56F8300 3-Phase AC Induction Motor V/Hz Control using Processor ExpertTM Targeting Document 56F8300 16-bit Digital Signal Controllers 8300ACIMTD Rev. 1 08/2005 freescale.com Document Revision History Version History Description of Change Rev 0 Initial release Rev 1 Updating format; adding references to 56F8100 family and 56F8367EVM 3-Phase AC Induction Motor V/Hz Control, Rev. 1 2 Freescale Semiconductor 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop This application demonstrates a principal of the Volts per Hertz (V/Hz) control of the 3-Phase AC Induction motor in closed-loop using the 56F8346, 56F8357 or 56F8367 EVM board, Optoisolation board, and 3-phase AC BLDC high-voltage power stage. Applications developed for this demonstration board were not designed for the 56F8100 devices. The 56F8300 demonstration board does, however, fully support 56F8100 software development. 1. Specifications This application performs principal control of the 3-phase AC induction motor using a 56F8300 processor. The control technique sets the speed (rpm or Hz) of the magnetic field and calculates the phase voltage amplitude according to a V/Hz table. This table is private to the application and reflects AC induction motor parameters (Base Voltage/frequency; Boost Voltage/frequency; DC Boost Voltage). The incremental encoder is used to derive the actual rotor speed. The closed-loop system is characterized by a feedback signal (Actual speed), derived from a quadrature decoder in the controlled system. This signal monitors the actual behavior of the system, and is compared with the reference signal (Required Speed). The magnitude and polarity of the resulting error signal are directly related to the difference between the required and actual values of the controlled variable, which may be the speed of a motor. The error signal is amplified by the controller, and the controller output makes a correction to the controlled system, reducing the error signal. Protection is provided against drive faults Overcurrent, Overvoltage, Undervoltage, and Overheating. System Outline The system is designed to drive a 3-phase AC Induction Motor (ACIM). The application has the following specifications: • • • • • • • • • Volt per Hertz control technique used for ACIM control Closed-loop control Targeted for 56F8346, 56F8357 or 56F8367 EVM Running on 3-phase AC induction motor control development platform at variable line voltage 115V AC and 230V AC (range -15% to +10%) Motor mode Generator mode DCBus brake Minimum speed 50rpm Maximum speed 2250rpm at input power line 230V AC 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 3 • • • • • Maximum speed 1200rpm at input power line 115V AC Power stage and optoisolation board identification Fault protection Manual interface (RUN/STOP switch; UP/DOWN push buttons control; LED indication) PC master software remote control interface (speed set-up) PC master software remote monitor — PC master software monitor interface (required speed; actual motor speed; drive fault status; DCBus voltage level; identified power stage boards) Application Description The Volt per Hertz control algorithm is calculated on the Freescale 56F8300 devices. The algorithm generates the 3-phase PWM signals for AC induction motor inverter according to the user-required inputs, measured and calculated signals. The concept of the ACIM drive incorporates the following hardware components: • • • • AC induction motor-brake set 3-phase AC/BLDC high voltage power stage 56F8346, 56F8357 or 56F8367 EVM board Optoisolation box, which is connected between the power stage board and the EVM The AC induction motor-brake set incorporates a 3-phase AC induction motor and attached BLDC motor brake. The AC induction motor has four poles. The incremental position sensor (encoder) is coupled on the motor shaft. The detailed motor-brake specifications are listed in Table 1-1. 3-Phase AC Induction Motor V/Hz Control, Rev. 1 4 Freescale Semiconductor Table 1-1 Motor-Brake Specifications Set Manufactured EM Brno, Czech Republic Motor Specification Brake Specification Position Sensor (Encoder) Motor Type AM40V 3-Phase AC Induction Motor Pole-Number 4 Nominal Speed 1300rpm Nominal Voltage 3 x 200V Nominal Current 0.88A Brake Type SG40N 3-Phase BLDC Motor Pole-Number 6 Nominal Speed 1500rpm Nominal Voltage 3 x 27V Nominal Current 2.6A Type Baumer Electric BHK 16.05A 1024-12.5 Pulses per revolution 1024 The following software tools are needed for compiling, debugging, loading to the EVM, remote control and monitoring, RUN/STOP Switch and UP/DOWN Buttons: • • • Metrowerks CodeWarrior 6.0 PC master software Processor Expert v. 2.92 Measured quantities include: • • • DCBus voltage Power module temperature Rotor speed The faults used for drive protection: • • • • • Overvoltage (PC master software error message = “Overvoltage fault”) Undervoltage (PC master software error message = “Undervoltage fault”) Overcurrent (PC master software error message = “Overcurrent fault”) Overheating (PC master software error message = “Overheating fault”) Wrong hardware (PC master software error message = “Wrong HW used”) The 3-phase AC Induction Motor V/Hz application can operate in two modes: 1. Manual Operating Mode The drive is controlled by the RUN/STOP switch (S3). The motor speed is set by the UP (S2) and DOWN (S1) push buttons (Figure 1-1). If the application runs and motor spinning is disabled (i.e., the system is ready), the green user LED (LED2; see Figure 1-2 ) will blink. When motor 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 5 spinning is enabled, the green user LED will be on and the actual state of the PWM outputs are indicated by PWM output LEDs. If Overcurrent, Overvoltage or Overheating occur, or if the wrong system board is identified, the green user LED starts to flash quickly and the PC master software signals the identified type of fault. This state can be exited only by an application RESET. It is strongly recommended that you inspect the entire application to locate the source of the fault before starting it again. Refer to Table 1-2 for application states. UP / DOWN Buttons RUN / STOP Switch Figure 1-1 RUN/STOP Switch and UP/DOWN Buttons on the Daughter Card 3-Phase AC Induction Motor V/Hz Control, Rev. 1 6 Freescale Semiconductor User LEDs Yellow Green PWM Output LEDs Figure 1-2 USER and PWM LEDs on the Daughter Card Table 1-2 Motor Application States Application State Motor State Green LED State Stopped Stopped Blinking at a frequency of 2Hz Running Spinning On Fault Stopped Blinking at a frequency of 8Hz 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 7 2. PC Master Software (Remote) Operating Mode The drive is controlled remotely from a PC through the SCI communication channel of the CPU device via an RS-232 physical interface. The drive is enabled by the RUN/STOP switch, which can be used to safely stop the application at any time. The following control actions are supported: • • Set the Required Speed of the motor Set Close/Open loop by checking/unchecking the “Close Loop” checkbox; see Figure 1-3 PC master software displays the following information: • • • • • • Actual and Required Speed of the motor Phase voltage amplitude (related to given DCBus voltage) Application mode - RUN/STOP DCBus voltage and temperature of power module Drive Fault status Identified hardware If Overcurrent, Overvoltage, Undervoltage or Overheating occur, the internal fault logic is asserted and the application enters a fault state (the user LED will flash quickly). This state can be exited only by an application RESET. It is strongly recommended that you inspect the entire application to locate the source of the fault before starting it again. Project files for the PC master software are located in project directory in: ..\PC_Master\sdm_external_memory.pmp, which uses the Map file to run in the small memory model of the external memory ..\PC_Master\ldm_external_memory.pmp, which uses the Map file to run in the large memory model of the external memory ..\PC_Master\sdm_pROM-xRAM.pmp, which uses the Map file to run in the small memory model of the internal memory ..\PC_Master\ldm_pROM-xRAM.pmp, which uses the Map file to run in the large memory model of the internal memory ..\PC_Master\sdm_xROM-xRAM.pmp, which uses the Map file to run in the small memory model of the internal memory ..\PC_Master\ldm_xROM-xRAM.pmp, which uses the Map file to run in the large memory model of the internal memory Start the PC master software window’s application and choose the PC master software project for the desired PC master software Operating Mode. Figure 1-3 shows the PC master software control window for internal pROM-xRAM.pmp. 3-Phase AC Induction Motor V/Hz Control, Rev. 1 8 Freescale Semiconductor Figure 1-3 PC Master Software Control Window 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 9 2. Hardware Set-up Figure 2-1 illustrates the hardware set-up for the 3-phase AC Induction Motor Control V/Hz A Application - Closed Loop. Induction Motor Incremental Sensor Connector Motor Power Connector Optoisolation Board AC Power Line Connector 3-Ph, AC BLDC Power Stage Serial Cable to PC Daughter Card Power Supply Controller Board Parallel Cable to PC Figure 2-1 Set-up of the 3-phase AC Induction Motor Control Application - Closed Loop The correct order of phases (Phase A, Phase B, Phase C) for the AC induction motor shown in Figure 2-1 is: • • • Phase A = red wire Phase B = white wire Phase C = black wire When facing a motor shaft, the phase order is: Phase A, Phase B, Phase C; the motor shaft should rotate clockwise (i.e., positive direction, positive speed). For detailed information, see the 56F83xx EVM User Manual for the device being implemented. The serial cable is needed for the PC master software debugging tool only. 3-Phase AC Induction Motor V/Hz Control, Rev. 1 10 Freescale Semiconductor EVM Jumper Settings 2.1 EVM Jumper Settings For jumper settings, see the 56F8346 Evaluation Module Hardware User’s Manual, 56F8357 Evaluation Module Hardware User’s Manual or 56F8367 Evaluation Module Hardware User’s Manual. To execute the 3-phase AC Induction Motor Control V/Hz Application - Closed Loop, the 56F8300 Daughter Card requires the strap settings shown in Figure 2-2 and Table 2-1. Note: When running the EVM target system in a stand-alone mode from Flash, in the 56F8346EVM the JG9 jumper must be set in the 1-2 configuration to disable the command converter parallel port interface. In the 56F8357 or 56F8367 EVM, the JG3 jumper must be set in the 1-2 configuration to disable the command converter parallel port interface. Figure 2-2 56F8300EVM Daughter Card Jumper Reference 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 11 Table 2-1 56F8300EVM Daughter Card Jumper Settings Jumper Group Comment Connections JG1 Primary PFC 1-2, 3-4, 5-6, 7-8, 9-10 JG2 Secondary PFC NC JG3 Phase_IS / Over_I 2-3 JG4 Primary Zero-Crossing / Encoder 2-3, 5-6, 8-9 JG5 Secondary Zero-Crossing / Encoder 2-3, 5-6, 8-9 JG6 Primary Back-EMF / Phase-IS 1-2, 4-5, 7-8 JG7 Secondary Back-EMF / Phase-IS 1-2, 4-5, 7-8 JG8 Fault A Monitor 1-2, 3-4, 5-6 JG9 Fault B Monitor 1-2, 3-4, 5-6 JG10 Switch 1 1-2 JG11 Switch 2 1-2 JG12 Switch 3 (Run / Stop) 1-2 3. Build To build this application, open the 3ph_AC_VHz_CL.mcp project file and execute the Make command, as shown in Figure 3-1. This will build and link the 3-phase AC V/Hz Motor Control application and all needed Metrowerks and Processor Expert libraries. Figure 3-1 Execute Make Command 3-Phase AC Induction Motor V/Hz Control, Rev. 1 12 Freescale Semiconductor EVM Jumper Settings 4. Execute To execute the 3-phase AC V/Hz Motor Control application, choose the Program/Debug command in the CodeWarrior IDE, followed by the Run command. To execute the 3-phase AC V/Hz Motor Control application’s internal Flash version, choose the Program/Debug command in the CodeWarrior IDE. When loading is finished, in the 56F8346EVM, set jumper JG9 to disable the JTAG port and JG3 to enable boot from internal Flash, then push the RESET button. In the 56F8357 or 56F8367 EVM, set jumper JG3 to disable the JTAG port and JG4 to enable boot from internal Flash, then push the RESET button. For more help with these commands, refer to the CodeWarrior tutorial documentation in the following file, located in the CodeWarrior installation directory: <...>\CodeWarrior Manuals\PDF\Targeting_56800E.pdf For jumper settings, see the 56F8346 Evaluation Module Hardware User’s Manual, 56F8357 Evaluation Module Hardware User’s Manual or 56F8367 Evaluation Module Hardware User’s Manual. Once the application is running, move the RUN/STOP switch to the RUN position and set the required speed with the UP/DOWN push buttons. Pressing the UP/DOWN buttons should incrementally increase the motor speed until it reaches maximum speed. If successful, the 3-phase AC Induction motor will be spinning. Note: If the RUN/STOP switch is set to the RUN position when the application starts, toggle the RUN/STOP switch between the STOP and RUN positions to enable motor spinning. This is a protection feature that prevents the motor from starting when the application is executed from CodeWarrior. You should also see a lighted green LED, which indicates that the application is running. If the application stops, the green LED blinks at a frequency of 2Hz. 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 13 3-Phase AC Induction Motor V/Hz Control, Rev. 1 14 Freescale Semiconductor EVM Jumper Settings 3-Phase AC Induction Motor V/Hz Control, Rev. 1 Freescale Semiconductor 15 How to Reach Us: Home Page: www.freescale.com E-mail: [email protected] USA/Europe or Locations Not Listed: Freescale Semiconductor Technical Information Center, CH370 1300 N. Alma School Road Chandler, Arizona 85224 +1-800-521-6274 or +1-480-768-2130 [email protected] Europe, Middle East, and Africa: Freescale Halbleiter Deutschland GmbH Technical Information Center Schatzbogen 7 81829 Muenchen, Germany +44 1296 380 456 (English) +46 8 52200080 (English) +49 89 92103 559 (German) +33 1 69 35 48 48 (French) [email protected] Japan: Freescale Semiconductor Japan Ltd. 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Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. This product incorporates SuperFlash® technology licensed from SST. © Freescale Semiconductor, Inc. 2004, 2005. All rights reserved. 8300ACIMTD Rev. 1 08/2005