UM0251 User manual
SEMITOP 2 Power Board
Introduction
The SEMITOP 2 Power Board (STEVAL-IHM008V1) is designed to evaluate the advantages of using a 3-Phase Inverter with an ST Power module for motor control. It can be driven by a control board via six in-line connectors. This demo board can work directly from either an AC or DC power supply. The auxiliary power supply is located on the Power Board and works with applications rated above 50VDC. Some of the many advantages include: Quick to install and easy to run. Re-usable design (the Gerber files are available for free). The original partition design between the Power Board and the control board provides very effective system noise immunity. Note: Please read Section 2: Safety and operating instructions on page 5 before attempting any operations using the SEMITOP 2 Power Board. The SEMITOP 2 3-Phase Inverter Board enables you to evaluate a three-phase power inverter using ST's dedicated chip set. When connected to a motor, the Power Board demonstrates possible configurations for smooth, silent, and efficient motor operation. The design boards are well-suited for several kinds of applications which require 6-step commutation or 6-signal PWM (sine wave-modulated) output, including: 3-Phase AC Induction motor control 3-Phase PMDC/AC or BLDC/AC (Trapezoidal driven) motor control 3-Phase PMAC or BLAC (sinusoidal driven) motor control Single- and 3-phase UPS (Uninterruptable Power Supply) This evaluation board offers customization options as well, making it an excellent choice as an original platform for a more complete and dedicated system. Special care has been taken during the layout process to provide a very low level of interference between the power and the signal noise. This makes the system quite solid under almost all operating conditions. This evaluation kit consists of two (2) boards: 1. 2. SEMITOP 2 3-Phase Inverter main evaluation board (1000W nominal rated power) ControlBD-7FMC2 control board
Warning:
The high voltage levels used to operate the motor drive can present a serious electrical shock hazard. This kit must be used only in a power laboratory only by engineers and technicians who are experienced in power electronics technology.
June 2006
Rev 1
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Contents
UM0251
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 1.2 Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Related documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2
Safety and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 2.2 2.3 2.4 SEMITOP 2 Power Board intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SEMITOP 2 Power Board installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electronic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SEMITOP 2 Power Board operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 4
Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 4.2 4.3 4.4 4.5 Environmental safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SEMITOP 2 Power Board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bulk capacitor jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Downloading the firmware into the ST7FMC Microcontroller . . . . . . . . . . 11 Mandatory checks before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5
3-phase AC induction motor control software (open loop) . . . . . . . . . 13
5.1 5.2 5.3 5.4 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Potentiometer commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6
3-phase AC induction motor control software (closed loop) . . . . . . . 15
6.1 6.2 6.3 6.4 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Potentiometer commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7
3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (open loop) 17
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Contents
7.1 7.2 7.3
Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8
3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (closed loop) 18
8.1 8.2 8.3 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9
3-phase PMAC or BLAC (sinusoidal driven) motor control software (open loop) 19
9.1 9.2 9.3 9.4 9.5 Hardware modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Potentiometer commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10
3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop) 21
10.1 10.2 10.3 10.4 10.5 Hardware modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Motor direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Potentiometer commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Appendix A SEMITOP 2 Power Board characteristics. . . . . . . . . . . . . . . . . . . . . 24
A.1 A.2 A.3 Front-end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Auxiliar y supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Appendix B SEMITOP 2 Power Board schematic diagram . . . . . . . . . . . . . . . . . 26 Appendix C Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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General information
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1
General information
This document provides instructions on setting up and using the following SEMITOP 2 Power Board evaluation configurations for various types of applications:
3-phase AC induction motor control software 3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software 3-phase PMAC or BLAC (sinusoidal driven) motor control software
1.1
Terms and abbreviations
Table 1 lists common abbreviations used in this document. Table 1. List of abbreviations
Description
Abbreviation
BLAC BLDC
CCW CW GUI
Brushless AC Brushless DC Counter Clockwise Clockwise Graphical User Interface Permanent Magnet AC Permanent Magnet DC
PMAC PMDC
1.2
Related documentation
UM0121: ControlBD-7FMC2 Reference Design Graphical User Interface (GUI) UM0122: Motor Drive Reference Design Manual
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Safety and operating instructions
2
Safety and operating instructions
During assembly and operation, the SEMITOP 2 Power Board poses several inherent hazards, including bare wires, moving or rotating parts, and hot surfaces. There is danger of serious personal injury and damage to property, if the Kit or its components are improperly used or installed incorrectly. All operations involving transportation, installation and use, as well as maintenance are to be carried out by skilled technical personnel (national accident prevention rules must be observed). For the purpose of these basic safety instructions, "skilled technical personnel" are suitably qualified people who are familiar with the installation, use, and maintenance of power electronic systems.
2.1
SEMITOP 2 Power Board intended use
The SEMITOP 2 Power Board is a component designed for demonstration purposes only, and shall not be used for electrical installation or machinery. The technical data as well as information concerning the power supply conditions shall be taken from the documentation and strictly observed.
2.2
SEMITOP 2 Power Board installation
The installation and cooling of the SEMITOP 2 Power Board must comply with the specifications and the targeted application. For more information, refer to Chapter 4: Getting started on page 8.
The motor drive converters shall be protected against excessive strain. In particular, no components are to be bent, or isolating distances altered, during the course of transportation or handling. No contact shall be made with electronic components and contacts. The boards contain electrostatically sensitive components that are prone to damage through improper use. Electrical components must not be mechanically damaged or destroyed (to avoid potential health risks).
2.3
Electronic connections
Applicable national accident prevention rules must be followed when working on the main power supply with a motor drive. The electrical installation shall be completed in accordance with the appropriate requirements (e.g., cross-sectional areas of conductors, fusing, PE connections). For more information, refer to Chapter 4: Getting started on page 8.
2.4
SEMITOP 2 Power Board operation
A system architecture which supplies power to the Reference Design Boards shall be equipped with additional control and protective devices in accordance with the applicable
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Safety and operating instructions
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safety requirements (e.g., compliance with technical equipment and accident prevention rules). Note: Do not touch the Design Boards after disconnection from the voltage supply, as several parts and power terminals which contain possibly energized capacitors need to be allowed to discharge.
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Electrical characteristics
3
Electrical characteristics
Table 2 summarizes the electrical characteristics of the SEMITOP 2 Power Board. Table 2. Voltage ratings
Values Power Board parameters Min. AC input voltage range with on-board auxiliary supply and double rectification AC input voltage range with on-board auxiliary supply and voltage doubler DC input voltage range with on-board auxiliary supply External auxiliary supply source 50V 25V 70V 14V Max. 260V 135V 370V 18V
Note:
For a complete list of Control Board features, programming information and electrical characteristics, please refer to user manuals UM0121 and UM0122.
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Getting started
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4
Getting started
This user manual covers most system features, starting with the front-end main power supply to the power stages, including the operation of the +5V/+15V power supply and microcontroller. This kit includes the following key components: Motor control-dedicated microcontrollers L6386 half-bridge drivers 600V Insulated Gate Bipolar Transistor (IGBT) SEMITOP 2 module VIPer12 auxiliary supply smart power switch Small-Signal Bipolar Transistors STTH108 and BAS70W Diodes 78L05 voltage regulator M95040 EEPROM memory P6KE400A and 1.5KE400A TransilTM diodes (optional) Figure 1. SEMITOP 2 Power Board (STEVAL-IHM008V1)
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Getting started
4.1
Environmental safety considerations
The Power Boards must only be used in a power laboratory. The high voltage used in any AC drive system presents a serious shock hazard. A complete laboratory setup consists of an isolated AC power supply, the SEMITOP 2 Power Board, an AC Induction motor, and isolated (laboratory) power supplies for +15V (as needed). The SEMITOP 2 Power Boards are not electrically isolated from the AC input. This topology is very common in AC drives. The microprocessor is grounded by the integrated Ground of the DC bus. The microprocessor and associated circuitry are hot and MUST be isolated from user controls and serial interfaces.
Note:
Any measurement equipment must be isolated from the main power supply before powering up the motor drive. To use an oscilloscope with the demos, it is safer to isolate the AC supply AND the oscilloscope. This prevents a shock occurring as a result of touching any SINGLE point in the circuit, but does NOT prevent shocks when touching TWO or MORE points in the circuit. An isolated AC power supply can be constructed using an isolation transformer and a variable transformer. A schematic of this AC power supply is in the Application Note, "AN438, TRIAC + Microcontroller: Safety Precautions for Development Tools." (Although this Application Note was written for TRIAC, the isolation constraints still apply for fast switching semiconductor devices such as IGBTs.)
Warning:
SEMITOP 2 Power Boards have no isolation shield or any other type of protection case. The demonstration board must be handled very carefully, as high potential (energy) parts are open and can be touched. The user MUST avoid connecting or removing cables during operation of an electric motor, or touching any part of the system when it is connected to the main power supply.
Ca ution:
Isolating the application rather than the oscilloscope is highly recommended in all cases. After turning the motor off, the DC-link capacitor may still hold voltage for several minutes (refer to the LEDs on the control board). Do NOT expose the evaluation kits to ambient temperatures of over 35C, as this may harm the components or reduce their lifetimes. For more information on the evaluation software and libraries, refer to Application Notes AN1291, AN1083, and AN1276.
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4.2
Caution:
SEMITOP 2 Power Board connections
Before supplying power to the boards, verify the connection integrity and make sure there are no unintended earth/ground loops caused by peripheral (e.g., test) equipment (e.g., PC or oscilloscope).
Cables
Choose the appropriate gauge wiring for the motor's current ratings. Note: Electrostatic charges may accumulate on a floating motor and increased voltage may be present due to energized capacitors which need to be allowed to discharge.
Straps and jumpers
Recommended configuration for main power supply range between 180VAC and 260VAC: Several jumpers allow the two bulk capacitors to function in serial (current with one path to follow) or parallel (current with at least two paths to follow) configuration: Three jumpers allow for operation with Double Rectification. This is enabled by soldering jumpers J2-J3, J9-J10, and J4-J5, and keeping J12-J13 open (see Figure 2).
Recommended configuration for main power supply range below 130VAC: This will double the main power supply voltage and, consequently, the output voltage available to the motor. For example, a main power supply voltage of 120VAC will produce a bus voltage of approximately 320 VDC. This higher output voltage allows the motor to draw less current. Three jumpers enable the Voltage Doubler. This is enabled by soldering jumpers J1-J6, J7-J11, and J12-J13, and keeping J4-J5 open (see Figure 2).
Note:
Care must be taken when operating the motor in this mode. Input voltage must be kept below 135 VACRMS. If this value is exceeded for any reason, the bulk capacitors will be protected by the optional TransilTM diode TR1 (P6KE400A D0-15 or 1.5KE400A D0-201) and clamp to the high voltage DC bus.
4.3
Bulk capacitor jumpers
AC Input
AC Input bulk capacitors must be installed according to the line voltage and power ratings BEFORE plugging in the board.
DC Input
DC Input bulk capacitors must be installed according to the supply line inductance and softstar t conditions BEFORE plugging in the board. Table 3. Recommended bulk capacitor values (typ)
Capacitance (F/100W) 47 220 Input Voltage (VAC) 230 120
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Getting started
4.4
Downloading the firmware into the ST7FMC Microcontroller
For configuring the ControlBD-7FMC2 for each evaluation application, it is necessary to download the proper binary source code (.S19 file) into the microcontroller. For a complete description of the download procedure, please refer to User Manual UM0121: ControlBD- 7FMC2 Reference Design Graphical User Interface (GUI) for details.
Open loop applications
For "Open Loop" applications, the binary file provided with AC software library can be downloaded into the ST7FMC code memory as it is. This can be done with the Datablaze Programmer utility. Please refer to User Manual UM0121, "ControlBD-7FMC2 Reference Design Graphical User Interface (GUI)" for details.
Closed loop applications
Unlike "Open Loop" applications, when using a "Closed Loop" application, a new ".S19" binary file must be generated using the RDK-GUI PC software tool provided with the companion CD-ROM.
Viewing parameter settings
The settings provided for this binary code can be viewed in the main (basic parameters) window of the Reference Design RDK-GUI tool after selecting the corresponding motor option.
4.5
Mandatory checks before operation
You must perform the following verifications before switching ON the evaluation board: Ensure that the jumpers are correctly configured. The motor is correctly connected and grounded. A control board with validated software is plugged into the Power Board There are no metal parts on, below, or around the PC boards. There are no unintended earth/ground loops caused by peripheral devices (e.g., test) or equipment (e.g., PC or oscilloscope). The motor and mechanical load are safely housed so that rotating parts cannot be inadvertently accessed and cause injury (e.g., loose clothing, long hair).
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Getting started Figure 2. SEMITOP 2 Power Board connections (top view)
Tacho input
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Motor connections
Note:
Heat-sink is not provided.
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Mains 220/120Vac
VDC bus input
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3-phase AC induction motor control software (open loop)
5
3-phase AC induction motor control software (open loop)
The software operates the ControlBD-7FMC2 board in Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometers P2 and P3 respectively set the voltage and frequency levels.
5.1
Start-up procedure
1. 2. 3. 4. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase induction motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Remove the control board jumpers J11 and J12, and set jumper J10 between points 1 and 2. Set potentiometers P2 and P3 to full Counter Clockwise (CCW) position. Potentiometer P3 is the Frequency setting. Full CCW to full Clockwise (CW) corresponds to a range of 10Hz to 340Hz, with increments of 1Hz. Monitor one of the three motor currents using an isolated current probe. Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-). Set potentiometer P3 to approximately 60Hz (1/4 turn CW). Set Switch S2 to ON.
5. 6. Note:
In the Idle state, a green LED will be flashing, and then it will stay on. 7. 8.
Note:
In the Run state, the red LED will light up. The motor current should remain at zero, although some switching noise may be observed. 9. Slowly rotate potentiometer P2 CW to begin increasing the Voltage setting from zero. You should start to see a 60Hz (approximately) current build-up in the motor and then the motor should begin to rotate.
10. Continue to increase the setting until the motor reaches the expected speed for this excitation frequency. Keep in mind that some slip will be expected. The current waveform should remain fairly sinusoidal. If the waveform becomes highly distorted or exceeds the motor rating, decrease the Voltage setting (potentiometer P2).
Warning:
The entire circuit board and motor output terminals are always "hot" with respect to earth ground, even when the drive is in a stopped condition.
5.2
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor.
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The controller always enforces a maximum slew limit on changes to the frequency of excitation applied to the motor. In practice this softens the motion of the motor, causing it to ramp up to the commanded frequency (speed) when going from STOP to RUN. Decreasing the frequency and voltage applied to the motor slowly decreases the speed (to zero). Note: It is acceptable to start or stop the drive at any time and speed because of the slew limit.
5.3
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, then swap any two of the three motor wires.
5.4
Potentiometer commands
P2 sets the voltage applied from the minimum value (0) to the maximum VBUS. This setting is internally limited with a V/F curve (refer to User Manual UM0121). P3 sets the motor frequency and thus the motor speed. Use P3 to set the stator frequency as well. The contribution of P3 is 10Hz when it is in the maximum CCW position and will increment downward by 1Hz resolution to reach 340Hz by rotating the potentiometer to full CW position.
Note:
For configuration of the software library with the RDK-GUI, see User Manual UM0121.
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3-phase AC induction motor control software (closed loop)
6
3-phase AC induction motor control software (closed loop)
The software operates the ControlBD-7FMC2 board in a Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometer (P3) sets the target rotor frequency from 10 to 340 Hz (for one pole pair motor).
6.1
Start-up procedure
1. 2. 3. 4. 5. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase induction motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Remove the control board jumpers J11 and J12, and set jumper J10 between points 1 and 2. Connect the two tachogenerator terminals into connectors FST8 and FST9. Set the potentiometer (P3) to full CCW position. Full CCW to full CW corresponds to a target rotor frequency range between 10 Hz and 340 Hz (for one pole pairs motor) in increments of 1Hz. Monitor one of the three motor currents using an isolated current probe. Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-). Set potentiometer P3 to approximately 60 Hz (1/4 turn CW). Set Switch S2 to ON.
6. 7. Note:
In the Idle state, a green LED will be flashing, and then it will stay on. 8. 9.
Note:
In the Run state, the red LED will light up. The motor current should remain at zero, although some switching noise may be observed. The motor should reach the target rotor frequency set by potentiometer P3. The current waveform should remain fairly sinusoidal. If the waveform becomes highly distorted or exceeds the motor rating, modify the V/ F curve (refer to User Manual UM0121).
Warning:
The entire circuit board and motor output terminals are always "hot" with respect to earth ground, even when the drive is in a stopped condition.
6.2
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor. The controller always enforces a maximum slew limit on changes to the frequency of excitation applied to the motor. In practice this softens the motion of the motor, causing it to
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ramp up to the commanded frequency (speed) when going from STOP to RUN. Decreasing the frequency and voltage applied to the motor slowly decreases the speed (to zero). Note: It is acceptable to start or stop the drive at any time and speed because of the slew limit.
6.3
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, then swap any two of the three motor wires.
6.4
Potentiometer commands
P3 sets the rotor target frequency and thus the motor speed. The contribution of P3 is 10Hz when it is in the maximum CCW position and will increment downward by 1Hz resolution to reach 340Hz (for one pole pair motor) by rotating the potentiometer to full CW position.
Note:
For configuration of the software library with the RDK-GUI, see User Manual UM0121.
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3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (open loop)
7
3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (open loop)
The software operates the ControlBD-7FMC2 board in Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometer (P1) sets the motor speed to a PWM duty cycle between 0% and 97%.
7.1
Start-up procedure
1. 2. 3. 4. 5. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase BLDC motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Set the control board jumper J10 between points 2 and 3, and jumpers J11 and J12 between points 1 and 2. Set the potentiometer (P1) to a predetermined position (e.g., center). Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-). Set Switch S2 to ON.
Note: Note:
In the Idle state, the green LED will light up. 6. In the Run state, the red LED will stay on. The motor will be pulled into alignment position first, then it will start to turn. If the motor starts successfully, adjust potentiometer P1 to change the motor speed.
7.2
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor. Potentiometer P1 sets the motor speed command. Since this is a voltage mode open loop control, it sets the PWM duty cycle from 0% to 97%. In order to detect the back EMF, the motor must first be started and brought up to a certain speed where the back EMF voltage (BEMF) can be detected. Before the motor is started, the controller will bring the rotor to a predetermined position. This is called the "alignment phase". After the rotor is in the alignment position, a fixed accelerating commutation command will be invoked by the microcontroller. If the acceleration rate is correct, the motor will be accelerated until the microcontroller can detect the BEMF and switch to Auto-switched mode.
7.3
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, then swap any two of the three motor wires.
Note:
For configuration of the software library with the RDK-GUI, see User Manual UM0121.
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3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (closed loop) UM0251
8
3-phase PMDC/AC or BLDC/AC (trapezoidal driven) motor control software (closed loop)
The software operates the ControlBD-7FMC2 board in Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometer (P1) sets the motor speed to a PWM duty cycle between 0% and 97%.
8.1
Start-up procedure
1. 2. 3. 4. 5. 6. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase induction motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Set the control board jumper J10 between points 2 and 3 and jumpers J11 and J12 between points 1 and 2. Set the potentiometer (P1) to a predetermined position (e.g., center). Monitor one of the three motor currents using an isolated current probe. Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-). Set Switch S2 to ON.
Note: Note:
In the Idle state, the green LED will light up. 7. In the Run state, the red LED will stay on. The motor will be pulled into alignment position first, then it will start to turn. If the motor starts successfully, adjust P1 to change the motor speed.
8.2
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor. Potentiometer P1 sets the motor target frequency speed command, and sets the rotor frequency between 50Hz and 200Hz (for two pole pairs motor). In order to detect the back EMF, the motor must first be started and brought up to a certain speed where the back EMF voltage (BEMF) can be detected. Before the motor is started, the controller will bring the rotor to a predetermined position. This is called the "alignment phase". After the rotor is in the alignment position, a fixed accelerating commutation command will be invoked by the microcontroller. If the acceleration rate is correct, the motor will be accelerated until the microcontroller can detect the BEMF and switch to auto-switched mode.
8.3
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, then swap any two of the three motor wires.
Note:
For configuration of the software library with the RDK-GUI, see User Manual UM0121.
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UM0251
3-phase PMAC or BLAC (sinusoidal driven) motor control software (open loop)
9
3-phase PMAC or BLAC (sinusoidal driven) motor control software (open loop)
The software operates the ControlBD-7FMC2 board in Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometer P1 sets the voltage level index and potentiometer P3 can set the Phase Shift angle.
9.1
Hardware modifications
To use the SEMITOP 2 Power Board to drive a PMAC sensor motor, the user must remove resistors R27, R12, R28, R15, R29 and R17 and mount the resistors (4.7k) R19, R20, and R21.
Note:
In each of these cases, capacitors (10nF) C22, C23, and C24 capacitors must be mounted on the ControlBD-7FMC2 board.
9.2
Start-up procedure
1. 2. 3. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase PMAC motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Connect at least 1 Hall sensor signal to pin1 of the CON1 connector of the SEMITOP 2 Power Board. 4. 5. 6. 7. Pin 1: Hall sensor signal 1 Pin 2: Hall sensor signal 2 Pin 3: Hall sensor signal 3 Pin 4: +5 Volt Pin 5: GND
Note:
The CON1 connector has the following pin connections:
Connect the control board jumpers J11 and J12, and set jumper J10 between points 2 and 3. Set potentiometer P1 to between full CW position and full CCW position and potentiometer P3 to full CCW position. Monitor one of the three motor currents using an isolated current probe. Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-). Set Switch S2 to ON.
Note: Note:
In the Idle state, the green LED will stay on. 8. In the Run state, the red LED will light up. The motor may run poorly (e.g., discontinuous mode or oscillation) until the correct Phase Shift is set by potentiometer P3. 9. Slowly rotate potentiometer P3 CW to find the correct Phase Shift. The correct value is reached when the user notices the motor running well (without discontinuity).
19/31
3-phase PMAC or BLAC (sinusoidal driven) motor control software (open loop) Note:
UM0251
Make final adjustments to the Phase Shift by monitoring the current on the oscilloscope. The optimal Phase Shift normally minimizes the motor current amplitudes (see the Application Note AN1947 for more information). 10. Rotate potentiometer P1 in the CW direction until the motor has come up to the expected speed for this excitation level.
Note:
The current waveforms should remain fairly sinusoidal.
Warning:
The entire circuit board and motor output terminals are always "hot" with respect to earth ground, even when the drive is in a stopped condition.
9.3
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor. The controller always enforces a maximum slew limit on changes to the frequency of excitation applied to the motor. In practice this softens the motion of the motor, causing it to ramp up to the commanded frequency (speed) when going from STOP to RUN. Decreasing the frequency and voltage applied to the motor slowly decreases the speed (to zero).
Note:
It is acceptable to start or stop the drive at any time and speed because of the slew limit.
9.4
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, swap any two of the three motor wires, and execute the start-up procedure, beginning at Step 10.
9.5
Potentiometer commands
Potentiometer P1 sets the Voltage applied from the minimum value (0) to the maximum VBUS. This setting is internally limited with a V/F curve (refer to User Manual UM0121). Potentiometer P3 sets the Phase Shift (if this feature is selected by the user).
Note:
For configuration with the RDK-GUI, see User Manual UM0121.
20/31
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3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop)
10
3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop)
The software operates the ControlBD-7FMC2 board in Standalone mode. Push-button switch S2 controls the ON/OFF function and the on-board trimmer potentiometer P1 sets the target rotor speed from the minimum (maximum CCW position) to maximum speed (maximum CW position). Potentiometer P2 is disabled by default or sets the integral coefficient of the PI controller if this feature is selected by the user, and potentiometer P3 sets the Phase Shift (by default) or the proportional coefficient of the PI controller if this feature is selected. The user can set either the Phase Shift by using P3 or the PI parameter by using potentiometers P2 and P3. It is impossible to select both features simultaneously (this feature must be selected with the RDK-GUI, see User Manual UM0121).
10.1
Hardware modifications
To use the SEMITOP 2 Power Board to drive a PMAC sensor motor, the user must remove resistors R27, R12, R28, R15, R29 and R17 and mount resistors (4.7k) R19, R20 and R21.
Note:
In each of these cases, capacitors (10nF) C22, C23, and C24 capacitors must be mounted on the ControlBD-7FMC2 board.
10.2
Start-up procedure
1. 2. 3. Download the firmware into the ST7FMC memory as described in Section 4.4: Downloading the firmware into the ST7FMC Microcontroller. Connect a 3-phase PMAC motor (mechanically unloaded) to connectors FST4, FST6, and FST7. Sequencing is arbitrary and the direction of rotation will be set later. Connect at least 1 Hall sensor signal into pin 1 of the CON1 connector of SEMITOP 2 Power Board 4. 5. 6. 7. Pin 1: Hall sensor signal 1 Pin 2: Hall sensor signal 2 Pin 3: Hall sensor signal 3 Pin 4: +5 Volt Pin 5: GND
Note:
The CON1 connector has the following pin connections:
Connect the control board jumpers J11 and J12, and set jumper J10 between points 2 and 3. Set potentiometer P1 to between full CW position and full CCW position and potentiometer P3 to full CCW position. Monitor one of the three motor currents using an isolated current probe. Apply the main voltage supply to connectors FST3 and FST5, or a DC voltage supply to connectors FST1 (+) and FST2 (-).
21/31
3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop) Note: Note: In the Idle state, the green LED will stay on. 8. Set Switch S2 to ON. In the Run state, the red LED will light up.
UM0251
The motor may run poorly (e.g., discontinuous mode or oscillation) until the correct Phase Shift is set by P3. 9. Note: Slowly rotate potentiometer P3 CW to find the correct Phase Shift. The correct value is reached when the user notices the motor running well (without discontinuity).
Make final adjustments to the Phase Shift by monitoring the current on the oscilloscope. The optimal Phase Shift normally minimizes the motor current amplitudes (see the Application Note AN1947 for more information). 10. Set potentiometer P1 to the middle, between the maximum CCW and maximum CW position, and push switch S2. 11. Rotate potentiometer P1 until the motor has come up to the expected speed for this excitation level.
Warning:
The entire circuit board and motor output terminals are always "hot" with respect to earth ground, even when the drive is in a stopped condition.
10.3
Commands
Push switch S2 to start the motor. When the drive is running, push again switch S2 to stop the motor. The controller always enforces a maximum slew limit on changes to the frequency of excitation applied to the motor. In practice this softens the motion of the motor, causing it to ramp up to the commanded frequency (speed) when going from STOP to RUN. Decreasing the frequency and voltage applied to the motor slowly decreases the speed (to zero).
Note:
It is acceptable to start or stop the drive at any time and speed because of the slew limit.
10.4
Motor direction
If you wish to change the running direction of the motor, simply disconnect the drive from the main voltage supply, wait for the bulk capacitors to discharge, swap any two of the three motor wires, and execute the start-up procedure, beginning at Step 10.
10.5
Potentiometer commands
Potentiometer P1 sets the rotor target mechanical frequency and thus the motor speed from the minimum (maximum CCW position) to the maximum speed (maximum CW position). The PI regulator gives the value of the voltage index to reach the target speed. This setting is always internally limited with a V/F curve (refer to User Manual UM0121). Potentiometer P2 disabled by default or sets the integral coefficient of the microcontroller (when this feature is selected by the user).
22/31
UM0251
3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop) Potentiometer P3 sets the Phase Shift (by default) or sets the proportional coefficient of the microcontroller (when this feature is selected by the user).
Note:
For configuration of the software library with RDK-GUI, see User Manual UM0121.
23/31
SEMITOP 2 Power Board characteristics
UM0251
Appendix A
A.1
SEMITOP 2 Power Board characteristics
Front-end
The front-end section provides the supply voltage from the AC source via FST3 and FST5, or from the DC source via FST1 and FST2. The jumper settings are: The DC source is preferred during development. When operating with low DC voltage (<30VDC), an external 15V auxiliary voltage must be supplied via connector CON2 and jumpers J14 and J8 must be removed. When operating with double rectification, three straps will be installed between jumpers J4-J5, J2-J3, and J9-J10, respectively. When operating with the voltage doubler, three straps will be installed between jumpers J1-J6, J7-J11, and J12-J13, respectively.
The In-rush current protection is provided by resistor R6. This resistor is bypassed with Relay12A after voltage ramp-up.
A.2
Auxiliary supply
This Buck Converter uses a VIPer12A regulator that provides charging current for reliable start-up capability, an integrated PWM controller, and thermal as well as over-current protection. The PWM controller is very simple and does not require an external feedback compensation network. The regulation circuit is decoupled from the supply circuit using a separate diode (D1) and capacitor (C2) to supply the zener diode (D3) on the FB pin. D1 is a low voltage diode (e.g. 1N4148) that allows the voltage on VDD to reach the start-up value. D2 and C2 are essentially used to detect peak output voltage. To prevent disturbance resulting in possible output over-voltage or incorrect start-up, a zener diode (D6) is connected across the output circuit. For further details, refer to Application Notes AN1317 and AN1357. An insulated axial inductor may be used to provide a voltage oscillation filter. This type of inductor meets low cost considerations but it produces a high series resistance that adversely affects the efficiency of the converter. The current capacity of this type of inductor is determined, for any given package, by its series resistance. For example, a 1.5mH inductor has a current capacity of about 100mA since its series resistance is about 30R. The 5V is supplied from the 15V using an L78L05 three-terminal positive regulator. It provides internal current limiting and thermal shutdown. The 5V zener diode (D5) decreases the voltage regulator temperature for lifetime-sensitive applications.
Note:
When the line voltage is lower than 30V, an external 15V auxiliary power supply is mandatory. It must be plugged into CON2, and J14 and J8 must be removed.
A.3
Power stage
The default value of the sense resistor is 0.05. It must be adjusted depending on actual operating conditions. The RSENSE value, together with the resistors R38, R20, and R14
24/31
UM0251
SEMITOP 2 Power Board characteristics (mounted on the ControlBD-ST7FMC2 board), sets the maximum limit threshold for the motor current above which a hardware overcurrent protection event is validated. In this condition, the red LED starts to blink and the controller passes into the Reset state, where the motor does not run anymore. To rearm the controller, the AC (or DC) power supply must be turned off and it is necessary to wait for the bulk capacitors to discharge completely. The maximum limit for the motor current is fixed at 14.5A (peak value).
Note:
If the board is going to drive a sensorless BL(PM)DC motor, six phase voltage sense resistors must be present. If the Power Board is linked to three Hall Effect sensors via connector CON1, resistors R19, R20, R21, and capacitors C22, C23, and C24 (1nF) in the ControlBD-7FMC2 must be assembled while removing resistors R7, R10, and R12. To provide over-temperature protection during the Power Stage, a temperature sensor (e.g., LM335Z) must be installed on the heat sink and connected to connector CON3. The LM335Z is a precision temperature sensor circuit which operates as a 2-terminal zener diode and has the following features: can be easily calibrated if needed; breakdown voltage directly proportional to the absolute temperature at 10mV/K; dynamic impedance of less than 1% and operates within a range of current from 450A to 5mA without alteration of its characteristics; and if calibrated at +25C, it has a typical error rate of less than 1C over a 100C temperature range.
Unlike other sensors, the LM335Z has a linear output. The over-temperature protection threshold can be adjusted via R17 and R18 on the control board.
25/31
1 2
2
4
8 7 6 5
Figure 3.
1
1
FST 2 1 J3
VD D D RAI N
S ET 0 .2 3V R ES
J1 J2 D2 C3 +15V TP1 680K TP3 R3 330K +5V 3 C6 TP2 R2 D3 BZX84C 15 10uF/ 35V IC 1 VIP ER12ADI P 1 3
FB SOUR CE
2
1
1
1
1
1 2
T OKO 00499
2
100K-1/ 2W
100 K-1/ 2W
R6 1
2 1 Phas eB 1 5 10 11 7 12 13 8 15 STG3P2M10N 60B BD 4 3 2 1 Gate4 Gat e 1 BridgeGN D Gat e5 Gat e6 Gat e3 Gat e4 Ga t e 2 Em itt er2 R2 5 Emi tt er4 14
Phas eA Phas eB Phas eC
CONTROL BOARD
2
Em itt er6
5 D8 1N4148 Phas eC 2 1
2
10K Gate5
4
Re lay 4
4
1
3 Q7 BF
Re lay 3
3
1
Em itt er4
2 1
3 2 1
2 1
4 3 2 1
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
26/31
C1 R1 J 14 VIP ER12 ON/OFF TP4 ALL THE RESISTOR ACCURACY MUST BE R2 3 100K-1/ 2W 100K-1/ 2W STT H1 06 1 D1 C2 1N4148 2 2.2uF -25 V J5 1 1 J7 J8 1 Vin GND D6 BZX85C 16 2 1uF/ 50V 16V Vout C5 R22 C7 100uF/ 25V D7 STT H106 R5 2 D5 BZX85C 5V1 2 11 IC 2 L78L05ACZ J 11 J 10 J9 C4 22nF/ 50V L1 1mH 1 J6 + TR 1 trans il see manual HV Monitor R4 12K M2 BA 2 1 3 C8 100nF/ 400V 2 9 AC2 TP6 FST 4 BC Gate3 R24 10K Phas eA Gate1 +BU S BB 3 2 1 Gate2 Emi tt er2 4 6 16 AC1
+VD C
FST 1
Appendix B
+BU S
12/24/42-VDC
-VDC
AC1
AC2
J4
1
3
Relay 3
Bridge GND
J 12
J 13
4
Relay 4
1
1
C10
F1
8A
0 .22u F 275V-X2
SEMITOP 2 Power Board schematic diagram
TP5
PHASE
P ha se A
TP7 FST 6
120/230-VAC
FST 3
NEU TR AL
FST 5
+15V
P ha se B
TP8 R10 0.02/ 5W low induc. TP9
R9 100
FST 7
P ha se C
U2 BE
Com
RELAY12A NOT INSTALLED
1
SEMITOP 2 Power Board schematic diagram
3 BC337-25 R11 10K HV Monitoring +5V +15V
Gate6 Emi tt er6
R27
1K 1 R1 2 56K-1/2W
13 12 11 10 9 8 7 6 5 4 3 2 1 R1 4 33K FST 8 TACHO1 FST 9 TACHO2 CON 3 3 2 1 R26 10K
D9 STT H106 2 R13 120K-1/2W R28 1K R15 56K-1/2W R29 1K R17 56K-1/2W
1
D10 STT H106 2 R16 120K-1/2W
1
D11 STT H106 2 R18 120K-1/2 W
TEMPERATURE SENSOR
St ra p if not used
CON 1
fo r mechanical robustness
1 2 3 4 5
R19, R20, R21 NOT INSTALLED +5V C9 R19 4.7K R20 4.7K R21 4.7K
BA'
BB'
BC'
BD'
BE'
BF'
CON 2
SEMITOP 2 Power Board schematic diagram
15VDC-EXT
2 1
+15 V
100nF/ 50V +5V
UM0251
UM0251
Bill of material
Appendix C
Table 4.
Bill of material
Bill of material
Value / Part Number Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number ELCART 5-7716 ELCART 5-7716 ELCART 5-7716 ELCART 5-7716 ELCART 5-7716 ELCART 5-7716 R.S. R.S. R.S. EPCOS Electrolytic Electrolytic CK05CERAMIC Electrolytic CK05CERAMIC CK05CERAMIC POLYESTE R POLYESTE R EPCOS EPCOS ANY DO41 DO39 STSUPPLY ANY 85660P652 3495 C1224 ANY STSUPPLY STSUPPLY STSUPPLY 531-936 531-936 531-936 B43501A9477M R.S. 496-2198 R.S. R.S. 531-936 531-936
Index Qty
Reference
Package
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2 2 2 2 2 2 1 1 1 2 1 1 1 1 1 1
BA',BA BB',BB BC',BC BD',BD BE',BE BF',BF CON1 CON2 CON3 C1,C7 C2 C3 C4 C5 C6 C9 C8 C10 D1,D8
2 x2SIP100 2 x3SIP100 2 x2SIP100 2 x4SIP100 2 x2SIP100 2 x13SIP100 5SIP100 2SIP100 2SIP100 470uF/400V 2.2uF/50V 10uF/35V 22nF/50 100uF/25V 1uF/50V 100NF/50V 100nF/630V 0.22uF 275VX2 1N4148
Female connector Female connector Female connector Female connector Female connector Female connector strip line 5pin strip line 2pin strip line 3pin
16 17 18 19 20
1 1 2 5 1
D2,D7,D9,D10 STTH108 ,D11 D3 BZX84C15
27/31
Bill of material Table 4. Bill of material (continued)
Value / Part Number BZX85C5V1 BZX85C16 VDC + VDC PHASE Phase A NEUTRAL Phase B Phase C TACHO1 TACHO2 PCB fuse Holder +Fuse 8A VIPER12ADIP L78L05ACZ 2SIP100 2SIP100 1mH STG3P2M10N 60B BC337-25 strip line 2pin strip line 2pin R.S. R.S. TOKO STSUPPLY ST-SUPPLY
UM0251
Index Qty
Reference
Package
Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number ANY ANY R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834 R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834
21 22 23 24 25 26 27 28 29 30 31
1 1 1 1 1 1 1 1 1 1 1
D5 D6 FST1 FST2 FST3 FST4 FST5 FST6 FST7 FST8 FST9
DO39 DO39 PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Spade terminals PCB Fuse holder+ Fuse 8A
32
1
F1
PCB Fuse Holder+fus ELCART e 8A ST-SUPPLY ST-SUPPLY 531-936 531-936 03149
4/9950 STSUPPLY STSUPPLY R.S. R.S. R.S. 531-936 531-936 228-545
33 34 35 36 37 38 39 40 41 42
1 1 1 1 1 1 1 4 1 1
IC1 IC2 J8 J14 L1 M2 Q7
R1,R5,R22,R2 100K-1/2W-1% 3 R2 R3 680K-1/4W-1% 330K-1/4W-1%
28/31
UM0251 Table 4. Bill of material (continued)
Value / Part Number 12K-1/4W-1% 100 - 5W 100-1/4W-1% 0.05-5W lowinductive IRC LOB5 Ceramicver tical MEGGITELECTCOMP. SQM5 R.S.
Bill of material
Index Qty
Reference
Package
Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number
43 44 45 46 47 48 49 50 51 52 55 56
1 1 1 1 4 3 3 1 3 3 1 1 1
R4 R6 R9 R10
199-7703
DISTRE LEC
71-05-36
R11,R24,R25, 10K R26 R12,R15,R17 R13,R16,R18 R14 R19,R20,R21 R27,R28,R29 TR1 U2 56K-1/2W 120K-1/2W 33K-1/4W-1% 4.7K-1/4W-1% 1K-1/4W-1% transil relay-12A 1.5KE400A Tyco/SCH RAK 1.5KE400A SPCO12A 3.5mm STSUPPLY R.S. 376-206
SOCKET 8 SOCKET DIL 8 8DIP300 PIN DIL-X IC1 PIN
29/31
Revision history
UM0251
Revision history
Table 5.
Date 27-Jun-2006
Document revision history
Revision 1 Initial release. Changes
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UM0251
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