ST6 - Universal motor control evaluation board
Contents
1. VPP TEST RST PB7 AIN4 PB3 AIN1 PBS AIN2 PA2 PBO PBI ST62T00 16Pin Socket 9 vec Q1 D 4 BTB16 600CW 9 FUSE 10 1 NEUTRAL 11 14 Appendix 2 UMCO1EVAL PCB Layout APPENDIX 2 UMC0O1EVAL PCB LAYOUT 111 CAUTION HIGH VOLTAGE UNTUERSAL MOTOR CONTROL 12 14 Appendix 3 Bill of Materials APPENDIX 3 BILL OF MATERIALS Wem Quantity Reference SSCS on SSCS T00nF Ca o Fanaa eK R2 3 i R3 150R y el page 13 14 4 Notes Information furnished is believed to be accurate and reliable However STMicroelectronics assumes no responsibility for the consequences of use of such information nor for any infringement of patents or other rights of third parties which may result from its use No license is granted by implication or otherwise under any patent or patent rights of STMicroelectronics Specifications mentioned in this publication are subject to change without notice This publication supersedes and replaces all information previously supplied STMicroelectronics products are not authorized for use as critical components in life support devices or systems without the express written approval of STMicroel2. CONCLUSION Figure 3 Asymmetrical Gate Pulse 26 Sep 81 Reading Floppy Disk Drive 17 47 00 fag ttt alae 114 50 kS s DE y STOPPED 4 CONCLUSION The guidelines provided in this document have been given to help you use the Evaluation Board properly This Evaluation Board is designed for controlling universal motors but it can also be used for a wide variety of applications such as light dimmers thermostats and heating systems The main thing to check is that your loads especially the inductive load correspond to the pro grammed data maximum speed triggering pulse width etc Then after certain adjustments to your software and using the EPROM version of ST6200 MCU you are able to perform tests using your own universal motor With this evaluation board you can take your own measurements and see how much the 3rd harmonic current is reduced by using this method Fully detailed information about programming is given in Application Notes AN1448 and AN1449 10 14 3 Appendix 1 Schematic Diagram APPENDIX 1 UMCO1EVAL SCHEMATIC DIAGRAM D1 BZX85C5 6 D2 1N4148 02 220 16 470nF 400V RS 470R 1W 1 VDD o OSCIN OSCOUT NMI
3. 182 1200 3 5 2 193 0 743 0 188 0 142 1300 3 0 1 892 0 612 0 196 0 06 1400 2 25 1 386 0 33 0 2 0 116 1450 1 6 1 11 0 138 0 13 0 111 1480 0 3 0 77 0 107 0 022 0 01 Harmonic Current Limit A 2 30 1 14 0 77 0 4 Table 2 1500W Vacuum Cleaner Harmonic Currents measured at a fixed load using the asymmetrical phase angle control method Power Delay Time Harmonic Order amp Harmonic Currents A P Watt t ms t2 ms 3 5 7 9 535W 6 90 5 48 2 22 0 634 0 281 0 041 580W 6 90 5 13 2 170 0 532 0 280 0 072 700W 6 85 4 74 2 115 0 451 0 251 0 157 780W 6 85 4 36 1 974 0 437 0 241 0 185 940W 6 13 3 75 1 799 0 371 0 182 0 174 1000W 6 04 3 37 1 595 0 364 0 219 0 105 1050W 6 08 2 91 1 362 0 389 0 234 0 049 1100W 5 19 2 90 1 658 0 204 0 245 0 084 1150W 5 20 2 47 1 349 0 121 0 293 0 052 Harmonic Current Limit A 2 30 1 14 0 77 0 4 In order to suppress 3rd harmonic current in the power line an innovative cost saving solution is used This control method is based on the modulation of the phase angle delay times and is 6 14 ky FUNCTIONAL DESCRIPTION easily implemented using the ST62TOOC microcontroller software The test results shown in Table 2 prove the efficiency of this solution In Table 1 the figures in bold exceed harmonic current limit specifications 2 3 HARDWARE FEATURES 2 3 1 ST62T00C Microcontroller The MCU used in the UMCO1EVAL board is the ST62TOOC This i
4. shunt resistor R1 with a jumper before starting the motor 6 If you changed the software in the above steps don t forget to program the Option Byte setting as follows in you MCU D1 1 Hardware Watchdog Activation D6 1 RC network oscillator selection D8 1 LVD reset activation 2 FUNCTIONAL DESCRIPTION 2 1 PERFORMANCE The UMCO1EVAL board is designed to meet the following requirements Low cost Capacitive or resistive power supply is used to reduce the system cost as well as the size Simple voltage zero crossing detection circuit is provided via a current limiting resistor A crystal oscillator or external resonator are not used External RESET circuitry is NOT required 61000 3 2 Standards Using the dedicated software vacuum st6 file the board complies with the 3rd harmonics limits specified in standard IEC61000 3 2 Generic This board may also used in a wide variety of applications i e light dimmer power control universal motor control and thermostat control 2 2 MAIN FEATURES 2 2 1 Phase Angle Control The speed can be set using the potentiometer mounted on the board To generate the correct phase angle the voltage zero crossing signal must be detected On this board we use two current limiting resistors to perform voltage zero crossing The voltage at this port is clamped to OV and 5V by internal clamping diodes The microprocessor is able to calculate the phase angle and trigger the TRIAC It
5. to drop below 0 7V Then apply the mains voltage and try again to see if the board works Running with the provided SINTECH Universal Motor in Open Loop Mode When using the provided SINTECH universal motor in open loop mode the motor speed is changed by using the phase angle control through a TRIAC Check that the programmed triggering pulse of the TRIAC gates is compatible with the motor to be controlled see Section 3 2 When your motor is runing in open loop mode the shunt resistor R1 is not necessary and must be replaced by a jumper In low cost sensorless speed regulation mode resistor R1 is used to measure the peak motor current To run the motor in close loop mode please refer to the following applica tion note AN416 Sensorless Motor Drive with the ST62 MCU TRIAC The ST6200C MCU can detect the voltage zero crossing after which it can calculate the phase angle make the triggering pulse delay and trigger the TRIAC Before changing the motor control parameters please refer to Application Note AN1449 Running with your own Standard Universal Motor in Open Loop Mode When using your own universal motor in open loop mode your motor parameters should be checked i e the phase lag between motor current and input voltage The triggering ky FUNCTIONAL DESCRIPTION pulse width should be checked as well 5 3rd Harmonics Reduction Software When using 3rd harmonics reduction software with a 1500 W vacuum cleaner replace
6. triggered by a negative current i e sourced from the gate For more information please refer to the following application note AN1476 Low Cost Power Supply for Home Appliances 2 3 3 TRIAC Drive A BTB16 600CW device is used on the UMCO1EVAL Evaluation Board It is the most eco nomical AC power switch for operating directly on the 110V 230V mains It is directly driven by the MCU The triggering pulse is short in order to minimize the power supply size The Snub 7 14 Using the UMCO1EVAL Evaluation Board berless TRIAC is driven in quadrants and using 60 mA gate current provided by three parallel I O ports of the ST6200C This pulse is long enough to ensure that the TRIAC is latched at the end of the pulse Pulse length can be modified by software if another TRIAC or motor is used The BTB16 600CW is a Snubberless TRIAC It is used to turn off inductive loads without re quiring a snubber circuit therefore saving the cost and space of extra components It is able to drive a 1600 W vacuum cleaner connected to a 230V mains supply Table 3 sums up the characteristics of TRIAC and MCU performances with various sensitivi ties It also gives the gate current we suggest to control correctly the TRIAC for a minimum ambient temperature of 0 C with the power supply implemented on our board Table 3 TRIAC and MCU Sensitivity Characteristics Sensitivity Igt T Connection T amp TW Seri
7. 3 RACUN ra te 10 USING THE UMCO1EVAL EVALUATION BOARD 10 3 1 SYMMETRICAL PHASE ANGLE CONTROL PULSE 10 3 2 ASYMMETRICAL GATE PULSE 11 4 CONCLUSION icons ered eae BR a ck ead eh he hee ee 12 APPENDIX 1 UMCO1EVAL SCHEMATIC DIAGRAM 13 APPENDIX 2 UMCO1EVAL PCB 14 APPENDIX BILL OF MATERIALS 14 2 14 57 1 2 BLOCK DIAGRAM Figure 1 shows the block diagram of the UMCO1EVAL Evaluation Board Figure 1 Universal Motor Control Evaluation Board Block Diagram Motor Mains TRIAC Connector Connector BTB16 600 Zero Voltage Crossing Capacitive Power Speed Control Supply Potentiometer 1 3 LIST OF CONTENTS The following items are supplied in the package INTRODUCTION 2 55 O z Q One Universal Motor Control Evaluation Board ref UMCO1EVAL including the 5 62 00 MCU programmed with the software described in Application Note AN1449 A small Sintech Universal Motor 100 W A CD ROM including ST Motor Control product presentation and datasheet RC Oscillator Phase Angle Control Software programmed the 5 62 00 microcontroller umcvir7 st6 3rd Harmonics Reduction Software for 1 5 KW v
8. acuum cleaner application vacuum st6 file A User Manual this document 4 3 14 INTRODUCTION 1 4 GETTING STARTED By following this step by step procedure you can use the UMCO1EVAL Evaluation Board to first run the provided Sintech universal motor Later you can use the board to run your own AC universal motor To operate the board correctly use the following procedure WARNING All the following steps must be done by an electrically skilled technician because the 1 4 14 board has to be plugged to the MAINS voltage and because NO INSULATION is implemented between the MAINS voltage and the accessible conductive parts Connect the mains power supply to the MAINS connector on the Evaluation Board The SPEED SETTING potentiometer is used to control the speed of the universal motor Note that the soft start is implemented during speed adjustments The potentiome ter should not be turned too quickly in order to let the microprocessor take the new order into account Check that the motor is being controlled properly Use an oscilloscope to observe the motor winding currents If there are problems Check if the TRIAC gate triggering pulse is correct Check that the board is correctly powered by measuring 5V power supply for the microprocessor Check if the FUSE is blown disconnect the mains voltage before unplugging the fuse Reset the MCU by unplugging the mains voltage and waiting for VDD
9. ar UNIVERSAL MOTOR Sf CONTROL EVALUATION BOARD USER MANUAL 1 INTRODUCTION 1 1 TARGET APPLICATION UMCO1EVAL Evaluation Board is designed for a very low cost phase control system based on the 8 bit 5 62 00 microcontroller It can be used to control a universal motor pow ered by 230 V 50 Hz mains supply This type of motor is widely used in home appliances such as vacuum cleaners washing machines power tools and kitchen appliances In addition to performing a phase angle control algorithm the board offers many features such as soft start control and 3rd harmonics reduction Universal motors produce a strong 3rd harmonic current When the TRIAC conduction is not in full wave mode the actual motor current contains high amplitude 3rd harmonics which may not comply with the 3rd harmonics limits of Standard 61000 3 2 The UMCO1EVAL Evalu ation Board introduces an innovative cost saving solution for reducing 3rd harmonics WARNING The MCU is directly linked to the mains voltage supply No insulation is ensured between the accessible parts and the high voltage The UMCO1EVAL Evaluation Board must be used with care and only by persons qualified for working with electricity at mains voltage levels Certain precautions have to be taken during emulation to avoid damaging development tools For more information about safety precautions please refer to application note AN438 TRIAC and Microcontroller Safety Precautions for D
10. ectronics The ST logo is a registered trademark of STMicroelectronics 2001 STMicroelectronics All Rights Reserved Purchase of C Components by STMicroelectronics conveys a license under the Philips 2 Patent Rights to use these components an system is granted provided that the system conforms to the Standard Specification as defined by Philips STMicroelectronics Group of Companies Australia Brazil China Finland France Germany Hong Kong India Italy Japan Malaysia Malta Morocco Singapore Spain Sweden Switzerland United Kingdom U S A http www st com 4 14 14
11. es lat 5 Ig 10mA 1 Port 5 622 5 SW Series 10 Ig 20 1 Port 2 lar 25 Ig 40 mA 2 I O Ports in Parallel lo 20 CW Series 35 60 3 I O Ports in Parallel amp BW Series lat 50 80 4 I O Ports Parallel 3 USING THE UMCO1EVAL EVALUATION BOARD 3 1 SYMMETRICAL PHASE ANGLE CONTROL PULSE Figure 2 shows how the gate current pulses are defined for a universal motor The calculation of phase angle time is explained in Application Note AN1449 Since the universal motor is an induction motor running on an inductive load there is the risk of misfiring the TRIAC for one or several half cycles if a different power factor is applied So you should check that the programmed angle is compatible with your own motor If not please refer to AN1449 for instruction on how to change these values 8 14 4 Using the UMCO1EVAL Evaluation Board Figure 2 Gate Current Pulse 27 5 01 Reading Floppy Disk Drive 14 52 55 1 2 t 0 15 ms A f Hz 2 2 V Beh 188 kS s 1v 0 T 1 0 1 48 4 5 OC i STOPPED 3 2 ASYMMETRICAL GATE PULSE Figure 3 shows how the gate pulses are generated in asymmetrical control mode In this mode the phase angle is specifically modulated in order to suppress 3rd harmonic current in the power line 9 14
12. evelopment Tools This document gives all the information needed to operate the Evaluation Board how to con nect it how it works In order to modify specific information and parameters at design level please refer to the three following Application Notes AN1448 How to Reduce 3rd Harmonics with ST6200C Motor Control Software 1449 ST6200 Universal Motor Drive Software 1476 Low Cost Power Supply for Home Appliances October 2001 1 14 Table of Contents 3 1 1 TARGET APPLICATION ens 3 1 2 BLOCK DIAGRAM iid i Peek PEAS Wd BERS 5 1 3 LIST OF CONTENTS 255052 Seer ok ete ere ace ae ee 5 1 4 GETTING STARTED e sei eee a ee a 6 2 FUNCTIONAL DESCRIPTION 7 2 1 PERFORMANCE whee Whee Sw Sees 7 2 2 MAIN FEATURES urnar van Ble ened an bla eee Lae tee ewes 7 2 2 1 Phase Angle Control 7 AEE ES E E EAEE EEE E ee ae oe EE ee ts 7 2 2 3 3rd Harmonic Limitations 8 2 3 HARDWARE FEATURES 9 2 3 1 ST62TOOC 9 2 3 2 Capacitive Power 5 9 223
13. s a basic ST6 microcon troller that embeds a large number of features at minimum cost The peripheral hardware requirements have been reduced to the minimum A crystal oscillator or external resonator is not used Indeed the internal resonator of the ST62TOOC is used to generate the clock External RESET circuitry is not required due to the internal circuit of the 5 62 00 When programming the MCU EPROM you have to set the following three options D1 Hardware Watchdog Activation as it is not software enabled 06 RC network oscillator selection D8 Low Voltage Detection option in order to reset the MCU when the board is plugged to the mains supply 5 62 00 memory program space is 1024 bytes The size of the implemented software is 618 bytes In order to test longer programs ST62X01C with 2K bytes of program memory can also be installed instead of the ST62X00C in the DIL16 socket 2 3 2 Capacitive Power Supply In order to reduce the board price as much as possible a capacitive power supply is used in stead of a transformer based supply This supply can only source an average current lower than 10 mA For higher currents capacitor C1 cf Annex 1 can be replaced with one having a higher value A special characteristic of this power supply is that it is a negative supply where the Vdd ter minal is linked to Neutral That means that the Vss voltage is 5V below the Neutral value The TRIAC can be
14. will adjust the voltage applied to the motor 2 2 2 Soft Start When you start the motor the motor speed and the Back EMF are initially set to zero The mains voltage is applied directly to the motor winding Since the resistance of the motor winding is very small it will generate very high inrush current which is 10 to 15 times the nom inal current Using soft start software the voltage applied to the motor winding ramps up step by step Therefore the inrush current at start up will be reduced accordingly You can modify the ramping up steps and slope by using the software ky 5 14 FUNCTIONAL DESCRIPTION 2 2 3 3rd Harmonic Limitations At reduced speeds universal motors produce very high levels of 3rd harmonics in phase angle mode The strongest 3rd harmonics are produced when the conduction angle is approx imately 90 degrees refer to Table 1 Table 1 1500W Vacuum Cleaner Harmonic Currents measured at a fixed load using the symmetrical phase angle control method Power Delay Time Harmonic Order amp Harmonic Currents A P W t ms 3 5 7 9 250 6 9 1 918 0 92 0 275 0 2 320 6 5 2 122 0 931 0 322 0 213 535 5 75 2 474 0 92 0 453 0 175 590 5 55 2 513 0 923 0 478 0 156 780 5 0 2 601 0 883 0 502 0 127 900 4 5 2 576 0 859 0 44 0 162 1000 4 2 2 515 0 834 0 357 0 196 1050 4 0 2 448 0 82 0 306 0 194 1090 3 75 2 406 0 806 0 27 0 188 1130 3 6 2 331 0 793 0 232 0
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