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Motorola Embedded Motion Control
3-PhaseSwitched Reluctance
High-VoltagePower Stage
User’s Manual
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Important Notice to Users
While every effort has been made to ensure the accuracy of all information in this document, Motorola assumes no liability to any party for any loss or damage caused by errors or omissions or by statements of any kind in this document, its updates, supplements, or special editions, whether such errors are omissions or statements resulting from negligence, accident, or any other cause. Motorola further assumes no liability arising out of the application or use of any information, product, or system described herein: nor any liability for incidental or consequential damages arising from the use of this document. Motorola disclaims all warranties regarding the information contained herein, whether expressed, implied, or statutory, including implied warranties of merchantability or fitness for a particular purpose. Motorola makes no representation that the interconnection of products in the manner described herein will not infringe on existing or future patent rights, nor do the descriptions contained herein imply the granting or license to make, use or sell equipment constructed in accordance with this description.
Trademarks
This document includes these trademarks:
Motorola and the Motorola logo are registered trademarks of Motorola, Inc.
Motorola, Inc., is an Equal Opportunity / Affirmative Action Employer.
© Motorola, Inc., 2000; All Rights Reserved
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Sections
Section 1. Introduction and Setup. . . . . . . . . . . . . . . . . .11
Section 2. Operational Description . . . . . . . . . . . . . . . . .19
Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . .25
Section 4. Schematics and Parts List . . . . . . . . . . . . . . .31
Section 5. Design Considerations . . . . . . . . . . . . . . . . . .45
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User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Table of Contents
Section 1. Introduction and Setup
1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2. Operational Description
2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Modification for 1/2 and 3/4 Horsepower . . . . . . . . . . . . . . . . . . . . . 22
2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 3. Pin Descriptions
3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.1 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.2 Power Connectors J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.3 External Brake Connectors J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.4 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Section 4. Schematics and Parts List
4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 5. Design Considerations
5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3 Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5 Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9 Power Factor Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Figures
Figure Title Page
1-1 Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-2 3-Phase Switched Reluctance High-Voltage Power Stage . . . . . . . . . 131-3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151-4 PFC Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-1 40-Pin Ribbon Connector J14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-1 3-Phase HR High-Voltage Power Stage Overview . . . . . . . . . . . . . . 334-2 Gate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-3 3-Phase Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354-4 Current and Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 364-5 Power Factor Correction and Brake Gage Drive . . . . . . . . . . . . . . . . 374-6 Identification Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384-7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-1 Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465-2 Bus Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495-3 Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 505-4 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515-5 Phase A Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535-6 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545-7 PFC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555-8 PFC Zero Crossing Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
List of Tables
Table Title Page
2-1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212-2 Resistor Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222-3 JP801 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222-4 Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-1 Connector J14 Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-1 Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404-2 Printed Circuit Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 1. Introduction and Setup
1.1 Contents
1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Introduction
Motorola’s 3-phase, switched reluctance high-voltage power stage (HV SR power stage) is a 115/230 volt, 180 watt (1/4 horsepower), off-line power stage that is an integral part of Motorola’s embedded motion control series of development tools. The HV SR power stage is supplied in kit number ECPWRHiVSR.
In combination with one of the Embedded Motion Control series control boards and an Embedded Motion Control series optoisolation board, it provides a ready made software development platform for fractional horsepower off-line switched reluctance motors. Feedback signals are provided that allow control with a wide variety of algorithms. In addition, the HV SR power stage includes an active power factor correction (PFC) circuit that facilitates development of power factor correction algorithms.
An illustration of the systems architecture is shown in Figure 1-1. A line drawing appears in Figure 1-2.
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Features of the HV SR power stage are:
• 1-phase bridge rectifier
• Power factor switch and diode
• dc-bus brake IGBT and brake resistors
• 3-phase bridge inverter (6-IGBT’s)
• Individual phase and dc bus current sensing shunts with Kelvin connections
• Power stage temperature sensing diodes
• IGBT gate drivers
• Current and temperature signal conditioning
• Board identification processor (MC68HC705JJ7)
• Low voltage on-board power supplies
• Cooling fans
Figure 1-1. Systems’ Configurations
CONTROL BOARD
MOTOR
WORKSTATION
EMULATOR DSP EVM BOARD
MOTOR
WORKSTATION
b) 56800 DSPa) MICROCONTROLLER
OPTOISOLATIONBOARD
HIGH-VOLTAGEPOWER STAGE
HIGH-VOLTAGEPOWER STAGE
OPTOISOLATIONBOARD
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Introduction and SetupAbout this Manual
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Figure 1-2. 3-Phase Switched ReluctanceHigh-Voltage Power Stage
1.3 About this Manual
Key items can be found in the following locations in this manual:
• Setup instructions are found in 1.5 Setup Guide.
• Schematics are found in Section 4. Schematics and Parts List.
• Pin assignments for 40-pin connector J14 are shown in Figure 3-1.
• A pin-by-pin description of input and output signals is contained in 3.3 Signal Descriptions.
• For those interested in the reference design aspects of the board’s circuitry, a description is provided in Section 5. Design Considerations.
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Introduction and Setup
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1.4 Warnings
This development tool set operates in an environment that includes dangerous voltages and rotating machinery. To facilitate safe operation, input power for the HV AC power stage should come from a DC laboratory power supply, unless power factor correction is specifically being investigated.
An isolation transformer should be used when operating off an ac power line. If an isolation transformer is not used, power stage grounds and oscilloscope grounds are at different potentials, unless the oscilloscope is floating.
NOTE: Because the probe grounds, it is subjected to dangerous voltages in the case of a floated oscilloscope.
The user should be aware that:
• Before moving scope probes, making connections, etc., it is generally advisable to power down the motor supply.
• When high voltage is applied, using only one hand for operating the test setup minimizes the possibility of electrical shock.
• Operation in lab setups that have grounded tables and/or chairs should be avoided.
• Wearing safety glasses, avoiding ties and jewelry, using shields, and operation by personnel trained in high voltage lab techniques are advisable.
• Power transistors, the PFC coil, and motor can reach temperatures hot enough to cause burns.
• When powering down; due to storage in the bus capacitors, dangerous voltages are present until the power-on LED is off.
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Introduction and SetupSetup Guide
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1.5 Setup Guide
Setup and connections are very straightforward. The HV SR power stage connects to an embedded motion control optoisolation board via a 40-pin ribbon cable and can be powered either by a 140-volt to 230-volt dc power supply or with line voltage. For both safety reasons and ease of making measurements, it is strongly recommended that a dc supply is used, unless power factor correction is specifically being investigated. The power supply should be current limited to under 4 amps. Figure 1-3 depicts a completed setup.
A step-by-step setup procedure is described as:
1. Plug one end of the 40-pin ribbon cable that comes with the optoisolator kit into input connector J14. The other end of this cable goes to the optoisolation board’s 40-pin output connector.
2. Connect motor leads to output connector J13 located along the back edge of the top board. Phase A, phase B, and phase C are labeled Ph. A, Ph. B, and Ph. C. There are two connections for each phase, to accommodate the independent phase coil configuration that is used in switched reluctance motors.
Figure 1-3. Setup
Figure 1-3. Setup
ControlBoard
+12 VDC
40 Pin Ribbon
Standoffs
Standoffs
40 Pin RibbonPower Stage
Optoisolator
M
Mot orola
Dav e’sControlCent er
High VoltageMotor Supply
- + -- ++
Ph A
Ph B
Ph C
1
High VoltageMotor Supply
Standoffs
Standoffs
+12 Vdc
40 PinRibbon
40 PinRibbon
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3. Connect earth ground to the earth ground terminals on the top board and on the heat sink. The top board’s ground terminal is located in the front left-hand corner, and is marked with a ground symbol. The heat sink has a screw on its front edge that is also marked with a ground symbol.
4. Connect an isolated line, current limited dc power supply to connector J11 located on the front edge of the top board. The input voltage range is 140 Vdc to 230 Vdc. Current limit should be set for less than 4 amps. The dc supply’s polarity does not matter.
Either a 110-volt or 220-volt ac line that is coupled through an isolation transformer may be used in place of a dc supply to provide input power. The connection is made on connector J11. Bias voltages are developed by internal power supplies. One power input is all that is required.
CAUTION: Operation from an ac power line is significantly more hazardous than operation from a line isolated and current limited dc power supply.
An isolation transformer should be used when operating from an ac power line.
5. Setup the optoisolation and control boards.
6. The HV SR power stage is shipped with power factor correction (PFC) disabled. If power factor correction is desired, it is necessary to remove and re-solder power jumper JP201 from the no PFC position to the PFC position. This jumper is found on the left side of the top board, between the dc bus capacitor and PFC inductor. Circuit connections are illustrated in Figure 1-4. For first time setups, operation without power factor correction is recommended.
7. Apply power first to the optoisolator and then to the power stage. The green power-on LED in the upper right-hand corner lights, and both fans run when power is present.
NOTE: The optoisolation board powers the control board. The optoisolation board is not fully powered until power is applied to the power stage.
WARNING: Hazardous voltages are present. Please re-read all of the warnings in 1.4 Warnings carefully.
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Introduction and SetupSetup Guide
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Figure 1-4. PFC Jumper
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User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 2. Operational Description
2.1 Contents
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Modification for 1/2 and 3/4 Horsepower . . . . . . . . . . . . . . . . . . . . . 22
2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Description
Motorola’s embedded motion control series high-voltage (HV) switched reluctance (SR) power stage is a 180 watt (1/4 horsepower), 3-phase power stage that will operate off of dc input voltages from 140 volts to 230 volts and ac line voltages from 100 volts to 240 volts. In combination with one of Motorola’s Embedded Motion Control Series control boards and an optoisolation board, it provides a software development platform that allows algorithms to be written and tested, without the need to design and build a power stage. It supports a wide variety of algorithms for controlling switched reluctance motors.
Input connections are made via 40-pin ribbon cable connector J14. Pin assignments for the input connector are shown in Figure 3-1. 40-Pin Ribbon Connector J14. Power connections to the motor are made on output connector J13. Phase A, phase B, and phase C are labeled Ph. A, Ph. B, Ph. C on the board. Power requirements are met with a single external 140-volt to 230-volt dc power supply or an ac line voltage. Either input is supplied through connector J11. Current measuring circuitry is set up for 2.93 amps full scale. Both bus and phase leg currents are measured. A cycle-by-cycle overcurrent trip point is set at 2.69 amps.
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Operational Description
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The HV SR power stage has both a printed circuit board and a power substrate. The printed circuit board contains IGBT gate drive circuits, analog signal conditioning, low-voltage power supplies, power factor control circuitry, and some of the large passive power components. This board also has a MC68HC705JJ7 microcontroller used for board configuration and identification. All of the power electronics that need to dissipate heat are mounted on the power substrate. This substrate includes the power IGBTs, brake resistors, current-sensing resistors, a power factor correction MOSFET, and temperature sensing diodes. Figure 2-1 shows a block diagram.
Figure 2-1. Block Diagram
HV POWERINPUT SWITCH MODE
POWER SUPPLYPFC CONTROL
3-PHASE IGBT
GATE
PHASE CURRENTPHASE VOLTAGE
BUS CURRENTMONITOR
BOARDID BLOCK
SIGNALSTO/FROMCONTROL
BOARD
POWER MODULE
DRIVERS
SR MOTORTO 3-PHASE
DC BUS BRAKE
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Operational DescriptionElectrical Characteristics
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2.3 Electrical Characteristics
The electrical characteristics in Table 2-1 apply to operation at 25°C with a 160-Vdc supply voltage.
Table 2-1. Electrical Characteristics
Characteristic Symbol Min Typ Max Units
DC input voltage Vdc 140 160 230 V
AC input voltage Vac 100 208 240 V
Quiescent current ICC — 70 — mA
Min logic 1 input voltage VIH 2.0 — — V
Max logic 0 input voltage VIL — — 0.8 V
Analog output range VOut 0 — 3.3 V
Bus current sense voltage ISense — 563 — mV/A
Bus voltage sense voltage VBus — 8.09 — mV/V
Peak output current IPK — — 2.7 A
Brake resistor dissipation (continuous) PBK — — 50 W
Brake resistor dissipation (15 sec pk) PBK(Pk) — — 100 W
Total power dissipation Pdiss — — 85 W
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2.4 Modification for 1/2 and 3/4 Horsepower
The HV SR power stage can be modified to drive either 1/2 or 3/4 horsepower motors. To change maximum output power these steps apply:
1. Remove power and wait until the power-on LED is off.
2. If PFC jumper JP201 is in the PFC position, remove and resolder it into the no PFC position.
3. Make the resistor value changes shown in Table 2-2. These resistors set current amplifier gains. For 1/2 and 3/4 horsepower motors, lower gains allow for higher measured currents, and higher overcurrent trip points.
4. Configure identification coding jumper JP801 with the settings that are indicated in Table 2-3. This procedure allows software to interpret the new analog values correctly.
5. For 3/4 horsepower motors it is also necessary to add an additional 470-µF/400-volt bus capacitor. To install the capacitor, it is first necessary to remove PFC inductor L201. Mounting holes for the additional capacitor are located within L201’s footprint. Note that it is essential to orient the capacitor such that polarity is correct. Positive and negative connections are indicated by + and – silk screened labels on the board. In addition, the pad for the capacitor’s positive lead is square, and the pad for its negative lead is round.
Table 2-2. Resistor Value
Resistors1/4 HP(180 W)
1/2 HP(370 W)
3/4 HP(550 W)
R303, R305, R307, R314,R315, R318, R319, R322
75 kΩ 62 kΩ 56 kΩ
R301, R304, R311, R313,R316, R317, R320, R321
10 kΩ 15 kΩ 16 kΩ
Table 2-3. JP801 Settings
Position1/4 HP(180 W)
1/2 HP(370 W)
3/4 HP(550 W)
1-2 Open Short Open
3-4 Open Open Short
5-6 Open Open Open
7-8 Open Open Open
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Operational DescriptionFuse Replacement
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Once these changes have been made, configuration for either 1/2 or 3/4 horsepower is complete.
2.5 Fuse Replacement
A fast-blow fuse is located on the front right-hand corner of the top board. If this fuse has to be replaced these steps apply:
1. Remove power and wait until the power-on LED is off.
2. Remove the fuse’s protective case.
3. Replace the fuse with one of the selections shown in Table 2-4.
4. Replace the protective case.
5. Set the controller’s speed control input to 0 RPM.
6. Apply power and resume operation.
Table 2-4. Fuse Ratings
MotorHorsepower
RMSInput Current
(Amps)
FuseCurrent Rating
(Amps)
FuseVoltage Rating
(Volts)
FuseType
1/4 2.3 2.5 250 Fast blow
1/2 4.8 6.3 250 Fast blow
3/4 7.1 8 250 Fast blow
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Operational Description
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User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
24 Operational Description MOTOROLA For More Information On This Product,
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 3. Pin Descriptions
3.1 Contents
3.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.1 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.2 Power Connectors J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.3 External Brake Connectors J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.4 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Introduction
There are four connectors on the top board for making input and output connections. They are:
• J11 — Power input connector
• J12 — Brake connector
• J13 — Motor output connector
• J14 — 40-pin ribbon cable connector
Pin descriptions for each of these connectors are identified in this subsection. Pin assignments for the 40-pin ribbon connector, J14, are shown in Figure 3-1. In this figure, a schematic representation appears on the left, and a physical layout of the connector appears on the right. The physical view assumes that the board is oriented such that its title is read from left to right. Signal descriptions are provided in Table 3-1.
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Pin Descriptions
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3.3 Signal Descriptions
This subsection describes the signals.
3.3.1 40-Pin Ribbon Connector J14
Signal inputs are grouped together on a 40-pin ribbon cable connector, J14, located on the right side of the board. Pin assignments are shown in Figure 3-1. Signal descriptions are listed in Table 3-1.
3.3.2 Power Connectors J11
The power input connector, labeled J11, is located on the front edge of the board. It will accept dc voltages from 140 to 230 volts, or an isolated ac line input from 100 to 240 volts. In either case, the power source should be capable of supplying at least 200 watts.
3.3.3 External Brake Connectors J12
An optional external brake resistor can be connected to external brake connector J12, labeled Ext. Brake. The external resistor allows power dissipation to be increased beyond the 50 watts that brake resistors R6–R9 provide.
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Pin DescriptionsSignal Descriptions
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Figure 3-1. 40-Pin Ribbon Connector J14
40
3938
3736
3534
3332
3130
2928
2726
2524
2322
2120
1918
1716
1514
1312
1110
98
76
54
32
1
Shielding
PFC_z_cPFC_inhibit
PFC_PWMSerial_Con
Brake_controlShielding
Temp_sense
I_sense_CI_sense_B
I_sense_AI_sense_DCB
V_sense_DCB–15V_A
+15V_AGNDA
GNDA+3.3V_A
+5V_A+5V_A
GNDGND
PWM_CBShielding
PWM_CTShielding
PWM_BBShielding
PWM_BTShielding
PWM_ABShielding
PWM_AT
SCHEMATIC VIEW
J14
2
46
810
1214
1618
2022
2426
2830
3234
3638
40
1
35
79
1113
1517
1921
2325
2729
3133
3537
39
Shielding
ShieldingShielding
ShieldingShielding
GND+5V_D
+3.3V_AGNDA
–15V_AI_sense_DCB
I_sense_BTemp_sense
ShieldingSerial_Con
PFC_inhibit
PWM_AT
PWM_ABPWM_BT
PWM_BBPWM_CT
PWM_CBGND_PS
+5V_DGNDA
+15_AV_sense_DCB
I_sense_AI_sense_C
Brake_control
PFC_PWMPFC_z_c
Shielding
PHYSICAL VIEW
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Pin Descriptions
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Table 3-1. Connector J14 Signal Descriptions
Pin No.
Signal Name Description
1 PWM_ATPWM_AT is the gate drive signal for the top half-bridge of phase A. A logic high turns phase A’s top switch on.
2 Shielding Pin 2 is connected to a shield wire in the ribbon cable and ground on the board.
3 PWM_ABPWM_AB is the gate drive signal for the bottom half-bridge of phase A. A logic high turns phase A’s bottom switch on.
4 Shielding Pin 4 is connected to a shield wire in the ribbon cable and ground on the board.
5 PWM_BTPWM_BT is the gate drive signal for the top half-bridge of phase B. A logic high turns phase B’s top switch on.
6 Shielding Pin 6 is connected to a shield wire in the ribbon cable and ground on the board.
7 PWM_BBPWM_BB is the gate drive signal for the bottom half-bridge of phase B. A logic high turns phase B’s bottom switch on.
8 Shielding Pin 8 is connected to a shield wire in the ribbon cable and ground on the board.
9 PWM_CTPWM_CT is the gate drive signal for the top half-bridge of phase C. A logic high turns phase C’s top switch on.
10 Shielding Pin 10 is connected to a shield wire in the ribbon cable and ground on the board.
11 PWM_CBPWM_CB is the gate drive signal for the bottom half-bridge of phase C. A logic high turns phase C’s bottom switch on.
12 GND Digital and power ground
13 GND Digital and power ground, redundant connection
14 +5V digital Digital +5-volt power supply
15 +5V digital Digital +5-volt power supply, redundant connection
16 +3.3V analog Analog +3.3-volt power supply
17 GNDA Analog power supply ground
18 GNDA Analog power supply ground, redundant connection
19 +15V_A Analog +15-volt power supply
20 –15V_A Analog –15-volt power supply
21 V_sense_DCBV_sense_DCB is an analog sense signal that measures dc bus voltage. It is scaled at 8.09 mV per volt of dc bus voltage.
22 I_sense_DCBI_sense_DCB is an analog sense signal that measures dc bus current. It is scaled at 0.563 V per amp of dc bus current.
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Pin DescriptionsSignal Descriptions
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23 I_sense_AI_sense_A is an analog sense signal that measures current in phase A. It is scaled at 0.563 V per amp of dc bus current.
24 I_sense_BI_sense_B is an analog sense signal that measures current in phase B. It is scaled at 0.563 V per amp of dc bus current.
25 I_sense_CI_sense_C is an analog sense signal that measures current in phase C. It is scaled at 0.563 V per amp of dc bus current.
26 Temp_sense Temp_sense is an analog sense signal that measures power module temperature.
27 No connection
28 ShieldingPin 28 is connected to a shield wire in the ribbon cable and analog ground on the board.
29 Brake_control Brake_control is the gate drive signal for the brake IGBT.
30 Serial_Con Serial_Con is an identification signal that lets the controller know which power stage is present.
31 PFC_PWMPFC_PWM is a digital signal that controls the power factor correction circuit’s switch.
32 PFC_inhibitPFC_inhibit is a digital signal that is used to enable or disable the power factor correction circuit.
33 PFC_z_cPFC_z_c is a digital signal and its edges represent power line voltage 0 crossing events.
34 No connection
35 No connection
36 No connection
37 Shielding Pin 37 is connected to a shield wire in the ribbon cable and analog ground on the board.
38 No connection
39 No connection
40 No connection
Table 3-1. Connector J14 Signal Descriptions (Continued)
Pin No.
Signal Name Description
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3.3.4 Motor Output Connector J13
Power outputs to the motor are located on connector J13. Phase outputs are labeled Ph. A, Ph. B, and Ph. C. Pin assignments are:
• Pin 1: Ph. A — Pin 1 supplies power to motor Phase A. It is connected to bottom switch output signal Phase_AB. Either of the two phase A motor leads may be connected here.
• Pin 2: Ph. A — Pin 2 supplies power to motor Phase A. It is connected to top switch output signal Phase_AT. Either of the two phase A motor leads may be connected here.
• Pin 3: Ph. B — Pin 3 supplies power to motor Phase B. It is connected to bottom switch output signal Phase_BB. Either of the two phase B motor leads may be connected here.
• Pin 4: Ph. B — Pin 4 supplies power to motor Phase B. It is connected to top switch output signal Phase_BT. Either of the two phase B motor leads may be connected here.
• Pin 5: Ph. C — Pin 5 supplies power to motor Phase C. It is connected to bottom switch output signal Phase_CB. Either of the two phase C motor leads may be connected here.
• Pin 6: Ph. C — Pin 6 supplies power to motor Phase C. It is connected to top switch output signal Phase_CT. Either of the two phase C motor leads may be connected here.
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 4. Schematics and Parts List
4.1 Contents
4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Mechanical Characteristics
Mechanically, the HV SR power stage consists of an FR-4 circuit board, a 3.2-mm aluminum circuit board, two fans, a fan bracket, a heat sink, inter-board connectors, and standoffs. Construction is depicted in Figure 1-2. 3-Phase Switched Reluctance High-Voltage Power Stage. The aluminum circuit board, fans, and heat sink provide the thermal capability surface mounted power components. The FR-4 board contains control circuitry and through-hole mounted power components. The two boards plug together via 10 vertical connectors to, in effect, form a discrete power module.
Four holes on the top board are spaced to allow mounting standoffs such that a control board can be placed on top of the power stage. This configuration allows mounting control and power functions in one compact mechanical assembly.
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Schematics and Parts List
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4.3 Schematics
A set of schematics for the HV SR power stage appears in Figure 4-1 through Figure 4-7.
• An overview appears in Figure 4-1.
• Output transistor gate drive is shown in Figure 4-2.
• The 3-phase output stage appears in Figure 4-3.
• Current and temperature feedback circuits are shown in Figure 4-4.
• Power factor correction and brake gate drives are shown in Figure 4-5.
• The identification block is shown in Figure 4-6.
• The on-board power supply is shown in Figure 4-7.
Unless otherwise specified, resistors are 1/8 watt, have a ±5% tolerance, and have values shown in ohms. Interrupted lines coded with the same letters are electrically connected. Parts lists for the power substrate and printed circuit board appear in Table 4-1 and Table 4-2.
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Schematics and Parts ListSchematics
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Fig
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PFC_DC_BUS_BRAKE
PFC_PWM
PFC_z_cPFC_enable
PFC_I_sense_1
DCB_PFC_1DCB_PFC_2
GND
+15V_D+5V_D
+15V_A
GNDA
PFC_Source
Brake_control
DCB_Cap_neg
Brake_gate
V_sense_DCB_5V_sense_DCB_half_15
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1234
J3 CO
N/B
1
3456
2
I_sense_A
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Schematics and Parts List
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Fig
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C40
847
0nF
/50V
+15
V_D
+5V
_D
VC
C
+
C41
04.
7uF
/16V
+C
418
33uF
/25V
R40
112
0
U40
4ED
M74
ALS
1034
M
1110
+5V
_D
D40
1M
UR
S16
0T3
C40
447
0nF
/50V
Sou
rce_
BT
R40
212
0
C42
11n
F
+5V
_D
C42
31n
F
Gat
e_C
T
+15
V_D
C40
747
0nF
/50V
GN
D
+5V
_D
VC
C
C42
01n
F
+5V
_D
C41
58.
2pF
D40
7M
MS
Z52
51B
T1
D40
4M
BR
S13
0LT
3
Shu
t_D
own
D41
5M
MS
Z52
51B
T1
D40
5M
MS
Z52
51B
T1
R41
210
k
PW
M_A
B
+15
V_D
D41
2M
MS
Z52
51B
T1
U40
4BD
M74
ALS
1034
M
34
Sou
rce_
BB
Gat
e_B
T
C40
347
0nF
/50V
PW
M_C
B
R40
512
0
PW
M_B
B
Gat
e_A
T
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
34 Schematics and Parts List MOTOROLA For More Information On This Product,
Go to: www.freescale.com
Schematics and Parts ListSchematics
F
ree
sca
le S
em
ico
nd
uc
tor,
I
Freescale Semiconductor, Inc.n
c..
.
Fig
ure
4-3.
3-P
has
e O
utp
ut
Gate_PFC
Gate_AB
Gat
e_B
rake
DC
B_C
ap_N
eg
I_S
ense
_DC
B1
J2S
M/C
ON
/MC
RD
_SR
_500
_A -
mal
e
1234
9101112
17181920
Sou
rce_
BB
Gat
e_C
B
J1S
M/C
ON
/MC
RD
_SR
_500
_A -
mal
e
1234
9101112
17181920
Temp_sense2
Q1
SG
B10
N60
Q7
SG
B10
N60
Gat
e_B
T
Source_PFC
DC
_BU
S_I
N
J6S
M/C
ON
/MC
RD
_SR
_500
_D -
mal
e
123
6
89
10
Gate_BT
AC
_IN
_L2
Pha
se_C
T
sense
sense
R1
0.07
5 1
%
I_S
ense
_PF
C1
I_se
nse_
A2
Pha
se_B
B
Brake_Res
R8
250
Temp_sense1
DCB_Cap_Pos
I_sense_C1
Gat
e_B
B
D12
HF
A08
TB
60S
I_se
nse_
C2
Pha
se_C
B
Gat
e_A
T
Sou
rce_
CB
Source_CB
Tem
p_se
nse2
sense
sense
R3
0.07
5 1
%
D14
BA
V99
LT1
I_se
nse_
A1
J7S
M/C
ON
/MC
RD
_SR
_500
_D -
mal
e
123
6
89
10
DC
_BU
S_O
UT
R9
250
Bra
ke_R
es
Gate_CB
J5S
M/C
ON
/MC
RD
_SR
_500
_D -
mal
e
123
6
89
10
sense
sense
R4
0.07
5 1
%
D6
HF
A16
TA
60C
S
AC_IN_L2
D8
10E
TS
08S
Sou
rce_
AB
I_Sense_PFC1
D4
HF
A16
TA
60C
S
I_se
nse_
B2
Phase_CB
AC
_IN
_L1
Sou
rce_
PF
C
Gate_Brake
sense
sense
R2 0.07
5 1
%
Phase_AT
I_Sense_DCB1
Gat
e_A
B
I_sense_C2
AC_IN_L1
I_S
ense
_DC
B2
Q8
MT
B8N
50E
I_Sense_PFC2
R6
250
DC_BUS_IN
Gate_CT
J4S
M/C
ON
/MC
RD
_SR
_500
_C -
mal
e
1
456
DC
B_C
ap_P
os
I_sense_B2
Gat
e_C
T
I_Sense_DCB2
Gate_AT
Phase_CT
I_se
nse_
B1
J8S
M/C
ON
/MC
RD
_SR
_500
_E -
mal
e
1234
Gat
e_P
FC
J9S
M/C
ON
/MC
RD
_SR
_500
_E -
mal
e
1234
Phase_BT
Tem
p_se
nse1
D3
HF
A16
TA
60C
SQ
4S
GB
10N
60D
5H
FA
16T
A60
CS
Pha
se_A
T
Phase_BB
DC_BUS_OUT
D7
10E
TS
08S
I_se
nse_
C1
Source_BB
I_sense_B1
D10
10E
TS
08S
I_sense_A2
I_S
ense
_PF
C2
Q5
SG
B10
N60
I_sense_A1
R7
250
J3S
M/C
ON
/MC
RD
_SR
_500
_B -
mal
e
1
3456
2
D9
10E
TS
08S
Source_AB
Q3
SG
B10
N60
Pha
se_B
T
J10
SM
/CO
N/M
CR
D_S
R_5
00_B
- m
ale
1
3456
2
D2
HF
A16
TA
60C
S
Q2
SG
B10
N60
sense
sense
R5
0.07
5 1
%
Q6
SG
B10
N60
D13
BA
V99
LT1
D11
HF
A08
TB
60S
Gate_BB
Phase_AB
Pha
se_A
BD
1H
FA
16T
A60
CS
DCB_Cap_Neg
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Schematics and Parts List 35 For More Information On This Product,
Go to: www.freescale.com
Schematics and Parts List
F
ree
sca
le S
em
ico
nd
uc
tor,
I
Freescale Semiconductor, Inc.n
c..
.
Fig
ure
4-4.
Cu
rren
t an
d T
emp
erat
ure
Fee
db
ack
I_se
nse_
BG
ND
AR
312
10k
Tem
p_se
nse_
2
+3.
3V_A
GN
DA
R30
775
k-1%
R32
010
k-1%
R31
110
k-1%
+C
306
3.3u
F/1
0V
R32
275
k-1%
R30
668
0k
I_se
nse_
A2
Ove
rcur
rent
Det
ectio
n+
15V
_D
R31
047
0
GN
DA
Shu
t_D
own_
Ope
n C
.
I_se
nse_
DC
B1
I_se
nse_
B1
R31
610
k-1%
R30
575
k-1%
+15
V_D
R32
110
k-1%
I_se
nse_
C1
Tem
pera
ture
Sen
sing
+3.
3V_A
I_se
nse_
DC
B
(1.6
5V +
/- 1
.65V
@ +
/- Im
ax)
GN
D
+ -
U30
3B
LM39
3D
5 67
8 4
GN
DA
+-
U30
1BM
C33
502D
567
R32
410
0k-1
%
GN
DA
R32
533
.2k-
1%
C30
368
0pF
R32
339
0
GN
DA
I_se
nse_
C2
+3.
3V_A
I_se
nse_
DC
B
R31
710
k-1%
+15
V_D
+15
V_D
I_se
nse_
DC
B2
+3.
3V_A
+-
U30
1AM
C33
502D
321
84
C30
510
0nF
R30
375
k-1%
GN
D
(1.6
5V +
/- 1
.65V
@ +
/- Im
ax)
I_se
nse_
A
Pha
se C
urre
ntS
ensi
ng
R30
91.
2k
C30
710
0nF
GN
DA
+-
U30
2AM
C33
502D
321
84
C30
410
0nF
+-
U30
2BM
C33
502D
567
U30
4LM
285M
8
5
4
R31
975
k-1%
Tem
p_se
nse_
1
GN
DA R
313
10k-
1%
R30
81.
2k
+3.
3V_A
GN
DA
Over-curent
threshold =
3.15V
GN
DA
R31
475
k-1%
+ -
U30
3A
LM39
3D
3 21
8 4
R31
575
k-1%
GN
DA
GN
D
+3.
3V_A
I_se
nse_
B2
DC
Bus
Cur
rent
Sen
sing
GN
D
GN
D
C30
110
0nF
Tem
p_se
nse
I_se
nse_
A1
I_se
nse_
C(1
.65V
+/-
1.6
5V @
+/-
Imax
)
1.65
V r
ef+
3.3V
_A
R31
875
k-1%
R30
110
k-1%
GN
DA
I_se
nse_
DC
B
R30
410
k-1%
R30
2
2.21
k-1%
C30
210
nF
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
36 Schematics and Parts List MOTOROLA For More Information On This Product,
Go to: www.freescale.com
Schematics and Parts ListSchematics
F
ree
sca
le S
em
ico
nd
uc
tor,
I
Freescale Semiconductor, Inc.n
c..
.
Fig
ure
4-5.
Po
wer
Fac
tor
Co
rrec
tio
n a
nd
Bra
ke G
age
Dri
ve
R22
86.
81k-
1%
GN
D
R21
72.
7k
R20
23.
3k
R22
5
274k
-1%
GN
D
DC
B_P
FC
_2R
220
33k
U20
1A
MC
74V
HC
T00
AD
1 23
DC
B_C
ap_p
os
R22
1
33k
R22
6
4.87
k-1%
C20
310
0nF
R21
84.
7k
PF
C_g
ate
+
C20
947
0uF
/400
V
C20
722
nF
PF
C_S
ourc
e
GN
DA
R20
9
10k-
1%
U20
1B
MC
74V
HC
T00
AD
4 56
+15
V_A
U20
1D
MC
74V
HC
T00
AD
12 1311
R20
4
100
R21
510
k
C21
310
nF/3
000V
R22
925
5-1%
R21
627
0k
GN
D
L201
4.9m
H/2
.3A
R20
5
1k-1
%
+5V
_D
U20
1C
MC
74V
HC
T00
AD
9 108
GN
DA
Bu
s V
olt
age
Sen
sin
g
GN
D
GN
D
GN
D
PF
C_P
WM
R22
310
k
GN
D
R22
210
k
PF
C G
ate
Dri
ve
GN
DA
GN
D
VC
C
C21
21n
F
C20
5
22nF
R23
06.
81k-
1%
D20
2M
MS
Z52
51B
T1
ref_
h =
11.
76V
+15
V_D
+5V
_D
Out
BIn
B
GN
D
InA
NC
NC
Out
A
VC
CU
202
MC
3315
2D
2
3
5
6
781 4
R20
1
3.92
k-1%
R22
4
274k
-1%
DC
B_C
ap_n
eg
R21
0
33
R21
43.
3k
Bra
ke_c
ontr
ol
GN
DA
V_s
ense
_DC
B_h
alf_
15
+15
V_D
+15
V_A
(3.2
4V @
DC
-Bus
= 4
00V
)
PF
C O
pti
on
:
no
PF
C(d
efau
lt s
etti
ng
)
C20
410
nF
+ -
U20
3BLM
393D
5 67
8 4
C20
1
6.8n
F
+15
V_D
GN
D
R22
7
274k
-1%
GN
D
R21
310
k
R20
610
0k
D20
3S
M/1
N41
48
GN
D
+
C20
210
uF/3
5V
Zer
o C
ross
ing
Det
ecti
on
PF
C_e
nabl
e
C20
6 10nF
Bra
ke_g
ate
GN
D
PF
C_z
_c
C21
11n
F
+15
V_D
R20
810
k
+15
V_A
PF
C
+5V
_D
GN
D
JP20
1P
FC
Jum
per
1
2
3
R21
268
1-1%
+15
V_D
GN
D
C21
410
nF/3
000V
R21
9
33k
D20
1M
MS
Z52
51B
T1
+5V
_D
ref_
l = 1
1.72
V
R20
368
.1-1
%
GN
D
+15
V_D
C20
822
nF/6
30V
DC
+15
V_D
GN
DA
R20
712
.1k-
1%
Ear
th_G
ND
GN
DA
R21
110
k
+ -
U20
3ALM
393D
3 21
8 4
DC
B_P
FC
_1
Bra
ke G
ate
Dri
ve
V_s
ense
_DC
B
PF
C_I
_sen
se_1
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Schematics and Parts List 37 For More Information On This Product,
Go to: www.freescale.com
Schematics and Parts List
F
ree
sca
le S
em
ico
nd
uc
tor,
I
Freescale Semiconductor, Inc.n
c..
.
Fig
ure
4-6.
Iden
tifi
cati
on
Blo
ck
X80
1 4MH
zG
ND
+5V
_D
Coding bit #
7 6 5 4
U80
1
MC
68H
C70
5JJ7
DW
_MO
D
12345678910
20
1918 17161514131211
PB
1/A
N1
PB
2/A
N2
PB
3/T
CA
PP
B4/
TC
MP
PB
5P
B6
PB
7
PA
5P
A4
PA
3
PB
0
VC
CG
ND
OS
C1
OS
C2
RE
SE
TIR
Q
PA
0P
A1
PA
2
+5V
_D
GN
D
GN
D
Iden
tific
atio
n
R80
410
k
+5V
_D
DE
FAU
LT S
ETT
ING
S:
0 - P
TB0
= H
1 - P
TB1
= H
2 - P
TB2
= L
3 - P
TB3
= H
4 - P
TB4
= H
5 - P
TB5
= H
6 - P
TA6
= H
7 - P
TA7
= H
C80
210
nFR
803
10k
R80
110
k
+5V
_D
R80
510
k
+C
801
10uF
/6.3
V
GN
D
3 2 1 Coding bit #
JP80
1
SM
/JU
MP
ER
4x2
12
34
56
78
GN
D
+5V
_D
GN
D
+5V
_D
0 Coding bit #
R80
210
k
+5V
_D
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
38 Schematics and Parts List MOTOROLA For More Information On This Product,
Go to: www.freescale.com
Schematics and Parts ListSchematics
F
ree
sca
le S
em
ico
nd
uc
tor,
I
Freescale Semiconductor, Inc.n
c..
.
Fig
ure
4-7.
Po
wer
Su
pp
ly
U10
7M
C79
L15A
CD
5
21
367G
nd
Vin
Vou
tV
inV
inV
inR
106
2.21
k/1%
+15
V_D
GN
D
GN
D
R10
92.
21k/
1%
FB
U10
2T
OP
202Y
AI
3
1
2D
C
S
+5V
_D
+F
AN
D11
0M
BR
0530
T1
C11
210
0nF
R10
31.
0k
R10
0
1.0k
+
C10
8 33uF
/25V
R11
327
GN
DA
GN
DA
U10
0S
FH
6106
14
23
GN
D
D10
4
MB
RS
1100
T3
+
C10
222
0uF
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Pow
er_p
os
+15
V_A
D11
1M
BR
0530
T1
U10
3T
NY
254P
7
4
8
5
2
3
1
6
SE
NS
Dra
in
S SBP
S
Pow
er_p
os+
15V
_A
D10
9M
BR
0530
T1
-15V
_A Pow
er_p
os
R11
227
-15V
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+
C12
933
uF/2
5V
U11
0M
C78
PC
33N
TR
1
2
3
5V
in
GND
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Vou
t
+
C12
810
uF/6
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+
C11
333
uF/2
5V
+15
V_D
+F
AN
D10
6M
BR
S11
00T
3
C11
010
0nF
GN
DA
+
C10
322
0uF
/10V
C10
9
100n
F
GN
D
U10
1T
L431
BC
D
1
8
23
76
R10
21.
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5
MB
RS
1100
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R11
027
R11
127
R10
5
820
C10
010
pF/5
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7M
MS
Z52
42B
T1
C10
510
0nF
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117
47uF
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U10
8M
C78
L15A
CD
81
VIN 2
VO
UT
36
7
+5V
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GN
D
D11
3
GR
EE
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ED
GC
101
Gro
und_
Con
nect
ion
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FH
6106
14
23
C12
51n
F/1
kV
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L15A
CD
81
VIN 2
VO
UT
36
7
GN
D
GN
D
R10
427
0
FB
GN
DA
GN
D
T10
1S
M/T
rafo
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D15
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IN1 2
10 89
53 4
76
1112
GN
DA
D10
3
MB
RS
1100
T3
-FA
N
GN
D
+3.
3V_A
R11
533
0
C11
410
0nF
R10
856
+
C11
133
uF/2
5V
D10
1M
BR
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3
4
1
GN
D
-FA
N
R11
41.
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1
1.0k
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310
0nF
+
C10
7
33uF
/25V
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V_D
C12
710
0nF
+17
V_D
C12
610
0nF
+
C10
122
0uF
/10V
+C
122
100u
F/1
6V
D10
8M
MS
Z52
31B
T1
+15
V_D
GN
D
D10
0
P6S
MB
200A
T3
Pow
er_n
eg
C12
410
0pF
/500
V
+15
V_A
C11
6
100n
F
T10
0
SM
/Tra
fo_E
FD
20/1
2PIN
1 2
10 89
53 4
76
1112
+F
AN
-FA
N
+C
104
10uF
/6.3
V
GN
D
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Pow
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3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Schematics and Parts List 39 For More Information On This Product,
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Schematics and Parts List
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4.4 Parts Lists
The HV SR power stage’s parts content is described in Table 4-1 for the power substrate and in Table 4-2 for the printed circuit board.
Table 4-1. Power Substrate Parts List
Qty Reference Description Manufacturer Part #
6D1, D2, D3, D4, D5, D6
8A/600V Ultrafast Rectifier International Rectifier HFA08TB60S
4 D7, D8, D9, D10 10A/800V Rectifier International Rectifier 10ETS08S
2 D11, D12 8A/600V Ultrafast Rectifier International Rectifier HFA08TB60S
2 D14, D13 Dual Diode – Temp Sensing On Semiconductor BAV99LT1
2 J1, J2 SM/CON/MCRD_SR_500_A — male Fisher Elektronik SL 11 SMD 104 20Z
2 J3, J10 SM/CON/MCRD_SR_500_B — male Fisher Elektronik SL 10 SMD 104 6Z
1 J4 SM/CON/MCRD_SR_500_C — male Fisher Elektronik SL 10 SMD 104 6Z
3 J5, J6, J7 SM/CON/MCRD_SR_500_D — male Fisher Elektronik SL 10 SMD 104 10Z
2 J8, J9 SM/CON/MCRD_SR_500_E — male Fisher Elektronik SL 10 SMD 104 4Z
7Q1, Q2, Q3, Q4, Q5, Q6, Q7
10A/600V IGBT Infineon SGB10N60
1 Q8 8A/500V MOSFET On Semiconductor MTB8N50E
Table 4-2. Printed Circuit Board Parts List (Sheet 1 of 5)
Qty Reference Description Part # Manufacturer
19
C1, C2, C105, C109, C110, C112, C114, C116, C123, C126, C127, C203, C301, C304, C305, C307, C401, C405, C409
100nF/25V Vitramon VJ0805U104MXXA_
1 C100 10pF/500V Vishay Sprague Typ:5GAQ10, Serie: 562C
3 C101, C102, C103 220uF/10V AVX TPSE227K010R0100
3 C104, C128, C801 10uF/6.3V Sprague 293D106X_6R3B2_
8C107, C108, C111, C113, C129, C416, C417, C418
33uF/25V AVX TPSE336K025R0200
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
40 Schematics and Parts List MOTOROLA For More Information On This Product,
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Schematics and Parts ListParts Lists
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1 C117 47uF/16V Any available
1 C122 100uF/16V AVX TPSE107K016R0100
5C204, C206, C302, C425, C802
10nF Vitramon VJ0805U103MXXA_
1 C124 100pF/500V Vishay Sprague Typ:5GAT10, Serie: 562C
1 C125 1nF/1kV muRata DE0505E102Z1K
1 C201 6.8nF Vitramon VJ0805A682JXA_
1 C202 10uF/35V Sprague 293D106X_035D2_
2 C207, C205 22nF Vitramon VJ0805A223JXA_
1 C208 22nF/630VDC WIMA MKP10
1 C209 470uF/400V Philips Components 15746471
8C211, C212, C419, C420, C421, C422, C423, C424
1nF Vitramon VJ0805A102JXA_
2 C213, C214 10nF/ 3000V Thomson 5ST410MCMCA
1 C303 680pF Vitramon VJ0805A681JXA_
1 C306 3.3uF/10V Sprague 293D335X_010A2_
3 C402, C406, C410 4.7uF/16V Sprague 293D475X_016B2_
6C403, C404, C407, C408, C411, C412
470nF/50V Vitramon VJ1206U474MXAA_
3 C413, C414, C415 8.2pF Vitramon VJ0805A8R2DXA_
1 D1 Disk Varistor EPCOS SOIV-S-10K250
1 D100 Transient Suppressor On Semiconductor P6SMB200AT3
1 D101 6A/60V Shottky On Semiconductor MBRD660CT
4D102, D401, D408, D413
1A/600V Ultrafast On Semiconductor MURS160T3
4D103, D104, D105, D106
1A/100V Schottky On Semiconductor MBRS1100T3
1 D107 12V Zener On Semiconductor MMSZ5242BT1
1 D108 5.1V Zener On Semiconductor MMSZ5231BT1
4D109, D110, D111, D112
.0.5A/30V Schottky On Semiconductor MBR0530T1
1 D113 Green LED Kingbright L-934GT
Table 4-2. Printed Circuit Board Parts List (Sheet 2 of 5)
Qty Reference Description Part # Manufacturer
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Schematics and Parts List 41 For More Information On This Product,
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Schematics and Parts List
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8D201, D202, D403, D405, D407, D410, D412, D415
22V Zener On Semiconductor MMSZ5251BT1
1 D203 SMD/1N4148 FairChild 1N4148LL-34
6D402, D404, D406, D409, D411, D414
1A/30V Schottky On Semiconductor MBRS130LT3
1 F1 Fuse Holder MULTICOMP MCHTE15M
1 JP201 Power Jumper — Wire, D = 1.5mm, L = 12mm
1 JP801 4X2 Jumper Pads — —
2 J2, J1 20 Pin Female Header Fisher Elektronik BL 2 20Z
2 J3, J10 6 Pin Female Header Fisher Elektronik BL 1 6Z
1 J4 6 Pin Female Header Fisher Elektronik BL 1 6Z
3 J5, J6, J7 10 Pin Female Header Fisher Elektronik BL 1 10Z
2 J9, J8 4 Pin Female Header Fisher Elektronik BL 1 4Z
2 J11, J12 2 Pole Terminal Block Weidmuller LP 7.62/2/90
1 J13 3 Pole Terminal Block Weidmuller LP 7.62/3/90 — see note!
1 J1440 Pin Connector — male
Fischer Elektronik ASLG40G
1 L201 4.9mH/2.3A Thompson Television Compon. SMT4 ref G6982-01
1 R1 Inrush Limiter Rhopoint Components SG190
4R100, R101, R102, R103
1.0k Dale CRCW1206-102J
1 R104 270_ Dale CRCW0805-271J
1 R105 820_ Dale CRCW0805-821J
2 R106, R109 2.21k–1% Any available —
1 R108 56_ Any available —
4R110, R111, R112,R113
27_ Dale CRCW1206-270J
1 R114 1.0k Dale CRCW0805-102J
1 R115 330_ Dale CRCW0805-331J
1 R201 3.92k–1% Any available —
Table 4-2. Printed Circuit Board Parts List (Sheet 3 of 5)
Qty Reference Description Part # Manufacturer
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
42 Schematics and Parts List MOTOROLA For More Information On This Product,
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Schematics and Parts ListParts Lists
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18
R208, R211, R213, R215, R223, R312, R403, R404, R407, R408, R411, R412, R414, R801, R802, R803, R804, R805
10k Dale CRCW0805-103J
2 R202, R214 3.3k Dale CRCW0805-332J
1 R203 68.1–1% Any available
2 R204, R413 100_ Dale CRCW0805-101J
1 R206 100k Dale CRCW0805-104J
1 R207 12.1k–1% Any available
1 R210 33_ Dale CRCW0805-330J
1 R212 681_–1% Any available
1 R216 270k Dale CRCW0805-274J
1 R217 2.7k Dale CRCW0805-272J
1 R218 4.7k Dale CRCW0805-472J
1 R219 33k Dale CRCW0805-333J
2 R220, R221 33k Dale CRCW0805-333J
1 R222 10k Dale CRCW0805-103J
3 R224, R225, R227 274k–1% Any available —
1 R226 4.87k–1% Any available —
2 R228, R230 6.81k–1% Any available —
1 R229 255_–1% Any available —
9R209, R301, R304, R311, R313, R316, R317, R320, R321
10k–1% Dale CRCW0805-103F
1 R302 2.21k–1% Any available
1 R205 1k–1% Dale CRCW0805-102F
8R303, R305, R307, R314, R315, R318, R319, R322
75k–1% Dale CRCW0805-753F
1 R306 680k Dale CRCW0805-684J
2 R308, R309 1.2k Dale CRCW0805-122J
1 R310 470_ Dale CRCW0805-471J
1 R323 390_ Dale CRCW0805-391J
Table 4-2. Printed Circuit Board Parts List (Sheet 4 of 5)
Qty Reference Description Part # Manufacturer
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Schematics and Parts List 43 For More Information On This Product,
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Schematics and Parts List
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1 R324 100k–1% Dale CRCW0805-104F
1 R325 33.2k–1% Any available —
6R401, R402, R405, R406, R409, R410
120_ Dale CRCW0805-121J
1 T100 SMPS Transformer Tronic Praha s.r.o TRONIC 99 060 09
1 T101 SMPS Transformer Tronic Praha s.r.o TRONIC 00 003 73
2 U100, U104 Optocoupler Infineon SFH6106-2
1 U101 Voltage Reference On Semiconductor TL431BCD
1 U102 SMPS Controller Power Integration TOP202YAI
1 U103 SMPS Controller Power Integration TNY254P
2 U108, U106 15V Voltage Regulator On Semiconductor MC78L15ACD
1 U107 –15V Voltage Regulator On Semiconductor MC79L15ACD
1 U110 3.3V Voltage Regulator On Semiconductor MC78PC33NTR
1 U201 Quad NAND Gate On Semiconductor MC74VHCT00AD
1 U202 Gate Driver On Semiconductor MC33152D
2 U203, U303 Dual Comparator On Semiconductor LM393D
2 U301, U302 Rail-to-Rail Op Amp On Semiconductor MC33502D
1 U304 Voltage Reference National Semiconductor LM285M
3 U401, U402, U403 Gate Driver International Rectifier IR2112S
1 U404 Hex Driver Fairchild DM74ALS1034M
1 U801 Programmed MCU Motorola MC68HC708JJ7CDW
1 X801 4MHz Resonator muRata CSTCC4.00MG
1 — Sticker —
0 R107 NOT POPULATED — —
0 C115, C210 NOT POPULATED — —
Table 4-2. Printed Circuit Board Parts List (Sheet 5 of 5)
Qty Reference Description Part # Manufacturer
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
44 Schematics and Parts List MOTOROLA For More Information On This Product,
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User’s Manual — 3-Phase Switched Reluctance High-Voltage Power Stage
Section 5. Design Considerations
5.1 Contents
5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3 Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5 Cycle-by-Cycle Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9 Power Factor Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Overview
From a systems point of view, the HV SR power stage fits into an architecture that is designed for software development. In addition to the hardware that is needed to run a motor, a variety of feedback signals that facilitate control algorithm development and a PFC circuit are provided.
Circuit descriptions for the HV SR power stage appear in this subsection.
5.3 Phase Outputs
The output stage is configured as a dual output per phase, 3-phase, bridge with IGBT output transistors. It is simplified considerably by high-voltage integrated gate drivers that have a cycle-by-cycle current limit feature. A schematic that shows one phase is illustrated in Figure 5-1.
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
MOTOROLA Design Considerations 45 For More Information On This Product,
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Design Considerations
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Fig
ure
5-1.
Ph
ase
A O
utp
utGN
D
U40
4AD
M74
ALS
1034
M
12
+15
V_D
Q2
SG
B10
N60
R40
310
k
R41
3
100
+C
416
33uF
/25V
C41
38.
2pF
U40
1
IR21
12S
123456789 10 11 12 13 14 15 16
LOC
OM
VC
Cn/
cn/
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BH
On/
cn/
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DD
HIN
SD
LIN
VS
Sn/
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212
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1H
FA
16T
A60
CS
D40
3M
MS
Z52
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T1
+5V
_D
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347
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/50V
+5V
_D
R40
410
k
GN
D
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1M
UR
S16
0T3
+5V
_D
D2
HF
A16
TA
60C
S
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BR
S13
0LT
3
D40
2M
BR
S13
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3
DC
B_C
ap_N
eg
+
C40
24.
7uF
/16V
Pha
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B
C40
447
0nF
/50V
PW
M_A
B
Pha
se_A
TC
401
100n
F
U40
4BD
M74
ALS
1034
M
34
C41
91n
F
DC
B_C
ap_P
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sense
sense
R1
0.07
5 1
%
C42
01n
F
GN
D
Q1
SG
B10
N60
PW
M_A
T
R41
410
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D40
5M
MS
Z52
51B
T1
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Design ConsiderationsPhase Outputs
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At the input, pull down resistors, R403 and R404, set a logic low in the absence of a signal. Open input pull down is important, since it is desirable to keep the power transistors off in case of either a broken connection or absence of power on the control board. The drive signal is buffered by U404A and U404B. This part has a minimum logic 1 input voltage of 2.0 volts and maximum logic 0 input voltage of 0.8 volts, which allows for inputs from either 3.3-volt or 5-volt logic. Gate drive is supplied by an International Rectifier IR2112. Under-voltage lockout and cycle-by-cycle current limiting are also provided by the IR2112. Under-voltage lockout is set nominally at 8.4 volts. Current limiting is discussed further in 5.5 Cycle-by-Cycle Current Limiting.
One of the more important design decisions in a motor drive is selection of gate drive impedance for the output transistors. In Figure 5-1, resistor R402, diode D404, and the IR2112’s nominal 500-mA current sinking capability determine gate drive impedance for the lower half-bridge transistor. A similar network is used on the upper half-bridge. These networks set turn-on gate drive impedance at approximately 120 ohms, and turn-off gate drive to approximately 500 mA. These values produce transition times of approximately 200 ns.
Transition times of this length represent a carefully weighed compromise between power dissipation and noise generation. Generally speaking, transition times longer than 250 ns tend to get power hungry at non-audible PWM rates; and transition times under 50 ns create di/dt’s so large that proper operation is difficult to achieve. The HV SR power stage is designed with switching times at the higher end of this range to minimize noise.
Anti-parallel diode softness is also a first order design consideration. If the anti-parallel diodes in an off-line motor drive are allowed to snap, the resulting di/dt’s can cause noise management problems that are difficult to solve. In general, it is desirable to have peak to zero di/dt approximately equal the applied di/dt that is used to turn the anti-parallel diodes off. The HFA16TA60CS soft recovery rectifiers that are used in this design are targeted at this kind of reverse recovery characteristic.
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Design Considerations
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5.4 Bus Voltage and Current Feedback
Feedback signals proportional to bus voltage and bus current are provided by the circuitry shown in Figure 5-2. Bus voltage is scaled down by a voltage divider consisting of R224–R230. The values are chosen such that a 400-volt maximum bus voltage corresponds to 3.24 volts at output V_sense_DCB. An additional output, V_sense_DCB_half_15 provides a reference that is used in zero crossing detection.
Bus current is sampled by resistor R4 in Figure 4-3. 3-Phase Output and amplified by the circuit in Figure 5-2. This circuit provides a voltage output suitable for sampling with A/D inputs. An MC33502 is used for the differential amplifier. With R315 = R319 and R316 = R317, the gain is given by:
A = R315/R316
The output voltage is shifted up by 1.65 V to accommodate both positive and negative current swings. A ±3000 mV voltage drop across the sense resistor corresponds to a measured current range of ±2.93 amps. In addition to providing an A/D input, this signal is also used for cycle-by-cycle current limiting. A discussion of cycle-by-cycle current limiting follows in 5.5 Cycle-by-Cycle Current Limiting.
5.5 Cycle-by-Cycle Current Limiting
Cycle-by-cycle current limiting is provided by the circuitry illustrated in Figure 5-3. Bus current feedback signal I_sense_DCB is filtered with R308 and C303 to remove spikes, and then compared to a 3.15-volt reference in U303B. The open-collector output of U303B is pulled up by R414. Additional filtering is provided by C413, C414, and C415. The resulting signal is fed into the IR2112 gate driver’s shutdown input on all three phases. Therefore, when bus current exceeds 2.69 amps, all six output transistors are switched off.
The IR2112’s shutdown input is buffered by RS latches for both top and bottom gate drives. Once a shutdown signal is received, the latches hold the gate drive off for each output transistor, until that transistor’s gate drive signal is switched low, and then is turned on again. Hence, current limiting occurs on a cycle-by-cycle basis.
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Design ConsiderationsCycle-by-Cycle Current Limiting
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Figure 5-2. Bus Feedback
V_sense_DCB
GNDAGNDA
R225274k-1%
R323 390
(1.65V +/- 1.65V @ +/- Imax)
+3.3V_A
R227274k-1% R228
6.81k-1%
R317 10k-1%
R324100k-1%
R2306.81k-1%
DC Bus CurrentSensing
C307100nF
R224274k-1%
I_sense_DCB
I_sense_DCB1
C305100nF
GNDA
I_sense_DCB2 +
-
U302AMC33502D
3
21
84
R229255-1%
GNDA
GNDA
GNDA
V_sense_DCB_half_15
I_sense_DCB
1.65V ref
U304LM285M
8
5
4
R315 75k-1%
Bus VoltageSensing
R316 10k-1%
DCB_Cap_pos
+C306
3.3uF/10V
(3.24V @ DC-Bus = 400V)
R32533.2k-1%
+3.3V_A
R2264.87k-1%
R31975k-1%
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Design Considerations
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Figure 5-3. Cycle-by-Cycle Current Limiting
A Top Out
R413
100
GNDA
PWM C Bottom
+5V_D
C413 8.2pF
R306 680k
PWM B Top
B Top Out
C415 8.2pF
R41410k +5V_D
C Bottom Out
PWM C Top
R3091.2k
U401
IR2112S
123456789
10111213141516
LOCOMVCC
n/cn/cVSVBHOn/c
n/cVDDHINSDLINVSSn/c
PWM B Bottom
+5V_D
B Bottom Out
R31210k
U403
IR2112S
123456789
10111213141516
LOCOMVCC
n/cn/cVSVBHOn/c
n/cVDDHINSDLINVSSn/c
+3.3V_A
PWM A Top
+
-
U303B
LM393D
5
67
84
GNDA
+15V_D
A Bottom Out
PWM A Bottom
C Top Out
GND
+5V_D
R310470
C414 8.2pF
R3081.2k
C303680pF
I_sense_DCB
U402
IR2112S
123456789
10111213141516
LOCOMVCC
n/cn/cVSVBHOn/c
n/cVDDHINSDLINVSSn/c
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Design ConsiderationsTemperature Sensing
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5.6 Temperature Sensing
Cycle-by-cycle current limiting keeps average bus current within safe limits. Current limiting by itself, however, does not necessarily ensure that a power stage is operating within safe thermal limits. For thermal protection, the circuit in Figure 5-4 is used. It consists of four diodes connected in series, a bias resistor, and a noise suppression capacitor. The four diodes have a combined temperature coefficient of –8.8 mV/°C. The resulting signal, Temp_sense, is fed back to an A/D input where software can be used to set safe operating limits.
Due to unit-to-unit variations in diode forward voltage, it is highly desirable to calibrate this signal. To do so, a value for Temp_sense is read at a known temperature and then stored in non-volatile memory. The measured value, rather than the nominal value, is then used as a reference point for further readings.
Figure 5-4. Temperature Sensing
R3022.2 kΩ –1%
C301100 nF
BAV99LT1
D13
PIN 26, CONNECTOR J14
+3.3V_A
BAV99LT1
D14
Temp_sense
GNDA
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Design Considerations
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5.7 Phase Current Sensing
Sampling resistors provide phase current information for all three phases. These resistors sample current in the lower phase legs which in a switched reluctance output directly measures phase current. The circuitry for phase A is shown in Figure 5-5.
Referencing the sampling resistors to the negative motor rail makes the measurement circuitry straightforward and inexpensive. Current is sampled by resistor R1, and amplified by differential amplifier U302B. This circuit provides a voltage output suitable for use with A/D inputs. An MC33502 is again used for the differential amplifier. With R301 = R304 and R303 = R305, the gain is given by:
A = R303/R301
The output voltage is shifted up by 1.65 V to accommodate both positive and negative current swings. A ±300-mV voltage drop across the shunt resistor corresponds to a measured current range of ±2.93 amps.
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Design ConsiderationsPhase Current Sensing
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Figure 5-5. Phase A Current Sensing
1.65V ref
C307100nF
+
-
U302BMC33502D
5
67
DCB_Cap_Pos
GNDA
R324100k-1%
D2HFA16TA60CS
D1HFA16TA60CS
R303 75k-1%
Q1SGB10N60
R30575k-1%
GNDA
I_sense_A
R304 10k-1%
Gate_AT
Q2SGB10N60
+3.3V_A
DCB_Cap_Neg
R32533.2k-1%
U304LM285M
8
5
4
+C306
3.3uF/10V
Phase_AT
Gate_AB
GNDA
sense
sense
R10.075 1%
Phase_AB
R323 390
R301 10k-1%
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Design Considerations
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5.8 Brake
A brake circuit is included to dissipate re-generative motor energy during periods of active deceleration or rapid reversal. Under these conditions, motor back EMF adds to the dc bus voltage. Without a means to dissipate excess energy, an overvoltage condition could easily occur.
The circuit shown in Figure 5-6 connects R6–R9 across the dc bus to dissipate energy. Q7 is turned on by software when the bus voltage sensing circuit in Figure 5-2 indicates that bus voltage could exceed safe levels. On-board power resistors R6–R9 will safely dissipate up to 50 watts continuously or up to 100 watts for 15 seconds. Additional power dissipation capability can be added externally via brake connector J12.
Figure 5-6. Brake
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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Design ConsiderationsPower Factor Correction
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5.9 Power Factor Correction
A power factor correction (PFC) circuit is included to facilitate development of software that includes PFC control features. The objective of the PFC hardware and software are to draw sinusoidal current from the ac line in an attempt to approach as closely as possible a unity power factor. Without PFC, current is drawn from the ac line at the peak of the sine wave, when the ac line voltage exceeds the dc bus voltage. PFC circuitry is illustrated in Figure 5-7.
Figure 5-7. PFC Circuitry
I_Sense_PFC2
R209
10k-1%
C21310nF/3000V
R205
1k-1%
C20722nF
D910ETS08S
R201
3.92k-1%
+15V_D
U201C
MC74VHCT00AD
9
108
C21410nF/3000V
GND
+15V_A
sense
sense
R50.075 1%
no PFC
GND
PFC_PWM
R20810kC201
6.8nFC205
22nF
PFC_enable
+15V_D
AC_IN_L2
R203
68.1-1%
R21510k
GND
+
-
U203ALM393D
3
21
84
R21033
JP201
PFC Jumper1
2
3
+5V_D
U201B
MC74VHCT00AD
4
56
Q8MTB8N50E
R2143.3k
GND
+C209
470uF/400V
C20610nF
D710ETS08S
OutBInB
GND
InA
NC NC
OutA
VCCU202
MC33152D
23
5
67
81
4
R21310k
GND
L201
4.9mH/2.3A
U201A
MC74VHCT00AD
1
23
R20712.1k-1%
GNDGND
GNDA
AC_IN_L1
D202MMSZ5251BT1
D1010ETS08S
D12
HFA08TB60SD810ETS08S
Earth_GND
PFC
I_Sense_PFC1
R206 100k
R212681-1%
R21110k
PFC_I_sense_1
C20822nF/630VDC
3-Phase Switched Reluctance High-Voltage Power Stage User’s Manual
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Design Considerations
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Looking toward the top of Figure 5-7, Q8, L201, D12, and the bus capacitors form a boost power supply. The configuration allows current to be drawn from the ac line, when line voltage is lower than the dc bus voltage. Pulse width modulation is controlled by software, and augmented by the analog circuitry in the lower half of Figure 5-7. Voltage feedback is provided by the bus voltage sensing circuit in Figure 5-2. A zero cross feedback signal, PFC_z_c, is also used. PFC_z_c is produced by the circuit shown in Figure 5-8.
In this circuit, R219, R220, and R221 provide a relatively high impedance connection to the rectified line voltage, and form an 11:1 voltage divider with R222. D203 clamps the divided down voltage to approximately 15.7 volts. Comparator U203B then compares this signal to an 11.8-volt reference. Approximately 40 mV of hysteresis and a small reduction to the reference voltage are added by R216. The result is a logic high at output PFC_z_c when the comparator’s input voltage falls below 11.72 volts. This output remains high until 11.76 volts is reached on the next cycle.
Figure 5-8. PFC Zero Crossing Feedback
GNDA
C2111nF
R220
33k
sense
sense
R50.075 1%
+15V_D
GND
R221
33k
R2184.7k
D910ETS08S
R216 270k
+15V_D
+
-
U203BLM393D
5
67
84
I_Sense_PFC1
D203SM/1N4148
D710ETS08S
D1010ETS08S
PFC_z_c
AC_IN_L2
GNDA
+15V_D
D810ETS08S
R219
33k
R2172.7k
R22310k
R22210k
AC_IN_L1
+5V_D
GND
I_Sense_PFC2
User’s Manual 3-Phase Switched Reluctance High-Voltage Power Stage
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MEMC3PSRHVPSUM/D
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