Data Sheet No. PD60362 IRMCS1071 Sensorless Motor Drive Platform for Appliance Based on iMOTIONTM Chipset Features Product Summary IRMCK171 - iMOTIONTM digital control IC - based system MCETM (Motion Control Engine) - high efficiency sinusoidal sensorless control of Permanent Magnet motors Supports both interior and surface permanent magnet motor sensorless control Single shunt current feedback reconstruction No external current or voltage sensing OP amp circuit required 230V/250W output power with IRAM336-025SB, TM iMOTION Integrated Power Module Bootstrap diode included in IRAM336-025SB Continuous output current Loss minimization Space Vector PWM Two-channel analog output (PWM) Embedded 8-bit high speed microcontroller (8051) for flexible I/O and man-machine interface Isolated JTAG programming port for emulation/debugger I2C serial interface RS232C baud rate (typ.) 0.6 Arms* Maximum output current 0.9 Apeak** Maximum Internal clock 128 MHz Sensorless control computation time 48 µsec max MCE program RAM 12K bytes Data RAM Program OTP 2K bytes 20K bytes min A/D input channels 5 A/D converter resolution 12 bits A/D converter conversion speed 2 µsec Analog output (D/A) resolution 8 bits 57.6K bps * Upgradeable to higher current with larger heat sink ** Limited by current feedback gain resistor values. MCE DesignerTM tool for easy operation Flexible drive configuration RS232 interface Over-current fault protection Over-voltage / Under-voltage protection Zero Vector Braking control EMI Filter included Description IRMCS1071 is a reference design for IRMCK171, which is a high performance motion control IC designed primarily for appliance applications. It’s mainly aimed to achieve simple, low cost and high performance solutions for advanced appliance motor control. The system contains an integrated power module, IRAM336-025SB, which is also a part of iMOTIONTM chipset. The user can readily evaluate high performance sensorless control with MCEDesignerTM software without spending development effort usually required in the traditional DSP or microcontroller based system. The complete B/Ms, schematics and layout are provided so that the user can adapt and tailor the design per application needs. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. IRMCS1071 Table of Contents Overview........................................................................................................................................................... 3 Safety Precautions........................................................................................................................................ 4 Debris When Unpacking ............................................................................................................................... 6 Hardware Description ....................................................................................................................................... 7 PCB............................................................................................................................................................... 7 Isolation Boundary ........................................................................................................................................ 7 Power ........................................................................................................................................................ 7 Crystal ....................................................................................................................................................... 8 Reset Circuit .............................................................................................................................................. 8 EEPROM ................................................................................................................................................... 8 Digital I/O................................................................................................................................................... 8 Analog Input .............................................................................................................................................. 8 Single Shunt Current Feedback ................................................................................................................ 8 Socket........................................................................................................................................................ 8 IRAM.......................................................................................................................................................... 8 Power Supply ............................................................................................................................................ 8 EMI Filter ................................................................................................................................................... 8 DC Bus Capacitor...................................................................................................................................... 8 System Installation and Operation ................................................................................................................... 9 Specifications.................................................................................................................................................. 10 List of Figures Figure 1 Typical Application Block Diagram Using IRMCK171........................................................................ 3 Figure 2 Top View of IRMCS1071.................................................................................................................... 7 List of Tables Table 1 IRMCS1071 Electrical Specification .............................................................................................. 10 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 2 IRMCS1071 Overview IRMCS1071 is a reference design platform for inverter-controlled appliance motor drive applications based on iMOTIONTM chipset. It contains IRMCK171 digital motion control IC, and IRAM336-025SB, integrated power module. IRMCK171 is International Rectifier’s new integrated circuit device primarily designed as a one-chip solution for sensorless permanent magnet motor control in appliance applications. Unlike a traditional microcontroller or DSP, IRMCK171 provides a built-in closed loop sensorless control algorithm using a unique Motion Control Engine (MCETM) for surface/interior permanent magnet motors with sinusoidal back EMF. IRMCK171 also employs a unique single shunt current reconstruction circuit to eliminate additional analog/digital circuitry and enables a direct shunt resistor interface to the IC. The MCETM consists of a collection of control elements, motion peripherals, a dedicated motion control sequencer and dual port RAM to map internal signal nodes. Motion control programming is achieved by using a dedicated graphical compiler integrated into the MATLAB/SimulinkTM development environment. Sequencing, user interface, host communication, and upper layer control tasks can be implemented in the 8051 high-speed 8-bit microcontroller. The 8051 microcontroller is equipped with a JTAG port to facilitate emulation and debugging tools. Figure 1 shows a typical application schematic using the IRMCK171. IRMCK171 has 32K bytes of program OTP and 12K of program RAM. At power up, 12K of the program stored in OTP is copied to RAM for high speed execution by the MCE processor. The 8051 program is executed directly form OTP by the 8051 processor. The IC on the reference board comes with preprogrammed OTP. Both 8051 application program and MCE firmware is ready for execution. IRMCK171 comes in a 48-pin QFP package. IRAM336-025SB is an integrated power module developed and optimized for appliance motor control. Together with IRMCK171 it offers highly integrated solution for single shunt PM motor control. The module has several built-in protection features such as temperature feedback, shoot through prevention, under voltage lockout and shutdown. Furthermore, the module features a combination of highly efficient high voltage MOSFETs and the industry benchmark 3-phase HVIC driver. The bootstrapped power supplies for the high side drivers can be generated using internal bootstrap diodes eliminating the need for isolated power supplies. Appliance Inverter Passive EMI Filter HVIC Gate Drive & Protection Circuit Switch Mode Power Supply Motor (PMSM or IM) IRMCK171 3.3V 5 Analog Input Up to 12 Digital Input/Output I2C Interface UART interface Figure 1 Typical Application Block Diagram Using IRMCK171 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 3 IRMCS1071 Safety Precautions In addition to the precautions listed throughout this manual, please read and understand the following statements regarding hazards associated with development system. ! ! ! ATTENTION: The ground potential of the IRMCS1071 system is biased to a negative DC bus voltage potential. 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 LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: IRMCS1071 system contains dc bus capacitors which take time to discharge after removal of main supply. Before working on drive system, wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs 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. 4 IRMCS1071 ! ! ! ! ! ATTENTION: IRMCS1071 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 under sizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction. 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: Do not connect power factor correction capacitors to drive output terminals U, V, and W. Doing so may result in equipment damage or bodily injury. ATTENTION: IRMCS1071 system includes a field-weakening control function. However, if a drive trip occurs in field-weakening operation, excessive DC bus overvoltage will result. Users should take the necessary precautions to protect against DC bus over-voltage. 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. 5 IRMCS1071 Debris When Unpacking IRMCS1071 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. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 6 IRMCS1071 Hardware Description A top view of IRMCS1071 is shown in Figure 2. RS232 Connector JTAG Connector Power Supply Isolation Boundary Magnetic Isolator Diode Bridge Rectifier Reset Switch Digital I/O IRMCK171 IC with socket EMI Filter IRAM Powermodule NTC Power LED Earth Ground DC Bus Capacitor Figure 2 Top View of IRMCS1071 PCB The printed circuit board has two electrical layers and its size is 4.5 x 5 inches. Isolation Boundary Note that there are two different grounds on this system. The RS232 connector and JTAG connector are isolated by magnetic isolators so that the user can connect their debugger and computer without isolating the computer. However, the user should keep in mind that most parts of the hardware have negative DC bus ground and it is necessary to isolate the scope when waveforms are measured. Power IRMCK171 requires only a 3.3V power supply. Internally, the controller creates a 1.8V and a 1.2V required for the ADC. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 7 IRMCS1071 Crystal A 4 MHz crystal is used to generate the system clock. Actual system frequency is adjustable by changing Phase Locked Loop configuration through Special Function Registers. For more information regarding the clock, please refer to the IRMCK171/IRMCK143 Reference Manual. Reset Circuit IRMCK171 doesn’t require external RC circuit for reset. The reset switch can be used to initialize the JTAG debugger. For more information regarding reset, please refer to the IRMCK171/IRMCK143 Reference Manual. EEPROM The board is equipped by an EEPROM. With the provided setup the EEPROM is not used but it provides the user with the option of storing drive parameters etc. Digital I/O Only some of the digital I/O’s are used in IRMCS1071. However, all general purpose I/O’s are connected to a header (J2). In addition, a number of test points have been added for easy debug of the system. Analog Input Analog channels are connected to test points for ease of use. Single Shunt Current Feedback IRMCK171 contains an high speed Operational Amplifier for single shunt current reconstruction. Resistors and capacitors for amplifier circuit are placed very close to the pins. Note that there is a separate trace from shunt resistor instead of sharing a plane with negative DC bus ground to get better current feedback. Socket The control IC is mounted in a 48 pin socket to make replacement easy. If the user wishes to update the IC’s software, e.g. when updating the 8051 program, replacement can be done without soldering. IRAM IRAM336-025SB in mounted on a heat sink. Voltage across a 500 mΩ shunt is fed to ‘Itrip’ pin of IR2136 high voltage gate driver IC through low pass filter with 400 nsec time constant to initiate the over-current shutdown (Gatekill). For more information regarding IRAM, please refer to IRAM datasheet. Power Supply Switch mode power supply operates at about 80 kHz and generates 15V(VCC), 3.3V and isolated 5V. 6.5V (VPP) is generated from 15V by a linear regulator. EMI Filter Passive EMI filter on the board consists of two 0.1 µF X-caps and two 2.2 nF Y-caps and a 1 mH common mode inductor. DC Bus Capacitor A 100 µF, 400 V, 85°C electrolytic capacitor is used to supply instantaneous power to the IRAM. IRMCS1071 does not have a dynamic braking unit. In case of field weakening operation, it is recommended to use an external regenerative unit or a braking unit for safety. GND and DCP can be used for connecting an external unit. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 8 IRMCS1071 System Installation and Operation For information regarding hardware/software installation and operation, please refer to the IRMCS1071 Quick Start Guide. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 9 IRMCS1071 Specifications TC = 25°C unless specified Parameters Input Power Voltage Frequency Input current Input line impedance Output Power Watts Current Host interface (RS232C) TXD, RXD JTAG interface TMS, TDI, TCK, TDO D/A 8- bit 2 Channel A/D 12-bit DC bus voltage Maximum DC bus voltage Minimum DC bus voltage Current feedback Current sensing device Resolution Latency Protection Output current trip level Short circuit delay time Critical over voltage trip Over voltage trip Under voltage trip Power Device IRAM336-025SB System environment Ambient temperature Values 115V-230Vrms, -20%, +10% 50/60 Hz 2A rms @nominal output 4%∼8% recommended 200W continuous power 0.6 ARMS nominal Conditions TA =40°C, RthSA=1.0 °C/W Vin=230V AC, fPWM=10kHz, fO=60Hz, TA=40°C, RthSA=1.0 °C/W, Vertically mounted to help air flow RthSA limits ∆TC to 10°C during overload 10V Typical 57.6 Kbps, single ended 3.3V Interface with FS2 debugger 0-3.3V output 8051 software needs modification to use it. 0 – 1.2V DC bus, single shunt current, AIN1-AIN4 400V Should not exceed 400V more than 30 sec 120V Single shunt reconstruction 12-bit 1 pwm cycle 1.2A peak, typical Maximum 5 µsec 380V 360V 120V PCB design may reduce the resolution Detection from shunt on negative DC bus line-to-line short, line-to-DC bus (-) short Re-scalable Re-scalable Re-scalable 6 MOSFET + IR2136 gate driver +3 bootstrap diode + NTC 0 to 40°C 95% RH max. (Non-condensing) Table 1 IRMCS1071 Electrical Specification This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 10 IRMCS1071 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. 11