IRMCS2011 International Rectifier • 233 Kansas Street, El Segundo, CA 90245 ! USA IRMCS2011 Complete Encoder Based Servo Drive Design Platform iMOTIONTM Development System IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 Data and specifications subject to change without notice. 3/18/2004 REFERENCE DESIGN IRMCS2011 Complete Encoder Based Servo Drive Design Platform iMOTIONTM Development System Features Product Summary ! Low cost complete AC servo drive design platform ! ! ! IRMCK201 IC for complete servo control Simple design with IR2175 current sensing HVIC 230V/750W maximum output power with 600V/16A advanced Plug-N-DriveTM IGBT module Speed loop bandwidth (adjustable) 400 Hz (typ) PWM carrier frequency 70 kHz max ! ! High bandwidth torque loop response Hardware current loop execution time Flexible drive configuration (PMAC or induction motor) Enhanced low speed regulation by 1/T algorithm ! ! ! ! ! Quadrature encoder interface Continuous output current Low cost A/D interface with multiplexer Overload output current ! ! ! ! ! TM ServoDesigner tool for easy operation RS232C/RS422 and fast SPI interface (standard) Parallel interface for microcontroller expansion or debug port Over-current and ground fault protection Current loop bandwidth (-3dB) Max SPI comm. speed 5 kHz (typ) 6 µsec 5.0 Arms (750W) 15 Arms 6 MHz Slave SPI configuration Max RS232C speed 57.6 kbps Over-voltage / Under-voltage protection Dynamic Braking control with brake IGBT/FWD Discrete I/Os (START, STOP, FAULT, FLTCLR, SYNC, IFBCAL, PWMACTIVE) Configuration data retention at power up/down Description IRMCS2011 is a complete servo drive design platform for AC servo drive applications up to 750W. The system contains the latest advanced motion control IC, IRMCK201, and the ServoDesignerTM software. The complete B/Ms and schematics are provided so that the user can adapt and tailor the design per application needs. The system does not require any software code development due to unique Motion Control Engine implemented in the IRMCK201 IC. User can readily evaluate high performance servo control without spending development effort usually required in the traditional DSP or microcontroller based system. IRMCS2011 contains advanced iMOTIONTM chipset such as IR2175 monolithic current sensing ICs and IRAMX16UP60A intelligent power module which enables simple and cost effective motion control design. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. REFERENCE DESIGN IRMCS2011 Table of Contents 1. Overview....................................................................................................................................................................... 4 2. Getting Started .............................................................................................................................................................. 5 2.1 Safety Precautions................................................................................................................................................... 5 2.2 Unpacking and Inspecting....................................................................................................................................... 6 3. Preparing the Motor ...................................................................................................................................................... 7 3.1 Readily Drivable Motor List ................................................................................................................................... 7 3.2 Assembling Encoder Connector.............................................................................................................................. 7 3.3 Motor Power Cable ................................................................................................................................................. 8 4. Hardware Installation .................................................................................................................................................... 8 4.1 Safety Precautions................................................................................................................................................... 8 4.2 Input Power Wiring................................................................................................................................................. 9 4.3 Motor Wiring .......................................................................................................................................................... 9 4.4 Encoder Connection.............................................................................................................................................. 10 4.5 RS232 Connection ................................................................................................................................................ 10 5. Software Installation ................................................................................................................................................... 11 5.1 Installing from the CD .......................................................................................................................................... 11 5.2 ServoDesigner Startup .......................................................................................................................................... 11 Step 1. RS232 Connection ...................................................................................................................................... 11 Step 2. Numeric Format .......................................................................................................................................... 11 6. Running the System .................................................................................................................................................... 13 6.1 Power-On .............................................................................................................................................................. 13 6.2 Running motor with ServoDesigner...................................................................................................................... 13 Step 1. Opening the Configuration File .................................................................................................................. 13 Step 2. Checking Communication Status ................................................................................................................ 13 Step 3. Motor Configuration ................................................................................................................................... 14 Step 4. Starting Angle ............................................................................................................................................. 14 Step 5. Running the Motor ...................................................................................................................................... 14 Step 6. Reference Speed.......................................................................................................................................... 14 Step 7. Drive Status................................................................................................................................................. 15 7. Motion Control Engine ............................................................................................................................................... 16 7.1 Motion Control Engine (MCE) Based Complete Servo Control........................................................................... 16 8. New Motor Adaptation ............................................................................................................................................... 17 9. Appendix..................................................................................................................................................................... 19 9.1 External I/O........................................................................................................................................................... 19 9.2 RS232C Connector ............................................................................................................................................... 19 9.3 Parallel Interface Port............................................................................................................................................ 20 10. Specifications ............................................................................................................................................................ 23 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 2 REFERENCE DESIGN IRMCS2011 List of Figures Figure 1. IRMCS2011 System Block Diagram................................................................................................................. 4 Figure 2. Encoder Interface Connector, J2........................................................................................................................ 7 Figure 3. Power Terminal Block, J1 ................................................................................................................................. 9 Figure 4. Motor Wiring Connection ................................................................................................................................. 9 Figure 5. Encoder Connector, J2..................................................................................................................................... 10 Figure 6. RS232 Connector, J6 ....................................................................................................................................... 10 Figure 7. The Connection Dialog.................................................................................................................................... 11 Figure 8. The Numeric Display Format Dialog .............................................................................................................. 12 Figure 9. Open a Configuration File ............................................................................................................................... 13 Figure 10. Communication Status Indicator ................................................................................................................... 14 Figure 11. Setup for Reference Speed Function ............................................................................................................. 15 Figure 12. IRMCK201 Based Complete Servo Control ................................................................................................. 16 Figure 13. EXCEL Spreadsheet Inputs ........................................................................................................................... 18 Figure 14. External I/O Connector, J7 ............................................................................................................................ 19 Figure 15. RS232C Connector, J6 .................................................................................................................................. 19 Figure 16. Parallel Interface Port, J9............................................................................................................................... 20 Figure 17. Register Write/Read Timing (Intel) ............................................................................................................... 21 Figure 18. Register Write/Read Timing (Motorola) ....................................................................................................... 22 List of Tables Table 1. Motor Connections.............................................................................................................................................. 9 Table 2. Microprocessor Interface Module Signal Definitions....................................................................................... 20 Table 3. IRMCS2011 Electrical Specification ................................................................................................................ 23 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 3 REFERENCE DESIGN IRMCS2011 1. Overview The IRMCS2011 is a design platform for a complete servo drive system based on IRMCK201 IC. The system is based on configurable Motion Control Engine implemented by hardware logics in the IRMCK201. The system has a simple and low cost yet very flexible structure, made possible by advanced IR motion components including the IRAMX16UP60A IGBT module, and IR2175 monolithic current sensing high voltage IC. These components together with IRMCK201 IC simplify hardware construction, and perform complete servo amplifier functions. Figure 1 shows the IRMCS2011 system block diagram. Since all control logic is implemented in hardware logic as opposed to programmed software, unmatched parallel computation is achieved resulting in high bandwidth torque control. Despite the fact that technology is based on hardware logic implementation, its design flexibility allows the user to configure different types of motors, position feedback devices, and communication protocols. The system also allows feedforward control in addition to existing PI control. Design cycle time can be greatly shortened. Unlike a traditional DSP or microcontroller, the architecture is based on configurable register interface, and does not require any programming to complete customization for specific application needs. The user only has to configure the drive using ServoDesignerTM interactive design tool and it takes just a matter of hours instead of months and years. Once the user become satisfied with function and performance, he can generate his own design using IRMCS2011 schematics and B/Ms. AC Power EEPROM IRMCK201 Multi-Axis Host other host controller + + - Host Register Interface jθ - e + Space Vector PWM A/D MUX DC bus feedback IGBT module BRAKE IRAMX16UP60A Dead time IR2136 or select A/D interface DC bus dynamic brake control RS232C or RS422 SPI Interface Analog Speed Reference TM iMOTION Chip Set FAULT Parallel Interface Configuration Registers Ks + dt + Monitoring Registers jθ e 1/T counter speed measurement 2/3 Period/Duty counters IR2175 Period/Duty counters IR2175 Quadrature Decoding Encoder Motor Figure 1. IRMCS2011 System Block Diagram This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 4 REFERENCE DESIGN IRMCS2011 2. Getting Started 2.1 Safety Precautions In addition to the precautions listed throughout this manual, you must read and understand the following statements regarding hazards associated with AC servo development system. ! ATTENTION: Some ground potential of the IRMCS2011 system is biased to a negative DC bus voltage potential and kept high voltage potential while power is on. When measuring voltage waveform by oscilloscope, the scope ground needs to be isolated. Failure to do so may result in personal injury or death. Darkened display LED is not an indication that capacitors have discharged to safe voltage levels. ! ATTENTION: The IRMCS2011 system contains high voltage capacitors which take time to discharge after removal of main supply. Before working on drive system, ensure isolation of mains supply from line inputs [R, S, T]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LED is not an indication that capacitors have discharged to safe voltage levels. ! ! ATTENTION: Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: The surface temperatures of the drive may become hot, which may cause injury. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 5 REFERENCE DESIGN IRMCS2011 ! ! ATTENTION: The IRMCS2011 system contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference applicable ESD protection handbook and guideline. ATTENTION: An incorrectly applied or installed drive can result in component damage or reduction in product life. Wiring or application errors such as undersizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction. 2.2 Unpacking and Inspecting The IRMCS2011 system is shipped with packing materials that need to be removed prior to installation. ! ATTENTION: Failure to remove all debris and packing materials, which are unnecessary for system installation, may result in overheating or abnormal operating condition. After unpacking, check the items. The following hardware pieces are contained in the IRMCS2011 system. • • • IRMCS2011 board with integrated heat sink Serial RS232C cable with 9-pin D-sub connectors for ServoDesignerTM development tool Installation CD Before you install and start up the system, check if there is any damaged component. In that case, stop proceeding and contact our technical support. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 6 REFERENCE DESIGN IRMCS2011 3. Preparing the Motor 3.1 Readily Drivable Motor List If the motor is one of the following, it can be run immediately without commissioning. • • • • • • • • • Sanyo Denki 400W 8-pole servo motor with 2000-pulse encoder (P30B06040DXS00M,) Sanyo Denki 750W 8-pole servo motor with 2000-pulse encoder (P30B08075DXS00M) Sanyo Denki 1.5kW 8-pole servo motor with 2000-pulse encoder (P20B10150DXS00M) Glentek 160W 4-pole servo motor with 2000-pulse encoder (GMB2010-17-E-02100005) Glentek 1.0kW 6-pole servo motor with 5000-pulse encoder (GMB3530-24-E-02200109) Glentek 1.2kW 6-pole servo motor with 5000-pulse encoder (GMB3530-37-E-02200109) Glentek 600W 6-pole servo motor with 5000-pulse encoder (GMB3530-48-E-02200109) Pacific Scientific 800W 8-pole servo motor with 2048-pulse encoder (PMB23C-00114-00) Reliance Electric 2HP 4-pole induction motor with 1024-pulse encoder (P14A5805) If any other motor is used, adaptation and re-configuration is required, which can be accomplished using the ServoDesignerTM tool. 3.2 Assembling Encoder Connector Prepare the connector assembly to the encoder cables. • Assemble 15-pin male D-Sub connector, referring to Figure 2. • Make sure that the encoder is a 5V type. If it is not a 5V type, proper modification is required. For permanent magnet motors: • Eleven pins are used: A+ (pin 2), A- (pin 3), B+ (pin 4), B- (pin 5), Z+ (pin 6), Z- (pin 7), HALL_A (pin 10), HALL_B (pin 11), HALL_C (pin 12), 5V(pin 1 or pin 9) and GND (pin 8 or pin 15). • If hall sensors have differential output, connect only positive sides and leave negative sides open. For induction motors: • Only six pins are used because z-pulse is not necessary for an induction machine. The six pins are: A+ (pin 2), A- (pin 3), B+ (pin 4), B- (pin 5), 5V(pin 1 or pin 9) and GND (pin 8 or pin 15). • Disable Z_pulse by connecting Z+ to GND and Z- to 5V. upper row J2 15 1 9 low row 8 HVDD A+ AB+ BZ+ ZVSS HVDD HALL-A HALL-B HALL-C NA NA VSS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Sanyo Denki’s encoder cable wire A+ = Blue A- = Brown B+ = Green B- = Purple Z+ = White Z- = Yellow +5V_BB (5V) = Red VSS (0V) = Black DSUB-15 Figure 2. Encoder Interface Connector, J2 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 7 REFERENCE DESIGN IRMCS2011 3.3 Motor Power Cable Prepare the motor power cable, which has four wires: U, V, W and E (earth ground). Proper size and length of cable should be used. 4. Hardware Installation 4.1 Safety Precautions ! ! ! ATTENTION: Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait three minutes after removing power to discharge the bus voltage. Do not attempt to service the drive until bus voltage has discharged to zero. Failure to do so may result in bodily injury or death. ATTENTION: The drive is intended to be commanded by control input that will start and stop the motor. A device that routinely disconnects then reapplies input power to the drive for the purpose of starting and stopping the motor should not be used. Failure to follow this guideline may result in damage of equipment, and/or bodily injury or death. ATTENTION: Do not connect power factor correction capacitors to drive output terminals U, V, and W. Failure to do so may result in equipment damage or bodily injury. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 8 REFERENCE DESIGN IRMCS2011 4.2 Input Power Wiring Connect AC 115V or single-phase 230V or three-phase 230V power. For single phase 100V-230V AC power, use R and T for connection. For three phase 230V power, use R/S/T for connection as shown in Figure 3. Insert a power contactor switch rated at 250V/30A in series with AC power cables. Figure 3. Power Terminal Block, J1 If full power rating is needed, use three-phase 230V power. Otherwise output power should be de-rated. Proper size and length of cable should be used. 4.3 Motor Wiring Connect motor power and ground wires to terminal block J1 of IRMCS2011 board as shown in Figure 4. Figure 4. Motor Wiring Connection For Sanyo Denki, Glentek or Pacific Scientific motors, the colored wires should be connected to the associated Terminal Block pins of the IRMCS2011 board as shown in Table 1. Sanyo Denki’s motor cable wire RED WHITE BLACK GREEN/YELLOW Glentek motor Pacific Scientific motor cable wire cable wire RED (pin A) BLUE BLUE (pin C) VIOLET BLACK (pin B) BROWN GREEN (pin D) GREEN/YELLOW Table 1. Motor Connections Terminal block pin This document is the property of International Rectifier and may not be copied or distributed without expressed consent. U V W E 9 REFERENCE DESIGN IRMCS2011 4.4 Encoder Connection Plug the encoder connector into J2 as shown in Figure 5. Make sure that encoder signals are connected properly. Incorrect connection of encoder signals will result in improper rotor position and/or incorrect communication. The shell of the connector is grounded to the chassis for shield termination. Figure 5. Encoder Connector, J2 4.5 RS232 Connection Connect the serial cable between the computer COM port and J6 as shown in Figure 6. If there is more than one COM port, please remember which one you are using. Make sure that the cable is connected properly. Incorrect connection of the serial cable will result in communication errors and/or incorrect communication. The shell of the connector is grounded to the chassis for shield termination. Figure 6. RS232 Connector, J6 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 10 REFERENCE DESIGN IRMCS2011 5. Software Installation 5.1 Installing from the CD The distributed CD contains all necessary documents and software files. Load the CD into the CD-ROM drive on your PC and double-click “IRMCS2011.exe”. It will ask you for a password, which is in the file “iMOTION Install IRMCS2011.pdf”. After you enter the password, an automated procedure will install all necessary software on your PC. The default location for the installation is “C:\Program Files\iMOTION”. 5.2 ServoDesigner Startup You should follow the instructions in this section the first time you use ServoDesigner to verify your installation and test the reference design. These “quick start” instructions assume that you’re using one of the supported motors listed in section 3.1. If not, you’ll need to enter motor configuration parameters before you can begin testing. Refer to “ServoDesigner User’s Guide” and “IRMCK201 Application Developer’s Guide” for more information. Step 1. RS232 Connection ServoDesigner communicates with the IRMCS2011 using a COM port on your PC. Before you start the application, you should attach an RS232 cable to the DB9 connector on the reference platform and connect it to an available COM port on your PC. The first time you start ServoDesigner, a Connection dialog (shown in Figure 7) appears and presents you with a list of available COM ports on your system. Select the COM port to which you have connected the RS232 cable. Figure 7. The Connection Dialog The Connection dialog also allows you to enable and disable product ID and version checking and status polling. You should have “Product ID and version checking” disabled and “Status polling” enabled! When you click OK in the Connection dialog, your selections are saved so they can be used next time you start the application. (The dialog won’t appear on startup again.) If you want to change your selections later on, you can access the Connection dialog through the Preferences menu. The currently configured COM port is shown on the status bar at the bottom of ServoDesigner’s main display. Step 2. Numeric Format The first time you start ServoDesigner, the Numeric Display Format dialog appears, as shown in Figure 8. This dialog allows you to select either decimal or hexadecimal format for numeric display. Click the blue button to switch between hexadecimal and decimal. When you click OK, your setting is saved so it can be used next time you run ServoDesigner. (The dialog won’t appear on startup again.) If you want to change the setting later on, you can access the Numeric Display Format dialog through the Preferences menu. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 11 REFERENCE DESIGN IRMCS2011 Figure 8. The Numeric Display Format Dialog Note: Regardless of which display option you choose, you can always enter values in decimal or hexadecimal. ServoDesigner interprets a value you enter as hexadecimal if it begins with “0x” (0x222), and otherwise as decimal (222). This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 12 REFERENCE DESIGN IRMCS2011 6. Running the System 6.1 Power-On Apply AC 115V – AC 230V power to the system. Immediately after power-on, the red LED (surface mount LED located at the right side of the board) will lit on/off indicating the on-board DC bus has been established. 6.2 Running motor with ServoDesigner Step 1. Opening the Configuration File You need to open a configuration file. The configuration file contains the register, functional and monitor definitions that make up ServoDesigner’s tree view. To start, you should open one of the default files that are shipped with the release. Later, when you’ve modified the register values, function definitions and/or tunable parameters, you’ll want to save your custom configuration in another file. A default configuration file for each supported motor is shipped with the release. The file names include the part number of your product and the part number of the motor, with the file extension “.irc”. For example, one of the configuration files for the IRMCS2011 product is named “IRMCK201-GMB2010-17-E.irc”. The files are located in the iMOTION\ServoDesigner directory. To open a configuration file, select Open from the File menu or click the toolbar button that shows an open folder. Browse for the file you want and click OK. An example is shown in Figure 9. Figure 9. Open a Configuration File Note: Configuration files are saved in text format, but you should not edit the files manually. If you need to make changes to a configuration file, open the file in ServoDesigner, make the changes as described later in this document, and then save the changes by selecting Save or Save As… from the File menu. Step 2. Checking Communication Status Until you open a configuration file, the COM port status at the bottom of ServoDesigner’s main display shows “Inactive”. When you open a file, ServoDesigner attempts to establish contact with the IRMCS2011 by executing a read operation. If ServoDesigner receives a reply to its request, the COM port status shows “Up.” If no reply is received, the status changes to “Down.” A “Down” status usually means the reference platform is not powered on, the RS232 cable is not connected, or the cable is connected to the wrong COM port. Figure 10 shows how communication status should appear before you continue your testing . This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 13 REFERENCE DESIGN IRMCS2011 Figure 10. Communication Status Indicator Note: If you disable status polling in the Connection dialog, ServoDesigner does not attempt to establish contact with the reference platform, and the COM port status shows “Inactive” even after you open a configuration file. Step 3. Motor Configuration The Configure Motor function is one of the pre-defined operations in ServoDesigner’s Function Definitions section. This function initializes the host registers for normal operation. If you click the Configure Motor entry in the tree view, a list of the registers that are written when this operation is executed is displayed in the right pane of the main window. The “Value to Write” column shows the value that will be written to each register. You can click the “+” symbol to the left of the Configure Motor function to access detailed information about each of the registers. To execute the Configure Motor function, click the Configure Motor toolbar button (the icon shows a hammer and wrench) or double-click on the Configure Motor entry in the tree view. Once this function is executed correctly, the LED will turn to blinking green. Step 4. Starting Angle For induction motor operation, skip this step. This function reads the Hall A, B, C inputs and uses the motor magnet position data read from your configuration file to determine the starting position of the motor. (See “ServoDesinger User’s Guide” for more information about motor configuration parameters.) To execute the function, click the Starting Angle toolbar button (the icon shows the characters “ABC”) or double-click the Starting Angle entry in the tree view. Step 5. Running the Motor Start Motor and Stop Motor functions are also pre-defined Function Definitions. To start the motor, click the Start Motor toolbar button (the green traffic signal) or double-click the Start Motor entry in the tree view. To stop the motor, click the Stop Motor toolbar button (the red traffic signal) or double-click the Stop Motor entry in the tree view. When the motor is running, the far right hand status bar pane should show drive status “Run” with a green indicator. When the motor is stopped, the drive status should be “Stop” with a yellow indicator. If a drive fault occurs, the status changes to “Fault” with a red indicator. The status is “Inactive” (blue indicator) when the COM port status is “Down” or “Inactive.” Step 6. Reference Speed ServoDesigner provides a special built-in function that allows you to easily control the motor’s reference speed and direction. To modify the settings, see Figure 11. First, locate the Reference Speed entry in the Function Definitions section of the tree view. Right-click on the entry and select Properties. In the Properties dialog, you can enter the desired speed in RPM and the direction (forward or reverse). In the dialog, you can also specify the host register to which the speed/direction setting is written. You should not modify this setting unless you redefine the host register map. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 14 REFERENCE DESIGN IRMCS2011 After entering a speed and selecting forward or reverse, click OK in the dialog and then double-click the Reference Speed entry in the tree view to execute the operation. ServoDesigner calculates the appropriate value to be written the host register (based on your specified speed and direction) and performs the write operation. Figure 11. Setup for Reference Speed Function Step 7. Drive Status The Info button on the toolbar (letter “i”) executes the pre-defined Drive Status function, which reads a group of host registers associated with the function. To get drive status, click the Info button or double-click the Drive Status entry in the tree view. After you’ve executed the function, click on Drive Status in the tree view (if it’s not already selected). In the right pane of the main window, the values read from the Drive Status registers are shown in the Current Value column. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 15 REFERENCE DESIGN IRMCS2011 7. Motion Control Engine 7.1 Motion Control Engine (MCE) Based Complete Servo Control Figure 12 shows the detailed algorithm block diagram including various parameters which can be configured through the host register interface. Closed loop current and velocity control are implemented in the IRMCK201 IC on the IRMCS2011 board. The closed loop current control algorithm is based on a synchronously rotating frame. The velocity control is available as an outer loop control of the current control and can be disabled in order to configure torque control mode. Additional configuration allows feedforward control, selection of the position feedback devices, induction machine vector control, and selection of communication protocol. Closed Loop Velocity Control, Sequencing Control Update Rate = PWM carrier frequency / 2 2 Closed Loop Current Control Update Rate = PWM carrier frequency x1 or x 2 MUX EXT_REF A/D interface DCV_FDBK Feedforward path enable VQLIM+ SPDKI Velocity Control Enable SPDKP Reference Select START STOP DIR FLTCLR SYNC Sequence Control FAULT PWM ACTIVE + RAMP - IQLIMAccel Rate + RS232C/ RS422 Interface RTS CTS jθ e VD PI 6 VQS Space Vector PWM VDS Dead time Slip gain 4096 I2 I3 I1 I1 x I2 I3 SPI Slave Interface SDI CS Host Register Interface 17 Parallel Interface IQ Monitoring Registers PWMmode 2Pen Dtime PWMen AngleScale MaxEncCount VDLIM+ Slip gain enable SpdScale + dt O InitZval 3 + Quadrature Decoding ID 3 IQ scale 4096 I2 I3 O O I2 I1 x I2 I3 I1 I1 x I2 I1 I3 I3 ID scale 2 Gate Signals FAULT 0 SCK SDO Serial EEPROM VQ VDLIM- Configuration Registers BRAKE - Decel Rate RCV SND Data Address Control IDREF IQLIM+ + + PI - Optional CurrentSense GSenseL GSenseU ModScl CURKP + PI 8 channel Serial A/D Interface 2 DC bus dynamic brake control VQLIMCURKI IQREF INT_REF CNVST CLK DATA EncType InitZ Optional CurrentSense jθ e 2/3 Encoder A/B/Z Encoder Hall A/B/C Zpol IV IR2175 interface Motor Phase Current V IW IR2175 interface Motor Phase Current W 4096 I2C EEPROM Interface Current Offset W Current Offset V Communication Modules Figure 12. IRMCK201 Based Complete Servo Control This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 16 REFERENCE DESIGN IRMCS2011 8. New Motor Adaptation New motor can be configured by simple EXCEL spreadsheet. EXCEL spreadsheet template is provided in the shipment with the filename “IRMCx201-DriveParams.xls”. This spreadsheet facilitates configuration of parameters which need to go into each host registers inside of the IRMCK201 IC. The spreadsheet calculates current feedback/speed feedback scaling, Proportional plus Integral (PI) gains of current and speed regulators, PWM carrier frequency, deadtime, etc, based on simple motor nameplate and published data input. The output of this spreadsheet is text file containing one-to-one corresponding each registers’ values. User can use the ServoDesignerTM to read this output into the associated registers. For detailed operation, please refer to “3.1 Drive Parameter Setup” in IRMCK201 Application Developer’s Guide. 1 Motor Selection : (Type the number here!) P30B06040DXS00M password : 201 "=================== Motor Information (RPM) Rated Speed (Lq) L_phase (R_Stator) R_phase (Amps) Rated Amps (NLC)No Load Current (Jm) Inertia of Motor (Kt) Torque Constant (Ke) Voltage Constant Poles (PPR) Encoder PPR Wire-Saving Encoder? =========================" 3000 rpm 0.00644 H 1.4 ohms/ph 2.7 Arms 0 Arms 2.55E-05 Kg-m2 0.533 N-m/Arms 18.6 V ln-rms/krpm 8 2000 pulse/revolution TRUE ( TRUE / FALSE ) "================== Application Information (line to line Inductance) / 2 (line to line Resistor) / 2 (necessary for IM) voltage is line to neutral rms ======================" "-------------------------- General ---------------------------" Max RPM (Vdc_Nom) Nominal Vdc (OvLoad) Max pu motor current at rated speed 4500 rpm 310 Volts 3 pu "--------------- Speed Regulator Tuning Speed Regulator BW Positive Speed Rate limit Negative Speed Rate limit Inertia of Load (measured) SpdLpRate 200 rad/sec 1000 rpm/sec 1000 sec to rate speed 0 Kg-m2 2 1 SpdLoop per this # of CurLoop "--------------------- Current Limits Motoring Limit ---------------" ----------------------" 200 % This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 17 REFERENCE DESIGN IRMCS2011 200 % Regen Limit "---------- Inverter Switching Frequency (fc) Pwm carrier freq Dead_Time " ------------ Current Regulator Tuning (Ireg_BW) Current Reg BW -------------" 10 KHz 0.5 usec --------------- " 2500 rad/sec "============== Advance Information (Platform fixed) ===============" Note: Below values are fixed for IRMCS2011 platform however can be changed for other platform (Clk) IRMCK201 clock freq DC Bus Scaling (Vdc_Scl) I_Torque (I_Trq_Rated) (Mod_Pk) - U_Alpha U_Beta max linear modulation 33.333 MHz 8.1875 cts/Volt 4095 cts for rated Amps 2355 Cts " ---------- Desired Speed feedback Scaling (Spd_Scale) 16384 cts/(Max RPM) " -------------- Current Feedback Scaling Current Shunt Resistor Max H/W Current ---------" -------------" "================== Commutation Information Angle of Z-pulse (based on UV line to line voltage) Mid Angle when Hall CBA is 001 Mid Angle when Hall CBA is 010 Mid Angle when Hall CBA is 011 Mid Angle when Hall CBA is 100 Mid Angle when Hall CBA is 101 Mid Angle when Hall CBA is 110 10 mOhm 26 Apeak ====================" 272 degree 120 degree 240 degree 180 degree 0 degree 60 degree 300 degree Figure 13. EXCEL Spreadsheet Inputs This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 18 REFERENCE DESIGN IRMCS2011 9. Appendix 9.1 External I/O Connect External I/O Connector (J7) as needed. All inputs are 5V tolerant and high true logic. User supplied power supply -10V +10V Pin definition Pin 1: Analog input (+/-10V) Pin 2: Analog GND Pin 3: N/A (open) Pin 4: N/A (open) Pin 5: N/A (open) Pin 6: Digital GND Pin 7: FAULT status output (3.3V when FAULT) Pin 8: SYNC status output (3usec width of active low pulse at every carrier frequency period) Pin 9: PWMACTIVE output (3.3V when PWM active) Pin 10: +5V Pin 11: START input (high to activate) Pin 12: STOP input (high to activate) Pin 13: Ifb offset calibration input (high to activate) Pin 14: Fault Clear input (high to activate) Pin 15: N/A (open) Pin 16: Digital GND GND 10k ohm potentiometer J7 Top View 1 GND 2 GND START 5V STOP FLTCLR 15 GND 16 IFBCAL Figure 14. External I/O Connector, J7 9.2 RS232C Connector IRMCS2011 has one serial RS232C connector (J6) on the board. The connector is D-sub 9 pin standard PC female connector and directly connectable to PC serial port. As shown in Figure 15, pin 2 is send-signal and pin 3 is receive-signal, and both are 10V signal level. The baud rate is fixed at 57.6 kbps. The signal format is 8 bits, no parity, 1 stop bit. RS232 Interface J6 1 2 3 4 5 6 7 8 9 TX1 RX1 No connection DB9RF Figure 15. RS232C Connector, J6 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 19 REFERENCE DESIGN IRMCS2011 9.3 Parallel Interface Port IRMCS2011 provides an 8bit parallel interface port to facilitate microprocessor interface. Interface is generic and able to interface most common 8bit parallel interface such as MCS8051, some Motorola 8bit uP, MicroChip, etc. Figure 16 shows the connection diagram. The connector, J5, is a 2-by-10 header connector pins. Each signal is 3.3V level and data bus is multiplexed. Table 2 summarizes each signal definition. +3.3V_BB Parallel Port J5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 HP_Data0 HP_Data1 HP_Data2 HP_Data3 HP_Data4 HP_Data5 HP_Data6 HP_Data7 NA NA NA NA HP_nCS HP_nWE HP_nOE HP_A HDR2X10 Figure 16. Parallel Interface Port, J9 Signal I/O1 HP_nCS HP_nOE HP_nWE HP_A HP_Data I Active low Host Port Chip Select I Active Low Host Port Output Enable I Active low Host Port Write Enable I Host Port Register Address. 1 = Address register, 0 = Data Register I/O Bidirectional Host Port data bus Table 2. Microprocessor Interface Module Signal Definitions Description Figure 17 and Figure 18 show detailed timing requirements for register read and write operations depending on the type of microprocessor (Intel or Motorola type). All values are in nanoseconds. The data bus output is activated by the logical combination (!nCS && !nOE && new), which allows read and write operations to be either nWe/nOE (Intel) or nCS (Motorola) driven. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 20 REFERENCE DESIGN IRMCS2011 Row 1 2 3 4 5 6 7 C C C C C D D Name TsuADDR TsuData Tpw_nCSnWE ThData ThAddr Tacc ThData Min 10 0 60 60 Max 0 0 35 35 Comment HP_A to HPnCS or HP_nWE (which ever occurs last) low setup time HP_D to HPnCS or HP_nWE (which ever occurs last) low setup time Minimum pulswidth for nCS and nWE Minimum data hold time from HP_nWE or HPnCS (whichever occurs last) low Minimum address hold time from HP_nWE or HPnCS (whichever occurs last) low HP_nCS or HP_nOE (whichever occurs last) to Data access time HP_nCS or HP_nOE (whichever occurs last) to Data invalid/Hi- TsuADDR ThAddr HP_A TsuData Tpw_nCSnWE ThData HP_nCS HP_nWE HP_nOE Tacc ThData HP_DATA Figure 17. Register Write/Read Timing (Intel) This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 21 REFERENCE DESIGN IRMCS2011 Row 1 2 3 4 5 6 7 C C C C C D D Name TsuADDR TsuData Tpw_nCSnWE ThData ThAddr Tacc ThData Min 10 0 60 60 Max 0 0 35 35 Comment HP_A to HPnCS low setup time HP_D to HPnCS low setup time Minimum pulswidth for nCS Minimum data hold time from HPnCS low Minimum address hold time from HPnCS low HP_nCS to Data access time HP_nCS to Data invalid/Hi-Z TsuADDR ThAddr HP_A TsuData Tpw_nCSnWE ThData HP_nCS HP_nWE HP_nOE Tacc ThData HP_DATA Figure 18. Register Write/Read Timing (Motorola) This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 22 REFERENCE DESIGN IRMCS2011 10. Specifications TC=25°C unless specified Parameters Input Power Voltage Frequency Input current Input line impedance Output Power Watt Current Host interface (SPI) SCLK,CS,MISO,MOSI, SYNC Host interface (RS232C/422) Tx, Rx Host interface (Parallel Port) HP_nCS, HP_nOE, HP_nWE, HP_A, HP_DATA[8] D/A 8 bit 4 Channel A/D 12 bit 2 channel Discrete I/O Input Output Current feedback Current sensing device Resolution Latency Protection Output current trip level Ground fault trip level Over-temperature trip level Short circuit delay time DC bus voltage Maximum DC bus voltage Minimum DC bus voltage Encoder Interface Incremental encoder Hall A/B/C initialization Power Module IRAMX16UP60A 3-phase HVIC System environment Ambient temperature Values Conditions 115V-230Vrms, -20%, +10% 50/60 Hz 7A rms @nominal output 4%∼8% recommended TA=40°C, RthSA=1.0 °C/W 750W continuous power 5.0 Arms nominal, 15 Arms Overload Vin=230V AC, fPWM=10kHz, fO=60Hz, TA=40°C, RthSA=1.0 °C/W ZthSA limits ∆TC to 10°C during overload 3.3V logic level Isolated, maximum 6MHz 10V Maximum 57.6k bps, single ended, configurable for RS422 up to 1Mbps 3.3V 8 bit parallel interface compatible with 8051, MicroChip, other µP. 0-3.3V output Output is buffered with 4mA drive capability ±10V for reference input, 5V for DC bus input 4 bit, START, STOP, FLTCLR, IFBCAL 3 bit, PWMACTIVE, FAULT, SYNC IR2175, direct interface 10 bit (7.5 nanoseconds counting resolution) 8.3 usec 5V tolerant, Isolated, Active High logic 133 MHz internal IRMCK201 clock IR2175 PWM output (130 kHz) 35A peak, ±10% 35A peak, ±10% 110°C, ±5% 2.5 µsec Case temperature line-to-line short, line-to-DC bus (-) short 400V 120V Should not exceed 400V for > 30 sec VCC=15V ± 10%, VDD=5V ± 5% Maximum 2 MHz All differential signals are converted to single ended signals including index pulse Programmable wire saving/dedicated A/B/C 6 IGBT/FRED + IR2136 gate driver, integrated overtemp protection Bootstrap power supply for high side circuit 0 to 40°C 95%RH max. (non-condensing) Table 3. IRMCS2011 Electrical Specification This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 23 REFERENCE DESIGN IRMCS2011 IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105 http://www.irf.com Data and specifications subject to change without notice. Sales Offices, Agents and Distributors in Major Cities Throughout the World. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 24