Application
NOTES:
First Release February 23, 2007
Using the BCIM Controller with Powerex IPMs
Introduction:
The BCIM board features a three phase AC motor controller IC at its core. The board is
designed to provide an interface between the controller and Powerex IPM design kits. The
BCIM board provides PWM signals for the IGBTs in the three legs of a 3 phase inverter plus a
brake signal.
Using this board along with Powerex IPM design kits allows designers to be able to quickly
verify their Power circuit layout and also gives them an opportunity to see a working control
circuit layout.
The information in this document pertains only to the board and its external connections. For
information specific to the controller please contact Freescale Semiconductor.
Building the BCIM board:
The BCIM kit comes as a bare board along with all of the parts listed in the bill of materials.
The PCB is a two layer board and all of the components are through hole. You will need to refer
to Figure 4 shown at the end of this document which shows the complete component layout in
order to complete the board.
BCIM Connections:
The BCIM controller board has three connectors, CN1, CN2 and CN3. CN2 is a 2-pin connector
that brings in an 8-24V DC power supply and converts it to a regulated 5V supply for the control
logic. CN1 is a 10-pin connector for bringing out the 5V logic power supply and all of the
control signals for the high and low sides of a three phase inverter plus brake. The 10-pin
connector is also used for bringing the fault feedback to the controller. CN3 is connector that
brings in a divided DC bus voltage for feedback into the MC3PHAC MCU.
BCIM Power Requirements:
The BCIM will use a maximum of 200mA from the 5VDC supply for a total of 1W needed at the
output of the 5V regulator. In addition the 5V regulator will have a voltage drop of anywhere
between 3V (8V-5V) and 19V (24V-5V) which will mean an additional 0.6W to 3.8W of power
loss.
Connecting the BCIM to L-series IPM development kits:
The 10-pin connector on the BCIM is made to connect directly to the 10-pin connectors used in
the BP6A and BP7A L-series IPM development kits through 10 conductors. Again, this will
provide the proper interface between the
controller and IPM for all of the control
signals including the brake, the 5V logic
power supply and the fault feedback from
the IPM to the MCU.
The 24V or 15V control power that is
needed for the IPM development boards
can be shared with the BCIM board or
separate power supplies can be used.
Figure 1 shows how the connection is
made from the BCIM to the BP6A/BP7A.
Figure 1. BCIM to BP7A/BP6A
Connecting the BCIM to Super Mini
DIP-IPM and Mini DIP-IPM
Demonstration Boards:
The BCIM can also be connected to the
Super Mini DIP-IPM and Mini DIP-IPM
demonstration boards (DK-PS21562/3/4
and DK-PS21962/3/4) in much the same
way that it connects to the BP6A and
BP7A boards. The input connectors for
these kits do differ in a few ways and so
the connection will be somewhat different.
The main differences are that there is no
brake pin for the Mini/Super Mini demo
boards and the +15V supply is part of the
10 pin connector as opposed to having its
own separate connector. Another
difference in the connectors is that the
input control signal pins (Up, Un, Vp, Vn,
etc.) are in a different order so the
connection wires between the BCIM and
the development board will need to be
permutated.
An illustration of how to connect the BCIM board to the Mini/Super Mini Demo boards is shown
in Figure 2.
Setting the 6-Position DIP-Switch:
The first four of the six switch positions of the IPM are as follows:
Position 1: 60Hz+
Position 2: 60HzPosition 3: 50Hz+
Position 4: 50HzThe four switch positions are designed to allow the user to control either a 50Hz or 60Hz motor
using either active high or
Figure 2: BCIM to DK-PS21XXX
active low control logic.
It is important that only one of the first four positions is in the ON state at any time to prevent
erroneous operation.
The L-series IPM development boards are designed to bring active low logic to the IPMs control
pins and require either position 2 or position 4 to be ON where position 2 is used for a 60Hz
motor and position 4 is for a 50Hz motor.
The development kits for the DIP-IPM modules are designed for bringing active high logic to the
control pins and therefore either position 1 or position 3 should be ON. In this case position 1 is
for a 60Hz motor while position 3 is used for 50Hz motors.
Positions 5 and 6 are the start/stop and forward/reverse positions. Changing position 5 to ON or
OFF will start or stop the motor respectively. Position 6 works in the same manner where ON is
reverse and OFF is forward.
Speed and Acceleration Control:
P1 and P2 marked speed and acceleration on the board are rotated clockwise to increase their
value or rotated counterclockwise to decrease their value.
The speed control changes the motor current waveform frequency from 1 to 128 Hz and the
acceleration rate can be adjusted to a value between 0.5 and 128 Hz/s.
BCIM Feedback Controls:
The BCIM has two feedback controls: the fault signal feedback and the bus voltage level
feedback.
The fault feedback is set up on the board to be active low. If low level logic comes back to the
BCIM board because one of the IPMs protection functions have been activated the PWM signals
from the controller will be immediately disabled. Once the fault clears and a high logic signal is
being fed back to the board the motor controller starts a fault retry timer and the PWM signals
are re-enabled after the duration of the programmed timeout value.
The bus voltage feedback control is monitored from pin 2 to pin 3 of CN3. The nominal voltage
feedback level is 3.5V. The voltage level required to assert the brake signal is 3.85V.
Any voltage reading outside of 1.75V minimum and 4.47V maximum constitutes a fault
condition and the PWM signals are disabled. Once the voltage returns to an acceptable value the
fault retry timer starts and PWM is re-enabled once the programmed timeout value is reached.
The board also employs deceleration control via the MC3PHAC and the voltage feedback input
on the board. The acceleration value set by P2 is also used to set the deceleration value and is
equivalent in magnitude. However, when the voltage exceeds 3.85V, the deceleration rate is
moderated to control the bus voltage. If bus voltage monitoring is not desired it must be disabled
by placing a jumper wire between pins 2 and 3.
Figure 3. BCIM Circuit Schematic
Figure 4. Component Layout:
Table 1. Bill of Materials:
Item
Description
C2, C4, C5,
C6
C7, C8, C9,
C10
C11
CAP 50V .1UF RADIAL
CERAMIC X7R
CAP 10UF 50V ELECT
FC RADIAL
CAP 4700PF 100V
CERAMIC MONO 10%
Diode Zener 5.1V 0.5W
LED 3MM 565NM
GREEN TINT
CERAMIC RESONATOR
4.0 MHZ
BC Components
A104K15X7RF5TAA
Digikey PN
BC1084CT-ND
Panasonic
EEU-FC1H100
P11250-ND
EPCOS, Inc.
B37981M1472K054
495-1053-1-ND
Diodes Inc.
Avago Technologies
1N5231B-T
HLMP-1521
1N5231BDICT-ND
516-1298-ND
Panasonic
ZTT-4.00MG
X902-ND
R1, R2
Resistor, 1Ω, 1/4 W
-
-
-
R3, R20
R4, R21
R5
R6, R7, R8,
R9
R10
R11
R12, R13,
R14, R15,
R19
R16
R17
R18
CN1
Resistor, 1.5kΩ, 1/4 W
Resistor, 3.6kΩ, 1/4 W
Resistor, 3.9kΩ, 1/4 W
Resistor, 4.7kΩ, 1/4 W
-
-
-
Resistor, 6.8kΩ, 1/4 W
Resistor, 8.2kΩ, 1/4 W
Resistor, 10kΩ, 1/4 W
-
-
-
Resistor, 12kΩ, 1/4 W
Resistor, 1MΩ, 1/4 W
Resistor, 5.1kΩ, 1/4 W
10 pos. 0.1” right angle
single row header
2 pos. 0.1” right angle
single row header
3 pos. 0.1” right angle
single row header
AC MOTOR
CONTROLLER 28-DIP
REG 5 VOLT 1A TO220
TRANS NPN SW HS
200MA 40V TO92
POT 5K OHM 9MM SQ
RTANG PLAST
SWITCH 6 POS DIP
EXTENDED UNSLD
SWITCH TACT 6MM
260GF H=4.3MM
Tyco Electronics/Amp
1-640457-0
A1930-ND
Tyco Electronics/Amp
640457-2
A1926-ND
Tyco Electronics/Amp
640457-3
A19480-ND
Freescale
MC3PHACVPE
MC3PHACVPE-ND
ON Semiconductor
Philips
MC7805CTG
2N3904
MC7805CTGOS-ND
568-1366-1-ND
Bourns
3310C-001-502
3310C-001-502-ND
Grayhill
78B06
GH1237-ND
Omron
B3F-1005
SW793-ND
DZ1
LED1
CR1
CN2
CN3
IC1
IC2
T1, T2
P1, P2
SW1
SW2
Manufacturer
Man PN
Table 2 lists additional application notes for development boards designed for use with the
BCIM. Clicking on the application note name will bring up the associated pdf document. The
linked application notes provide additional specifications and application circuit examples as
well as information about associated accessory products.
Table 2. Additional Reading
Application Note
Product Type
IPM Module Application
BP7A
6/7 Channel
L-Series IPM Development
Board
600V Module 50 to 300A
1200V Module 25 to 150A
BP6A
6 Channel
L-Series IPM Development
Board
600V Module 450 to 600A
1200V Module 200 to 450A
DK-PS2156X
Mini DIP-IPM
Development Board
600V Module 20A to 30A
DK-PS2196X
Super Mini DIP-IPM
Development Board
600V Module 5 to 20A