UM1823 User manual 1 kW three-phase motor control evaluation board featuring L6390 drivers and STGP10H60DF IGBT Introduction This document describes the 1 kW three-phase motor control evaluation board featuring the L6390 high and low-side drivers and the STGP10H60DF IGBT. The evaluation board is an AC/DC inverter that generates a three-phase waveform for driving three or two-phase motors such as induction motors or PMSM motors up to 1000 W with or without sensors. The main device presented in this user manual is a universal, fully evaluated, and populated design consisting of a three-phase inverter bridge based on the 600 V STMicroelectronics™ IGBT STGP10H60DF in a TO-220 package mounted on a heatsink, and the L6390 highvoltage high-side and low-side driver featuring an integrated comparator for hardware protection features such as overcurrent and overtemperature. The driver also integrates an operational amplifier suitable for advanced current sensing. Thanks to this advanced characteristic, the system has been specifically designed to achieve an accurate and fast conditioning of the current feedback, therefore matching the typical requirements in field oriented control (FOC). The board has been designed to be compatible with single-phase mains, supplying from 90 VAC to 285 VAC or from 125 VDC to 400 VDC for DC voltage. With reconfiguration of the input sourcing, the board is suitable also for low-voltage DC applications up to 35 VDC. This document is associated with the release of the STEVAL-IHM023V3 evaluation board. Figure 1. STEVAL-IHM023V3 evaluation board December 2014 DocID026975 Rev 1 1/49 www.st.com 49 Contents UM1823 Contents 1 2 3 System introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 Target applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 Safety and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.1 General terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.2 evaluation board intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.3 evaluation board installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3.5 evaluation board operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2 The board schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3 Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.3.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.3.2 Inrush limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3.3 Brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3.4 Gate driving circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.3.5 Overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.3.6 Current sensing amplifying network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.3.7 The tachometer and Hall/encoder inputs . . . . . . . . . . . . . . . . . . . . . . . . 23 2.3.8 Temperature feedback and overtemperature protection . . . . . . . . . . . . 23 Hardware setting of the STEVAL-IHM023V3 . . . . . . . . . . . . . . . . . . . . . 24 3.1 Hardware settings for six-step (block commutation) control of BLDC motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.2 Hardware settings for “Field Oriented Control” (FOC) in single-shunt topology current reading configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.3 Hardware settings for FOC in three-shunt configuration . . . . . . . . . . . . . 27 4 Description of jumpers, test pins, and connectors . . . . . . . . . . . . . . . 30 5 Connector placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2/49 DocID026975 Rev 1 UM1823 Contents 6 Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 9 Using STEVAL-IHM023V3 with STM32 PMSM FOC SDK . . . . . . . . . . . 44 9.1 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 9.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 9.3 Software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 9.4 STM32 FOC firmware library customization . . . . . . . . . . . . . . . . . . . . . . . 45 10 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 11 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 12 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DocID026975 Rev 1 3/49 49 List of figures UM1823 List of figures Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. 4/49 STEVAL-IHM023V3 evaluation board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Motor control system architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STEVAL- IHM023V3 schematic - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STEVAL- IHM023V3 schematic - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STEVAL- IHM023V3 schematic - part 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 STEVAL- IHM023V3 schematic - part 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 STEVAL- IHM023V3 schematic - part 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 STEVAL- IHM023V3 schematic - part 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power supply block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Gate driving network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Three-shunt configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Six-step current sensing configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 NTC placement on the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEVAL-IHM023V3 connectors placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Silk screen - top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Silk screen - bottom side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Copper tracks - top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Copper tracks - bottom side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DocID026975 Rev 1 UM1823 List of tables List of tables Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8. Table 9. Table 10. Table 11. Table 12. Table 13. Current reading configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Jumper settings for high-voltage BLDC motor in six-step control . . . . . . . . . . . . . . . . . . . . 24 Jumper settings for low-voltage BLDC motor in six-step control . . . . . . . . . . . . . . . . . . . . 25 Jumper settings for high-voltage PMAC or generic AC motor in single-shunt FOC control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Jumper settings for low-voltage BLDC motor in single-shunt FOC control. . . . . . . . . . . . . 27 Jumper settings for FOC of HV PMSM, BLDC, or AC IM in three-shunt configuration for current reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jumper settings for FOC of LV PMSM or BLDC in three-shunt configuration for current reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Jumpers description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Connector pinout description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Testing pins description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 STEVAL-IHM023V3 motor control workbench parameters . . . . . . . . . . . . . . . . . . . . . . . . 45 Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DocID026975 Rev 1 5/49 49 System introduction UM1823 1 System introduction 1.1 Main characteristics The information below lists the converter specification data and the main parameters set for the STEVAL-IHM023V3 evaluation board. 1.2 6/49 • Minimum input voltage 125 VDC or 90 VAC • Maximum input voltage 400 VDC or 285 VAC • With applied input voltage doubler - the range is from 65 VAC to 145 VAC • Voltage range for low-voltage motor control applications from 18 VDC to 35 VDC • Possibility to use auxiliary +15 V supply voltage • Maximum output power for motors up to 1000 W • Regenerative brake control feature • Input inrush limitation with bypassing relay • + 15 V auxiliary power supply based on buck converter with VIPer™16 • IGBT power switch STGP10H60DF in TO-220 package - compatible with other ST IGBTs or power MOSFETs in TO-220 package • Fully populated board conception with testing points and isolated plastic safety cover • Motor control connector for interface with ST motor control dedicated kits • Tachometer input • Hall/encoder inputs • Possibility to connect BEMF daughterboard for sensorless six-step control of BLDC motors • PCB type and size: – Material of PCB - FR-4 – Double-sided layout – Copper thickness: 60 µm – Total dimensions of evaluation board: 127 mm x 180 mm. Target applications • Washing machines • Home appliances • Medical applications - rehabilitative beds • High-power, high-efficiency water pumps for heating applications. DocID026975 Rev 1 UM1823 System introduction 1.3 Safety and operating instructions 1.3.1 General terms Warning: During assembly, testing, and operation, the evaluation board poses several inherent hazards, including bare wires, moving or rotating parts, and hot surfaces. There is a danger of serious personal injury and damage to property, if the kit or components are improperly used or installed incorrectly. The kit is not electrically isolated from the AC/DC input. The evaluation board is directly linked to the mains voltage. No insulation has been placed between the accessible parts and the high-voltage. All measurement equipment must be isolated from the mains before powering the board. When using an oscilloscope with the evaluation board, it must be isolated from the AC line. This prevents a shock from occurring as a result of touching any single point in the circuit, but does NOT prevent shocks when touching two or more points in the circuit. Do not touch the evaluation board after disconnection from the voltage supply, as several parts and power terminals, which contain energized capacitors, need to be allowed to discharge. All operations involving transportation, installation and use, as well as maintenance, are to be carried out by skilled technical personnel (national accident prevention rules must be observed). For the purpose of these basic safety instructions, “skilled technical personnel” are suitably qualified people who are familiar with the installation, use and maintenance of powered electronic systems. 1.3.2 evaluation board intended use The STEVAL-IHM023V3 evaluation board is a component designed for evaluation purposes only and is not to be used for electrical installation or machinery. The technical data as well as information concerning the power supply conditions should be taken from the documentation and strictly observed. 1.3.3 evaluation board installation The installation and cooling of the evaluation kit boards must be in accordance with the specifications and the targeted application. • The motor drive converters are protected against excessive strain. In particular, no components are to be bent or isolating distances altered during the course of transportation or handling. • No contact must be made with other electronic components and contacts. • The boards contain electro-statically sensitive components that are prone to damage through improper use. Electrical components must not be mechanically damaged or destroyed. DocID026975 Rev 1 7/49 49 System introduction 1.3.4 UM1823 Electrical connections Applicable national accident prevention rules must be followed when working on the main power supply with a motor drive. The electrical installation must be completed in accordance with the appropriate requirements. 1.3.5 evaluation board operation A system architecture which supplies power to the evaluation board should be equipped with additional control and protective devices in accordance with the applicable safety requirements (e.g. compliance with technical equipment and accident prevention rules). 8/49 DocID026975 Rev 1 UM1823 Board description 2 Board description 2.1 System architecture A generic motor control system can be basically schematized as the arrangement of four main blocks (see Figure 2 below). • A control block - its main task is to accept user commands and motor drive configuration parameters and to provide all digital signals to implement the proper motor driving strategy. An ST evaluation board based on the STM32™ microcontroller can be used as a control block thanks to the motor control connector. • A power block - makes a power conversion from the DC bus transferring to the motor by means of a three-phase inverter topology. The power block is based on high-voltage (high and low-side) drivers (L6390) and power switches (STGP10H60DF) in TO-220 packages. • The motor itself - the STEVAL-IHM023V3 evaluation board is able to properly drive any PMSM, but the FOC itself is conceived for sinusoidal-shaped BEMF. The evaluation board is also suitable for driving any three or two-phase asynchronous motor or low-voltage BLDC motors. • Power supply block - able to work from 90 VAC to 285 VAC or from 125 VDC to 400 VDC. With reconfiguration of the power stage with jumpers, the board can also be used for low-voltage applications from 18 VDC to 35 VDC. By supplying the electronic parts on the board through an external + 15 V connector, the board can be used for a wide voltage range up to 400 VDC. Please refer to Section 3 for detailed settings of the jumpers according to the required application. Figure 2. Motor control system architecture &RQWUROEORFN 02725 3RZHUVXSSO\ 3RZHUEORFN $09 Referring to the above motor control system architecture, the STEVAL-IHM023V3 includes the power supply and the power block hardware blocks. DocID026975 Rev 1 9/49 49 DocID026975 Rev 1 J4 1 2 3 4 5 vo ltage of f BC847 R2 3 R104 Q1 2 +Bus C7 2 100 nF A B W1 6 1 R114 +15 V 3 2 C7 1 100 nF R113 C3 0 R2 4 R3 1 4 3 R107 1 vo ltage of f R3 4 R33 C2 6 100 nF C2 5 W4 C6 5 100 pF R3 5 +15V Brake control Q5 BC847 R2 8 M_phase_C M_phase_B M_phase_A C7 3 100 nF C7 0 10 pF H1/A + C7 4 10 pF BC847 Q14 C6 9 10 pF R110 R111 U4 2 TS391ILT 5 +15 V Q16 BC847 Q1 7 BC847 Q15 BC847 Software brak e R3 2 R2 5 D2 9 B ZX 84B13V BC847 4.7 nF Q1 3 7 12 13 R117 R116 U11F M74HC14M1R 10 U11E M74HC14M1R 8 U11D M74HC14M1R 6 U11C M74HC14M1R 4 14 11 9 5 3 U11B M74HC14M1R R109 R1 8 Q1 8 BC847 R2 6 R27 D11 R121 D2 8 LED Red D2 6 STTH2L06 R2 9 R Brak e J6 2 1 C2 9 2.2 nF M_ph ase_A AM07502 Q3 STGP10H60DF Q4 BC847 R2 0 Tach o C2 8 100 nF R19 N.C. W7 +Bus D12 R21 C2 4 100 nF R120 5. +15 V C2 7 100 nF R2 2 Tacho sensor Q2 BC857B Brake control R3 0 +15 V Tach o 1 2 J8 Vdd_m icro C75 1nF Vdd_m icro BAT48JFILM R106 220R D2 5 BZX 84B13V R105 +5 V Vdd_micro En coder/hall H1/A+ H2/B+ H3/Z+ + 3.3/5 V GND R112 2 + 1 R115 BAT48JFILM - 10/49 U11A M74HC14M1R 2.2 + Hall/encoder Board description UM1823 The board schematic Figure 3. STEVAL- IHM023V3 schematic - part 1 DocID026975 Rev 1 Viper INPUT 4 3 2 1 J1 1 Source 2 Source 3 Source 4 Source 8 1 2 3 4 D8 STTH1L06A R108 N.C. COMP VDD 5 6 LIM 7 FB /50 V C16 + H D9 BZV55C18SMD L2 C12 C13 47 nF N.C. R10 R9 R6 R3 R1 100 nF /25 V R12 N.C. D6 STTH1L06A C18 C19 + C14 220 nF Vol tage_doubler W14 C5 4.7 nF/Y2 C1 4.7 nF/Y2 Drain1 Drain2 Drain3 Drain4 /450 V + KBU6K D1 R8 U3 VIPer16LD Buck converter VR1 relay_ B 16 15 14 13 C15 L1 C4 150 nF/X 2 F1 FUSE-1 6.25 A TEMP relay_ A + - DC_bus_voltage + + /250 V /250 V +15 V +5 V C3 C2 C9 10 nF C6 100 nF 3 IN GND 1 OUT 2 U1 LD1117S33TR SOT223 R5 D2 BAT48JFILM +3.3 V linear R7 R4 R2 W1 1 C7 100 nF + C8 3 Bus_voltage Vdd_m icro +Bus 2 Input part with bridge AM07503 /6.3 V +3.3 V Vdd_ micro +5 V UM1823 Board description Figure 4. STEVAL- IHM023V3 schematic - part 2 11/49 49 12/49 DocID026975 Rev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oard description UM1823 Figure 5. STEVAL- IHM023V3 schematic - part 3 R4 2 DocID026975 Rev 1 C3 8 10 nF t R4 4 RT 1 Het_temperat ure TP24 TP11 TP10 TP 9 TP 8 TP 7 TP 6 TP 5 TP 4 TP 3 TP 2 TP 1 R4 3 +15 V OCP of f Cu rrent _B Cu rrent _A PW M-C- H PW M-C- L PW M-B- H PW M-B- L PW M-A- H U5 TP21 TP20 TP19 TP18 TP17 TP16 TP15 TP22 TP14 TP23 16 15 14 13 12 11 10 9 R5 1 Vboot HV G OU T NC NC LVG CP + OP + Test pins PW M-A- L phase_C phase_B +5 V Vdd_micro !L IN !S D/OD HIN Vc c DT OP OPOU T GN D C39 100 pF D16 BAT48JFILM R4 6 phase_A C3 7 470 nF Cu rrent_A 1 nF C3 6 1 2 3 4 5 6 7 8 L6390D C3 1 330 pF A R45 R41 R39 R37 R4 9 N.C. ref +15 V +3.3 V Brake con trol Bus_vo ltage M_phase_C M_phase_B M_phase_A Cu rrent _C C41 33 pF R5 2 C3 2 C3 3 BAT48JFILM +3.3 V !S D C3 4 C3 5 10 pF 10 pF R40 1 R3 8 1 Heatsink temperature PW M-A- H PW M-A- L R3 6 +3.3 V HV H/L side driver channel ref R5 4 +3.3 V R5 0 R123 3 2 3 3 2 +Bus 3SH 470 pF C5 7 R8 4 4 + 3 - 5 2 C5 6 100 nF Het NTC comparator R56 N.C. W9 Q7 STGP10H60DF 1SH phase_A Q6 STGP10H60DF U9 TS3431BILT R5 5 1 1 2 Het_temperat ure 1 C4 0 2.2 nF R122 R5 R4 D141 N4148 D131 N4148 U8 TS391ILT 1 C_ E AM07505 !S D +3.3 V UM1823 Board description Figure 6. STEVAL- IHM023V3 schematic - part 4 D15 13/49 49 14/49 EM_STOP PW M-B- H PW M-B- L DocID026975 Rev 1 C4 6 10 pF C5 2 330 pF R7 4 C4 5 10 pF R6 1 1 R5 +15 V R6 4 !S D !S D 1 nF C4 7 R7 OCP of f Cu rre nt_B Vdd_m icro 470 nF C4 8 1 2 3 4 5 6 7 8 Vboot HV G OU T NC NC LVG CP + OP + U6 C50 100 pF D20 BAT48JFILM W10G ain_1 1 R69 !L IN !S D/OD HI N Vc c DT OP OPOU T GN D L6390D C4 2 330 pF 16 15 14 13 12 11 10 9 R7 7 B C5 1 33 pF R7 3 N.C. R65 R62 R60 C4 3 C4 4 R58 BAT48JFILM Vdd_micro R6 3 R5 7 +3.3 V HV H/L side driver channel +3.3 V R7 0 R6 D181 N4148 D171 N4148 C4 9 2 nF 2 3 2 3 2 1 3 R7 W11 1 A B R7 1 N.C. 1 1 R6 8 R81 R8 R7 8 3. R76 Q9 STGP10H60DF phase_B Q8 STGP10H60DF +Bus AM07506 +3.3 V C_ E Board description UM1823 Figure 7. STEVAL- IHM023V3 schematic - part 5 D19 PW M-C- H PW M-C- L R8 9 R8 2 R8 7 1 R8 5 1 C5 8 10 pF +3.3 V C5 9 10 pF !S D R9 0 +15 V 1 nF C6 0 DocID026975 Rev 1 OCP of f Cu rrent_C C62 100 pF Vboot HVG OUT NC NC LVG CP + OP+ D24 BAT48JFILM R9 2 !L IN !S D/OD HI N Vc c DT OP OPOU T GN D U7 16 15 14 13 12 11 10 9 R98 1k C C5 4 BAT48JFILM Vdd_ micro R94 1k 470 nF C61 1 2 3 4 5 6 7 8 L6390D C5 3 330 pF HV H/L side driver channel R91 R88 R86 R83 C6 4 33 pF R9 6 N.C. C5 5 R100 +3.3 V R93 1k D2 2 1N4148 D21 1N4148 R9 C6 3 2.2 nF R9 5 1 R101 1 1 3 2 3 2 R102 N.C. W1 3 Q11 STGP10H60DF phase_C Q10 STGP10H60DF +Bus 3SH 1SH AM07507 C_ E UM1823 Board description Figure 8. STEVAL- IHM023V3 schematic - part 6 D23 15/49 49 Board description 2.3 Circuit description 2.3.1 Power supply UM1823 The power supply in the STEVAL-IHM023V3 evaluation board is implemented as a multifunctional block which allows to supply the inverter in all ranges of input voltage up to 285 VAC or 400 VDC. If the input AC voltage does not surpass 145 VAC, it is possible to apply the input voltage doubler, this is done by shorting the W14 jumper. This configuration almost doubles the input AC voltage to a standard level and allows to evaluate the motor control application with a low level of input AC voltage. For high-voltage applications it is necessary to set W3 jumpers to position “HIGH VOLTAGE”, the auxiliary power supply for supplying all active components on the evaluation board is implemented as a buck converter based on the U6 VIPer16L which works with fixed frequency 60 kHz. The output voltage of the converter is +15 VDC voltage which is fed into the L6390 drivers as supply voltage as well as into the linear regulator L78L33ACD and L78M05ACDT. The linear regulator provides +3.3 VDC and +5 VDC for supplying the operational amplifiers and other related parts placed on the evaluation board. The selection of supply voltage for hardware peripherals placed on the board is done with jumper W1. In the “3.3 V” position the supply voltage selected is +3.3 V and in the “5 V” position it is +5 V. Thanks to jumper W6, it is possible to supply the connected MCU driving board with related supply voltage. In this case, the maximal consumptive current of the MCU unit has not overreached 50 mA. Please refer to the ST released VIPer16LD datasheet for further information on this concept. For low-voltage applications, the step-down converter must be disabled by setting the W3 jumper to position “<35 V ONLY”. In this case, the other linear regulator, L7815, is connected directly on the bus line, to provide auxiliary voltage + 15 VDC. Note: Please note that the voltage range in this kind of application must be in the range + 18 VDC to + 35 VDC. For low-voltage DC motor applications which require a voltage lower than + 18 VDC, a dual supply mode can be used. Voltage on the input connector is normally linked through power switches to the motor and an external auxiliary voltage is fed through the J3 connector from an external power source. The voltage of the external power supply used must be in the range + 14.8 V to + 15.5 V with maximal consumption current 0.5 A. The information regarding the value of the supply bus voltage on the main filtering capacitors is sensed with the voltage divider built around R2, R4, and R7 and is fed into the dedicated control unit through the J5 connector. The proper voltage partitioning for applied resistors values is 0.0075. The presence of +15 VDC on the board is indicated with green LED D7. For a better understanding of the concept, Figure 9 describes the power supply in a block diagram. 16/49 DocID026975 Rev 1 UM1823 Board description Figure 9. Power supply block diagram '&%86 0$;9'& 9'& %869'& /LQHDUUHJXODWRU / /LQHDUUHJXODWRU /0 ,1387 %ULGJH UHFWLILHU 9'& 9'& : %XFNFRQYHUWHU 9,3HU/' /LQHDUUHJXODWRU /'6 : 9ROWDJH GRXEOHU $0 2.3.2 Inrush limitation The input stage of the evaluation board is provided with the 10 Ω NTC resistor to eliminate input inrush current peak during charging of the bulk capacitors. To achieve a higher efficiency of the inverter, it is possible to bypass the NTC after the startup phase. The NTC bypass signal is provided from the MCU board through the J5 connector. The yellow D27 LED diode is turned off when the inrush NTC is bypassed. The STEVAL-IHM023V3 evaluation board contains only a basic EMI filter based on X2 and Y2 capacitors. The main function of this evaluation board is as a universal testing platform. For this reason, the EMI filter is not able to absorb EMI distortion coming from the inverter for all ranges of the applications used and the design of the filter is up to the user. The EMI filter must be designed according to the motor and final target applications used. The heatsink itself is connected to the earth pin in the input J1 connector. If the evaluation board is used only with DC voltage, it is recommended to connect the heatsink to a negative voltage potential - common ground. 2.3.3 Brake function The hardware brake feature has been implemented on the STEVAL-IHM023V3 evaluation board. This feature connects the external resistive load applied to the J6 connector to the bus to eliminate overvoltage generated when the motor acts as a generator. Such a connected load must be able to dissipate all motor generated energy. The brake feature functions automatically in the case of bus overvoltage. Voltage on the bus is sensed through the voltage divider with resistors R23, R24, and R31 and compared to the voltage reference built around the Zener diode D26. The brake dummy load is switched on when voltage on the bus reaches 440 VDC and is switched off when the voltage falls below 420 VDC. This voltage level has been chosen to be fully compliant with the possible use of front-end PFC stage. Another possibility, to activate the brake dummy load, is to use the external signal coming through the J5 motor connector (PWM_Brake signal) from the connected MCU board. This function is active with the jumper W5 in position “R_BRAKE”. The brake threshold levels can be modified by calculating R23, R24, and R34 new values. The D28 red LED diode indicates acting brake switch. DocID026975 Rev 1 17/49 49 Board description 2.3.4 UM1823 Gate driving circuit The gates of the switches of the IGBT used are controlled by the L6390D drivers. Please refer to the L6390 datasheet for a detailed analysis of the driver parameters. Figure 10 shows the correct driving of the IGBT. As can be seen, the charging current for the IGBT is different compared to the discharging current due to the diode used. The configuration used provides the best trade-off between efficiency and EMI distortion. Thanks to the high-performance L6390 driver, the deadtime insertion between the HVG and LVG outputs is hardware-guaranteed. In this case, considering the value of the deadtime resistors used to be 47 kΩ, the DT of about 600 ns is applied on the outputs in case: • The deadtime is not present on HIN and LIN inputs signals. • The deadtime present on HIN and LIN inputs is less than hardware-set DT. On the contrary, the hardware-set deadtime is not the sum of the deadtime present on the outputs between LVG and HVG if the deadtime present on the HIN and LIN inputs signals is higher than the hardware-set deadtime. Figure 10. Gate driving network R41 10 Ω R45 120 Ω 2 D14 Q7 1 STGP10H60DF 1N4148 3 2.3.5 AM00472a Overcurrent protection Hardware overcurrent protection (OCP) is implemented on the board. This feature takes full advantage of the L6390 driver where an internal comparator is implemented. Thanks to the internal connection between the comparator output and shutdown block, the intervention time of the overcurrent protection is extremely low, ranging slightly above 200 ns. Please see Figure 11 below for details of the OCP. Considering that the overcurrent protection acts as soon as the voltage on the CP+ pin of the L6390 rises above (approximately equal to) 0.53 V, and considering the default value of the shunt resistor, it follows that the default value for the maximum allowed current is equal to: Equation 1 I SHUNT MAX V REF R1 = ---------------------- × 1 + -------- R SHUNT R2 with the default values this gives: ISHUNT_MAX = 7 A 18/49 DocID026975 Rev 1 UM1823 Board description Figure 11. Overcurrent protection +3.3 V R3 (R49, R73, R96) +5 V R1 (R47, R67, R95) Smart SD COMPARATOR + – VCC OPAMP OPOUT 7 10 CP+ VREF R2 (50, R70, R93) Shunt resistor 9 OP+ + – 6 OP– GND L6390 AM00473 The overcurrent protection can be disabled with software if the W5 jumper is set to the “OCP OFF” position. This may be necessary and is often useful when the user decides to make the brake operate by turning on the three low-side switches. In fact, if the motor acts as a generator, it's necessary to protect the hardware, preventing the bus voltage from exceeding a safety threshold. In addition to dissipating the motor energy on a brake resistor, it's possible to short the motor phases, preventing the motor current from flowing through the bulk capacitors. Please note that with disabling of the OCP, the evaluation board is not protected against any overcurrent event. 2.3.6 Current sensing amplifying network The STEVAL-IHM023V3 motor control evaluation board can be configured to run in various current reading configuration modes: • Three-shunt configuration - suitable for the use of field oriented control (FOC) • Single-shunt configuration - suitable for the use of FOC in a single-shunt configuration • Single-shunt six-step configuration - suitable for scalar control Configuration with a shunt resistor, where voltage amplified with an operational amplifier is sensed, was chosen as the current sensing networks. Single-shunt configuration requires a single op amp, three-shunt configuration requires three op amps. Just for compatibility purposes, one of them is common to both basic configurations. The configuration jumpers W10 and W11 allow the user to set the common op amp to achieve the compatibility between single-shunt six-step configuration (suitable for scalar control) and three-shunt or single-shunt FOC current reading configuration. Three-shunt FOC or single-shunt FOC current reading configuration The details of the three-shunt current sensing reading configuration are shown in Figure 12. In this configuration, the alternating signal on the shunt resistor, with positive and negative DocID026975 Rev 1 19/49 49 Board description UM1823 values, must be converted to be compatible with the single positive input of the microcontroller A/D converter used to read the current value. This means that the op amp must be polarized in order to obtain a voltage on the output that makes it possible to measure the symmetrical alternating input signal. The op amp is used in follower mode with the gain of the op amp set by resistor r and R: Equation 2 R+r G = -----------r It is possible to calculate the voltage on the output of the op amp, OP OUT - VOUT, as the sum of a bias, VBIAS, and a signal, VSIGN, component equal to: Equation 3 V OUT = V SIGN + VBIAS 3.3 V BIAS = --------------------------------------------------------- × G 1 1 1 -------- + -------- + ------ R1 R2 R3- × R3 I × R SHUNT V SIGN = --------------------------------------------------------- × G 1 1 1 ------- + -------- × R1 R1- + ------R2 R3 Total gain of the circuit including the resistors’ divider is equal to: Equation 4 V SIGN V SIGN G TOT = ---------------- = ---------------------------V IN R SHUNT × I with the default values this gives: • VBIAS = 1.7 V • G = 4.3 • GTOT = 1.7 • Maximum current amplifiable without distortion is 6.5 A. Please observe that the user can modify the max. current value by changing the values of the shunt resistors. 20/49 DocID026975 Rev 1 UM1823 Board description Figure 12. Three-shunt configuration +5 V Smart SD +3.3 V COMPARATOR + – 10 CP+ R3 (R52, R78, R97) VCC VREF (R53, R75, R99) 9 OP+ OPAMP OPOUT + – 7 R2 (R54, R76, R100) 6 OP – Shunt resistor L6390 R (R46, R66, R92) r (R48, R72, R94) GND AM00474 For previously mentioned FOC configurations it is necessary to set the proper gain by applying the W10 jumper and by applying the W11 jumper to the dash marked position. Six-step (block commutation) current reading configuration In case of six-step (also called block commutation) current control, only two of the motor phases conduct current at the same time. Therefore, it is possible to use only one shunt resistor placed on the DC link to measure the motor phase current. Moreover, as the current is always flowing on the shunt resistor in the same direction, only positive current must be measured, and in this case, the amplifying network needs to be properly designed. The details of single-shunt current sensing reading configuration are shown in Figure 13. In this configuration, the current sampling is done only when the value on the shunt resistor is positive. The only positive value read on the shunt resistor allows the setting of a higher gain for the op amp than the one set in the three-shunt reading mode. The op amp is used in follower mode with the gain of the op amp set by resistor r and R: Equation 5 R+r G = -----------r It is possible to calculate the voltage on the output of the op amp, OP OUT VOUT, as the sum of a bias, VBIAS, and a signal, VSIGN, component equal to: Equation 6 V OUT = V SIGN + VBIAS DocID026975 Rev 1 21/49 49 Board description UM1823 V BIAS R1 3.3 × ---------------------R1 + R2 = ----------------------------------------------------------------------- × G 1 1 1 ------- + ---------------------- + -------- × R4 R3 R1 + R2 R4 I × R SHUNT × R2 I × R SHUNT × R1 VSIGN = -------------------------------------------- + --------------------------------------------------------------------------------------------- × G R1 + R2 2 1 1 1 ------- + ---------------------- + -------- × ( R1 + R2 ) R3 R1 + R2 R4 Total gain of the circuit with the resistors’ divider is equal to: Equation 7 V SIGN VSIGN G TOT = ---------------- = -----------------------------V IN R SHUNT × I with the default values this gives: • VBIAS = 1.7 V • G = 4.98 • GTOT = 2.53 • Maximum current amplifiable without distortion is 6.5 A. Please observe that the user can modify the max. current value by changing the values of the shunt resistors. Figure 13. Six-step current sensing configuration +3.3 V +5 V Smart SD COMPARATOR R4 (R80) + – VCC 10 CP+ R2 (R79) VREF R1 (R75) OPAMP OPOUT 7 9 OP+ + – 6 OP– Shunt resistor R3 (R81) L6390 R (R66 + R69) r (R72) GND AM00475 For six-step configurations it is necessary to set the proper gain by removing the W10 jumper and applying the W11 jumper to the not marked position. 22/49 DocID026975 Rev 1 UM1823 Board description In Table 1 the mentioned setting of gain jumpers, for all possible current reading configurations, is shown. Table 1. Current reading configuration Gain configuration Jumper Six-step current reading 2.3.7 FOC current reading W10 Not present Present W11 Not marked position “-” position The tachometer and Hall/encoder inputs Both the tachometer and Hall/encoder inputs have been implemented on the board. In the case of using a Hall or encoder sensor, the W4 jumper must be connected and the W7 jumper disconnected. The W16 jumper set to dash marked “-” position allows to supply any connected Hall sensor with +5 VDC supply voltage. Setting the W16 jumper to not marked position supplies the Hall sensor with the same supply voltage as other hardware peripherals (+3.3 VDC or +5 VDC depend on the W1 jumper). The U11 Hex Schmitt inverter is used as the voltage level shifter for the connected Hall sensor. In the case of using a tachometer, the W4 jumper must be disconnected and the W7 jumper connected.This feature allows to test and evaluate a wide spectrum of various motors. 2.3.8 Temperature feedback and overtemperature protection Hardware overtemperature protection is implemented on the STEVAL-IHM023V3 evaluation board. This feature fully protects the switches against damage when temperature on the junction of the switches overruns a defined value. The temperature is sensed with an NTC resistor placed on the heatsink. The measured signal is fed through the J5 motor connector to the MCU control unit and can be read with an A/D converter. The signal is also fed to comparator U8 where it is compared with a 2.5 V reference voltage which is built around the U9 precision reference Tl431. The output signal of the comparator U8 is fed to the SD pin of the L6390D drivers to stop the commutation of the connected motor. With the value of the NTC resistor used equal to 10 kΩ, and resistor R44 equal to 3.6 kΩ, the shutdown temperature is around 70 °C. Figure 14. NTC placement on the heatsink DocID026975 Rev 1 23/49 49 Hardware setting of the STEVAL-IHM023V3 3 UM1823 Hardware setting of the STEVAL-IHM023V3 The STEVAL-IHM023V3 evaluation board can be driven through the J5 motor control connector by various MCU control units released by STMicroelectronics which feature a unified 34-pin motor connector. The evaluation board is suitable for both field oriented and scalar controls. In particular, it can handle output signal conditioning for different types of speed and/or position feedback sensors (such as tachometer, Hall sensors, and quadrature encoders) and different current sensing topologies (single-shunt resistor placed on DC bus or three-shunt resistors placed in the three inverter legs). 3.1 Hardware settings for six-step (block commutation) control of BLDC motors To drive any motor, the user must ensure that: • The motor control evaluation board is driven by a control board that provides the six output signals required to drive the three-phase power stage • The motor is connected to the J2 motor output connector • If using an encoder or Hall sensor connection, it is connected to connector J4 • If using a tachometer connection, it is connected to connector J8 • If using the brake control feature, connect a dissipative power load to J6 connector Table 2 below shows the jumper settings for any BLDC high-voltage motors in six-step (block commutation) control. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC. If the voltage doubler is applied, the input voltage must be in the range of 65 VAC to 145 VAC. Table 2. Jumper settings for high-voltage BLDC motor in six-step control Jumper Settings for any HV motor in six-step control “3.3 V” position for VDD = 3.3 V W1 “5 V” position for VDD = 5 V W3 “HIGH VOLTAGE” position Present for Hall sensor or encoder W4 Not present for connected tachometer “R_BRAKE” position for software handling of resistive brake (if any) W5 “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying stage from IHM023V2 (max. 50 mA) Present for connected tachometer W7 Not present for connected Hall sensor or encoder 24/49 W9 Single-shunt W10 Not present W11 Not marked position W13 Single-shunt DocID026975 Rev 1 UM1823 Hardware setting of the STEVAL-IHM023V3 Table 2. Jumper settings for high-voltage BLDC motor in six-step control (continued) Jumper Settings for any HV motor in six-step control Present for voltage doubler W14 Not present for standard voltage range Dash mark position of Hall/encoder with VDD W16 Not marked position for supplying Hall/encoder with +5 V Table 3 shows jumper settings for a low-voltage BLDC motor. Please confirm that the input voltage (mains voltage) of the evaluation board in this case is in the range of 18 VDC to 35 VDC. If it is necessary to supply the motor with a voltage lower than 18 VDC, please remove the W3 jumper and connect the auxiliary voltage to the J3 connector. This configuration is called “dual supply configuration”. In this configuration it may be necessary to modify R2, R4, and R7 resistors according to applied supply voltage. Table 3. Jumper settings for low-voltage BLDC motor in six-step control Jumper W1 Settings for any HV motor in six-step control “3.3 V” position for VDD = 3.3 V “5 V” position for VDD = 5 V W3 “<35 V ONLY” position W4 Present for Hall sensor or encoder Not present for connected tachometer W5 “R_BRAKE” position for software handling of resistive brake (if any) “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying stage from IHM023V2 (max. 50 mA) W7 Present for connected tachometer Not present for connected Hall sensor or encoder W9 Single-shunt W10 Not present W11 Not marked position W13 Single-shunt W14 Present for voltage doubler Not present for standard voltage range W16 Dash mark position of Hall/encoder with VDD Not marked position for supplying of Hall/encoder with +5 V DocID026975 Rev 1 25/49 49 Hardware setting of the STEVAL-IHM023V3 3.2 UM1823 Hardware settings for “Field Oriented Control” (FOC) in single-shunt topology current reading configuration To drive any motor, the user must ensure that: • The motor control evaluation board is driven by a control board that provides the six output signals required to drive the three-phase power stage • The motor is connected to the J2 motor output connector • If using an encoder or Hall sensor connection, it is connected to connector J4 • If using a tachometer connection, it is connected to connector J8 • If using the brake control feature, connect a dissipative power load to J6 connector Table 4 below shows the jumper settings for any high-voltage motors in single-shunt FOC configuration. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC. If the voltage doubler is applied, the input voltage must be in the range of 65 VAC to 145 VAC. Table 4. Jumper settings for high-voltage PMAC or generic AC motor in single-shunt FOC control Jumper W1 Jumper settings for FOC of HV PMSM, BLDC or AC IM in single-shunt configuration for current reading “3.3 V” position for VDD = 3.3 V “5 V” position for VDD = 5 V W3 “HIGH VOLTAGE” position W4 Present for Hall sensor or encoder Not present for connected tachometer W5 “R_BRAKE” position for software handling of resistive brake (if any) “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying control stage from IHM023v2 connector with VDD (max. 50 mA) W7 Present for connected tachometer Not present for connected Hall sensor or encoder W9 Single-shunt W10 Present W11 Dash mark position W13 Single-shunt W14 Not present W16 Dash marked position for supplying of Hall/encoder with VDD Not marked position for supplying of Hall/encoder with +5 V 26/49 DocID026975 Rev 1 UM1823 Hardware setting of the STEVAL-IHM023V3 Table 5 shows jumper settings for a low-voltage BLDC motor in single-phase FOC current control. Please confirm that the input voltage (mains voltage) of the evaluation board in this case is in the range of 18 VDC to 35 VDC. If it is necessary to supply the motor with a voltage lower than 18 VDC, please remove the W3 jumper and connect the auxiliary voltage to the J3 connector. In this configuration it may be necessary to modify R2, R4, and R7 resistors according to applied supply voltage. Table 5. Jumper settings for low-voltage BLDC motor in single-shunt FOC control Jumper W1 Settings for any LV BLDC motor in single-shunt FOC control “3.3 V” position for VDD = 3.3 V “5 V” position for VDD = 5 V W3 “<35 V ONLY” position W4 Present for Hall sensor or encoder Not present for connected tachometer W5 “R_BRAKE” position for software handling of resistive brake (if any) “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying control stage from IHM023v2 connector with VDD (max. 50 mA) W7 Present for connected tachometer Not present for connected Hall sensor or encoder W9 Single-shunt W10 Present W11 Dash mark position W13 Single-shunt W14 Not present W16 Dash marked position for supplying of Hall/encoder with VDD Not marked position for supplying of Hall/encoder with +5 V 3.3 Hardware settings for FOC in three-shunt configuration To drive any motor, the user must ensure that: • The motor control evaluation board is driven by a control board that provides the six outputs signals required to drive the three-phase power stage • The motor is connected to the J4 motor output connector • If using an encoder or Hall sensor connection, it is connected to connector J5 • If using a tachometer connection, it is connected to connector J6 • If using the brake control feature, connect a dissipative power load to J7 connector DocID026975 Rev 1 27/49 49 Hardware setting of the STEVAL-IHM023V3 UM1823 Table 6 below shows the jumper settings for three-shunt based FOC of any high-voltage PMSM, BLDC, or AC IM motor. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC. If the voltage doubler is applied, the input voltage must be in the range of 65 VAC to 145 VAC. Table 6. Jumper settings for FOC of HV PMSM, BLDC, or AC IM in three-shunt configuration for current reading Jumper Jumper settings for FOC of HV PMSM, BLDC or AC IM in three-shunt configuration for current reading W1 “3.3 V” position W3 “HIGH VOLTAGE” position W4 Present for Hall sensor or encoder Not present for connected tachometer W5 “R_BRAKE” position for software handling of resistive brake (if any) “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying control stage from IHM023v2 connector with VDD (max. 50 mA) W7 Present for connected tachometer Not present for connected Hall sensor or encoder W9 Three-shunt W10 Present W11 Silk screen marked position W13 Three-shunt W14 Not present W16 Silk screen marked position for supplying Hall/encoder with VDD Not marked position for supplying Hall/encoder with +5 V Table 7 shows jumper settings for three-shunt based FOC of any low-voltage PMSM or BLDC. Please confirm that the input voltage of the evaluation board in this case is in the range of 18 VDC to 35 VDC. If it is necessary to supply the motor with a voltage lower than 18 VDC, please remove the W3 jumper and connect the auxiliary voltage to the J3 connector. In this configuration it may be necessary to modify R2, R4, and R7 resistors according to the applied supply voltage. 28/49 DocID026975 Rev 1 UM1823 Hardware setting of the STEVAL-IHM023V3 Table 7. Jumper settings for FOC of LV PMSM or BLDC in three-shunt configuration for current reading Jumper Jumper settings for FOC of LV PMSM or BLDC in three-shunt configuration for current reading W1 “3.3 V” position W3 “<35 V ONLY” position W4 Present for Hall sensor or encoder Not present for connected tachometer W5 “R_BRAKE” position for software handling of resistive brake (if any) “OCP OFF” position for software handling of overcurrent protection disabling W6 Present for supplying control stage from IHM023v3 connector with VDD (max. 50 mA) W7 Present for connected tachometer Not present for connected Hall sensor or encoder W9 Three-shunt W10 Present W11 Silk screen marked position W13 Three-shunt W14 Not present W16 Silk screen marked position for supplying Hall/encoder with VDD Not marked position for supplying Hall/encoder with +5 V DocID026975 Rev 1 29/49 49 Description of jumpers, test pins, and connectors 4 UM1823 Description of jumpers, test pins, and connectors The following tables give a detailed description of the jumpers, test pins, and the pinout of the connectors used. Table 8. Jumpers description Jumper Selection “3.3 V” position W1 Description VDD = 3.3 V “5 V” position VDD = 5 V “<35 V” ONLY Linear regulator supplied from DC bus - input supply voltage < 35 VDC W3 “HIGH VOLTAGE” Buck converter supplied from bus Present Hall sensor or encoder connected W4 Not present Tachometer connected “R_BRAKE” Software brake feature applied “OCP OFF” OCP disabled W5 Present W6 Not present Present Supplying of MCU control board through J5 motor connector with VDD Separated voltage of MCU control board Tachometer connected W7 Not present Hall sensor or encoder connected Single-shunt Any single-shunt configuration Three-shunt Any three-shunt configuration W9 Present Gain for any FOC W10 Not present Gain for six-step control Dash position Gain for any FOC Free position Gain for six-step control Single-shunt Any single-shunt configuration Three-shunt Any three-shunt configuration W11 W13 Present W14 Not present Standard single-phase range Dash position Hall/encoder supplied by VDD Free position Hall/encoder supplied by +5 V W16 30/49 Voltage doubler applied (VIN = max. 145 VAC) DocID026975 Rev 1 UM1823 Description of jumpers, test pins, and connectors Table 9. Connector pinout description Name Reference Description / pinout J1 Supply connector 1 - PE-earth 2 - PE-earth 3 - L-phase 4 - N-neutral J2 Motor connector A - Phase A B - Phase B C - Phase C J3 15 V auxiliary supply connector 1 - GND 2 - +15 VDC J4 Hall sensors/ encoder input connector 1 - GND 1 - +VDD/+5 V 1 - Hall sensor input 1/ encoder A+ 1 - Hall sensor input 2/ encoder B+ 1 - Hall sensor input 3/ encoder Z+ Motor control connector 1 - Emergency stop 2 - GND 3 - PWM-1H 4 - GND 5 - PWM-1L 6 - GND 7 - PWM-2H 8 - GND 9 - PWM-2L 10 - GND 11 - PWM-3H 12 - GND 13 - PWM-3L 14 - HV bus voltage 15 - Current phase A 16 - GND 17 - Current phase B 18 - GND 19 - Current phase C 20 - GND 21 - NTC bypass relay 22 - GND 23 - Dissipative brake PWM 24 - GND 25 - +V power 26 - heatsink temperature 27 - PFC sync. 28 - Vdd_m 29 - PWM VREF 30 - GND 31 - Measure phase A 32 - GND 33 - Measure phase B 34 - measure phase C J5 DocID026975 Rev 1 31/49 49 Description of jumpers, test pins, and connectors UM1823 Table 9. Connector pinout description (continued) Name Reference Description / pinout J6 Dissipative brake 1 - Bus voltage 2 - Open collector J7 BEMF daughterboard connector 1 - Phase A 2 - Phase B 3 - Phase C 4 - Bus voltage 5 - 3.3 VDC 6 - VDD_micro 7 - GND 8 - PWM VREF J8 Tachometer input connector for AC motor speed loop control 1 - Tachometer bias 2 - Tachometer input Table 10. Testing pins description Number 32/49 Description TP1 Output phase A TP2 Output phase B TP3 Output phase C TP4 PWM - phase A - low-side TP5 PWM - phase A - high-side TP6 PWM - phase B - low-side TP7 PWM - phase B - high-side TP8 PWM - phase C - low-side TP9 PWM - phase C - high-side TP10 Current sensed in phase A TP11 Current sensed in phase B TP23 Current sensed in phase C TP13 Sensed tachometer/encoder/Hall signal A TP14 Sensed encoder/Hall signal B TP15 Sensed encoder/Hall signal Z TP16 Voltage on bus divider - bus voltage information TP17 Brake status - brake active in low state DocID026975 Rev 1 UM1823 Connector placement Table 10. Testing pins description (continued) Number 5 Description TP18 3.3 VDC TP19 15 VDC TP20 Reference voltage 2.5 V for overtemperature protection TP21 GND TP24 5 VDC Connector placement A basic description of the placement of all connectors on the board is visible in Figure 15. Figure 15. STEVAL-IHM023V3 connectors placement DocID026975 Rev 1 33/49 49 Bill of material 6 UM1823 Bill of material A list of components used to build the evaluation board is shown in Table 11. The majority of the active components used are available from STMicroelectronics. Table 11. Bill of material Qty 34/49 Reference Value / generic part number Package / class Manufacturer Y1 safety CAP - 4.7 nF Murata Manufacturing Co., Ltd. Elyt. capacitor, RM 10 mm, 30 x 45, 105 °C Panasonic 2 C1, C5 2.2 nF/Y1 2 C2, C3 1200 μF/250 V 1 C13 N.C. 1 C14 220 nF/25 V 1 C15 3.3 μF/450 V 1 C16 1 μF/50 V Elyt. capacitor, SMD 4 x 4 Panasonic 1 C19 100 μF/25 V Elyt. capacitor, SMD 8 x 8 Panasonic 9 C66, C67, C71, C72, C73, C26, C24, C27, C28, C6, C7, C17, C18, C10, C11 100 nF/25 V Capacitor, SMD 0805 3 C69, C70, C74 10 pF/25 V Capacitor, SMD 0805 1 C25 4.7 μF/25 V Elyt. capacitor, SMD 4 x 4 1 C29 2.2 nF/25 V Capacitor, SMD 0805 1 C30 4.7 nF/25 V Capacitor, SMD 0805 3 C31, C42, C53 330 pF/25 V Capacitor, SMD 0805 6 C32, C33, C43, C44, C54, C55 1 μF/50 V Capacitor, SMD 1206; 50 V 6 C34, C35, C45, C46, C58, C59 10 pF/25 V Capacitor, SMD 0805 4 C36, C47, C60, C75 1 nF/25 V Capacitor, SMD 0805 3 C37, C48, C61 470 nF/25 V Capacitor, SMD 0805 3 C39, C50, C62 100 pF/25 V Capacitor, SMD 0805 1 C4 150 nF/X2 Foil X2 capacitor, RM 22.5 mm 3 C40, C49, C63 2.2 nF/25 V Capacitor, SMD 0805 3 C41, C51, C64 33 pF/25 V Capacitor, SMD 0805 1 C52 330 pF/25 V Capacitor, SMD 0805 1 C65 100 pF/25 V Capacitor, SMD 0805 Capacitor, SMD 0805 Panasonic DocID026975 Rev 1 Panasonic Arcotronics UM1823 Bill of material Table 11. Bill of material (continued) Qty Reference Value / generic part number Package / class Manufacturer 1 C56 100 nF/25 V Capacitor, SMD 0805 1 C57 470 pF/25 V Capacitor, SMD 0805 1 C12 47 nF/25 V Capacitor, SMD 0805 2 C8, C68 22 μF/6.3 V Elyt. capacitor, SMD 4 x 4 2 C9, C38 10 nF/25 V Capacitor, SMD 0805 1 RT1 10 kΩ NTC EPCOS B57703M103G40 1 VR1 10 Ω NTC EPCOS B57364S100M 3 R1, R3, R6 100 kΩ Resistor, SMD 1206 1 R10 13 kΩ Resistor, SMD 0805, 1% 4 R11, R14, R120, R121 5.6 kΩ Resistor, SMD 0805 1 R12 N.C. 1 R13 160 Ω Resistor, SMD 1206 9 R112, R113, R114, R115, R116, R117, R109, R110, R111 4.7 kΩ Resistor, SMD 0805 1 R18 6.8 kΩ Resistor, SMD 0805 2 R19, R108 4 R2, R4, R23, R24 470 kΩ Resistor, SMD 1206, 1% 3 R21, R107, R106 220 Ω Resistor, SMD 0805 6 R22, R27, R20, R33, R74, R17 10 kΩ Resistor, SMD 0805 1 R25 560 Ω Resistor, SMD 0805 1 R32 9.1 kΩ Resistor, SMD 0805, 1% 1 R26 1 kΩ Resistor, SMD 0805, 1% 3 R28, R122, R123 2.2 kΩ Resistor, SMD 0805 1 R29 100 Ω Resistor, SMD 0805 1 R30 15 kΩ Resistor, SMD 0805 1 R31 27 kΩ Resistor, SMD 0805, 1% 1 R34 12 kΩ Resistor, SMD 0805, 1% 4 R35, R36, R57, R82 100 kΩ Resistor, SMD 0805 Panasonic N.C. DocID026975 Rev 1 35/49 49 Bill of material UM1823 Table 11. Bill of material (continued) 36/49 Qty Reference Value / generic part number 4 R37, R41, R58, R62 10 Ω Resistor, SMD 0805 6 R38, R59, R85, R40, R61, R87 1 kΩ Resistor, SMD 0805, 1% 4 R39, R45, R60, R65 120 Ω Resistor, SMD 0805 3 R42, R63, R89 3.3 kΩ Resistor, SMD 0805 3 R43, R64, R90 47 kΩ Resistor, SMD 0805, 1% 1 R44 3.6 kΩ Resistor, SMD 0805, 1% 3 R46, R66, R92 3.3 kΩ Resistor, SMD 0805, 1% 1 R49 2 R5, R9 120 Ω Resistor, SMD 0805 3 R52, R97, R78 3.3 kΩ Resistor, SMD 0805, 1% 3 R54, R76, R100 820 Ω Resistor, SMD 0805, 1% 3 R55, R71, R101 0.15 Ω Resistor, SMD 2512, 1%, 2 W 3 R56, R68, R102 N.C. 6 R67, R70, R75, R79, R50, R53 1 kΩ Resistor, SMD 0805, 1% 1 R69 680 Ω Resistor, SMD 0805, 1% 1 R7 7.5 Ω Resistor, SMD 0805, 1% 6 R72, R48, R47, R77, R51, R98 1 kΩ Resistor, SMD 0805, 1% 1 R73 N.C. 1 R8 51 kΩ Resistor, SMD 0805, 1% 1 R80 2.2 kΩ Resistor, SMD 0805, 1% 1 R81 33 Ω Resistor, SMD 0805, 1% 2 R83, R88 10 Ω Resistor, SMD 0805 1 R104 68 kΩ Resistor, SMD 0805 1 R84 2.2 kΩ Resistor, SMD 0805 2 R86, R91 120 Ω Resistor, SMD 0805 5 R93, R95, R99, R94, R103 1 kΩ 1 R96 N.C. 1 R105 220 kΩ Resistor, SMD 0805, 1% 1 L1 47 μH SMD choke, 0.5 A Panasonic 1 L2 2.2 mH SMD choke, 0.25 A Würth Elektronik Package / class Manufacturer N.C. Resistor, SMD 0805, 1% DocID026975 Rev 1 UM1823 Bill of material Table 11. Bill of material (continued) Qty Reference Value / generic part number Package / class 1 D1 KBU6K Diode bridge, 250 VAC, 8 A 7 D11, D12, D15, D16, D19, D20, D2, D23, D24 BAT48 Diode, SMD, SOD-323 8 D13, D5, D14, D17, D18, D21, D22, D10 1N4148 Universal diode, SMD, SOD80C 2 D25, D29 1 Manufacturer STMicroelectronics BZX84B13V Zener diode, SOT23, 13 V D3 STPS1150 Schottky diode, DO-241AC (SMA) STMicroelectronics 1 D4 SM6T36 Transil™, JEDEC DO214AA STMicroelectronics 2 D6, D8 HV diode, SMA STMicroelectronics 1 D7 LED GREEN Universal LED 3 mm, 2 mA 1 D9 BZV55C18SMD Zener diode, SOD80, 18 V 1 D27 LED YELLOW Universal LED 3 mm, 2 mA 1 D28 LED RED Universal LED 3 mm, 2 mA 1 D26 STTH2L06 HV diode, SMA 10 Q1, Q4, Q5, Q12, Q13, Q14, Q15, Q16, Q17, Q18 BC847 NPN transistor, SOT23 7 Q10, Q11, Q3, Q6, Q7, Q8, Q9 STGP10H60DF N-channel IGBT, TO220 1 Q2 BC857B PNP transistor, SOT23 1 F1 Holder Fuse holder 5 x 20 mm, KS21 SW 1 F1 6.25 A Fuse 6.25 A Slov., FST06.3, 5 x 20 mm 1 LS1 Finder 4031-12 1 U1 LD1117S33 1 U2 1 U3 2 U4, U8 TS391 Voltage comparator, SOT23STMicroelectronics 5 3 U5, U6, U7 L6390 HV low and high-side driver, STMicroelectronics SO-16 STTH1L06 STMicroelectronics STMicroelectronics SCHURTER Relay 12 VDC Finder Linear regulator 3.3 V, SOT223 STMicroelectronics L7815 Linear regulator 15 V, TO220 STMicroelectronics VIPer16 Smart PWM driver, SO-16 STMicroelectronics DocID026975 Rev 1 37/49 49 Bill of material UM1823 Table 11. Bill of material (continued) Qty Reference Package / class Manufacturer 1 U9 TS3431 Voltage reference, SOT233L STMicroelectronics 1 U10 L78M05C Linear regulator 5 V, DPAK STMicroelectronics 1 U11 M74HC14 Hex Schmitt inverter SOP STMicroelectronics 3 TP1, TP2, TP3 18 TP4 - TP24 PCB terminal 1 mm Test pin 1 J1 Connector 4P Connector RM 5 mm, 4-pole PHOENIX CONTACT male horizontal Connector 4P Connector RM 5 mm, 4-pole PHOENIX CONTACT female parallel Connector 3P Connector RM 5 mm, 3-pole PHOENIX CONTACT male horizontal Connector 3P Connector RM 5 mm, 3-pole PHOENIX CONTACT female parallel 1 1 J2 1 N.C. 1 J3 Con. 5 mm, 2P Connector RM 5 mm, 2pole, screw PHOENIX CONTACT 1 J4 Connector 5P Autocom HE14 5-pin Stelvio Kontek 1 J5 MLW34G MLW connector 34-pin Tyco Electronics 1 J6 Con. 5 mm, 2P Connector RM 5 mm, 2pole, screw PHOENIX CONTACT 1 J7 Con. 2.54 mm 12-pin Pins RM 2.54 mm female, 12-pin 1 J8 Con. 5 mm, 2P Connector RM 5 mm, 2pole, screw 1 W1 Jumper 2.54 Three pins of break way + jumper in position 3.3 V 1 W10 Jumper 2.54 Two pins of break way + jumper 1 W11 Jumper 2.54 Three pins of break way + jumper in position 3.3 V 3 W13 Mounting hole Insulated jumper blue 1 3 1 38/49 Value / generic part number W3 Mounting hole Insulated jumper blue Three way HV selector, default three-shunt position HV insulated jumper, 5.08 mm, default three-shunt position Three way HV selector HV insulated jumper, 5.08 mm, default “HIGH VOLTAGE” position DocID026975 Rev 1 PHOENIX CONTACT UM1823 Bill of material Table 11. Bill of material (continued) Qty Reference Value / generic part number Package / class 1 W4 Jumper 2.54 Two pins of break way + jumper 1 W5 Jumper 2.54 Three pins of break way + jumper in position R_BRAKE 1 W6 Jumper 2.54 Two pins of break way 1 W7 Jumper 2.54 Two pins of break way 3 W9 Mounting hole Insulated jumper blue 1 Manufacturer Three way HV selector, default three-shunt position HV insulated jumper, 5.08 mm, default three-shunt position 1 W14 Wire jumper Not assembled 1 W16 Jumper 2.54 Three pins of break way + jumper in position 1 150 mm Het 1 Heatsink 150 mm of AL profile 8693 PADA Engineering 1 Het 2 Heatsink Heatsink for TO-220 with montage pin PADA Engineering 7 Clip for het Montage clip PADA 7704, TO-220, 10 mm PADA Engineering 1 Clip for het Montage clip PADA 7703, TO-220, 15 mm PADA Engineering 130 mm Isolation tape Isolation tape, 24 mm wide; approx. 130 mm long, self adhesive DocID026975 Rev 1 39/49 49 PCB layout 7 UM1823 PCB layout For this application a standard, double-layer, coppered PCB with a ~60 μm copper thickness was selected. The PCB material is FR-4. The dimensions of the board are: Length: 182 mm Width: 127 mm PCB thickness: 1.55 mm 40/49 DocID026975 Rev 1 UM1823 PCB layout Figure 16. Silk screen - top side DocID026975 Rev 1 41/49 49 PCB layout UM1823 Figure 17. Silk screen - bottom side 42/49 DocID026975 Rev 1 UM1823 PCB layout Figure 18. Copper tracks - top side Figure 19. Copper tracks - bottom side DocID026975 Rev 1 43/49 49 Ordering information 8 UM1823 Ordering information The evaluation board is orderable through the standard ordering system, the ordering code is: STEVAL-IHM023V3. The items delivered include the assembled evaluation board, board documentation, PCB fabrication data such as gerber files, assembly files (pick and place), and component documentation. 9 Using STEVAL-IHM023V3 with STM32 PMSM FOC SDK The “STM32 PMSM FOC firmware library” is part of the STM32 PMSM single/dual FOC SDK. In particular, it is a firmware library running on any STM32F103x and STM32F100x device which implements the “Field Oriented Control” (FOC) drive of three-phase “Permanent Magnet Synchronous Motors” (PMSM), both “Surface Mounted” (SM-PMSM) and “Internal” (I-PMSM). This section describes how to customize the firmware library by making use of the PC tool “ST MC Workbench” downloadable from www.st.com. 9.1 Environmental considerations Warning: The STEVAL-IHM023V3 evaluation board must only be used in a power laboratory. The voltage used in the drive system presents a shock hazard. The kit is not electrically isolated from the DC input. This topology is very common in motor drives. The microprocessor is grounded by the integrated ground of the DC bus. The microprocessor and associated circuitry are hot and MUST be isolated from user controls and communication interfaces. Warning: All measuring equipment must be isolated from the main power supply before powering up the motor drive. To use an oscilloscope with the kit, it is safer to isolate the DC supply AND the oscilloscope. This prevents a shock occurring as a result of touching any SINGLE point in the circuit, but does NOT prevent shocks when touching two or more points in the circuit. An isolated AC power supply can be constructed using an isolation transformer and a variable transformer. Note: 44/49 Isolating the application rather than the oscilloscope is highly recommended in any case. DocID026975 Rev 1 UM1823 9.2 Using STEVAL-IHM023V3 with STM32 PMSM FOC SDK Hardware requirements The following items are required to run the STEVAL-IHM023V3 together with the “STM32 PMSM FOC firmware library v3.4”. 9.3 • Any microcontroller evaluation board with MC connector • A high-voltage insulated AC power supply up to 230 VAC • A programmer/debugger dongle for control board (not included in the package). Refer to the control board user manual to find a supported dongle. Use of an insulated dongle is always recommended. • Three-phase brushless motor with permanent magnet rotor (not included in the package) • An insulated oscilloscope (as necessary) • An insulated multimeter (as necessary) Software requirements To customize, compile, and download the “STM32 FOC firmware library”, a toolchain must be installed. 9.4 STM32 FOC firmware library customization The ST motor control workbench can be used to customize the STM32 FOC firmware library. The required parameters for the power stage related to the STEVAL-IHM023V3 are reported in Table 12. Table 12. STEVAL-IHM023V3 motor control workbench parameters Variable Value Rated bus voltage information Min. rated voltage (V) 18 or 60 according to W3 position (respectively for “<35 V” and “HIGH VOLTAGE” positions) Max. rated voltage (V) 32 or 450 according to W3 position (respectively for “<35 V” and “HIGH VOLTAGE” positions) Nominal voltage (V) Depends on W3 position and application nominal bus voltage Bus voltage sensing Available Bus voltage divider 1/... 136 Available if W5 is set to R_BRAKE position, not available otherwise Dissipative brake Polarity Active high Driving signals Phases U, V, W high-side polarity DocID026975 Rev 1 Active high 45/49 49 Using STEVAL-IHM023V3 with STM32 PMSM FOC SDK Table 12. UM1823 STEVAL-IHM023V3 motor control workbench parameters (continued) Variable Value Phases U, V, W low-side polarity Active low Temperature sensing Available V0 (mV) 875 T0 (°C) 25 ΔV/ΔT (mV/°C) 28 Max. working temperature on sensor (°C) 70 Overcurrent protection Available Comparator threshold (V) 0.5 Overcurrent network gain (V/A) 0.075 Expected overcurrent threshold (A) 6.25 Overcurrent feedback signal polarity Active low Overcurrent protection disabling network Available if W5 is set to OCP OFF position, not available otherwise Overcurrent protection disabling network polarity Active low Current sensing Current reading topology Configurable Shunt resistor(s) value (Ω) 0.15 Amplifying network gain 1.7 T-noise (ns) 2000 T-rise (ns) 2000 Power switches 46/49 Min. deadtime (ns) 800 Max. switching frequency (kHz) 50 DocID026975 Rev 1 UM1823 10 Conclusion Conclusion This document describes the 1 kW three-phase motor control STEVAL-IHM023V3 evaluation board as a universal fully evaluated and adaptable motor control platform. 11 References 1. L6390 datasheet 2. VIPer16 datasheet 3. STGP10H60DF datasheet 4. UM0379 user manual 5. UM0580 user manual DocID026975 Rev 1 47/49 49 Revision history 12 UM1823 Revision history Table 13. Document revision history 48/49 Date Revision 03-Dec-2014 1 Changes Initial release. DocID026975 Rev 1 UM1823 IMPORTANT NOTICE – PLEASE READ CAREFULLY STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, enhancements, modifications, and improvements to ST products and/or to this document at any time without notice. Purchasers should obtain the latest relevant information on ST products before placing orders. ST products are sold pursuant to ST’s terms and conditions of sale in place at the time of order acknowledgement. Purchasers are solely responsible for the choice, selection, and use of ST products and ST assumes no liability for application assistance or the design of Purchasers’ products. No license, express or implied, to any intellectual property right is granted by ST herein. Resale of ST products with provisions different from the information set forth herein shall void any warranty granted by ST for such product. ST and the ST logo are trademarks of ST. All other product or service names are the property of their respective owners. Information in this document supersedes and replaces information previously supplied in any prior versions of this document. © 2014 STMicroelectronics – All rights reserved DocID026975 Rev 1 49/49 49