3-Phase AC/BLDC High Voltage Power Stage Board: Users Guide

3-Phase AC/BLDC High Voltage Power Stage Board
Users Guide
3PHACBLDCHVPSUG Rev. 1 01/2007
freescale.com
3-Phase AC/BLDC High-Voltage, Power-Stage Board

Users Guide
by: Petr Frgal Freescale Semiconductor Czech System Center

To provide the most up-to-date information, the revision of our documents on the World Wide Web will be the most current. Your printed copy may be an earlier revision. To verify that you have the latest information available, refer to http://www.freescale.com The following revision history table summarises changes contained in this document. For your convenience, the page number designators have been linked to the appropriate location.
Revision History
Date 01/2006 01/2007 Revision Level 0 1 Initial release After MCD team revision Description Page Number(s) N/A 70
3-Phase AC/BLDC High-Voltage, Power-Stage Board, Rev. 1 Freescale Semiconductor 3
3-Phase AC/BLDC High-Voltage, Power-Stage Board, Rev. 1 4 Freescale Semiconductor
List of Figures
Figure 1-1 Figure 1-2 Figure 1-3 Figure 2-1 Figure 3-1 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 Figure 4-14 Figure 4-15 Figure 4-16 Figure A-1 Figure A-2 Figure A-3 Figure A-4 Figure A-5 Figure A-6 Figure A-7 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure C-5 Figure C-6 System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-phase AC/BLDC High-Voltage Power Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-phase AC/BLDC High-Voltage Power Stage Setup Without External PFC. . . . . . . . . . Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-Pin Connector J8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Range - Board Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensing Circuit and Linearisation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . Back EMF sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Bus Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +18V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +15V_A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +5V_D Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +3.3V/+5V_A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analogue Sensing Range - Board Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +12V_Fan Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back EMF Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGBT Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Phase Power Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC bus Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Top Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Inner 1 Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Inner 2 Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Silkscreen Top Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Stage Board Silkscreen Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 13 15 18 27 31 33 34 35 36 37 38 41 42 43 43 44 44 45 46 46 48 49 50 51 52 53 54 62 63 64 65 66 67
3-Phase AC/BLDC High Voltage Power Stage Board, Rev. 1 Freescale Semiconductor 5
3-Phase AC/BLDC High Voltage Power Stage Board, Rev. 1 6 Freescale Semiconductor
Table of Contents
Chapter 1 Introduction
1.1 1.2 1.3 1.4 1.5 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Phase AC/BLDC High Voltage Power Stage Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 13 14
Chapter 2 Operational Description

2.1 2.2 2.3 2.4 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 17 18 19
Chapter 3 Pin Description

3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Terminal J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PFC Signals Connector J2 and PFC POWER Connectors J5 and J11 . . . . . . . . . . . . . . . . Jumper Terminals J3 and J7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Resistor Connector J4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Connector J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNI-3 Connector J8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Input Connector J9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earth Ground Terminal J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External -15V_A jumper J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 21 22 22 23 24 24 24 27 28 28
Chapter 4 Design Consideration

4.1 4.2 4.3 4.4 4.5 4.6 4.7 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-phase Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over-current and Undervoltage Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-Phase AC/BLDC High Voltage Power Stage Board*, Rev. 1 Freescale Semiconductor 7
29 29 29 32 34 34 35
4.8 4.9 4.10 4.11 4.12 4.12.1 4.12.2 4.12.3 4.12.4 4.12.5 4.12.6 4.12.7
Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Points and LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supplies and Voltage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +18V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +15V_A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +5V_D Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +3.3V_A/+5V_A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +12V_Fan Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +1.65V/2.5V Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 37 38 38 42 42 42 43 43 44 45 46
Appendix A. 3-phase AC/BLDC High Voltage Power Stage Board Schematics Appendix B. Bill of Materials Appendix C. 3-phase AC/BLDC High Voltage Power Stage Board Layouts
3-Phase AC/BLDC High Voltage Power Stage Board*, Rev. 1 8 Freescale Semiconductor
List of Tables
Table 2-1 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table B-1 Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector J2 Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PFC POWER Connector J5 Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PFC POWER Connector J11 Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumper J3 Setting Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumper J7 Setting Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector J6 Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector J8 Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 22 23 23 23 24 24 25 57
Chapter 1 Introduction
1.1 Contents
1.2 1.3 1.4 1.5 3-Phase AC/BLDC High Voltage Power Stage Outline . . . . . . . . . . . . . . . About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 13 14
1.2 3-Phase AC/BLDC High Voltage Power Stage Outline

Freescales 3-Phase AC high-voltage brushless dc (BLDC) power stage (HV AC power stage) is a 115/230 volt AC, 750 voltamps (one horsepower), off-line power stage that is an integral part of Freescales embedded motion control series of development tools. With one embedded-motion-control-series control board, it provides a ready-made, softwaredevelopment platform for one horsepower off-line motors. Feedback signals are provided that allow a variety of algorithms to control 3-phase AC induction and BLDC motors. The HV AC power stage also allows the connection of an external active power factor correction (PFC) board that facilitates development of PFC algorithms. Figure 1-1 shows an illustration of the system architecture. Figure 1-2 is an illustration of the board. The HV AC power stage features:
1-phase bridge rectifier dc-bus brake IGBT and brake antiparallel diode power and signal connectors for external PFC board 3-phase bridge inverter (6-IGBTs) Individual phase and dc bus-current-sensing shunts with Kelvin connections Power stage temperature sensing IGBT gate drivers Current and temperature signal conditioning 3-phase back-EMF voltage sensing and zero cross detection circuitry Low-voltage on-board power supplies Cooling fan
About this Manual
1.3 About this Manual

Key items are in the following locations in this manual:
Setup instructions 1.5 Setup Guide. Schematics Appendix A. 3-Phase AC/BLDC High Voltage Power Stage Board Schematics. Pin assignments Chapter 3 Pin Description Pin-by-pin description 3.3 Signal Descriptions. Description of reference design aspects of the boards circuitry Chapter 4 Design Consideration.
OPTOISOLATION
EMULATOR
OPTOISOLATION
WORKSTATION
WORKSTATION
CONTROL BOARD
HIGH-VOLTAGE POWER STAGE
DSP EVM BOARD
HIGH-VOLTAGE POWER STAGE
MOTOR
MOTOR
a) MICROCONTROLLER
b) 56800/E HYBRID CONTROLLER
Figure 1-1 System Configurations
Warnings
Figure 1-2 3-Phase AC/BLDC High-Voltage Power Stage
1.4 Warnings
This development tool set operates in an environment that includes dangerous voltages and rotating machinery. To facilitate safe operation, input power for the HV AC power stage should come from a currentlimited dc laboratory power supply, unless power-factor correction is specifically being investigated. An isolation transformer must be used when operating off an AC power line. If an isolation transformer is not used, the power stage grounds and oscilloscope grounds are at different potentials, unless the oscilloscope is floating.
Probe grounds. Therefore, the case of a floated oscilloscope is subjected to dangerous voltages.
Setup Guide
Be aware:
Before moving scope probes, making connections, etc., power down the high-voltage supply. When high voltage is applied, using only one hand for operating the test setup minimizes the possibility of electrical shock. Do not operate in lab setups that have grounded tables and/or chairs. Wear safety glasses, avoid ties and jewelry, use shields. Only personnel trained in high-voltage lab techniques should operate. Power devices and the motor can reach temperatures hot enough to cause burns.
When powering down, due to storage in the bus capacitors, dangerous voltages are present until all three power-on LEDs are off.
1.5 Setup Guide

Setup and connections for the HV AC power stage are straightforward. The power stage connects to an embedded motion-control-series control board via a 40-pin ribbon cable and can be powered by a 140 to 325-volt dc power supply or with line voltage. For safety reasons and ease of making measurements, use a dc supply, unless power-factor correction is specifically being investigated. Limit power supply to under eight amps. Figure 1-3 depicts a completed setup. The step-by-step setup procedure:
1. Plug one end of the 40-pin ribbon cable (that comes with the power stage kit) into the input connector J8. The other end of this cable goes to the embedded motion control board's 40-pin output connector (UNI-3 connector).
2. Connect motor leads to output connector J6, located along the back edge of the board. Phase A, phase B, and phase C are labelled Ph_A, Ph_B, and Ph_C.
For an AC induction motor, it does not matter which lead goes to which phase. For BLDC motors, it is important to get the wire color coded for phase A into the connector terminal labelled Ph_A, and so on for phase B and phase C.
3. Connect earth ground to the connector J5 pin 3. It is labelled Ground connections. 4. Connect a line-isolated, current-limited dc power supply to connector J9, located on the front edge of the board. The input voltage range is 140 to 325 Vdc. Current limit should be set for less than 8 amps. The dc supplys polarity does not matter.
A 115-volt or 230-volt AC line coupled through an isolation transformer may be used instead of a dc-supply to provide input power. The connection is made on connector J9. Internal power supplies develop bias voltages. Only one power input is required. WARNING Operation off an AC power line is significantly more hazardous than operation from a line isolated and current limited dc power supply. An isolation transformer should be used when operating off an AC power line.
5. Optional PFC The power stage allows connection of an external PFC board. Connect a power terminal on the PFC board to the PFC POWER connectors J5 and J11. The control signals are connected via a 10-pin ribbon cable to the PFC SIGNAL connector J2. To run the power stage without a PFC, interconnect the pins J5.1 (PFC_Neg2) and J5.2
Setup Guide
(PFC_Neg1), J11.1 (PFC_Pos2) and J11.2 (PFC_Pos1) by a power-jumper wires (manufacturer setting). 6. Optional braking resistor If braking mode is investigated during motor operation, an external resistor must be connected to the connector J4, Brake resistor. 7. Set up the control board. For safety reasons and avoiding damaging the computer, insert any galvanic isolation, as an opto box, between the control board and computer. 8. Apply power to the power stage. All green power-on LEDs (+18V and +5V_D in the center, +12V in the upper left-hand corner) light, and the fan runs when power is present. If the fan does not run, check if the jumper J1 is installed (default setting). The power stage powers the control board.
WARNING Hazardous voltages are present. Re-read all of 1.2 Warnings carefully.
Setup Guide
Freescale Semiconductor 3-ph. AC/BLDC High Voltage Power Stage 1 Freescale Semiconductor Embedded Motion Control Series Control Board 2 J11 1 2 3 J5
R brake J4 40-Pin Ribbon Cable
J8 140 - 325 Vdc 115 - 230 Vac J9 J6 Motor
Hall/Encoder Connector 1 2 3 4 5 6
Phase_C Phase_B Phase_A
3 2 1
ENCODER HOME HALL C / ENCODER INDEX HALL B / ENCODER PHASE B HALL A / ENCODER PHASE A GND +5V
Figure 1-3 3-Phase AC/BLDC High-Voltage Power Stage Setup Without External PFC
Chapter 2 Operational Description

2.1 Contents
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4 Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Introduction
Freescales embedded motion-control series high-voltage (HV) ACAC power stage is a 750voltamps (one horsepower), 3-phase power stage that will operate off dc input voltages from 140 V to 325 V, and AC line voltages from 100 V to 240 V. With an embedded motion-controlseries control boards, it provides a software-development platform that allows algorithms to be written and tested without designing and building a power stage. It supports a variety of algorithms for AC induction and brushless dc (BLDC) motors. The high-voltage AC-power stage has a printed circuit board. The printed circuit board contains an input rectifier, brake IGBT and diode, bridge IGBTs, IGBT-gate-drive circuits, analog-signal conditioning, low-voltage power supplies, and some large, passive, power components. All power devices that need to dissipate heat and a temperature sensor are mounted on a heatsink situated below the printed circuit board (Figure 1-2). Figure 2-1 shows a block diagram. Input connections are made via 40-pin ribbon-cable connector J8. Figure 3-1 shows pin assignments for the input connector. Power connections to the motor are made on output connector J6. Phase A, phase B, and phase C are labelled Ph_A, Ph_B, and Ph_C on the board. Power requirements are met by a single external 140V to 325V dc-power supply or an AC-line voltage. Either input is supplied through connector J9. An external brake resistor can be connected via connector J4. The power stage can be extended by an external PFC board. PFC board connection is made via power connectors J5, J11 and signal connector J2. Current measuring circuitry is set up for 8 amps full scale. Both bus and phase leg currents are measured. An overcurrent trip point is set at 10 amps.
Electrical Characteristics
INPUT
PFC POWER
MOTOR
BRAKE RESISTOR
J9
PFC CONTROL
J5
J11
J6
J4
1-PH RECTIFIER
J2
3-PH IGBT BRIDGE
BRAKE IGBT + DIODE
IGBT DRIVERS
UNI-3
J8
POWER SUPPLY
+15V_D, +5V_D, +15V_A +3.3/5V_A, +12V_FAN
SIGNAL CONDITIONING
INPUT, DC BUS, PHASE voltages and currents, ZERO cross, temperature
Legend:
Module
Connector
Figure 2-1 Block Diagram
2.3 Electrical Characteristics

The electrical characteristics in Table 2-1 apply to operations at 25C with a 325-Vdc powersupply voltage.
Fuse replacement
Table 2-1 Electrical Characteristics

Characteristic dc input voltage AC input voltage Quiescent Current* Logic 1 Input Voltage Logic 0 Input Voltage Input Resistance Analog Output Range** Bus Current Sense Voltage Bus Current Sense Offset Bus Voltage Sense Voltage Bus Voltage Sense Offset Continuos Output Current ***) Total Power Dissipation (per MOSFET) *** Deadtime (build in IR2133) Symbol Vdc Vac ICC VIH VIL RIn VOut ISense Ioffset VBus Voffset IC PD toff Min 140 100 1.5 0.9 0 Typ TBD 10 206.25 +VREF 8.09 0 250 10 TBD Max 325 240 1.7 1 3.3 Units V V mA V V k V mV/A V mV/V V A W ns
* Measured with an input power of 24V. ** Range set according +3.3V_A/+5V_A Power Supply *** The values are measured at 25C, for other temperatures the values may be different
2.4 Fuse replacement

A fast blow fuse is located on the front left side behind the PFC power connector J5. If this fuse needs replaced, follow these steps:
1. Remove power and wait until all power-on LEDs are off.
2. 3. 4. 5. 6.
Remove the fuses protective case. Replace the fuse with a new one F 250V/6A. Replace the protective case. Set the controllers speed control input to zero RPM. Apply power and resume operation.
Fuse replacement
Chapter 3 Pin Description

3.1 Contents
3.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.3 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Introduction
Inputs, outputs, and jumper terminals are located on twelve connectors available on the board: Fan PFC signals Jumper J3 and J7 Brake resistor PFC power 3-pin motor 40-pin UNI-3 Line input Earth ground connection External -15V_A jumper
Pin descriptions for each connector and the test points are identified in the following information. Figure 3-1 shows the pin assignments for the UNI-3 connectors. Table 3-7 shows the signal descriptions. The 3-phase AC/BLDC High-Voltage Power Stage contains several connectors that serve for a connection of a power supply, for motor phases connection, and other functions. The input power supply attached to the J9 line AC input must not be less than 100V or higher than 230V, or a DC power supply between 140V and 325V. The output for the motor is done by a 3-way connector J6. See 3.3.5 Motor Connector J6 for more details.
Signal Descriptions
3.3 Signal Descriptions

Pin descriptions are identified in this subsection. 3.3.1 Fan Terminal J1 Cooling efficiency can be increased by using a fan mechanically mounted on a heat-sink. To use a fan, set the jumper plug on Fan Terminal J1. 3.3.2 PFC Signals Connector J2 and PFC POWER Connectors J5 and J11 These connectors allow connecting an external PFC board that facilitates development of PFC algorithms. On the PFC signals connector, control and sensing signals are available for an external PFC board. Table 3-1 shows the pin connections and descriptions. Signals V-IN and I_IN from the PFC signals connector can be shared with BEMF sense signals, or with phasecurrent sense signals on the UNI-3 connector, to further evaluate these signals in the controller board, according to the PFC algorithms.
Table 3-1 Connector J2 Signal Descriptions

Pin No. 1 2 3 Signal Name PWM_PFC GND V_IN Description Signal for PFC transistor control connected only to PFC_PWM pin 31 of UNI-3 connector Digital and power supply ground V_IN is an sense signal from an external PFC board. Connection is determined by the settings of the J3 and J7 jumper terminals. I_IN is an sense signal from an external PFC board. Connection is determined by the settings of the J3 and J7 jumper terminals. +3.3-volt or +5-volt power supply depends on board configuration power supply ground Reference signal Vref for current sensing offset Digital +5-volt power supply Digital +18-volt power supply Digital and power supply ground
4 5 6 7 8 9 10
I_IN +3.3_A/+5V_A GNDA +Vref +5V_D +18V_D GND
Table 3-2 and Table 3-3 shows pin descriptions of the PFC POWER Connectors J5 and J11. To supply the board through the J9 line input connector, a power wire jumpers should be plugged. Connect a power wire jumpers between pins DCB_Pfc_Pos1 and DCB_Pfc_Pos2, DCB_Pfc_Neg1 and DCB_Pfc_Neg2 to select line input as the source for the power stage board (see Figure 1-3). Pin 3 of J5 connector is used as ground connection. It is marked with a ground symbol. You can also supply the power stage from an external PFC board. Then do not plug
Signal Descriptions
jumpers, or remove them if plugged, and connect the external PFC board according to Table 32 and Table 3-3. The external PFC can then be controlled by signals available on the PFC signals connector J2.
Table 3-2 PFC POWER Connector J5 Descriptions
Pin Number 1 2 3 Signal Name DCB_Pfc_Neg2 DCB_Pfc_Neg1 Earth_GND Description Negative bus input and external PFC board negative bus input. Negative output from input bridge rectifier and external PFC board negative output from input bridge rectifier. Ground connection for the line input and external PFC board ground.
Table 3-3 PFC POWER Connector J11 Descriptions

Pin Number 1 2 Signal Name DCB_Pfc_Pos2 DCB_Pfc_Pos1 Description Positive bus input and external PFC board positive bus input. Positive output from input bridge rectifier and external PFC board positive output from input bridge rectifier.
3.3.3 Jumper Terminals J3 and J7 Table 3-4 and Table 3-5 show jumper terminal settings for selected configurations. Each table row means one option of configuration and determines the pins shorted by a jumper plug.
Table 3-4 Jumper J3 Setting Descriptions

Shorted pins 1-3 5-3 2-4 6-4 Description BEMF_sense_C signal from UNI-3 connector J8 is connected to BEMF_sense_C signal on power stage board BEMF_sense_C signal from UNI-3 connector J8 is connected to V_IN signal on PFC signals connector J2 BEMF_sense_B signal from UNI-3 connector J8 is connected to BEMF_sense_B signal on power stage board BEMF_sense_B signal from UNI-3 connector J8 is connected to V_IN signal on PFC signals connector J2
Signal Descriptions
Table 3-5 Jumper J7 Setting Descriptions

Shorted pins 1-3 5-3 2-4 6-4 Description I_sense_C signal from UNI-3 connector J8 is connected to I_sense_C signal on power stage board I_sense_C signal from UNI-3 connector J8 is connected to V_IN signal on PFC signals connector J2 I_sense_B signal from UNI-3 connector J8 is connected to I_sense_B signal on power stage board I_sense_B signal from UNI-3 connector J8 is connected to I_IN signal on PFC signals connector J2
3.3.4 Brake Resistor Connector J4 A brake resistor can be connected to brake-resistor connector J4. The brake resistor allows power dissipation and can be controlled through the brake control situated on pin 29 of the UNI3 connector J8. 3.3.5 Motor Connector J6 Power outputs to the motor are located on connector J6. Phase outputs are labelled Ph_A, Ph_B, and Ph_C. Table 3-6 contains pin assignments. Section 1.5 Setup Guide shows how to connect the motor. On an induction motor, any one of three phase windings can be connected here. For brushless dc motors, you must connect the wire color coded for phase A into the connector terminal labelled Ph_A, and so on for phase B and phase C.
Pin Number 1 2 3 Signal Name Ph_A Ph_B Ph_C Description Phase_A supplies power to motor phase A. Phase_B supplies power to motor phase B. Phase_C supplies power to motor phase C.
3.3.6 UNI-3 Connector J8 Signal inputs and outputs are grouped together on the 40-pin ribbon cable connector J8, located on the boards right-side edge. Figure 3-1 shows pin assignments. In this figure, a schematic representation appears on the left, and a physical layout of the connector appears on the right. The physical view assumes that the board is oriented such that its title is read from left to right. Table 3-7 lists signal descriptions. The UNI-3 connector serves for interconnection with a control or EVM board.
Signal Descriptions
3.3.6.1 Changes to Standard UNI-3 Connection
The 3-Phase AC/BLDC High Voltage Power Stage Board board does not use full UNI-3 interface and brings a few UNI-3 signals changes. First, a change exists in the supply voltage, -15V_A on pin 20. -15V_A can be gained only from external power supply source - see 3.3.9 External 15V_A jumper J12. The serial communication pin 30 is unconnected, as are PFC_enable pin 32 and PFC_z_c pin 33. See Figure 3-1 for more details.

Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Signal Name PWM_AT Shielding PWM_AB Shielding PWM_BT Shielding PWM_BB Shielding PWM_CT Shielding PWM_CB GND GND +5V digital +5V digital +3.3/5V_A GNDA GNDA Description Gate drive signal for the top half-bridge of phase A. A logic high turns phase As top switch on. Pin 2 is connected to a shield wire in the ribbon cable and ground on the board. Gate-drive signal for the bottom half-bridge of phase A. A logic high turns phase As bottom switch on. Pin 4 is connected to a shield wire in the ribbon cable and ground on the board. Gate drive signal for the top half-bridge of phase B. A logic high turns phase Bs top switch on. Pin 6 is connected to a shield wire in the ribbon cable and ground on the board. Gate drive signal for the bottom half-bridge of phase B. A logic high turns phase Bs bottom switch on. Pin 8 is connected to a shield wire in the ribbon cable and ground on the board. Gate-drive signal for the top half-bridge of phase C. A logic high turns on phase Cs top switch. Pin 10 is connected to a shield wire in the ribbon cable and ground on the board. Gate-drive signal for the bottom half-bridge of phase C. A logic high turns phase Cs bottom switch on. Digital and power ground Digital and power ground, redundant connection Digital +5-volt power supply Digital +5-volt power supply, redundant connection Analog +3.3-volt or +5-volt power supply Analog-power supply ground Analog-power supply ground, redundant connection
Signal Descriptions
Table 3-7 Connector J8 Signal Descriptions (Continued)

Pin Number 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal Name +15V_A -15V_A V_sense_DCB I_sense_DCB I_sense_A I_sense_B I_sense_C Temp_sense NC Shielding Brake_control Serial_Con PFC_PWM PFC_enable PFC_z_c Zero_cross_A Zero_cross_B Zero_cross_C Shielding BEMF_sense_A BEMF_sense_B BEMF_sense_C Analog +15-volt power supply Analog -15-volt power supply Analog-sense signal that measures bus voltage. It is scaled at 8.09V per volt of dc bus voltage. Analog-sense signal that measures bus current. It is scaled at 8.09V per amp of dc bus current. Analog-sense signal that measures current in phase A. It is scaled at 50V per amp of dc bus current. Analog-sense that measures current in phase B. It is scaled at 0.563V per amp of dc bus current. Analog-sense signal that measures current in phase C. It is scaled at 0.563 volts per amp of dc bus current. Analogu-sense signal that measures temperature on the heatsink. No connection Pin 28 is connected to a shield wire in the ribbon cable and ground on the board. Gate-drive signal for the brake IGBT. No connection Digital signal that controls the power factor correction circuits switch. No connection No connection Digital signal used for sensing phase A back-EMF zero-crossing events. Digital signal used for sensing phase B back-EMF zero-crossing events. Digital signal used for sensing phase C back-EMF zero-crossing events. Pin 37 is connected to a shield wire in the ribbon cable and ground on the board. Analog-sense signal that measures phase A back EMF. It is scaled at 8.09mV per volt of dc bus voltage. Analog-sense signal that measures phase B back EMF. It is scaled at 8.09mV per volt of dc bus voltage. Analog-sense signal that measures phase C back EMF. It is scaled at 8.09mV per volt of dc bus voltage. Description
Signal Descriptions
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BEMF_sense_C BEMF_sense_B BEMF_sense_A Shielding Zero_cross_C Zero_cross_B Zero_cross_A PFC_z_c PFC_enable PFC_PWM Serial_Con BRAKE_control Shielding NC Temp_sense I_sense_C I_sense_B I_sense_A I_sense_DCB V_sense_DCB_5 -15V_A +15V_A GNDA GNDA +3.3/+5V_A +5V_D +5V_D GND GND PWM_CB Shielding PWM_CT Shielding PWM_BB Shielding PWM_BT Shielding PWM_AB Shielding PWM_AT
PWM_AT PWM_AB PWM_BT PWM_BB PWM_CT PWM_CB GND +5V_D GNDA +15V_A V_sense_DCB_5 I_sense_A I_sense_C NC BRAKE_control PFC_PWM PFC_z_c Zero_cross_B Shielding BEMF_sense_B
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Shielding Shielding Shielding Shielding Shielding GND +5V_D NC GNDA -15V_A I_sense_DCB I_sense_B Temp_sense Shielding Serial_Con PFC_enable Zero_cross_A Zero_cross_C BEMF_sense_A BEMF_sense_C
PHYSICAL VIEW
SCHEMATIC VIEW Figure 3-1 40-Pin Connector J8 3.3.7 Line Input Connector J9 The line input connector, labelled J9, is located on the front edge of the board. It accepts dc voltages from 140V to 315V or an isolated AC line input from 100V to 230V. In either case, the power source should be capable of supplying at least 750 watts.
Signal Descriptions
3.3.8 Earth Ground Terminal J10 One hole is used as earth ground connection J10. The J10 hole is used for mounting and ground connection of the heatsink. Connect an earth ground to the earth ground terminal on the heat sink. The heat sink has a screw on its front edge that is marked with a ground symbol. As mentioned in previous chapters, the 3-phase AC/BLDC High-Voltage Power Stage board contains more grounds. These grounds are connected into one point. If necessary, the user can remove ground connection GC400 to disconnect the grounds and perform measurements. 3.3.9 External -15V_A jumper J12 An external -15V power supply source can be connected to the power stage board through jumper J12 to supply boards connected through UNI-3 connector J8 by -15V_A (pin 20).
Chapter 4 Design Consideration

4.1 Contents
4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Phase Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Voltage and Current Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over-current and Undervoltage Functions. . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Points and LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supplies and Voltage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 29 30 32 34 35 35 36 37 38 38 42
4.2 Overview
From a systems point of view, the HV AC power stage fits into an architecture designed for software development. In addition to the hardware needed to run a motor, a variety of feedback signals that facilitate control algorithm development are provided. A set of schematics for the 3phase AC/BLDC High-Voltage Power-Stage appears in the following section. Circuit descriptions for the HV AC power stage appear in 4.3 3-Phase Bridge through 4.12 Power Supplies and Voltage Reference. One phase leg of the 3-phase bridge is examined in 4.3 3Phase Bridge. Bus voltage and bus current feedback are discussed in 4.4 Bus Voltage and Current Feedback. Safety functions are highlighted in 4.5 Over-current and Undervoltage Functions. Temperature sensing is discussed in 4.6 Temperature Sensing. Back-EMF signals appear in 4.7 Back EMF Signals. Phase current sensing is discussed in 4.8 Phase Current Sensing. The brake is highlighted in 4.9 Brake. Power-factor correction is discussed in 4.10 External Power Factor Correction. Test Points description and LED description are made in 4.11 Test Points and LED Indication, and finally, all power supplies and Voltage reference are described in 4.12 Power Supplies and Voltage Reference.
3-Phase Bridge
4.3 3-Phase Bridge

The output stage is configured as a 3-phase bridge with IGBT-output transistors. It is simplified considerably by a high-voltage, integrated-gate driver that has an over-current and undervoltage limit feature. Figure 4-1 shows a schematic of one phase. At the input, pull-down resistors R207 and R208 set a logic low in the absence of a signal. Open input pull-down is important because the power transistors must stay off in case of a broken connection or an absence of power on the control board. The drive signal is buffered and inverted by U200A and U200B. This part has a minimum logic 1 input voltage of 1.2V and a maximum logic 0 input voltage of 0.5V, which allows for inputs from 3.3V or 5V logic. An international rectifier, IR2133, supplies gate drive. IR2133 also provides undervoltage lockout and over-current. Undervoltage lockout is 8.2V/8.6V volts, depending on the current threshold. IR2133 has an implemented 250 ns deadtime insertion. Current limiting and undervoltage lockout are discussed further in 4.5 Over-current and Undervoltage Functions. One important design decisions in a motor drive is the selection of gatedrive impedance for the output transistors. In Figure 4-1, resistor R206, diode D203, and the IR2133 nominal 420-mA current sinking capability determine gate-drive impedance for the lower half-bridge transistor. A similar network is used on the upper half-bridge. These networks set turn-on gate drive impedance at approximately 75 and turn-off gate drive to approximately 420 mA. These values produce transition times of approximately 200 ns. Transition times of this length represent a carefully weighed compromise between power dissipation and noise generation. Generally, transition times longer than 250 ns tend to get power hungry at non-audible PWM rates; transition times under 50 ns create di/dts so large that proper operation is difficult to achieve. The HV AC power stage is designed with switching times at the higher end of this range to minimize noise. Anti-parallel diode softness is also a primary design consideration. If the anti-parallel diodes in an off-line motor drive are allowed to snap, the resulting di/dts can cause noise management problems difficult to solve. In general, the peak to zero di/dt should be approximately equal to the di/dt applied to turn off the anti-parallel diodes. The SKP10N60 IGBTs used in this design are targeted at this kind of reverse recovery.
14
Freescale Semiconductor
DCB_Cap_Pos C201 MBRS130LT3 D201 GND U201 22 25 HIN1 LIN1 HIN2 LIN2 HIN3 LIN3 VB2 HO2 VS2 LO2 VB3 HO3 VS3 LO3 COM 8 I_sense_A1 I_sense_A2 I_Sense_DCB2 14 13 12 9 17 16 15 10 VB1 HO1 VS1 LO1 MBRS130LT3 D203 20 19 18 11 VCC 23 26 24 27 4 U200B MM74HCT14M 21 C202 1uF/50V D200 MURS160T3 1 GND 10nF U200A MM74HCT14M VCC 2 +5V_D TP201 Gate_AT R201 0 R202 75 +15V_D D202 MMSZ5251BT1 Q300 SKP10N60 GND TP204 Gate_AB R204 0 R206 75 Q303 SKP10N60 3 R208 10k 28 1 2 3 5 4 6 FAULT ITRIP FLT-CLR CAO CA+ CASD VSS IR2133S 7 GND D205 MMSZ5251BT1 sense R300 0.050-1% sense
TP202 PWM_AT
PWM_AT
TP203 PWM_AB
PWM_AB
Figure 4-1 Phase Output
3-Phase AC/BLDC High Voltage Power Stage Board, Rev. 1
R207 10k
3-Phase Bridge
31
Bus Voltage and Current Feedback
4.4 Bus Voltage and Current Feedback

Figure 4-2 shows the circuitry that provides feedback signals proportional to bus voltage and bus current. Bus voltage is scaled down by a voltage divider consisting of R135, R138, R142, R144, R147, R150, and R152. The values are chosen such that a 400-volt bus voltage corresponds to 3.235V at output V_sense_DCB. An additional output, V_sense_DCB_half_15, provides a reference used in zero-crossing detection. Bus current is sampled by resistor R303 in Figure A5 and amplified in IR2133s operational amplifier (Figure 4-2). This circuit provides a voltage output suitable for sampling with A/D (analog-to-digital) inputs. IR2133s operational amplifier is used as a differential amplifier for bus-current sensing. With R200 = R217, R218 = R226, and R221 = R227, the gain is given by: A = R227/(R200+R226) The output voltage is shifted up by +Vref to accommodate positive and negative current swings. A 400-mV voltage drop across the sense resistor corresponds to a measured current range of 8 amps. The default current range 8 amps is marked on the actual PCB board (see Figure 43). In addition, a -I signal is connected to the ITRIP input of IR2133 and provides an over-current triggering function. A discussion of over-current limiting follows in 4.5 Over-current and Undervoltage Functions. The output is connected to the UNI-3 pin 22 I_sense_DCB. V_dcb is scaled at 8.09mV per volt of the DC bus voltage and connected to the UNI-3 pin 21 V_sense_DCB_5. The shunt resistor is represented by a 0.050-ohm resistance Isabellenhutte SMV SMD precision resistor, the same as the phase current measurement resistors.
Bus Voltage and Current Feedback
+5V_D 2 R203 6.8k 1
J200 N/P
TP115 V_dcb
DCB_Cap_pos GND R135 330k-1% +18V_D C207 4.7uF/35V C203 100nF GND VCC VB1 HO1 VS1 LO1 VB2 HO2 VS2 LO2 VB3 HO3 VS3 LO3 COM 21 20 19 18 11 17 16 15 10 14 13 12 9 8 GND TP212 Idcb+ GNDA I_sense_DCB2 TP122 V_dcb_s TP120 V_dcb_ZC R144 220k-1% V_sense_DCB_half_15 R147 6.8k-1% u- < 7.5V u- = 6.60V @ DC-Bus = 400V R142 6.8k-1% R138 270k-1%
FAULT DISABLE
R205 3.6k TP215 FAULT D204 RED U201 22 25 23 26 24 27 28 1 2 3 5 4 6 7 GND HIN1 LIN1 HIN2 LIN2 HIN3 LIN3 FAULT ITRIP FLT-CLR CAO CA+ CASD VSS IR2133S
GND
2 1
R150 270-1% 3.235V @ DC-Bus = 400V V_sense_DCB R152 6.8k-1%
R217 1.6k-1% +Vref R221 7.5k-1% C200 47pF
R218 220-1% R222 1k TP200 I_trip 0.50V @ +Ifault
R200 1.6k-1%
R225 n/p R226 220-1%
C206 1nF I_sense_DCB1
TP126 Idcb_s
R227 7.5k-1%
DC Bus Current Sensing
+3.3/5V_A
U100B MC33502D D101 BAT42
Figure 4-2 Bus Feedback
7 I_sense_DCB 1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Imax = 8A at Vref = 3.3V
TP214 Idcb-
Over-current and Undervoltage Functions
Figure 4-3 Current Range - Board Detail
4.5 Over-current and Undervoltage Functions

IR2133 provides over-current and undervoltage functions (Figure 4-2). Bus current feedback signal, I_sense_DCB1, is filtered with R222 and C206 to remove spikes, and this signal is fed into the IR2133 current comparator input ITRIP. Therefore, when bus current exceeds 10 amps, all six output transistors are switched off. After a fault state is detected, all six gate drivers are off until the fault state is cleared by the low level on pin FLT-CLR. To clear a fault state, switch the power stage off and leave it off until all LEDs are off. Then you can switch the power stage on.
WARNING Fault functions can be disabled, but then the power stage board is not protected against shortouts. This is not recommended because if an over-current appears, the power stage board can be damaged.
The undervoltage function is implemented internally. The IR2133s supply voltage is sensed internally. If this voltage is lower than 8.2V/8.6V, depending on the current threshold, the fault state is evaluated.
Temperature Sensing
4.6 Temperature Sensing

The IR2133 safety functions keep the bus current and voltage within safe limits. Current limiting by itself, however, does not necessarily ensure that a power stage is operating within safe thermal limits. For thermal protection, the circuit in Figure 4-4 is used. It consists of a voltage divider from an NTC thermistor, resistor R111 and R114 for linearisation. The temp_sense signal is fed back to an A/D input where software can be used to set safe operating limits.
+3.3/5V_A
TP106 Temp
R111 3.6k-1%
Temp R114 5.1k-1% 2 GNDA 1 RV100 10k
Figure 4-4 Temperature Sensing Circuit and Linearisation Chart
4.7 Back EMF Signals

Back EMF and zero-crossing signals are included to support sensorless algorithms for brushless dc motors and dead time distortion correction for AC induction motors. Referring to Figure 4-5, which shows circuitry for phase A, the raw phase voltage is scaled down by a voltage divider consisting of R126, R127, R128, R132, and R133. One output from this divider produces back EMF sense voltage BEMF_sense_A. Resistor values are chosen such that a 400-volt maximum phase voltage corresponds to a 3.235-volt maximum A/D input. BEMF_sense_A is led directly to the UNI-3 pin 38 without any offset correction (see Figure A-1). A zero-crossing signal is obtained by comparing the scaled motor phase voltage BEMF_A_ZC to the scaled bus voltage. Comparator U103B performs this function, producing zero-crossing signal Zero_cros_A. The V_sense_DCB_half_15 is provided by the R5135, R138, R142, R144, R147, R150, and R152 resistor divider from the bus voltage (see Figure 4-2).
Phase Current Sensing
Phase_A 400V max TP111 BEMF_A R126 330k-1%
TP112 BEMF_A_ZC
R127 330k-1%
u+ <15V u+ = 2*V_sense_DCB_half_15 u+ = 13.30V/13.06V @400V
R129 10M
+5V_D R130 10k
R128 150k-1%
R131 470k 5 + 7 U103B LM393D TP114 ZC_A
TP113 BEMF_A_s 3.235V @ Phase_A = 400V BEMF_sense_A
R132 22k-1%
C108 10pF
Zero_cros_A
R133 6.8k-1% GNDA u- = 6.60V @400V V_sense_DCB_half_15 C100 22pF
The comparators' hysteresis VH = 240mV
GNDA
GNDA
Figure 4-5 Back EMF sensing
4.8 Phase Current Sensing

Sampling resistors provide phase current information for all three phases. Because these resistors sample current in the lower phase legs, they do not directly measure phase current. However, given phase voltages for all three phases, phase current can be constructed mathematically from the lower phase leg values. This information can be used in vector-control algorithms for AC induction motors. The measurement circuitry for one phase is shown in Figure 4-6. Referencing the sampling resistors to the negative motor rail makes the measurement circuitry straightforward and inexpensive. Current is sampled by resistor R300 and amplified by the differential amplifier U100A. This circuit provides a voltage output suitable for sampling with A/D inputs. An MC33502D is used as a differential amplifier. With R115 = R120 and R116 = R118 R117 = R119, the gain is given by: A = R115/(R116+R117) The input voltage is shifted up by +Vref to accommodate both positive and negative current swings. A 400-mV voltage drop across the shunt resistor corresponds to a measured current range of 8 amps. As a source for +Vref we use the voltage reference described in 4.12.7 +1.65V/2.5V Reference.
Brake
The gain of this op. amplifier is 4.12 with the +Vref offset, i.e. the output 1.65V corresponds to 8A. The output is connected to the UNI-3 pin 22.
R115 TP107 IcI_sense_C1 TP108 Ic+ I_sense_C2 R118 220-1% C104 47pF R119 1.6k-1% R120 7.5k-1%
8
7.5k-1% R116 220-1% R117 1.6k-1% 2 3

4
GNDA
TP109 Ic_s 1
1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Imax = 8A at Vref = 3.3V I_sense_C
TP110 +Vref +15V_A C106 100nF + R121 6.2k C107 10uF/20V R122 100k-1% 5 LM285M U102 GNDA R124 33k-1% R156 0 N/P R123 47k-1% R125 1k-1%
8
1.65V/2.5V ref
+Vref GNDA
GNDA
Default +Vref=1.65V For +Vref=2.5V solder R156 or a wire jumper
Figure 4-6 Phase Current Sensing
4.9 Brake
An external brake resistor can be connected to dissipate re-generative motor energy during periods of active deceleration or rapid reversal. Under these conditions, motorback EMF adds to the dc bus voltage. Without a means to dissipate excess energy, an overvoltage condition could easily occur. The circuit shown in Figure 4-7, with an external dissipative resistor connected to J4, serves to dissipate energy across the dc bus. Q306 is turned on by software when the bus voltage sensing circuit in Figure 4-2 indicates that bus voltage could exceed safe limits. Power dissipation capability depends, of course, on the capability of the externally connected dissipative resistor. The MC33152 is a dual MOSFET predriver of up to 18V. This board uses its A channel to drive the braking resistance MOSFET.
+ U100A MC33502D +3.3/5V_A C105 100nF
External Power Factor Correction
DCB_Cap_Pos +18V_D C300 10uF/35V

+
D300 HFA04TB60S
C301 100nF GND TP302 PWM_brake U300 1 NC 2 InA

6
TP301 V_brake MBRS130LT3 D301 8 R304 0 R305 75 Q306 SGP10N60 TP300 Gate_brake Brake_res Brake_res
VCC
NC
Brake_control
OutA 7
R306 10k
4 InB GND
3
OutB 5
D302 MMSZ5251BT1
MC33152D GND GND
GND GND
Figure 4-7 Brake
4.10 External Power Factor Correction

An external active Power Factor Correction circuit can be connected to the power stage board through connectors J5 and J11. See 3.3.2 PFC Signals Connector J2 and PFC POWER Connectors J5 and J11 for a connection description. Supplying the power stage board from the line-input requires connecting a power jumpers. The external PFC board is a controlled from a controller or an EVM board. Pin connections are in sections 3.3.2 PFC Signals Connector J2 and PFC POWER Connectors J5 and J11 and 3.3.6 UNI-3 Connector J8.
4.11 Test Points and LED Indication

Some voltages and currents of the 3-Phase AC/BLDC High Voltage Power Stage Board can be sensed, whilst some are connected to the UNI-3 pins. Those are: back-EMF voltage, phase current, bus-power voltage, bus current, zero-crossing signals, brake-control signal, PWM signal for all 6 swiches of the 3-phase power bridge, and the heatsink temperature. Test points have different colors for better signal recognition. Black refers to raw signals. Green is for a signal scaled to the MCU range or for control signals. White indicates all grounds. Red is for positive voltage power supplies. The 3-phase AC/BLDC High-Voltage Power-Stage contains 61 test points to allow the user to easily check the voltage of all important points: TP100 Ia Phase A current sense resistor test point for node I_sense_A1. TP101 Ia+ Phase A current sense resistor test point for node I_sense_A2.
Test Points and LED Indication
TP102 Ia_s Phase A current output test point for node I_sense_A, scaled at 0.275V/0.417V per amp of phase current A and shifted by 1.65V/2.5V. TP103 Ib Phase B current sense resistor test point for node I_sense_B1. TP104 Ib+ Phase B current sense resistor test point for node I_sense_B2. TP105 Ib_s Phase B current output test point of node I_sense_B, scaled at 0.275/0.417 volts per amp of phase current B and shifted by 1.65V/2.5V. TP106 Temp Temperature sensing testing point. TP107 Ic Phase C current sense resistor test point for node I_sense_C1. TP108 Ic+ Phase C current sense resistor test point for node I_sense_C2. TP109 Ic_s Phase C current output test point of node I_sense_C, scaled at 0.275/0.417 volts per amp of phase current C and shifted by 1.65V/2.5V. TP106 Temp Temperature sensing test point. TP110 +Vref Reference voltage test point. TP111 BEMF_A Back EMF phase A test point. TP112 BEMF_A_ZC Phase A zero-crossing test point, scaled at 33.25V per volt of phase voltage A. TP113 BEMF_A_s Back EMF phase A test point, scaled at 8.09V per volt of phase voltage A. TP114 ZC_A Phase A zero-crossing test point. TP115 V_dcb Bus voltage test point. TP116 BEMF_B Back EMF phase B test point. TP117 BEMF_B_ZC Phase B zero-crossing test point, scaled at 33.25V per volt of phase voltage B. TP118 BEMF_B_s Back EMF phase B test point, scaled at 8.09V per volt of phase voltage B. TP119 ZC_B Phase B zero-crossing test point. TP120 V_dcb_ZC Half of bus voltage test point used for zero-crossing comparison. TP121 BEMF_C Back EMF phase C test point. TP122 V_dcb_s Bus voltage test point, scaled at 8.09V per volt. TP123 BEMF_C_ZC Phase C zero-crossing test point, scaled at 33.25V per volt of phase voltage C. TP124 ZC_C Phase C zero-crossing test point. TP125 BEMF_C_s Back EMF phase C test point, scaled at 8.09V per volt of phase voltage C. TP126 Idcb_s Bus current scaled and shifted +1.65V/+2.5V.
TP200 I_trip Over-current and under-voltage shut-down test point of 3-phase bridge driver U201. TP201 Gate_AT TP200 I_trip Top transistor gate of phase A test point. TP202 PWM_AT PWM control signal for top transistor gate of phase A, test point on connector J8 pin. TP203 PWM_AB PWM control signal for bottom transistor gate of phase A, test point on connector J8 pin. TP204 Gate_AB Bottom transistor gate of phase A test point. TP205 Gate_BT Top transistor gate of phase B test point. TP206 PWM_BT PWM control signal for top transistor gate of phase B, test point on connector J8 pin. TP207 PWM_BB PWM control signal for bottom transistor gate of phase B, test point on connector J8 pin. TP208 Gate_BB Bottom transistor gate of phase B test point. TP209 PWM_CT PWM control signal for top transistor gate of phase C, test point on connector J8 pin. TP210 Gate_CT Top transistor gate of phase C test point. TP211 PWM_CB PWM control signal for bottom transistor gate of phase C, test point on connector J8 pin. TP212 Idcb+ Bus current sense resistor test point for node I_sense_DCB2. TP213 Gate_CB Bottom transistor gate of phase C test point. TP214 Idcb Bus current sense resistor test point for node I_sense_DCB1. TP215 FAULT Over-current or undervoltage of the 3-phase bridge driver IR2133 test point. TP300 Gate_brake Brake transistor gate test point. TP301 V_brake Brake resistor voltage test point. TP302 PWM_brake PWM control signal for brake transistor gate, test point on connector J8 pin 29 Brake Control. TP303 AC1 Main input voltage test point on connector J9 pin 1. TP304 AC2 Main input voltage test point on connector J9 pin 2. TP400 GNDA Analog ground test point. TP401 +3.3V/5V_A This point is the output of the U401 linear voltage regulator. It serves as the power supply for the on-board op. amplifiers and for supplying the temperature measuring circuit. It is connected to the PFC signals connector J2. TP402 +18V This point is an output of the U402 switching step-up/down inverter. It serves as the power supply for U401, U404 and +18V_D digital supplies.
TP403 +18V_D This point is an output of the U402 switching step-up/down inverter. It serves as the power supply for the comparators, for the MOSFET driver and the 3-phase bridge driver, and as the source for U403 in generating +5V_D. It is connected to the PFC signals connector J2. TP404 +15V_A This point is an output of the U404 linear voltage regulator. It serves as the power supply for the voltage reference source. It is connected to the UNI-3 connector J8 pin 19. TP405 +12VFAN This point is the output of the U400 step-up/down inverter. It serves as a power supply for the fans only. TP406 GNDA Analog ground test point. TP407 GND Ground test point. TP408 GND Ground test point. TP409 GND Ground test point. TP410 GND Ground test point. TP411 +5V_D This point is the output of the U403 switching step-down inverter. It serves as the power supply for the on-board logic ICs. It is connected to the UNI-3 connector J8 pins 14 and 15 and to the PFC signals connector J2. TP412 V_dcb_1 Bus voltage test point. TP413 V_dcb_2 Bus voltage test point.
This board also contains four LEDs as indicators: D204 Indicates over-current or undervoltage of the 3-phase bridge driver IR2133 (see Figure 4-2). D400 Indicates that the +12V_Fans level is properly generated. D403 Indicates that the +18V level is properly generated. D407 Indicates that the +5V_D level is properly generated.
For more details see Figure 4-8.

TP402 +18V +12V_FANS +5V_D
R407 3.6k
R413 2.7k
R400 820
D403 GREEN
D400 GREEN
D407 GREEN
GND
GND
GND
Figure 4-8 LED Indication

Power Supplies and Voltage Reference
4.12 Power Supplies and Voltage Reference

The 3-phase AC/BLDC High-Voltage Power-Stage contains devices that require various voltage levels of +18V, +15V, +12V and +5V or +3.3V. 4.12.1 Input Power Supply All power supplies are served from bus voltage. Bus can be supplied from two sources, from the line input across the power bridge or from the external PFC board. The power source should be able to deliver at least 8 amps.
TP303 AC1 F300 AC1 Fuse R307 DCB_Pfc_Pos1 SG-200 DCB_Pfc_Pos2 DCB_Cap_Pos
+ 1
4 -
i
D303 GBU605 C302 10nF/3000V Earth_GND + C305 470uF/400V + C304 470uF/400V D304 V14E250 2 3 C303 10nF/3000V
AC2 TP304 AC2
DCB_Pfc_Neg1
DCB_Pfc_Neg2
DCB_Cap_Neg
Figure 4-9 DC Bus Power Supply 4.12.2 +18V Power Supply The +18V level is generated by means of the LNK306P switching step-up/down inverter (see Figure 4-10) that generates this level from bus voltage. This inverter can supply up to 300 mA. This voltage level serves the LM317LD and MC78L15ACD linear regulators, comparators, 3phase bridge driver and brake gate driver. +18V_D is directly supplied from LNK306P. If the LNK306P inverter operates properly, the D403 green LED is lit.
C401 2 N/P R402 18.7k C404 100nF 1
+
R403 2k U402 3 4 5 BP FB D LNK306P S S S S 8 7 2 1 D402 BYV26C + C405 10uF/35V D401 1N4005 TP402 +18V R405 +18V_D 0 TP403 +18V_D
TP412 V_dcb_1 R406 DCB_Cap_Pos 0
L400 1mH
+ C406 4.7uF/400V
+ C400 150uF/20V
R407 3.6k
D403 GREEN
GND
Figure 4-10 +18V Power Supply 4.12.3 +15V_A Power Supply The +15V_A power supply is generated from the +18V level by means of the MC78L15ACD linear voltage regulator (see Figure 4-11). It can supply up to 100 mA. The +15V_A level is used to supply the linear voltage reference LM285M. It is connected to the UNI-3 connector J8 pin 19.
TP402 +18V R408 8 1 0 2 + C408 1uF/50V U404 MC78L15ACD VI VO GND1 GND2 GND3 GND4 1
TP404 +15V_A +15V_A
C407 100nF
GNDA
2 3 6 7 GNDA
GNDA
Figure 4-11 +15V_A Power Supply 4.12.4 +5V_D Power Supply An important voltage level for this board is +5V_D. This voltage level is obtained by the LM2674M switching step-down inverter and can supply up to 500 mA (Figure 4-12). The +5V_D level is used to supply the on-board logic ICs. It is connected to the PFC signals connector J2 and to the UNI-3 connector J8 pins 14 and 15.
+18V_D R414 0 4 7 5 6
U403 FB CB VIN ON/OFF GND VSW LM2674M-5.0 1
C414 10nF L403 8 R415 68uH R400 820 1 0 TP411 +5V_D +5V_D
+ C415 2 22uF/20V
D406 SS22 2
+ C416 120uF/10V
D407 GREEN
GND
GND
GND
GND
GND
Figure 4-12 +5V_D Power Supply 4.12.5 +3.3V_A/+5V_A Power Supply The +3.3V/+5V power supply is generated from the +18V level by means of the LM317LD linear voltage regulator (see Figure 4-13). Its capable of sinking up to 100 mA. This voltage level serves the on-board operational amplifiers and for supplying the temperature-measuring circuit. It is also connected to the PFC signals connector J2 and to the UNI-3 connector J8 pin 16. Output voltage level can be set to 3.3V or 5V according to the analog-voltage range used on the controller board (see Figure 4-14). Default output voltage is set at 3.3V_A. To select +5V_A, remove resistor R419. This description is also available on the actual PCB board (see PCB board picture and Figure 4-13).
TP402 +18V R404
MBRS130LT3 U401 LM317LD 1 2 3 4 R416 620 V IN OUT1 OUT2 ADJ NC2 OUT4 OUT3 NC1 R417 100 8 7 6 5
R401 0
+3.3/5V_A
D408
0 C402 100nF R411 240
+3.3/5V_A TP401 C403 100nF
Default +3.3V_A For +5V_A remove R419
GNDA
R418 820
R419 47
GNDA
Figure 4-13 +3.3V/+5V_A Power Supply
Figure 4-14 Analogue Sensing Range - Board Detail

WARNING Set +3.3V_A/+5V_A Power Supply output voltage level according to the analog-voltage range used on the controller board. When you change the +3.3V_A/+5V_A power supply output voltage level, also change the voltage-reference level.
4.12.6 +12V_Fan Power Supply Bus voltage generates +12V_Fan Power Supply by means of the LNK306P step-down/up inverter (see Figure 4-15). This power supply is used only for supplying fans with +12V up to 200 mA.
C409 2
+ +
2.2uF/50V R409 13k C410 100nF

1
R410 2.05k
2
+ C411 10uF/35V L402
D404 1N4005
U400 3 4 5 BP FB D LNK306P S S S S 8 7 2 1
TP405 +12V FAN
+12V_FANS
470uH R413 2.7k D405 BYV26C

2 1
+ C412 4.7uF/400V
2
+ C413 180uF/16V D400 GREEN
GND
Figure 4-15 +12V_Fan Power Supply 4.12.7 +1.65V/2.5V Reference The +1.65V/2.5V reference is generated from the +15V_A level by means of the LM285M linear voltage reference (see Figure 4-16). This reference serves to shift the phase-current-sensing values. It can sink up to 20 mA. The default voltage reference level value is +1.65V.
TP110 +Vref +15V_A C106 100nF + R121 6.2k C107 10uF/20V R122 100k-1% 5 LM285M U102 GNDA R124 33k-1% R156 0 N/P R123 47k-1% R125 1k-1% 8 1.65V/2.5V ref +Vref
GNDA
Figure 4-16 Voltage Reference

WARNING Set the voltage reference level according to the analog voltage range used on the controller board. When you change the voltage reference level, also change the +3.3V_A/+5V_A Power Supply output voltage level.
Appendix A. 3-Phase AC/BLDC High Voltage Power Stage Board Schematics
2 1
1 2
1 2
1 2
1 2 3
1 2 3
GNDA +3.3/5V_A +15V_A
GND
+18V_D GND
+5V_D +18V_D
DCB_Pfc_Pos2 DCB_Pfc_Pos1
DCB_Pfc_Neg2 DCB_Pfc_Neg1
Earth_GND
Brake_res
+18V_D
+Vref
+Vref
GND
48
J1 HDR 2X1 +12V_FANS +12V_FANS +5V_D +18V_D +18V_D +5V_D FAN1 FAN_60x60x25 Use J10 (PE connection) as one of the holes for mounting heatsink +12V_FANS +3.3/5V_A +15V_A +15V_A +3.3/5V_A Power Supplies DCB_Cap_Pos GNDA DCB_pos J3 1 3 5 Use J6:3 as PE connection +3.3/5V_A +5V_D +18V_D +Vref +18V_D GND GND GNDA GND 1 3 5 2 4 6 JUMPERS_2_CH J7 +15V_A +18V_D +Vref 2 4 6 JUMPERS_2_CH J8 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CON/40 BEMF_sense_C BEMF_sense_B BEMF_sense_A Sheilding Zero_cross_C Zero_cross_B Zero_cross_A PFC_z_c PFC_enable PFC_PWM Serial_Con Brake_control Sheilding Temp_sense I_sense_C I_sense_B I_sense_A I_sense_DCB V_sense_DCB GNDA GND GND GNDA GND +3.3/5V_A +Vref +5V_D +18V_D 10 9 8 7 6 5 4 3 2 1 CON/10 J2 GND +18V_D +5V_D +Vref GNDA +5V_A I_IN V_IN GND PWM_PFC
FAN
Line Input
GND
Brake resistor
J4 J11
PFC
J5
Motor
J6
PFC signals
J9
J10
PWM_AT PWM_AB PWM_BT PWM_BB PWM_CT PWM_CB
Gate_AT Gate_AB Source_AT Source_AB Gate_BT Gate_BB Source_BT Source_BB
Gate_AT Gate_AB
Source_AB Gate_BT Gate_BB Source_BB Gate_CT Gate_CB Source_CB
BEMF_sense_C BEMF_sense_B BEMF_sense_A Zero_cros_C Zero_cros_B Zero_cros_A Temp I_sense_C I_sense_B I_sense_A V_sense_DCB I_sense_DCB
Phase_A Phase_B Phase_C I_sense_A1 I_sense_A2 I_sense_B1 I_sense_B2 I_sense_C1 I_sense_C2
Phase_A Phase_B Phase_C I_sense_A1 I_sense_A2 I_sense_B1 I_sense_B2 I_sense_C1 I_sense_C2 DCB_pos DCB_Cap_pos I_sense_DCB_out
Gate_CT Gate_CB Source_CT Source_CB
1 2 J12 External -15V_A
+15V_A +3.3/5V_A +5V_D GNDA GND
I_sense_DCB1 I_sense_DCB2 I_sense_DCB_out IGBT Drivers
I_Sense_DCB1 I_Sense_DCB2 AC1 AC2 Power Circuit
DCB_Cap_Pos DCB_Cap_Neg Brake_control
GND Analog sensing
PWM_CB Sheilding PWM_CT Sheilding PWM_BB Sheilding PWM_BT Sheilding PWM_AB Sheilding PWM_AT
UNI-3
Figure A-1 Power Stage Overview
I_sense_A1 TP101 Ia+ I_sense_A2 R104 220-1% C101 47pF
R102 1.6k-1% 2 R105 1.6k-1% R106 7.5k-1% 3
I_sense_DCB_out
1 + U101A MC33502D +3.3/5V_A
I_sense_A +3.3/5V_A D101 BAT42
U100B MC33502D
1.65V/2.5V ref
C103 100nF GNDA
TP103 IbI_sense_B1 TP104 Ib+ I_sense_B2
R108 220-1% C102 47pF
R109 1.6k-1% 6 R110 5 R113 7.5k-1%
R107 7.5k-1% 7 + TP105 Ib_s 1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Imax = 8A at Vref = 3.3V I_sense_B
1.65V/2.5V ref
Phase Currents Sensing
R112 220-1%
1.6k-1% U101B MC33502D
R114 5.1k-1%
GNDA
R115 TP107 IcI_sense_C1 TP108 Ic+ I_sense_C2 R118 220-1% C104 47pF R119 1.6k-1% R120 7.5k-1% 7.5k-1% R116 220-1% R117 1.6k-1% 2 3
+Vref +Vref +15V_A +15V_A 1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Imax = 8A at Vref = 3.3V I_sense_C GNDA +3.3/5V_A +3.3/5V_A
GNDA
TP109 Ic_s 1
U100A MC33502D +3.3/5V_A
GNDA
TP110 +Vref +15V_A C106 100nF + R121 6.2k C107 10uF/20V R122 100k-1% 5 LM285M U102 GNDA R124 33k-1% R156 0 N/P R123 47k-1% R125 1k-1% 1.65V/2.5V ref +Vref
C105 100nF
GNDA
GNDA
Figure A-2 Phase Current Sensing
GNDA
TP102 1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Ia_s Imax = 8A at Vref = 3.3V
Freescale Semiconductor 3-Phase AC/BLDC High Voltage Power Stage Board, Rev. 1 49
TP126 Idcb_s R103 TP100 Ia7.5k-1% R101 220-1% 6 7
I_sense_DCB 1.65V +/- 1.65V @ +/- Imax 2.50V +/- 2.50V @ +/- Imax Imax = 8A at Vref = 3.3V
+3.3/5V_A
TP106 Temp
R111 3.6k-1%
Temp
RV100 10k
3 R155 22k-1% 3.235V @ Phase_C = 400V BEMF_sense_C TP125 BEMF_C_s R100 6.8k-1% GNDA C113 10pF 2 u- = 6.60V @400V V_sense_DCB_half_15 C100 22pF
+ 4
50
Phase_A 400V max TP111 BEMF_A R126 330k-1% 5 6 + 7 U104B LM393D 330k and 150k resistors have "SM/R_1206" footprint in order to withstand high voltage drop (<200V). TP112 BEMF_A_ZC GND R127 330k-1% u+ <15V u+ = 2*V_sense_DCB_half_15 u+ = 13.30V/13.06V @400V +18V_D R129 10M +5V_D R130 10k 5 TP113 BEMF_A_s 3.235V @ Phase_A = 400V BEMF_sense_A Phase_B 400V max TP116 BEMF_B R134 330k-1% GNDA R137 330k-1% TP117 BEMF_B_ZC R139 150k-1% u+ <15V u+ = 2*V_sense_DCB_half_15 u+ = 13.30V/13.06V @400V R133 6.8k-1% GNDA R132 22k-1% C108 10pF 6 + 7 U103B LM393D TP114 ZC_A TP115 V_dcb Zero_cros_A +18V_D R128 150k-1% R131 470k GND GND GNDA GNDA
The comparators' hysteresis VH = 240mV

R136 10M +18V_D C109 +5V_D 10nF R141 470k 3 GND 1 U103A LM393D TP119 ZC_B +5V_D R140 10k Zero_cros_B
DCB_Cap_pos R135 330k-1%
R138 270k-1%
+ -
R142 6.8k-1%
TP118 BEMF_B_s 3.235V @ Phase_B = 400V BEMF_sense_B Phase_C 400V max TP121 BEMF_C R146 330k-1%
R143 22k-1%
C110 10pF
TP120 V_dcb_ZC
R144 220k-1% V_sense_DCB_half_15
R145 6.8k-1% GNDA GND R148 10M GNDA +18V_D R149 330k-1% TP123 BEMF_C_ZC R151 150k-1% u+ <15V u+ = 2*V_sense_DCB_half_15 u+ = 13.30V/13.06V @400V C112
C111 10nF GND TP122 V_dcb_s
R147 6.8k-1%
u- < 7.5V u- = 6.60V @ DC-Bus = 400V
R150 270-1% 3.235V @ DC-Bus = 400V V_sense_DCB R152 6.8k-1%
+5V_D 10nF GND R153 10k 1 U104A LM393D TP124 ZC_C Zero_cros_C GNDA
R154 470k
GND
GNDA
GNDA
Figure A-3 Back EMF Sensing
C201
+5V_D +5V_D
MBRS130LT3 D201
R201 0 D200 MURS160T3 R202 75 +18V_D
TP201 Gate_AT Gate_AT
TP202 PWM_AT PWM_AT
GND
10nF 1
2 1
GND
U200A MM74HCT14M VCC 2
14
R203 6.8k
J200 N/P
C202 1uF/50V
D202 MMSZ5251BT1
FAULT DISABLE
GND R205 +18V_D C207 4.7uF/35V C203 100nF GND VCC VB1 HO1 VS1 LO1 VB2 HO2 VS2 LO2 VB3 HO3 VS3 LO3 COM 21 20 19 18 11 17 16 15 10 14 13 12 9 8 GND TP212 Idcb+ C205 1uF/50V I_sense_DCB2 1.6k-1% +Vref R221 7.5k-1% C200 47pF 220-1% R222 1k TP200 I_trip 0.50V @ +Ifault D212 MURS160T3 MBRS130LT3 D211 C204 1uF/50V D207 MURS160T3 MBRS130LT3 D203 R204 0 R206 75 MBRS130LT3 D206 TP204 Gate_AB
Source_AT
TP203 PWM_AB PWM_AB 3
GND
4 U200B MM74HCT14M TP215 FAULT D204 RED
Gate_AB D205 MMSZ5251BT1 TP205 Gate_BT Source_AB Gate_BT
3.6k
R207 10k TP206 PWM_BT GND PWM_BT TP207 PWM_BB PWM_BB
R208 10k
GND U201
R209 0 R210 75 +18V_D
U200C MM74HCT14M 5 6
22 25 23 26 24 27
HIN1 LIN1 HIN2 LIN2 HIN3 LIN3 FAULT ITRIP FLT-CLR CAO CA+ CASD VSS IR2133S
D208 MMSZ5251BT1
Source_BT R211 0 R214 75 TP208 Gate_BB Gate_BB D210 MMSZ5251BT1 TP210 Gate_CT Source_BB
8 U200D MM74HCT14M 28 1 2 3 5 4 6 7 GND
D209 MBRS130LT3
R212 10k TP209 PWM_CT GND PWM_CT TP211 PWM_CB PWM_CB
R213 10k
U200E MM74HCT14M 11 10
R215 0 R216 75 +18V_D
Gate_CT D213 MMSZ5251BT1
13
12 U200F MM74HCT14M
R217
R218
R219 10k
R220 10k
Source_CT MBRS130LT3 D214 R223 0 R224 75 TP213 Gate_CB Gate_CB D215 MMSZ5251BT1 Source_CB I_sense_DCB1
GND R225 n/p R226 220-1% TP214 IdcbR227 7.5k-1% I_sense_DCB_out C206 1nF
+18V_D +18V_D +Vref +Vref +5V_D +5V_D
R200 1.6k-1%
DC Bus Current Sensing

GND GND
Figure A-4 IGBT Drivers
sense
DCB_Cap_Neg I_Sense_DCB1
sense
C301 100nF GND TP302 PWM_brake U300 1 NC 2 InA

6
GND
GND
GND
52
DCB_Cap_Pos DCB_Cap_Pos Q300 SKP10N60 Gate_AT Phase_A Gate_BT Phase_B Q303 SKP10N60 Gate_AB Source_AB I_sense_A1 I_sense_A2 R303 0.050-1% GND sense Gate_BB Source_BB I_sense_B1 R300 0.050-1% I_sense_B2 sense R301 0.050-1% I_sense_C2 Q301 SKP10N60 Gate_CT Phase_C Q304 SKP10N60 Gate_CB Source_CB I_sense_C1 sense R302 0.050-1% Q305 SKP10N60 Q302 SKP10N60 D300 HFA04TB60S TP301 V_brake Brake_res Brake_res
Brake_gate Brake_source DCB_Cap_Neg
Q306 SGP10N60
sense
sense
sense
I_Sense_DCB2
+18V_D C300 10uF/35V
+18V_D MBRS130LT3 D301 8 7 R304 0 R305 75 Brake_gate TP300 Gate_brake GND
+18V_D
VCC
NC OutA
GND
Brake_control
R306 10k
4 InB GND MC33152D
OutB
D302 MMSZ5251BT1 Brake_source
Figure A-5 3-Phase Power Bridge
+ 1
4 -
TP303 AC1 F300 AC1 Fuse R307 DCB_Pfc_Pos1 SG-200 DCB_Pfc_Pos2 DCB_Cap_Pos
i
D303 GBU605 C302 10nF/3000V Earth_GND + C305 470uF/400V + C304 470uF/400V D304 V14E250 2 3 C303 10nF/3000V
AC2 TP304 AC2
DCB_Pfc_Neg1
DCB_Pfc_Neg2
DCB_Cap_Neg
Figure A-6 DC bus Power Supply
C404 100nF
U402 3 4 5 BP FB D LNK306P S S S S 8 7 2 1 D402 BYV26C
C409
2.2uF/50V R409 13k C410 100nF GNDA GNDA GNDA +18V_D TP405 +12V FAN +18V_D +12V_FANS +15V_A +15V_A +12V_FANS +12V_FANS R413 2.7k +3.3/5V_A +3.3/5V_A + C413 180uF/16V +5V_D D400 GREEN TP400 TP406 GNDA GNDA GC400 GROUND CONNECTION GND +18V_D R414 0 GND 4 7 5 6 U403 FB CB VIN ON/OFF GND VSW LM2674M-5.0 1 L403 8 R415 68uH R400 820 0 C414 10nF TP411 +5V_D +5V_D GND GNDA GNDA GND TP408 TP407 TP409 TP410 GND GND GND GND +5V_D GNDA
R410 2.05k U400
+ C411 10uF/35V
D404 1N4005
TP413 V_dcb_2 R412 0
L402 8 7 2 1 470uH
3 4 5
BP FB D LNK306P
S S S S
+ C412 4.7uF/400V
D405 BYV26C
+ C415
GND
GND
GND
GND
22uF/20V
D406 SS22
+ C416 120uF/10V
D407 GREEN
GND
Figure A-7 Power Supplies
2 3 6 7
GND
+ C408 1uF/50V 1
GND1 GND2 GND3 GND4
54
C401 2 N/P R402 18.7k + C405 10uF/35V D401 1N4005 C402 100nF TP402 +18V R404 0 GNDA R407 3.6k R418 820 R411 240 1 MBRS130LT3 U401 LM317LD 1 2 3 4 R416 620 V IN OUT1 OUT2 ADJ NC2 OUT4 OUT3 NC1 R417 100 8 7 6 5 R401 0 +3.3/5V_A TP401 C403 100nF +3.3/5V_A
+ +
D408 R403 2k L400 1mH + C400 150uF/20V R405 0 D403 GREEN R408 0 8
Default +3.3V_A For +5V_A remove R419
R419 47
GNDA
TP403 +18V_D +18V_D
+ C406 4.7uF/400V
TP404 +15V_A U404 MC78L15ACD VI VO 1 +15V_A
C407 100nF
+ +
Appendix B. Bill of Materials

Table B-1 Parts List
DESIGNATORS C100 C101, C102, C104, C200 C206 C103, C105, C106, C301, C402, C403, C404, C407, C410, C203 C107 C108, C110, C113 C109, C111, C112, C201, C414 C409 C401 C207 C202, C204, C205, C408 C300, C405, C411 C302, C303 C304, C305 C400 C406, C412 C413 C415 C416 D200, D207, D212 D201, D203, D206, D209, D211, D214, D301, D408 D101 D202, D205, D208, D210, D213, D215, D302 D204 D300 D303 D304 D400, D403, D407 D401, D404 QUANTITY 1 4 DESCRIPTION 22pF size 0805 47pF size 0805 1nF size 0805 10 1 3 5 1 1 1 4 3 2 2 1 2 1 1 1 3 8 1 7 1 1 1 1 3 2 100nF size 0805 10F/ 20V size C 10pF size 0805 10nF size 0805 2.2F/ 50V size B N/P 4.7F/ 35V size B 1F/ 50V size B 10F/ 35V size C 10nF/ 3000V 470F/ 400V 150F/ 20V 4.7F/ 400V 180F/ 16V 22F/ 20V size D 120F/ 10V 1A/600V Ultrafast Rectifier size SMA 1A/30V Schottky Rectifier size SMB BAT42 size MINIMELF 20V Zener Diode SOD-123 Red Display LED size 0805 4A/600V Ultrafast Rectifier D2-Pak 6A/500V Bridge Rectifier Varistor V14E250 Green Display LED size 0805 1A/600V Recovery Rectifier DO-41 MANUFACTURER ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE PANASONIC ANY ACCEPTABLE SANYO ANY ACCEPTABLE SANYO ANY ACCEPTABLE SANYO ON SEMICONDUCTOR ON SEMICONDUCTOR ANY ACCEPTABLE ON SEMICONDUCTOR ANY ACCEPTABLE INTERNATIONAL RECTIFIER DIODES INCORPORATED LITTELFUSE ANY ACCEPTABLE ON SEMICONDUCTOR ECKATS103MF 20SVP150M 16SVP180MX 20SVP100M MURS160T3 MBRS130LT3 MMSZ5250BT1 HFA04TB60S GBU605 V14E250 1N4005 PART NUMBER -

DESIGNATORS D402, D405 D406 FAN1 F300 GC400 J12, J200 J1 J2 J3, J7 J4, J9, J11 J5, J6 J8 J10 L400 L402 L403 Q300, Q301, Q302, Q303, Q304, Q305 Q306 RV100 R225 R130, R140, R153, R207, R208, R212, R213, R219, R220, R306 R100, R133, R142, R145, R147, R152 R101, R104, R108, R112, R116, R118, R218, R226 R102, R105, R109, R110, R117, R119, R200, R217 R103, R106, R107, R113, R115, R120, R221, R227 R111 R114 R121 R122 R123 QUANTITY 2 1 1 1 1 2 1 1 2 2 2 1 1 1 1 1 6 1 1 1 10 DESCRIPTION 1A/600V Fast Recovery Rectifier SOD-57 2A/20V Schottky Rectifier/ DO-214AA FAN 60x60x25 Fuse 6A ground connection N/P HDR 2x1 CON/10 JUMPERS_2_CH CON/TOP 1.5 GS 2/90 CON/TOP 1.5 GS 3/90 CON/40 ground connection 1.2mH 470mH 68mH 10A/600V Fast IGBT TO-220AB 10A/600V Fast IGBT TO-220AB 10 k Thermistor N/P 10 k Resistor 1/10W size 0805 6.8 k Resistor 1/10W 1% size 0805 220 Resistor 1/10W 1% size 0805 1.6 k Resistor 1/10W 1% size 0805 7.5 k Resistor 1/10W 1% size 0805 3.6 k Resistor 1/10W 1% size 0805 5.1 k Resistor 1/10W 1% size 0805 6.2 k Resistor 1/10W size 0805 100 k Resistor 1/10W 1% size 0805 47 k Resistor 1/10W 1% size 0805 MANUFACTURER VISHAY VISHAY ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE CAMDEN ELECTRONICS CAMDEN ELECTRONICS ANY ACCEPTABLE COILCRAFT COILCRAFT COILCRAFT INFINEON TECHNOLOGIES INFINEON TECHNOLOGIES EPCOS ANY ACCEPTABLE ANY ACCEPTABLE PART NUMBER BYV26C SL22 MLW10G CTB0110/2 CTB0110/3 MLW40G RFB1010-122 RFB1010-471 DO3308P-683ML_ SKP10N60 SGP10N60 B57703M103G -
6 8
ANY ACCEPTABLE ANY ACCEPTABLE
ANY ACCEPTABLE
8 1 1 1 1 1
ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE

DESIGNATORS R124 R125 R126, R127, R134, R135, R137, R146, R149 R128, R139, R151 R129, R136, R148 R131, R141, R154 R132, R143, R155 R138 R144 R150 R201, R204, R209, R211, R215, R223, R304, R156 R202, R206, R210, R214, R216, R224, R305 R203 R205, R407 R222 R401, R404, R405, R406, R408, R412, R414, R415 R300, R301, R302, R303 R307 R400 R402 R403 R409 R410 R411 R416 R417 R418 R419 R413 QUANTITY 1 1 7 3 3 3 3 1 1 1 7 DESCRIPTION 33 k Resistor 1/10W 1% size 0805 1 k Resistor 1/10W 1% size 0805 330 k Resistor 1/4W 1% size 1206 150 k Resistor 1/4W 1% size 1206 10 M Resistor 1/10W size 0805 470 k Resistor 1/10W size 0805 22 k Resistor 1/10W 1% size 0805 270 k Resistor 1/4W 1% size 1206 220 k Resistor 1/4W 1% size 1206 270 Resistor 1/10W 1% size 0805 0 Resistor 1/10W size 0805 MANUFACTURER ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE PART NUMBER -
7 1 2 1 8 4 1 1 1 1 1 1 1 1 1 1 1 1
75 Resistor 1/10W size 0805 6.8 k Resistor 1/4W size 1206 3.6 k Resistor 1/10W size 0805 1 k Resistor 1/10W 1% size 0805 0 Resistor 1/4W size 1206 50 m Resistor 1% size 4723 7A Inrush Current Limiter 820 Resistor 1/10W size 0805 15 k Resistor 1/10W size 0805 2 k Resistor 1/10W size 0805 13 k Resistor 1/10W size 0805 2.05 k Resistor 1/10W size 0805 240 Resistor 1/10W size 0805 620 Resistor 1/10W size 0805 100 Resistor 1/10W size 0805 820 Resistor 1/10W size 0805 47 Resistor 1/10W size 0805 2.7 k Resistor 1/10W size 0805
ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ISABELLENHTTE RHOPOINT COMPONENTS ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE
SMV-R050-1.0 SG200 -

DESIGNATORS TP100, TP101, TP103, TP104, TP107, TP108, TP111, TP112, TP115, TP116, TP117, TP120, TP121, TP123, TP200, TP201, TP204, TP205, TP208, TP210, TP212, TP213, TP214, TP300, TP301, TP303, TP304, TP412, TP413 TP102, TP105, TP106, TP109, TP110, TP113, TP114, TP118, TP119, TP122, TP124, TP125, TP202, TP203, TP206, TP207, TP209, TP211, TP215, TP126, TP302 TP400, TP406, TP407, TP408, TP409, TP410 TP401, TP402, TP403, TP404, TP405, TP411 U100, U101 U102 U103, U104 U200 U201 U300 U400, U402 U401 U403 U404 QUANTITY DESCRIPTION MANUFACTURER PART NUMBER
29
Test Point Black 1mm
ANY ACCEPTABLE
21
Test Point Green 1mm
ANY ACCEPTABLE
6 6 2 1 2 1 1 1 2 1 1 1
Test Point White 1mm Test Point Red 1mm Operational Amplifier/ SOIC-8 Voltage Reference/SOIC-8 Comparators/ SOIC-8 Schmitt Inverter/ SOIC-14 3-Phase Bridge Driver/SOIC-28 MOSFET Driver/ SOIC-8 Step-Up/Down Inverter/SOIC-8 Voltage Regulator/SOIC-8 Step-Down Inverter/SOIC-8 MC78L15ACD/SOIC-8
ANY ACCEPTABLE ANY ACCEPTABLE ON SEMICONDUCTOR NATIONAL SEMICONDUCTOR FREESCALE FAIRCHILD SEMICONDUCTOR INTERNATIONAL RECTIFIER FREESCALE POWER INTEGRATIONS FREESCALE NATIONAL SEMICONDUCTOR FREESCALE
MC33502D LM285M LM393D MM74HCT14M IR2133S MC33152D LNK306P LM317LD LM2674M-5.0 MC78L15ACD
Appendix C. 3-Phase AC/BLDC High Voltage Power Stage Board Layouts
Figure C-1 Power Stage Board Top Layer
Figure C-2 Power Stage Board Bottom Layer
Figure C-3 Power Stage Board Inner 1 Layer
Figure C-4 Power Stage Board Inner 2 Layer
Figure C-5 Power Stage Board Silkscreen Top Layer
Figure C-6 Power Stage Board Silkscreen Bottom Layer
How to Reach Us:

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3-Phase AC/BLDC High Voltage Power Stage Board

3PHACBLDCHVPSUG Rev. 1 01/2007

3-Phase AC/BLDC High-Voltage, Power-Stage Board

by: Petr Frgal Freescale Semiconductor Czech System Center

3-Phase AC/BLDC High-Voltage, Power-Stage Board, Rev. 1 Freescale Semiconductor 3

3-Phase AC/BLDC High-Voltage, Power-Stage Board, Rev. 1 4 Freescale Semiconductor

Chapter 2 Operational Description

Chapter 3 Pin Description

Chapter 4 Design Consideration

1.2 3-Phase AC/BLDC High Voltage Power Stage Outline

About this Manual

1.3 About this Manual

HIGH-VOLTAGE POWER STAGE

DSP EVM BOARD

HIGH-VOLTAGE POWER STAGE

b) 56800/E HYBRID CONTROLLER

Figure 1-1 System Configurations

Figure 1-2 3-Phase AC/BLDC High-Voltage Power Stage

1.5 Setup Guide

R brake J4 40-Pin Ribbon Cable

J8 140 - 325 Vdc 115 - 230 Vac J9 J6 Motor

Phase_C Phase_B Phase_A

Chapter 2 Operational Description

3-PH IGBT BRIDGE

BRAKE IGBT + DIODE

Figure 2-1 Block Diagram

2.3 Electrical Characteristics

Table 2-1 Electrical Characteristics

2.4 Fuse replacement

Chapter 3 Pin Description

3.3 Signal Descriptions

Table 3-1 Connector J2 Signal Descriptions

I_IN +3.3_A/+5V_A GNDA +Vref +5V_D +18V_D GND

Table 3-3 PFC POWER Connector J11 Descriptions

Table 3-4 Jumper J3 Setting Descriptions

Table 3-5 Jumper J7 Setting Descriptions

3.3.6.1 Changes to Standard UNI-3 Connection

Table 3-7 Connector J8 Signal Descriptions

Table 3-7 Connector J8 Signal Descriptions (Continued)

Chapter 4 Design Consideration

4.3 3-Phase Bridge

Figure 4-1 Phase Output

3-Phase AC/BLDC High Voltage Power Stage Board, Rev. 1

Bus Voltage and Current Feedback

4.4 Bus Voltage and Current Feedback

Bus Voltage and Current Feedback

+5V_D 2 R203 6.8k 1

R150 270-1% 3.235V @ DC-Bus = 400V V_sense_DCB R152 6.8k-1%

R217 1.6k-1% +Vref R221 7.5k-1% C200 47pF

R218 220-1% R222 1k TP200 I_trip 0.50V @ +Ifault

R225 n/p R226 220-1%

C206 1nF I_sense_DCB1

DC Bus Current Sensing

U100B MC33502D D101 BAT42

Figure 4-2 Bus Feedback

Over-current and Undervoltage Functions

Figure 4-3 Current Range - Board Detail

4.5 Over-current and Undervoltage Functions

4.6 Temperature Sensing