This document describes 3-phase inverter power asynchronous electric m

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Complete inverter based ST7MC STGP6NC60HD power 3-phase asynchronous PMAC motors
This document describes 3-phase inverter power asynchronous electric motors PMAC (permanent magnet motors Nominal input voltage inverter VAC, with standard single-phase connection. 3-phase3-phase inverter based 8-bit ST7FMC motor control microcontroller, while auxiliary power source based VIPer12AS. high voltage gate drivers designed around L6388, IGBT transistors based STGP6NC60HD. main targets this application very cost 3-phase inverters permanent magnet motors, with software modification, also 3-phase asynchronous motors where high efficiency cost required. standard low-power, high-efficiency 3-phase motor applications suitable this solution include:
circulating water pumps heating systems single-family houses surplus water pumps home appliances, such washing machines dishwashers small power transfer pumps waste water sewage singe family houses transfer pumps condensation water furnace applications
This application note associated with release 3-phase inverter demonstration board STEVAL-IHM019V1 (Figure Figure STEVAL-IHM019V1 demonstration board
June 2009
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www.st.com
Contents
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Contents
Demonstration board features
Main characteristics Circuit description
Software inverter
Basic description control method Software description Programming instructions
Electrical performance
Waveforms results Test results: compliance with rules 61000-4-4 BURST immunity
3.2.1 3.2.2 3.2.3 3.2.4 List equipment Test conditions Test signal Test setup
3.10
Conclusion Test results: compliance with rules 61000-4-5 surge tests List equipment Test conditions Test signal Test setup Conclusion Power consumption load standby power
Functional test
Board description placement connectors operating elements board Mandatory checks before operation Startup behavior auxiliary source Power-down auxiliary source
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Contents
Thermal measurement Bill material layout Ordering information Conclusion References Revision history
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List tables
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List tables
Table Table Table Table Table Table Table Passed voltage (positive negative) bursts Passed voltage (common line earth) Passed voltage (differential line line) load consumption Temperature components Bill material Document revision history
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List figures
List figures
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure STEVAL-IHM019V1 demonstration board Synoptic diagram converter STEVAL-IHM019V1 schematic diagram. ST7MC macrocell configuration motors Main motor control state diagram Memory Output phases working condition Output phases working condition zoom Test setup burst immunity Test setup surge tests Placement connectors operating elements board Connecting bi-phase PMAC motor Connecting tri-phase motor Startup Power-down Copper tracks side Copper tracks bottom side Silk screen side Silk screen bottom side
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Demonstration board features
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Demonstration board features
Main characteristics
information below provides inverter specification data main parameters demonstration board.
Minimum input voltage: Maximum input voltage: Maximum output power: Adjustable switching frequency between 1.95 15.66 kHz, depending software Possible with types electric motors: Bi-phase permanent magnet motors sinusoidal voltage waves restored with phase displacement between them 3-phase motors three sinusoidal voltage waves restored with phase displacement 120° between them
Variable speed setting connected motor Inverter efficiency Compliant with EN61000-6-3 EN61000-6-2 type size: Material Double-sided layout Copper thickness: Total diameter demonstration board:
components included demonstration board kit:
Motor control-dedicated microcontroller ST7FMC1K4T6 L6388 half-bridge drivers insulated gate bipolar transistor (IGBT) STGP6NC60HD VIPer12AS auxiliary supply smart power switch STTH1L06U diodes 78L05 voltage regulator SMBJ188A-TR Transildiodes
Note:
complete 3-phase inverter power motors demonstration board designed demonstration purposes only should used only laboratory conditions!
Circuit description
simple 3-phase inverter described this application note intended applications where required output power range main reason relative simplicity solution cost-effectiveness. This allows inverter small, power bi-phase motors applications with starting capacitors, offer customers inverter solution PMAC motors with higher efficiency, better control capability further added value, same application. input requirements mentioned above, application does include feedback parts, such tacho-generators hall
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Demonstration board features sensors, which means that works open loop. inverter based ST7FMC family 8-bit microcontrollers. These controllers scalar control method. proposed application, ST7FMC1K4T6 microcontroller used, offering Flash memory RAM. board assembled with programming connector possible change software based application requirements. synoptic diagram converter provided Figure showing basic topology inverter. motor supplied three half-bridges with PWM. driving signals provided through high voltage half-bridge gate drivers. Figure Synoptic diagram converter
schematic diagram converter shown Figure input part inverter, before diode bridges, contains input filter. head filter, varistor together with varistor protect inverter against surge pulses. resistor added series with input line eliminate inrush current peaks during connection board mains. capacitors capacitors together with common mode choke work input filter compliant with radio disturbance standards. compliant with relevant standards, input section should evaluated based type application implemented, output power layout PCB. Transil included protect against problems related surges burst peaks. self-supplying auxiliary supply source implemented with step-down converter (buck) based VIPer12AS converter. output voltage used supplying high-voltage L6388 gate drivers. voltage applied VIPer12AS, which works high side switch. This means that corresponding supply feedback loop circuitry floating. supply circuit consists high voltage diode capacitor C14, voltage diode capacitor
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22nF
680uH
VIPer12AS
150k
10uF
220nF
Drain4 Source2 Drain3 Source1 Drain2 Drain1
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+5V_sou ource
680uH
NTC1
+325V 5VDC
78L05AC
+15V
BZX85C5V1
100n
Figure
22uF/10V
5VDC
92-275
100n
150uF/400V
150k
LL4148
STTH1L06U 600V
592-275
330n-X2
50n-X2
P6KE KE400A
BZX85C15
Test_p _pins
LIN1
HIN1
230V~
5VDC
Demonstration board features
1000DIL B250C10
LIN2
HIN2
100n
+15V
1000uH 200mA
Phase_A
5VDC
100uF
BZX85C18
LIN3
HIN3
Output_p hase
Phase_C
Phase_B
speed ction
100R
STTH1L06U 600V
3*_half-bridg
+325V 5VDC
2u2/16V
ON/OFF
M_GND
M_GND
Speed
Start/Stop
LL4148
LIN1
NC60HD STGP6NC
470k
HIN1
Vboot
300R
Phase_A
+15V
470k
100nF/40 400VA
L6388
NC60HD STGP6NC
470n
Vbus
STEVAL-IHM019V1 schematic diagram
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connector
LL4148
ontrol_part
M_GND
LIN2
HIN2
300R
LIN2
2u2/16V
STGP6NC NC60HD
LL4148 300R
HIN3
LIN3
LIN1
HIN2
+15V
Vboot
Phase_B
L6388
470n
STGP6NC NC60HD
HIN1
LL4148
16MHz
300R
30pF
LSCS
100nF
LIN3
2u2/16V
LL4148
NC60HD STGP6NC
300R
HIN3
H_sp
(HS)MCO3 MCO2(HS) (HS)MCO4 MCO1(HS) (HS)MCO5 MCO(HS) MCES Vpp/ICC CCSEL OSC1 PD7(HS)/TDO OSC2 PD6(HS)/RDI AIN0/PWM0/PA3 PD5/AIN15/ICCD CCDATA AIN1/ARTIC1/PA5 PD4/EXTCLK_A/AIN14/ICCCLK MCVREF/PB PD3/ICAP_1A/AIN13 MCIA/PB PD2/ICAP2_A/MCZEM/AIN12 CDEM MCIB/PB PD1(HS)/OCMP1_A/MCPWMN/MCD MCIC/PB PD0/OCMP2_A/MCPWMW/AIN11 OAP/PC2 RESET OAN/PC3 Vdd_0 AIN6/MCC CCFI1/OAZ Vss_0 MCCR CCREF/PC4 VAREF
100nF
Vbus
+15V
470n
Vboot
Phase_C
LSCS
ST7FMC1K4T6
L6388
220R
NC60HD 0.1R STGP6NC
10nF
470R
LL4148
0.1R
300R
ON/OFF
M_GND
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STEVAL-IHM019 TEVA 019V1
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Demonstration board features voltage feedback loop provided diode capacitor Diode ensures proper startup converter. supply controller with voltage, lowvoltage standard regulator L78L05 used with related passive parts Zener diode pre-regulator. used board TS7FMC1K4T6 from motor control dedicated family. type used Flash memory RAM. clock signal generated internal oscillator stabilized with crystal connector with several resistors, used sending programming instructions controller. Capacitor resistors connected internal operational amplifier optionally used feedback circuit overcurrent protection. Information regarding value voltage obtained from voltage divider with resistors speed motor controlled through potentiometer R13. ON/OFF switch SW1. High output signals from channels also connected test pins. This allows simple checking signals during evaluation testing solution dedicated motors. high-voltage gate drivers. gate drivers L6388 devices, which have inputs both high side IGBT transistors contain protection features like some similar circuits from STMicroelectronics' family high-voltage gate drivers. L6388, fixed deadtime protects switch against hard switching. Resistors series with gates transistors chosen according IGBT used. values resistors provide rise fall times representing best trade-off between compliance maximum efficiency. this application, STGP6NC60HD IGBT selected power switch. IGBTs offer lower losses compared MOSFETs during freewheeling commutation co-packaged diode, which have better parameters than parasitic diodes within structure standard MOSFET. Also, price IGBTs advantage this type application.
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Software inverter
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Software inverter
Basic description control method
Figure shows basic concept internal structure ST7MC microcontroller motor configuration. Figure ST7MC macrocell configuration motors
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Software inverter more information about used this application, please refer ST7MC1 device datasheet. driving method employed standard scalar control method working open loop without feedback regulation. basic principle keep ratio constant order have constant torque. major advantage this solution relative simplicity quick implementation.
Software description
software written structured, well-commented ANSI language. programming ST7MC PMAC sine wave motor control software library developed ST7FMC controllers used. Please refer application note AN1947 "ST7MC PMAC sine wave motor control software library" explanation software further details about software concept used. library described application note consists several modules that contain convenient functions scalar control, compatible with Cosmic Metrowerks compilers. basic description function main structure described Figure Figure Main motor control state diagram
memory ST7MC family shown Figure
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Software inverter Figure Memory
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this application, software used designed driving bi-phase permanent magnet motors circulating water pumps with sinusoidal voltage waves restored with phase displacement between them. target STEVAL-IHM019V1 demonstration board offer relatively high-efficiency driving solution commonly-used permanent magnet motor. software easily modified 3-phase motors using ST7FMC library ANSI language motors. description this library found application note AN1904 "ST7MC 3-phase induction motor control software library". well-commented software source allows simple evaluation application accordance with costumer's needs. Each L6388 high-voltage driver provides fixed dead-time together with additional dead-time adjustable software, provides approximately dead-time protect against crossconduction IGBT each inverter. Overcurrent detection implemented software, hardware includes this feature using internal operational amplifier controller core. With modification software, possible implement this feature into solution. Depending motor used, necessary adjust shunt resistors R30. overall code less than that will ST7FMC1K4T6 memory. Free space allows designer adapt software their needs. Application development supported optimized compilers assembler-linker tool chain, which seamlessly integrated integrated development environments facilitate debugging fine-tuning application. Cosmic ANSI Compiler available free version that outputs code. more information demonstration software libraries, please refer application notes, including AN1904, AN1905, AN1947 others. additional information about concept, software description, etc., please refer www.st.com.
Programming instructions
programming board through connector, ST7-STICK programmer used. which connects through parallel port connector, STX-RLINK connections which also includes tool set. Both programmers allow power supplied application through internal power source, without connecting demonstration board mains.
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Software inverter When programming demonstration board using self-supply source based ViPer12AS, please take into account that board galvanically isolated!
Warning:
Please observe safety instructions rules stated Section Functional test. more information about programmers please refer www.st.com
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Electrical performance
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Electrical performance
Waveforms results
Figure shows side gate voltage waves during turning motor. Figure Output phases working condition
CH1: voltage bulk capacitor voltage CH2: gate voltage CH3: gate voltage CH4: gate voltage
Figure shows gate voltage inverter this picture, conduction dead-time clearly observed.
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Electrical performance
CH1: gate voltage CH3: gate voltage CH4: auxiliary supply
3.2.1
Test results: compliance with rules 610004-4 BURST immunity
List equipment
generator 800, test Power supply isolation transformer Load motor heating water pump (bi-phase PMAC motor) Motor driver demonstration board STEVAL-IHM019V1
3.2.2
Test conditions
Temperature ambient: 21.5 Humidity: Supply voltage: Load: water pump
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Electrical performance
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3.2.3
Test signal
Polarity: positive/negative Burst duration: Burst period: Duration time: minimum Applied power supply lines line
Test executed when drivers switched meaning that water pump running.
3.2.4
Test setup
test executed power supply lines (AC), supply voltage VAC. Test setup seen Figure Figure Test setup burst immunity
LOADS Water pump
power source GENERATOR
0.1m thick isolation
0.1m thick isolation
Metal plane
Table
Test
Passed voltage (positive negative) bursts
Mode device Working Mode device Working Burst positive
Burst negative
Conclusion
Application functionality influenced applied burst disturbance. application (PCB devices) compliant with 61131-4-4 (see Table
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Electrical performance application passed burst testing with criteria (with influence functionality without damage).
Test results: compliance with rules 610004-5 surge tests List equipment
generator Test Power supply isolation transformer Load bi-phase PMAC motor heating water pump Motor driver demonstration board STEVAL-IHM019V1
Test conditions
Temperature ambient: 21.5 Humidity: Supply voltage: Load: water pump
Test signal
According 61000-4-5; level line line, line earth)
Polarity: positive/negative Duration time events; repetition angle degree each test condition level1 level2 1000 level level Common mode power supply lines line earth) Differential mode power supply lines line line)
Test executed when drivers switched meaning that water pump running.
Test setup
test executed power supply lines (AC) line line line earth PE), supply voltage VAC. Test setup seen Figure
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Electrical performance Figure Test setup surge tests
LOADS Water pump
SURGE GENERATOR power source
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0.1m thick isolation
0.1m thick isolation
Metal plane
Table
Passed voltage (common line earth)
Mode device Common line earth Working Surge positive/negative line earth app. with angle (0,90,180,270)
Table
Passed voltage (differential line line)
Mode device Differential line line Working Surge positive/negative line earth app. with angle (0,90,180,270)
Conclusion
Application functionality influenced applied surge disturbances. application compliant with 61000 -4-5 line earth line line). Measured values visible Table Table
Note:
application passed surge testing with influence functionality without damage kV).
3.10
Power consumption load standby power
Table shows power consumption standby, with motor stopped.
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Electrical performance
Table
load consumption
0.90
0.51
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Functional test
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Functional test
Warning:
electrically isolated from input. others parts directly linked mains voltage. insulation ensured between accessible parts high voltage. demonstration board must only used power laboratory. high voltage used drive system presents serious shock hazard. This must used with special care only persons qualified working with electricity mains voltage levels. measurement equipment must isolated from mains before powering board. When using oscilloscope with demo, must isolated from line. This prevents shock from occurring result touching single point circuit, does prevent shocks when touching MORE points circuit. touch short heat sinks. heat sinks have voltage potential. When programming through connector, make sure board unplugged plugged insulated mains plug avoid computer damage.
Board description placement connectors operating elements
Figure shows placement input output connectors operating elements PCB. Figure Placement connectors operating elements board
Fuse
Output phases
connector
Input Connector
Speed Potentiometer
Start/Stop Button
ON/OFF
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Functional test
board
Warning: demonstration board isolation shield other type protective case! operations involving transportation, installation use, well maintenance carried skilled technical personnel (national accident prevention rules must observed). purposes these basic safety instructions, "skilled technical personnel" suitably qualified people familiar with installation, use, maintenance power electronic systems.
Mandatory checks before operation
following steps must performed before operating demonstration board:
Before connecting working with board, please refer safety instructions beginning this chapter! Ensure there metal objects below around board, there unintended ground loops caused peripherals (i.e., test equipment). Check that testing motor well-mounted testing stand. Wear only close-fitting clothes without loose items, remove jewelry, decorative chains metal watches.
First, connect bi-phase PMAC motor output connector, accordance with Figure With modification software 3-phase motor, connect this motor accordance with Figure Both input output connectors allow reconnecting wires simply quickly, without need drill, pulling screw part from connector. software included with demonstration board predisposed biphase motor. 3-phase asynchronous motors, software. must modified. programming evaluating software, programming through connector. Figure Connecting bi-phase PMAC Figure Connecting 3-phase motor motor
Second, connect input voltage (single-phase voltage range VAC, turn motor, press START/STOP button. startup sequence motor indicated LED. After short period, turns until startup sequence. When startup sequence finished motor working
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Functional test
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nominal conditions, turns motor adjusted required values adjusting SPEED potentiometer R13, again state. pressing START/STOP button, motor goes into state. Turning potentiometer right position increases speed motor, turning left decreases speed. driving signals from linked testing pins TP6, allowing simple connection oscilloscope probes evaluation software functions.
Warning:
entire circuit board motor output terminal always "hot" with respect earth ground, even when drive stopped condition. When programming through connector, make sure board plugged into insulated mains plug avoid computer damage! After testing procedure, disconnect first input voltage from connector. Then disconnect load from connector. After disconnecting connector, DC-link capacitor still hold voltage several minutes! using 3-phase motor, change running direction motor. Disconnect inverter from mains voltage supply connector, wait bulk capacitors discharge, swap three motor wires again connect supply voltage.
Start-up behavior auxiliary source
Figure shows start-up behavior converter VIPer12AS, both auxiliary voltages (+12 visible separately. Figure Startup
CH1: voltage bulk capacitor voltage CH3: auxiliary voltage CH4: auxiliary voltage
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Functional test
Power-down auxiliary source
result unplugging board from mains visible Figure shown illustration, auxiliary self-supplying voltage (also regulated clear transition motor turns without presence restart trials other incorrect behavior. Figure Power-down
CH1: voltage bulk capacitor voltage CH2: gate voltage CH3: auxiliary voltage CH4: auxiliary voltage
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Thermal measurement
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Thermal measurement
thermal analysis major components board shown Table measurements made after 30-minute working condition with load: water pump motor running test bench simulate standard equivalent load singlehouse heating system. Table
Q1-Q6
Temperature components VAC(1)
Component description Diode bridge ViPer12AS L6388 IGBT power switches Bulk capacitors Temperature [°C]
ambient temperature measurements 25°C
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Bill material
Bill material
list components used build demonstration board provided Table majority active components used available from STMicroelectronics.
Table
Line
Bill material
Reference Part value 330n-X2 150n-X2 150uF/400V 22nF 10uF/50V 220nF 100n 100n 100nF/400VAC 22uF/10V 100uF/25V 2u2/16V 2u2/16V 2u2/16V 100nF/400VAC 470n 470n 470n 30pF 30pF 100nF 100nF 10nF P6KE400A B250C1000DIL Description safety safety safety 330n safety 220n Aluminium ELCAP 150M 400V 25x25 105C CERCAP general purpose Aluminium ELCAP 2.5x25 105C CERCAP general purpose CERCAP general purpose CERCAP general purpose Through hole foil RM15 Aluminium ELCAP 2.5x10 105C Aluminium ELCAP 100M 5x16 105C CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose Through hole foil RM15 CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose CERCAP general purpose Transil Diode bridge Manufacturer Murata Murata Epcos Epcos Epcos Rubycon Epcos Rubycon Rubycon Epcos STMicroelectronics Vishay
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Bill material Table
Line
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Bill material (continued)
Reference NTC1 Part value BAV103 BAV103 BAV103 BAV103 BAV103 BAV103 BAV103 STTH1L06A STTH1L06A BZV55C15 BZV55C5V1 BZV55C18 connector 680uH 680uH 1000uH STGP6NC60HD STGP6NC60HD STGP6NC60HD STGP6NC60HD STGP6NC60HD STGP6NC60HD 592-275 592-275 150k 150k 470k 470k Description Universal diode Universal diode Universal diode Universal diode Universal diode Universal diode Universal diode Fast switching power rectifier Fast switching power rectifier Zener diode Zener diode 5,1V Zener diode Fuse with fuse holder connector PTR, RM=5.08mm connector PTR, RM=5.08mm MLW10G connector Common mode choke amorphous core Power inductor Power inductor Power inductor B57237S100M000 Power IGBT TO220 Power IGBT TO220 Power IGBT TO220 Power IGBT TO220 Power IGBT TO220 Power IGBT TO220 Varistor 275V E100J Varistor 275V E100J standard film resistor 1206 standard film resistor 1206 standard film resistor 1206 standard film resistor 1206 Manufacturer Fairchild Fairchild Fairchild Fairchild Fairchild Fairchild Fairchild STMicroelectronics STMicroelectronics Vishay Vishay Vishay Agilent Schrack Vogt electronic Vogt electronic Vogt electronic Vishay Epcos STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Vishay Vishay Vishay Vishay Vishay Vishay
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Line
Bill material Bill material (continued)
Reference Part value 100R 300R 300R 300R 300R 300R 300R 220R 470R 0.1R 0.1R 100k Start/Stop Test Test Test Test Test Test Description standard film resistor 0805 standard film resistor 0805 Resistive trimmer with shaft standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 0805 standard film resistor 2512 standard film resistor 2512 standard film resistor 0805 standard film resistor 1206 standard film resistor 0805 Breakaway Breakaway Breakaway Breakaway Breakaway Breakaway Manufacturer Vishay Vishay Piher Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay
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Bill material Table
Line
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Bill material (continued)
Reference Part value Test VIPer12AS L78L05ACD L6388D L6388D L6388D ST7FMC1K4T6 16MHz Description Breakaway converter Standard voltage regulator SO-8 package High voltage gate driver High voltage gate driver High voltage gate driver controller crystal 16MHz Manufacturer STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Vishay
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layout
layout
this application double layer coppered selected. material copper thickness dimensions board are:
Length: Width: thickness: 1.55
Figure Copper tracks side
Figure Copper tracks bottom side
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layout Figure Silk screen side
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Figure Silk screen bottom side
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Ordering information
Ordering information
demonstration board orderable through standard STMicroelectronics ordering system, under order code STEVAL-IHM019V1. deliverable contains fully-assembled application board, board documentation, fabrication data (such Gerber files), assembly files (pick place) component documentation.
Conclusion
This document describes very simple, cost-effective solution driving small power motors specified applications, provides designers platform evaluating solution directly suited costumer needs.
References
STMicroelectronics VIPer12AS device datasheet STMicroelectronics L6388 device datasheet STMicroelectronics ST7FMC1K4T6 device datasheet STMicroelectronics STGP6NC60HD device datasheet STMicroelectronics application note AN1904 "ST7MC 3-phase induction motor control software library" STMicroelectronics application note AN1947 "ST7MC PMAC sine wave motor control software library"
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Revision history
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Revision history
Table
Date 01-Jun-2009
Document revision history
Revision Initial release. Changes
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This document describes 3-phase inverter power asynchronous electric m

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