EVBUM2775/D Compact Intelligent Power Module (IPM) Motor Control Development Kit (MDK) 1 kW www.onsemi.com This User Guides refer to revision 0.4 of the SECO-1KW-MCTRL-GEVK evaluation board. EVAL BOARD USER'S MANUAL 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. Features * 850 W complete motor control solution with AC mains * * Collateral * * * * * * * * SECO-1KW-MCTRL-GEVB Universal Controller Board (UCB) NFAQ1060L36T NCP1632 FCPF125N65S3 NCP1063 NCS2003 NCS2250 * * * * * 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. (c) Semiconductor Components Industries, LLC, 2020 November, 2020 - Rev. 0 1 Publication Order Number: EVBUM2775/D EVBUM2775/D Overview The block diagram of the whole system is represented in Figure 1. The picture of the real board is in the Figure 2 and Figure 3. Figure 1. Block Diagram of the Evaluation Board Figure 2. Picture of the Evaluation Board - Top Side www.onsemi.com 2 EVBUM2775/D Figure 3. Picture of the Evaluation Board - Bottom Side (Top Side) (Bottom Side) Figure 4. Picture of the UCB Adapter PREREQUISITES Hardware Software * Downloadable GUI * Binary file * SECO-1 kW-MCTRL-GEVB (includes power board * * * and adapter for UCB) AC power cord one-phase Universal Controller Board (UCB) or pin-compatible controller board USB isolator (5 kV optical isolation) www.onsemi.com 3 EVBUM2775/D SPECIFICATION The specification and main features can be seen in the Table 1. Table 1. EVALUATION BOARD SPECIFICATIONS Parameters Values Conditions/comments INPUT Voltage 230 Vrms15% OUTPUT Power Current per IPM leg DC BUS Voltage 850 W Input 230 VAC, fPWM = 16 kHz, TA = 25C 5 Arms TC = 100C 390 V Higher voltage value is created by interleaved PFC with NCP1632 working as a booster CURRENT FEEDBACK Current sensing resistors Op Amp power supply 39 mW 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 www.onsemi.com 4 EVBUM2775/D SAFETY PRECAUTIONS It is mandatory to read the following precautions before manipulating 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 voltage waveform by oscilloscope, the scope's ground needs to be isolated. Failure to do so may result in personal injury or death The ground potential of the system is NOT biased to an earth (PE) potential. When connecting the MCU board via USB to the computer, the appropriate galvanically isolated USB isolator have to be used. The recommended isolation voltage of USB isolator is 5 kV SECO-1KW-MCTRL-GEVB system contains DC bus capacitors which take time to discharge after removal of the main supply. Before working on the drive system, wait ten minutes for capacitors to discharge to safe voltage 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/or equipment 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 or excessive ambient temperatures may result in system malfunction. Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait ten minutes after removing power to discharge the bus capacitors. Do not attempt to service the drive until the bus 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 in overheating or abnormal operating condition. www.onsemi.com 5 EVBUM2775/D SCHEMATICS AND LAYOUT Input EMI Filter To meet customer requirements and make the evaluation board a basis for development, all necessary technical data like schematics, layout and components are included in this chapter. Also simple measurements were done to show the functionality of individual stages. Figure 5 depicts schematic from AC input to rectifier input. This circuitry include a passive EMI filter consisting of elements C16, L5, CY1, CY3, CY4, C51, L4 and C17. 4A PHASE_EMI_IN R1 2R2 AC_IN i F1 AC_IN i AC_IN i L4 AC_IN i PHASE_EMI_OUT AC_L 150 mH 10 A PHASE_EMI_01 L_IN AC_IN i R2 680k 1-1L5 R4 680k R3 C16 1 mF 1-2 C17 680 nF C51 680 nF 2-2 2-1 2 x 2.2 mH R5 680k NEUTRAL_EMI_OUT NEUTRAL_EMI_IN N_IN i NEUTRAL_IN i NEUTRAL_IN CY3 4700 pF PE PE CY4 4700 pF PE i CY1 4700 pF GND i G_PFC Figure 5. Schematic of EMI filter www.onsemi.com 6 AC_N EVBUM2775/D Interleaved PFC Stage critical mode. It drives two mosfets 180 phase shifted. The most important at design should be focused significant inductance value of selected PFC coils. It significantly specifies working range. Figure 6 depicts schematic from rectifier input to DC link output. Activation of stage (connection to 15 V DC power supply) is via J2 (soldered pads). In higher power applications to utilize full capacity power of mains and reduce harmonics is PFC-regulators generally required. This high power application use interleaved PFC stages, where may reduce inductor size, input and output capacitors ripple current. In overall, power components are smaller include capacitors. The NCP1632 as voltage mode IC for interleaved PFC applications used in conduction AC_L PHASE_PFC_IN D4 GBU6K DC_PFC_IN TP22 DC_IN i D1 DCLINK_POS TP1 DCLINK_POS DC_LINK 1N5406RLG AC_N NEUTRAL_PFC_IN C4 1 mF 5 TR1 R6 3M9 3 8 TP23 i DC_IN 8 TR2 2 750314724 R12 3M9 2 1 J2 D6 D3 U1 VCC ZCD1 16 DRV1 14 5 V reg 4 OSC ZCD2 1 5 VC DRV2 11 control blocks 3 RT Latch 10 15 REF5V C13 C11 68 pF 2m2 330 nF C12 R18 11k5 220 nF C3 R32 22k 100 nF NCP1632 D9 C15 1 nF G_PFC G_PFC G_PFC G_PFC MMSD4148T1G R37 R36 143k C14 22k R35 15k R8 1M8 10R R13 Q2 10k MMBT589LT1G R16 1M8 R15 1M8 Q3 R20 FCPF125N65S3 560k R19 820k D5 FFSPF1065A MMSD4148T1G R25 10R D7 R28 Q4 10k MMBT589LT1G 0R TP26 R29 0R OVP 8 13 GND R22 R33 R34 120k 270k 5k1 9 CS C7 TP25 R14 R9 1M8 FFSPF1065A Q1 FCPF125N65S3 FB 2 6 FFOLD C6 C42 470 mF G_PFC i DC_IN R11 22k MMSD4148T1G R7 SMF15AT1G R21 3M9 7 BO C5 3 750314724 D2 TP24 12 100 nF 100 mF 5 TP28 2 R10 22k R17 3M9 soldered pads 15VDC 15VDC R26 1k8 R27 1k C10 10 nF C9 1 nF R24 27k C8 1 nF TP27 470 nF G_PFC G_PFC G_PFC G_PFC G_PFC G_PFC R30 R31 0R075 0R075 D8 NTSS3100 G_PFC Figure 6. Schematic of interleaved PFC stage www.onsemi.com 7 G_PFC G_PFC G_PFC G_PFC G_PFC R23 27k EVBUM2775/D Basic tests and measurements were done. The results of efficiency, power factor, power losses, load transients and startup can be seen in the Figures 7-13. The used load was Halogen light bulb. Efficiency PFC stage 97.00% 96.80% 96.60% Efficiency [%] 96.40% 96.20% 96.00% 930 W load 95.80% 466 W load 95.60% 155 W load 95.40% 95.20% 95.00% 190 200 210 220 230 240 250 260 270 Input AC voltage [V] Figure 7. Efficiency of PFC Stage for Various Value of Input AC Voltage and Load Power factor PFC stage 0.998 0.978 Efficiency [%] 0.958 0.938 933 W load 0.918 466 W load 0.898 155 W load 0.878 0.858 0.838 190 200 210 220 230 240 250 260 270 Input AC voltage [V] Figure 8. Power Factor of PFC Stage for Various Value of Input AC Voltage and Load www.onsemi.com 8 EVBUM2775/D Power factor PFC stage 0.998 0.978 Efficiency [%] 0.958 0.938 933 W load 0.918 466 W load 0.898 155 W load 0.878 0.858 0.838 190 200 210 220 230 240 250 260 270 Input AC voltage [V] Figure 9. Power Losses of PFC Stage for Various Value of Input AC Voltage and Load Figure 10. Load Transient 155 W to 930 W at 230 V AC Input www.onsemi.com 9 EVBUM2775/D 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 www.onsemi.com 10 EVBUM2775/D Figure 13. Start to 930 W at 230 V AC Input, Inrush Current www.onsemi.com 11 EVBUM2775/D Auxiliary 15 V Power Supply The NCP1063 is used as converter 390 V to 15 V output to supply PFC, IPM and Control board (Arduino Due). The maximal power delivered is up to 4.6 W. Figure 14 depicts schematic of 15 V auxiliary power supply. Figure 15 shows startup of the converter. IC1 DC_LINK L1 D14 DCLINK_POS TP20 8 1 mH MRA4007T3G 7 DRAIN 99V V reg VCC 2 DRAIN C2 100 nF control block 3 5 R47 C35 100 nF C36 10 mF R49 15k TP21 1 LIM/OPP + COMP OTA - D15 MMSD4148T1G R48 56k Vref 2.7 V FB GND C1 10 mF C38 47 nF C37 330 nF 4 D16 MURA160T3G R50 15k NCP1063AP60 TP3 L2 15VDC 470 mH D17 MURA160T3G G_PFC G_PFC G_PFC C39 220 mF G_PFC G_PFC C40 C41 220 mF 150 nF G_PFC Figure 14. Schematic of Auxiliary 15V Power Supply Figure 15. Start Up to Open Circuit, to 50 mA and to 300 mA at 390 V DC Input www.onsemi.com 12 R51 15k G_PFC G_PFC 15VDC EVBUM2775/D IPM Stage This stage uses NFAQ1060L36T IPM for 3-phase motor drives containing three-phase inverter, gate drivers for the inverter and a thermistor. It uses ON Semiconductor's Insulated Metal Substrate (IMS) Technology. Very important function is over-current protection which is deeply described in chapter - Current Measurement and Over-Current Protection. 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 (soldered pads). In the figure 15 is shown schematics of IPM stage also with DC link voltage measurement (voltage divider containing R46, R52, R53 and R55). Signals from 39 mW shunt resistors are going to current measurement and over-current protection circuits. www.onsemi.com 13 Figure 16. Schematic of IPM Stage ITRIP IPM_SENSE 3V3 3V3 IPM CONTROL 15VDC 2 soldered pads J1 V_DCLINK TEMPERATURE FAULT IPM_SENSE V_DCLINK C26 TP6 NT3 C27 TP7 C28 TP8 G_IPM C20 C21 100 nF 330 mF G_IPM D10 C29 TP10 C30 TP11 C31 TP12 R44 2M R58 100R TP17 G_IPM C34 1 nF TP4 G_IPM 100 pF 100 pF 100 pF 100 pF 100 pF 100 pF 100 pF G_IPM R54 100R R43 100R R42 100R R41 100R R40 100R R39 100R R38 100R 2 C19 NT2 G_PFC NT1 2 TEMPERATURE FAULT ENABLE ENABLE LBW LBW HBW HBW LBV LBV HBV HBV LBU LBU HBU HBU IPM_CTRL 1 2 1 15VDC R56 5k1 TP14 R57 5k1 TP15 R45 39k TP16 G_IPM 250 nF C18 14 9 11 8 5 7 4 6 3 12 RCIN TH2 G_IPM R62 10k FAULT ENABLE LIN3 HIN3 LIN2 HIN2 HIN2 LIN1 HIN1 HIN1 C43 1 nF logic control control IGBT IGBT drivers drivers VCC VCC VCC G_IPM R60 0R039 G_IPM R59 0R039 R61 0R039 W,VS3 VB3 V,VS2 VB2 U,VS1 U, VS2 VB1 U2 NFAQ1060L36T ITRIP 10 1 TP2 TH1 13 DCLINK_POS i VSS VSS 1 DCLINK_POS U- 17 1 2 VDD VDD 38 VCC VCC V- 18 14 W- www.onsemi.com 19 SMF15AT1G DC_LINK 20 22 26 28 32 34 C22 G_IPM R55 6k8 TP18 C33 22 mF 100 nF i AC_OUT SMF15AT1G D13 TP13 W W_pos V_pos U_pos C_sense W_OUT C_SENSE 3PHASE_OUT V_DCLINK V_OUT V_OUT SMF15AT1G D12 TP9 V i AC_OUT AC_OUT i 22 mF C25 C32 100 nF C24 100 nF i 330k R53 SMF15AT1G D11 TP5 3PHASE_OUT U 22 mF U_OUT U_OUT i AC_OUT AC_OUT i C23 330k 330k AC_OUT R52 R46 EVBUM2775/D EVBUM2775/D Current Measurement and Over-Current Protection be careful about the maximal time constant value according short circuit safe operating area (see datasheet of IPM, NFAQ1060L36T- for VCE = 400 V is 4 ms). Output from comparator is connected to ITRIP pin of IMP module. As was mentioned in previous chapter, IPM has fault pin and its voltage level is high during normal state. An over-current condition is detected if the voltage on the ITRIP pin is larger than the reference voltage (typically 0.5 V). After a shutdown propagation delay of typically 1.1 ms, the FAULT output is switched on. The FAULT output is held on for a time determined by the resistor and capacitor connected to the RCIN pin (IPM pin 12). If R44 = 2 M and C34 = 1 nF, the FAULT output is switched on for 1.65 ms (typical). The over-current protection threshold should be set to be equal or lower to 2 times the module rated current. The reaction of the protection can be seen in the Figure 18 and 19. System is also using ENABLE pin of the IPM. After the over-current fault, fault signal is generated and sent to microcontroller which disable the IPM via ENABLE pin (programmed by user). New operation is possible after microcontroller reset. Schematic of current measurement and over-current protection can be seen in the Figure 17. Information about currents is provided via 39 mW shunt resistors. Voltage drop from shunt resistor is going to input of operational amplifier (op-amp) NCS2003 which gain is set to 4.99 with 1k resistor and 4k99 resistor connected as negative feedback. U7 (TLV431) is creating 1.65 V reference which is connected to non-inverting input of op-amps. This connection provides voltage offset at the output of op-amps, which is needed for negative current measurement. Overcurrent protection is offered by NCS2250 comparator. Comparator threshold is set by voltage divider which consists of R68, R71 and C48. Signals from shunt resistors are going via R78, R81 and R84 connected to non-inverting input. These resistors together with C58 are also acting as low pass filter for high frequency signals interference. On the one hand, with insufficient filtering the over- current protection can react for lower values of current even if there is 350 ns blanking time on ITRIP pin of IPM to improve noise immunity (see datasheet of IPM). On the other hand, when we are designing this filter it is needed to 3V3 5 C50 100 pF OUT 4 IN- 1k C57 10 nF 1 V_pos G_IPM C54 R80 10 nF R83 3V3 4k99 U4 NCS2003SN2T1G 1k 3 IN+ G_IPM C53 100 pF 4 IN- R72 OUT 2 W_pos 5 4k99 R70 I_U C59 100 nF I_SENSE I_U C62 10 nF I_V 1 I_V 1k 3 IN+ OUT 2 4 IN- VSS R75 1k R68 21.5 k 100R 215k 3V3 NCS2250SN2T3G 5 R84 3 IN+ 4 IN- 2 100R C61 VDD 100R R79 1k 4k99 R76 R81 C48 R77 680R G_IPM R87 R78 1 47 mF Q5 1 OUT ITRIP R82 3k C60 10 nF C58 15 nF R71 1k 100 nF G_IPM G_IPM G_IPM G_IPM G_IPM Figure 17. Schematic of Current Measurement and Overcurrent Protection www.onsemi.com 15 I_W 1 3 A REF K 2 G_IPM 1k C56 100 pF I_W C63 C64 100 nF 10 nF 1V65 R73 5 4k99 3V3 R86 4k99 10 nF U5 NCS2003SN2T1G C55 VDD G_IPM R85 VSS C_SENSE C49 100 nF VDD R69 3 IN+ VSS U_pos G_IPM 2 R67 1k VDD R74 3V3 C52 4k99 U3 10 nF NCS2003SN2T1G C_SENSE VSS 3V3 U7 TLV431 I_SENSE EVBUM2775/D Figure 18. Reaction of Over-current Protection Figure 19. Reaction of Over-current Protection - Detail www.onsemi.com 16 EVBUM2775/D Control Board Headers Schematic of control board headers can be seen in the Figure 20. The headers have Arduino Due footprint. The applied control board has to contain 3V3 power supply as it is also used for supplying current measurement op amps and comparator for over-current protection. Low pass filters for current and voltage measurement signals are placed closed to the headers (see CON4). When connecting the control board to the PC, do not forget to use isolator. 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 IPM_SENSE FAULT IPM_SENSE V_DCLINK 1 2 3 4 5 6 7 8 V_DCLINK TEMPERATURE I_SENSE FAULT I_SENSE I_U I_V I_W TEMPERATURE R63 R64 R65 R66 1k 1k 1k 1k 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 IPM_CTRL ENABLE LBU LBV LBW IPM CONTROL HBW HBV HBU CON3 CON4 C47 1 nF G_IPM C46 470 pF G_IPM C45 470 pF G_IPM C44 470 pF G_IPM G_IPM 3V3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 CON7 CON6 G_IPM 15VDC Figure 20. Schematic of Control Board Headers Layout Evaluation 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 www.onsemi.com 17 3V3 EVBUM2775/D Figure 22. Internal Layer 1 Figure 23. Internal Layer 2 Figure 24. Bottom Layer Routing and Bottom Assembly www.onsemi.com 18 EVBUM2775/D Bill of Materials Table 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 mF Wurth Electronik 865080540004 1 2. C2 100 nF Wurth Electronik 885012206071 1 3. C3, C5 100 nF Wurth Electronik 885012206095 2 4. C4, C16 1 mF Wurth Electronik 890334026027CS 2 5. C6 100 mF Wurth Electronik 875115652007 1 6. C7 330 nF Murata GRM188R71C334JA01D 1 7. C8, C9 1 nF Wurth Electronik 885012006044 2 8. C10, C52, C54, C55, C57, C62, C64 10 nF Wurth Electronik 885012206089 7 9. C11 2m2 Wurth 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 Wurth Electronik 885012006063 1 14. C17, C51 680 nF Wurth Electronik 890334026020CS 2 15. C18 250 nF TDK B58031I9254M062 1 16. C19, C26, C27, C28, C29, C30, C31, C50, C53, C56 100 pF Wurth Electronik 885012006057 10 17. C20 100 nF Wurth Electronik 885012207072 1 18. C21 330 mF Wurth Electronik 875075661010 1 19. C22, C24, C32 100 nF Wurth Electronik 885012105018 3 20. C23, C25, C33 22 mF TDK C4532X7R1E226M250KC 3 21. C34, C43, C47 1 nF Wurth Electronik 885012206083 3 22. C35 100 nF Wurth Electronik 890334025017CS 1 23. C36 10 mF Rubycon 450BXF10M10X16 1 24. C37 330 nF Wurth Electronik 885012207101 1 25. C38 47 nF Wurth Electronik 885012206093 1 26. C39, C40 220 mF Wurth Electronik 860040474004 2 27. C41 150 nF Murata GRM188R71H154KAC4D 1 28. C42 470 mF Wurth Electronik 861141486024 1 29. C44, C45, C46 470 pF Wurth Electronik 885012006061 3 30. C48, C49, C59, C63 100 nF Wurth Electronics 885012206046 4 31. C58 15 nF Wurth Electronik 885012206090 1 32. C60 10 nF Wurth Electronik 885012206065 1 33. C61 47 mF Murata GRM188R60J476ME15D 1 34. CON1 Black TE Connectivity 6ESRM-P 1 35. CON2 Green Wurth Elektronik 691313710003 1 36. CON3 610 036 218 21 Wurth Elektronik 61003621821 1 www.onsemi.com 19 EVBUM2775/D Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD No. Designator Comment Manufacturer Part number Quantity 37. CON4, CON6, CON7 610 008 13 321 Wurth Elektronik 61000813321 3 38. CON5 691 313 510 002 Wurth Elektronik 691313510002 1 39. CY1, CY3, CY4 4700 pF Murata DE1E3KX472MA4BN01F 3 40. D1 1N5406RLG ON Semiconductor 1N5406RLG 1 41. D2, D5 FFSPF1065A ON Semiconductor FFSPF1065A 2 42. D3, D7, D9, D15 MMSD4148T1G ON Semiconductor MMSD4148T1G 4 43. D4 GBU6K ON Semiconductor GBU6K 1 44. D6, D10, D11, D12, D13 SMF15AT1G ON Semiconductor SMF15AT1G 5 45. D8 NTSS3100 ON Semiconductor NTSS3100T3G 1 46. D14 MRA4007T3G ON Semiconductor MRA4007T3G 1 47. D16, D17 MURA160T3G ON Semiconductor MURA160T3G 2 48. F1 10 A Schurter 0031.8201 1 49. F2 4A Schurter 0034.3123 1 50. FC1 Fuse cover Schurter 0853.0551 1 51. HSA, HSB SK 489 50 mm black anodized 2 52. HSC SK 92 30 mm natural anodized 1 53. HSD SK 447 37.5 mm black anodized 1 54. IC1 NCP1063AP60 ON Semiconductor NCP1063AP60G 1 55. J_AC_OUT 691 351 500 003 Wurth Elektronik 691351500003 1 56. J_DC390V 691 351 500 002 Wurth Elektronik 691351500002 1 57. L1 1 mH Wurth Elektronik 744731102 1 58. L2 470 mH Wurth Elektronik 744731471 1 59. L4 150 mH Wurth Elektronik 7447076 1 60. L5 2 x 2.2 mH Wurth Elektronik 744824622 1 61. NAC1, NAC2 nut M3 ISO4032 62. Q1, Q3 FCPF125N65S3 ON Semiconductor FCPF125N65S3 2 63. Q2, Q4 MMBT589LT1G ON Semiconductor MMBT589LT1G 2 64. Q5 NCS2250SN2T3G ON Semiconductor NCS2250SN2T3G 1 2 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 www.onsemi.com 20 EVBUM2775/D Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD No. Designator Comment Manufacturer Part number Quantity 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 SPEER ELECTRONICS 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 50 HEX7 6 102. SDA, SDB, SDD, SHC1, SHC2, SQA, SQB M3x16 DIN7985 7 103. SHSA1, SHSA2, SHSB1, SHSB2 spacer for M3 104. ST1, ST2, ST3, ST4, ST5, ST6 Spacer M3 M/F 6/30 HEX7 105. TP1, TP2 RED Wurth Elektronik 963030042 4 6 Keystone Electronics www.onsemi.com 21 5005 2 EVBUM2775/D Table 3. BILL OF MATERIALS OF THE EVALUATION BOARD No. Designator Comment Manufacturer Part number Quantity 106. TP3, TP17, TP24 ORANGE Keystone Electronics 5008 3 107. TP4, TP18, TP21 WHITE Keystone Electronics 5007 3 108. TP5, TP9, TP13, TP22 BROWN Keystone Electronics 5120 4 109. TP6, TP7, TP8, TP10, TP11, TP12, TP14, TP25, TP26 YELLOW Keystone Electronics 5009 9 110. TP15, TP16 BLUE Keystone Electronics 5122 2 111. TP20, TP23, TP28 PURPLE Keystone Electronics 5124 3 112. TP27 BLACK Keystone Electronics 5006 1 113. TR1, TR2 750314724 Wurth Elektronik 750314724 2 114. U1 NCP1632 ON Semiconductor NCP1632DR2G 1 115. U2 NFAQ1060L36T ON Semiconductor NFAQ1060L36T 1 116. U3, U4, U5 NCS2003SN2T1G ON Semiconductor NCS2003SN2T1G 3 117. U7 TLV431 ON Semiconductor TLV431CSN1T1G 1 118. WAC1, WAC2, WHSA1, WHSA2, WHSB1, WHSB2, WPDA, WPDB, WPDD, WPQA, WPQB, WSHC1, WSHC2, WSHD1 plain washer M3 DIN125A 14 119. WHAD, WHAQ, WHBD, WHBQ AOS 220 18x12x1.5 D3.1 4 120. WSDA, WSDB, WSDD, WSQA, WSQB spring washer M3 DIN7980 5 Table 4. BILL OF MATERIALS OF THE UCB ADAPTER No. Designator Comment Manufacturer Part number Quantity 1. C1 10uF, 50V Wurth Elektronik 885012108022 1 2. C2, C11, C12 10uF, 10V Wurth Elektronik 885012107010 3 3. C3 100uF, 25V Wurth Elektronik 865080449011 1 4. C4, C5 100nF, 16V Wurth Elektronik 885012206046 2 5. C15, C21 10nF, 50V Wurth Elektronik 885012206089 2 6. C16 470nF, 50V Wurth Elektronik 885012207102 1 7. C19, C20 22uF, 10V Wurth Elektronik 885012209006 2 8. C23 470pF, 50V Wurth Elektronik 885012006061 1 9. D1, D2, D3, D4, D5, D6, D7, D8, D9, D10 BAT54S ON Semiconductor BAT54S 10 10. D11, D12 MBR230LSFT1G ON Semiconductor MBR230LSFT1G 2 11. D13 MBRS2040LT3G ON Semiconductor 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 www.onsemi.com 22 EVBUM2775/D Table 4. BILL OF MATERIALS OF THE UCB ADAPTER No. Designator Comment Manufacturer 15. 16. Part number Quantity J8 61000621821 J9 694106105102 Wurth Elektronik 61000621821 1 Wurth Elektronik 694106105102 1 17. JB1, JB2 18. L1 10139781-121402LF Amphenol 10139781-121402LF 2 22uH, 3A Wurth Elektronik 7447714220 19. R1, R6 0R 1 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 ON Semiconductor FAN8303MX 1 28. U2 NCP1117ST33T3G ON Semiconductor NCP51460SN33T1G 1 29. U3 NCP1117ST50T3G ON Semiconductor NCP1117ST50T3G 1 30. C1 10uF, 50V Wurth Elektronik 885012108022 1 31. C2, C11, C12 10uF, 10V Wurth Elektronik 885012107010 3 32. C3 100uF, 25V Wurth Elektronik 865080449011 1 33. C4, C5 100nF, 16V Wurth Elektronik 885012206046 2 34. C15, C21 10nF, 50V Wurth Elektronik 885012206089 2 35. C16 470nF, 50V Wurth Elektronik 885012207102 1 36. C19, C20 22uF, 10V Wurth Elektronik 885012209006 2 37. C23 470pF, 50V Wurth Elektronik 885012006061 1 38. D1, D2, D3, D4, D5, D6, D7, D8, D9, D10 BAT54S ON Semiconductor BAT54S 10 39. D11, D12 MBR230LSFT1G ON Semiconductor MBR230LSFT1G 2 40. D13 MBRS2040LT3G ON Semiconductor 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 22uH, 3A 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 56. U1 FAN8303MX ON Semiconductor FAN8303MX 1 57. U2 NCP1117ST33T3G ON Semiconductor NCP51460SN33T1G 1 58. U3 NCP1117ST50T3G ON Semiconductor NCP1117ST50T3G 1 1 www.onsemi.com 23 EVBUM2775/D GRAPHICAL USER INTERFACE Open loop operation (V/F) In general, the implementation of FOC requires at least: 1 Timer 4 ADC channels (see Note below) USART/SPI for communications Capture/PWM * * * * In order to facilitate fast evaluation of the power stage, the user can select open loop operation option within the GUI menu. FOC closed loop operation Modern control drives implement the well-known Field Oriented Control (FOC) control-strategy; FOC provides efficient motor-drive for a wide range of motor-speeds, fast dynamic response, a low harmonic content of currents, and reduced losses [8-10]. FOC should achieve: * High control bandwidth * Low current distortion * Control capability at low speeds Figure 25. Graphical User Interface for Controlling the Motor in the Open Loop NOTE: One channel for the voltage level of the VSI H-Bridge, and three channels for the - three - phase currents that flow towards the motor. However, it is possible to implement the FOC strategy with only three ADC channels (two channels for current and one channel for the voltage), as we can measure two-phase currents and mathematically calculate the third one. That implementation requires one shunt-resistor less. Compact IPM, thought, comes already with three shunt-resistors. www.onsemi.com 24 EVBUM2775/D During the communication with control board and PC, using of USB isolator is very important because of safety. In the Figure 26 can be seen evaluation board with USB isolator (5 kV optical isolation). Figure 26. Evaluation Board with Control Board and USB Isolator www.onsemi.com 25 EVBUM2775/D REFERENCES [7]. Datasheet of NCS2250, available on ON Semiconductor website [8]. J.A. Santisteban, R.M. Stephan, "Vector control methods 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 by Springer-Verlag, 2010. [10]. J.R Hendershot, T.J.E. Miller, "Design of Brushless Permanent-Magnet Machines," published in the USA by Motor Design Books LLC, 2010. [1]. Datasheet of IPM NFAQ1060L36T, available on ON Semiconductor website [2]. Datasheet of NCP1632, available on ON Semiconductor website [3]. Application note - Key Steps to Design an Interleaved PFC Stage Driven by the NCP1632, available on ON Semiconductor website [4]. Datasheet of NCP1063, available on ON Semiconductor website [5]. Application note - Universal AC Input, 12V 0.35 A Output, 4.2 Watt Non-isolated Power Supply, available on ON Semiconductor website [6]. Datasheet of NCS2003, available on ON Semiconductor website www.onsemi.com 26 ON Semiconductor and the ON Semiconductor logo are trademarks of Semiconductor Components Industries, LLC dba ON Semiconductor or its subsidiaries in the United States and/or other countries. ON Semiconductor owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. A listing of ON Semiconductor's product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent-Marking.pdf. ON Semiconductor is an Equal Opportunity/Affirmative Action Employer. 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