IRMCS2031 International Rectifier • 233 Kansas Street, El Segundo, CA 90245 ! USA IRMCS2031 Complete Sensorless 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. 4/13/2004 Reference Design Advance Information IRMCS2031 Complete Sensorless Drive Design Platform iMOTIONTM Development System Features ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Product Summary Low cost complete AC sensorless drive design platform IRMCK203 IC for complete sensorless control Simple design with IR2175 current sensing HVIC 230V/750W maximum output power with 600V/16A advanced Plug-N-DriveTM IGBT module Wide speed range and high speed operation Support any permanent magnet AC motors Speed operation range (typical) High speed operation Speed accuracy Speed resolution PWM carrier frequency Low loss/EMI Space Vector PWM Sensorless control computation time No voltage feedback sensing Continuous output current Low cost A/D interface with multiplexer 4-channel D/A output for diagnostics/monitoring TM ServoDesigner tool for easy operation RS232C/RS422 and fast SPI interface Parallel interface for microcontroller expansion Over-current and ground fault protection Overload output current Maximum modulation index Max RS232C speed Optional RS422 communication 5 to 100% 100,000rpm (2pole) 0.01% 15bit 60 kHz max 10 usec 5 Arms (750W) 15 Arms (750W) 1.2 57.6 kbps 1Mbps Over-voltage / Under-voltage protection Dynamic Braking control with brake IGBT/FWD Discrete I/Os (START/STOP, FAULT, FLTCLR, SYNC ESTOP, PWMEN) Configuration data retention at power up/down Description IRMCS2031 is a complete sensorless drive design platform for industrial/appliance applications up to 1.0 HP output power. The system contains the latest advanced motion control IC, IRMCK203, 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 requires any software code development due to unique Motion Control Engine implemented in the IRMCK203 IC. User can readily evaluate high performance sensorless control without spending development effort usually required in the traditional DSP or microcontroller based system. IRMCS2031 contains advanced iMOTION chipset such as IR2175 monolithic current sensing ICs and IRAMX16A60A intelligent power module, which enable 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 IRMCS2031 Overview The IRMCS2031 is a design platform for a complete Sensorless drive system based on the IRMCK201 digital motion control IC. The system is based on configurable control engine implemented by hardware logics in the IRMCK203. The system has a simple and low cost structure, made possible by an advanced IR motion components including the IRAMX16UP60A IGBT module, and IR2175 monolithic current sensing high voltage IC. These components together with the IRMCK203 simplify hardware implementation. Since all control logic is implemented in hardware logic as opposed to programmed software, unmatched parallel computation is achieved resulting in higher bandwidth control and higher motor operating frequency (15 usec minimum PWM loop cycle). Despite of hardware logic implementation, its design flexibility allows the user to configure Permanent Magnetic ac motors (Sinusoidal Back EMF) with different motor parameters and different types of communication protocols. AC Power Analog Monitor IRMCS2031 EEPROM Analog Speed Reference IRMCK203 select A/D interface 4 channel D/A Host Controller SPI Interface Parallel Interface RAMP + + Host Register Interface jθ - - e + Space Vector PWM A/D Dead time FAULT Monitoring Registers e 2/3 Plug-N-DriveTM IGBT module IRAMY20UP60A Rotor Angle/ speed Estimator jθ DC bus feedback BRAKE - Configuration Registers MUX IR2136 RS232C or RS422 DC bus dynamic brake control Period/Duty counters IR2175 Period/Duty counters IR2175 Motor Figure 1. IRMCS2031 System Block Diagram This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 2 REFERENCE DESIGN IRMCS2031 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 IRMCS2031 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 LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: The IRMCS2031 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 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. ATTENTION: The IRMCS2031 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 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 3 REFERENCE DESIGN IRMCS2031 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. ! ! ! 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. 4 REFERENCE DESIGN IRMCS2031 Debris When Unpacking The IRMCS2031 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. 5 REFERENCE DESIGN IRMCS2031 Hardware Installation Check All Hardware The following hardware pieces are contained in the IRMCS2031 system. • • • IRMCS2031 board with integrated heat sink Serial RS232C cable with 9-pin Dsub connectors for ServoDesignerTM development tool Two 10 m Ohms shunt resistors Step 1. Connect motor power and ground cables to the IRMCS2031 board. Step 2. Connect AC115V 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. Insert a power contactor switch rated at 250V/30A in series with AC power cables. J1 B V P R S T U W Figure 2. Power Connector, J1 Step 3. Connect motor power lead. Follow the color code connection below. RED = U WHITE = V BLACK = W Connect Earth Ground terminal to the heatsink. IRMCS203 1 Earth Ground Wire MOTOR Figure 3. Earth Ground Connection This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 6 REFERENCE DESIGN IRMCS2031 Step 5. (Optional) J7 Connector, External I/O Connect External I/O Connector (J7) as needed. All inputs are 5V tolerant. Pin definition GND -10V +10V User supplied power supply 10k ohm potentiometer J7 Top View 16 15 GND CALIB START FAULT Clear 5V STOP GND 2 1 Pin 1 : Analog input (+/-10V) Pin 2: N/A (open) Pin 3: N/A (open) Pin 4: N/A Pin 5: N/A Pin 6: 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: PWMEN status 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: CALIB input (high to activate) Pin 14: FAULT CLR input (high to activate) Pin 15: N/A (open) Pin 16: GND Figure 4. J7 Connector connection Step 6. (Optional) J8 Connector, Analog Output monitoring 1 8 J8 Top View Figure 5. J8 Connector connection Pin Definition Pin 1: Channel 1 Analog output (0-5V) Pin 2: GND Pin 3: Channel 2 Analog output (0-5V) Pin 4: GND Pin 5: Channel 3 Analog output (0-5V) Pin 6: GND Pin 7: Channel 4 Analog output (0-5V) Pin 8: GND Step 7. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 7 REFERENCE DESIGN IRMCS2031 Connect the RS232C cable between 9-pin D-sub connector and PC. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 8 REFERENCE DESIGN IRMCS2031 Installing the Software The ServoDesignerTM tool is distributed on the CD-ROM. Load the CD into the CD-ROM drive on your PC and double-click “IRMCS2031.exe”. It requires the password which also can be found in the same CD-ROM. The automated procedure installs all necessary software on your PC. The default location for the installation is “C:\Program Files\Accelerator”. Power-On the System Apply AC115V – AC230Vpower to the system. Immediately after power-on, the power supply RED LED (located at the bottom left corner of the board) will light indicating the on-board DC bus has been established. The second LED (surface mount LED located at the top side of the board) should also start blinking on/off RED. Getting Started For quick start with preconfigured parameters, the following motor is supported with a preconfigured motor file. • Sanyo Denki motor (400W: type P30B06040DXS00M) If any other motor is used, reconfiguration is required. Configurable parameters are required to tailor design to various applications (motor and load). These configurable parameters can be modified via the host register interface (using the ServoDesigner tool) through the communication interface. In the IRMCS2031 product, a design spreadsheet (Drive parameters translator) is provided to aid the user for ease of drive start-up. Using the spreadsheet, the user enters high-level parameters such as motor nameplate information, maximum application speed, current limit, speed and current regulator bandwidth. This high-level user information is translated to engineering parameters (directly used by the drive). Figure gives an overview of the commissioning steps. Please refer to the IRMCK203 Application Developer’s Guide for detailed drive commissioning description. Enter high level design parameters (Motor nameplate, Current limits, Max speed, overload etc..) User parameters Drive Parameters Translator Translate input parameters to drive parameters Engineering parameters ServoDesigner Input and download drive parameters Refine drive parameters IRMCS2031 Figure 6. Overview of Drive Commissioning This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 9 REFERENCE DESIGN IRMCS2031 Shunt Resistor and Current Rating Two 20m Ohms current sensing shunt resistors are equipped as default resistors at factory shipment (R34 and R36 located on the bottom side of PCB). With these resistors, IRMCS2031 can deliver up to ±13A maximum peak current to the motor including overshoot of current regulation. When using any higher power motor with a rating greater than 3Arms and less than 6Arms continuous current, then 10m Ohm shunt resistors are recommended in place of the 20m Ohm shunt resistors. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 10 REFERENCE DESIGN IRMCS2031 RS232C connector IRMCS2031 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 8, pin2 is send signal and pin3 is receive signal, and both are 10V signal level. The baud rate is fixed at 57.6kbps. The signal format is 8bit, no parity, 1 stop bit configuration. J6 RS232 Interface 1 2 3 4 5 6 7 8 9 TX1 RX1 No connection DB9RF Figure 5. RS232C connector RS-232 Register Access The IRMCK203 includes an RS-232 interface channel that provides a direct connection to the host PC. The software interface combines a basic "register map" control interface with a simple communication protocol to accommodate potential communication errors. For more detailed information, please refer to IRMCx201 Application Development Guide.doc RS-232 Register Write Access A Register write operation consists of a command/address byte, byte count, register data and checksum. When the IRMCK203 receives the register data, it validates the checksum, writes the register data, and transmits and acknowledgement to the host. Command / Address Byte Byte Count 1-6 bytes of register data Checksum Register Write Operation Command Acknowledgement Byte Checksum Register Write Acknowledgement This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 11 REFERENCE DESIGN IRMCS2031 7 6 5 1=Read/ 0=Write Bit Position 4 3 2 1 0 1 0 Register Map Starting Address Command/Address Byte Format 7 6 5 1=Error/ 0=OK Bit Position 4 3 2 Register Map Starting Address Command Acknowledgement Byte Format The following example shows a command sequence sent from the host to the IRMCK203 requesting a two-byte register write operation: 0x2F Write operation beginning at offset 0x2F 0x02 Byte count of register data is 2 0x00 Data byte 1 0x04 Data byte 2 0x35 Checksum (sum of preceding bytes, overflow discarded) A good reply from the IRMCK203 would appear as follows: 0x2F Write completed OK at offset 0x2F 0x2F Checksum An error reply to the command would have the following format: 0xAF Write at offset 0x2F completed in error 0xAF Checksum RS-232 Register Read Access A register read operation consists of a command/address byte, byte count and checksum. When the IRMCK203 receives the command, it validates the checksum and transmits the register data to the host. Command / Address Byte Byte Count Checksum Register Read Operation Command Acknowledgement Byte Register Data (Byte Count bytes) Checksum Register Read Acknowledgement (transfer OK) This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 12 REFERENCE DESIGN IRMCS2031 Command Acknowledgement Byte Checksum Register Read Acknowledgement (error) The following example shows a command sequence sent from the host to the IRMCK203 requesting four bytes of read register data: 0xA0 Read operation beginning at offset 0x20 (high-order bit selects read operation) 0x04 Requested data byte count is 4 0xA4 Checksum A good reply from the IRMCK203 might appear as follows: 0x20 Read completed OK at offset 0x20 0x11 Data byte 1 0x22 Data byte 2 0x33 Data byte 3 0x44 Data byte 4 0xCA Checksum An error reply to the command would have the following format: 0xA0 Read at offset 0x20 completed in error 0xA0 Checksum RS-232 Timeout The IRMCK203 receiver includes a timer that automatically terminates transfers from the host to the IRMCK203 after a period of 32 msec. RS-232 Transfer Examples The following example shows a normal exchange executing a register write access. Host Write Request Data... FPGA Perform write operation ACK (OK) Request complete The example below shows a normal register read access exchange. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 13 REFERENCE DESIGN IRMCS2031 Host FPGA Read Request Perform read operation ACK (OK) Data... Request complete The following example shows a register write request that is repeated by the host due to a negative acknowledgement from the IRMCK203. Host FPGA Write Request Data... Error in processing (e.g., bad checksum) ACK (error) resend Write Request Data... Perform write operation ACK (OK) Request complete In the final example, the host repeats a register read access request when it receives no response to its first attempt. Host FPGA Read Request … time out, resend Read Request Perform read operation ACK (OK) Data... Request complete This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 14 REFERENCE DESIGN IRMCS2031 SPI interface connector SPI Interface IRMCS2031 has one SPI interface connector (J4) on the board. The connector is a 6pin header and its pin assignement are shown below. The signal level is 3.3V with 5V tolerant input. Maximum transimission speed is 6MHz. J4 MISO SCLK MOSI SYNC CS 1 2 3 4 5 6 HDR6 Figure 6 SPI interface connector SPI Register Access When configured as an SPI device read only and read/write operations are performed using the following transfer format: Command Byte Data Byte 0 ……………. Data Byte N Data Transfer Format 7 Read Only 6 5 Bit Position 4 3 2 1 0 Register Map Starting Address Command Byte Format Data transfers begin at the address specified in the command byte and proceed sequentially until the SPI transfer completes. Note that accesses are read/write unless the “read only” bit is set. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 15 REFERENCE DESIGN IRMCS2031 Parallel Interface Port IRMCS2031 provides a 8bit parallel interface port to facilitate microprocessor interface. Interface is generic and be able to interface most common 8bit parallel interface such as MCS8051, some Motorola 8bit uP, MicroChp,etc. Figure 9 shows the connection diagram. The connector, J5, is an 2-by-10 header connector pins. Each signal is 3.3V level and data bus is multiplexed. Table 1 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 7 Parallel Interface Port Signal HP_nCS HP_nOE HP_nWE HP_A HP_Data I/O1 I I I I I/O Table 2. Description Active low Host Port Chip Select Active Low Host Port Output Enable Active low Host Port Write Enable Host Port Register Address. 1 = Address register, 0 = Data Register Bidirectional Host Port data bus Microprocessor Interface Module Signal Definitions Figures 10 and 11 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. Figures 4 and 5 show example connections for Intel 8051 and Motorola 64K/Coldfire microprocessors. 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- This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 16 REFERENCE DESIGN IRMCS2031 TsuADDR ThAddr HP_A TsuData Tpw_nCSnWE ThData HP_nCS HP_nWE HP_nOE Tacc ThData HP_DATA Figure 8. 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 Register Write/Read Timing (Intel) 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 9. Register Write/Read Timing (Motorola) This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 17 REFERENCE DESIGN IRMCS2031 Specifications TC=25°C unless specified Parameters Input Power Voltage Frequency Input current Input line impedance Output Power kW Current Host interface (SPI) SCLK,CS,MISO,MOSI, SYNC Host interface (RS232C) SND,RCV Host interface (Parallel Port) HP_nCS,HP_nOE,HP_nWE, HP_A,HP_DATA[8] D/A 10 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 Power Module IRAMX16UP60A 3-phase HVIC System environment Ambient temperature Values Conditions 115V-230Vrms, -20%, +10% 50/60 Hz 6A rms @nominal output 4%∼8% recommended TA=40°C,RthSA=1.0 °C/W 750W continuous power 5 Arms nominal, 15 Arms Overload Vin=230V AC, fPWM=8kHz, fO=60Hz, TA=40°C,RthSA=1.0 °C/W ZthSA limits ∆TC to 10°C during overload 3.3V logic level Galvanic 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 uP. 0-5V output Output are buffered with 4mA drive capability ±10V for reference input, 5V for DCbus input 4 channel additional input available (optional) 4 bit, START, STOP, FLTCLR, CALIB 3 bit, PWMACTIVE, FAULT, SYNC 5V tolerant, Isolated, Active High logic IR2175, direct interface 10 bit (7.5 nanoseconds counting resolution ) 8.3 usec 133 MHz internal IRMCK203 clock 2175 PWM output (120 kHz) 27.5A peak, ±10% 35A peak, ±10% 110°C, ±5% 2.5 usec Case temperature line-to-line short, line-to-DC bus (-) short 400V 85V Should not exceed 400V for > 30 sec VCC=15V ± 10%,VDD=5V ± 5% 6 IGBT/FRED + IR2136 gate driver, integrated overcurrent/overtemp protection Bootstrap power supply for high side circuit 0 to 40°C 95%RH max. (non-condensing) Table 1. Fixed by IRAM16XUP60A module IRMCS2031 Electrical Specification This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 18 REFERENCE DESIGN IRMCS2031 IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105 Data and specifications subject to change without http://www.irf.com notice. January 6, 2004 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. 19 REFERENCE DESIGN IRMCS2031 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 20