,6 D1,2,3,4,5,6 D7,8,9,10,11,12 D13 D14,15,16,17,18,19 DZ1,2,3,4,5,6 R1,5,9 R2,3,4,6,7,8,10,11,12,52,53,54,55,56,57 R13 R15-17 R15-17,40-42,44-46,48-50 R18 R43,47,51 R19-24 R19-24,31 R25-30 R25-30 R32 RN1 C1-6 C7a,C7b C8,9 C10-18 C10-18,21,22,25,26,28,30,31 C20,29 C19,23,24,27 JP5 JP3,4 J1 J2,3 J4 J5 J6 Component Type 74LS07 74LS07 * HP4504 HP4504 MPIC2112 MPIC2112 or MPIC2113 MPIC2113 78L05 78L05 7805 MGPxxN60 or MGWxxN60D * MSRx60 * MUR160 MUR160 1N4004 1N4004 1N4148 1N4148 1N4748A 1N4748A (22V) 1R0, 0.5 W, 1% 22R, 0.5 W, 1% shunt, 3-5 W, 1% * 1M5, 0.5 W, 1% * 75k, 0.5 W, 1% 150k, 0.5 W, 1% 2K2, 0.5 W, 1% 330R, 0.5 W, 1% 620R, 0.5 W, 1% 8x10k Resistor Network 220nF/100 V, 10% 4n7/1000 V, 10% 100µF/400 F/400 V, 10% electrolytic * 100nF/100 V, 10% 1000µF/35 V, 10% electrolytic 10µF/35 V, 10% electrolytic jumper 2 pins jumper 3 pins 40 pin boxed header 4 pin screw terminals 5 mm 3 pin screw terminals 7.5 mm 2 pin screw terminals 7.5 mm 15 pin connector (in line) * * can be customized For More Information On This Product, Go to: www.freescale.com AN1590 AN1590 Mi c r o c ont MC 6 8 H r o l l e r B o a r d C(7)08 MP 1 6 Sensor Board 3-Phas e Powe r Board Freescale Semiconductor, Inc. OPTIONS Freescale Semiconductor, Inc. Figure A-3. Example of a Motor Control System AN1590 AN1590 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. How to Reach Us: Home Page: www.freescale.com Freescale Semiconductor, Inc. E-mail: support@freescale.com USA/Europe or Locations Not Listed: Freescale Semiconductor Technical Information Center, CH370 CH370 1300 N. Alma School Road Chandler, Arizona 85224 +1-800-521-6274 or +1-480-768-2130 support@freescale.com Europe, Middle East, and Africa: Freescale Halbleiter Deutschland GmbH Technical Information Center Schatzbogen 7 81829 Muenchen, Germany +44 1296 380 456 (English) +46 8 52200080 (English) +49 89 92103 559 (German) +33 1 69 35 48 48 (French) support@freescale.com Japan: Freescale Semiconductor Japan Ltd. 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AN1590/D AN1590/D For More Information On This Product, Go to: www.freescale.com