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SEMICONDUCTOR APPLICATION NOTE
Order this document AN1590/D
AN1590
HIGH VOLTAGE MEDIUM POWER BOARD THREE PHASE MOTORS
Ivan Skalka, Leos Chalupa, Radim Visinka Industrial System Application Laboratory Motorola, Roznov Radhostem, Czech Republic
Freescale Semiconductor, Inc.
INTRODUCTION
This application note discusses member Motor Control Kit, developed Motorola. Motorola offers wide variety microcontrollers, analog power devices which leads many possible types control power boards suitable different applications. Motor Control takes advantage this portfolio allowing optimum combination boards selected, based customer requirements.
This application note describes explains High Voltage (HV) Power Board with Isolated Gate Transistors such IGBT (Isolated Gate Bipolar Transistor) maximum DC-Bus voltage maximum DC-Bus current. power board very suitable driving three phase induction motors, three phase synchronous motors, three phase Brushless (BLDC) motors Switch Reluctance (SR) motors with power ratings
Stepper Motor Power Board Phase Power Board Microcontroller Board HC16Y1 Microcontroller Board HC08MP16 Microcontroller board HC05MC4
Power Board with discrete IGBTs
Power Board Power Board with
UNI-2
Figure 1-1.
Members Motor Control
This document contains information products under development. Motorola reserves right change discontinue these products without notice.
MOTOROLA LTD., 1997. trademarks recognized.
AN1590/D More Information This Product, www.freescale.com
FEATURES
High Voltage Power Board with discrete IGBTs been developed member Motor Control Kit. This means that power board must meet some common requirements most important interface between control power boards. block diagram power board shown Figure 2-1.
High Voltage Power Board
Power devices TO220+Diode Interface micro board Opto isolation Drivers
COPACK Customer circuit area
motor
Freescale Semiconductor, Inc.
Extra Board
Opto Opto
SENSING: Voltage Current SENSING: Phase A,B,C Voltage
Figure 2-1. Features included are:
Block diagram High Voltage Power Board
interface which meets UNI-2 specification opto isolation
input gates (buffers inverters) signals support multiple package options power switches DC-Bus current sensing DC-Bus voltage sensing
phase A,B, voltage sensing
resistor dividers high voltage lines sensing measurement points important signals variable configuration
connection boards necessary whole system (microcontroller board, extra boards) provided through common interface UNI-2 (connector J1). definition interface covers several possibilities order keep compatibility with present power boards actually available. base area with holes which allows placement several different connectors. Refer Figure 2-2. description each functionality. MOTOROLA More Information This Product, www.freescale.com AN1590
UNI-2 Interface Connector
Opto
more details refer UNI-2 specification.
Present interface UNI-1
connectors
interface UNI-2
connectors
interface UNI-2
connector
Reserved Reserved Reserved Vbus Isense
Atop Abot Btop Bbot Ctop Cbot Reserved Reserved Reserved Fault Phase Phase Phase Reserved Reserved Vtemp Analog Analog
Ctrl1 Ctrl2 Ctrl3 Ctrl4 Ctrl5 Ctrl6 Reserved Reserved Reserved Fault Sense1 Sense2 Sense3 Reserved Reserved Vtemp Analog Analog
Ctrl1 Ctrl2 Ctrl3 Ctrl4 Ctrl5 Ctrl6 Reserved Reserved Reserved Fault Sense1 Sense2 Sense3 Reserved Reserved Vtemp Analog Analog
Reserved Reserved Reserved1 Vbus Isense
Reserved Reserved Reserved
Freescale Semiconductor, Inc.
Vbus Isense
14+16 pins Some analog signals
14+20 pins analog signals 0-5V
Figure 2-2.
Interface connector
pins analog signals 0-5V
Signals Ctrl1 Ctrl6 Sense1 Sense3 defined three phase power board follows: Ctrl1- signal transistor phase (Atop) Ctrl2 signal bottom transistor phase (Abot)
Ctrl3 signal transistor phase (Btop)
Ctrl4 signal bottom transistor phase (Bbot) Ctrl5 signal transistor phase (Ctop) Ctrl6 signal bottom transistor phase (Cbot)
Sense1 either analog signal which represents voltage current phase digital signal. analog form represents maximal value sensed quantity. Sense2 either analog signal which represents voltage current phase digital signal. analog form represents maximal value sensed quantity. Sense3 either analog signal which represents voltage current phase digital signal. analog form represents maximal value sensed quantity.
would ideal define ground signals exclusively occupy side connector allow easier layout, compatibility with UNI-1 excludes this possibility. There ground lines between signals interface cable avoid distortion signals. definition interface includes some spare pins which available user. There spare pins connector pins) solution spare pins connector pins) solution. AN1590 More Information This Product, www.freescale.com
When power stage supplied directly from line, opto isolation used fulfil safety requirements. high speed Motorola's opto-isolator HCPL0453 (surface mount package) suitable device this application. ideally suited applications requiring fast propagation delay times industrially noisy environments includes internal Faraday shield detector, which gives device high level noise immunity. layout Power Board done strictly with through-holes. This enables easy replacement damaged parts when application developed. Because this reason, compatible device HP4504 used. When opto-isolator used necessary connect together through
Opto-isolation
order provide convenient cost effective gate drive solution, member Motorola's MPIC family chosen control system design using MPIC2112 simple requires only external components.
Driver Isolated Gate Transistor
Freescale Semiconductor, Inc.
high voltage driver IC's designed directly drive gates power devices. They provide level shifting that required drive high side bridge circuits commonly used motor drives other power applications. They capable withstanding floating supply offset voltages volts.
shut-down input MPIC2112 used switch IGBT's shut-down signal. outputs MPIC2112 will turn when input goes high outputs will remain off, even after input returns low, until next rising edge respective inputs. This will happen when fault signal from microcontroller (pin goes high.
+15V isol
MGP20N60 MSR860
N.C. N.C.
N.C.
220nF
1N4148 MUR160
MPIC2112
MUR160 220nF
MGP20N60
MSR860
1N4148
Figure 2-3.
Example Power Stage Solution
Figure 2-3. shows solution driving Isolated Gate Transistors.
Resistors R2,R4 (R6, R10, R12) limit switching speed course also turn-off time. Increasing value series gate resistors causes amplitude negative spike decreases, while turn-off time linear function series gate resistance. Experimental results show that (R7, R11) suppresses negative spikes transistor more effectively than (R7, R11) also less effect turn-off time.
Resistors R52,R53 (R54, R55, R56, R57) diodes D14,D15 (D16, D17, D18, D19) different turn-off turn-on times when such function required. diode (D11, D12) another method suppressing negative spike most important parameter diode turn-on time. this case resistor (R7, R11) limits current through diode.
Motorola allows guarantees operation MPIC drivers maximum (pin More Information This Product, www.freescale.com
AN1590
Power Board supports multiple package options power switches (TO220,TO247 TO264). This also makes possible mount discrete TMOS transistors IGBTs with discrete fly-back diodes copack (IGBT with build-in diode) devices only. following table summarises combinations.
Device package type Discrete power switch Discrete diode Copack IGBT TO220 TO220 TO220 TO247 TO264 TO247* TO264*
Power Devices
only T-MOS where internal diode used instead discrete
Freescale Semiconductor, Inc.
Table 2-1. Figure 2-3. shows possible configuration power stage. MGP20N60 MSR860 Collector-Emitter voltage Reverse voltage
Motorola MGP20N60 IGBTS MSR860 diodes used with following characteristics: Collector current continuous Rectified forward current
emitter high side transistor collector side transistor disconnected make possible measurement current through every Isolated Gate Transistor. Before using this board each point pair: PH1-PH2, PH3-PH4, PH5-PH6 must connected. layout also designed easy mounting heatsink because power switches in-line.
2.5.1
Sensing DC-Bus Voltage Sensing
DC-Bus voltage feedback signals. on-board resistor divider (R15-R18) over voltage suppressor provided (D13). customer circuit area used needed buffering, filtering amplifying. Figure 2-4. shows example:
voltage max. 1N4004
Isolation amplifier
Amplifier
150pF
10nF
100nF 150pF
+15V
max.
HCPL7800 Customer circuit area
-15V
MC34082
Vout
Figure 2-4.
DC-Bus Voltage Sensing
AN1590
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2.5.2
resistor dividers phase output lines (R40-R51) give possibility sense phase voltages. These provide feedback sensorless drive, dead time compensation other feedback techniques. buffering, filtering amplifying circuit similar that DC-Bus voltage sensing.
Phase A,B,C Voltage Sensing
2.5.3
current sense resistor placed series with Isolated Gate Transistor's emitters. current sense resistor grounded different ways (See Jumpers Ground Reference.). This useful different methods sensing current, with without relationship voltage sensing. Figure 2-5. shows example:
pass filter Isolation amplifier 1N4004 10nF
DC-Bus Current Sensing
Amplifier 150pF 100nF 150pF
Freescale Semiconductor, Inc.
IGBTs Rsense
max. MC34082
HCPL7800
MC34082
Vout
Customer circuit area
Figure 2-5.
DC-Bus Current Sensing
customer circuit area enables customise Power Board functions (such buffering, filtering, amplifying, limiting limit detection sensed signals). over(under)-voltage over-current detection designed board using this possibility.
Customer Circuit Area
feedback signals well power supply voltages available close customer circuit area.
isolation customer circuit area provides possibility place very easy opto isolation device feedback signals. extra board used handle feedback signals (see Figure 2-1.), then mounted onto Power Board above customer circuit area. Figure A-1. Schematic.
Power connected power board through and/or and/or interface connector (refer Figure specifications). important power supply lines included interface connector this configuration allows boards supplied from board which simplifies system. Connector dedicated power side microcontroller side when optoisolators used. There also voltage regulators placed on-board: power side microcontroller side. power supply considerations, should taken into account whether opto-isolators used many voltages +15V,.) needed microcontroller side power side. Then right case chosen minimal number power supplies reached. Power side (through created board U11.
Power Supply
example. necessary voltages power board with opto-isolators voltage sensing (HCPL7800 MC34082 Figure 2-4.) are: Microcontroller side (through created board U12. (through
voltages also available microcontroller other board through MOTOROLA More Information This Product, www.freescale.com AN1590
CONFIGURATION Jumper Signals
Jumper selects between pull-up pull-down configurations.
logic integrated circuit inserted between microcontroller's outputs optoisolator's inputs, because following reasons: Creates possibility invert easy drive signals (PWM) IGBT. Creates capability drive opto-couplers with logic input levels.
Creates capability drive IGBT drivers when opto-isolation used.
Freescale Semiconductor, Inc.
explanation following. every microcontroller able sink logical level. Therefore integrated circuit been included provide extra current drive other devices. When non-isolated application being developed, first step implementation isolated version with compatible functions signals. opto-couplers invert signal, thus additional compensate this function creates easy transition from isolated non-isolated version.
Creates easy transition from isolated application non-isolated version application during development.
Figure schematic diagram different types Isolated Gate Transistor's drive signals shown.
from connector
100nF MPIC2112
74LS05 74LS07
IGBT
HP4504
Figure 3-1.
Adjusting Signal Isolated Gate Transistor
When logic gates used, necessary connect together pins 1-2, 3-4, 5-6, 8-9, 10-11, 12-13
NOTE
Jumper resistor network ensure turn level Isolated Gate Transistors when connector disconnected.
WARNING
jumper correctly, then power switches could turned during power turn off. this happen when DC-Bus capacitor already charged, then will cause short circuit damage Power Board.
AN1590
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shut down inputs (pin IGBT drivers (MPIC2112) connected either ground opto-coupler's (U13) output (fault signal) using jumper JP3. Jumper gives possibility ground fault signal microcontroller side, required.
Jumpers Fault Signal
WARNING
power supply voltage fails "Micro side" application using opto-couplers, then opto-couplers' outputs high state. means that signals (See Figure A-1. Schematic.) Power Board will damaged. prevent such case, shut-down inputs must connected opto-coupler's output. value resistor secures that output opto-coupler will high faster than other opto-couplers' outputs. Thus shut down circuit IGBT driver excited before input (PWM) signals
Freescale Semiconductor, Inc.
Different motor control applications require ground potential referenced differently (before after current sensing resistor R13). jumpers allow select ground reference whole application accordingly (see Figure A-1. Schematic).
Jumpers Ground Reference
When Power Board used non-isolated (the "Micro side" isolated from "Power side") configuration, then soldering bridge must established.
Soldering Bridge Isolated Non-isolated Configuration
Solder thick wire here isolation used
Figure 3-2.
Soldering Bridge
mechanical design Power Board offers different connection possibilities additional boards through UNI-2 interface. Figure A-3. shows possible configuration. Some boards mounted customer circuit area they next Power Board PCB. boards share necessary signals connectors UNI-2 interface. Thus variable flexible system achieved. More Information This Product, www.freescale.com
Additional PCBs
AN1590
DRIVER ISOLATED GATE TRANSISTORS RELIABILITY CONSIDERATIONS
Since high current switching high speed done without some difficulties, there some subtle aspects which must taken into account when designing such circuits. layout probably more important than schematic. Optimization layout requires minimize stray inductances which severely affect behaviour board. Stray inductances main current path store significant amount energy and, turn-off switching device, following problems occur: High voltage spikes Additional power dissipation switching devices absorbed inductive energy Noise generation Negative spikes MPIC2112
Freescale Semiconductor, Inc.
noise disturb control circuit cause misfire switching devices. excessive negative voltage spike damage control (latch-up).
typical half-bridge circuit, that employs Isolated Gate Transistors MPIC2112, shown Figure 4-1. critical stray inductances, which affect behaviour circuit, located high current path. wiring inductance between Isolated Gate Transistors decoupling capacitor. Therefore Figure A-1. there decoupling electrolytic capacitor, and/or located very close Isolated Gate Transistors capacitor split into parts decrease influence stray inductances Ls2.
MPIC2112 Lload Rload
Figure 4-1.
Half Bridge with Stray Inductance
LAYOUT HIGH SPEED HIGH CURRENT LINES
power board been designed double-sided board. layout design strictly recommended common autorouter. problems usually occur when autorouter allowed place high speed, high current lines without guidance this kind circuit. general rules listed below, that minimize difficulties layouts: High current switching lines short wide possible Minimize stray inductances Avoid loops Minimize area remaining high current loops Locate proper high frequency decoupling close Isolated Gate Transistors "three-to-one rule": trace width should less than length Minimize length lines between MPIC Isolated Gate Transistor, Isolation (opto isolation) Isolation gaps between high voltage lines Isolated Gate Transistors case TO220 used, then middle transistor must bent line good isolation between soldering pads (VDE regulation isolation distance). More Information This Product, www.freescale.com
AN1590
STARTING ACTIVITIES
Consider polarization signal opto-isolators. Before using this power board three phase motors, perform following steps: Consider opto isolation. When opto-isolators omitted, then connect solder bridge between ground power side ground microcontroller side (located close interface connector J1). Consider many power supplies needed control board power board including voltages. Choose jumper select ground reference application.
Connect points PH1-PH2, PH3-PH4, PH5-PH6 with wires which only long necessary current measurement.
Freescale Semiconductor, Inc.
jumpers JP3, JP4, when shutdown signal MPIC2112 drivers required. Wire connector (only needed) from points PH1, PH3, PH5. Connect control signals connector (UNI-2 interface) customer circuit area create desired circuit feedback signals.
Turn auxiliary power supplies (such +5V, ±15V DC-Bus power supply still turned OFF. Check signals, especially IGBT gate signals. Check switching sequence without motor DC-Bus voltage possible. Connect DC_Bus power supply Finally, slowly increase DC-Bus voltage required value check DC-Bus current continuously. Connect motor (check DC-Bus current continuously).
SAFETY CONSIDERATIONS WARNING
When working with opto-isolators touch board components outside isolation barrier When working with opto-isolators powered directly from line, connect computer, scope development system outside isolation barrier. this case necessary isolation transformer. When working without opto-isolators, connect computer, scope development system when powered directly from line. this case necessary isolation transformer.
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AN1590
APPENDIX
board provides number useful measurement points.
MP10 MP11 MP12 MP13 MP14 MP15 MP16 MP17 MP18 MP19 MP20 MP21 MP22 MP23 MP24 MP25 MP26 MP27 MP28 MP29 MP30 MP31 MP32 Gate Atop Gate Abot Phase Gate Btop Gate Bbot Phase Gate Ctop Gate Cbot Phase Shunt sensing Fault signal (shut-down signal) Atop from microcontroller Abot from microcontroller Btop from microcontroller Bbot from microcontroller Ctop from microcontroller Cbot from microcontroller Isol. Isol. Isol. Isol. Phase voltage (divided down-to 0-15V) Phase voltage (divided down-to 0-15V) Phase voltage (divided down-to 0-15V) Ground Reference Isolated
List Measurement's Points
Freescale Semiconductor, Inc.
AN1590
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MUR860 isol 220nF 220nF MUR160 1N4148 100nF MGP20N60 MUR860 MUR160 100nF +15V isol isol Analog isol GNDP 100nF 1N4148 MGP20N60 MUR860 1N4148 MGP20N60 MUR160 1N4148 MGP20N60 HP4504 HP4504 100nF MPIC2112 220nF MUR160 MP15 HP4504 MP16 MP17 HP4504 100nF MP14 MPIC2112 100nF 220nF MP18 HP4504 MP19 MP20 HP4504 100nF N.C. N.C. N.C. 100nF 100nF GNDS
8*10k
Across supply voltage pins 74LS07
isol +15V isol
MUR860 GNDP N.C. N.C. N.C. 1N4148 220nF MUR160 MGP20N60 GNDP MUR860 MPIC2112 220nF MUR160 GNDP -15V isol +15V isol isol isol DC_Bus 1N4004 CON15 MP13 GNDP 1N4148 DC_Bus MP11 100uF/400V MP12 100uF/400V GNDP MP10 GNDP MGP20N60 MUR860 HP4504 BF10 GNDF -15V isol 10uF/50V N.C. N.C. N.C. 10uF/50V
GNDS
MP29 150k
74LS07
74LS07
Power Board
74LS07
74LS07
74LS07
MP30 150k
74LS07
Figure A-1. Schematic
Micro side Customer Circuit Area
MP24 +15V isol -15V isol MP22 MP23 isol GNDS
MP25
MP26
MP27
MP28
GNDS
100nF
7805
100nF
100nF
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Power side Customer Circuit Area
10uF/50V
GNDS
GNDS
GNDS
MP31 150k
1000uF/35V
Analog
Analog
GNDF
1000uF/35V
78L05
100nF
100nF
100nF
10uF/50V
100nF
MP21
Solder bridge. Junction when optoisolation used. dist.
MP32
AN1590
Analog isol
Analog isol
Connector motor Power supply connector isol.
Point measurement
Co-pack IGBT+Diode
Freescale Semiconductor, Inc.
Customer circuit area microcontroller side
Wire connection
Interface connector Isolation barrier
Area heatsink
Customer circuit area power side
Soldering bridge
Ileg Signals customer circuit area
Power supply connector
Current probe
Figure A-2. Layout
AN1590
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Table A-1. List components
Component Reference U2,3,4,5,6,7,13 U8,9,10 Q1,2,3,4,5,6 D1,2,3,4,5,6 D7,8,9,10,11,12 D14,15,16,17,18,19 DZ1,2,3,4,5,6 R1,5,9 R15-17,40-42,44-46,48-50 R43,47,51 R19-24,31 R25-30 C1-6 C7a,C7b C8,9 C10-18,21,22,25,26,28,30,31 C20,29 C19,23,24,27 JP3,4 J2,3 Component Type 74LS07 HP4504 MPIC2112 MPIC2113 78L05 7805 MGPxxN60 MGWxxN60D MSRx60 MUR160 1N4004 1N4148 1N4748A (22V) 1R0, 22R, shunt, 1M5, 75k, 150k, 2K2, 330R, 620R, 8x10k Resistor Network 220nF/100 4n7/1000 100µF/400 electrolytic 100nF/100 1000µF/35 electrolytic 10µF/35 electrolytic jumper pins jumper pins boxed header screw terminals screw terminals screw terminals connector line)
Freescale Semiconductor, Inc.
customized
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AN1590
OPTIONS
Freescale Semiconductor, Inc.
Sensor
Board
Figure A-3. Example Motor Control System AN1590
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C(7)08
3-Phas
Powe
Board
Freescale Semiconductor, Inc.
products sold Motorola's Terms Conditions Supply. ordering product covered this document Customer agrees bound those Terms Conditions nothing contained this document constitutes forms part contract (with exception contents this Notice). copy Motorola's Terms Conditions Supply available request. Motorola reserves right make changes without further notice products herein. Motorola makes warranty, representation guarantee regarding suitability products particular purpose, does Motorola assume liability arising application product circuit, specifically disclaims liability, including without limitation consequential incidental damages. "Typical" parameters vary different applications. operating parameters, including "Typicals", must validated each customer application customer's technical experts. Motorola does convey license under patent rights rights others. Motorola products designed, intended, authorized components systems intended surgical implant into body, other applications intended support sustain life, other application which failure Motorola product could create situation where personal injury death occur. Should Buyer purchase Motorola products such unintended unauthorized application, Buyer shall indemnify hold Motorola officers, employees, subsidiaries, affiliates, distributors harmless against claims, costs, damages, expenses, reasonable attorney fees arising directly indirectly, claim personal injury death associated with such unintended unauthorized use, even such claim alleges that Motorola negligent regarding design manufacture part. Motorola !are registered trademarks Motorola, Inc. Motorola, Inc. Equal Opportunity/Affirmative Action Employer. Customer should ensure that most date version document contacting local Motorola office. This document supersedes earlier documentation relating products referred herein. information contained this document current date publication. subsequently updated, revised withdrawn.
reach MFAX: RMFAX0@email.sps.mot.com TOUCHTONE (602) 244-6609 INTERNET: http://Design-NET.com USA/EUROPE: Motorola Literature Distribution; P.O. 20912; Phoenix, Arizona 85036. 1-800441-2447 JAPAN: Nippon Motorola Ltd.; Tatsumi-SPD-JLDC, Toshikatsu Otsuki, Seibu-Butsuryu-Center, 3-14-2 Tatsumi Koto-Ku, Tokyo 135, Japan. 03-3521-8315 HONG KONG: Motorola Semiconductors H.K. Ltd.; Ping Industrial Park, Ting Road, N.T., Hong Kong. 852-26629298
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