EVBUM2775 - Compact Intelligent Power Module (IPM) Motor ...
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EVAL BOARD USER’S MANUAL www. onsemi.com © Semiconductor Components Industries, LLC, 2020 September, 2021 − Rev. 2 1 Publication Order Number: EVBUM2775/D Compact Intelligent Power Module (IPM) Motor Control Development Kit (MDK) 1 kW EVBUM2775/D This User Guides refer to revision 0.4 of the SECO−1KW−MCTRL−GEVK evaluation board. Description This user guide provides practical guidelines for compact Intelligent Power Module (IPM) evaluation board with interleaved power factor Correction (PFC) SECO−1KW−MCTRL−GEVB including its main features and key data. The board is fully compatible with the Universal Controller Board (UCB), based on the Xilinx Zynq−7000 SoC, which embeds FPGA logic and two ARM Cortex−A9 processors. As such, the system is fit for high−end control strategies and enables operation of a variety of motor technologies (AC induction motor, PMSM, BLDC, etc.). The board was developed to support customers during their first steps designing application with IPM and PFC. The design was tested as described in this document but not qualified regarding safety requirements or manufacturing and operation over the whole operating temperature range or lifetime. The board is intended for functional testing under laboratory conditions and by trained specialists only. Collateral • SECO−1KW−MCTRL−GEVB • Universal Controller Board (UCB) • NFAQ1060L36T • NCP1632 • FCPF125N65S3 • NCP1063 • NCS2003 • NCS2250 EVAL BOARD USER’S MANUAL Features • 850 W complete motor control solution with AC mains supply 230 Vrms ±15 %, EMI filter, 2−channel interleaved Power Factor Correction (PFC) • Compatible with Universal Controller Board (UCB) FPGA−controller based on Xilinx Zynq− 7000 SoC • User−friendly GUI with V/f and FOC control use cases for rapid evaluation • Highly integrated power module NFAQ1060L36T containing an inverter power stage for a high voltage 3−phase inverter in a DIP−S3 package • PFC stage using NCP1632 controller, FCPF125N65S3 NMOS power transistors and FFSPF1065A diodes • DC/DC converter producing auxiliary power supply 15VDC – non−isolated buck converter using NCP1063 • 3 phase current measurement using 3 x NCS2003 operational amplifier • Over current protection using NCS2250 comparator Attention: The SECO−1kW−MCTRL−GEVB is powered by AC Mains, and exposed to high voltage. Only trained personnel should manipulate and operate on the system. Ensure that all boards are properly connected before powering, and that power is off before disconnecting any boards. It is mandatory to read the Safety Precautions section before manipulating the board. Failure to comply with the described safety precautions may result in personal injury or death, or equipment damage.
Transcript of EVBUM2775 - Compact Intelligent Power Module (IPM) Motor ...
EVAL BOARD USER’S MANUALwww.onsemi.com
© Semiconductor Components Industries, LLC, 2020
September, 2021 − Rev. 21 Publication Order Number:
EVBUM2775/D
Compact Intelligent Power Module (IPM) MotorControl Development Kit (MDK) 1kW
EVBUM2775/D
This User Guides refer to revision 0.4 of theSECO−1KW−MCTRL−GEVK evaluation board.
Description
This user guide provides practical guidelines for compactIntelligent Power Module (IPM) evaluation board withinterleaved power factor Correction (PFC)SECO−1KW−MCTRL−GEVB including its main featuresand key data. The board is fully compatible with theUniversal Controller Board (UCB), based on the XilinxZynq−7000 SoC, which embeds FPGA logic and two ARMCortex−A9 processors. As such, the system is fit forhigh−end control strategies and enables operation of avariety of motor technologies (AC induction motor, PMSM,BLDC, etc.). The board was developed to support customersduring their first steps designing application with IPM andPFC. The design was tested as described in this documentbut not qualified regarding safety requirements ormanufacturing and operation over the whole operatingtemperature range or lifetime. The board is intended forfunctional testing under laboratory conditions and bytrained specialists only.
Collateral• SECO−1KW−MCTRL−GEVB
• Universal Controller Board (UCB)
• NFAQ1060L36T
• NCP1632
• FCPF125N65S3
• NCP1063
• NCS2003
• NCS2250
EVAL BOARD USER’S MANUAL
Features• 850 W complete motor control solution with AC mains
supply 230 Vrms ±15 %, EMI filter, 2−channelinterleaved Power Factor Correction (PFC)
• Compatible with Universal Controller Board (UCB)FPGA−controller based on Xilinx Zynq− 7000 SoC
• User−friendly GUI with V/f and FOC control use casesfor rapid evaluation
• Highly integrated power module NFAQ1060L36Tcontaining an inverter power stage for a high voltage3−phase inverter in a DIP−S3 package
• PFC stage using NCP1632 controller, FCPF125N65S3NMOS power transistors and FFSPF1065A diodes
• DC/DC converter producing auxiliary power supply15VDC – non−isolated buck converter using NCP1063
• 3 phase current measurement using 3 x NCS2003operational amplifier
• Over current protection using NCS2250 comparator
Attention: The SECO−1kW−MCTRL−GEVB is powered by AC Mains, and exposed to high voltage. Only trainedpersonnel should manipulate and operate on the system. Ensure that all boards are properly connected beforepowering, and that power is off before disconnecting any boards. It is mandatory to read the Safety Precautionssection before manipulating the board. Failure to comply with the described safety precautions may result inpersonal injury or death, or equipment damage.
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Overview
The block diagram of the whole system is represented inFigure 1. The picture of the real board is in the Figure 2 andFigure 3.
Figure 1. Block Diagram of the Evaluation Board
Figure 2. Picture of the Evaluation Board – Top Side
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Figure 3. Picture of the Evaluation Board – Bottom Side
Figure 4. Picture of the UCB Adapter
(Top Side) (Bottom Side)
PREREQUISITES
Hardware• SECO−1 kW−MCTRL−GEVB (includes power board
and adapter for UCB)• AC power cord one−phase
• Universal Controller Board (UCB) or pin−compatiblecontroller board
• USB isolator (5 kV optical isolation)
• HF ferrite clamp i.e. WE 7427154
Software• Downloadable GUI
• Binary file
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SPECIFICATION
The specification and main features can be seen in theTable 1.
Table 1. EVALUATION BOARD SPECIFICATIONS
Parameters Values Conditions/comments
INPUT
Voltage 230 Vrms±15%
OUTPUT
Power 850 W Input 230 VAC, fPWM = 16 kHz, TA = 25°C
Current per IPM leg ±5 Arms TC = 100°C
DC BUS Voltage 390 V Higher voltage value is created by interleaved PFC withNCP1632 working as a booster
CURRENT FEEDBACK
Current sensing resistors 39 m
Op Amp power supply 3.3 V
Set Op Amp gain 5
Set output offset 1.65 V Because of negative current measurement
Overcurrent protection 9 Apeak Configured by shunt resistors and comparator threshold(voltage divider)
AUXILIARY POWER SUPPLY
15 V 4.6 W Used NCP1063
CONTROL
Board with Microcontroller and 3V3 power supply Arduino DUE headers
Type of control V/f, Field Oriented Control (Sensor−less)
Supported type of motors ACIM, PMSM, BLDC
APPLICATION
White goods (washers), Industrial fans, Industrial automation
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SAFETY PRECAUTIONS
It is mandatory to read the following precautions beforemanipulating the SECO−1KW−MCTRL−GEVB.
Table 2.
SECO−1KW−MCTRL−GEVB
The ground potential of the system is biased to a negative DC bus voltage potential. When measuring voltagewaveform by oscilloscope, the scope’s ground needs to be isolated. Failure to do so may result in personalinjury or death
The ground potential of the system is NOT biased to an earth (PE) potential. When connecting the MCU boardvia USB to the computer, the appropriate galvanically isolated USB isolator have to be used. The recommendedisolation voltage of USB isolator is 5 kV
SECO−1KW−MCTRL−GEVB system contains DC bus capacitors which take time to discharge after removal ofthe main supply. Before working on the drive system, wait ten minutes for capacitors to discharge to safe volt-age levels. Failure to do so may result in personal injury or death.
Only personnel familiar with the drive and associated machinery should plan or implement the installation, start−up and subsequent maintenance of the system. Failure to comply may result in personal injury and/orequipment damage.
The surfaces of the drive may become hot, which may cause injury.
SECO−1KW−MCTRL−GEVB system contains parts and assemblies sensitive to Electrostatic Discharge (ESD).Electrostatic control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with electrostatic control procedures, refer to applicable ESD protection handbooks and guidelines.
A drive, incorrectly applied or installed, can result in component damage or reduction in product lifetime. Wiring or application errors such as under sizing the motor, supplying an incorrect or inadequate AC supply orexcessive ambient temperatures may result in system malfunction.
Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Waitten minutes after removing power to discharge the bus capacitors. Do not attempt to service the drive until thebus capacitors have discharged to zero. Failure to do so may result in personal injury or death.
SECO−1KW−MCTRL−GEVB system is shipped with packing materials that need to be removed prior to installation. Failure to remove all packing materials which are unnecessary for system installation may result inoverheating or abnormal operating condition.
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SCHEMATICS AND LAYOUT
To meet customer requirements and make the evaluationboard a basis for development, all necessary technical datalike schematics, layout and components are included in thischapter. Also simple measurements were done to show thefunctionality of individual stages.
Input EMI FilterFigure 5 depicts schematic from AC input to rectifier
input. This circuitry include a passive EMI filter consistingof elements C16, L5, CY1, CY3, CY4, C51, L4 and C17.
Figure 5. Schematic of EMI filter
R1
2R2
R5680k
R2680k
R4680k
F1
10 A
PE
C16
L4
1−1
2−1
1−2
2−2
L5
2 x 2.2 mH
C17680 nF
CY3
4700 pF
CY4
4700 pF
AC_L
AC_N
L_IN
N_IN
CY14700 pF
C51680 nF
PHAS
E_EM
I_01
PHASE_EMI_OUT
PHASE_EMI_IN
NEUTRAL_EMI_IN NEUTRAL_EMI_OUT
PE
iAC_IN
iAC_IN
iAC_IN
iAC_IN
iAC_IN
iNEUTRAL_IN
iNEUTRAL_IN
iPE
iGND
4 A
G_PFC
R31 F
150 H
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Interleaved PFC StageIn higher power applications to utilize full capacity power
of mains and reduce harmonics is PFC−regulators generallyrequired. This high power application use interleaved PFCstages, where may reduce inductor size, input and outputcapacitors ripple current. In overall, power components aresmaller include capacitors. The NCP1632 as voltage modeIC for interleaved PFC applications used in conduction
critical mode. It drives two mosfets 180° phase shifted. Themost important at design should be focused significantinductance value of selected PFC coils. It significantlyspecifies working range.
Figure 6 depicts schematic from rectifier input to DC linkoutput. Activation of stage (connection to 15 V DC powersupply) is via J2 (soldered pads).
Figure 6. Schematic of interleaved PFC stage
C4R63M9
R123M9
R173M9
R213M9
R22120kC7
330 nF
G_PFC G_PFC
R81M8
R151M8
R19820k
R2327kC8
1 nF
G_PFC
R91M8
R161M8
R20560k
R2427k
G_PFC
C91 nF
ZCD2 1
FB 2
RT3
OSC4
VC5
FFOL
D6
BO7
OVP 8
CS9
Latch 10
DRV2 11
VCC12
GND
13
DRV1 14
REF5V15
ZCD1 16
controlblocks
U1
NCP1632
R1811k5
R37143k
R33270k
R345k1 C13
68 pF
C151 nF
G_PFC
R3515k
C11 C12
220 nF
G_PFC
R3222k
R3622k
D9
MMSD4148T1G
C14
470 nF
R1022k
R1122k
D1
1N5406RLG
Q1FCPF125N65S3
Q2
MMBT589LT1G
D3
MMSD4148T1GR7
10R
R14
0R
R1310k
G_PFC
R261k8
R310R075
R300R075 D8
NTSS3100
G_PFC
R271k
D6
SMF15AT1G
C1010 nF
C5
100 nF
Q3FCPF125N65S3
Q4MMBT589LT1G
D7
MMSD4148T1GR25
10RR29
0R
R2810k
G_PFC
D2
FFSPF1065A
D5
FFSPF1065A
5
2
8
3
TR1
7503147245
2
8
3
TR2
750314724
C3
100 nF
G_PFC
C6
DC_LINK
21
J2
sold
ered
pad
s
AC_L
AC_N
15VDC
G_PFC G_PFC G_PFC G_PFC G_PFC
G_PFCC42
G_PFC
15VDC
TP1TP22
TP24
TP25
TP26
TP23
TP27
DCLINK_POS
D4GBU6K
TP28
PHASE_PFC_IN
NEUTRAL_PFC_IN
DC_PFC_IN iDC_IN
i DC_IN
i DC_IN
DCLINK_POS
1 F
100 F 22
470 F
5 V reg
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Basic tests and measurements were done. The results ofefficiency, power factor, power losses, load transients and
startup can be seen in the Figures 7−13. The used load wasHalogen light bulb.
Figure 7. Efficiency of PFC Stage for Various Value of Input AC Voltage and Load
95.00%
95.20%
95.40%
95.60%
95.80%
96.00%
96.20%
96.40%
96.60%
96.80%
97.00%
190 200 210 220 230 240 250 260 270
Effi
cien
cy [%
]
Input AC voltage [V]
Efficiency PFC stage
930 W load
466 W load
155 W load
Figure 8. Power Factor of PFC Stage for Various Value of Input AC Voltage and Load
0.838
0.858
0.878
0.898
0.918
0.938
0.958
0.978
0.998
190 200 210 220 230 240 250 260 270
Effi
cien
cy [%
]
Input AC voltage [V]
Power factor PFC stage
933 W load
466 W load
155 W load
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Figure 9. Power Losses of PFC Stage for Various Value of Input AC Voltage and Load
0.838
0.858
0.878
0.898
0.918
0.938
0.958
0.978
0.998
190 200 210 220 230 240 250 260 270
Effi
cien
cy [%
]
Input AC voltage [V]
Power factor PFC stage
933 W load
466 W load
155 W load
Figure 10. Load Transient 155 W to 930 W at 230 V AC Input
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Figure 11. Load Transient 930 W to 155 W at 230 V AC Input
Figure 12. Start up to Open Circuit, 155 W and 930 W at 230 V AC Input
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Figure 13. Start to 930 W at 230 V AC Input, Inrush Current
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Auxiliary 15 V Power SupplyThe NCP1063 is used as converter 390 V to 15 V output
to supply PFC, IPM and Control board (Arduino Due). Themaximal power delivered is up to 4.6 W. Figure 14 depicts
schematic of 15 V auxiliary power supply. Figure 15 showsstartup of the converter.
Figure 14. Schematic of Auxiliary 15V Power Supply
DC_LINK
D15MMSD4148T1G
L2
L1
1 mH
D17MURA160T3G
D14
MRA4007T3G
C35100 nF
C36
C1
DRAIN8
DRAIN7
COMP5
GND1
VCC2
LIM/OPP3
FB 4
block
9V reg
2.7 V
Vref+
−OTA
control
IC1
NCP1063AP60
G_PFC G_PFC G_PFC G_PFC
C39 C40
G_PFC
C41
150 nF
R5115k
G_PFC
R4856k
R5015k
R4915k C38
47 nF
D16
MURA160T3GC37330 nF
G_PFC G_PFC
C2100 nF
15VDC15VDC
TP21
TP20DCLINK_POS
TP3
R47
10 F
470 H
220 F 220 F
10 F
9 V reg
Figure 15. Start Up to Open Circuit, to 50 mA and to 300 mA at 390 V DC Input
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IPM StageThis stage uses NFAQ1060L36T IPM for 3−phase motor
drives containing three−phase inverter, gate drivers for theinverter and a thermistor. It uses onsemi’s Insulated MetalSubstrate (IMS) Technology. Very important function isover−current protection which is deeply described inchapter – Current Measurement and Over−CurrentProtection. Module also contains fault pin which is keeping
high level during normal state. Activation of IPM stage(connection to 15 V DC power supply) is via J1 (solderedpads). In the figure 15 is shown schematics of IPM stage alsowith DC link voltage measurement (voltage dividercontaining R46, R52, R53 and R55). Signals from 39 m
shunt resistors are going to current measurement andover−current protection circuits.
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Figure 16. Schematic of IPM Stage
R38
100R
VSS 1
VDD2
HIN
13
HIN
24
U,V
S132
VB
134
VCC38
HIN
35
LIN
16
LIN
27
LIN
38
FAU
LT9
ITRIP 10
EN
AB
LE
11
RC
IN12
TH1 13
TH
214
U− 17
V− 18
W− 19
VB
228
V,V
S226
VB
322
W,V
S320
IGB
T
driv
ers
VC
C
VC
C
VC
C
cont
rol
logi
c
U2
NFA
Q10
60L
36T
R39
100R
R40
100R
R41
100R
R42
100R
R43
100R
C23
D11
SM
F15A
T1G
C25
D12
SM
F15A
T1G
C33
D13
SM
F15A
T1G
C26
100
pF
C27
100
pF
C28
100
pF
C29
100
pF
C30
100
pF
C31
100
pF
C22
100
nF
C24
100
nF
C32
100
nF
C21
C20
100
nF
D10
SMF15A
T1G
R44
2M
C34
1 n
F
R57
5k1
R45
39kC
18
250
nF
IPM
CO
NT
RO
L
LB
U
HB
U
HB
V
LB
V
HB
W
LB
W
EN
AB
LE
IPM
_CT
RL
IPM
_SE
NSE
V_D
CL
INK
TE
MP
ER
AT
UR
E
FAU
LT
IPM
_SE
NSE
15V
DC
DC
_LIN
K
U_O
UT
V_O
UT
W_O
UT
3P
HA
SE
_O
UT
3PH
ASE
_OU
T
G_I
PM
G_I
PMG
_IPM
12
NT
2
G_I
PM
R58
100R
3V3
G_I
PM
G_I
PM
R56
5k1
C19
100
pF
G_I
PM
R54
100R
R46
330k
R52
330k
R53
330k
R55
6k8
TP5
U TP9
V TP1
3W
TP6
TP7
TP8
TP1
0
TP1
1
TP1
2
TP1
7
TP1
4
TP1
5
TP1
6
TP2
TP4
G_I
PM
V_D
CL
INK
FAU
LT
TE
MP
ER
AT
UR
E
EN
AB
LE
HB
U
LB
U
HB
V
LB
V
HB
W
LB
W
15V
DC
V_O
UT
R59
0R03
9R
600R
039
R61
0R03
9
G_I
PM
U_p
os
V_p
os
W_p
os
C_s
ense
C_S
EN
SE
ITR
IP
C43
1 n
F
R62
10k
G_I
PM
21
J1 sold
ered
pad
s
3V3
U_O
UT
V_D
CL
INK
i
AC
_O
UT
iA
C_O
UT
iA
C_O
UT
i
DC
LIN
K_P
OS
iA
C_O
UT
iA
C_O
UT
iA
C_O
UT
12
NT
1
12
NT
3
G_P
FC
DC
LIN
K_P
OS
TP1
8
330
F
22
F
22
F
22
F
cont
rol
IGB
T
driv
ers
VB
1
U, V
S2H
IN1
HIN
2
VSS
VCC
VDD
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Current Measurement and Over−Current ProtectionSchematic of current measurement and over−current
protection can be seen in the Figure 17. Information aboutcurrents is provided via 39 m shunt resistors. Voltage dropfrom shunt resistor is going to input of operational amplifier(op−amp) NCS2003 which gain is set to 4.99 with 1k resistorand 4k99 resistor connected as negative feedback. U7(TLV431) is creating 1.65 V reference which is connectedto non−inverting input of op−amps. This connectionprovides voltage offset at the output of op−amps, which isneeded for negative current measurement.
Overcurrent protection is offered by NCS2250comparator. Comparator threshold is set by voltage dividerwhich consists of R68, R71 and C48. Signals from shuntresistors are going via R78, R81 and R84 connected tonon−inverting input. These resistors together with C58 arealso acting as low pass filter for high frequency signalsinterference. On the one hand, with insufficient filtering theover− current protection can react for lower values of currenteven if there is 350 ns blanking time on ITRIP pin of IPM toimprove noise immunity (see datasheet of IPM). On theother hand, when we are designing this filter it is needed to
be careful about the maximal time constant value accordingshort circuit safe operating area (see datasheet of IPM,NFAQ1060L36T− for VCE = 400 V is 4 s). Output fromcomparator is connected to ITRIP pin of IMP module. Aswas mentioned in previous chapter, IPM has fault pin and itsvoltage level is high during normal state. An over−currentcondition is detected if the voltage on the ITRIP pin is largerthan the reference voltage (typically 0.5 V). After ashutdown propagation delay of typically 1.1 s, the FAULToutput is switched on. The FAULT output is held on for atime determined by the resistor and capacitor connected tothe RCIN pin (IPM pin 12). If R44 = 2 MΩ and C34 = 1 nF,the FAULT output is switched on for 1.65 ms (typical). Theover−current protection threshold should be set to be equalor lower to 2 times the module rated current. The reaction ofthe protection can be seen in the Figure 18 and 19. Systemis also using ENABLE pin of the IPM. After theover−current fault, fault signal is generated and sent tomicrocontroller which disable the IPM via ENABLE pin(programmed by user). New operation is possible aftermicrocontroller reset.
Figure 17. Schematic of Current Measurement and Overcurrent Protection
C49
100 nF
I_U
I_V
I_W
R77680R
R791k
R823k
1
K2
A3
U7TLV431
52
VSS
VD
D
IN−4
IN+3
OUT 1Q5
NCS2250SN2T3G
3V3
R67
1k
R69
1k
C50100 pF
U_pos
V_pos
W_pos
C_SENSE
C_SENSE
R70
1k
R72
1k
C53100 pF
R73
1k
R75
1k
C56100 pF
G_IPM
R78
100RR76
215k
C6010 nF
R81
100R
R84
100R
3V3
G_IPM
ITRIP
I_SENSEI_V
I_W
I_U
I_SENSE
C61
3V3
G_IPM
R6821.5 k
R711kC48
100 nF
G_IPM
G_IPM
C5815 nF
G_IPM
R80
4k99
R85
4k99
R87
4k99
R834k99
R864k99
R744k99C52
10 nF
C54
10 nF
C55
10 nF
G_IPM
G_IPM
C5710 nF
1V65
52
VSS
VD
D
IN−4
IN+3
OUT 1
U3NCS2003SN2T1G
52
VSS
VD
D
IN−4
IN+3
OUT1
U4NCS2003SN2T1G
52
VSS
VD
D
IN−4
IN+3
OUT 1
U5NCS2003SN2T1G
3V3
G_IPM
G_IPM
C59100 nF
C6210 nF
3V3
C63100 nF
C6410 nF
G_IPM
3V3
47 F
RE
F
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Figure 18. Reaction of Over−current Protection
Figure 19. Reaction of Over−current Protection − Detail
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Control Board HeadersSchematic of control board headers can be seen in the
Figure 20. The headers have Arduino Due footprint. Theapplied control board has to contain 3V3 power supply as itis also used for supplying current measurement op amps and
comparator for over−current protection. Low pass filters forcurrent and voltage measurement signals are placed closedto the headers (see CON4). When connecting the controlboard to the PC, do not forget to use isolator.
Figure 20. Schematic of Control Board Headers
1
4
2
5
3
6
7
8
CON6
1
4
2
5
3
6
7
8
CON7
IPM CONTROL
LBU
HBU
HBV
LBV
HBW
LBW
ENABLEIPM_CTRL
IPM_SENSEV_DCLINK
TEMPERATURE
FAULT
IPM_SENSE
3V3
12
34
6
8
10
12
14
16
5
7
9
11
13
15
17
19
18
20
2122
2324
26
28
30
32
34
36
25
27
29
31
33
35
CON3
15VDC
G_IPM
R63
1kR64
1kR65
1kR66
1k
C47
1 nF
C46470 pF
C45470 pF
C44470 pF
G_IPM G_IPM G_IPM G_IPM
1
4
2
5
3
6
7
8
CON4
I_SENSE I_V
I_W
I_U
I_SENSE
3V3
FAULT
TEMPERATURE
V_DCLINK
G_IPM
LayoutEvaluation board consist of 4 layers. Following figures
are showing all the layers. Board size is 280x112 mm.
Figure 21. Top Layer Routing and Top Assembly
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Figure 22. Internal Layer 1
Figure 23. Internal Layer 2
Figure 24. Bottom Layer Routing and Bottom Assembly
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SoftwareFOC has been widely used during the last decade as an
efficient way to control various types of motors over widespeed ranges. The controller optimizes the efficiency of thesystem as it produces the required motor torque with thelowest possible phase−currents, by maintaining a 90° anglebetween the rotor flux and current. Moreover, it providesfast dynamic response and a low current harmonic content.Numerous scientific and technical papers in literaturedescribe thoroughly the FOC operation. We would like tonote that the analysis of FOC falls beyond the scope of thisdocument. For a more comprehensive description of FOCoperation, the reader may refer to the correspondingreferences. [8]−[10].
UCB with Pre−flashed Firmware
(UCB acquired as part of SECO−1KW−MCTRL−GEVK)
If you acquired the UCB as part of the onsemi kit, thecontroller is already flashed with V/F control and FOCcontrol. The user does not have to perform any furtheractions for booting. It is noted however, that booting fromthe flash, the SD−socket at UCB should be empty. With theflashed controller, the user can control the motor via thegraphical user interface (GUI) of Figure 25. Download andinstall Strata Developer Studio to access the GUI. Once thisstep is done, UCB can be connected and powered up, StrataDeveloper Studio will detect the board automatically anddisplay the board as connected.
To open the GUI, click Hardware controls next to theconnected board. With the GUI, the user can select betweenthe V/F and FOC strategy. The GUI also assists the end−userto configure and tune the foremost V/F and FOC parameters,while it also provides visual representation of key electricalvariables, such as the DC−Link voltage and temperature ofIPM, the RMS value of the inverter output current andvoltage, and the motor speed.
Rewriting Flash Memory or SD−card Image
(Important when UCB not acquired as part of theSECO−1KW−MCTRL−GEVK)
In case the user wants to rewrite the flash memory with thedefault V/F−FOC control, he can use the boot−image andfsbl.elf files that are accessible via the link in [12]. Todownload the boot−image and fsbl.elf, click the link in [12]and download the latest version of software; boot−imageand fsbl.elf files are included in the UCB_firmware of thedownloaded software file.
The following guide contains material on how to load theboot image:• Flashing QSPI memory [11] (link)
To boot from SD card, copy the boot image that is found in[12] into the root directory of the SD card. Then place theSD card into the SD socket of UCB. Upon power−up theUCB will automatically boot from the SD card.
Figure 25. Graphical User Interface (GUI) in Strata Developer Studio
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Electromagnetic CompatibilityDue to the inherent high frequency common mode noise
generated by the power switches, it is stronglyrecommended to install a ferrite clamp on the motor wires.
This will prevent disturbing other electronic devices in thevicinity, including the UCB.
The recommended CM filter setup is depicted in thepicture below.
Figure 26. Recommended EMC Filter
USB IsolatorDuring the communication with control board and PC,
using of USB isolator is very important because of safety.
In the Figure 27 can be seen evaluation board with USBisolator (5 kV optical isolation).
Figure 27. Evaluation Board with Control Board and USB Isolator
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Bill of MaterialsTable 3 provides bill of materials of the evaluation board.
Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD
No. Designator Comment Manufacturer Part number Quantity
1. C1 10 F Würth Electronik 865080540004 1
2. C2 100 nF Würth Electronik 885012206071 1
3. C3, C5 100 nF Würth Electronik 885012206095 2
4. C4, C16 1 F Würth Electronik 890334026027CS 2
5. C6 100 F Würth Electronik 875115652007 1
6. C7 330 nF Murata GRM188R71C334JA01D 1
7. C8, C9 1 nF Würth Electronik 885012006044 2
8. C10, C52, C54,C55, C57, C62,
C64
10 nF Würth Electronik 885012206089 7
9. C11 22 Würth Electronik 885012206027 1
10. C12 220 nF Murata GRM188R71H224KAC4D 1
11. C13 68 pF Murata GRM1885C1H680JA01D 1
12. C14 470 nF Murata GRM188R61H474KA12D 1
13. C15 1 nF Würth Electronik 885012006063 1
14. C17, C51 680 nF Würth Electronik 890334026020CS 2
15. C18 250 nF TDK B58031I9254M062 1
16. C19, C26, C27,C28, C29, C30,C31, C50, C53,
C56
100 pF Würth Electronik 885012006057 10
17. C20 100 nF Würth Electronik 885012207072 1
18. C21 330 F Würth Electronik 875075661010 1
19. C22, C24, C32 100 nF Würth Electronik 885012105018 3
20. C23, C25, C33 22 F TDK C4532X7R1E226M250KC 3
21. C34, C43, C47 1 nF Würth Electronik 885012206083 3
22. C35 100 nF Würth Electronik 890334025017CS 1
23. C36 10 F Rubycon 450BXF10M10X16 1
24. C37 330 nF Würth Electronik 885012207101 1
25. C38 47 nF Würth Electronik 885012206093 1
26. C39, C40 220 F Würth Electronik 860040474004 2
27. C41 150 nF Murata GRM188R71H154KAC4D 1
28. C42 470 F Würth Electronik 861141486024 1
29. C44, C45, C46 470 pF Würth Electronik 885012006061 3
30. C48, C49, C59,C63
100 nF Wurth Electronics 885012206046 4
31. C58 15 nF Würth Electronik 885012206090 1
32. C60 10 nF Würth Electronik 885012206065 1
33. C61 47 F Murata GRM188R60J476ME15D 1
34. CON1 Black TE Connectivity 6ESRM−P 1
35. CON2 Green Würth Elektronik 691313710003 1
36. CON3 610 036 218 21 Würth Elektronik 61003621821 1
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Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD
No. QuantityPart numberManufacturerCommentDesignator
37. CON4, CON6,CON7
610 008 13 321 Würth Elektronik 61000813321 3
38. CON5 691 313 510 002 Würth Elektronik 691313510002 1
39. CY1, CY3, CY4 4700 pF Murata DE1E3KX472MA4BN01F 3
40. D1 1N5406RLG onsemi 1N5406RLG 1
41. D2, D5 FFSPF1065A onsemi FFSPF1065A 2
42. D3, D7, D9, D15 MMSD4148T1G onsemi MMSD4148T1G 4
43. D4 GBU6K onsemi GBU6K 1
44. D6, D10, D11, D12,D13
SMF15AT1G onsemi SMF15AT1G 5
45. D8 NTSS3100 onsemi NTSS3100T3G 1
46. D14 MRA4007T3G onsemi MRA4007T3G 1
47. D16, D17 MURA160T3G onsemi MURA160T3G 2
48. F1 10 A Schurter 0031.8201 1
49. F2 4 A Schurter 0034.3123 1
50. FC1 Fuse cover Schurter 0853.0551 1
51. HSA, HSB SK 489 50 mmblack anodized
2
52. HSC SK 92 30 mmnatural anodized
1
53. HSD SK 447 37.5 mmblack anodized
1
54. IC1 NCP1063AP60 onsemi NCP1063AP60G 1
55. J_AC_OUT 691 351 500 003 Würth Elektronik 691351500003 1
56. J_DC390V 691 351 500 002 Würth Elektronik 691351500002 1
57. L1 1 mH Würth Elektronik 744731102 1
58. L2 470 H Würth Elektronik 744731471 1
59. L4 150 H Würth Elektronik 7447076 1
60. L5 2 x 2.2 mH Würth Elektronik 744824622 1
61. NAC1, NAC2 nut M3 ISO4032 2
62. Q1, Q3 FCPF125N65S3 onsemi FCPF125N65S3 2
63. Q2, Q4 MMBT589LT1G onsemi MMBT589LT1G 2
64. Q5 NCS2250SN2T3G onsemi NCS2250SN2T3G 1
65. R1 2R2 TDK B57237S0229M000 1
66. R2, R4, R5 680k Vishay CRCW1206680KFKEA 3
67. R3, R47 320 V TDK B72214S0321K101 2
68. R6, R12, R17, R21 3M9 Vishay CRCW12063M90FKEA 4
69. R7, R25 10R Panasonic ERJ6ENF10R0V 2
70. R8, R9, R15, R16 1M8 Vishay CRCW12061M80FKEA 4
71. R10, R11, R32,R36
22k Panasonic ERJ3EKF2202V 4
72. R13, R28 10k Panasonic ERJ6ENF1002V 2
73. R14, R29 0R Panasonic ERJ6GEY0R00V 2
74. R18 11k5 Panasonic ERJ3EKF1152V 1
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Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD
No. QuantityPart numberManufacturerCommentDesignator
75. R19 820k Panasonic ERJU08F8203V 1
76. R20 560k Panasonic ERJU08F5603V 1
77. R22 120k Panasonic ERJ3EKF1203V 1
78. R23, R24 27k Panasonic ERJ3EKF2702V 2
79. R26 1k8 Panasonic ERJ3EKF1801V 1
80. R27, R63, R64,R65, R71, R79
1k Panasonic ERJ3EKF1001V 6
81. R30, R31 0R075 Bourns CRA2512−FZ−R075ELF 2
82. R33 270k Panasonic ERJ3EKF2703V 1
83. R34, R56, R57 5k1 Panasonic ERJ3EKF5101V 3
84. R35, R49, R50,R51
15k Panasonic ERJ3EKF1502V 4
85. R37 143k Panasonic ERJ3EKF1433V 1
86. R38, R39, R40,R41, R42, R43,R54, R58, R78,
R81, R84
100R Panasonic ERJ3EKF1000V 11
87. R44 2M Vishay CRCW06032M00FKEA 1
88. R45 39k Panasonic ERJ3EKF3902V 1
89. R46, R52, R53 330k Vishay CRCW1206330KFKEA 3
90. R48 56k Panasonic ERJ3EKF5602V 1
91. R55 6k8 Panasonic ERJP08F6801V 1
92. R59, R60, R61 0R039 KOA SPEERELECTRONICS
TLRH3AWTTE39L0F 3
93. R62 10k Panasonic ERJ3EKF1002V 1
94. R66, R67, R69,R70, R72, R73,
R75
1k Panasonic ERJ3RBD1001V 7
95. R68 21k5 Panasonic ERJ3EKF2152V 1
96. R74, R80, R83,R85, R86, R87
4k99 TT Electronics PCF0603R−4K99BT1 6
97. R76 215k Panasonic ERJ3EKF2153V 1
98. R77 680R Panasonic ERJ3EKF6800V 1
99. R82 3k Panasonic ERJ3EKF3001V 1
100. SAC1, SAC2,SHA1, SHA2,SHB1, SHB2,
SHD1
M3x8 DIN7985 7
101. SB1, SB2, SB3,SB4, SB5, SB6
Spacer M3 F/F 50HEX7
6
102. SDA, SDB, SDD,SHC1, SHC2, SQA,
SQB
M3x16 DIN7985 7
103. SHSA1, SHSA2,SHSB1, SHSB2
spacer for M3 Wurth Elektronik 963030042 4
104. ST1, ST2, ST3,ST4, ST5, ST6
Spacer M3 M/F6/30 HEX7
6
105. TP1, TP2 RED KeystoneElectronics
5005 2
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Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD
No. QuantityPart numberManufacturerCommentDesignator
106. TP3, TP17, TP24 ORANGE KeystoneElectronics
5008 3
107. TP4, TP18, TP21 WHITE KeystoneElectronics
5007 3
108. TP5, TP9, TP13,TP22
BROWN KeystoneElectronics
5120 4
109. TP6, TP7, TP8,TP10, TP11, TP12,TP14, TP25, TP26
YELLOW KeystoneElectronics
5009 9
110. TP15, TP16 BLUE KeystoneElectronics
5122 2
111. TP20, TP23, TP28 PURPLE KeystoneElectronics
5124 3
112. TP27 BLACK KeystoneElectronics
5006 1
113. TR1, TR2 750314724 Würth Elektronik 750314724 2
114. U1 NCP1632 onsemi NCP1632DR2G 1
115. U2 NFAQ1060L36T onsemi NFAQ1060L36T 1
116. U3, U4, U5 NCS2003SN2T1G onsemi NCS2003SN2T1G 3
117. U7 TLV431 onsemi TLV431CSN1T1G 1
118. WAC1, WAC2,WHSA1, WHSA2,WHSB1, WHSB2,WPDA, WPDB,WPDD, WPQA,WPQB, WSHC1,WSHC2, WSHD1
plain washer M3DIN125A
14
119. WHAD, WHAQ,WHBD, WHBQ
AOS 22018x12x1.5 D3.1
4
120. WSDA, WSDB,WSDD, WSQA,
WSQB
spring washer M3DIN7980
5
Table 4. BILL OF MATERIALS OF THE UCB ADAPTER
No. Designator Comment Manufacturer Part number Quantity
1. C1 10 F, 50 V Wurth Elektronik 885012108022 1
2. C2, C11, C12 10 F, 10 V Wurth Elektronik 885012107010 3
3. C3 100 F, 25 V Wurth Elektronik 865080449011 1
4. C4, C5 100 nF, 16 V Wurth Elektronik 885012206046 2
5. C15, C21 10 nF, 50 V Wurth Elektronik 885012206089 2
6. C16 470 nF, 50 V Wurth Elektronik 885012207102 1
7. C19, C20 22 F, 10 V Wurth Elektronik 885012209006 2
8. C23 470 pF, 50 V Wurth Elektronik 885012006061 1
9. D1, D2, D3, D4,D5, D6, D7, D8,
D9, D10
BAT54S onsemi BAT54S 10
10. D11, D12 MBR230LSFT1G onsemi MBR230LSFT1G 2
11. D13 MBRS2040LT3G onsemi MBRS2040LT3G 1
12. J1 61001011921 Wurth Elektronik 61001011921 1
13. J2, J3, J5, J6, J7 61000811921 Wurth Elektronik 61000811921 5
14. J4 61003621821 Wurth Elektronik 61003621821 1
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Table 4. BILL OF MATERIALS OF THE UCB ADAPTER
No. QuantityPart numberManufacturerCommentDesignator
15. J8 61000621821 Wurth Elektronik 61000621821 1
16. J9 694106105102 Wurth Elektronik 694106105102 1
17. JB1, JB2 10139781−121402LF Amphenol 10139781−121402LF 2
18. L1 22 H, 3 A Wurth Elektronik 7447714220 1
19. R1, R6 0R 2
20. R3 0R 1
21. R4 270R 1
22. R5 560R 1
23. R7, R8 470R 2
24. R45 22k 1
25. R46 3k 1
26. R47 56k 1
27. U1 FAN8303MX onsemi FAN8303MX 1
28. U2 NCP1117ST33T3G onsemi NCP51460SN33T1G 1
29. U3 NCP1117ST50T3G onsemi NCP1117ST50T3G 1
30. C1 10 F, 50 V Wurth Elektronik 885012108022 1
31. C2, C11, C12 10 F, 10 V Wurth Elektronik 885012107010 3
32. C3 100 F, 25 V Wurth Elektronik 865080449011 1
33. C4, C5 100 nF, 16 V Wurth Elektronik 885012206046 2
34. C15, C21 10 nF, 50 V Wurth Elektronik 885012206089 2
35. C16 470 nF, 50 V Wurth Elektronik 885012207102 1
36. C19, C20 22 F, 10 V Wurth Elektronik 885012209006 2
37. C23 470 pF, 50 V Wurth Elektronik 885012006061 1
38. D1, D2, D3, D4,D5, D6, D7, D8,
D9, D10
BAT54S onsemi BAT54S 10
39. D11, D12 MBR230LSFT1G onsemi MBR230LSFT1G 2
40. D13 MBRS2040LT3G onsemi MBRS2040LT3G 1
41. J1 61001011921 Wurth Elektronik 61001011921 1
42. J2, J3, J5, J6, J7 61000811921 Wurth Elektronik 61000811921 5
43. J4 61003621821 Wurth Elektronik 61003621821 1
44. J8 61000621821 Wurth Elektronik 61000621821 1
45. J9 694106105102 Wurth Elektronik 694106105102 1
46. JB1, JB2 10139781−121402LF Amphenol 10139781−121402LF 2
47. L1 22 , 3 A Wurth Elektronik 7447714220 1
48. R1, R6 0R 2
49. R3 0R 1
50. R4 270R 1
51. R5 560R 1
52. R7, R8 470R 2
53. R45 22k 1
54. R46 3k 1
55. R47 56k 1
56. U1 FAN8303MX onsemi FAN8303MX 1
57. U2 NCP1117ST33T3G onsemi NCP51460SN33T1G 1
58. U3 NCP1117ST50T3G onsemi NCP1117ST50T3G 1
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REFERENCES
[1]. Datasheet of IPM NFAQ1060L36T, available ononsemi website
[2]. Datasheet of NCP1632, available on onsemiwebsite
[3]. Application note − Key Steps to Design anInterleaved PFC Stage Driven by the NCP1632,available on onsemi website
[4]. Datasheet of NCP1063, available on onsemiwebsite
[5]. Application note − Universal AC Input, 12V0.35 A Output, 4.2 Watt Non−isolated PowerSupply, available on onsemi website
[6]. Datasheet of NCS2003, available on onsemiwebsite
[7]. Datasheet of NCS2250, available on onsemiwebsite
[8]. J.A. Santisteban, R.M. Stephan, “Vector controlmethods for induction machines: an overview,”IEEE Transactions on Education, Vol 44, no 2,pp−170−175, May 2001.
[9]. M. Ahmad, “High Performance AC Drives:Modelling Analysis and Control,” published bySpringer−Verlag, 2010.
[10]. J.R Hendershot, T.J.E. Miller, “Design ofBrushless Permanent−Magnet Machines,”published in the USA by Motor Design BooksLLC, 2010.
[11]. Boot from flash[12]. Boot/image download link[13]. Strata Developer Studio
www.onsemi.com1
onsemi, , and other names, marks, and brands are registered and/or common law trademarks of Semiconductor Components Industries, LLC dba “onsemi” or its affiliatesand/or subsidiaries in the United States and/or other countries. onsemi owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. Alisting of onsemi’s product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent−Marking.pdf. onsemi is an Equal Opportunity/Affirmative Action Employer. Thisliterature is subject to all applicable copyright laws and is not for resale in any manner.
The evaluation board/kit (research and development board/kit) (hereinafter the “board”) is not a finished product and is not available for sale to consumers. The board is only intendedfor research, development, demonstration and evaluation purposes and will only be used in laboratory/development areas by persons with an engineering/technical training and familiarwith the risks associated with handling electrical/mechanical components, systems and subsystems. This person assumes full responsibility/liability for proper and safe handling. Anyother use, resale or redistribution for any other purpose is strictly prohibited.
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You are responsible for determining whether the board will be suitable for your intended use or application or will achieve your intended results. Prior to using or distributing any systemsthat have been evaluated, designed or tested using the board, you agree to test and validate your design to confirm the functionality for your application. Any technical, applications ordesign information or advice, quality characterization, reliability data or other services provided by onsemi shall not constitute any representation or warranty by onsemi, and no additionalobligations or liabilities shall arise from onsemi having provided such information or services.
onsemi products including the boards are not designed, intended, or authorized for use in life support systems, or any FDA Class 3 medical devices or medical devices with a similaror equivalent classification in a foreign jurisdiction, or any devices intended for implantation in the human body. You agree to indemnify, defend and hold harmless onsemi, its directors,officers, employees, representatives, agents, subsidiaries, affiliates, distributors, and assigns, against any and all liabilities, losses, costs, damages, judgments, and expenses, arisingout of any claim, demand, investigation, lawsuit, regulatory action or cause of action arising out of or associated with any unauthorized use, even if such claim alleges that onsemi wasnegligent regarding the design or manufacture of any products and/or the board.
This evaluation board/kit does not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC,CE or UL, and may not meet the technical requirements of these or other related directives.
FCC WARNING – This evaluation board/kit is intended for use for engineering development, demonstration, or evaluation purposes only and is not considered by onsemi to be a finishedend product fit for general consumer use. It may generate, use, or radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuantto part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment may cause interference with radiocommunications, in which case the user shall be responsible, at its expense, to take whatever measures may be required to correct this interference.
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The board is provided to you subject to the license and other terms per onsemi’s standard terms and conditions of sale. For more information and documentation, please visitwww.onsemi.com.
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