dsPICDEM MCHV Development System Users Guide

dsPICDEM™ MCHV
Development System
User’s Guide
 2009 Microchip Technology Inc.
DS70605A
Note the following details of the code protection feature on Microchip devices:
•
Microchip products meet the specification contained in their particular Microchip Data Sheet.
•
Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the
intended manner and under normal conditions.
•
There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our
knowledge, require using the Microchip products in a manner outside the operating specifications contained in Microchip’s Data
Sheets. Most likely, the person doing so is engaged in theft of intellectual property.
•
Microchip is willing to work with the customer who is concerned about the integrity of their code.
•
Neither Microchip nor any other semiconductor manufacturer can guarantee the security of their code. Code protection does not
mean that we are guaranteeing the product as “unbreakable.”
Code protection is constantly evolving. We at Microchip are committed to continuously improving the code protection features of our
products. Attempts to break Microchip’s code protection feature may be a violation of the Digital Millennium Copyright Act. If such acts
allow unauthorized access to your software or other copyrighted work, you may have a right to sue for relief under that Act.
Information contained in this publication regarding device
applications and the like is provided only for your convenience
and may be superseded by updates. It is your responsibility to
ensure that your application meets with your specifications.
MICROCHIP MAKES NO REPRESENTATIONS OR
WARRANTIES OF ANY KIND WHETHER EXPRESS OR
IMPLIED, WRITTEN OR ORAL, STATUTORY OR
OTHERWISE, RELATED TO THE INFORMATION,
INCLUDING BUT NOT LIMITED TO ITS CONDITION,
QUALITY, PERFORMANCE, MERCHANTABILITY OR
FITNESS FOR PURPOSE. Microchip disclaims all liability
arising from this information and its use. Use of Microchip
devices in life support and/or safety applications is entirely at
the buyer’s risk, and the buyer agrees to defend, indemnify and
hold harmless Microchip from any and all damages, claims,
suits, or expenses resulting from such use. No licenses are
conveyed, implicitly or otherwise, under any Microchip
intellectual property rights.
Trademarks
The Microchip name and logo, the Microchip logo, dsPIC,
KEELOQ, KEELOQ logo, MPLAB, PIC, PICmicro, PICSTART,
rfPIC and UNI/O are registered trademarks of Microchip
Technology Incorporated in the U.S.A. and other countries.
FilterLab, Hampshire, HI-TECH C, Linear Active Thermistor,
MXDEV, MXLAB, SEEVAL and The Embedded Control
Solutions Company are registered trademarks of Microchip
Technology Incorporated in the U.S.A.
Analog-for-the-Digital Age, Application Maestro, CodeGuard,
dsPICDEM, dsPICDEM.net, dsPICworks, dsSPEAK, ECAN,
ECONOMONITOR, FanSense, HI-TIDE, In-Circuit Serial
Programming, ICSP, ICEPIC, Mindi, MiWi, MPASM, MPLAB
Certified logo, MPLIB, MPLINK, mTouch, nanoWatt XLP,
Omniscient Code Generation, PICC, PICC-18, PICkit,
PICDEM, PICDEM.net, PICtail, PIC32 logo, REAL ICE, rfLAB,
Select Mode, Total Endurance, TSHARC, WiperLock and
ZENA are trademarks of Microchip Technology Incorporated
in the U.S.A. and other countries.
SQTP is a service mark of Microchip Technology Incorporated
in the U.S.A.
All other trademarks mentioned herein are property of their
respective companies.
© 2009, Microchip Technology Incorporated, Printed in the
U.S.A., All Rights Reserved.
Printed on recycled paper.
Microchip received ISO/TS-16949:2002 certification for its worldwide
headquarters, design and wafer fabrication facilities in Chandler and
Tempe, Arizona; Gresham, Oregon and design centers in California
and India. The Company’s quality system processes and procedures
are for its PIC® MCUs and dsPIC® DSCs, KEELOQ® code hopping
devices, Serial EEPROMs, microperipherals, nonvolatile memory and
analog products. In addition, Microchip’s quality system for the design
and manufacture of development systems is ISO 9001:2000 certified.
DS70605A-page ii
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV DEVELOPMENT
SYSTEM USER’S GUIDE
Safety Notice
The safety notices and operating instructions provided should be adhered to, to
avoid a safety hazard. If in any doubt, consult your supplier.
WARNING – This system must be earthed (grounded) at all times.
CAUTION – The system should not be installed, operated, serviced or modified
except by qualified personnel who understand the danger of electric shock
hazards and have read and understood the user instructions. Any service or
modification performed by the user is done at the user’s own risk and voids all
warranties.
WARNING – The output terminals are NOT isolated from the incoming AC mains
supply and may be at up to 410V with respect to ground, regardless of the input
mains supply voltage applied. These terminals are live during operation AND for
five minutes after disconnection from the supply. Do not attempt to access the
terminals or remove the cover during this time.
WARNING – The unit may obtain power through the output terminals if these are
connected to a rotating motor acting as a generator. If this is the case, then the
previous warning also applies (i.e., the output terminals are live when connected
to the generator and for five minutes after the generator has been stopped). Note
that this case can arise even when the unit has been disconnected from the
incoming AC mains supply.
CAUTION – If a motor is connected to the output of this unit, the frame should be
connected to the output protective ground terminal provided. Particular care
should be taken to mechanically guard such a motor, bearing in mind that
unexpected behavior is likely to result from the process of code development.
CAUTION – For continued protection against the risk of fire, replace the fuse with
one of the same type only (i.e., Fast Act Fuse 15A/250 V).
 2009 Microchip Technology Inc.
DS70605A-page iii
dsPICDEM™ MCHV Development System User’s Guide
• The system is intended for evaluation and development purposes and
should only be operated in a normal laboratory environment as defined by
IEC 61010-1:2001.
• Clean with a dry cloth only.
• Operate flat on a bench, do not move during operation and do not block the
ventilation holes.
• The system should not be operated without all the supplied covers fully
secured in place.
• The system should not be connected or operated if there is any apparent
damage to the unit.
• The unit is designed to be connected to the AC mains supply via a standard
non-locking plug. As the unit has no mains switch, this plug constitutes the
means of disconnection from the supply and thus the user must have
unobstructed access to this plug during operation.
DS70605A-page iv
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV DEVELOPMENT
SYSTEM USER’S GUIDE
Table of Contents
Chapter 1. Introduction
1.1 Overview ........................................................................................................ 7
Chapter 2. Getting Started
2.1 Board Components ...................................................................................... 13
2.2 User Interface ............................................................................................... 14
2.3 Connecting the System ................................................................................ 15
2.4 Power Sequences ........................................................................................ 19
Chapter 3. Running the Demonstration
Chapter 4. Hardware
4.1 Power Factor Correction (PFC) Stage Board ............................................... 29
4.2 Power Module Stage .................................................................................... 33
4.3 Electrical Specifications ................................................................................ 43
Appendix A. Board Layout and Schematics
 2009 Microchip Technology Inc.
DS70605A-page v
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page vi
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV DEVELOPMENT
SYSTEM USER’S GUIDE
Preface
NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and
documentation are constantly evolving to meet customer needs, so some actual dialogs and/
or tool descriptions may differ from those in this document. Please refer to our web site
(www.microchip.com) to obtain the latest documentation available.
Documents are identified with a “DS” number. This number is located on the bottom of each
page, in front of the page number. The numbering convention for the DS number is
“DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the
document.
For the most up-to-date information on development tools, see the MPLAB® IDE on-line help.
Select the Help menu, and then Topics to open a list of available on-line help files.
INTRODUCTION
This preface contains general information that will be useful to know before using the
dsPICDEM™ Motor Control High-Voltage (MCHV) Development System. Topics
discussed in this preface include:
•
•
•
•
•
•
•
•
Document Layout
Conventions Used in this Guide
Warranty Registration
Recommended Reading
The Microchip Web Site
Development Systems Customer Change Notification Service
Customer Support
Document Revision History
DOCUMENT LAYOUT
This user’s guide describes how to use the dsPICDEM™ MCHV Development System.
The document is organized as follows:
• Chapter 1. “Introduction” – This chapter introduces the dsPICDEM™ MCHV
Development System and provides a brief overview of its features.
• Chapter 2. “Getting Started” – This chapter provides information on getting
started with the dsPICDEM™ MCHV Development System.
• Chapter 3. “Running the Demonstration” – This chapter describes the demonstration software that is preloaded on the dsPIC33F device that accompanies the
dsPICDEM™ MCHV Development System.
• Chapter 4. “Hardware” – This chapter describes the hardware on the
dsPICDEM™ MCHV Development System.
• Appendix A. “Board Layout and Schematics” – This appendix provides
diagrams of the hardware layout, as well as schematic diagrams for the
dsPICDEM™ MCHV Development System.
 2009 Microchip Technology Inc.
DS70605A-page 1
dsPICDEM™ MCHV Development System User’s Guide
CONVENTIONS USED IN THIS GUIDE
This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS
Description
Arial font:
Italic characters
Initial caps
Quotes
Underlined, italic text with
right angle bracket
Bold characters
N‘Rnnnn
Text in angle brackets < >
Courier New font:
Plain Courier New
Represents
Referenced books
Emphasized text
A window
A dialog
A menu selection
A field name in a window or
dialog
A menu path
MPLAB® IDE User’s Guide
...is the only compiler...
the Output window
the Settings dialog
select Enable Programmer
“Save project before build”
A dialog button
A tab
A number in verilog format,
where N is the total number of
digits, R is the radix and n is a
digit.
A key on the keyboard
Click OK
Click the Power tab
4‘b0010, 2‘hF1
Italic Courier New
Sample source code
Filenames
File paths
Keywords
Command-line options
Bit values
Constants
A variable argument
Square brackets [ ]
Optional arguments
Curly braces and pipe
character: { | }
Ellipses...
Choice of mutually exclusive
arguments; an OR selection
Replaces repeated text
Represents code supplied by
user
DS70605A-page 2
Examples
File>Save
Press <Enter>, <F1>
#define START
autoexec.bat
c:\mcc18\h
_asm, _endasm, static
-Opa+, -Opa0, 1
0xFF, ‘A’
file.o, where file can be
any valid filename
mcc18 [options] file
[options]
errorlevel {0|1}
var_name [,
var_name...]
void main (void)
{ ...
}
 2009 Microchip Technology Inc.
Preface
WARRANTY REGISTRATION
Please complete the enclosed Warranty Registration Card and mail it promptly.
Sending in the Warranty Registration Card entitles users to receive new product
updates. Interim software releases are available at the Microchip web site.
RECOMMENDED READING
This user’s guide describes how to use the dsPICDEM™ MCHV Development System.
The device-specific data sheets contain current information on programming the specific
microcontroller or digital signal controller devices. Other useful documents are listed
below. The following Microchip documents are available and recommended as
supplemental reference resources:
MPLAB® IDE Simulator, Editor User’s Guide (DS51025)
This user’s guide is a comprehensive guide that describes installation and features of
Microchip’s MPLAB Integrated Development Environment (IDE), as well as the editor
and simulator functions in the MPLAB IDE environment.
Readme Files
For the latest information on using other tools, read the tool-specific Readme files in the
Readme subdirectory of the MPLAB IDE installation directory. The Readme files contain
updated information and known issues that may not be included in this user’s guide.
MPASM™ Assembler, MPLINK™ Object Linker, MPLIB™ Object Librarian User’s
Guide (DS33014)
This user’s guide describes how to use the Microchip MPASM Assembler, the MPLINK
Object Linker and the MPLIB Object Librarian.
dsPIC33FJ12MC202 PIM Information Sheet (DS70314)
This document provides device specific information for the dsPIC33FJ12MC202 PIM
device. The dsPIC33FJ12MC202 is a high-performance 16-bit digital signal controller
within a small 28-pin 6x6 mm QFN package.
dsPIC33FJ32MC204 PIM Information Sheet (DS70316)
This document provides device specific information for the dsPIC33FJ32MC204 PIM
device. The dsPIC33FJ32MC204 is a high-performance 16-bit digital signal controller
within a small 44-pin QFN package.
dsPIC33FJ128MC804 PIM Information Sheet (DS70326)
This document provides device specific information for the dsPIC33FJ128MC804 PIM
device. The dsPIC33FJ128MC804 is a high-performance 16-bit digital signal controller
within a small 44-pin QFN package.
dsPIC33FJ256MC710 PIM Information Sheet (DS70564)
This document provides device specific information for the dsPIC33FJ256MC710 PIM
device. The dsPIC33FJ256MC710 is a high-performance 16-bit digital signal controller
within a 100-pin TQFP package.
dsPIC33FJ12MC201/202 Data Sheet (DS70265)
This data sheet contains device specific information for the dsPIC33FJ12MC201/202
Digital Signal Controller (DSC) Devices. The dsPIC33F devices contain extensive
Digital Signal Processor (DSP) functionality with a high performance 16-bit
microcontroller (MCU) architecture.
dsPIC33FJ32MC202/204 and dsPIC33FJ16MC304 Data Sheet (DS70283)
This data sheet provides device specific information for the dsPIC33FJ32MC202/204
and dsPIC33FJ16MC304 motor control family of devices.
 2009 Microchip Technology Inc.
DS70605A-page 3
dsPICDEM™ MCHV Development System User’s Guide
dsPIC33FJ32MC302/304, dsPIC33FJ64MCX02/X04, and dsPIC33FJ128MCX02/
X04 Data Sheet (DS70291)
This data sheet contains device specific information for the dsPIC33FJ32MC302/304,
dsPIC33FJ64MCX02/ X04, and dsPIC33FJ128MCX02/X04 motor control family of
devices.
dsPIC33FJXXXMCX06/X08/X10 Data Sheet (DS70287)
This data sheet contains device specific information for the dsPIC33FJXXXMCX06/
X08/X10 motor control family of devices.
To obtain any of these documents, visit the Microchip web site at www.microchip.com.
THE MICROCHIP WEB SITE
Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser, the web site contains the following
information:
• Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents,
latest software releases and archived software
• General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program
member listing
• Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices,
distributors and factory representatives
DEVELOPMENT SYSTEMS CUSTOMER CHANGE NOTIFICATION SERVICE
Microchip’s customer notification service helps keep customers current on Microchip
products. Subscribers will receive e-mail notification whenever there are changes,
updates, revisions or errata related to a specified product family or development tool of
interest.
To register, access the Microchip web site at www.microchip.com, click on Customer
Change Notification and follow the registration instructions.
The Development Systems product group categories are:
• Compilers – The latest information on Microchip C compilers and other language
tools. These include the MPLAB C18 and MPLAB C30 C compilers; MPASM™
and MPLAB ASM30 assemblers; MPLINK™ and MPLAB LINK30 object linkers;
and MPLIB™ and MPLAB LIB30 object librarians.
• Emulators – The latest information on Microchip in-circuit emulators.This
includes the MPLAB ICE 2000 and MPLAB ICE 4000.
• In-Circuit Debuggers – The latest information on the Microchip in-circuit
debugger, MPLAB ICD 2.
• MPLAB® IDE – The latest information on Microchip MPLAB IDE, the Windows®
Integrated Development Environment for development systems tools. This list is
focused on the MPLAB IDE, MPLAB SIM simulator, MPLAB IDE Project Manager
and general editing and debugging features.
• Programmers – The latest information on Microchip programmers. These include
the MPLAB PM3 and PRO MATE II device programmers and the PICSTART®
Plus and PICkit™ 1 development programmers.
DS70605A-page 4
 2009 Microchip Technology Inc.
Preface
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
•
•
•
•
Distributor or Representative
Local Sales Office
Field Application Engineer (FAE)
Technical Support
Customers should contact their distributor, representative or field application engineer
(FAE) for support. Local sales offices are also available to help customers. A listing of
sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
DOCUMENT REVISION HISTORY
Revision A (June 2009)
This is the initial released revision of this document.
 2009 Microchip Technology Inc.
DS70605A-page 5
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page 6
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV
DEVELOPMENT SYSTEM
USER’S GUIDE
Chapter 1. Introduction
1.1
OVERVIEW
The Microchip dsPICDEM™ MCHV Development System is intended to aid the user in
the rapid evaluation and development of a wide variety of motor control applications
using a dsPIC® Digital Signal Controller (DSC). This development system is targeted
to control Brushless DC (BLDC) motors, Permanent Magnet Synchronous Motors
(PMSM), and AC Induction Motors (ACIM) in sensor or sensorless operation.
This flexible and cost-effective tool can be configured in different ways for use with
Microchip’s specialized Motor Control DSCs. The dsPICDEM™ MCHV Development
System supports the dsPIC33F Motor Control device family, and offers a mounting
option to connect either a 28-pin SOIC device or a generic 100-pin Plug-In Module
(PIM).
The system has a three-phase power module device that contains the motor inverter
and the gate driver’s circuitry. The circuit drives a BLDC, PMSM, or ACIM motor using
different control techniques without requiring any additional hardware. It also has
Power Factor Correction (PFC) circuitry in order to provide a full set of tools used in
motor control applications. Figure 1-1 provides a photograph of the dsPICDEM™
MCHV Development System. A block diagram that shows the main components of the
system is provided in Figure 1-2.
The rated continuous output current from the inverter is 6.5A (RMS). This allows up to
approximately 2 kVA output when running from a 208V to 230V single-phase input voltage in a maximum 30ºC (85ºF) ambient temperature environment. Therefore, the system is ideally suited for running a standard 3-Phase Induction Motor of up to 1.4 kW
(1.8 HP) rating or a slightly higher rated industrial servo-motor. The power module is
capable of driving other types of motors and electrical loads that do not exceed the
maximum power limit and are predominantly inductive. Furthermore, single-phase
loads can be driven using one or two of the inverter outputs.
The unit is capable of operating from 90V up to a maximum of 265V. A more detailed
explanation of power limitations is provided in Chapter 4. “Hardware”.
Note:
 2009 Microchip Technology Inc.
It is recommended to carefully read the hardware section mentioned above
before attempting to use the system.
DS70605A-page 7
dsPICDEM™ MCHV Development System User’s Guide
FIGURE 1-1:
DS70605A-page 8
dsPICDEM™ MCHV DEVELOPMENT SYSTEM
 2009 Microchip Technology Inc.
SYSTEM BLOCK DIAGRAM
External
Programmer/
Debugger
PFC Stage Board
Power Module Board
Voltage
Feedback
Circuitry
(VBUS and Motor)
Non-isolated
ICSP connector
VBUS
VAC Zero
Crossing
PFC Current
Feedback
Circuitry
Rectifier
dsPIC® DSC
15V, 3.3V, A-3.3V
Alternative
15V PSU
Power
Module
MOTOR
Isolated User Interface
RS-232/
USB
SKDE
POT, PB, RESET
Introduction
DS70605A-page 9
90V-265V
15V PSU
Alternative
3.3V/A3.3V
TX
PFC Feedback Signals
EMI Choke,
In-rush current
protection, FUSE
Fault
Circuitry
PFC Fault
3.3VA-3.3V
Hall
Sensors
Current
Feedback
Circuitry
PFC PWM
RX
PFC Circuitry
HALL
Sensors
Circuitry
User
Interface
VAC Voltage
Feedback
ICSP™
commands
 2009 Microchip Technology Inc.
FIGURE 1-2:
dsPICDEM™ MCHV Development System User’s Guide
1.1.1
Features
The following are some of the key features of the dsPICDEM™ MCHV Development
System.
Supported Devices:
• 28-pin to 100-pin dsPIC33FJXXXMC202 PIM (MA330014) with a dsPIC33F Motor
Control device (U11) socket
• 44-pin to 100-pin dsPIC33FJXXXMCX04 PIM (MA330017 and MA330018) with a
dsPIC33F Motor Control device (U11) socket
• 100-pin to 100-pin dsPIC33FJXXXMCX10 PIM (MA330013) with a dsPIC33F
Motor Control device (U11) socket
• dsPIC33FJ12MC202 Motor Control device in a SOIC package (U12) footprint
Motor Control Interfaces:
• Three-phase inverter bridge with a power rating of 400V/6.5A (J17)
• Hall sensors/Quadrature Encoder Interface (QEI) for sensored motor control
algorithms (J9)
• Phase voltage feedback for sensorless BLDC operation
• DC bus current sense resistor for single shunt vector control
• Phase current sense resistor for dual shunt vector control
• Overcurrent protection
Input/Output Control Switches:
-
One isolated push button (S1)
Isolated reset push button (RESET)
Isolated 10 k potentiometer (POT1)
LED indicator for PWM outputs
Isolated Communication Ports:
- UART communication via USB (J6)
- UART communication via RS-232 (J8)
Built-In Isolated Programmer/Debugger (J20):
- Starter Kit-type programmer/debugger (daughter card)
Power Supply Connectors:
- Power Tab Fast-On connectors (BP1 and BP2) for the power stage
- Auxiliary 24V power input connector (J15) for the dsPIC DSC device and
low-power circuitry (non-populated)
- Auxiliary 15V and 3.3V regulators for regulating auxiliary power supply
(non-populated)
Programming Connectors:
- ICSP™ connector for programming a dsPIC DSC device (J18), non-isolated
- ICSP connector for programming the PIC18LF2450 USB module to the UART
Bridge (J1), isolated
- ICSP connector for programming the Starter Kit Programmer/Debugger
(SKDE), isolated PIC18F67J50 (J4)
DS70605A-page 10
 2009 Microchip Technology Inc.
Introduction
Power Factor Corrector:
-
Maximum input voltage 90 VAC-265 VAC
Current Feedback circuitry
VAC input voltage sensing
Zero-crossing detection
DC bus sensing
Overcurrent protection (The maximum power available is specified in
Section 4.3 “Electrical Specifications”.)
Built-In Power Supplies:
- 15V power supply, maximum power available 11W
- 3.3V power supply, maximum power available 2W
Additional Protection Circuitry:
- 250 VAC/15A fuse
- In-rush current limiter
- EMI filter
 2009 Microchip Technology Inc.
DS70605A-page 11
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page 12
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV
DEVELOPMENT SYSTEM
USER’S GUIDE
Chapter 2. Getting Started
2.1
BOARD COMPONENTS
The dsPICDEM™ MCHV Development System comprises two stages:
• PFC Stage
The first stage is integrated by the Power Factor Correction (PFC) circuitry, the
full-bridge rectifier, the 15V power supply, and the 3.3V power supply.
• Power Module Stage
The second stage is the power module board. This board contains the dsPIC DSC
connector, the isolated user interface connectors, and the motor drive.
Figure 2-1 shows an interior view of the system.
FIGURE 2-1:
dsPICDEM™ MCHV DEVELOPMENT SYSTEM
 2009 Microchip Technology Inc.
DS70605A-page 13
dsPICDEM™ MCHV Development System User’s Guide
2.2
USER INTERFACE
The dsPICDEM™ MCHV Development System has the following components to
interact with the user. Figure 2-2 shows a photograph of the front of the system.
• Input/Output Control Switches (Figure 2-2):
- One isolated push button (S1)
- Isolated reset push button (RESET)
- Isolated 10 kΩ potentiometer (POT1)
- LED indicator for PWM outputs
• PWM Outputs (Figure 2-2)
- Enable and disable jumpers (J7)
• Isolated Communication Ports (Figure 2-2):
- UART communication via USB (J6)
- UART communication via RS-232 (J8)
- Communication Ports Selector (J2, J3)
• Built-In Isolated Programmer/Debugger (Figure 2-2)
- Starter Kit type programmer/debugger (J20)
• Motor Connectors (Figure 2-3):
- Three-phase inverter bridge connector with a power rating of 400V/6.5A (J17)
- Hall sensors/Quadrature encoder interface for sensored motor control
algorithms (J9)
• Power Supply Connector (Figure 2-4)
- AC power inlet specified for 40VAC-220VAC 10Amps max (J1)
FIGURE 2-2:
dsPICDEM™ MCHV DEVELOPMENT SYSTEM (FRONT)
POT1
J8
J20
S1
J6
Reset
PWM LED
Indicators
J7
J2,J3
DS70605A-page 14
 2009 Microchip Technology Inc.
Getting Started
FIGURE 2-3:
dsPICDEM™ MCHV DEVELOPMENT SYSTEM (LEFT SIDE)
J1
FIGURE 2-4:
dsPICDEM™ MCHV DEVELOPMENT SYSTEM (RIGHT SIDE)
3-Phase Inverter
Bridge Connector
Hall Sensors/
QEI Connector
2.3
CONNECTING THE SYSTEM
CAUTION
The user must be aware of the operating procedures outlined below and ensure that
they are followed. Failure to do so may result in damage to the system.
2.3.1
Power Connections
It is recommended that cables used for the power connections should be terminated
with blue or red insulated crimp terminals. If crimp terminals are not used, care should
be taken to ensure that stray strands of wire do not short to adjacent terminals or the
enclosure. If possible, all wires should be stripped and tinned with solder before
connecting to the dsPICDEM™ MCHV Development System terminals.
 2009 Microchip Technology Inc.
DS70605A-page 15
dsPICDEM™ MCHV Development System User’s Guide
For the AC mains supply input, standard double-insulated, 3-core flex cable should be
used with a minimum current rating of 10A (1 mm2 18 AWG). A computer power cable
can be used.
Note:
The system is designed for installation category II. Therefore, the incoming
mains cable should be wired into a standard non-locking 2-pin in addition
with a earth ground type plug.
The recommended output cable size is 1.0 to 1.5 mm2 (18-16 AWG) and it should have
a 600V rating. This cable should also be double insulated or have a protective ground
screen. Access to the terminal screws is provided via holes in the lid of the enclosure.
A slotted screwdriver should be used.
Note:
The user should only access the power terminals when the system is fully
discharged (see the “Safety Notice” on page iii).
Figure 2-6 provides the locations of all connectors. Corresponding tables that describe
each connection are provided in the relevant section.
FIGURE 2-5:
dsPICDEM™ MCHV DEVELOPMENT SYSTEM CONNECTIONS
6
8
4
9
5
10
7
11
14
15
12
13
3
2
1
The power connections are listed in Table 2-1.
DS70605A-page 16
 2009 Microchip Technology Inc.
Getting Started
TABLE 2-1:
POWER CONNECTIONS
Number
1
2.3.2
Name
Type
Neutral
Input
2
Earth Ground
Input
3
Live (Fused)
Input
4
Motor Phase 1 (M1)
Output
5
Motor Phase 2 (M2)
Output
6
Motor Phase 3 (M3)
Output
7
Hall Sensor A (HA)
Input
8
Hall Sensor B (HB)
Input
9
Hall Sensor C (HC)
Input
10
Hall Sensors, 5V power supply terminal
Output
11
Hall Sensors, Ground terminal
Output
Host/Communication Connections
A mini-USB-to-USB certified cable and a standard DB9 male-to-female cable should
be used to connect the dsPICDEM™ MCHV Development System to the host
computer.
The communication port connectors are listed in Table 2-2. Refer to Figure 2-5 for their
exact location.
TABLE 2-2:
COMMUNICATION PORT CONNECTORS
Number
12
Name
Type
USB-to-UART connector
Input/Output
13
RS-23- to-UART connector
Input/Output
14
USB connector for the Starter Kit programmer/debugger
Input/Output
15
Non-isolated ICSP™ connector for device programming/debugging
Input/Output
2.3.2.1
CONNECTION SEQUENCE
The recommended connection sequence is listed below. The user should ensure that
the following sequence is met before connecting the system to the mains, a motor and
a host computer.
Note:
Before making any connection, verify that the system is not powered and it
is fully discharged. The system is completed discharged when the red LED
D13 is OFF.
1. Connect the motor terminals R, Y, and B (also known as RWB or 123 or ABC) to
the connection nodes M1, M2, and M3 (4, 5, and 6 in Figure 2-5), respectively.
2. Follow the next steps if position sensors are utilized to control the motor. If not,
proceed to step 3.
a) If the motor position is sensed with Hall Sensors, connect the terminals A, B,
and C to the connection nodes HA, HB, and HC (7, 8, and 9 in Figure 2-5),
respectively. Also, connect the positive terminal +5V to the connection node
+5V and the ground terminal to the connection node GND (10 and 11 in
Figure 2-5).
b) If the motor position is sensed with a Quadrature Encoder, connect the terminals phase A, phase B, and Index to the connection nodes HA, HB, and
HC (7, 8, and 9 in Figure 2-5), respectively.
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DS70605A-page 17
dsPICDEM™ MCHV Development System User’s Guide
3. Connect the communication ports.
a) If R-S32 communication is used, connect the DB9 male connector to the
RS-232 port. Connect the other end to the host PC (12 in Figure 2-5).
b) If USB communication is used, connect the mini-USB male terminal to the
mini-USB female connector labeled “USB” (12 in Figure 2-5). Connect the
other end to the host PC.
Note:
The Microchip serial emulator driver (mchpcdc.inf) should be installed on
you PC in order to activate the USB-to-Serial emulator. The emulator driver
is contained in the CD shipped with the dsPICDEM™ MCHV Development
System.
4. Connect the SKDE cable. Connect the USB cable to the mini USB female
connector labeled “Program/Debug” (14 in Figure 2-5). Connect the USB male
terminal to the USB ports of the host PC.
Note:
The built-in programmer/debugger is supported in MPLAB IDE 8.33 or
higher.
5. Power Cord connection. Make sure the power cord is disconnected from the AC
mains before connecting the female terminal of the power cable to the AC input
connector (1, 2, and 3 in Figure 2-53) of the dsPICDEM™ MCHV Development
System.
Note:
DS70605A-page 18
The unit is designed to be connected to the AC mains supply via a standard
non-locking plug. As the unit has no mains switch, this plug constitutes the
means of disconnection from the supply. Therefore, the user must have
unobstructed access to this plug during operation.
 2009 Microchip Technology Inc.
Getting Started
2.4
POWER SEQUENCES
The user should ensure that the following power sequences are adhered to.
2.4.1
Power-up Sequence
The unit is powered-up when the power cable is connected to the AC mains. To verify
that the unit is powered make sure that the LEDs D6, D13, D17 and D18 are ON.
Note:
2.4.2
The unit is designed to be connected to the AC mains supply via a standard
non-locking plug. As the unit has no mains switch, this plug constitutes the
means of disconnection from the supply and thus the user must have
unobstructed access to this plug during operation.
Power-down Sequence
1. Stop firing all power devices by removing the PWM OUTPUTS shunt jumper.
2. Turn OFF the incoming AC supply by disconnecting the power cord from the
mains.
3. Wait until the red DC bus LED indicator (D13) located next to the DC bus P
connector has gone out (this will take 5 minutes or less).
2.4.3
Programming/Debugging an Application Code Using the
Built-in Starter Kit Programmer/Debugger
The MPLAB Starter Kit Programmer/Debugger for the dsPICDEM™ MCHV Development System may be used with MPLAB IDE, the free integrated development environment, which is available from Microchip’s web site (www.microchip.com). MPLAB IDE
allows the Starter Kit to be used as an in-circuit debugger as well as a programmer for
the following devices.
•
•
•
•
dsPIC33FJ12MC202
dsPIC33FJ32MC204
dsPIC33FJ128MC804
dsPIC33FJ256MC710
In-circuit debugging allows you to run, examine and modify your program for the device
embedded in the Starter Kit hardware. This greatly assists you in debugging your
firmware and hardware together.
Special Starter Kit software interacts with the MPLAB IDE application to run, stop, and
single-step through programs. Breakpoints can be set and the processor can be reset.
Once the processor is stopped, the register’s contents can be examined and modified.
For more information on how to use MPLAB IDE, reference the following
documentation:
• “MPLAB IDE User’s Guide” (DS51519)
• “MPLAB IDE Quick Start Guide” (DS51281)
• MPLAB IDE Online Help
2.4.4
Setting Up an Application for Debug
To prepare the application for debug:
1. Launch MPLAB IDE, and then open the application project. The related workspace will be open. For information on projects and workspaces, see the MPLAB
IDE documentation mentioned at the beginning of this chapter.
2. Select Project>Build All to build the application code. The build’s progress will be
visible in the Build tab of the Output window.
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DS70605A-page 19
dsPICDEM™ MCHV Development System User’s Guide
3. Select Debugger>Select Tool>Starter Kits. MPLAB IDE will change to add Starter
Kit debug features (Figure 2-6): (1) the status bar will show Starter Kits as the
debug tool, (2) a Starter Kit debug toolbar will be added, (3) the Debugger menu
will change to add Starter Kit debug functions and (4) the Output window will display communication status between MPLAB IDE and the stater kit on the Starter
Kit Debugger tab.
FIGURE 2-6:
DS70605A-page 20
STARTER KIT AS A DEBUG TOOL
 2009 Microchip Technology Inc.
Getting Started
4. Select Debugger>Program to program the application code into the dsPIC33F
DCS device on the Starter Kit. The debug programming progress will be visible
in the Starter Kit tab of the Output window.
Note:
2.4.4.1
Debug executive code is automatically programmed in the upper program
memory of the Starter Kit device when the Starter Kit is selected as a
debugger. Debug code must be programmed into the target device to use
the in-circuit debugging capabilities of the Starter Kit.
RUNNING THE APPLICATION
The Starter Kit executes in either real-time (Run) or steps (Step Into, Step Over, and
Animate) real-time execution occurs when you select Run in MPLAB IDE. Once the
device code is halted, either by Halt or a breakpoint, you can step.
Toolbar buttons can be used for quick access to commonly used debug operations.
Refer to Section 3.3 “Running the Example Application” in the “MPLAB Starter Kit
for dsPIC® Digital Signal Controllers User’s Guide” (DS51700).
Note:
All the peripherals are frozen when the “Halt” button is pressed to stop the
program execution.
To see how these options function, do the following:
1. Select Debugger>Reset>Processor Reset or click the Reset button to reset the
program.
2. Select Debugger>Run or click the Run button. Observe how the application
operates.
3. Select Debugger>Halt or click the Halt button to stop the program execution. A
green solid arrow will mark the line of code in the File window where the program
halted.
4. Select Debugger>Step Into or click the Step Into button to step the program execution once. The green solid arrow will move down one line of code in the File
window. Repeatedly click the button to step through the code.
5. Select Debugger>Reset>Processor Reset click the Reset button to reset the
program again. The arrow will disappear, meaning the device is reset.
 2009 Microchip Technology Inc.
DS70605A-page 21
dsPICDEM™ MCHV Development System User’s Guide
2.4.4.2
DEBUGGING THE APPLICATION
MPLAB IDE provides an editor and several debug features such as breakpoints and
Watch windows to aid in application code debugging.
2.4.4.2.1
Editing Application Code
To view application code so it may be edited, do one of the following:
Select Edit>New to create new code or Edit>Open to search for and open an existing
code file, or double click a file in the Project window to open an existing code file. See
an example Project window in Figure 2-7.
FIGURE 2-7:
PROJECT EXAMPLE
Existing Code
For more information on using the MPLAB Editor to create and edit code, see the
MPLAB Editor Help.
DS70605A-page 22
 2009 Microchip Technology Inc.
Getting Started
2.4.4.2.2
Using Breakpoints and Mouseovers
To set a breakpoint in code:
1. Double click the gutter: Double click in the window gutter next to the line of code
where you want the breakpoint. Double click again to remove the breakpoint.
Note:
Double click must be set up for breakpoints. Select the Edit>Properties, and
click the ASM/C/BAS File Type tab, and then select the “Double-click Toggles Breakpoint” check box.
2. Pop-up Menu: Place the cursor over the line of code where you want the breakpoint. Then, right-click to pop up a menu and select Set Breakpoint. Once a
breakpoint is set, “Set Breakpoint” will become “Remove Breakpoint” and “Disable breakpoint”. Other options on the popup menu under Breakpoints are for
deleting, enabling, or disabling all breakpoints.
3. Breakpoint Dialog: Open the Breakpoint dialog (Debugger>Breakpoints) to set,
delete, enable, or disable breakpoints. See the MPLAB IDE Help for more
information on this dialog.
A breakpoint set in code will appear as a red hexagon with a “B” as shown in Figure 2-8.
FIGURE 2-8:
BREAKPOINT EXAMPLE
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dsPICDEM™ MCHV Development System User’s Guide
Once code is halted, hovering over a variables opens a tool tip window that contains
the current value of the variable.
Note:
2.4.4.2.3
This feature must be configured. Select Edit>Properties and click the
Tooltips tab, and select the “Enable Variable Mouseover Values” check
box.
Using Watch Windows
To use a Watch window:
1. The Watch window is made visible on the desktop by selecting View>Watch. It
contains four selectable Watch views (via tabs) in which to view variables (SFRs,
symbols and absolute addresses).
2. Select an SFR or Symbol from the list and click the related Add button to add it
to the Watch window. Or click in the “Address” column and enter an absolute
address.
A Watch window populated with an SFRs and Symbols will look like Figure 2-9. For
more on using Watch windows, see MPLAB IDE Help.
FIGURE 2-9:
2.4.5
WATCH WINDOW EXAMPLE
Programming an Application
When the program is successfully debugged and running, the next step is to program
the device for stand-alone operation in the finished design. When doing this, the
resources reserved for debug are released for use by the application. To program the
application, use the following steps:
1. Disable Starter Kits as a debug tool by selecting Debugger>Select Tool>None.
2. Select Starter Kits as the programmer in the Programmer>Select Programmer
menu.
3. Select Programmer>Program.
At this point, the application code will run independently.
DS70605A-page 24
 2009 Microchip Technology Inc.
Getting Started
2.4.6
Determining Device Support and Reserved Resources
Due to the built-in in-circuit debugging capability of ICD devices and the ICSP function
offered by the debugger, the Starter Kit uses some on-chip resources when debugging.
It also uses program memory and file register locations in the target device during
debugging. These locations are not available for use by user code. In the MPLAB IDE,
registers marked with an “R” in the register display represents reserved registers.
For information on device resources that are needed for in-circuit debugging, please
refer to the MPLAB ICD 2 Help, found in MPLAB IDE under Help>Topics. The device
reserved resource information found under “Resources Used By MPLAB ICD 2” is the
same for the Starter Kit.
2.4.7
Troubleshooting
2.4.7.1
DEBUG CONNECTION PROBLEMS
While using the Starter Kit as a debugger, you may receive the error “Starter Kit not
connected to this computer” when programming the device. This can result from
communication being lost between the Starter Kit and MPLAB IDE. To resolve this:
1. Unplug the USB cable from the Starter Kit.
2. Plug the USB cable back into the Starter Kit.
MPLAB IDE should automatically reconnect to the Starter Kit. If this does not work, do
the following:
1. Check the USB connection between the PC and Starter Kit at both ends.
2. If using a USB hub, make sure it is powered.
3. Make sure the USB port is not in use by another device.
2.4.7.2
PROGRAMMING PROBLEMS
If during the course of developing your own application you can no longer program the
device on the Starter Kit, you may have set device configuration bits to code protect or
some other state that prevents programming. To view the settings of the configuration
bits, select Configure>Configuration bits.
2.4.8
Settings Dialog and Info Tab
When you select Debugger>Settings or Programmer Settings, you will open the Starter
Kit Settings dialog.
Currently, there is only one tab (Info) on this dialog, which provides the following
information:
• Firmware Version: The version of firmware on the Starter Kit board.
• Debug Exec Version: The version of the debug executive that is loaded into the
dsPIC33F device program memory to enable debug operation.
 2009 Microchip Technology Inc.
DS70605A-page 25
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page 26
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV
DEVELOPMENT SYSTEM
USER’S GUIDE
Chapter 3. Running the Demonstration
This chapter describes the demonstration software that is preloaded on the dsPIC33F
device. This application software, which is based on application note AN984, demonstrates how to use the dsPICDEM™ MCHV Development System for controlling an AC
induction motor (ACIM). For more information on this application note please refer to
the following Microchip web page: www.microchip.com/dscmotor
To run the demo, follow these basic steps:
Note:
Before making any connection, verify that the system is not powered and it
is fully discharged. The system is completed discharged when the red LED
D13 is off.
1. Connect the system by connecting the AC Induction Motor to the motor
connector.
2. Power up the dsPICDEM™ MCHV Development System by connecting the
power cord to the mains. To verify that the unit is powered, make sure that the
LEDs D6, D13, D17, and D18 are ON. The very first time you connect the system
to any host PC, you should briefly see a popup balloon in the system tray (lower
right of desktop) that states (1) new hardware has been found, (2) drivers are
being installed, and (3) new hardware is ready for use. If you do not see these
messages and the Starter Kit does not work, try reconnecting the USB. If this
does not work, see Section 2.4.7 “Troubleshooting”.
Note:
The unit is designed to be connected to the AC mains supply via a standard
non-locking plug. As the unit has no mains switch, this plug constitutes the
means of disconnection from the supply. Therefore, the user must have
unobstructed access to this plug during operation.
3. When powered up, the application will turn on the LEDs PWM1L1, PWM1L2 and
PWM1L3.
To use the application, follow these steps:
a) Make sure the PWM OUTPUT shunt jumper is installed.
b) To start/stop the motor, press the switch labeled “PUSHBUTTON”.
c) To increase the motor speed, rotate the potentiometer labeled “POT”
clockwise. To reduce the speed, rotate the potentiometer counterclockwise.
 2009 Microchip Technology Inc.
DS70605A-page 27
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page 28
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV
DEVELOPMENT SYSTEM
USER’S GUIDE
Chapter 4. Hardware
This chapter describes the hardware components of the dsPICDEM™ MCHV
Development System.
Topics covered include:
• Power Factor Correction (PFC) Stage Board
• Power Module Stage
• Electrical Specifications
4.1
POWER FACTOR CORRECTION (PFC) STAGE BOARD
This board has two main functions; the first one is to provide the required power supplies to the power module board stage. The second function is to create the power bus
rail that will be used to energize the motor through the power module.
Note:
4.1.1
The circuits for the hardware described in this section are shown in
Appendix A. “Board Layout and Schematics”.
AC Supply Input
The AC supply input stage of the board consists of the following components,:
• F1 –15A/250 VAC fast acting fuse (only replace with a part of the same rating)
• C1, C2 – Film capacitors to aid in the suppression of AC supply transients and to
also provide a low impedance return path for any currents that flows from the
power device tabs to the heat sink and enclosure due to capacitive coupling
• C3 – Film capacitor to aid in the suppression of AC supply transients.
• R1 – A metal oxide varistor located across the incoming supply lines to suppress
high energy transients.
• L1 – 2.3 mH/15A Choke inductor for suppressing EMI
• C4 – Film capacitor to aid in the suppression of EMI
• C5, C6 – Film capacitors to aid in the suppression of AC supply transients and to
also provide a low impedance return path for any currents that flow from the
power device tabs to the heat sink and enclosure due to capacitive coupling
• R7 – A 1W high-voltage resistor, which acts to discharge C4
• R6 – A resistor with a negative temperature coefficient that acts to limit the surge
of input current that would occur at initial application of power due to the discharged DC bus capacitance. The initial nominal cold resistance is 1 Ohm, which
reduces once current flows and the device heats up.
• BR1 – A single-phase bridge rectifier to convert the incoming AC into DC suitable
for input to the power conditioning stage.
 2009 Microchip Technology Inc.
DS70605A-page 29
dsPICDEM™ MCHV Development System User’s Guide
4.1.2
Active Power Factor Correction (PFC)
The active PFC circuit is essentially a simple boost chopper with the control aimed at
shaping the input current to follow the incoming mains supply waveform. The purpose
of the different parts of the circuit is described below.
• L6 – A high frequency axial inductor with a single layer winding on a ferrite core.
This component is in series with the main inductor (L7) to reduce the effect of the
self-capacitance of its winding. Without L6, significant high frequency (15 MHz)
ringing of the inductor current occurs at every transistor turn-on, which would
increase EMI and the PFC transistor switching loss.
• L7 – A power inductor with three stacked toroidal cores made from a
powdered-iron material to limit the core loss while maintaining good energy
storage density. The particular cores used are Magnetics 0077083A7. A simple
multi-layer winding is used which results in moderate copper loss but significant
self-capacitance. Sixty-six turns of 1.5 mm diameter enameled copper wire is
used. The design offers a good compromise between cost, core loss and size for
this application. The nominal inductance is 1 mH at 10A.
• Q2 – A 600V TO-247 IGBT. As the tab of the device is not isolated, a thermally
conductive insulator is used. When closed, Q2 increase the energy stored in the
inductor L7. When open, energy stored in the inductance is transferred to the DC
bus capacitors (C30-C32). Energy is also drawn from the AC supply during this
time. By appropriate control of the switches, the input current waveform can be
profiled to obtain good power factor and low harmonic distortion.
• D12 – A 600V TO-247 diode optimized for use at high switching frequency. As the
tab of the device is not isolated, a thermally conductive insulator is used.
• C28, R31, R32, R33, D11 – A “snubber” that acts to damp high frequency
oscillations and limit the rate of change of voltage across Q2
• C30, C31, C32 – 470 µF/450V electrolytic capacitors which act as the main DC
bus energy storage capacitors.
• R25, R26, C25, D8, Q1, R27, R28 – A lever shifter to boost the PWM signal coming from the dsPIC DSC
• U19 – Microchip TC4421A gate drive IC. This contains a low resistance complementary push-pull MOSFET pair and input circuitry suitable for interfacing to a
wide range of input voltages. It is an ideal choice for this application allowing up to
10A of peak gate drive current to switch Q2 rapidly and therefore achieve low
switching loss. It also has a small footprint allowing it to be located physically
close to the transistors allowing a low inductance gate circuit layout.
• D9, C26, C27 – These components act to provide a dynamic level shifting circuit
to U19 while Q2 switch. Inductance of the power tracking between the source of
Q2 due to the physical board layout means there is a substantial transient voltage
between the +15V supply point reference at R28 and the source of Q2. This
simple low cost circuit allows the power supply of U19 to move transiently.
• R75, R29 and D10 – These components control the current and voltage to turn on
and turn off the IGBT. R29 controls the rising time and the di/dt when the IGBT is
turned on. R29 in parallel with R75 control the falling time and the di/dt when the
IGBT is turned off.
• The power factor corrector design is based on the application note AN1106, for
more information on this application note please refer to one of the following
Microchip Web sites:
- www.microchip.com/smps
- www.microchip.com/dscmotor
DS70605A-page 30
 2009 Microchip Technology Inc.
Hardware
4.1.3
PFC Feedback Circuitry
In a DSC-based PFC, the relevant analog parameters and the control loops need to be
redefined and discretized. This enables changeover from existing hardware to its digital
counterpart easier and more logical.
The PFC is an AC-to-DC converter, which converts the AC input voltage to a DC voltage and maintains sinusoidal input current at a high input power factor. In a DSC-based
PFC, three inputs signals are required to implement the current control.
The input rectifier (BR1) converts (shown in Section 4.1.1 “AC Supply Input ”) the
alternating voltage at power frequency into unidirectional voltage. This rectified voltage
is fed to the chopper circuit to produce a smooth and constant DC output voltage to the
load. The chopper circuit is controlled by the PWM switching pulses generated by the
dsPIC DSC device, based on three measured feedback signals:
•
•
•
•
Rectified input voltage
AC input voltage zero-crossing event
Rectified input current
DC bus voltage
The rectified input voltage is measured in two stages:
• Signal conditioning: R22, R23, R24, C24, and D7 convert and filter the AC input
voltage waveform from 90-265 VAC to 0-3.3 VAC. D7 limit the maximum voltage
to 3.3V. C24 along with R22, R23 form a low-pass filter. The circuit is shown in
Appendix A.
• Amplification: the operational amplifier MCP6024 (U13B) amplifies the conditioned AC input voltage; R45, R46, R47, R48, R49 and R51 set the gain. The
MC6024 also shifts the conditioned AC input voltage to a 1.65V DC level. Therefore, the voltage applied to the dsPIC DSC ADC channel varies within 0-3.3V. The
offset is controlled by R50, R53, and R54. R39 and C39 filter out the
high-frequency noise.
AC input voltage zero-crossing event is sensed using a voltage divider (R2-R5) and two
opto-couplers (U1 and U2). The circuit is shown in Appendix A.
Rectified input current is measured using the shunt resistor R34 and the operational
amplifier MCP6024 (U13A); R38, R39, R40, R41, R42 and R43 set the gain. R43 shifts
the voltage present at the shunt resistor to a 1.65V DC level. Therefore, the voltage
applied to the dsPIC DSC ADC channel varies within 0-3.3V. The offset is controlled by
R43, R53, and R54. R44 and C37 filter out the high-frequency noise. The circuit is
shown in Appendix A.
DC bus voltage, the DC bus voltage is sensed at the power module stage. Please refer
to Section 4.2.4 “Feedback Circuitry”.
4.1.4
Power Supplies
The PFC stage board provides the 15 volts power supply required to fire the power
module IGBTs. The 15 volts power supply is built using a low power off-line SMPS primary switcher. The switching frequency is fixed to 60 kHz, the feedback signal to the
power supply is provided by and opto-coupler. The output voltage is regulated at 15V
with a maximum output current of 0.750 A, the resultant maximum power is 11.25 W.
The input voltage range for this power supply is from 90 VAC to 260 VAC.
The PFC stage board also provides the 3.3 volts to powering-up the dsPIC DSC, the
isolation circuitry, the communication ports, the Starter Kit programmer, etc. It also generates the 3.3 volts for powering the analog circuits and the analog reference for the
Analog-To-Digital converter.
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DS70605A-page 31
dsPICDEM™ MCHV Development System User’s Guide
The 3.3 volts rail is created using a step-down regulator which is attached to the 15
volts regulator. The maximum output current is 0.650 A, thus the resultant maximum
power is 2.145 W.
The 3.3 volts rail required for the analog circuits such as the current feedback and the
Analog-to-digital converter is generated by a decoupling circuitry attached to the 3.3
volts regulator.
4.1.5
Fault Circuitry
Given the development nature of the system, robust independent FAULT protection is
provided on the PFC Stage Board. Two different fault categories are used to indicate a
FAULT to the dsPIC® DSC.
DC Bus Overcurrent, this fault signal is generated when the maximum current limit of
15A is reached. The comparison of the threshold value and the actual current is done
by comparator U8. The threshold limit is set by R56 and R57. R69 is a shunt jumper
resistor that can disconnect the overcurrent fault to the dsPIC DSC.
DC Bus Overvoltage, this fault signal is generated when the maximum voltage limit on
the DC bus rails is reached. The threshold value is set to 432 V. The comparison of the
threshold value and the actual DC bus voltage is done by comparator U7. The threshold limit is set by R60, R61 and R62. R66 is a shun jumper resistor that can disconnect
the overvoltage fault to the dsPIC DSC.
Note:
4.1.6
Both comparators are open-drained and need an external pull-up resistor.
Both circuits share this pull-up resistor creating an OR condition at the
output.
Board Connectors
The PFC stage board has four tab fast-on connectors, one AC inlet and one 14-pin
keyed connector for attaching a flat cable.
For the AC mains supply input, standard double-insulated, 3-core flex cable should be
used with a minimum current rating of 10A (1 mm2 18 AWG). A computer power cable
can be used. The recommended cable size is 1.0 to 1.5 mm2 (18-16 AWG) and it
should have a 600V rating. This cable should also be double insulated or have a
protective ground screen.
Note 1:
2:
The system is designed for installation category II. Therefore, the
incoming mains cable should be wired into a standard non-locking 2-pin
in addition with an earth ground type plug.
The unit is designed to be connected to the AC mains supply via a
standard non-locking plug. As the unit has no mains switch, this plug
constitutes the means of disconnection from the supply. Therefore, the
user must have unobstructed access to this plug during operation.
The tab fast-on connectors AC_N and AC_L provides the connections to the bridge
rectifier BR1. The recommended cable size is 16-18 AWG or 1.0 to 1.5mm2. It is also
recommended that cables used for the power connections should be terminated with
blue or red crimp terminals. If crimp terminals are not used, care should be taken to
ensure that stray strands of wire do not short to adjacent terminals or the enclosure. If
possible, all wires should be stripped and tinned with solder before connecting to the
dsPICDEM MCHV development board terminals.
DS70605A-page 32
 2009 Microchip Technology Inc.
Hardware
The fast-in connectors PFC_OUT “+” and PFC_OUT “-” provide DC bus voltage to the
Power Module Stage. The recommended cable size is 16-18 AWG or 1.0 to 1.5mm2. It
is also recommended that cables used for the power connections should be terminated
with blue or red crimp terminals. If crimp terminals are not used, care should be taken
to ensure that stray strands of wire do not short to adjacent terminals or the enclosure.
If possible, all wires should be stripped and tinned with solder before connecting to the
dsPICDEM MCHV development board terminals.
Note:
The user should only access the power terminals when the system is fully
discharged (see the “Safety Notice” on page iii).
The 14-pin keyed connector provides the signals and power supply rails from and to
the Power Stage. These signals are shown in Table 4-1.
TABLE 4-1:
14-PIN KEYED CONNECTORS
Number
4.2
Name
Type
1
3.3V, digital rail
Output
2
Not Connected
NC
3
3.3V, analog rail
Output
4
AC input voltage feedback
Output
5
Ground, analog rail
Output
6
AC input current feedback
Output
7
Fault (Overcurrent OR Overvoltage condition)
Output
8
VAC zero crossing signal
Output
9
Ground, digital rail
Output
10
PWM signal for the PFC IGBT
11
Ground, digital rail
12
Not Connected
13
15V
14
Not Connected
Input
Output
NC
Output
NC
POWER MODULE STAGE
This board has two main functions; the first is to control the motor using a dsPIC DSC
and a Power Module and the associated feedback signals for each control algorithm.
The second is to provide the safety means to interact with the user.
Note:
4.2.1
The circuits for the hardware described in this section are shown in
Appendix A. “Board Layout and Schematics”.
Plug-In Module Configuration
This section summarizes the resistor configuration required to connect the PIM pins to
dsPIC DSC pins. The following PIMs can be configured on the dsPICDEM™ MCHV
Development System:
•
•
•
•
dsPIC33FJ256MC710 PIM (MA330013)
dsPIC33FJ12MC202 PIM (MA330014)
dsPIC33FJ32MC204 PIM (MA330017)
dsPIC33FJ128MC804 PIM (MA330018)
Note:
 2009 Microchip Technology Inc.
When using PIMs, make sure that the 28-pin SOIC dsPIC DSC is removed
from the dsPICDEM™ MCHV Development System.
DS70605A-page 33
dsPICDEM™ MCHV Development System User’s Guide
Table 4-2, Table 4-3, and Table 4-4 describe the PIM configuration details.
TABLE 4-2:
PIM Pin
Number
dsPIC33FJ12MC202 PIM CONFIGURATION DETAILS
dsPIC33FJ12MC202
dsPIC33FJ32MC202
dsPIC33FJ64MC202
dsPIC33FJ128MC202
dsPIC33FJ32MC302
dsPIC33FJ64MC802
dsPIC33FJ128MC802
Labels on the
dsPICDEM™ MCHV
Development System
Pin
Number
PIM Resistor
Configuration
Pin Name
93
PWM1L1
23
PWM1L/RP15/CN11/RB15
R19
94
PWM1H1
22
PWM1H1/RP14/CN12/RB14
R18
98
PWM1L2
21
PWM1L2/RP13/CN13/RB13
R17
99
PWM1H2
20
PWM1H2/RP12/CN14/RB12
R16
100
PWM1L3
19
TMS/PWM1L3/RP11/CN15/RB11
R15
3
PWM1H3
18
TDI/PWM1H3/RP10/CN16/RB10
R12
71
PWM2L1
15
TDO/PWM2L1/SDA1/RP9/CN21/RB9
R14, Remove R13
18
FAULT
14
TCK/PWM2H1/SCL1/RP8/CN22/RB8
R11
19
PFC_FLT
15
TDO/PWM2L1/SDA1/RP9/CN21/RB9
Remove R13
26
PGC
9
PGEC3/SOSCO/T1CK/CN0/RA4
Not applicable
27
PGD
8
PGED3/SOSCI/RP4/CN1/RB4
Not applicable
63
OSI
6
OSCI/CLKI/CN30/RA2
Not applicable
64
OSO
7
OSCO/CLKO/CN29/RA3
Not applicable
25
IPFC
27
PGED2/AN0/VREF+/CN2/RA0
R24, Remove R27
24
VACZX_VAC_POT
28
PGEC2/AN1/VREF-/CN3/RA1
R25, Remove R26
35
VBUS
1
PGED1/AN2/RP0/CN4/RB0
R20, Remove R28
41
MONITOR_1
2
PGEC1/AN3/RP1/CN5/RB1
R21, Remove R31
42
MONITOR_2
3
AN4/RP2/CN6/RB2
R22, Remove R30
43
MONITOR_3
4
AN5/RP3/CN7/RB3
R23, Remove R29
—
HA/QEA
—
Not connected
Not applicable
—
HB/QEB
—
Not connected
Not applicable
—
HC/INDX
—
Not connected
Not applicable
—
VA
—
Not connected
Not applicable
—
VB
—
Not connected
Not applicable
—
VC
—
Not connected
Not applicable
—
IA
—
Not connected
Not applicable
—
IB
—
Not connected
Not applicable
—
IBUS
—
Not connected
Not applicable
—
VAC
—
Not connected
Not applicable
—
POT
—
Not connected
Not applicable
—
VACZX
—
Not connected
Not applicable
70
RX
70
INT0/RP7/CN23/RB7
R10, Remove R9
84
TX
84
ASCL1/RP6/CN24/RB6
R32, Remove R7 and R8
—
USB_RX
—
Not connected
Not applicable
—
USB_TX
—
68
BTN
DS70605A-page 34
Not connected
Not applicable
ASDA1/RP5/CN27/RB5
R6, Remove R5 and R33
 2009 Microchip Technology Inc.
Hardware
TABLE 4-3:
PIM Pin
Number
dsPIC33FJ32MC204 AND dsPIC33FJ128MC804 PIM CONFIGURATION DETAILS
Labels on the
dsPICDEM™ MCHV
Development System
dsPIC33FJ32MC204
dsPIC33FJ64MC804
dsPIC33FJ128MC804
Pin
Number
PIM Resistor
Configuration
Pin Name
93
PWM1L1
15
PWM1L1/RP15/CN11/RB15
R11
94
PWM1H1
14
PWM1H1/RP14/CN12/RB14
R10
98
PWM1L2
11
PWM1L2/RP13/CN13/RB13
R9
99
PWM1H2
10
PWM1H2/RP12/CN14/RB12
R7
100
PWM1L3
9
PGEC2/PWM1L3/RP11/CN15/RB11
R8
3
PWM1H3
8
PGED2/PWM1H3/RP10/CN16/RB10
R6
78
PWM2L1
3
PWM2L1/RP23/CN17/RC7
R31
18
FAULT
44
SCL1/RP8/CN22/RB8
R4
19
PFC_FLT
1
SDA1/RP9/CN21/RB9
R1
26
PGC
42
PGEC3/ASCL1/RP6/CN24/RB6
Not applicable
27
PGD
41
PGED3/ASDA1/RP5/CN27/RB5
Not applicable
63
OSI
30
OSCI/CLKI/CN30/RA2
Not applicable
64
OSO
31
OSCO/CLKO/CN29/RA3
Not applicable
25
IPFC
19
AN0/VREF+/CN2/RA0
R12
24
VACZX_VAC_POT
20
AN1/VREF-/CN3/RA1
R13
35
VBUS
21
PGED1/AN2/C2IN-/RP0/CN4/RB0
R14
41
MONITOR_1
22
PGEC1/AN3/C2IN+/RP1/CN5/RB1
R22
42
MONITOR_2
23
AN4/RP2/CN6/RB2
R25
43
MONITOR_3
24
AN5/RP3/CN7/RB3
R21
72
HA/QEA
37
RP20/CN25/RC4
R29
76
HB/QEB
38
RP21/CN26/RC5
R30
77
HC/INDX
2
PWM2H1/RP22/CN18/RC6
R32
—
VA
—
Not connected
Not applicable
—
VB
—
Not connected
Not applicable
—
VC
—
Not connected
Not applicable
—
IA
—
Not connected
Not applicable
—
IB
—
Not connected
Not applicable
—
IBUS
—
Not connected
Not applicable
—
VAC
—
Not connected
Not applicable
—
POT
—
Not connected
Not applicable
—
VACZX
—
Not connected
Not applicable
70
RX
43
INT0/RP7/CN23/RB7
R3, Remove R26
84
TX
33
SOSCI/RP4/CN1/RB4
R20
—
USB_RX
—
Not connected
Not applicable
—
USB_TX
—
Not connected
Not applicable
68
BTN
4
RP24/CN20/RC8
R2, Remove R18
 2009 Microchip Technology Inc.
DS70605A-page 35
dsPICDEM™ MCHV Development System User’s Guide
TABLE 4-4:
PIM Pin
Number
dsPIC33FJXXXMC710 PIM CONFIGURATION DETAILS
Labels on the
dsPICDEM™ MCHV
Development System
dsPIC33FJ64MC710
dsPIC33FJ128MC710
dsPIC33FJ256MC710
Pin Number
PIM Resistor
Configuration
Pin Name
93
PWM1L1
93
PWM1L/RE0
Not applicable
94
PWM1H1
94
PWM1H/RE1
Not applicable
98
PWM1L2
98
PWM2L/RE2
Not applicable
99
PWM1H2
99
PWM2H/RE3
Not applicable
100
PWM1L3
100
PWM3L/RE4
Not applicable
3
PWM1H3
3
PWM3H/RE5
Not applicable
78
PWM2L1
78
OC4/RD3
Not applicable
18
FAULT
18
AN20/FLTA/INT1/RE8
Not applicable
19
PFC_FLT
19
AN21/FLTB/INT2/RE9
Not applicable
26
PGC
26
PGEC1/AN6/OFCA/RB6
Not applicable
27
PGD
27
PGED1//AN7/RB7
Not applicable
63
OSI
63
OSC1/CLKIN/RC12
Not applicable
64
OSO
64
OSC2/CLKO/RC15
Not applicable
25
IPFC
25
PGED3/AN0/CN2/RB0
Not applicable
24
VACZX_VAC_POT
24
PGEC3/AN1/CN3/RB1
Not applicable
35
Not applicable
35
AN11/RB11
Not applicable
23
VBUS
23
AN2/SS1/CN4/RB2
Not applicable
41
Not applicable
41
AN12/RB12
Not applicable
22
MONITOR_1
22
AN3/INDX/CN5/RB3
Not applicable
42
Not applicable
42
AN13/RB13
Not applicable
21
MONITOR_2
21
AN4/QEA/CN6/RB4
Not applicable
43
Not applicable
43
AN14/RB14
Not applicable
20
MONITOR_3
20
AN5/QEB/CN7/RB5
Not applicable
80
HA/QEA
80
IC6/CN19/RD13
Not applicable
47
HB/QEB
47
IC7/U1CTS/CN20/RD14
Not applicable
48
HC/INDX
48
IC8/U1RTS/CN21/RD15
Not applicable
—
VA
—
Not connected
Not applicable
—
VB
—
Not connected
Not applicable
—
VC
—
Not connected
Not applicable
—
IA
—
Not connected
Not applicable
—
IB
—
Not connected
Not applicable
—
IBUS
—
Not connected
Not applicable
—
VAC
—
Not connected
Not applicable
33
POT
33
AN9/RB9
Not applicable
79
VACZX
79
IC5/RD12
Not applicable
49
RX
49
U2RX/CN17/RF4
Not applicable
50
TX
50
U2TX/CN18/RF5
Not applicable
—
USB_RX
—
Not connected
Not applicable
—
USB_TX
—
Not connected
Not applicable
68
BTN
68
IC1/RD8
Not applicable
DS70605A-page 36
 2009 Microchip Technology Inc.
Hardware
4.2.2
Power Supplies
The system default configuration is to get the 15V, 3.3V and 3.3V analog rail voltages
from the PFC stage board. However, it is also possible to use an external 24V power
supply to generate these voltages.
U19, C70, C73, C71 and C74 regulate the voltage applied to the system via J15 (28V
max). The output of the regulator is connected to the system through R109. The circuit
is shown in Appendix A. “Board Layout and Schematics”.
Note:
It is the responsibility of the user to populate these components if an
external power supply is used.
U18, C67, R110, C68, D16, D15, L3, R111, R112 and C75 regulate the 15 volts to create a 3.3V digital rail. This auxiliary 3.3V digital rail is applied to the system through
R106. The circuit is shown in Appendix A. “Board Layout and Schematics”.
Note:
It is the responsibility of the user to populate these components if an
external power supply is used.
R114, R107, C69, and C72 form a decoupling circuit for generating a 3.3V rail for the
analog circuitry such as the ADC reference and the current feedback reference. This
auxiliary 3.3V analog rail is applied to the system through R108.
Note:
4.2.3
It is the responsibility of the user to populate these components if an
external power supply is used.
Power Module
The three-phase inverter is embedded in a power module (U16). This power module
contains:
•
•
•
•
•
•
•
•
•
•
600V/30A 3-phase IGBT Inverter Bridge
Gate driver circuitry for each IGBT
Three Independent connections to the negative DC bus for current sensing
Short-circuit protection circuitry
Thermal Shutdown
Gate Driver Power Supply Undervoltage protection
Gate Driver Power Supply Overvoltage protection
Single-grounded power supply
Isolation of 2.5 kV per minute
Maximum switching frequency: 20 kHz
The dsPIC DSC provides the PWM signals to this power module in order to turn on/off
the IGBT, and therefore apply power to the motor phases.
R95 sets the threshold limit for the overcurrent circuitry. If this voltage is greater than
0.5 V (typical), a fault signal is asserted and the low-side IGTBs are turned off. R94 and
C53 form a low-pass RC filter that filters out the frequencies above 88.4 kHz.
C56 sets the fault pulse duration, the value of C56 is given by the following equation:
C56 = 18.3E-6 x 1.8E-3 seconds. Therefore, the fault pulse duration is 54 µs
The power module fault output pin (VFO) is open-collector configured. R50 pulls up the
fault output to the analog 3.3V rail. R53 and C40 form a low-pass RC filter that filters
out the frequencies above 53 kHz.
For more information about this power module please refer to the manufacturer’s data
sheet.
 2009 Microchip Technology Inc.
DS70605A-page 37
dsPICDEM™ MCHV Development System User’s Guide
4.2.4
Feedback Circuitry
The Power Module Stage provides three different methods to sense the motor position.
These signals are also useful to determine the speed, the torque, current consumption
and the applied voltage.
Hall Sensors, the hall sensors circuitry is designed to attach open-collector configured
sensors. It has a pull-up resistor at the hall sensor inputs (R23, R24, and R25) and a
voltage divider (R26-R29, R27-R30, R28-R31) in order to scale the input waveforms to
the dsPIC DSC logic levels. C25-C27 and R26-R28 form a low-pass RC filter for each
hall sensor signal.
Phase Voltage Feedback circuitry for each phase is compounded by a voltage divider,
a current limiter and a low-pass RC filter. R79, R84 and R92 scale the phase M1 voltage in order to match the dsPIC DSC logic levels. R85 limits the current going to the
ADC pin (< 6mA). C51, R79 and R84 form the low-pass filter. The phase M2 and M3
has the exact same circuitry as shown in the schematic.
DC Bus Voltage Feedback is compounded by a voltage divider and a low-pass RC
filter. R75, R76 and R81 scale the DC bus voltage in order to match the dsPIC DSC
logic levels. C47, R75 and R76 form the low-pass filter.
Inverter Leg Shunt Resistor Feedback, a shunt resistor is located between the emitter of the low side switches M1 and M2 and the “-DC bus”. A simple differential amplifier
circuit is used as shown in Appendix A. The operation of the circuit used for the M1
phase leg is described below:
The current is measured using the shunt resistor R86 and the operational amplifier
MCP6024 (U13A); R32, R33, R34, R36, R37 and R38 set the gain. R38 shifts the voltage present at the shunt resistor to a 1.65V DC level. Hence the voltage applied to the
dsPIC DSC ADC channel varies within 0-3.3V. The offset is controlled by R59, R60,
R38 and U13D. R35 and C34 filter out the high-frequency noise.
The same topology is used for the phase M2.
DC Bus Current Feedback, a shunt resistor is located between the shunt resistors of
side switches M1 and M2 and the “-DC bus”. A simple differential amplifier circuit is
used as shown in the schematic. The operation of the circuit used for sensing the DC
bus current is described as follows:
The current is sensed using the shunt resistor R95 and the operational amplifier
MCP6024 (U13C); R51, R52 and R49 set the gain. R58 shifts the voltage present
at the shunt resistor to a 1.65V DC level. Hence the voltage applied to the dsPIC
DSC ADC channel varies within 0-3.3V. The offset is controlled by R59, R60, R58
and U13D. R54 and C42 filter out the high-frequency noise.
Note:
DS70605A-page 38
It is possible to select any of these feedback signals using jumpers J12, J13
and J14, please refer to Section 4.2.8 “User Interfaces” for more
information.
 2009 Microchip Technology Inc.
Hardware
4.2.5
Fault Circuitry
In addition to the fault signal generated by the power module, the system can also
create a DC bus overcurrent fault.
DC Bus Overcurrent, this fault signal is generated when the maximum current limit of
15A is reached. The comparison of the threshold value and the actual current is done
by comparator U14. The threshold limit is set by R42 and R47. R69 is a shunt jumper
resistor that can disconnect the overcurrent fault from the dsPIC DSC.
Note:
4.2.6
The comparator is open-drained and needs an external pull-up resistor.
Both the power module output and the comparator output share this pull-up
resistor creating an OR condition at the output.
Isolation
The power supply used by the push buttons, communication ports, and the SKDE programmer/debugger is isolated from the power supply used by the power module or the
dsPIC DSC. An isolated 3.3V rail is generated from the digital 3.3V rail using a
DC-to-DC converter (U10). This converter provides galvanic isolation rated up to
1000 VDC/1 second.
4.2.7
Communication Ports
The power module stage board provides two methods for transmitting/receiving data to
and from the system. Both communication methods are powered using the isolated
3.3V rail.
UART-to-USB communication port is based on a PIC18LFJ2450 device with a serial
emulator firmware. This device translates the USB signals to dsPIC DSC UART compatible signals. The firmware used for this serial emulator is enclosed in the CD shipped
along with the unit. Isolation for the UART-to-USB communication port is provided by
U25.
UART-to-RS-232 communication port is based on a RS-232 transceiver (U9). This
device translates the dsPIC DSC UART signals to UART compatible signals. Isolation
for the UART-to-RS-232 communication port is provided by U25.
Shunt jumpers J2 and J3 select the communication port. Table 4-5 shows the possible
configurations.
TABLE 4-5:
COMMUNICATION PORT CONFIGURATION
Designator
Position
J2
1-2
2-3
Connects USB receive line to RX.
J3
1-2
Connects UART transmit line to TX.
2-3
Connects USB transmit line to TX.
 2009 Microchip Technology Inc.
Description
Connects UART receive line to RX.
DS70605A-page 39
dsPICDEM™ MCHV Development System User’s Guide
4.2.8
User Interfaces
There are two types of user interfaces, isolated and non-isolated:
• Isolated interfaces:
- Potentiometer labeled “POT” (R14)
- RESET push button
- PUSH BUTTON (S1)
- PWM OUTPUT enable shunt jumper (J7)
- Communication Port Selection shunt jumper (J2 and J3)
- ICSP programmer/debugger connector for SKDE (J4)
- ICSP programmer/debugger connector for UART-to-USB converter (J1)
• Non-Isolated interfaces:
- 15V Power Supply LED (D17)
- 3.3V Power Supply LED (D18)
- PWM2L1, PWM1L1, PWM1H1, PWM1L2, PWM1H2, PWM1L3, PWM1H3
LEDs
- USB communication LED (D1)
- USB cable connected LED (D3)
- SKDE USB cable connected LED (D21)
- SKDE Power On LED (D19)
- ICSP programmer/debugger connector for dsPIC DSC (J18)
- Feedback Selection Shunt Jumpers J11, J12, J13, and J14.
Table 4-6 shows the multiple feedback signals that can be selected.
TABLE 4-6:
Designator
Position
J11
1-2
Connects AC input voltage zero-crossing event to
VACZX_VAC_POT
3-4
Connects AC input voltage to VACZX_VAC_POT
5-6
Connects the POT voltage to VACZX_VAC_POT
J12
J13
J14
DS70605A-page 40
MULTIPLE FEEDBACK SIGNALS
Description
1-2
Connects Phase M1 shunt current feedback to MONITOR_1
3-4
Connects Phase M1 voltage feedback to MONITOR_1
5-6
Connects Hall A/QEA sensor signal to MONITOR_1
1-2
Connects Phase M2 shunt current feedback to MONITOR_2
3-4
Connects Phase M2 voltage feedback to MONITOR_2
5-6
Connects Hall B/QEB sensor signal to MONITOR_2
1-2
Connects DC bus shunt current feedback to MONITOR_3
3-4
Connects Phase M3 voltage feedback to MONITOR_3
5-6
Connects Hall C/INDEX sensor signal to MONITOR_3
7-8
Connects the POT voltage to MONITOR_3
 2009 Microchip Technology Inc.
Hardware
4.2.9
Hardware for Programming and Debugging
The dsPICDEM™ MCHV Development System, with its built-in SKDE debugger/programmer, provides an all-in-one solution for debugging and programming applications
using MPLAB IDE. The Starter Kit’s debugging/programming operations are controlled
by a PIC18F67J50 MCU running at 48 MHz. The PIC18F67J50’s built-in USB engine
provides the communications interface between the Starter Kit and the host PC.
Power to the Starter Kit is provided via the isolated 3.3V rail. Proper Starter Kit main
system power is indicated by the green LED D19. The PIC18F67J50 MCU accomplishes debugging or programming of the target dsPIC33F by controlling the target’s
MCLR, PGC1/EMUC1, and PGD1/EMUD1 signals. A Microchip 25LC010A serial
EEPROM is used to store the Starter Kit’s serial number and debug control information.
Isolation for the MCLR, PGC1/EMUC1, and PGD1/EMUD1 signals is provided by the
digital isolators U22, U23, U1 and U3.
4.2.10
Board Connectors
Figure 4-1 provides the locations of the connectors. The Power Module Stage Board
connectors are listed in Table 4-6.
FIGURE 4-1:
POWER MODULE BOARD CONNECTORS
17
3
5
2
4
1
16
15
6
12
11
 2009 Microchip Technology Inc.
13
14
7
8
9
10
DS70605A-page 41
dsPICDEM™ MCHV Development System User’s Guide
TABLE 4-7:
POWER MODULE STAGE BOARD CONNECTORS
Number
Designator
Type
1
Motor Phase 1 (M1)
Output/Power
2
Motor Phase 2 (M2)
Output/Power
3
Motor Phase 3 (M3)
Output/Power
4
DC Bus “+”
Input/Power
5
DC Bus “-”
Input/Power
6
Hall Sensor A (HA)
Input
7
Hall Sensor B (HB)
Input
8
Hall Sensor C (HC)
9
Hall Sensors, 5V power supply terminal
Output/Power
10
Hall Sensors, Ground terminal
Output/Power
11
UART-to-USB connector
Input/Output
12
UART-to-RS-232 connector
Input/Output
13
USB connector for the Starter Kit Programmer/Debugger
Input/Output
14
Isolated ICSP™ programmer/debugger connector for SKDE
(J4)
Input/Output
15
Isolated ICSP programmer/debugger connector for
UART-to-USB converter (J1)
Input/Output
16
ICSP programmer/debugger connector for dsPIC DSC (J18)
Input/Output
17
14-pin keyed connector (J16)
Input
Input/Output/Power
The 14-pin keyed connector provides the signals and power supply rails from and to
the Power Module Stage. These signals are shown in Table 4-8.
TABLE 4-8:
14-PIN KEYED CONNECTORS
Number
DS70605A-page 42
Name
Type
1
3.3V, digital rail
Output
2
Not Connected
NC
3
3.3V, analog rail
Output
4
AC input voltage feedback
Output
5
Ground, analog rail
Output
6
AC input current feedback
Output
7
Fault (Overcurrent or Overvoltage condition)
Output
8
VAC zero crossing signal
Output
Output
9
Ground, digital rail
10
PWM signal for the PFC IGBT
11
Ground, digital rail
12
Not Connected
13
15V
14
Not Connected
Input
Output
NC
Output
NC
 2009 Microchip Technology Inc.
Hardware
4.3
ELECTRICAL SPECIFICATIONS
The maximum power and current capability of the system is dictated by the allowable
temperature rise of the different components. Establishing maximum limits is not simple
given the host of different ways the user may use the system. The voltage and the
nature of the electrical load used both affects the dissipation that occurs. In determining
the allowable limits for the power semiconductors, the following assumptions have
been made:
• Heat sink is at 70°C (worst case)
• Thermal resistance of the insulating thermal pad is 3°C/W
TABLE 4-9:
INVERTER ELECTRICAL SPECIFICATIONS
Parameter
Min
Typ
Max
Units
DC Bus
40
310
400
VDC
Current
0.1
6.5(1)
10(1)
A
Power Rating
4
2015(2)
4000(2)
Watts
Switching Frequency
0
—
20
kHz
Note 1:
2:
The system continuously operated during one hour, 15 kHz switching
frequency and the PFC boost circuit disabled.
It is possible to increase the available maximum output power up to
4000W by using an external ventilation mechanism attached to system
near to the power module. To provide additional air flow, a conventional
AC muffin fan can be used (Comair-rotron part number 028021 or
028023). An alternative bonded fin heat sink with fans attached is also an
option (C&H Technology, Inc. part number CH5117F).
TABLE 4-10:
PFC ELECTRICAL SPECIFICATIONS
Parameter
DC Bus
Current
Power Rating
Switching Frequency
Note 1:
2:
 2009 Microchip Technology Inc.
Min
Typ
Max
Units
90
380
400
VDC
0.1
2.6(1)
3.5(1)
A
9
1000(2)
1400(2)
Watts
0
50
100
kHz
The system continuously operated during one hour, 50 kHz switching
frequency.
It is possible to increase the available maximum output power up to
1400W by using an external ventilation mechanism attached to system
near to the PFC IGBT. To provide additional air flow, a conventional AC
muffin fan can be used (Comair-rotron part number 028021 or 028023).
An alternative bonded fin heat sink with fans attached is also an option
(C&H Technology, Inc. part number CH5117F).
DS70605A-page 43
dsPICDEM™ MCHV Development System User’s Guide
NOTES:
DS70605A-page 44
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV
DEVELOPMENT SYSTEM
USER’S GUIDE
Appendix A. Board Layout and Schematics
FIGURE A-1:
PFC STAGE BOARD LAYOUT (TOP)
 2009 Microchip Technology Inc.
DS70605A-page 45
dsPICDEM™ MCHV Development System User’s Guide
DS70605A-page 46
2
2
3
1
4
1
3
6
2
4
3
2
1
2
1
4
5
1
3
4
3
4
3
4
2
PFC STAGE SCHEMATIC (SHEET 1 OF 3)
1
FIGURE A-2:
 2009 Microchip Technology Inc.
Board Layout and Schematics
FIGURE A-3:
PFC STAGE SCHEMATIC (SHEET 2 OF 3)
 2009 Microchip Technology Inc.
DS70605A-page 47
dsPICDEM™ MCHV Development System User’s Guide
FIGURE A-4:
DS70605A-page 48
PFC STAGE SCHEMATIC (SHEET 3 OF 3)
 2009 Microchip Technology Inc.
Board Layout and Schematics
FIGURE A-5:
POWER MODULE STAGE BOARD LAYOUT (TOP)
 2009 Microchip Technology Inc.
DS70605A-page 49
dsPICDEM™ MCHV Development System User’s Guide
FIGURE A-6:
DS70605A-page 50
POWER MODULE STAGE BOARD LAYOUT (BOTTOM)
 2009 Microchip Technology Inc.
Board Layout and Schematics
FIGURE A-7:
POWER MODULE STAGE SCHEMATIC (SHEET 1 OF 6)
 2009 Microchip Technology Inc.
DS70605A-page 51
dsPICDEM™ MCHV Development System User’s Guide
D16
DS70605A-page 52
SS1P3L
D15
POWER MODULE STAGE SCHEMATIC (SHEET 2 OF 6)
BAT17
FIGURE A-8:
 2009 Microchip Technology Inc.
Board Layout and Schematics
FIGURE A-9:
POWER MODULE STAGE SCHEMATIC (SHEET 3 OF 6)
 2009 Microchip Technology Inc.
DS70605A-page 53
dsPICDEM™ MCHV Development System User’s Guide
FIGURE A-10:
DS70605A-page 54
POWER MODULE STAGE SCHEMATIC (SHEET 4 OF 6)
 2009 Microchip Technology Inc.
Board Layout and Schematics
FIGURE A-11:
POWER MODULE STAGE SCHEMATIC (SHEET 5 OF 6)
 2009 Microchip Technology Inc.
DS70605A-page 55
dsPICDEM™ MCHV Development System User’s Guide
FIGURE A-12:
DS70605A-page 56
POWER MODULE STAGE SCHEMATIC (SHEET 6 OF 6)
 2009 Microchip Technology Inc.
dsPICDEM™ MCHV DEVELOPMENT
SYSTEM USER’S GUIDE
Index
A
M
Application Debug Setup ......................................... 19
Application Debugging ............................................. 22
Application Programming ......................................... 24
Microchip Internet Web Site ....................................... 4
C
Communication Port Connectors ............................. 17
Connection Sequence.............................................. 17
Customer Notification Service.................................... 4
Customer Support ...................................................... 5
D
DC BUS Current Feedback...................................... 38
DC BUS Overcurrent................................................ 39
DC BUS Voltage Feedback ..................................... 38
Demonstration Software .......................................... 27
Documentation
Conventions ........................................................ 2
Layout ................................................................. 1
dsPICDEM™ MCHV Development System
Features............................................................ 10
Overview ............................................................. 7
System Block Diagram ....................................... 9
P
PFC Stage.......................................................... 13, 29
Phase Voltage Feedback ......................................... 38
PIM Configuration .................................................... 33
Power Connections ............................................ 15, 17
Power Module .......................................................... 37
Power Module Stage.......................................... 13, 33
Power Supplies ........................................................ 37
Power-down Sequence ............................................ 19
Power-up Sequence................................................. 19
Programming and Debugging .................................. 19
Programming Problems ........................................... 25
R
Reading, Recommended ........................................... 3
Running the Starter Kit Application .......................... 21
S
Safety Notice..............................................................iii
System Connections ................................................ 16
H
T
Hall Sensors............................................................. 38
Hardware Components ............................................ 29
Troubleshooting ....................................................... 25
I
Using Breakpoints and Mouseovers ........................ 23
Using Watch Windows ............................................. 24
Interface Components.............................................. 14
Internet Address......................................................... 4
Inverter Leg Shunt Resistor Feedback..................... 38
 2009 Microchip Technology Inc.
U
W
Warranty Registration ................................................ 3
WWW Address........................................................... 4
DS70605A-page 57
Worldwide Sales and Service
AMERICAS
ASIA/PACIFIC
ASIA/PACIFIC
EUROPE
Corporate Office
2355 West Chandler Blvd.
Chandler, AZ 85224-6199
Tel: 480-792-7200
Fax: 480-792-7277
Technical Support:
http://support.microchip.com
Web Address:
www.microchip.com
Asia Pacific Office
Suites 3707-14, 37th Floor
Tower 6, The Gateway
Harbour City, Kowloon
Hong Kong
Tel: 852-2401-1200
Fax: 852-2401-3431
India - Bangalore
Tel: 91-80-3090-4444
Fax: 91-80-3090-4080
India - New Delhi
Tel: 91-11-4160-8631
Fax: 91-11-4160-8632
Austria - Wels
Tel: 43-7242-2244-39
Fax: 43-7242-2244-393
Denmark - Copenhagen
Tel: 45-4450-2828
Fax: 45-4485-2829
India - Pune
Tel: 91-20-2566-1512
Fax: 91-20-2566-1513
France - Paris
Tel: 33-1-69-53-63-20
Fax: 33-1-69-30-90-79
Japan - Yokohama
Tel: 81-45-471- 6166
Fax: 81-45-471-6122
Germany - Munich
Tel: 49-89-627-144-0
Fax: 49-89-627-144-44
Atlanta
Duluth, GA
Tel: 678-957-9614
Fax: 678-957-1455
Boston
Westborough, MA
Tel: 774-760-0087
Fax: 774-760-0088
Chicago
Itasca, IL
Tel: 630-285-0071
Fax: 630-285-0075
Cleveland
Independence, OH
Tel: 216-447-0464
Fax: 216-447-0643
Dallas
Addison, TX
Tel: 972-818-7423
Fax: 972-818-2924
Detroit
Farmington Hills, MI
Tel: 248-538-2250
Fax: 248-538-2260
Kokomo
Kokomo, IN
Tel: 765-864-8360
Fax: 765-864-8387
Los Angeles
Mission Viejo, CA
Tel: 949-462-9523
Fax: 949-462-9608
Santa Clara
Santa Clara, CA
Tel: 408-961-6444
Fax: 408-961-6445
Toronto
Mississauga, Ontario,
Canada
Tel: 905-673-0699
Fax: 905-673-6509
Australia - Sydney
Tel: 61-2-9868-6733
Fax: 61-2-9868-6755
China - Beijing
Tel: 86-10-8528-2100
Fax: 86-10-8528-2104
China - Chengdu
Tel: 86-28-8665-5511
Fax: 86-28-8665-7889
Korea - Daegu
Tel: 82-53-744-4301
Fax: 82-53-744-4302
China - Hong Kong SAR
Tel: 852-2401-1200
Fax: 852-2401-3431
Korea - Seoul
Tel: 82-2-554-7200
Fax: 82-2-558-5932 or
82-2-558-5934
China - Nanjing
Tel: 86-25-8473-2460
Fax: 86-25-8473-2470
Malaysia - Kuala Lumpur
Tel: 60-3-6201-9857
Fax: 60-3-6201-9859
China - Qingdao
Tel: 86-532-8502-7355
Fax: 86-532-8502-7205
Malaysia - Penang
Tel: 60-4-227-8870
Fax: 60-4-227-4068
China - Shanghai
Tel: 86-21-5407-5533
Fax: 86-21-5407-5066
Philippines - Manila
Tel: 63-2-634-9065
Fax: 63-2-634-9069
China - Shenyang
Tel: 86-24-2334-2829
Fax: 86-24-2334-2393
Singapore
Tel: 65-6334-8870
Fax: 65-6334-8850
China - Shenzhen
Tel: 86-755-8203-2660
Fax: 86-755-8203-1760
Taiwan - Hsin Chu
Tel: 886-3-6578-300
Fax: 886-3-6578-370
China - Wuhan
Tel: 86-27-5980-5300
Fax: 86-27-5980-5118
Taiwan - Kaohsiung
Tel: 886-7-536-4818
Fax: 886-7-536-4803
China - Xiamen
Tel: 86-592-2388138
Fax: 86-592-2388130
Taiwan - Taipei
Tel: 886-2-2500-6610
Fax: 886-2-2508-0102
China - Xian
Tel: 86-29-8833-7252
Fax: 86-29-8833-7256
Thailand - Bangkok
Tel: 66-2-694-1351
Fax: 66-2-694-1350
Italy - Milan
Tel: 39-0331-742611
Fax: 39-0331-466781
Netherlands - Drunen
Tel: 31-416-690399
Fax: 31-416-690340
Spain - Madrid
Tel: 34-91-708-08-90
Fax: 34-91-708-08-91
UK - Wokingham
Tel: 44-118-921-5869
Fax: 44-118-921-5820
China - Zhuhai
Tel: 86-756-3210040
Fax: 86-756-3210049
03/26/09
DS70605A-page 58
 2009 Microchip Technology Inc.
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