User Guide for FEBSPM3SPM45_M01MTCA Motion SPM3/45H Evaluation Board Compatible with: SPM3V2_V4 & SPM45H Modules Featured Fairchild Product: FNB41560 (SPM45H SPM) Direct questions or comments about this evaluation board to: “Worldwide Direct Support” http://www.fairchildsemi.com/support/evaluationboards/ © 2012 Fairchild Semiconductor Corporation 1 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 Table of Contents 1. Overview of the Evaluation Board (EVB) ................................................................................. 3 2. Key Features ............................................................................................................................... 5 3. Specifications ............................................................................................................................. 6 3.1. Safety Precautions ***** WARNING ***** .................................................................7 3.2. Test Configuration #1 .......................................................................................................9 3.3. Test Configuration #2 .....................................................................................................10 3.4. Test Configuration #3 .....................................................................................................11 4. External Connections ............................................................................................................... 12 5. Schematics ................................................................................................................................ 13 6. PCB and Assembly Images ...................................................................................................... 19 7. Bill of Materials........................................................................................................................ 22 8. Key Parameter Design .............................................................................................................. 24 8.1. Current-Sensing Circuit ..................................................................................................24 8.2. Short Circuit Protection(SCP) Circuit ............................................................................25 9. VBUS Sense Circuit.................................................................................................................... 26 10. Test Waveforms ...................................................................................................................... 26 10.1. Bulk Capacitor Ripple Current .......................................................................................26 10.2. NTC Temperature ...........................................................................................................27 11. References ............................................................................................................................... 27 12. Revision History ..................................................................................................................... 28 © 2012 Fairchild Semiconductor Corporation 2 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 This user guide supports the SPM3V2_V4 / SPM45H evaluation board, identifiable by the marking FEBSPM3SPM45_M01MTCA on the topside of the PCB. It should be used in conjunction with SPM3V2_V4 / SPM45H product datasheets, as well as Fairchild Semiconductor’s application notes and technical support team available through the website at http://www.fairchildsemi.com. 1. Overview of the Evaluation Board This motion Smart Power Module (SPM®) evaluation board is designed to evaluate Fairchild Semiconductor’s SPM3V2_V4 and SPM45H SPM families of parts. The motion SPM is installed as the motor power module on the evaluation board to drive a three-phase AC Induction Motor (ACIM), Brushless DC (BLDC) motor, Brushless AC (BLAC) motor, or Permanent-Magnet Synchronous Motor (PMSM). A Switched-Mode Power Supply (SMPS) is integrated into the design, along with the necessary bulk capacitors and microcontroller (MCU) interface circuitry. This allows evaluation of Fairchild’s motion SPM products with a minimum investment of time, expense, and peripheral equipment. As this board is designed for a wide variety of motor types, not all included circuitry is required for all types of motors. Some motor types may require some additional circuitry be added, depending on the control algorithms being implemented. By default, the FNB41560 (600 V/15 A SPM45H) is installed as the motor power module, as shown in Figure 9. It is possible to replace the provided SPM45H module with a part from the SPM3_V2 family (i.e. FSBB30CH60, 600 V/30 A) per Figure 10 or the SPM3_V4 family (i.e. FSBB30CH60C, 600 V/30 A) per Figure 11. Depending on the power level of the device, some additional discrete component value changes may be required. The most common reason to consider a SPM3V2_V4 device over the SPM45H family is to increase motor power level. The evaluation board is designed to connect to either AC or DC power sources feeding current to the motor. There are three example test configurations in Section 3. The threephase motor output terminals (U, V, W) from the SPM should be connected to the motor windings. Three bootstrap power supply circuits are designed into the evaluation board, one per phase. A bootstrap capacitor, charge resistor for charging the capacitor, and the blocking diode for high-voltage isolation make up each bootstrap supply. With SPM45H and SPM3_V4 modules, R50-55 and D5-7 are not required. These extra bootstrap positions are provided for compatibility with SPM3_V2 modules. The microcontroller (MCU) or motion-controller development board connects to this SPM board via the provided connector. Six low-pass filters are used between the signal input connector and the gate input signal pins of the FNB41560. Short-circuit current protection is provided by a single shunt resistor, op amp, and low-pass filter. Additional circuitry is included to monitor bus voltage, inverter phase current, and module temperature. This evaluation board is designed to support a wide array of test conditions and requirements. © 2012 Fairchild Semiconductor Corporation 3 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 Figure 1. Top View, 140 mm x 160 mm Figure 2. Bottom View, 140 mm x 160 mm © 2012 Fairchild Semiconductor Corporation 4 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 2. Key Features AC Line Input Connection On-Board Bulk Capacitors Bulk Capacitor Charge Indicator On-Board High-Voltage SMPS - +15.75 VDC, +5 VDC, +3.3 VDC Outputs Short-Circuit Current Protection Triple Open-Emitter Connections to Negative DC Link MCU Interface Connections - 3 High-Side, 3 Low-Side Gate Drive Inputs - Fault Output - Bus Voltage Sense Output - 3-Phase Current Sensing, Amplified NTC Output Signal (when applicable) Current Sense Resistors (when applicable) 1 2 3 4 J1 J2 1 UH 2 VH 3 WH 4 UL 5 VL 6 WL VIU VIV VIW GND Over- Current Sense UH A B C 3 P 4 U 5 V 6 W VH WH SPM Module UL 7 Fo 8 Rth 9 Vfo 10 +5V 11 +3.3V VL WL A Fo 7 Rth GND 13 +15.75V n/c Shunt 9 N Resistors +5v Bridge Rectifier +3.3V 14 C 8 Vfo 12 B P SMPS +15.75V GND Bulk Capacitors L N 1 3 N J4 1 Vbus_sense 2 GND J3 Figure 3. © 2012 Fairchild Semiconductor Corporation 5 Block Diagram FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3. Specifications This evaluation board has been designed and optimized for the conditions in Table 1. Table 1. Electrical and Mechanical Requirements Evaluation Board Minimum Maximum Units VIN_AC 90 265 VAC VIN_DC 125 390 VDC fIN_AC 50 60 Hz Output Voltage 390 VDC IOUT (per Phase) 7(1,3,4) ARMS IOUT (per Phase) 15(2,3,4,5) ARMS PS1 (SMPS) VIN_AC 90 265 VAC fVIN_AC 47 63 Hz Output Voltage 1 3.3 VDC Output Current 1 0.15 A Output Voltage 2 5.0 VDC Output Current 2 0.15 A Output Voltage 3 15.75 VDC Output Current 3 0.06 A Notes: 1. See test configuration 1. 2. See test configuration 2 or 3. 3. A cooling fan may be required when operated for extended periods at high currents. Monitoring heat sink temperature near the thermal interface of the SPM is recommended when testing at high currents to ensure device remains within maximum thermal operating limits. 4. AC input voltage at 220 VAC. 5. This board is supplied with FNB41560 SPM45H motion SPM, rated at 600 V/15 A (TC=25°C, non-switching). In typical applications, the FNB41560 would realistically be limited to 7.5 ARMS (TC=100°C, 16 kHz switching). When the provided SPM is replaced with a high-current part, like the FSBB30CH60C (SPM3), operation to 15 ARMS may be possible. Additional electrical/thermal component changes may be necessary to support the higher currents. See test configurations. © 2012 Fairchild Semiconductor Corporation 6 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3.1. Safety Precautions ***** WARNING ***** Before applying power to the FEBSPM3SPM45_M01MTCA evaluation board, it is imperative that all involved personnel read and understand the safety precautions and understand the power on/off procedures. The FEBSPM3SPM45_M01MTCA evaluation board operates at lethal voltages and has bulk capacitors that store significant charge. Accidental contact can lead to lab equipment damage, personnel injury, and may be fatal. Please be exceptionally careful when probing and handling this board. Always observe normal laboratory precautions, including: All connected computers and measurement equipment MUST be isolated from the AC mains before operating voltages are applied to the board. Alternatively, AC/DC power to the board may be isolated. When using an oscilloscope with this board, it must be isolated from the AC line. Alternatively, high-voltage (700 V+) isolated probes may be utilized. See Figure 4 and Figure 5 for areas on the board that must be avoided due to the presence of HIGH VOLTAGES. When bulk capacitors are charged, avoid contact with board circuitry. Start with a clean working surface, clear of any conductive material. Be careful while turning on the power switch to the AC source. Never probe or move a probe on the board while the AC line voltage is present. LED D8 indicates high voltage is present on the high-voltage bus. Be aware! Ensure the bulk capacitors are discharged before disconnecting the AC motor and the MCU. One way to do this is to remove the main power source while the motor is still motoring with the MCU active. The motor then discharges the output capacitors and the module is safe to disconnect. Figure 4. High Voltage Areas (Top Side) © 2012 Fairchild Semiconductor Corporation 7 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 Figure 5. High-Voltage Areas (Bottom Side) © 2012 Fairchild Semiconductor Corporation 8 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3.2. Test Configuration #1 Use this configuration for motor current less than 7 ARMS. This is the default configuration (see Figure 6). 1. Attach the 3-phase motor and MCU connections. 2. Connect the AC line voltage to J3 to charge the bulk capacitors and operate the SMPS. The SMPS does not operate until the AC input voltage is greater than 90 VAC. 3. Fault indicator LED (D3) turns on when AC power is initially applied. 4. Press switch SW2 to reset the fault-detect circuit, turning off fault indicator D3. 5. Operate the MCU firmware to rotate the motor. More advanced control algorithms may require additional connections to the MCU (i.e.: phase current sensing, motor winding BEMF sensing, and bus voltage sensing). FAIRCHILD + F1 BD1 + SEMICONDUCTOR RT1 C39 C40 Motor 1 C21 R21 P4 R24 U4 C30 JP1 R16 R17 L 1 3 J2 R9 R11 C42 C13 4 ZD4 R6 ZD3 R4 ZD2 5V AC Line Voltage Figure 6. © 2012 Fairchild Semiconductor Corporation 15.75V 3.3V MCU GND J1-1 J4-1 P5 R59 FEBSPM3SPM45_M01MTCA 2 1 3 J3 C17 C14 C5 N C33 C41 R40 FSL206MR R22 C24 R23 C16 R8 C12 C10 C11 R7 C9 C8 C7 C3 R12 S3 S2 S1 SW2 Q1 C15 C1 R5 D3 R47 ZD1 Fault Indicator Reset C38 D3 JP2 R44 C32 R51 R53 C28 1 R55 U2 R46 C27 D5 R43 C19 R48 R45 D4 Q2 C37 R13 R50 D6 D7 R32 R34 R38 R36 R52 R54 U5 C31 SW2 R56 R33 R35 R39 R37 R57 R10 C18 R58 WARNING HIGH VOLTAGE R28 R30 M-U R15 N M-V R42 D8 R29 R31 Warning D8 Indicates High Voltage is present ZD5 M-V M-U R64 C20 M-W P M-W R14 C36 R49 C26 C34 HIGH VOLTAGE C29 R41 R25 C35 WARNING R26 R27 C22 R63 R20 R62 R19 R61 R18 C25 R60 Test Configuration #1 9 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3.3. Test Configuration #2 Use this configuration for motor currents greater than 7 ARMS. Modifications are required (see Figure 7). 1. Additional cooling and/or larger heat sink is required. 2. Variable transformer is recommended to slowly ramp VAC input to bulk capacitors. 3. Make a short connection in parallel with RT1, using RT2 mounting holes. 4. Attach a three-phase motor and MCU connections. 5. Connect the AC line voltage to J3 through a variable transformer to charge the bulk capacitors and operate the SMPS. The SMPS does not operate until the AC input voltage is greater than 90 VAC. 6. Slowly adjust the variable transformer for the desired AC voltage. 7. Fault indicator LED (D3) turns on when AC power is initially applied. 8. Press switch SW2 to reset the fault-detect circuit, turning off fault indicator D3. 9. Operate the MCU firmware to rotate the motor. More advanced control algorithms may require additional connections to the MCU (i.e.: phase current sensing, motor winding BEMF sensing, and bus voltage sensing). FAIRCHILD + F1 BD1 + SEMICONDUCTOR RT1 C39 C40 Motor 1 C21 R21 U4 P4 R24 JP1 R16 R17 L 1 2 1 3 J3 N C33 C41 R40 3 J2 C14 C5 ZD1 R9 R11 C42 C13 4 ZD4 R6 ZD3 R4 ZD2 R5 D3 C24 R23 C17 C16 C12 C10 C11 C9 R8 C3 R7 C1 C8 C7 C15 FSL206MR R22 R47 R12 S3 S2 S1 Q1 SW2 Fault Indicator Reset C38 D3 JP2 R33 R35 R39 R37 U5 C31 R51 R53 C28 1 R55 U2 R46 C27 D5 R43 C19 R48 R45 D4 Q2 C37 R13 R50 D6 D7 R32 R34 R38 R36 R52 R54 SW2 15.75V 5V 3.3V GND J1-1 J4-1 P5 R59 FEBSPM3SPM45_M01MTCA R56 R44 C32 R57 R10 C18 R58 WARNING HIGH VOLTAGE C30 M-U R15 N M-V R42 R28 R30 D8 R29 R31 Warning D8 Indicates High Voltage is present ZD5 M-V M-U R64 C20 M-W M-W R14 C36 R49 C26 C34 P C29 R41 R25 R20 HIGH VOLTAGE R26 R27 C35 WARNING R63 C22 R62 R19 R61 R18 C25 R60 Variable Transformer MCU Figure 7. Test Configuration #2 © 2012 Fairchild Semiconductor Corporation 10 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3.4. Test Configuration #3 Use this configuration for motor currents greater than 7 ARMS. Modifications are required (see Figure 8). 1. Additional cooling and/or larger heat sink is required. 2. Remove JP1 and JP2 AC line jumpers. This removes power to the bridge rectifier. The AC line voltage is only applied to the SMPS. 3. Attach the three-phase motor and MCU connections. 4. Connect the AC line voltage to J3 to power the SMPS. 5. Fault indicator LED (D3) turns on when AC power is initially applied. 6. Press switch SW2 to reset the fault-detect circuit, turning off fault indicator D3. 7. Connect an isolated high-power DC power supply to the P and N terminals. 8. Adjust the DC supply for the desired DC voltage. 9. Operate the MCU firmware to rotate the motor. More advanced control algorithms may require additional connections to the MCU (i.e.: phase current sensing, motor winding BEMF sensing, and bus voltage sensing). FAIRCHILD + F1 BD1 + SEMICONDUCTOR RT1 C39 C40 Motor 1 C21 R21 U4 R42 JP1 R16 R17 L 1 3 J2 ZD1 R10 C18 R9 R11 C42 C13 R6 4 ZD4 R4 D3 ZD3 R5 ZD2 DC Power Supply 15.75V 5V GND 3.3V J1-1 J4-1 P5 R59 FEBSPM3SPM45_M01MTCA 1 2 C16 C14 C5 3 J3 C33 C41 R40 C17 R12 C12 C10 C11 C9 R8 C3 R7 C1 C8 C15 C24 R23 N R22 S3 S2 R47 C7 D3 S1 Q1 SW2 Fault Indicator Reset C38 FSL206MR R51 R53 JP2 C28 R33 R35 R39 R37 D5 R55 U2 R46 C27 R43 C19 R48 R45 D4 Q2 C37 R13 R50 D6 D7 R32 R34 R38 R36 R52 R54 1 SW2 R56 R44 C32 R57 U5 C31 R58 WARNING HIGH VOLTAGE C30 M-U R15 N M-V P4 R24 R28 R30 D8 R29 R31 Warning D8 Indicates High Voltage is present M-U ZD5 M-V M-W R64 C20 M-W R14 C36 R49 C26 C34 P C29 R41 R25 R20 HIGH VOLTAGE R26 R27 C35 WARNING R63 C22 R62 R19 R61 R18 C25 R60 MCU Figure 8. Test Configuration #3 © 2012 Fairchild Semiconductor Corporation 11 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 3.5. Power-Off Procedure 1. Remove the AC line voltage or high-power DC power supply while the MCU is enabled. 2. Allow the motor to discharge the bulk capacitors, as indicated by D3 going off when the bus capacitors are fully discharged. It is good practice to have an isolated DMM attached to the board to ensure the bus voltage is at a safe level prior to handling or manipulating electrical connections. 4. External Connections Signal Interface J1 J2 J3 J4 ¼” Spade Terminals © 2012 Fairchild Semiconductor Corporation Pin Function 1 High-Side Input Signal from MCU (Phase U), active HIGH 2 High-Side Input Signal from MCU (Phase V), active HIGH 3 High-Side Input Signal from MCU (Phase W), active HIGH 4 Low-Side Input Signal from MCU (Phase U), active HIGH 5 Low-Side Input Signal from MCU (Phase V), active HIGH 6 Low-Side Input Signal from MCU (Phase W), active HIGH 7 Fault-Out Signal to MCU, active LOW 8 RTH 9 VFO, active LOW 10 SMPS +5 V Output 11 SMPS +3.3 V Output 12 GND 13 SMPS +15.75 V Output 14 N/C 1 Current-Sense Output (Phase U) 2 Current-Sense Output (Phase V) 3 Current-Sense Output (Phase W) 4 Signal GND 1 AC Line Input (Hot) 3 AC Neutral Input (Neutral) 1 +Bus Voltage Sample Output 2 -Bus Voltage Sample Output P Positive DC Link Input Connection N Negative DC Link Input Connection U Motor Output Connection (Phase U) V Motor Output Connection (Phase V) W Motor Output Connection (Phase W) 12 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 5. Schematics C1 33µF 35V C2 104 2012 VB(U) 26 VS(U) 25 ZD3 VB(V) 1N4749 VB(V) 24 VS(V) VS(V) 23 ZD4 VB(W) 1N4749 VB(W) 22 VS(W) 21 VS(U) C3 33µF 35V C5 33µF 35V C4 104 2012 C6 104 2012 VS(W) 2 IN_UH 1 2 IN_VH 1 2 IN_WH 1 1 2 IN_UL 2 IN_VL 1 1 2 IN_WL R4 100R 2012 R5 100R 2012 R6 100R 2012 R7 100R 2012 R8 100R 2012 R9 100R 2012 IN(UH) 20 IN(VH) 19 IN(WH) 18 VB(U) C7 C8 C9 C10 C11 C12 102 2012 15 IN(UL) 14 IN(VL) 13 IN(WL) VFO VS(V) R13 6.8k 2012 1 2 2 P COM P VS(W) U P 3 4 M-U 1 1 U 2 2 5 V VB(W) IN(UH) IN(VH) V IN(WH) 1 2 VCC(L) W 6 W IN(UL) 12 7 N U VFO N V 8 N V CSC N W 9 N W IN(WL) 10 CSC R12 62 1 2 2 1 C130 2 0.1µF 630V COM IN(VL) 1 M-V VCC(H) 11 1 RTH RTH 1 VB(V) 16 COM VTH VS(U) 17 VCC +5V U1 SPM45 FNB41560 VB(U) ZD2 1N4749 N U 1 2 M-W 1 2 1 R14 2 NuN Nu+ 1 R16 2 Nv+ 1 Nv- 1 R15 2 R17 R17+ N 2 R17- 1 2 1 2 Nw- Nw+ 2 Single Sense C17 333 +5V 15.75V ZD1 1N4749 C16 220µF 35V C15 104 2012 C18 105 2012 C19 104 2012 COM Figure 9. FEBSPM3SPM45_M01MTCA with SPM45 © 2012 Fairchild Semiconductor Corporation 13 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 1 R51 1 1 R53 VS(U) C3 33µF 35V 1 VB(U) ZD2 1N4749 C2 104 2012 ZD3 VB(V) 1N4749 C4 104 2012 ZD4 VB(W) 1N4749 C6 104 2012 VS(W) IN_WH IN_VH IN_UH IN_WL IN_VL IN_UL 1 1 1 1 1 1 1 VS(W) 20 VB(W) 19 18 17 VS(V) 16 VB(V) 15 14 VS(U) 12 VB(U) 11 10 R4-R9 100R 2012 9 8 7 C7 C8 C9 102 2012 C10 C11 C12 6 5 4 3 2 1 R12 62 2 MMBD4148 R52 D6 2 n/c R54 MMBD4148 D7 2 U1 SPM3_V2 FSBB30CH60 n/c 13 2 2 2 2 2 2 2 n/c VS(V) C5 33µF 35V D5 2 2 1 C1 33µF 35V R50 n/c n/c R55 MMBD4148 2 n/c 1 Single Sense VS(W) VB(W) P 27 P P 1 1 2 2 VCC(H3) IN(WH) VS(V) M-W VB(V) VCC(H2) W 26 1 U 1 2 2 IN(VH) M-V VS(U) VB(U) V 25 1 V 2 VCC(H1) Cfod C130 2 0.1µF 630V M-U IN(UH) Csc 1 U 24 1 W 2 1 2 Vfo 1 IN(WL) IN(VL) IN(UL) COM Vcc(L) Nw Nv Nu 23 22 NV R14 2 1 N R16 2 Nv+ 21 Nu- Nu+ NU NW 1 1 Nv- R15 2 R17 R17+ N 2 1 2 R17- 1 2 Nw- Nw+ C17 333 +5V 15.75V Cfod C38 ZD1 1N4749 Figure 10. © 2012 Fairchild Semiconductor Corporation C16 220µF 35V C15 104 2012 C18 105 2012 C19 104 2012 CAP NP COM FEBSPM3SPM45_M01MTCA with SPM3_V2 14 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 VB(U) C1 33µF 35V C2 104 2012 U1 SPM3_V4 VS(U) VB(V) C3 33µF 35V C5 33µF 35V VS(W) C4 104 2012 20 VB(W) 19 VS(V) 18 VB(W) 17 C6 104 2012 VS(W) VS(V) 16 VB(V) 15 14 IN_WH IN_VH IN_UH IN_WL IN_VL IN_UL 1 1 1 1 1 1 13 2 2 2 2 2 2 VS(U) 12 VB(U) 11 10 R4-R9 100R 2012 9 8 7 C7 C8 C9 102 2012 C10 C11 C12 6 5 4 3 2 1 R12 62 2 1 Single Sense FSBB30CH60C P VS(W) VB(W) P 27 P 1 1 2 2 VCC(H3) IN(WH) VS(V) M-W VB(V) VCC(H2) W 26 1 U 1 2 2 IN(VH) M-V VS(U) VB(U) V 25 1 V 2 VCC(H1) Cfod C130 2 0.1µF 630V M-U IN(UH) Csc 1 1 U 24 W 2 1 2 Vfo 1 IN(WL) IN(VL) IN(UL) COM Vcc(L) Nw Nv Nu 23 22 NV R14 2 1 N R16 2 Nv+ 21 Nu- Nu+ NU NW 1 1 Nv- R15 2 R17 R17+ N 2 1 2 R17- 1 2 Nw- Nw+ C17 333 +5V 15.75V Cfod C38 ZD1 1N4749 Figure 11. © 2012 Fairchild Semiconductor Corporation C16 220µF 35V C15 104 2012 C18 105 2012 C19 104 2012 CAP NP COM FEBSPM3SPM45_M01MTCA with SPM3_V4 15 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 +5V P R18 78.7K R60 22K R21 C22 101 R62 22K Nw+ R15 Nw- C21 101 R26 1.0K 1% 1.0K 1% Nu- R30 1.0K 1% R16 C26 101 U4 FAN4274 +Vs 3 Nv+ R32 1.0K 1% Nv- R34 1.0K 1% +In1 2 6 R33 1.8K 1% C27 101 +In2 Out2 -In2 -Vs U5 FAN4274 3 R35 1.8K 1% +In1 2 J2 1 C29 101 7 R42 Out2 -In2 -Vs +5V C30 101 8 C35 101 1 R43 39K 1% C41 1µF DNP Single Sense 7 4 R44 7.87K 1% R39 1.8K 1% C32 101 R40 8.2K 101 C33 VIU VIV VIW GND 1 2 3 4 39K 1% C31 101 +In2 6 1 2 3 4 R41 39K 1% -In1 5 R37 1.8K 1% Out1 C36 1µF DNP 8 4 +Vs R33 1.8K 1% R17 / Single R38 R17- 1.0K 1% Out1 -In1 5 R29 1.8K 1% C28 101 R36 R17+ 1.0K 1% D8 HV charge indicator LED C34 101 R27 1.8K 1% Nu+ R14 C24 101 C25 R24 101 R25 1.0K 1% 1.8K 1% R28 ZD5 MM3Z47VB R23 +5V R61 22K R64 22K R22 78.7K R19, R21, R23: 78.7k R19 R63 22K R20 78.7K 15.75V FSL206MR +5V 15.75V Gnd 5V 3.3V Ac N Daughter1 2 N 1 2 3 Conn AC F1 FUSE CL-11 RT2 DNP Jumper BR1 1 JP2 Jumper 2 - + P 4 CL-11 RT1 3 Figure 12. © 2012 Fairchild Semiconductor Corporation DFB2560 1 L JP1 J5 CN2 2 J3 3.3V 4 5 6 7 C40 680uF, 450V J4 CN1 Ac L C39 680uF, 450V 1 2 3 R49 62K N Power Supply, HV Charge Indicator and Current Sense 16 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 +5V 3.3V R10 4.7K R11 FO 100R 2012 R47 330 Q2 2N2907A D3 LED R45 100K Vfo C13 102 2012 C14 102 R48 3.3K R46 3.3K Q1 2N2222A D4 SW2 2 MMBD4148SE 1 Switch n/c C37 0.1µF, 16V P R56 510K J1 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IN_UH IN_VH IN_WH IN_UL IN_VL +5V 3.3V IN_WL FO 15.75 RTH Vfo R58 510K n/c 1 2 R57 510K Vbus_Sense R59 20K C42 15nF COM Figure 13. © 2012 Fairchild Semiconductor Corporation Fault, VBUS_SENSE, J1 and J4 17 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 1 D1 ~ D4 1N4007 C3 4.7µF 400V R1 OPEN 0805 C4 4.7µF 400V 4 3 C1 1nF 250V Vstr LS 8 Drain 7 Drain 6 Drain Vcc 2 Vfb GND 1 R7 0W 0805 GND C5 1nF 1kV 15.75V / 60mA 6 D7 UF4004 C9 220µF 25V 2 C10 NC R13 OPEN 1206 L4 5µH 3 U1 FSL206MR L2 22µH F1 1A 250V R6 200kW 1206 D5 1N4007 5 L R5 200kW 1206 R3 51kW 1206 R2 OPEN 0805 C2 100nF 250VAC L3 Shot T1 EE16 L1 680µH C8 10nF 0805 R4 200W 1206 10 5V / 150mA C11 220µF 10V D8 SB360 8 C6 C7 10µF 100nF 50V D6 1N4148 R8 0W 0805 C12 220µF 10V R9 220W 1206 U2 MMBT2222A SOT23 R12 NC 1206 R11 10kW 1206 C14 NC 0805 LDO U3 KA78RM33 D-PAK Z1 MM3Z4V7B SOD-323F 3.3V / 150mA C13 220µF 10V R10 510W 1206 N Figure 14. PS1 Schematic Note: 6. This power supply is significantly larger in power levels that is typically required in motor control applications. The increased output capacity of this supply is to support the testing and evaluation process and may be used to power select MCU development boards. See the output current limits in the Specification section. © 2012 Fairchild Semiconductor Corporation 18 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 6. PCB and Assembly Images Figure 15. Figure 16. © 2012 Fairchild Semiconductor Corporation 19 Top Layer Bottom Layer FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 SW2 R57 D4 R48 R49 + R46 R45 R47 Q2 P HIGH VOLTAGE R56 D3 C37 Q1 WARNING N R58 Fault Indicator Reset U2 C19 R63 + C26 R28 R30 R26 C22 R19 C34 R20 C35 RT1 C29 R41 1 C21 R21 C25 U4 ZD1 C30 C36 R24 R25 R42 R32 R34 R38 R36 R29 R31 R27 R14 R33 R35 R39 R37 C28 C33 C41 R40 R44 C32 R15 R17 1 R16 C24 R23 C16 R43 U5 C31 C27 R22 C17 R10 C18 J1-16 Warning D8 Indicates High Voltage is present R12 C14 R11 R62 D5 C12 R9 C39 R64 ZD5 R50 C11 C13 M-U D8 C38 C10 R8 R61 R52 M-V M-U R7 R60 R54 M-V D6 R6 M-W D7 C9 R51 C15 C8 R5 R53 S3 C7 R4 J1-1 R13 C5 ZD4 C42 R59 J4-1 C40 M-W R55 ZD3 C3 S1 S2 R18 ZD2 C1 C20 3.3V 5V GND 15.75V BD1 P5 FSL206MR J2 2 1 N JP1 3 J3 JP2 4 P4 L F1 WARNING HIGH VOLTAGE FAIRCHILD SEMICONDUCTOR FEBSPM3SPM45_M01MTCA Figure 17. © 2012 Fairchild Semiconductor Corporation 20 Top Assembly FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 C2 C4 C6 U1 Figure 18. © 2012 Fairchild Semiconductor Corporation 21 Bottom Assembly FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 7. Bill of Materials Item Qty. Reference Part Number Value Description Manufacturer Package Fairchild Semiconductor Thru-Hole 1 1 BR1 DFB2560 25 A 600 V, Bridge Rectifier 2 3 C1, C3, C5 EEE-FK1V330P 33 µF Capacitor, SMD, Alum, 35 V Panasonic - ECG SMD 3 4 C2, C4, C6, C15 C0805C104K5RACTU 100 nF Capacitor, SMD, Ceramic, 50 V Kemet 805 4 1 C16 EKZE350ELL221MH15D 220 µF Capacitor, Alum, 35 V, Radial United Chemi-Con Thru-Hole 5 2 C17, C38 C0805C333K5RACTU 33 nF Capacitor, Ceramic, 50 V, X7R Kemet 805 6 2 C18, C41 GRM21BR71H105KA12L 1 µF Capacitor, Ceramic, 50 V, X7R Murata 805 7 1 C20 ECQ-E6104KF 0.1 µF ECQ-E6104KF Panasonic Thru-Hole 8 14 C21, C22, C24, C25, C26, C27, C28, C29, C30, C31, C32, C33, C34, C35 C0805C101K5GACTU 100 pF Capacitor, Ceramic, 50 V, X7R Kemet 805 9 1 C37 C0805C104K4RACTU 0.1 µF Capacitor, Ceramic, 16 V, X7R Kemet 805 10 2 C39, C40 EET-UQ2W681EA 680 µF Capacitor, Alum, 450 V, Radial Panasonic Thru-Hole 11 1 C42 C0805C153K5RACTU 15 nF Capacitor, Ceramic, 50 V, X7R Kemet 805 12 9 C7, C8, C9, C10, C11, C12, C13, C14, C19 C0805C102K5RACTU 1 nF Capacitor, SMD, Ceramic, 25 V, X7R STD 805 13 1 D3, D8 CMD15-21VRD/TR8 LED, 100V, 200 mA Chicago Mini Light 1206 14 4 D4, D5, D6, D7 MMBD4148 1 µF Capacitor, SMD, Ceramic,50 V, X5R STD SOT-23 15 1 F1 0326025.HXP 10 A Fuse Cover .32x1.42x5" 16 3 F1C 840836 Fuse Cover Richco Plastic Co. 17 2 F1CLP BK/1A1907-05 Fuse Clip (6.35 mm) Cooper Bussman TE Connectivity Thru-Hole 18 1 J1 22-28-4163 Conn Header 16 Pin 0.1 Vert Gold 19 1 J2 09-65-2048 4 Pin Header 3.96 mm Pitch Molex Thru-Hole 20 1 J3 09-65-2038 3 Pin Header 3.96 mm Pitch Molex Thru-Hole 21 1 P4 09-50-1031 3 Pin rcpt 3.96 mm Pitch Molex Thru-Hole 22 1 P5 09-50-1041 4 Pin rcpt 3.96 mm Pitch Molex Thru-Hole 23 1 PS1 FSL206MR 15.75 V, 5 V, 3.3 V SMPS Fairchild Semiconductor 24 1 Q1 MMBT2222A Transistor, NPN, 40 V, 1 A Fairchild Semiconductor SOT-23 25 1 Q2 MMBT2907A Transistor, PNP, 60 V, 0.8 A Fairchild Semiconductor SOT-23 26 1 R10 MCR10EZPJ472 4.7 kΩ Resistor, 1/8 W, 5% ROHM 805 27 1 R12 MCR10EZHJ620 62 kΩ Resistor, 1/8 W, 5% ROHM 805 28 1 R13 MCR10EZPF6801 6.8 kΩ Resistor, 1/8 W, 5% ROHM 805 © 2012 Fairchild Semiconductor Corporation 22 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 Item Qty. Reference Part Number Value Description Manufacturer Package R14, R15, R16, R17 BR3FB15L0 (Optional) 0.015 Ω Resistor, 3 W, ±1% Stackpole ELEC. Thru-Hole 29 4 30 4 R14, R15, R16, R17 BR3FB10L0 0.010 Ω Resistor, 3 W, ±1% Stackpole ELEC. Thru-Hole 31 6 R18, R19, R20, R21, R22, R23 MCR10EZPF7872 78 kΩ Resistor, 1/8 W, 5% ROHM 805 32 8 R24, R26, R28, R30, R32,R 34, R36, R38 MCR10EZPF1001 1.0 kΩ Resistor, 1/8 W, 5% ROHM 805 33 8 R25, R27, R29, R31, R33,R 35, R37, R39 MCR10EZPF1801 1.8 kΩ Resistor, 1/8 W, 5% ROHM 805 34 7 R4, R5, R6, R7, R8, R9, R11 MCR10EZPJ101 100 kΩ Resistor, 1/8 W, 5% ROHM 805 35 1 R40 MCR10EZPF8201 8.2 kΩ Resistor, 1/8 W, 5% ROHM 805 36 3 R41, R42, R43 MCR10EZHF3902 39 kΩ Resistor, 1/8 W, 5% ROHM 805 37 1 R44 MCR10EZPF7871 7.87 kΩ Resistor, 1/8 W, 5% ROHM 805 38 1 R45 MCR10EZPJ104 100 kΩ Resistor, 1/8 W, 5% ROHM 805 39 2 R46, R48 MCR10EZPJ332 3.3 kΩ Resistor, 1/8 W, 5% ROHM 805 40 1 R47 MCR10EZPJ331 330 kΩ Resistor, 1/8 W, 5% ROHM 805 41 1 R49 62 kΩ Resistor, 1/8 W, 5% ROHM 805 42 3 R56, R57, R58 MCR10EZHF5103 510 kΩ Resistor, 1/8 W, 5% ROHM 805 43 1 R59 MCR18EZPF2002 20 kΩ Resistor, 1/8 W, 5% ROHM 805 44 5 R60, R61, R62, R63, R64 MCR18EZPF2202 22 kΩ Resistor, 1/8 W, 5% ROHM 805 45 1 RT1 CL-11 12 A Inrush current limiter, 0.02 W GE Sensing Thru-Hole 46 0 RT2 DNP 47 1 SW1 KSR223GNCLFG 48 5 U, V, W, P, N 63824-1 Switch Tactile, SPST, C&K Components n/c, 32 V Tab Terminal NOTE8 SMD Thru-Hole SPM45H SPM Fairchild Semiconductor Thru-Hole Dual, Low Cost, RRIO CMOS Amp Fairchild Semiconductor MSOP 8Lead 49 1 U1 FNB41560 50 2 U4, U5 FAN4274IMU8X 51 4 ZD1, ZD2, ZD3, ZD4 1N4749ATR 24 V ZD1,ZD2,ZD3,ZD4 Fairchild Semiconductor DO-41 52 1 ZD5 MM3Z47VB 47 V Diode, Zener, 200 mW Fairchild Semiconductor SOD-323F Notes: 7. DNP = Do Not Populate. 8. U1 replaceable, depending on design requirements. © 2012 Fairchild Semiconductor Corporation 23 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 8. Key Parameter Design 8.1. Current-Sensing Circuit To simplify current-sensing circuit design, this evaluation board has open-emitter DClink terminals (NU, NV, NW) for current sensing. Refer to reference design RD-344 for a more detailed explanation. In this example, the ideal sense resistor value is 8 mW The board includes a default sense resistor of 10 mW The actual sense resistor value used is typically a balance between noise-levels at small currents and sense-resistor losses. Calculation Conditions Installed SPM: FNB41560 Op Amp: FAN4274 Resistance of Sense Resistor: 8 mW Voltage Gain: 13.9 Bandwidth: 86 kHz Refer to Figure 15 Figure 19. © 2012 Fairchild Semiconductor Corporation Current-Sensing Circuit 24 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 8.2. Short-Circuit Protection (SCP) Circuit One shunt resistor is used for sensing short-circuit (SC) current. The related circuit is composed of an external shunt resistor, op amp, RC low-pass filter, fault indicator circuit, and fault output pin. Refer to reference design RD-344 for a more detailed explanation of the SCP circuit shown in Figure 16. In this example, the ideal shunt resistor value is 8 mW The default shunt resistor used on this board is a 10 mWThe actual shunt resistor value used is typically a balance between component count (if op amp is required due to small resistor value) and shunt-resistor losses. During a short-circuit condition, the SPM VFO pin is actively pulled down via the internal open-collector transistor. This event lights the fault indicator LED (D3) and sends the low FO signal to the MCU via J1-9. To reset fault and its indicator D3, press fault-reset switch SW2. Calculation Conditions Installed SPM: FNB41560 Op Amp: FAN4274 Resistance of Shunt Resistor: 8 mW SC Trip Current: 22.5 A (1.5 x IC (rated current), can be lowered by the designer) SC Trip Reference Voltage: VSC(min)=0.45 V, VSC(typ)=0.5 V, VSC(max)=0.55 V Refer to Figure 16 Alternatively, a larger value shunt resistor could be used without requiring an op amp at the expense of higher losses in the sense resistor. Figure 20. © 2012 Fairchild Semiconductor Corporation Short-Circuit Protection Circuit 25 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 9. VBUS Sense Circuit This evaluation board is equipped with a VBUS sense output. As seen in Figure 18, the voltage divider network is in parallel with bulk capacitors C39 and C40. With a VBUS of 300 VDC, a nominal output of ~3.9 VDC is typical at J4-1. R58 510K R59 20K 2 1 2 C42 15nF 2 2 1 1 J4 1 2 Vbus_sense 1 2 R57 510K 1 P R56 510K COM Figure 21. VBUS Sense Circuit 10. Test Waveforms 10.1. Bulk Capacitor Ripple Current Figure 22. © 2012 Fairchild Semiconductor Corporation Bulk Capacitor Ripple Voltage Under Varying Load Currents 26 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 10.2. NTC Temperature RT1 operating temperature measured at varying load currents. Figure 23. NTC Temperature 11. References RD-344: Fairchild Motion-SPM FNA41560 – Three Shunt Design RD-345: Fairchild Motion-SPM FNA41560 – Single Shunt Design AN-9021: A Novel IGBT Inverter Module for Low-Power Drive Applications AN-9035: Smart Power Module Motion-SPM in Mini-DIP User’s Guide AN-9041: PFCM Design Guide with Analog PFC IC AN-9042: Smart Power Module Tiny-DIP SPM® User's Guide AN-9043: Smart Power Module DIP SPM® User's Guide AN-9044: Smart Power Module Motion SPM® in Mini DIP SPM® AN-9070: Smart Power Module Motion SPM® in SPM45H AN-9071: Smart Power Module Motion SPM® in SPM45H Thermal Performance Information AN-9072: Smart Power Module Motion SPM® in SPM45H Mounting Guidance © 2012 Fairchild Semiconductor Corporation 27 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1 12. Revision History Date Revision Description January 2013 1.0.0 Initial Release April 2013 1.0.1 Add output voltage specification to Table 1 Evaluation Board, list U1 in BOM WARNING AND DISCLAIMER Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Users’ Guide. Contact an authorized Fairchild representative with any questions. This board is intended to be used by certified professionals, in a lab environment, following proper safety procedures. Use at your own risk. The Evaluation board (or kit) is for demonstration purposes only and neither the Board nor this User’s Guide constitute a sales contract or create any kind of warranty, whether express or implied, as to the applications or products involved. Fairchild warrantees that its products meet Fairchild’s published specifications, but does not guarantee that its products work in any specific application. 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Customers who inadvertently purchase counterfeit parts experience many problems such as loss of brand reputation, substandard performance, failed applications, and increased cost of production and manufacturing delays. Fairchild is taking strong measures to protect ourselves and our customers from the proliferation of counterfeit parts. Fairchild strongly encourages customers to purchase Fairchild parts either directly from Fairchild or from Authorized Fairchild Distributors who are listed by country on our web page cited above. Products customers buy either from Fairchild directly or from Authorized Fairchild Distributors are genuine parts, have full traceability, meet Fairchild's quality standards for handling and storage and provide access to Fairchild's full range of up-to-date technical and product information. Fairchild and our Authorized Distributors will stand behind all warranties and will appropriately address any warranty issues that may arise. Fairchild will not provide any warranty coverage or other assistance for parts bought from Unauthorized Sources. Fairchild is committed to combat this global problem and encourage our customers to do their part in stopping this practice by buying direct or from authorized distributors. EXPORT COMPLIANCE STATEMENT These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations for the ultimate destination listed on the commercial invoice. Diversion contrary to U.S. law is prohibited. U.S. origin products and products made with U.S. origin technology are subject to U.S Re-export laws. In the event of re-export, the user will be responsible to ensure the appropriate U.S. export regulations are followed. © 2012 Fairchild Semiconductor Corporation 28 FEBSPM3SPM45_M01MTCA • Rev. 1.0.1