IRMCS3043

Preliminary Datasheet IRMCS3043 Sensorless Motor Drive Platform with Integrated PFC for Appliance Based on iMOTIONTM Chipset Features  Product Summary TM                  IRMCF343 - iMOT ION digital con trol IC–based system TM MCE (Motion Control Eng ine) - Ha rdware based computation engine fo r high efficiency sinusoidal sensorless control of Permanent Magnet moto rs Integrated digital powe r factor correction (PFC ) Supports both inte rio r and su rface permanent magnet moto r sensorless contro l Single shunt cu rren t feedback reconstruction No external current o r voltage sensing OP amp circuit required 230V/1700W continuous power with Trench IGBT for PFC and In tegrated Power Module for inverter Harmonics comp lying w ith EN61000-3-2 Class -A Loss minimization Space Vec tor P WM Two-channel analog output (P WM) Embedded 8-bit high speed microcontroller (8051) for flexib le I/O and man-machine contro l JTAG progra mming port fo r emu lation /debugger 2 I C serial interface to EEPROM MCEDesigner TM Continuous input power Continuous output current Maximum over load output current Maximum Internal clock ( SYSCLK) Sensorless control computation time RAM loaded from external EEPROM Data RAM A/D input channels A/D conver ter resolution A/D conver ter conversion speed 8051 instruc tion execution speed Analog output (PWM) resolution RS232C baud rate (typ.) * Upgr adeable to higher c urrent w ith larger heat sink ** Changeable by modifying the har dw are. 1700W * 6.0 Ar ms* 20 Apeak** 128 MHz 11 µsec typ. 48 Kbytes 8 Kbytes 5 12 bits 2 µ s ec 2 SYSCLK 8 bits 57.6 Kbps tool for easy operation Flexible d rive configuration RS232C interface Over-current and over-vo ltage/under-voltage protection EMI filter and switch-mode powe r supply included Description IRMCS3043 is a refe rence design platform fo r IR MCF343, a high performance RAM-based motion control IC design ed primarily for appliance applications, up to 1.7kW continuous input power. It’s mainly a imed to achieve simple, low cost a nd high performance solutions for advanced appliance motor control. It consists of an active PFC frond-end and an inverter stage, both of which are controlled by the IRMCF343 digita l IC simultan eously. The power s tage contains a Trench IG BT (IRGP4063DPbF) for the PFC and an integra ted power m odule (IR AMX16UP60A-2) fo r the inverter, which a re part o f TM TM iMOTION chipset. Use rs can readily evaluate high performance sensorless control with MCEDesigner software without spending development effort usually required in the traditio nal DSP or m icrocontrolle r based system. The complete B/Ms, schematics and layout are provided so that the user can adapt and tailor the design per application needs. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. IRMCS3043 Table of Contents 1 Introduction ........................................................................................................................................................................ 3 1.1 Overview ..................................................................................................................................................................... 3 1.2 Safety Precau tions ...................................................................................................................................................... 4 1.3 Debris When Unp ack ing ............................................................................................................................................ 6 2 Hardware Descrip tion ........................................................................................................................................................ 7 2.1 PCB.............................................................................................................................................................................. 7 2.2 Isolation Boundary ..................................................................................................................................................... 7 2.3 IRMCF343 .................................................................................................................................................................. 8 2.3.1 Power.................................................................................................................................................................... 8 2.3.2 Crystal .................................................................................................................................................................. 8 2.3.3 Reset Cir cuit ........................................................................................................................................................ 8 2.3.4 EEPRO M ............................................................................................................................................................. 8 2.3.5 Digital I /O ............................................................................................................................................................ 8 2.3.6 Analog Ou tput ..................................................................................................................................................... 8 2.3.7 Motor Sing le-Shunt Curren t Feedb ack .............................................................................................................. 8 2.3.8 PFC Curren t Feedb ack ........................................................................................................................................ 8 2.3.9 AC Input Voltag e Feedback ............................................................................................................................... 8 2.3.10 DC Bus Voltage Feedback................................................................................................................................ 8 2.4 Input Diode Br idge Rectif ier ..................................................................................................................................... 8 2.5 PFC IGBT and Diod e ................................................................................................................................................. 9 2.6 PFC Inductor ............................................................................................................................................................... 9 2.7 IRA M........................................................................................................................................................................... 9 2.8 Power Supply .............................................................................................................................................................. 9 2.9 EMI Filter .................................................................................................................................................................... 9 2.10 DC Bus Capacitors ................................................................................................................................................... 9 3 Specifications ................................................................................................................................................................... 10 List of Figures Figure 1. Figure 2. I RMCS3043 System Block Diagram ................................................................................................................... 3 Top View of I RMCS3043 ..................................................................................................................................... 7 List of Tables Table 1. I RMCS3043 Electr ical Specif ication ................................................................................................................... 10 This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 2 IRMCS3043 1 Introduction 1.1 Overview IRMCS3043 is a refer ence design platform for complete in verter-con trolled appliance mo tor drive applications based on iMOTION TM chip set, up to 1.7kW continuous inpu t power. By using th e I RMCF343 dig ital control IC, it provides a one-chip solu tion that simultaneously contro ls PFC frond-end circuit and one perman ent magnetic (PM) A C motor (sinusoidal b ack EMF) w ithou t requ iring mo tor position sensors. IRMCF343 is Intern ational Rectifier’s new in tegrated circuit d evice pr imarily designed as a one-ch ip so lution for sensorless permanent magnet motor control w ith in tegrated PFC in applian ce app lications. Un lik e a trad itional micro controller or DSP, IRMCF343 provides a built- in closed-loop sensorless control algorithm using a uniqu e Motion Control Engine ( MCETM) for surface/in ter ior perman ent magnet mo tors with sinusoidal back EMF . IRMCF343 also employs a un ique sing le shunt current reconstruction circu it to eliminate additional an alog/d igita l circu itry and en ables a dir ect shunt r esistor in terf ace to the I C. Th e MCETM consists of a co llection of control elemen ts, motion per ipherals, a ded icated motion con trol sequencer and dual port RA M to map internal signal nodes . Motion control programming is ach ieved by using a ded icated graph ical comp iler integrated into the MA TLA B/SimulinkTM dev elopment environment. Sequ encing, user interf ace, host communication, and upper lay er control tasks can b e implemented in th e 8051 high-speed 8- bit microcontro ller. The 8051 microcontroller is equ ipped with a JTAG port to facilitate emulation and debuggin g tools. Using the MCETM, I RMCF343 also achieves simu ltaneous d igital PFC contro l of the frond-end cir cuit that provides a r egulated DC bus voltag e to the inver ter. Figure 1 shows the I RMCS3043 system block diagram. In th is p latform, th e PFC topo logy is implemented as the convention al boost PFC; however , the IRMCF343 I C can also contro l the bridgeless PFC topology. Please contact the iMOTION ™ team for support if you need to con trol the brid geless PFC using I RMCF343. The I RMCS3043 power stage contains a Trench IG BT (IRG P4063DPbF) for the PFC and an integrated power module (IRA MX16UP60A-2) for the inverter. Th e Trench IG BTs, part of I R’s iMO TION ™ in tegrated design platform, h ave lower collector-to-emitter satur ation voltage (V CE(ON)) an d total switch ing energy (ETS) than punch-through (PT) and non-punch-through (NPT) type IGBTs. The combin ation of low V CE(ON) and ETS r esult in reduced power dissip ation and higher pow er density. I RA MX16UP60A-2 is an integrated power module d evelop ed and op timized for appliance mo tor con trol. Host communication Integrated Power Module In te g ra te d P o w e r M o d u le Appliance Inverter with PFC Passive EMI Filter Galvanic isolation PFC Gate Drive IRMCF 343 Multiple Output Power Supply 1.8V IR2136 Motor (PMSM or IM ) 3. 3V EEPROM Digial I /O Analog Input 2 18 2 Figure 1. IRMC S3043 Syst em Block D iagram This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 3 IRMCS3043 1.2 Safety Precautions In addition to th e precautions listed throughout this manu al, please r ead and understand th e following statements regarding hazards associated w ith development system. ! ! ! ! ATTENTION: The ground potential of th e I RMCS3043 system is biased to a neg ative DC bus voltage potential. When measuring vo ltage waveform b y oscilloscope, th e scope ground needs to be isolated. Failure to do so may r esult in personal injury or death. Darkened disp lay LEDs is not an indication that cap acitors have discharg ed to safe voltag e levels. ATTENTION: I RMCS3043 system con tains dc bus capacitors which tak e time to disch arge after remov al of main supply. Before working on dr ive system, wait three minutes for capacitors to d isch arge to saf e voltage lev els. Failure to do so may resu lt in personal in jury or death . Darkened display LED is no t an indication th at capacitors have discharged to saf e voltag e levels. ATTENTION: Only personnel familiar w ith th e drive and associated mach inery should p lan or implement th e installation , star t-up, and subsequen t maintenan ce of the system. Failure to comply may result in p ersonal in jury and /or equip ment damage. ATTENTION: Th e surface temp eratur es of the driv e may beco me hot, which may cause injury. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 4 IRMCS3043 ! ATTENTION: I RMCS3043 system contains ESD ( Electr ostatic D isch arge) sensitiv e par ts and assemblies. Static contro l precautions are r equired wh en installing, testing, servicing or repair ing this assembly. Component damag e may resu lt if ESD control procedures are no t followed . If you are not familiar w ith static control procedures, refer ence applicab le ESD protection h andbook and guidelin e. ! ATTENTION: An incorrectly applied or installed driv e can result in co mponent damage or reduction in product life. Wir ing or application errors such as undersizing th e motor, supplying an in correct or inadequ ate A C supply , or excessiv e ambient temp eratures may resu lt in system malfun ction. ! ! ATTENTION: Remove and lo ck ou t power from the drive b efore you d isconnect or reconnect w ires or perform service. Wait three minu tes after removing power to discharg e th e bus voltage. Do not attempt to service the driv e until bus voltag e has d isch arged to zero. Failure to do so may resu lt in bodily in jury or death. ATTENTION: Do no t connect power f actor corr ection inductors to driv e outpu t terminals U, V, and W. Failur e to do so may resu lt in equipment damage or bodily injury. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 5 IRMCS3043 1.3 Debris When Unpacking IRMCS3043 system is shipp ed with p acking mater ials th at need to be removed prior to installation. ATTENTION: Failure to remove all debris and packing materials which are unnecessary for system installation may resu lt in overheating or abnormal operating condition. ! This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 6 IRMCS3043 2 Hardware Description A top v iew of IRMCS3043 is shown in Figure 2 . Figure 2. Top View of IRMC S3043 ! 2.1 2.2 P CB WARNIN G: Ex cep t the RS232 connector, all the circu its are dir ectly biased to the negativ e DC bus of the power stage, and J7 JTAG , J6 D/A outpu t and J8 dig ital I /O connectors are no t isolated from th e power ground. If an FS2 debugger or oscilloscope is needed for debugging or measurement, ensure it is isolated from th e power ground. Oth erwise, severe damage will occur to th e PCB and /or the equ ipmen t. The PCB h as two electrical lay ers and its size is 6.5 x 8.0 inches. Isolation Boundary Note that there are two d ifferen t grounds on this system. The RS232 connector is isolated by opto couplers so that users can connect a computer w ithout iso lating it. However , users should keep in mind that most par ts of the hardwar e This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 7 IRMCS3043 have negativ e DC bus ground and it is necessary to isolate the scope when w aveforms are measur ed and/or to isolate the FS2 debugger wh en debugging is conducted. 2.3 IRMCF343 2.3.1 Power IRMCF343 requir es 3.3V and 1.8V. VDD1 is 3.3V used for I /O and VD D2 is 1.8V for dig ital logic. AVDD is 1.8V for analog and PLLVD D is for PLL. Only one so urce of 1.8V is shared in I RMCS3043 system. Typical current v alu e for 1.8V is less th an 100 mA . 2.3.2 Crystal A 4 MH z crystal is used to gen erate th e system clock. Th e actual system frequency is adjustab le by changing the Ph ase Locked Loop configuration through Special Function Reg isters. For more information regard ing clock, please ref er to the I RMCF34x and I RMCF37x User’s Gu ide. 2.3.3 Reset Circuit IRMCF343 doesn’t requ ire external RC cir cuit for reset. The reset sw itch is used when th e JTAG debugger is started. For more information r egarding r eset, please r efer to the IRMCF34x and I RMCF37x User’s Gu ide. 2.3.4 EEPROM Boot load takes place at pow er-up to load 8051 cod e and MCE code from an ex ternal EEPRO M to in ternal RA M of IRMCF343. EEPRO M can be written using th e MCED esigner tool. 2.3.5 Digital I/O Most of the digital I /O’s are connected to header J8 for th e u ser’s convenien ce. 2.3.6 Analog Output Analog D /A outpu t channels are connected to head er J6 for ease of use. 2.3.7 Motor Single-Shunt Current Feedback IRMCF343 contains an Op erational Amp lif ier for the sing le shunt mo tor curren t reconstruction cir cuit. Resistors and capacitors for th e amplifier circuit are p laced very close to th e pins. Note th at, to provid e better curren t feedback , th ere is a separate trace from th e shunt resistor instead of sharing a plan e w ith negativ e D C bus ground. 2.3.8 PFC Current Feedback IRMCF343 con tains an Op erational Amplifier for PFC current feedb ack. The PFC curren t f eedback signal is obtain ed through a shunt resistor that is in ser ies w ith the PFC inductor and located at the neg ative D C bus side. Resistors and cap acitors for the amplifier circu it are placed v ery close to th e pins. No te that, to provide better current feedback, there is a separate tr ace from the shunt resistor instead of sharing a p lain w ith negativ e D C bus ground. 2.3.9 AC Input Voltage Feedback IRMCF343 contains an Oper ational Amp lif ier for A C input voltag e f eedback which is mainly used for PFC contro l. The A C input vo ltage signal is ob tained through a proprietary differ ential amplifier circu it and control logic that is embedded inside of th e I RMCF343 IC, togeth er w ith a f ew external resistors and capacitors. 2.3.10 DC Bus Voltage Feedback The D C bus voltage feedback is used in both mo tor control and PFC control. This is imp lemented through a voltage divider cir cuit, and the scaled-down analog signal is fed in to an AD C input p in (AIN0) of I RMCF343. 2.4 Input Diode Bridge Rectifier One piece of I R25XB08H diode bridge r ectif ier is mounted on a heat sink under th e board. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 8 IRMCS3043 2.5 PFC IGBT and Diode At the PFC frond-end, on e p iece of IRGP4063DPbF tr ench IGBT and one p iece of 30ETH06 hyperfast d iode ar e mounted on the same heat sink under the bo ard. A 15-mΩ shunt resistor is in series w ith th e inductor current flow ing path at th e negativ e D C bus sid e. The shunt provides PFC current feedback as w ell as ov er-current protection (OCP). The voltag e across the shunts is fed to a compar ator cir cuit. The co mparator in itiates the over-curren t shu tdown (PGatekill) , and the PG atekill signal is fed to I RMCF343 I C. Th e O CP is about 20A peak . For mor e information regarding trench IGBTs and hyperfast d iode, please r efer to their d atasheets. 2.6 PFC Inductor One piece of PFC inductor is provided separ ately from th e PCB, and should b e connected to the J2 connector. Th e inductor shown in Figure 2 is 1.5mH at 15A Idc, w ith 10Ar ms curr ent r ating. You can use your own inductor for th e evalu ation and test. Th e choice of inductor invo lves tr ade- offs in PFC contro l p erformance ( current ripp le, h armonics and power factor), switch ing fr equency, cost, space, pow er loss and EMI no ise. The PFC sw itching frequen cy for the IRMCS3043 is 30kHz, and the typical r ecommended reasonable inductance r ange is about 1mH to 1.5mH . 2.7 IRAM At th e inverter side, on e piece of I RA MX16UP60A-2 is mo unted on th e same heat sink under the board. Th ere are two 20-mΩ shunt resistors (in parallel) th at are inserted into the n egativ e D C bus and ex ternal to the I RA M. These shunts provide motor curren t feedback as well as over- current protection. The voltag e across the shun ts is fed to a comparator circuit. The comp arator initiates the over-current shutdown ( CGatek ill), and the CGatek ill signal is fed to both th e I RA M and I RMCF343 I C. W ith the 10-mΩ shunt resistan ce and thresho ld set up of the co mparator, the OCP current is about 20A peak. For more information r egarding IRA M, please r efer to I RA M datasheet. 2.8 Power Supply The switch ed-mode power supply (SMPS) oper ates at about 80 KHz and g enerates 15V(V CC), 5V and 3.3V . A 1.8V DC voltag e is gen erated from 3 .3V by a lin ear r egulator I RU1208. All these vo ltages are b iased to th e neg ative D C bus. In addition, this SMPS also gener ates an isolated 12V which is used for the RS232 communication. 2.9 EMI Filter The passive EMI f ilter on th e bo ard consists of two 1-µF X-caps, two 4 .7-nF Y- caps and a 4- mH common-mode inductor. 2.10 DC Bus Capacitors Three pieces of 470-µF, 450 V, 85°C electro lytic capacitors are used as th e D C bus capacitors. This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 9 IRMCS3043 3 Specifications TC = 25°C unless specified Parameters Input Voltage F requency Input current Watts Values 220V-230Vrms, -20%, +10% 50/60 Hz 8A rms @nom inal output 1700W continuous power Conditions TA=40°C, RthSA=0.36 °C /W Vin=230V AC, fPWM_PFC =30kHz, fPWM_inverter =6kHz, fO=60Hz, TA=40°C, RthSA=0.36 °C/W Input power > 1500W RthSA limits ΔTC to 10°C during overload Typical 57.6 Kbps, single ended Interface w ith FS2 debugger (NOT isolated from the negative DC bus) 8051 software needs modification to use it. DC bus voltage, single -shunt moto r current, AC input voltage, AC input current, AIN1 Should not exceed 400V for > 30 sec Configurable by PFC Input line impedance Input power facto r Harmonic current Output Curren t Host In terface (RS232C) T XD, RXD JTAG inte rface T MS , T D I , T C K , T D O D/A 8 - b i t 2 Ch a n n e l A/D 12 -bit DC bus voltage Maximum DC bus voltage Nominal DC bus voltage PFC Current Feedback Curren t sensing device Resolution La tency Motor Current Feedback Curren t sensing device Resolution La tency Protection PFC curren t trip level Motor current trip level Critical over voltage trip Over voltage trip Under voltage trip Power Devices T rench IGBT for PFC IPM for inverte r System Environment Ambient temperatu re 4%∼8% recommended >99% Comply with EN61000-3-2 Class-A 6 Arms nomina l, 10 A rms Overload 10V 3.3V 0-3.3V output 0-1.2V 400V 370V Shunt resistor 12-bit 1 PWM cycle Single shunt reconstruction 12-bit 1 PWM cycle 20A peak, ±10% 20A peak, ±10% 430V 410V 120V IRGP4063DPbF IRAMX16UP60A-2 0 to 40°C Detection from shunt on inductor current return path Detection from shunt on negative DC bus Re-scalable Re-scalable Re-scalable 95% RH max. (Non-condensing) Table 1. IRMC S3043 Electrical Specification This document is the property of International Rectifier and may not be copied or distributed without expressed consent. 10 IRMCS3043 IR WORLD H EA D Q U ARTERS: 233 K ans as St., El Segundo, Califo rnia 90245, Tel: (310) 252-7105 http://ww w.ir f .com D ata and specifications subject to change without notice. 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. 11