Freescale Semiconductor, Inc... Freescale Semiconductor, Inc. 56F805 3-Phase AC Induction Motor V/Hz Control using Processor ExpertTM Targeting Document 56F805 Hybrid Controller 805ACIMTD/D Rev. 0, 09/2003 MOTOROLA.COM/SEMICONDUCTORS For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. Specifications 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 56F805EVM board, Optoisolation board, and 3-phase AC BLDC high-voltage power stage. 1. Specifications Freescale Semiconductor, Inc... This application performs principal control of the 3-phase AC induction motor using the 56F805 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 56F805EVM 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 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) 2 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Specifications Application Description The Volt per Hertz control algorithm is calculated on the Motorola 56F805 device. 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: Freescale Semiconductor, Inc... • • • • AC induction motor-brake set 3-phase AC/BLDC high voltage power stage 56F805EVM board Optoisolation box, which is connected between the power stage board and the 56F805EVM 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. Table 1-1. Motor-Brake Specifications Set Manufactured Motor Specification Brake Specification Position Sensor (Encoder) EM Brno, Czech Republic 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 MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 3 Freescale Semiconductor, Inc. Specifications 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) Freescale Semiconductor, Inc... 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 (S6). The motor speed is set by the UP (S2-IRQB) and DOWN (S1-IRQA) push buttons (Figure 1-1). If the application runs and motor spinning is disabled (i.e., the system is ready), the green user LED (LED3; see Figure 1-2 ) will blink. When motor 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. Figure 1-1. RUN/STOP Switch and UP/DOWN Buttons 4 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Specifications Figure 1-2. USER and PWM LEDs MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 5 Freescale Semiconductor, Inc. Specifications 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 Freescale Semiconductor, Inc... 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: ..\PC_Master\external memory.pmp, uses Map file to run in External Memory ..\PC_Master\internal pROM-xRAM.pmp, ..\PC_Master\internal xROM-xRAM.pmp, use Map file to run in Flash 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. 6 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Hardware Set-up Figure 1-3. PC Master Software Control Window 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. MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 7 Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Hardware Set-up 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 56F805 Evaluation Module Hardware Reference Manual. The serial cable is needed for the PC master software debugging tool only. 2.1 EVM Jumper Settings To execute the 3-phase AC Induction Motor Control V/Hz Application - Closed Loop, the 56F805 board requires the strap settings shown in Figure 2-2 and Table 2-1. 8 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Hardware Set-up 1 9 6 3 3 JG10 JG6 3 3 7 2 4 1 1 JG14 JG12 3 2 1 JG13 7 2 1 JG4 1 USER 7 4 1 JG14 9 6 3 JG10 PWM JG15 J2 Y1 J23 JG17 JG6 1 3 2 1 JG13 JG12 JTAG DSP56F805EVM 1 JG15 JG1 JG2 1 1 JG16 1 1 JG18 JG16 U1 JG1 1 3 J24 3 2 1 JG4 Freescale Semiconductor, Inc... 8 JG3 J29 JG8 JG8 1 S/N 3 U15 S4 S5 S6 GP1 S1 GP2 S2 RUN/STOP S3 1 LED3 P3 IRQA IRQB RESET JG2 J31 JG7 1 JG9 JG11 P1 U9 JG5 U10 JG5 P1 3 JG9 JG3 1 3 2 JG18 7 JG17 1 JG7 JG11 8 Figure 2-2. 56F805EVM Jumper Reference MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 9 Freescale Semiconductor, Inc. Hardware Set-up Table 2-1. 56F805EVM Jumper Settings Freescale Semiconductor, Inc... Jumper Group Comment Connections JG1 PD0 input selected as a high 1-2 JG2 PD1 input selected as a high 1-2 JG3 Primary UNI-3 serial selected 1-2, 3-4, 5-6, 7-8 JG4 Secondary UNI-3 serial selected 1-2, 3-4, 5-6, 7-8 JG5 Enable on-board parallel JTAG Command Converter Interface NC JG6 Use on-board crystal for CPU oscillator input 2-3 JG7 Select CPU’s Mode 0 operation upon exit from reset 1-2 JG8 Enable on-board SRAM 1-2 JG9 Enable RS-232 output 1-2 JG10 Secondary UNI-3 Analog temperature input unused NC JG11 Use Host power for Host target interface 1-2 JG12 Primary Encoder input selected for Quadrature Encoder signals 2-3, 5-6, 8-9 JG13 Secondary Encoder input selected 2-3, 5-6, 8-9 JG14 Primary UNI-3 3-Phase Current Sense selected as Analog Inputs 2-3, 5-6, 8-9 JG15 Secondary UNI-3 Phase A Overcurrent selected for FAULTA1 2-3 JG16 Secondary UNI-3 Phase B Overcurrent selected for FAULTB1 1-2 JG17 CAN termination unselected NC JG18 Use on-board crystal for CPU oscillator input 1-2 Note: When running the EVM target system in a stand-alone mode from Flash, the JG5 jumper must be set in the 1-2 configuration to disable the command converter parallel port interface. 10 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Build 3. Build Freescale Semiconductor, Inc... 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 For more information about these commands, see: <...>\CodeWarrior Manuals\PDF\Targeting_56800.pdf MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 11 Freescale Semiconductor, Inc. Execute 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, set jumper JG5 to disable the JTAG port and JG7 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_56800.pdf For jumper settings, see the 56F805 Evaluation Module Hardware User’s Manual. Freescale Semiconductor, Inc... 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. 12 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Execute MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 13 Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Execute 14 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com MOTOROLA Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Execute MOTOROLA 3-Phase AC Induction Motor Control V/Hz Application - Closed Loop For More Information On This Product, Go to: www.freescale.com 15 Freescale Semiconductor, Inc. HOW TO REACH US: USA/EUROPE/LOCATIONS NOT LISTED: Motorola Literature Distribution; P.O. Box 5405, Denver, Colorado 80217 1-303-675-2140 or 1-800-441-2447 JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu Minato-ku, Tokyo 106-8573 Japan 81-3-3440-3569 Freescale Semiconductor, Inc... ASIA/PACIFIC: Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, 2 Dai King Street, Tai Po Industrial Estate, Tai Po, N.T., Hong Kong 852-26668334 TECHNICAL INFORMATION CENTER: 1-800-521-6274 Information in this document is provided solely to enable system and software implementers to use Motorola products. There are no express or implied copyright licenses granted hereunder to design or fabricate any integrated circuits or integrated circuits based on the information in this document. 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