IRADK31 revA International Rectifier • 233 Kansas Street, El Segundo, CA 90245 • USA 1/3 HP- Phase Brushless DC (BLDC) Motor Controller Using IR3101/3/4 By Roger N. Khourey TOPICS COVERED Overview Features General Safety Note, Installation & Protection System Description Mechanical and Electrical Description System connection and GUI Operation Technical Data Mode Operation Circuit Description Figure 1. IRADK31 Reference Design Kit 1. Overview The IRADK31 Reference Design Kit (Figure 1) is an electronic controller for driving a 1/3HP (see Table 1) 3-phase Motor from either a single phase 120VAC or 230VAC. The circuit provides all the necessary functions, including software driven High performance Micro Controller, for starting and operating the motor. It also includes an AC on/off switch, EMI filter and the rectification stage with a buck-converter system that provides the auxiliary +15V and +5V supply. This controller is software driven through a Graphical User Interface (GUI) that enables the user to control the entire electrical system and motor parameters. In addition, it allows the user to monitor the DC Bus current, motor speed, and detects fault conditions. 2. Features • • • • • www.irf.com Fused 120/230VAC input. AC input on/off switch and EMI filter. NTC inrush current limiter 3-Phase, variable voltage output. Opto-isolated RS-232 serial link interface to the Graphic User Interface software. 1 IRADK31 • • • • • Integral auxiliary power supply of +15V and +5V. Fault protection for over current condition. Stand-alone Mode and fully software driven (PC Mode) using Graphical User Interface. PIC18F2431 motor control MCU from Microchip Technology Inc. with Power PWM module and Hi-speed 10-bit A/D converter. RJ11 connector for MPLAB ICD2 that provides programming or In-Circuit debugger interface. 3. General Safety Note This controller operates at high voltage to control rotating machinery. Qualified, skilled personnel conversant with all applicable safety standards must operate this equipment. Do not connect any interface cables to the controller when power is present. 4. Installation This controller must be placed on an insulated surface. Proper mating cables must be used for the GUI and motor interfaces (refer to Figure 2). Do not make any alterations or soldered connections to the printed wiring board. Verify that the input selector switch matches the AC supply voltage. 5. Protection Before handling the controller, check that the AC input voltage applied to J1 is turned off, and the AC on/off switch, SW4 is set to position “0”. CAUTION: High voltage is present on the motor connector J6 during operation. 6. System Description 6.1 Power Modules The IR3101/3/4 are FredFET Half-Bridge with integrated driver IC for motor drive applications. The IR310X are developed for electronic motor control in appliance applications, such as Dishwashing machine pumps and Fan Motors. These 500V power modules (IR3101 and IR3103) contain 2 FredFETs with soft recovery commutation diodes, and one Half-Bridge IC driver. Note that the IR3104 is a 600V module. www.irf.com 2 IRADK31 6.2 Motor Controller This motor controller is a single-phase 120V/230VAC input that can utilize 3 IR3101/03/04 modules that are used in a standard inverter configuration. The system is based on a high computational performance, 8-Bit Micro controller with 10-bit A/D converter, used to generate the PWM information and implement the motor control loop. The system operates in an open loop mode, as defined by the firmware. However, this controller has the provision to operate in closed loop mode. This controller can be operated in Stand-alone Mode or PC Mode. It can be operated in Stand-alone Mode even after connecting the RS-232 cable into J5 but prior to connecting the GUI with the controller. Once the GUI is connected with the controller the system will become operational in PC Mode and the user cannot operate in Stand-alone Mode, until the system is reset again. Refer to Section 7 and Appendix A for further explanation of Mode Operation. Two LEDs (Green and Red) are used to monitor the status of the control board. Both LEDs will blink on and off at initial power on, indicating normal board operation. These LEDs have the following features: • Green: Indicates the Hall sensors level, 3 hall sensors combined. If the motor shaft is rotated by hand, this LED will blink on and off. Once the motor ramps up at higher rate, the blink rate of this LED will increase. • Red: In normal operation condition indicates the direction of rotation command. On for forward, Off for reverse. It will blink on and off when over current fault condition occurs. When a Fault is detected the green light, below the Motor Speed Tachometer on the Control Panel, will turn Red. A detected fault guarantees PWM drive shutdown and complete protection for the power stage and the power modules. A fault condition is detected when an over current condition occurs. The firmware current limit can be set in the system limits from the setup parameters window (refer to Fault Condition and Current Limit in section 8 for details). 6.3 Auxiliary Power Supply The auxiliary power supply uses an IR2153 self-oscillating half-bridge driver in a buck topology that delivers the +15V auxiliary supply. The 15V is fed through a linear regulator (LM7805) that delivers the +5V to the remaining circuitry. Both the +15V and +5V are referenced to the DC bus return. The auxiliary power supply operates with a constant on time at variable frequency. Voltage regulation is maintained over a DC bus voltage variation from 80V to 400V. www.irf.com 3 IRADK31 6.4 Connection Diagram WARNING SW1 is an AC Input Voltage Selector switch. DO NOT apply 230VAC when this switch is set to 115VAC – this will result in sever damage to the system and personal injury due to the very high voltage produced by the voltage doubler circuit on the DC Bus. Figure 2 illustrates a typical connection block diagram. The printed wiring board has been designed to minimize ground loop currents with particular attention to reducing EMI generation. Output Phase W Output Phase V Output Phase U Earth J6 SW4 on/off Switch U8 J1 EMI Filter Section Line U7 U6 DC Rectifier Section 1 Earth 1 1 Neutral Power Modules PIC18F2431 J2 Control Section Auxiliary Supply Section SW2 SW3 J4 J5 ICD D10 D11 RS-232 R28 JP1 1 234 5 6 Hall Sensors Motor Led Feedback Flash Progmming and debugging Serial / USB Communication GUI (Computer) Figure 2. IRADK31 Typical Connection Diagram 6.5 GUI and Micro Controller The use of the GUI enables the user to control motor speed and direction, monitors the DC Bus current and Fault conditions, and program motor parameters and other control factors. The GUI also enables the users to set motor and system parameters such as motor type, motor voltage and current, AC input voltage, and PWM frequency. In addition, it allows the www.irf.com 4 IRADK31 user to set the system limits such as current and motor speed. All the setup parameters are uploaded via serial link. The PIC18F2431 MCU from Microchip Technology Inc. is responsible for all board functions, including communication through the RS-232 interface. Moreover, the Microcontroller introduces design enhancements that make it a logical choice for many high performance, power and motor control applications. Special peripherals include: • • • 14-bit resolution Power Control PWM Module (PCPWM) with programmable dead time insertion. Motion Feedback Module (MFM), including a 3-channel Input Capture (IC) Module and Quadrature Encoder Interface (QEI). High-speed 10-bit A/D Converter (HSADC). The MFM Quadrature Encoder Interface provides precise rotor position feedback and/or velocity measurement. The MFM 3X input capture or external interrupts can be used to detect the rotor state for electrically commutated motor applications using Hall Sensor feedback, such as BLDC drives. The microcontroller also features Flash program memory and an internal RC oscillator with built-in Low Power modes, fail-safe clock monitoring and Enhanced USART module. 7. Mechanical and Electrical Description The printed wiring board is a double-sided 122.7 x 127 mm board using a mixed technology of SMT and through-hole components. The layout of the connectors, indicators and user controls is shown in Figure 3. www.irf.com 5 IRADK31 J6 TP1 Output Phases SW1 SW4 U8 1 U7 U6 115V o E 1 TP2 1 N TP3 1 L 120/230VAC Input 230V J1 Power Modules PIC18F2431 TP4 J2 SW2 SW3 TP5 J4 LEDs D10 D11 ICD J3 J5 RS-232 R28 Hall Sensor JP1 1 234 5 6 Figure 3. IRADK31 Connectors and indicators layout Power Switch (SW4) This is the AC on/off power switch. When set to position “0” power is disconnected from the board. When set to position “1” AC power will be applied to the board. 120/230VAC Input Terminal (J1) This is the main connector for the AC 120/230VAC input power with earth ground connection. Main AC input power (Line, Neutral and Earth Ground) is to be connected as shown in Figure 2. Line terminal: Input AC voltage (120V or 230V) phase. Neutral Terminal: Input AC voltage (120V or 230V) neutral. Earth: Ground connection (recommended connection to reduce the EMI noise). 115V/230V Selector Switch (SW1) WARNING: SW1 must be operated ONLY when the AC power is disconnected from terminal J1. Ignoring this warning will result in damage to the board and/or severe personal injury. www.irf.com 6 IRADK31 This is the voltage selector switch to set the correct rectifier configuration to the AC input. Prior to connection the system to the AC input, carefully check the position of SW1. Set to 115V when applying power from 110/120VAC source, or set to 230V when applying power from a 220/230VAC source. Output Phases Terminal (J6) This is the terminal for motor connection, output from 3-phase inverter circuit driven by PWM signals to the motor (i.e. motor voltages). These signals are referenced to the negative DC power rail, which is NOT a ground potential. CAUTION: Beware of electric shock hazard. DO NOT connect any grounded test equipment such as an Oscilloscope to these test terminals. Always isolate your equipment from Earth Ground. Connect the motor phase inputs (U, V, and W) from this terminal as depicted in Figure 2. Hall Sensor connector (JP1) This is Motor’s Hall Sensors feedback connector that allows for detecting the rotor state and position. RS-232 Port (J5) A standard 9-pin D-shell female type connector (DB9F) that provides an Opto-isolated RS232 serial link with the PC to control and monitor the development board. RS-232 Serial Link: A standard 9-pin D Female connector is used for the RS-232 serial link. The pins used on this connector are the RxD, TxD, GND, RTS, and DTR. The RTS and DTR signals provide sufficient current to drive the Opto-couplers. The current drawn from these pins is far below permissible limits for the RS-232 drivers. The GUI should work with any of the available COM ports on the PC. There is no restriction on COM port. COM1 is the GUI’s default port. The serial cable may be connected or disconnected (With no AC power applied to the controller) at any time without having to restart your computer. A USB 2.0 to Serial Adapter (P/N: USB-2920) is available from www.cables4computer.com may be used as an option. Ensure that the port selection in the GUI is set to COM3 with Baud Rate at 9600 when using this adapter. www.irf.com 7 IRADK31 MPLAB ICD2 Connector (J4) A 6-wire RJ-11 jack is provided as a programming or In-Circuit Debugger interface. This will also allow users to use development tools, such as MPLAB ICD2, while the board is under power. Note that this connector is referenced to the –DC Bus. LEDs D10, D11, and SW2, SW3, R28 At initial power on, LEDs D10 (Red) and D11 (Green) blink on and off at a fixed rate. Rotating potentiometer R28 can change the blinking rate. Clockwise (CW) slows the blinking rate and counterclockwise (CCW) increases the blinking rate. When R28 is near the end position on CCW, both LEDs may look like they are on all the time because they are blinking at a faster rate. The functions of D10, D11, SW2, SW3, and R28 are as follows: Stand-alone Mode (Also referred as Manual mode): - Green LED: Indicates the Hall sensors level, 3 hall sensors combined when the motor rotates. If the motor shaft is rotated by hand, this LED will blink on and off. - Red LED: In normal operation indicates the direction of rotation command. On for forward, Off for reverse. It will blink on and off, if hardware over current fault condition occurs (using the last downloaded parameters). - SW2: This switch is used to toggle between Run and Stop. - SW3: This switch is used to toggle between Forward and Reverse. - R28: Used to control the Motor speed. PC Mode (Also referred as GUI mode): - Green LED: Indicates the Hall sensors level, 3 hall sensors combined when the motor rotates. If the motor shaft is rotated by hand, this LED will blink on and off. - Red LED: In normal operation indicates the direction of rotation command. On for forward, Off for reverse. It will blink on and off if an over current fault condition occurs. - SW2, SW3: They are not used in PC Mode. GUI command is used instead. - R28: Not used with this mode. Test Points (TP1 – TP5) These test points are used for voltage and signal monitoring purposes. TP1, TP2: For monitoring the +DC Bus and –DC Bus, respectively • TP3: Current Feedback signal. • TP4: +15V auxiliary power supply. • TP5: +5V auxiliary power supply. Jumper (J2) This is the reset jumper to the microcontroller. When shorted, it resets the microcontroller and starts the firmware from beginning. This jumper is default to open. www.irf.com 8 IRADK31 Jumper (J3) This jumper is connected across the diode of Opto-isolator, OP3. It allows the user to externally apply an Opto-isolated PWM signal into the microcontroller for debugging purposes. Jumpers JX1 – JX3 These jumpers are used to connect or disconnect the Sensorless Feedback circuit. Their defaults are in the open position and not used with the current firmware version provided with this kit. Connecting the inverter to the motor WARNING SW1 is an AC Input Voltage Selector switch. DO NOT apply 230VAC when this switch is set to 115VAC – this will result in sever damage to the system and personal injury due to the very high voltage produced by the voltage doubler circuit on the DC Bus. Use a 3-phase connected BLDC motor, rated at 1/3 HP or less. Provide a 3-wire, 2A minimum rated cable for the motor connection, and a 3-wire 2A minimum rated cable for the AC mains connections. Ensure that the ground connection is also connected to the earth terminal of J1. The motor phases can be connected in any sequence, only the rotation direction will be affected. Make all necessary connections, including the serial link with the PC before applying AC power. Note: Connecting both the RS-232 serial cable into J5 and the RJ-11 cable into J4 simultaneously will disable communication between the GUI and the system. When operating the motor, only connect the serial link cable into J5 and when programming or debugging the microcontroller, only connect the RJ-11 cable into J4. 8. System Connection and GUI Operation WARNING When energized, the power produced by the IRADK31 Board – particularly from the 3-phase inverter – can cause severe equipment damage or personal injury. Always use the proper precautions when working around the board, or power electronic equipment. Whenever possible, use the IRADK31 Board with the safety shield installed. Connect the IRADK31 board to the motor as illustrated in Figure 2. Ensure that the Voltage Select switch, SW1, is set to the appropriate voltage being supplied to the board. Set SW4 www.irf.com 9 IRADK31 switch to position “1” to supply AC power to the board. Verify that the Red and Green LEDs are flashing, indicating that power to the board has been established. Launch the Microchip Motor Control GUI (MotorControlIR2.exe). appear is the Control Panel as illustrated in Figure 4. The first screen will Figure 4. IRADK31 GUI Control Panel This the main display for the application. User can control motor speed and rotation direction in a way that is similar to Stand-alone Mode. The user can also monitor motor speed and DC Bus Current. The Control Panel also allows users to access to the Setup and Pattern Programming displays. Main features: • Motor Speed: This displays the actual speed of the motor in RPM, as determined by Hall sensors, in both tachometer and digital (text) formats. The RPM speed is relative to the Hall sensor frequency and the number of pole pairs in the motor. It can be determined from the following equation: RPM = • ( F hall ).(60) pole _ pairs The full-scale value is determined by the speed limit defined in the Setup window plus an additional margin. The upper boundary of the green range represents the motor’s rated www.irf.com 10 IRADK31 speed. The upper blue boundary is set to scale the maximum safe speed well into the red area. This boundary is halfway between the rated and full-scale speeds. The values may be changed in the Setup Display to reflect the actual performance limitations of the motor. • Fault Display: A scrolling text indicates the state of the fault conditions monitored by the board. Under normal conditions, it will display a scrolling “No Fault” message and a green indicator. If an over current fault condition occurs, the indicator will change to blinking red; the text will also change to red, and the message will indicate “Over Current Fault”. • Fault Condition and Current Limit: Hardware – The trip level is determined by the threshold voltage (1.66V) at the input of comparator U5:B, set by resistors R30 and R35. With a gain of 4, set by U5:A, this becomes 0.415V (1.66V/4). When this voltage is across shunt resistor R2, the corresponding current is 0.415V/0.2Ω, or 2.075A at output “FAULTA”. Therefore, the maximum safe current limit for the hardware is 2.1A. Firmware – This current feedback limit at output U5:A (IDC) is converted to voltage, filtered and fed into the microcontroller’s A/D port. The microcontroller detects when this limit is exceeded and determines when to shutdown the PWM signals if an actual over current condition occurs. • Set Speed: The user can set the target run speed for the motor with this spin box by either direct entry or using the up/down controls. The motor speed can be changed while the motor is rotating. Since the algorithm is an open loop type, actual speed may vary depending on motor parameters and actual load. • Direction: The direction indicator is shown with a left and right arrows, and text of the motor revolution to the default direction. The motor direction can be changed from either clockwise or counterclockwise while the motor is rotating. Doing so, the motor will ramp down and then ramp back up in the opposite direction. • DC Bus Current: This displays the current drawn for the DC Bus in Amperes. Information is given in analog gauge and digital (text) format. As with the speed display, the different color zones represent average safe and hazardous operating ranges, based on the Current Limit defined in the Setup window. The actual safe operating range should be determined from the motor’s nameplate and maximum current rating of the power module being used. The maximum current rating of the modules used with this Reference Design Kit are as follows: IR3101: 1.6A (Electrical Output Power at 512W) IR3103: 0.8A (Electrical Output Power at 256W) IR3104: 0.5A (Electrical Output Power at 160W) • Run/Stop: Allows the user to start and stop the motor. Entering the desired speed value in the Set Speed display and pressing the <Enter> key will also start the motor. www.irf.com 11 IRADK31 To start the motor, click on the Run button and observe that the motor skips twice before it starts rotating in full speed. This is to allow the hall sensors to be aligned in the proper position before the motor fully accelerates. • Connect/Abort: this button can establish or break a serial link connection with the board. When a link is established, the Connect label changes to Abort, and COM Setup becomes unavailable. When the link is broken; by clicking on Abort, COM Select becomes available for configuration. Press the COM Setup and verify that the COM Port and Baud Rate are set as shown in Figure 5. Note that the COM port can be set to either COM1 or COM2 depending on where the serial link cable is connected on your PC. Figure 5. COM Port and Baud Rate Settings Dialog Selecting the Auto Connect button can enable the Auto Connect feature. Once communication is established, the message “Connected to PIC18F2431 on COMx at xxxxbps (default value is 9600bps). Firmware Version: 1.0” will appear in the message window at the bottom of the control panel. (“x” represents the COM port actually selected; the actual baud rate depends on the setting used). Also, the message “Brushless DC Motor-Open Loop Control on IR31xx Demo board” will appear on the top of the control panel. The connection indicator in the lower left corner of the control panel window should change to solid green. You are now ready to work with the Motor Control GUI. From the control Panel, press the Setup button and verify that the Motor Parameters Window is displayed as shown in Figure 6. www.irf.com 12 IRADK31 Figure 6. Typical Motor Parameters Setup Window Users can define the individual settings for the motor being used. If the appropriate information is included in the firmware, most of the values will auto-populate, or at least be limited to a smaller subset of choices. Features or parameters that are not used will be masked or grayed out. There are three categories that the user can modify: • Motor parameters, which define the actual motor and sensor hardware that are used. • System (control) parameters, which define the control variables. • System limits, which define the hardware maximum ratings. Controls are also provided to save or load parameters for later use, or restore default settings. Note: Users have to download the settings to the connected board after any changes to see the effect of the new parameters. The following parameters are masked out: • Motor Parameter 9a. www.irf.com 13 IRADK31 • System Parameters 1 through 6. • V/F Curve button (not available for the IRADK31 Motor Controller Board). Motor Parameters These are generally self-explanatory. Information on the motor hardware itself (items 1 through 6) can be found on the motor’s nameplate or in its data sheet (see section 9.1 for motor recommendation). The “Motor Type” filed is auto-populated with the motor type identified upon connection. Selecting the appropriate check boxes in “Feed back Devices” selectively enables the configuration for motion feedback sensors. When only “Hall Sensor” check box is selected the sensor angle and Motion Filter Prescaler (MFM) may be configured; the other options are disabled. When optical encoders are enabled, the Encoder PPR (pulses per revolution), and MFM Filter may be configured; Hall Sensors configuration is unavailable. QEI update mode is default to X4 and cannot be changed. The recommended setting for the MFM Filter Prescaler to be used with the IRADK31 is “Filter Disabled”. Note that the Hall Sensors and optical sensors are not mutually exclusive. It is possible for some control methods to use both types at once. For the IRADK31, only the Hall Sensor option is available. Selecting the “None” option in “Feed back Devices” disables all sensor configuration options. Information on the sensor type and arrangement can be found in the motor data sheet. System Parameters The system parameters options can only be used with BLDC motors with the firmware provided with this demo kit. Acceleration and deceleration rate are defined as RPS/sec for most applications. Input voltage is the AC input voltage applied to the board. The input voltage should be kept at 220VAC, regardless of actual AC input applied. Because the board has a voltage doubler on the input rectifier side, when 115/120V AC is supplied, the DC Bus voltage would be 320V with voltage doubler circuit. When the input voltage is 220/230V Ac, the DC Bus voltage would also be 320V without voltage doubler circuit. The calculated DC Bus voltage supplied to the buck converter is given as 2 times the AC input (when 120VAC is applied) times 1.414, with the on-board voltage doubler enabled. When the on-board voltage doubler is not used and 230VAC is applied to the board the DC Bus voltage would be 230V times 1.414. The PWM frequency determines the resolution of the control firmware. The drop-down combo box presents a fixed range of values. www.irf.com 14 IRADK31 System Limits The system limits reflect the maximums of both the motor and the board being used. Voltage limit: Not used by the firmware provided with this Kit. Current Limit: Refer to the Fault Condition and Current Limit discussion in section 8. Speed Limit: Is set at the value given in the motor’s data sheet, or at a predetermined speed set by the particular motor data file. CAUTION Not all motors may be able to run at the maximum speed defined by the Speed Limit parameter. It should be regarded as an upper limit and not the motor’s expected maximum speed. Storing and Using Setting Profiles Once the parameters for a particular motor are established, it would be nice to preserve them for future use. Users have several options from the Setup display to do just that. Clicking on the Save button allows the current settings to be stored in a file, while clicking on the Load button selects and loads a file with saved settings. Both commands used the conventional Windows dialogs for opening and saving files. Setting profiles are saved as motor data files (.mcd extension). Neither of these affects the parameters currently in effect in the on-board firmware. The Default button replaces all of the current settings with the default settings associated with the current motor type. This may be useful for quickly starting over when a set of parameters has been extensively modified and isn’t working. The Download button transfers the currently displayed parameters to the on-board firmware. It only changes the parameters, and not the control firmware itself. Note 1: Attempting to load a motor data file that does not match the currently loaded motor and/or control method type will generate an error message. 2: Remember that downloading a profile to the IRADK31 Controller board only downloads variable values. It does not download new firmware. Similarly, loading and saving profiles only loads or saves the motor data file to the computer, but does not load or save the file on the on-board firmware. www.irf.com 15 IRADK31 9. Technical Data Table 1 indicates the electrical specification of the IRADK31 Reference Design Kit. Table 1. IRADK31 Electrical Specifications Input Voltage: 120VAC / 60Hz and 230VAC / 50Hz. Output Phases: 3-Phase, 1/3 HP, 512W BLDC Motor. Protection: Fused AC line with on/off power switch, NTC, and Transient Suppression Varistor. Motor Over current shutdown Filtering: X and Y capacitors with Common Mode Choke. Indicator and status Monitor: Two LEDs for System communication and normal operation status, as well as Fault condition indicator (Red LED) and GUI for setting and monitoring system parameters. RS-232 Interface: Opto-Isolated RS-232 serial interface. 9.1 Motor Recommendation The following BLDC motor type is recommended to use with this Reference Design Kit: Manufacturer: Bodine Electric Co. S/N: 3307ERGB0006 Type: 34B4BEBL Voltage: 130V Current: 2.0A RPM: 2500 HP: ¼ Phase: 3 www.irf.com 16 IRADK31 10. Appendix A – MODE OPERATION 10.1 WHICH MODE TO USE? Before setting up the development board, it is necessary to decide which operation mode is appropriate for what you want to do. There are two choices: • Stand-alone Mode: The IRADK31 Board is connected to a power supply and a motor, but not to a computer. Motor operation is controlled through the two push buttons, SW2 and SW3 (Start/Stop and direction) and the potentiometer, R28 (Speed). This is a simple demonstration of the board’s capability, and is useful for verifying the board’s operation. It can also work as fast “sanity check” of newly programmed control firmware. • PC Mode: The IRADK31 Board is also connected to a host computer through a serial interface. In this configuration, motor operation is controlled through a GUI application on the computer; speed cannot be controlled from the potentiometer on the board. The GUI allows more sophisticated motor operation, with controllable speed, and real-time monitoring of motor operation. Since both modes start with the same set-up procedure, we will start by describing the set-up for the Stand-alone mode. Setting up the PC mode involves adding the serial interface to the Stand-alone mode, and is covered later in this discussion. 10.2 SETTING UP THE IRADK31 BOARD: STAND-ALONE MODE For evaluating the IRADK31 Board, the simplest configuration is to use the board by itself, with no computer connection. This setup involves the following: 1. Connecting power to the board 2. Connecting the motor to the board (see Figure 2). 3. Verifying operation For the sake of simplicity, we will assume that we are using the development board in its default configuration for BLDC. This means that board jumpers are not installed and the PIC18F2431 device has been programmed with BLDC control firmware. This also assumes the use of a motor with built-in sensors for commutation, spaced at 60°. Some motors have Hall sensors spaced at 120°. Correct Hall Sensor spacing can be found in the data sheet for the motor being used. www.irf.com 17 IRADK31 10.3 SETTING UP THE IRADK31 BOARD: PC MODE While the Stand-alone mode is useful for simple testing, the PC mode allows more robust motor control. Configuring the IRADK31 Board for PC mode requires very little additional effort beyond the set up for Stand-alone mode. 10.3.1 Host Computer Requirements To use the IRADK31 Board in PC mode, the computer being used must meet the following hardware and software requirements: • PC-compatible system with an Intel Pentium class or higher processor, or equivalent, with a minimum clock speed of 133 MHz. • A minimum of 16 MB RAM. • A minimum of 16 MB available hard disk space. • CD-ROM drive (for use with the accompanying CD). • One available standard serial port, with a matching COM port available through the operation system. • 1 Optional USB Port. • Any 32-bit version of Microsoft Windows (Windows 98, Windows NT, Windows 2000 or Windows XP). 10.3.2 Installing the Motor Control GUI The installation of the host software package is completely automated and does not require any user intervention or configuration once the process is started. The process is identical for all 32-bit Windows operating systems. Users with Windows NT-based desktops (NT 4.0, 2000 and XP) should not need administrative rights to their systems for this installation. Closing all background applications before proceeding is helpful, but not required. Note: It is possible that some organizations may implement a desktop computer policy sufficiently restrictive to prevent the user from loading any software at all. In theory, this can be done with any 32-bit Windows operating system on a network – including Windows 95. If this describes your situation, contact your local Information Services provider for assistance installing this software. To install the host software, insert the Software and Documentation CD into the CDROM drive. Open the CD in Explorer view, and locate the “GUI” folder. Unzip the file “Microchip MC_Rev2.zip” and copy its contents in to the folder “Microchip IRADK31 MC” that you create on your system. www.irf.com 18 IRADK31 Note: An error may be reported when executing the MotorControlIR2 file with Windows Operating System running in Region/Language other than US/English, which displays the following message: ‘6.3’ is not a valid floating point value. To avoid this error message set Windows Region/Language to US/English. The Microchip MC_Rev2 zip file contains the following files: MotorControlIR2.exe PIC18_BLDC_OL.ini MCDemo.ini You may wish to create other folders and copy valuable files from the CD such as the motor parameter data, the PIC18F2431 hex file, and data sheets for future reference. Create a short cut on your desktop for the MotorControIR2 file. Double-click on that file to launch the GUI control panel as shown in Figure 4. Now you are ready to proceed with the operation of the GUI and controller as described in section 8 of this document. www.irf.com 19 20 A B C 1 -DC 10uF 450V C28 +DC EGND 3 2 1 0R R17 SW4 R3 4.7uF 25V 2 C17 11K 0.1uF 470K R1 2A 250V NTC CX1 470pF C18 3 2 1 CT RT VCC IR2153 U1 0.1uF 250VAC F1 RV1 C4 ZENER 18V D2 AC Power 56R R68 VB 1.8mH 2A EMI1 LO VS HO 5 6 7 8 1 2 CON3 3 4 J1 3 CX2 3 0.1uF 250VAC 0.1uF C3 1K R4 22 ohm R14 MURS160 D3 10nF 275VAC CY3 MOV RV2 4 KBPC608 1 3 D1 L1 4 IRU431 U3 1 1mH 0.53A MURS160 D4 IRFR420A Q1 2 4 1 2 2 3 4 D 1 COM 4 5 6 Power Supply 2 3 2.4K R16 27K R15 TP4 LL4148 D5 V80212M SW1 R2 1 VIN 5 LM7805C U2 0.2R 1W VOUT 3 TP3 -DC 82K TP2 R67 470uF 250V 82K C2 R66 470uF 250V TP1 C1 +DC 5 GND 2 +15V 47uF 25V C16 TP5 IF +DC AGND VDD 6 6 A B C D 21 A B C 1 6 5 4 3 2 1 Shield 5HEADER JP1 IF VDD 1K 2 0.1uF C8 R11 1K 1K 1K R8 R7 R24 1K R5 2 0.1uF C9 2 3 JX3 JX2 1K R12 JUMPER JUMPER JUMPER JX1 1K R10 1K R9 1K R6 VDD 8 4 D 1 3K R29 1 MCP6002 U5A BE1 BE2 BE3 HALL3 HALL2 HALL1 IDC 3 3 FAULTA RB7/PGD RB6/PGC RB5/PWM4 RB4/PWM5 RB3/PWM3 RB2/PWM2 RB1/PWM1 RB0/PWM0 VDD VSS RC7/RX/DT RC6/TX/CK RC5/INT2 RC4/INT1 R35 2.2K 5 7 MCP6002 470 4 5 28 27 26 25 24 23 22 21 20 19 18 17 16 15 MCLR VDD VSS RB7 RB6 RB3 RJ11 MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RA4/AN4 AVDD AVSS OSC1/CLKI/RA7 OSC2/CLKO/RA6 RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/INT0 PIC18F2431 J4 6 RC0 FAULTA RC2 RC3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0.1uF 0.1uF U4 C7 C6 470 R22 4.7K 20MHZ Y1 470 R23 10K R18 VDD 5 R30 33pF C20 33pF C19 IDC HALL1 HALL2 HALL3 MCLR U5B VDD Manual Speed Adj. 0.1uF R25 2K R28 VDD C5 JUMPER J2 4 Microcontroller and Current Sensing AVDD 1 2 3 4 5 6 VDD VDD VDD PGD PGC MCLR RX TX RC5 RC4 PGD PGC PWM4 PWM5 PWM3 PWM2 PWM1 PWM0 6 6 A B C D 22 A B C D 1 1 DB9 J5 1 6 2 7 3 8 4 9 5 JUMPER J3 470 R37 2 1 2 8.2K 8.2K 3 4 VDD R39 HMHA2801 OP3 470 R40 LL4148 D6 R38 2 RC2 3 LL4148 2 1.5K R13 1K 1 D8 2 3 470 3 4 VDD RC3 RC0 R36 HMHA2801 OP2 1 HMHA2801 OP1 VDD 4 R41 LL4148 D7 ZENER 30V D9 3 2.2K R42 TX VDD 470 GREEN D11 RED 470 R27 D10 R26 680pF C21 RX 4 4 RS-232 Interface PTS645SL50 SW3 PTS645SL50 SW2 FWD/RVS START 4.7K 5 R33 VDD 4.7K R31 VDD 5 4.7K R34 4.7K R32 RC5 RC4 6 6 A B C D 23 A B C D 1 1 +DC IF 2.2uF 25V C22 4 3 2 1 CON4 J6 PWM0 PWM1 +15V M1 2.2uF 25V C25 +15V 2 2 11 10 9 8 6 5 4 3 2 1 VDD NC VO VB COM VSS NC LIN HIN VCC IR3101 U6 2.2uF 25V C23 PWM2 PWM3 3 3 M2 2.2uF 25V C26 +15V 11 10 9 8 6 5 4 3 2 1 VDD NC VO VB COM VSS NC LIN HIN VCC IR3101 U7 4 4 2.2uF 25V C24 PWM4 PWM5 M3 2.2uF 25V C27 +15V Power Modules / PWM Outputs 5 5 11 10 9 8 6 5 4 3 2 1 VDD NC VO VB COM VSS NC LIN HIN VCC IR3101 U8 6 6 A B C D 24 A B C D 1 1 13 12 MCP6544 U9D 14 M3 M2 M1 +DC 560K R52 560K R47 560K R46 560K R43 2 2 560K R53 560K R49 560K R48 560K R44 0.1uF C14 560K R54 0.1uF C13 560K R51 0.1uF C12 560K R50 560K R45 27K R55 R57 27K R62 27K R61 27K R60 27K R59 27K R58 27K 10K R21 10K R20 10K 3 27K 0.1uF R19 R56 C10 3 9 10 MCP6544 U9C 6 5 MCP6544 U9B 2 3 MCP6544 U9A 1M R65 1M R64 R63 1M VDD VDD 8 7 1 0.1uF C11 4 4 BE3 BE2 BE1 Sensorless Feedback Circuit 4 11 5 5 6 6 A B C D