UM0252 User manual
SEMITOP 3 Power Board
Introduction
The SEMITOP 3 Power Board (STEVAL-IHM009V1) 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 a 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 3 Power Board. The SEMITOP 3 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 3 3-Phase Inverter main evaluation board (3000W 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.
July 2006
Rev 2
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www.st.com
Contents
UM0252
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 3 Power Board intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SEMITOP 3 Power Board installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electronic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SEMITOP 3 Power Board operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 4
Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 4.2 4.3 4.4 Environmental safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SEMITOP 3 Power Board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Downloading the firmware into the ST7FMC Microcontroller . . . . . . . . . . 10 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
7.1 Star t-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Contents
7.2 7.3
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 3 Power Board characteristics. . . . . . . . . . . . . . . . . . . . . 23
A.1 A.2 A.3 Front-end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Auxiliar y supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Power stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Appendix B SEMITOP 3 Power Board schematic diagram . . . . . . . . . . . . . . . . . 25 Appendix C Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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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 3 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 3 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 3 Power Board intended use
The SEMITOP 3 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 3 Power Board installation
The installation and cooling of the SEMITOP 3 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 3 Power Board operation
A system architecture which supplies power to the SEMITOP 3 Power Board shall be equipped with additional control and protective devices in accordance with the applicable
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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 3 Power Board. Table 2. Voltage ratings
Values Power Board parameters Min. DC input voltage range with on-board auxiliary supply External auxiliary supply source 70V 14V Max. 370V 18V
Note:
For a complete list of Control Board features and programming information, 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 3 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 3 Power Board (STEVAL-IHM009V1)
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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 3 Power Board, an AC Induction motor, and isolated (laboratory) power supplies for +15V (as needed). The SEMITOP 3 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 3 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 3 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. Be sure that a jumper is placed between pins 1 and 2 of Jumper J2. Note: 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. Input voltage must be kept below 130 VDC. 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
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 into the microcontroller.
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.
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Getting started
4.4
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 3 Power Board connections (top view)
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VDC Bus Input
Motor Connections
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Mo tor Braker
Tacho 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 4.3: 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 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: 7. 8. Note:
In the Idle state, a green LED will be flashing, and then it will stay on.
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 4.3: 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 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: 8. 9. Note:
In the Idle state, a green LED will be flashing, and then it will stay on.
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 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).
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3-phase AC induction motor control software (closed loop) Note:
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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 4.3: 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 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) UM0252
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 4.3: 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 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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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 3 Power Board to drive a PMAC sensor motor, the user must remove resistors R30, R12, R31, R15, R32 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 4.3: 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 3 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 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).
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3-phase PMAC or BLAC (sinusoidal driven) motor control software (open loop) Note:
UM0252
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.
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UM0252
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 3 Power Board to drive a PMAC sensor motor, the user must remove resistors R30, R12, R31, R15, R32 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 4.3: 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 3 Power Board
Note:
The CON1 connector has the following pin connections: 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 4. Connect the control board jumpers J11 and J12, and set jumper J10 between points 2 and 3. 5. Set potentiometer P1 to between full CW position and full CCW position and potentiometer P3 to full CCW position. 6. Monitor one of the three motor currents using an isolated current probe. 7. Apply the DC voltage supply to connectors FST1 (+) and FST2 (-). 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.
Note: Note:
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3-phase PMAC or BLAC (sinusoidal driven) motor control software (closed loop)
UM0252
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). 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.
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UM0252
SEMITOP 3 Power Board characteristics
Appendix A
A.1
SEMITOP 3 Power Board characteristics
Front-end
The front-end section provides the supply voltage 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. Place a jumper between pins 1 and 2 of Jumper J2.
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 R10 is 0.02. It must be adjusted depending on actual operating conditions. The RSENSE value, together with the resistors R38, R20, and R14 (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 34A (peak value).
23/30
SEMITOP 3 Power Board characteristics Note:
UM0252
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.
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UM0252
F ST 1
+ VDC
VDC
1 1N 4148 2 1 2 2 D1 4 C3 8 7 6 5 +15V R2 680K IC 1 VIPER 12AD IP +5V R3 330K H V Monitoring C6 R4 12K 3
VDD DRAIN
SET RES
Appendix B
INPUT
J 14 VIPER 12 ON/OFF 2
Figure 3.
F1
16A
R 22 T R1 SEE-MAN U AL 1 1 C7
FB SOURCE
10 0K -1/ 2W
C 10 1 2 C4 22nF /50V 50V J8 2 2
T OKO 0 0499
C 11 R 23 1 2 Vin GN D D6 BZX8 5C16 1uF /50V 16V 2 Vout R 25
F ST 2
D7 STT H 108 1
10 0K -1/ 2W R 24 D3 2. 2uF/ 25V ZX8 4C15 B 25V 10uF /35V 35V 0.23V 3 + L1 1m H/ 350mA D5 BZX8 5C5V1 11 IC 2 L78L05AC Z STT H 108 D 2 C2 C1
see manual
10 0K -1/ 2W 10 0K -1/ 2W C5 100uF /25V 25V
- VDC
BA 2 1 Phas eA C8 100nF /400V 400V 15 16 Gat e1 M3
ST G3 P3 M25N6 0
ALL THE RE SISTORS ACCURACY M UST BE <1%
BB 3 2 1 Gat e2 Emit ter2 R 27 10K-1/ 4W-1% P has e A P has e B P has e C 2 1 1 20 19 7 24 23 14 26 25 21 22 Gat e3 Phas eB
2 3 8 9 12 13
F ST 4
P hase A
+15V
BC
F ST 3
F ST 6
C ON TR O L BOARD
P hase B
2
B rak e Motor
Gat e4 C ON4 G at e1 G at e2 G at e3 G at e4 E m itt er 2 E m itt er 4 G at e5 G at e6 E m itt er 6 R 28 10K-1/ 4W-1% 2 1 R 35 BF R 34 47K-1/ 4W-1% 10K-1/ 4W-1% Gat e5 Phas eC C om Emit ter4
D8
R 33 10K-1/ 4W-1% 1 2 4 3 2 1
BD
F ST 7
STT H 3R06
P hase C
R 10 0. 02R-5W 5W
1
F ST 5 BE
Q8 BC 557B
R 26 47K-1/ 4W-1%
Q7
2
1
Q9
3
SEMITOP 3 Power Board schematic diagram
R 11 47k
BC 547B
H V Monitoring +5V +15V Gat e6 Emit ter6
13 12 11 10 9 8 7 6 5 4 3 2 1 R 14 33K TACHO1 F ST 8 F ST 9 C ON3 3 2 1 TACHO1 R 29 10K-1/ 4W-1%
D% R 30 1K-1/ 4W-18 STT H 108 1 2 R 12 56K1/ 2W R 13 120K-1/ 2W D 19 R 31 1K-1/ 4W-1% STT H 108 1 2 R 15 56K-1/ 2W R 16 120K-1/ 2W R 32 1K-1/ 4WD 20 -1% 1 R 17 56K-1/ 2W STT H 108 2 R 18 120K-1/ 2W
TEMPERATURE SENSOR
Strap if not used
C ON1
for mechanical robustness
C ON2
1 2 3 4 5 +15V 2 1 C9
+5V R 19 4. 7K 100nF /50V 50V R 20 4. 7K R 21 4. 7K
R19, R20, R21 NOT INSTAL LED T itle:
Power Board SEMITOP3
Organis ation name: Siz e +5V D ate:
D rawn by: M .D i Gu
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
15VDC- EXT
SYSTEMS LAB
D ocum ent Number F riday, April 28, 2006 Sheet
Approv ed by: G.R a
SEMITOP 3 Power Board schematic diagram
BA'
BB'
BC '
BD '
BE'
BF'
SEMITOP 3 Power Board schematic diagram
25/30
1
of
Bill of material
UM0252
Appendix C
Table 3.
Bill of material
Bill of material
Value / Part Number 2x2SIP100 2x3SIP100 2x2SIP100 2x4SIP100 2x2SIP100 2x13SIP100 CON1 CON2 CON4 SEE-MANUAL 2.2uF/25V 10uF/35V 22nF/50V 100uF/25V 1uF/50V 100nF/400V 100nF/50V 1N4148 STTH108 BZX84C15 BZX85C5V1 BZX85C16 STTH3R06 Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number 5-7716 5-7716 5-7716 5-7716 5-7716 5-7716 531-936 531-936 531-936 ELCART ELCART ELCART ELCART ELCART ELCART R.S. R.S. R.S.
Index Qty
Reference
Package
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
2 2 2 2 2 2 1 2 1 4 1 1 1 1 1 1 1 1 5 1 1 1 1
BA' and BA BB' and BB BC' and BC BD' and BD BE' and BE BF' and BF CON1 CON2 and J8 CON4 C1, C7, C10 and C11 C2 C3 C4 C5 C6 C8 C9 D1 D2, D7, D18, D19 and D20 D3 D5 D6 D8
FEMALE FEMALE FEMALE FEMALE FEMALE FEMALE 5SIP100TRH 2SIP100TRH 4SIP100TRH electolyticTRH electolyticTRH electolyticTRH CK05Ceramic electolytic CK06Ceramic Polyester CK05Ceramic DO39-TRH DO41-TRH DO41-TRH DO41-TRH DO41-TRH ST ST
STTH108
ST
STTH3R06
ST
26/30
UM0252 Table 3. Bill of material (continued)
Value / Part Number
Bill of material
Index Qty
Reference
Package
Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834 534-834 247-3983 ST ST VIPER12ADIP L78L05ACZ 531-936 531-936 TOKO ST ST 03149 STG3P3M25N6 0 STGP7NC60HD R.S. R.S. R.S. ST ST 228-545 R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S. R.S.
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
FST1 FST2 FST3 FST4 FST5 FST6 FST7 FST8 FST9 F1 IC1 IC2 CON3 J14 L1 M3 Q7 Q8 Q9 R2 R3 R4 R10 R11 R12
VDC+ VDCBrake Motor Phase A Brake Motor Phase B Phase C TACHO1 TACHO2 16A VIPER12ADIP L78L05ACZ CON3 2SIP100 1mH/350mA STG3P3M25N6 0 STGP7NC60H D BC557B BC547B 680K-1/4W-1% 330K-1/4W-1% 12K-1/4W-1% 0.02R-5W 47k-1/4W-1% 56K1/2W
Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals Pcb-SpadeTerminals 6.3X32
3SIP100 STRIP-LINE
TO92 TO92
Low Inductive
IRC
LOB5
Distrelec
71-05-28
27/30
Bill of material Table 3. Bill of material (continued)
Value / Part Number
UM0252
Index Qty
Reference
Package
Manufacturer's Supplier's Manufactu ordering code / Supplier ordering rer Orderable Part code Number
49 50 51 52 53 54 55 56 57 58 34A
3 1 2 3 4 2 5 3 2 1 1
R13, R16 and R18 R14 R15 and R17 R19, R20 and R21 R22, R23, R24 and R25 R26 and R34 R27, R28, R29, R33 and R35 R30,R31,R32 F1-Pcb-FuseHolder TR1 Socket DIL 8 x Viper 12A
120K-1/2W 33K-1/4W-1% 56K-1/2W 4.7K-1/4W-1% Not Mounted 100K-1/2W 47K-1/4W-1% 10K-1/4W-1% 1K-1/4W-1% 410-7874 Transil See manual ST R.S. ST Not Mounted Not Mounted Not Mounted Not Mounted
28/30
UM0252
Revision history
Revision history
Table 4.
Date 30-Jun-2006 25-Jul-2006
Document revision history
Revision 1 2 Initial release. Updated A.1: Front-end on page 23. Changes
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UM0252
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