M o to r Co ntro l Applicatio n Kit
For XMC1000 Family
P M SM -L V-15 W
PMSM Low Voltage 15W Motor Card
Bo ard User's M anual
Revision 1.0, 2013-06-19
M icro co ntro ller
Edition 2013-06-19
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2013 Infineon Technologies AG
All Rights Reserved.
Legal Disclaimer
The information given in this document shall in no event be regarded as a guarantee of conditions or
characteristics. With respect to any examples or hints given herein, any typical values stated herein and/or any
information regarding the application of the device, Infineon Technologies hereby disclaims any and all
warranties and liabilities of any kind, including without limitation, warranties of non-infringement of
intellectual property rights of any third party.
Information
For further information on technology, delivery terms and conditions and prices, please contact the nearest
Infineon Technologies Office (www.infineon.com).
Warnings
Due to technical requirements, components may contain dangerous substances. For information on the types
in question, please contact the nearest Infineon Technologies Office.
Infineon Technologies components may be used in life-support devices or systems only with the express
written approval of Infineon Technologies, if a failure of such components can reasonably be expected to
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system. Life support devices or systems are intended to be implanted in the human body or to support and/or
PMSM LV15W Card
Revision History
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Revision 1.0, 2013-06-19
Trademarks of Infineon Technologies AG
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MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS
Technologies, Inc., USA. muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of
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SOLARIS™ of Sun Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software
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TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™
of Cadence Design Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™
of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited.
Last Trademarks Update 2011-11-11
Template: IFX_Template_2011-11-11.dot
PMSM LV15W Card
Table of Contents
1
Overview ........................................................................................................................................7
1.1
Key Features ................................................................................................................................... 7
1.2
Boot Mode Index (BMI) Configuration ............................................................................................. 7
1.3
Block Diagram ................................................................................................................................. 8
2
Hardware Description ....................................................................................................................9
2.1
Power ............................................................................................................................................. 9
2.2
SAMTEC 2x30pins connector ......................................................................................................... 11
2.3
Gate Driver and Power Stage ........................................................................................................ 12
2.4
Voltage and Current Measurements ............................................................................................. 13
2.4.1
Phase Current Measurement ........................................................................................................ 13
2.4.2
Phase Voltage Measurement ........................................................................................................ 16
2.5
Encoder and Hall Interface ............................................................................................................ 16
2.6
PMSM Motor ................................................................................................................................ 18
2.6.1
Motor Operating Range ................................................................................................................ 18
2.6.2
Geometry...................................................................................................................................... 19
3
Production Data ........................................................................................................................... 20
3.1
Schematics .................................................................................................................................... 20
3.2
Components Placement and Geometry ......................................................................................... 23
3.3
Bill of Materials ............................................................................................................................. 24
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PMSM LV15W Card
List of Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Block Diagram of PMSM Low Voltage 15W Motor Card in connection with XMC1300 CPU Card ...... 8
PMSM Low Voltage 15W Motor Card .............................................................................................. 9
Hardware Connection of Power Supply ......................................................................................... 10
SAMTEC 2x30pins connector to the CPU card ................................................................................ 11
Pin Mapping to XMC1300 CPU card with 2x30 pins SAMTEC Connector on PMSM Low Voltage 15W
Motor Card ................................................................................................................................... 11
Hardware connection of the Date Driver and Power Stage ............................................................ 13
Hardware Circuit Op-Amp of DC Link Current Sensing ................................................................... 14
Hardware Connection of Shunt Amplifier ...................................................................................... 15
Encoder Line Driver and Connector for differential encoder signals............................................... 17
Hall Sensor Connector Interface .................................................................................................... 17
EC 32 flat 32 mm, brushless 15 Watt Motor Specification.............................................................. 18
Motor Operating Range ................................................................................................................ 18
Motor Geometry ........................................................................................................................... 19
Schematic of SAMTEC Connector, Power Supply, Encoder Line Driver and Connector, Hall Sensor
Connector ..................................................................................................................................... 21
Schematic of Gate Driver, Power Stage, Shunt Amplifier, Motor Connector................................... 22
PMSM Low Voltage 15W Motor Card layout and geometry ........................................................... 23
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List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Power and ground signals connection to the SAMTEC 2x30pins connector.................................... 10
Gate Driver signals connection to the SAMTEC 2x30pins Connector .............................................. 13
Voltage and Current signals at the SAMTEC Connector .................................................................. 16
Encoder / hall signals at the SAMTEC connector ............................................................................ 17
PMSM Low Voltage 15W Motor Card BOM ................................................................................... 24
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PMSM LV15W Card
Introduction
This document describes the features and hardware details of the PMSM Low Voltage 15W Motor Card
(PMSM-LV-15W) designed to work with Infineon‟s XMC1300 CPU Card. This board is part of Infineon’s
XMC1000 Motor Control Application Kits.
1
Overview
The PMSM Low Voltage 15W Motor Card is an application expansion card of XMC1000 Motor Control. The
combination of PMSM Low Voltage 15 W Motor card and XMC1300 boot kit is the best kit to evaluate the motor
control capabilities of XMC1300. The main use case for this application card is to demonstrate the various motor
control algorithms (e.g. Block commutation with Hall sensor, V/F control, Field Orientation Control) by using
XMC1300 device including the toolchain. The focus is safe operation under evaluation conditions. The board is
not cost optimized and cannot be seen as reference design.
1.1
Key Features
The PMSM LV15W Card is equipped with the following features
Connection to XMC1300 CPU Cards via 2x30 pins (0.8mm pitch) SAMTEC HSEC8 connector
3 phase low voltage full bridge inverter using Infineon N-channel Dual OptiMOS power transistors
Gate Driver IC (6EDL04N02PR) with over-current detection circuit (ITRIP)
Current measurement by using single or triple shunts (amplified)
Positioning sensing via
o Hall sensor Interface
o Quadrature encoder interface for both single ended and differential signals
Input voltage range: 12V-24V +/- 20%
Power supply
o Low drop voltage regulator (5V) for hall sensor power supply
o Low drop voltage regulator (5V) for XMC1300 power supply
o Low dropout linear voltage regulator (15V) for MOSFET gate driver power supply
Maximum DC-link current: 3A & Maximum motor phase current: 3A
1.2
Boot Mode Index (BMI) Configuration
A micronctroller would normally have a few boot mode selection pins that determine its Boot Mode after power
on reset. However, the XMC1000 devices from Infineon, is a low pin count device, so the use of a few pins just
for Boot-up mode selection is not desirable.
The XMC1100, XMC1200 and XMC1300 bootkit are programmed to User mode with debug enabled (SWD0),
so that the application program will start to run after power-up. The selection of the port pin to be used depends
on BMI value. If the XMC1000 bootkits are programmed to SWD mode, the specified pin P0.14 and P0.15 are
used to communicate.
Referring the schematic connection of PMSM Low Voltage 15W Motor card, the hall sensor interface pin ENCIPOSIF.IN2 is connected to P0.15 at XMC1300 CPU card. Therefore, the XMC1300 CPU card has to be
programmed the BMI to SPD mode to avoid using P0.15 as programming pin. After the XMC1300 CPU card
BMI has changed, the DIP switch SWCLK on Jlink Debugger on XMC1300 CPU card has to be off. The user
code will run after power up and supports debugging using single pin debug protocol.
For more information about how to handle BMI for XMC1000 family, please refer to the XMC1000 Family
Tooling Guide.
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PMSM LV15W Card
1.3
Block Diagram
Figure 1 shows the block diagram of the PMSM Low Voltage 15W Motor Card in connection with XMC1300
CPU Card.
12V...24V
+5V
Plug
PMSM LV15W Card
Power Supply
CCU8
Gate Driver
3-Phase Power
Half-Bridge
Max 3A
FAULT#
ADC
Current & Voltage Sensing
ENENC
Encoder Line Driver
POSIF
ENENC#
Hall Interface
Figure 1
Encoder
Connector
Samtec
2x30pins
HSEC8
Connector
Hall Sensor
Connector
EN
Motor
Connector
+15V
Block Diagram of PMSM Low Voltage 15W Motor Card in connection with XMC1300 CPU
Card
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PMSM LV15W Card
2
Hardware Description
The following sections give a detailed description of the hardware and how it can be used.
Figure 2
2.1
PMSM Low Voltage 15W Motor Card
Power
The PMSM Low Voltage 15W Motor Card must be supplied by an external DC power supply (12V to 24V)
connected to its power jack X201. The power to be delivered by the external power supply depends on the
overall load mainly defined by the power consumption of the motor. The power supply unit (24V/1A) delivered
with the motor control kit is sufficient to drive the enclosed motor as well as the CPU card. The power supply
schematic is shown in Figure 3.
An on-board voltage regulator (IC203) steps down the 24 V input voltage from the power jack to 15 V (VDD15).
The input voltage up is regulated to an output voltage 15 V with a precision of 2%. The output voltage can be
configured to regulate between 2.5V and 20V. The 5 V supply for hall sensor VDD5 is derived from VDD15
regulated by LDO (IC201). Another LDO voltage regulator generates stable 5 V (VCC) out of VDD15 for
microcontroller power supply and operational amplifier.
Two power LEDs indicate the presence of the generated supply voltages.
Table 1
LED
V202
V201
Power LED
Power Rail
VDD15
VCC
Board User's Manual
Voltage
15 V
5V
Note
Must always be "ON"
Must always be "ON"
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Figure 3
Table 1
Hardware Connection of Power Supply
Power and ground signals connection to the SAMTEC 2x30pins connector
Pin No.
Signal Name
Description
13
VAGND
Analog ground
14
15
16
GND
VAREF
VDD
Digital ground
Analog VDD +5V
Digital VDDP +5V
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2.2
SAMTEC 2x30pins connector
The SAMTEC connector of the PMSM Low Voltage 15W Motor Card is the interface to the XMC1000 CPU card
e.g. XMC1300 CPU card as shown in Figure 4.
Figure 4
SAMTEC 2x30pins connector to the CPU card
Figure 5 is a view of the signal mapping between the PMSM Low Voltage 15W Motor card SAMTEC 2x30 pins
connector and the “XMC1300 CPU card”. It shows in details which pin of the XMC1300 is mapped to which
signal on the motor drive card. The inner rows show the general function of the 30 pins of the SAMTEC
connector, which is common for all CPU cards. The outer rows show the signals of the PMSM Low Voltage 15W
Motor Card.
The PMSM Low Voltage 15W Motor Card provides 5 functional groups of signals (marked by color code) at its
pins of the SAMTEC connector:
The encoder and hall sensor signals (ENCA, ENCB, ENCI): pin 43, 45 and 47
Control and TRAP signals (ENENC#, ENPOW, FAULT#, P0.4, P0.5): pin 37, 39, 41, 25 and 27
Voltage and current measurement signals: (UU, UV, UZ, AMP_IW...) located from pin 1 to 9
PWM signals for the 3 phase power stage (HIN1#, LIN1#, HIN2…): pin 17, 19, 29, 31, 33 and 35
Figure 5
Pin Mapping to XMC1300 CPU card with 2x30 pins SAMTEC Connector on PMSM Low
Voltage 15W Motor Card
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PMSM LV15W Card
2.3
Gate Driver and Power Stage
The power stage consists of three half-bridges using Infineon’s Dual N-channel OptiMOS™ power transistors.
They are selected for a safe operation area with huge headroom, hence no cooling is needed when using at
norminal current of 7.5 Ampere.
The gate driver (6EDL04N02PR) is Infineon’s 2nd generation full bridge driver to control power devices like
MOS-transistors or IGBTs in 3-phase systems. The gate driver offers several protection features like undervoltage lockout, signal interlocking of every phase to prevent cross-conduction and overcurrent detection.
Therefore, the current signal of the DC-link reference is measured in order to recognize overcurrent or
halfbridge short circuit events. A shunt resistor generates a voltage drop. A small RC-filter for attenuating
voltage spikes is recommended. Such spikes may be generated by parasitic elements in the practical layout.
In an error situation a FAULT# signal is generated and must be handled by the microcontroller. The FAULT#
signal changes to low state if an over-current condition has been detected by the ITRIP circuit. The ITRIP
current level is measured as the amplified voltage drop over the DC-link shunt (see Figure 6). The minimum
input voltage level to trigger an over-current event is specified at 375mV.
The external circuit at pin RCIN defines the overcurrent recovery of the drive system. This circuit consist of a
single capacitor
according to Figure 6. There is also the option for a path to the supply voltage Vcc via
resistor
. The fault-clear time
is dependent on the re-charging of
, because the system
recovers, when the threshold of the integrated Schmitt-trigger.
The datasheet specifies the typical fault clear time
= 1.9 ms which the current source needs to charge an
external capacitor of 1nF without pull up resistor. This parameter can be scaled linearly to any other capacitor
value and results immediately in the according fault clear time. This means with 22nF capacitor will realize a
fault clear time of 22 * 1.9 ms = 41.8 ms.
The microcontroller must provide the PWM signals (LIN1/2/3, HIN1/2/3) for the high-side and low-side switches.
The PWM signals must be generated high-active.
The gate driver must be enabled via signal ENPOW.
A phase current measurement is provided via shunt resistors
a) Single shunt (50 mΩ) in the DC-link path and/or
b) Triple shunt (50 mΩ) in the low-side path
The resistance of the shunts limits the system behaviour and may not fit to the low-ohmic power transistors.
This is intended as the main purpose of this board is to proof SW algorithms and methods over a wide range.
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PMSM LV15W Card
Figure 6
Hardware connection of the Date Driver and Power Stage
Table 2 shows the connection of the Gate Driver signals to the SAMTEC 2x30pins connector.
Table 2
Gate Driver signals connection to the SAMTEC 2x30pins Connector
Pin No.
19
25
27
29
31
33
35
Signal Name
FAULT#
ENPOW
HIN1
LIN1
HIN2
LIN2
HIN3
Description
This signal indicates over-current and under-voltage (low active)
High level enables the power stage (high active)
High-side logic input 1 (high-active)
Low-side logic input 1 (high-active)
High-side logic input 2 (high-active)
Low-side logic input 2 (high-active)
High-side logic input 3 (high-active)
37
LIN3
Low-side logic input 3 (high-active)
2.4
Voltage and Current Measurements
The phase current measurement is illustrated on the top side of Figure 8; the right side shows the voltage
divider for the voltage measurement.
2.4.1
Phase Current Measurement
The current measurement can be done via a single shunt (signal IZ) in the DC-link path or via triple shunts (IU,
IV, IW) at the low side. In both cases the measurement is dimensioned for the following requirements:
Motor power range up to 15W which leads to a nominal DC-link current of about 0.625 A. The phase current
range is -3 A to +3 A. The output of the operational amplifier (AMP_IU, AMP_IV, AMP_IW, and AMP_IZ) is
available at the PMSM Low Voltage 15 W Motor card connector and connected to ADC input channels of the
XMC1000 microcontroller. The DC offset voltage level is about 2.5V at the ouput of the Op -Amps when there is
no current flow through the shunts.
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PMSM LV15W Card
In order to get Op-Amp DC offset, AC gain, and DC link maximum current, the calculation can be done as
below:
Figure 7
Hardware Circuit Op-Amp of DC Link Current Sensing
To get the Op-Amp DC offset:
(
)
(
Op-Amp DC Offset
)
AC Gain
By substituting all the resistor value into the formula, the Op-Amp DC offset with 2.5V is generated. The AC gain
of the operation amplifier is set to 16.4, which leads to DC link phase current range of 0V @ -3 A and 5V @ +3
A. The DC-Link shunt resistor is 50 mΩ.
Assuming the
of the operation amplifier is 5 V,
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PMSM LV15W Card
(
Figure 8
)
Hardware Connection of Shunt Amplifier
The IAVG is the average current measurement of DC-link after low pass RC filter.
To get 159Hz cutoff frequency:
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PMSM LV15W Card
2.4.2
Phase Voltage Measurement
The phase voltage is directly measured using resistive dividers at the phases (signals UZ, UU, UV, and UW).
The divider is dimensioned to divide the measured voltage UZ, UU, UV, UW by factor 10.21. The formula to
calculate the phase voltage
from the measured voltage
is:
Table 3 summarizes all the voltage and current signals available at SAMTEC connector.
Table 3
Voltage and Current signals at the SAMTEC Connector
Pin No.
Signal Name
Description
2
4
AMP_IU
AMP_IV
Amplified shunt voltage output representing the current of phase U
Amplified shunt voltage output representing the current of phase V
6
9
10
1
3
5
AMP_IW
IAVG
SH1-1
UU
UV
UW
Amplified shunt voltage output representing the current of phase W
Amplified shunt voltage output representing the DC-link current after filter
Shunt voltage output representing the DC-link current
Divided voltage output of phase U (divided by 10.21)
Divided voltage output of phase V (divided by 10.21)
Divided voltage output of phase W (divided by 10.21)
7
UZ
Divided DC-link voltage (divided by 10.21)
2.5
Encoder and Hall Interface
A quadrature encoder can be used for detecting the actual rotor position. There are single-ended and differential
encoders, the board supports both types. For the differential types an encoder line receiver is required as the
microcontroller needs single ended signals.
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PMSM LV15W Card
Figure 9
Encoder Line Driver and Connector for differential encoder signals
The differential signals from the encoder (ENCA +/-, ENCB +/-, ENCI +/-) must be connected to the 10-pin
encoder connector X204 (Figure 9). The Encoder Line Driver must be enabled by the signal ENENC (set to 1).
In case of using a single ended encoder or a hall sensor the signals must be applied to the connector X203 and
the encoder line receiver must be disabled by setting the signal ENENC to low level (default). The signal
ENENC controls the transistor to enable/disable the supply to the hall interface as shown in Figure 10.
Figure 10
Hall Sensor Connector Interface
Table 4 summarizes all the encoder/hall sensors signals available at the SAMTEC connector
Table 4
Encoder / hall signals at the SAMTEC connector
Pin No.
Signal Name
Description
37
43
45
49
ENENC
POSIF.IN0
POSIF.IN1
POSIF.IN2
Enable signal for encoder line receiver (active high)
Encoder Channel A / Hall Channel A
Encoder Channel B / Hall Channel B
Encoder Channel I / Hall Channel C
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PMSM LV15W Card
2.6
PMSM Motor
In this section, the technical data of the motor can be found.
Please refer directly to Maxon Motor internet page http://www.maxonmotor.com/ for the latest information about
this ECflat motor with part number 267121.
Figure 11
EC 32 flat 32 mm, brushless 15 Watt Motor Specification
2.6.1
Motor Operating Range
Figure 12
Motor Operating Range
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PMSM LV15W Card
2.6.2
Figure 13
Geometry
Motor Geometry
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3
Production Data
3.1
Schematics
This chapter contains the schematics for the PMSM Low Voltage 15W Motor Card:
Figure 14: SAMTEC Connector, Power Supply, Encoder Line Driver and Connector, Hall Sensor
Connector
Figure 15: Gate Driver, Power Stage, Shunt Amplifier, Motor Connector
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PMSM LV15W Card
Figure 14
Schematic of SAMTEC Connector, Power Supply, Encoder Line Driver and Connector, Hall
Sensor Connector
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PMSM LV15W Card
Figure 15
Schematic of Gate Driver, Power Stage, Shunt Amplifier, Motor Connector
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PMSM LV15W Card
3.2
Figure 16
Components Placement and Geometry
PMSM Low Voltage 15W Motor Card layout and geometry
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PMSM LV15W Card
3.3
Bill of Materials
The list of material is valid for a certain assembly version for the PMSM Low Voltage 15W Motor Card. This
version is stated in the header of the Table 5.
Table 5
PMSM Low Voltage 15W Motor Card BOM
No.
Qty
Value
Device
Reference
Designator
1
1
HSEC8-130-01-L-RA
X202
2
1
MKDS1/2-3,81
3
1
MPT0, 5/5-2, 54
HSEC8 socket,
SAMTEC
3.81mm pitch, 2 way,
Phoenix
PC terminal block
4
5
1
1
52207-11
BUCHSE-LP-5A/SPC4007
Molex Connector
Connector Jack
X205
X201
6
7
8
9
1
5
1
1
PAK100/2500-10
no ass./0603/10V
4.7uF/10V/0805
47uF/50V/6.6
Connector
Capacitor
Capacitor
Electrolytic capacitor
X204
C111, C112, C113, C114, C119
C207
C203
10
11
12
13
14
15
4
1
1
3
5
3
33pF/10V/0603
10nF/10V/0603
22nF/25V/0603
220nF/25V/0603
100nF/0603
10uF/25V/0805
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
C108, C109, C110, C118
C115
C106
C102, C103, C105
C202, C204, C116, C206, C208
C117, C209, C101
16
17
2
3
150pF/0603
15nF/25V/0603
Capacitor
Capacitor
C104, C107
C210, C211, C212
18
19
2
4
22uF/25V
0R/0603
Capacitor
Resistor
C201, C205
R126, R146, R218, R220
20
21
22
23
24
25
4
4
6
3
4
1
no ass./0603
0R050/1206
68R/0603
120R/0603
1KR/0603
1K8R/0603
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
R148, R219, R102, R125
RS101, RS102, RS103, RS104
R103, R104, R105, R113, R114, R115
R207, R209, R210
R133, R134, R135, R150
R214
26
27
28
29
30
31
32
1
6
4
1
1
3
8
2KR/0603
3K3R/0603
5K1R/0603
6K8R/0603
8K25R/0603
10KR/0603
22K/0603
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
33
34
1
11
41K2R/0603
47KR/0603
Resistor
Resistor
2
100KR/0603
Resistor
R208
R211, R212, R213, R215, R216, R217
R119, R120, R121, R122
R205
R206
R101, R124, R201
R127, R128, R129, R140, R142, R144,
R145, R153
R202
R106, R107, R108, R109, R110, R111,
R112, R116, R117, R118, R203
R123, R149
35
Board User's Manual
24
X101
X203
Revision 1.0, 2013-06-19
PMSM LV15W Card
No.
Qty
Value
Device
Reference
Designator
36
37
38
39
3
2
1
1
BSZ0907ND
BCR198W
6EDL04N02PR
AD8618ARUZ
MOSFET
Transistor
Gate Driver
Operational Amplifier
Q101, Q102, Q103
T201, T202
IC101
U101
40
41
42
43
44
45
46
47
48
1
1
1
1
3
1
3
3
4
Quadrature Line Driver
Voltage Regulator
Voltage Regulator
Voltage Regulator
LED
Maxon Motor
Screw
Spacer
Support
U201
IC201
IC202
IC203
V201, V202, V203
PMSM101
49
1
AM26LS32ACPW
IFX20001MBV59
IFX25001TFV50
IFX25401TEV
LED-GRN/0603
ECF32-267121
Farnell 1419294
Farnell 1466915
Transparent (D7.9mm,
H2.2mm)
230VAC, 24VDC, 1A
50
7
No assembly
Test Pad
Board User's Manual
Power Supply
25
P0.4, P0.5, TP305, TP306, TP301,
TP302, TP309, TP303
Revision 1.0, 2013-06-19
w w w. i nf i n eo n. c om
Published by Infineon Technologies AG
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