100 W 3-phase inverter for BLDC sensorless motor
Contents
1. T lt _1 pr k 981 oe F ed b ZNS L NOA Wa lt m 5 ini m fei co py x hops mami _ su TENE P oN a tH als m iii Tio an E lid Ld mm w M sarana z SHANL Figure 10 Board schematic power block Board architecture 18 39 UM0522 Motor control operations 8 8 1 Note 8 2 Motor control operations Environmental considerations Warning STEVAL IHMO15V1 evaluation board must only be used in a power laboratory The voltage used in the drive system presents a shock hazard The kit is not electrically isolated from the DC input This topology is very common in motor drives The microprocessor is grounded by the integrated ground of the DC bus The microprocessor and associated circuitry are hot and MUST be isolated from user controls and communication interfaces Warning Any measurement equipment must be isolated from the main power supply before powering up the motor drive To use an oscilloscope with the kit it is safer to2. 6 1 1 Auten oh 6 1 2 Applications ee eae des woe bole MEPS EERE ERNES 6 2 System architecture 7 3 Safety and operating instructions 8 3 1 ET a o e 2 2 TII 8 3 2 Evaluation board intended use 8 3 3 Evaluation board installation 8 3 4 Electronic connections 8 3 5 Evaluation board operation 9 4 ST7FMC2S4T6 microcontroller functions 10 4 1 Main features 10 5 STD5NK52ZD 1 characteristics 12 6 Board electrical characteristics 13 7 Board architecture sassa 14 7 1 Power SUDDIV 2 94555 gasas ana a Er CR 14 7 2 Power peers pu rM 15 7 3 ICG connector 2 d RENI GR RACE WER RUNE ase aq 16 7 4 Board schematic 17 8 Motor control operations 19 8 1 Environmental considerations 19 8 2 Hardware requirements 19 8 3 Software requirements 20 8 3 1 Inst
3. X UM0522 Bill of material Table 8 Bill of materials continued Item Reference Part Footprint 32 1 FUSE 3A verticalecon TRH fusibile 33 IC1 VIPer12AS E 34 IC2 L78LO5ACZ 35 IC3 IC4 IC5 L6386D 36 IC6 ST7FMC2S4T6 37 J7 ICC HE10 male TRH 38 L1 1 mH 350 mA TRH PICTH 5 0mm 39 Q1 Q2 Q3 Q4 Q5 Q6 BC807 25 SOT23 40 Q7 Q8 Q9 Q10 Q11 Q12 STD5NK52ZD 1 41 R1 R6 R8 R11 R30 R33 R60 100 Q SMD 1206 42 R2 680 Q TRH 43 R3 330 Q TRH 44 R4 120 TRH 45 R23 120 SMD 1206 46 R5 R7 R9 R14 R32 R34 220 Q SMD 1206 47 R10 0 1 O3 W TRH 48 R12 R13 R15 R16 R17 R18 82 Q TRH 49 R19 19 SMD 1206 50 R20 R22 R35 R47 R26 R36 N M Not assy 51 R21 R31 R37 22 Q SMD 1206 52 R24 R25 100 kQ1 2W TRH 53 R38 R40 100 Q SMD 1206 54 R39 R41 R42 R59 100 SMD 1206 55 R43 N M NOT ASSY 56 R44 R45 2 7 Q SMD 1206 57 R46 1 50 SMD 1206 58 R51 560 SMD 1206 59 R52 R54 47 SMD 1206 60 R53 N M Not assy 61 R55 N M Not assy 62 R56 33 Q SMD 1206 63 R64 R65 R66 1 20 TRH 35 39 Bill of material UM0522 36 39 Table 8 Bill of materials continued Item Reference Part Footprint 50K code RS 100 1199 64 R61 R62 R63 12 64 x 10 e distrelec 50k cod 740218 0 82x 10 65 2 SW PUSH SMD 66 TR1 N M 67 x1 CSTCE16MOV53 RO TRH 3pin 68 15 5A NTC TRH 69 Nylon spacer 10 mm Any UM0522 References
4. 10 References This user manual provides information about using the STEVAL IHMO17V1 and its hardware features For additional information about supporting software and tools please refer to 1 ST7MC datasheet complete information about microcontroller features and peripherals 2 ST7MC motor control related application notes complete information about motor control libraries developed for the ST7MC microcontroller 3 STD5NK52ZD 1 datasheet complete information about the Power MOSFET devices included 4 Website and motor control forum http www st com mcu ky 37 39 Revision history UM0522 11 38 39 Revision history Table 9 Document revision history Date Revision Changes 07 Apr 2008 1 Initial release UM0522 Please Read Carefully Information in this document is provided solely in connection with ST products STMicroelectronics NV and its subsidiaries ST reserve the right to make changes corrections modifications or improvements to this document and the products and services described herein at any time without notice All ST products are sold pursuant to ST s terms and conditions of sale Purchasers are solely responsible for the choice selection and use of the ST products and services described herein and ST assumes no liability whatsoever relating to the choice selection or use of the ST products and services described herein No license express or impl
5. Closed loop parameter only in closed loop Integral coefficient Ki The value of the Integral Coefficient Ki of the proportional integrative PI regulator Proportional coefficient KP The value of the proportional coefficient Kp of the PI regulator Sampling time The regulation sampling time in milliseconds Change motor type the change motor type button enables the user to change the motor type see Figure 13 Advanced settings the advanced settings button enables the user to set the advanced parameters see Section 8 9 3 phase BLAC DC trapezoidal advanced settings on page 24 Generate source files the generate source files button enables the user to generate the configuration h files shown in Table 7 configuration h files save dialog window appears where the user can select in which folder to create the file User must choose the right Source directory in the firmware working folder see Section 8 5 Firmware description on page 21 3 BLAC DC trapezoidal advanced settings Clicking the advanced dialog box see Figure motor type parameters settings button see Figure 13 opens the advanced settings 14 This is where the advanced 3 phase BLAC DC trapezoidal are set X UM0522 Motor control operations Figure 14 3 phase BLAC DC trapezoidal advanced parameters window PMDC
6. N UM0522 YZ User manual 100 W 3 phase inverter for BLDC sensorless motor evaluation board Introduction The 100 W 3 phase inverter for the BLDC sensorless motor evalaluation board for brevity also referred with its order code STEVAL IHM017V1 is a complete development platform for BLDC sensorless motor application with nominal power up to 100 W It is based on a cost effective flexible and open design including a three phase inverter bridge based on the STD5NK52ZD 1 Power MOSFET package and an ST7MC 8 bit microcontroller with 16 Kbyte internal Flash memory The system has been designed to drive a three phase brushless motor with permanent magnet rotor exploiting trapezoidal sensorless control The STEVAL IHM017V1 features complete hardware for developing motor control applications based on ST7MC peripherals including motor control peripheral MTC The STEVAL IHMO 17V1 uses an in circuit communication ICC standard interface to connect to the host PC via In circuit debuggers programmers such as the inDART STX board from Softec The board is designed to support 230 Vac of bus voltage up to 100 W of input power It also includes a power supply stage with VIPer12A E as the buck converter to generate voltage reference for the driver and the microcontroller Figure 1 STEVAL IHM017V1 evaluation board April 2008 Rev 1 1 39 www st com Contents UM0522 Contents 1 OVervieW
7. 25 ST7VD active project configuration 27 System setup for programming phase 28 Option byte settings lt smsi a masas Gud ca Rede dorada Ras Y 29 Programming option auto window 30 System setup for running 30 UM0522 List of tables List of tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 ST7FMC2S4T6 functions csa Uu L u u eee ra 10 Absolute maximum 5 12 Board electrical characteristics 13 Configuration h 21 3 phase BLAC DC trapezoidal basic parameters 23 3 phase BLAC DC trapezoidal advanced parameters 25 Potentiometer functionality based on open closed loop driving strategy 32 Bill of materials assadas a ua a ala a rn 34 Document revision history 38 5 39 Overview UM0522 1 Overview 1 1 Features Input voltage 220 230 Vac Maximum power 100 W Power MOSFET STD5NK52ZD 1 4 4 520 V included 15 V auxiliary power supply connector Programming and debug support via 10 pin I
8. been switched to run state In run state D12 led is ON push again the start stop button to stop the motor The D12 LED is turned OFF and D13 LED is turned ON to indicate that the firmware has been switched to idle state 33 39 Bill of material UM0522 9 34 39 Bill of material Table 8 Bill of materials Item Reference Part Footprint 1 CON2 CON2 TRH pitch 2 54mm 2 C1 220 uF 450 V TRH pitch 10mm 3 C2 2 2 uF 50 V TRH pitch 2 54mm 4 C3 10 uF 50 V TRH pitch 3 5mm 5 C4 22 nF 50 V TRH pitch 2 54mm 6 C5 100 uF 25 V TRH pitch 3 5mm 7 C6 1 uF 50 V TRH pitch 2 54mm 8 C7 C11 C12 2 2 uF 16 V SMD 0805 9 C8 22 nF 400 V TRH pitch 15 24mm 10 C9 100 nF 50 V TRH pitch 2 54mm 11 C10 0 22 uF 275 V x2 TRH pitch 15 24mm 12 C13 C14 C15 C16 C19 C20 100 pF SMD 1206 13 C17 C22 C39 C48 1 SMD 1206 14 C18 N M Not assy 15 C23 C24 C25 C34 470 nF SMD 1206 16 C28 C40 C42 100 nF SMD 1206 17 C30 C49 C51 C52 10 nF SMD 1206 18 C36 N M Not assy 19 C37 C38 C41 N M Not assy 20 C50 1 SMD 1206 21 D1 1N4148 TRH Verticale 22 D2 D18 D19 D20 STTH1L06 TRH Verticale 23 D3 BZX84C15 TRH Verticale 24 D5 BZX85C5V1 TRH Verticale 25 D6 BZX85C16 TRH Verticale 26 D7 STTH108 TRH Verticale 27 D12 D13 LED SMD 1206 28 D21 BRIDGE 2KPB TRH 29 D22 D23 D24 D25 D26 D27 STTH1LO6A SMD 1406 30 J8 Morsetto a vite 3 poli pitch b5bmm 31 J9 Morsetto a vite 2 poli pitch b5bmm
9. connected to the STEVAL IHMO17 01 board and that the board is well supplied 13 After programming check LED behavior to verify that the firmware has been correctly downloaded Board connection After the board has been programmed the system can be configured as shown in Figure 19 This configuration is called a running configuration Remove the ICC flat cable from the board if present 1 Connect the insulated AC power supply to the J9 connector of STEVAL IHMO17V1 2 Connect the phases of the motor to the J8 connector of the board Figure 19 System setup for running phase UM0522 Motor control operations 8 15 Note At this point the system is ready to run If the hardware current limitation set by default for this board 8 A has to be modified go to next paragraph otherwise it is possible to skip to paragraph Section 8 16 Driving the BLDC motor trapezoidal sensorless on page 32 Changing the maximum current level allowed An overcurrent protection mechanism is included inside the board that protects the system disabling all the power switches if current that flows inside the motor is greater than a certain threshold If this occurs the red LED starts blinking This mechanism is called hardware current protection This threshold value is fixed by the hardware to 8 A To change this threshold to Imax expressed in A resistor R51 expressed must be modified according to equation
10. driving signals to the power block according to a driving strategy the latter one closely related to the motor type and characteristics Driving signals are constituted of 3 complementary PWM signals in the range of 0 5 V for providing logic inputs for high low side gate driver belonging to the power block In the system proposed three legs are present 3 phase inverter The power block based on the gate drivers L6386 and Power MOSFET STD5NK52ZD 1 converts the control signals from ST7MC MCU to power signals for the three phase inverter in order to drive the motor The board can be supplied by an AC power supply of 230Vac with a maximum input power of 100 W Please refer to Section 7 Board architecture on page 14 for more details on system architecture With the included Power MOSFET device STD5NK52ZD 1 the maximum rating of rectified voltage is 520 V and the maximum continuous current is 4 4 A at 25 C 7 39 Safety and operating instructions UM0522 3 3 1 3 2 3 3 3 4 8 39 Safety and operating instructions General Warning During assembly and operation STEVAL IHMO17V1 evaluation board poses several inherent hazards including bare wires moving or rotating parts and hot surfaces There is danger of serious personal injury and damage to property if the kit or its components are improperly used or installed incorrectly All operations involving transportation installation and use as well as maintenance
11. evaluation board NMCES Emergency stop OAP Operational amplifier positive input OAN Operational amplifier negative input MTC OAZ Operational amplifier output Current limitation reference MCPWMV PWM output V user for current reference MCZEM Not used in this evaluation board MCDEM Not used in this evaluation board MISO Master in slave out data not used in this evaluation board SPI Master out slave in data not used in this MOSI evaluation board SCK Serial clock not used in this evaluation board Received data input not used in this evaluation RDI board LINSCI Transmit data output not used in this evaluation TDO board AIN12 Trimmer R63 reading input 10 bit ADC AIN11 Trimmer R62 reading input AIN7 Trimmer P61 reading input ICCCLK Output serial clock ICC ICCDATA Input output serial data ICCSEL Vpp Programming voltage input PE2 Start stop pushbutton Other I O PB7 LED management 11 39 STD5NK52ZD 1 characteristics UM0522 5 STD5NK52ZD 1 characteristics The STD5NK52ZD 1 is a n channel Power MOSFET in the package 520 V 1 22 Q 4 4 Zener protected SuperMESH Figure 3 STD5NK52ZD 1 package and internal schematic diagram D 2 G 1 O IPAK O SC15010 S 3 Table 2 Absolute maximum ratings Symbol Parameter Value Unit Vps Drain source voltage Vgg 0 520 _ Drain gate voltage Ras 20 520 V Ves Gate source
12. isolate the DC supply AND the oscilloscope This prevents a shock occurring as a result of touching any SINGLE point in the circuit but does NOT prevent shocks when touching two or more points in the circuit An isolated AC power supply can be constructed using an isolation transformer and a variable transformer A schematic of this AC power supply is in the application note AN438 TRIAC 4 microcontroller safety precautions for development tools Although this application note was written for TRIAC the isolation constraints still apply for switching semiconductor devices such as MOFSETs Isolating the application rather than the oscilloscope is highly recommended in any case Hardware requirements To set up the STEVAL IHMO17V1 evaluation board system the following items are required The board STEVAL IHMO17V1 High voltage insulated AC power supply up to 230 Vac Softec inDART STX not included in the package Softec ICC isolation board not included in the package Two 10 pin flat cables not included in the package 3 phase brushless motor with permanet magnet rotor not included in the package Insulated oscilloscope as needed Insulated multimeter as needed 19 39 Motor control operations UM0522 8 3 8 3 1 20 39 Software requirements To customize compile and download the motor control firmware the following software must be installed STEVAL IHM017V1 GUI included in the CD ROM STVD
13. on is also indicated Configuring the firmware is performed by compiling a set of h files inside the source folder and writing a series of values as fields of define statements To do this configuration solid knowledge of the hardware and the architecture of the firmware is required Otherwise the configuration tool provided inside the CD ROM called STEVAL IHMO17V1 GUI can be used This allows the user to choose and set all required parameters visually and the software automatically generates the h files required refer to the h files that constitute the configurations related to the firmware in Table 4 Table 4 Configuration h files Firmware name Configuration files MTC Settings Sensorless h BLDC SL spec settings h version h For a detailed description of the configuration files and how to manually customize the related parameters see AN1905 21 39 Motor control operations UM0522 8 7 8 8 22 39 Motor type selection After STEVAL IHMO17V1 GUI is started the motor type choice dialog box appears see Figure 12 this window the user can choose the kind of motor For this evaluation board only the 3 phase BLAC DC motor trapezoidal is available Figure 12 Motor type choice window SF STEVAL IHMO17Y1 GUI ver 2 0 Motor Type Choice 3Phase BLAC DC Motor trapezoidal C is Ok Cancel Press the OK button 3 phase BLAC DC tra
14. the frequency of the sampling clock for D and Z events in kHz s Defines in which state the unused MCI input is fixed either Grounded or Unused MCIx input Hi Z 25 39 Motor control operations UM0522 8 10 8 11 26 39 Table 6 3 phase BLAC DC trapezoidal advanced parameters continued Parameter name Description Zero crossing After D blanking window Sets the blanking window after a D event in microseconds us Z event counter filter Defines the number of counter events required to validate a Z event Threshold voltage Voltage set in volts for Z detection Demagnetization After C blanking window Sets the blanking window after a C event in microseconds us D event counter filter Defines the number of counter events required to validate a D event Demagnetization method Three methods are available all hardware or all software alternate hardware software Demagnetization time Fixed demagnetization time in microseconds us only with demagnetization methods all software Force duty cycle during demagnetization Allows using a different value of duty cycle rather than the one in run time setting Duty cycle Value of duty cycle percentage forced during demagnetization Stop condition Free wheeling DC current braking After stopping the motor continues to spin freely
15. voltage 30 V Ip Drain current continuous at Tc 25 C 4 4 A Ip Drain current continuous at Tc 100 C 2 7 A lpm Drain current pulsed 17 6 A Total dissipation at Tc 25 C 70 W 1 Pulse width limited by safe operating area Stresses above the limit shown in Table 2 may cause permanent damage to the device 12 39 UM0522 Board electrical characteristics 6 Board electrical characteristics Stresses above the limit shown in Table 3 may cause permanent damage to the devices present inside the board This is a stress rating only and functional operation of the device under these conditions is not implied Exposure to maximum rating conditions for extended periods may affect device reliability 15 V bias current measurement can be useful to check the working status of the board If measured value is considerably greater than typical value it means that some damage has occurred in the board Supply the control board using a 15 V power supply connected to CON2 observing the polarity Table 3 Board electrical characteristics Board parameters STEVAL IHMO17V1 Unit Min Max 15 V auxiliary supply range CON2 12 15 V 15 V bias current typical 23 23 mA Vpus J9 30 270 Vac 13 39 Board architecture UM0522 7 7 1 14 39 Board architecture The STEVAL IHM017V1 can be schematized as in Figure 4 Figure 4 Board architecture The h
16. 7 Equation 1 450 MAX For example if the desired threshold is 2 2 A it is required to use 51 200 A place holder named R53 in parallel to R51 is also included that can be useful if the calculated value is not a standard value resistor In this case it is possible to get better accuracy using two standard value resistors in parallel to get the calculated value For a lower value of current threshold in order to avoid noise on current feedback the shunt resistor R10 may be reduced in which case the formula that should be used is equation 2 Equation 2 45 CK lt Imax R54 If R51 and or R10 are changed the gui ini file must be modified This file is stored in the same folder as the STEVAL IHM017 01 GUI file First calculate the Amplification factor using equation 3 Equation 3 Open the gui ini file using the notepad and change the value of the following line MAX_CURRENT 4 4 AMP_SENS 5 6 R SENS 0 1 Replace the value 4 4 with Imax expressed in amps the value 5 6 with the A value calculated by equation 3 and 0 1 with the value of R10 31 89 Motor control operations UM0522 8 16 8 17 8 18 32 39 Remember to close and re open LVST7MC GUI to activate this modification and follow the instructions in Section 8 6 Configuring the firmware using GUI on page 21 Driving the BLDC motor trapezoidal sensorless Let s start the demonstratio
17. 7 for inDART STX V 3 11 also called ST7 Toolset downloadable from Softec s website www softecmicro com Cosmic compiler 517 C compiler 16 Kbyte free version 4 5c downloadable from Cosmic s website www cosmic software com Installing the software STEVAL IHMO17V1 GUI installation Insert the CD ROM provided with the kit and execute Setup exe 3 d party software installation Follow the instructions of the related software to install and configure STVD7 for inDARTSTX and cosmic compiler Installation note 1 Install the Cosmic compiler first Use the default installation folder CAProgram Files COSMIC CXST7_16Kbite Registration is required before using the product You can perform this procedure at any time by running the Imreg16k exe file inside Cosmic s installation folder Complete the form and click on the Register by email button You will receive a license file license lic that must be copied inside the installation folder under the license folder 2 Theninstall STVD7 for inDART STX During the first run of the software after installation a prompt for the configuration of the toolset should appear The toolset can be configured at any time by opening tools options inside STVD7 To do this click toolset and select the toolset menu tab select ST7Cosmic and configure as in Figure 11 Figure 11 STVD7 for InDART STX toolset configuration Options Toolbars Commands Edit Debug Styles Lan
18. AC or BLDC AC Advanced Settings Pw Settings Demagnetization Switches PWM Frequency KHz After C Blanking Window Switches PWM Minimum Off Time 2 5 vus D event Counter Filter Complementary PWM Signal Disabled C All Hardware Synchronous Rectification Alternate Hardware S oftware Dead Times us C All Software Force Duty Cycle during demagnetization Current Blanking Window s Current Event Counter Filter Current Loop Stop Condition D and Z Sampling Parameters Free Wheeling Sampling Clock 1000 DC Curent Braking Unused Input Grounded Zero Crossing After D Blanking Window Z event Counter Filter Cancel Threshold Voltage Table 6 8 phase BLAC DC trapezoidal advanced parameters Parameter name Description Switches PWM Pulse width modulation PWM frequency in kHz frequency PWM minimum off time microseconds us to detect the BEMF minimum off time Complementary PWM If synchronous rectification it is enable or not signal Deadtime Value of deadtime in us only if Complementary PWM enabled Current loop Current blanking Time window filter in milliseconds to prevent erroneous sampling of the window current after the PWM is turned ON Current event counter Defines the number of counter events required to validate a current filter limitation event D and Z sampling parameters Sampling clock Sets
19. Active brake obtained injected dc current into the motor Brake level Value of duty cycle percentage of PWM brake signal Brake time Duration in milliseconds of the active brake Changing the maximum current allowed by GUI The maximum current allowed by GUI has been set to 4 4 A This value may be changed by modifying the gui ini inside the folder where the STEVAL IHMO17V1 GUI file is installed Open the gui ini file using the notepad and change the value of the following line e CURRENT 4 4 Replace the value 4 4 with the desired value of current limitation expressed in ampere Remember that also the hardware current limitation must be changed accordingly see Section 8 10 Changing the maximum current allowed by GUI on page 26 to know how to modify this limitation Compiling the firmware Once the configuration files have been produced manually or using the GUI the binary executable file 5319 must be compiled and produced To do this the STVD7 for inDART STX is used with the Cosmic compiler see Section 8 3 Software requirements on page 20 1577 UM0522 Motor control operations Note 8 12 1 1 Run the STDV7 for inDART STX and choose file gt open workspace 2 Select the workspace file under the firmware working folder depending on the motor type see Section 8 5 Firmware description on page 21 3 The default project in use is opened by the environmen
20. CC connector e Three potentiometers for runtime settings e Start stop button e Reset button 1 2 Applications Refrigerator compressors Dishwasher pumps 6 39 ky UM0522 System architecture 2 System architecture A generic motor control system can be basically schematized as the arrangement of four main blocks see Figure 2 A control block whose main tasks are to accept user command and motor drive configuration parameters and to provide digital signals to implement the proper motor driving strategy e Apower block that makes a power conversion from DC bus transferring it into the motor by means of a three phase inverter topology e The motor itself The STEVAL IHMO17V1 board is able to drive a three phase brushless motor with permanent magnet rotor exploiting trapezoidal sensorless control e The power supply block is able to accept 230 Vac input voltage and provide the proper levels to supply both the control block and power block devices Figure 2 Motor control system architecture Control Block The system proposed by STEVAL IHMO 17V1 includes all the above hardware blocks apart the motor plus a software GUI that allows configuring the motor drive Moreover an open source C code is available derived from the ST7MC motor control libraries allowing easy customization and extension of control algorithms The core of the control block is constituted of an ST7MC MCU that provides the
21. Power MOSFET is turned on by means of R1 and R20 while the turnoff is performed by means of R1 and D22 15 39 Board architecture UM0522 7 3 16 39 Figure 7 Board layout Bus connector Start Stop button Auxiliary voltage connector Motor connecto PHASE A ICC connector Potentiometers ICC connector The ICC connector J7 is used to establish ICC communication for programming debugging purposes The pinout is shown in Figure 8 This connector is compatible with Softec s inDART STX board not included in the package Figure 8 ICC connector ICC_DATA ICCCLK RESET VPP GND UM0522 Board architecture 7 4 Board schematic Figure 9 Board schematic control block iNDBF1 22uF 16V 22uF 16V ICC connector HE 1p maig type IE S s pge a 54 07 d 17 39 UM0522 Nm nu d L wL oza sured xa sm z a z n cH Xs T T
22. Q es 34 10 Referentes a in a meee am 37 11 REVISION history 38 ky 3 39 List of figures UM0522 List of figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 4 39 STEVAL IHMO17V1 evaluation board 1 Motor control system 7 STD5NK52ZD 1 package and internal schematic 12 Board architecture Ti suysya usus eee 14 Power supply architecture ce 15 Gate driving 15 Board ass as Y ee He See ERR CE Eee p ed 16 ICC connector 6 sehe emere 16 Board schematic control block 17 Board schematic power 18 STVD7 for InDART STX toolset configuration 20 Motor type choice window cect 22 3 phase BLAC DC trapezoidal settings basic parameters window 22 3 phase BLAC DC trapezoidal advanced parameters window
23. alling the software 20 STEVAL IHMO17V1 GUI installation 20 3rd party software installation 20 Installation note 20 2 39 UM0522 Contents 8 4 Board SCG oe wee beds 21 8 5 Firmware description 21 8 6 Configuring the firmware using 21 8 7 Motor type selection 22 8 8 3 phase BLAC DC trapezoidal settings 22 8 9 3 BLAC DC trapezoidal advanced settings 24 8 10 Changing the maximum current allowed by GUI 26 8 11 Compiling the firmware 26 8 12 Programming firmware 27 8 19 Setup option byl IMPRESS 29 8 14 Board Connection ie eem xU eom bed d aasma kaba i oe 30 8 15 Changing the maximum current level allowed 31 8 16 Driving the BLDC motor trapezoidal sensorless 32 8 17 LED behavior after power on 32 8 18 Potentiometers functionality 32 9 Bill of mat rial uuu cece dice cede eevee CR CR S
24. ar voltage regulator L7805 to generate the microcontroller voltage reference see Figure 5 1574 UM0522 Board architecture 7 2 Figure 5 Power supply architecture 15V auxiliary supply CON2 Vbus Vdrivers 5 Buck converter Linear regulator T Vac 42 ViPer 12 E Da Rectifier ma Power stage The power stage is based on six power MOSFETs in full 3 phase bridge configuration In the board there are six STD5NK52ZD 1s an package Each device contains the freewheeling Zener diode Three L6386 have been used to drive the Power MOSFETs gates and for hardware current protection For each Power MOSFET in the 3 phase bridge the network shown in Figure 6 default configuration has been used as the starting configuration Figure 6 Gate driving network Turn on R20 D22 Turn off Default configuration Alternate configuration Turn off R21 22R In this default configuration the gate of the Power MOSFET is turned on by means of R1 and D22 while the turnoff is performed very fast by means of the Q1 transistor It is also possible to use the alternate configuration of the network See Figure 6 To set this configuration transistor Q1 resistor R5 and C13 must be removed from each network 6 The direction of the diode D22 must be inverted and a resistor R20 must be mounted In this alternate configuration the gate of the
25. are to be carried out by skilled technical personnel national accident prevention rules must be observed For the purposes of these basic safety instructions skilled technical personnel are suitably qualified people who are familiar with the installation use and maintenance of power electronic systems Evaluation board intended use The STEVAL IHMO 17V1 evaluation board is a component designed for demonstration purposes only and shall not be used for electrical installation or machinery The technical data as well as information concerning the power supply conditions shall be taken from the documentation and strictly observed Evaluation board installation The installation and cooling of the demonstration kit boards shall be in accordance with the specifications and the targeted application see Section 8 Motor control operations on page 19 The motor drive converters shall be protected against excessive strain In particular no components are to be bent or isolating distances altered during the course of transportation or handling No contact shall be made with other electronic components and contacts The boards contain electrostatically sensitive components that are prone to damage through improper use Electrical components must not be mechanically damaged or destroyed to avoid potential health risks Electronic connections Applicable national accident prevention rules must be followed when working on the main power su
26. board to the PC The green LED on the inDART STX board turns on The Windows operating system automatically detects the new hardware and loads the appropriate USB and inDART STX drivers Windows 2000 and Windows XP may issue a warning the first time the inDART STX power board is connected to the PC The USB driver used by inDART STX is not digitally signed by Microsoft however the user may safely ignore the warning since every kind of compatibility and security test has been carried out by Softec Microsystems 2 Connect the inDART board with the J7 connector using the 10 pin flat cable 3 Supply the control board using a 15 V power supply connected to CON2 observing the polarity Once the ST7VD for inDART has been installed the datablaze programmer utility that can be used to program the firmware using the inDART STX is automatically installed 4 Run the Softec datablaze programmer utility 5 Click the select device button on the toolbar 6 Inthe select device window select inDART STX in the programmer hardware box and ST7FMC2S4 as the device code and press OK UM0522 Motor control operations Note If an error occurs make sure that the inDART STX board is connected to the PC A green LED lights up if the board is connected 7 Click on the file pull down menu select load then code buffer 8 Inthe load file to code buffer dialog box format menu select Motorola S Rec settings 9 Click the b
27. d to limit the current at this level Detection mode The back EMF BEMF detection mode rotor position only sensorless control is allowed in this evaluation board Alignment phase Final duty cycle The percentage of final duty cycle applied at the end of alignment phase only in voltage mode Final current The value of current flowing inside the motor at the end of the alignment phase only in current mode Alignment duration The duration of the alignment phase in milliseconds ms Acceleration phase Mechanical acceleration rate Duty cycle The mechanical acceleration rate of the rotor during the ramp up in RPMs or Hz per second alternate between RPM and Hz settings by clicking on the RPM button The duty cycle percentage during the ramp up only in voltage mode Current reference The value of current flowing inside one of three phases of the motor at the end of the acceleration phase only in current mode Number of Z events before auto switched mode Electrical frequency The number of consecutive Z events that occur before the microcontroller runs the motor in autoswitched mode Minimum The minimum target rotor frequency in closed loop expressed in Hz Maximum The maximum target rotor frequency in closed loop expressed in Hz Run settings When the From RV1 checkbox is selected duty cycle value is defined by the RV1 potentio
28. eart of the evaluation board is the ST7MC microcontroller with a dedicated peripheral included to drive the three phase brushless motor with permanent magnet rotor exploiting trapezoidal sensorless control The board is provided with three potentiometers R61 R62 R63 used for tuning in real time some parameters related to the drive See Section 8 Motor control operations on page 19 Two LEDs green red are used to get information about the status of the system Their behavior is related to the drive See Section 8 Motor control operations on page 19 In normal functionality it is expected that the board is supplied by VBUS connector J9 but an auxiliary supply connector is included on the board to feed the drivers and the microcontroller This auxiliary supply can be useful for safety reasons for example it should be used to program or debug the device without feeding the board with high voltage One communication system can be established with the microcontroller e ICC used for programming debugging purposes Power supply The power supply is able to address a wide range of AC input voltage voltages from 30 Vac up to 270 Vac The alternate current input is rectified by a diodes bridge and bulk capacitor to generate a direct current bus voltage approximately equal 2 Vac minus the voltage drop on the bridge and ripple Then we have used a VIPer12A E based buck converter to generate voltage reference for driver 15 V and a line
29. guages Workspace Directories Toolset Root path C Program Files COSMIC CXST _16 Toolset sub paths relative to the Root path Bin path Include path Hst Lib path Lib Cancel UM0522 Motor control operations 8 4 Board setup 8 5 Firmware description To address the driving of 3 phase brushless motor with permanent magnet rotor exploiting the sensorless trapezoidal control it is required to use the firmware named BLDC_3PH_SL released for free Together with the installation of STEVAL IHMO17V1 GUI the BLDC SL firmware source code is installed on the inside the installation folder under the BLDC_3PH_SL folder The following files are present inside the working folder stw file STVD7 workspace file stp file STVD7 project file e source folder containing all c and h files required Note We suggest making a backup copy of the original working folder The following procedure modifes the original content of the workspace folder without leaving the possibility to return to a previous step 8 6 Configuring the firmware using GUI Before using the firmware it must be configured The term configure indicates the act of selecting a specific driving strategy such as open or closed loop voltage or current mode and so on The setting of customized parameters such as current limitation motor settings driving related parameters and so
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32. igurable window watchdog timer Nested interrupt controller with 14 interrupt vectors Two 16 bit timers One 8 bit auto reload timer Serial peripheral interface SPI not used in this evaluation board Serial communication interface LINSCI not used in this evaluation board Motor controller MTC peripheral with 6high sink pulse width modulator PWM output channels asynchronous emergency stop analog inputs for rotor position detection permanent magnet motor coprocessor including multiplier programmable filters blanking windows and event counters Operational amplifier and comparator for current limitation 10 bit analog to digital converter ADC with 11 inputs In circuit communication interface ICC debug Table 1 ST7FMC2S4T6 functions Description Function name depends on embedded software MCOO PWM outputs high side phase A MCO1 PWM outputs low side phase A MCO2 PWM outputs high side phase B MTC PWM outputs low side phase 4 PWM outputs high side phase MCO5 PWM outputs low side phase C Analog or digital input for position sensor or MIE MGIB B E M F detection 1574 UM0522 ST7FMC2S4T6 microcontroller functions Table 1 ST7FMC2S4T6 functions continued Functi vo Description unction name depends on embedded software MCV REF Not used in this
33. m Sets the current reference value from 0 A to value to maximun Value R61 maximum c rrent Allowed configured see Section 8 8 3 phase BLAC DC trapezoidal settings on page 22 R62 Sets the value of rising delay coefficient from 0 to 255 R63 Sets the value of rising delay coefficient from 0 to 255 UM0522 Motor control operations Note If during the configuration using GUI the from RV1 control has been unchecked then the value of the duty cycle or the value of current reference is not set by R61 but has a fixed value If during the configuration using GUI the from RV2 RV3 control has been unchecked then the value of the rising delay coefficient and the value of the falling delay coefficient are not set by P2 and P3 but have fixed values The value of rising and falling delay are expressed in 255 of last measured step time So 0 means no delay between zero crossing and commutation while 255 means that the delay between zero crossing and commutation is equal to last step time The maximum duty cycle allowed in voltage mode depends on the value of PWM frequency and the value of PWM min off time set by the GUI The maximum current allowed by GUI has been set to 4 4 A see Section 8 10 Changing the maximum current allowed by GUI on page 26 In idle state D13 led is ON push the start stop button to start the motor The D13 LED is turned OFF and D12 LED is turned ON to indicate that the firmware has
34. meter only for voltage mode or current reference is From RV1 defined by the RV1 potentiometer only for current mode or target speed is defined by the RV1 potentiometer only for closed loop if this box is unchecked the above parameters are set by the user Duty cycle The duty cycle percentage when the motor is run in open loop voltage mode 23 39 Motor control operations UM0522 8 9 24 39 Table 5 3 phase BLAC DC trapezoidal basic parameters continued Parameter name Description Current reference The value of current flowing inside one of three phases of the motor at run time in open loop current mode Target speed The target mechanical rotor Speed in RPMs or Hz if speed regulation is set to closed loop alternate between RPM and Hz settings by clicking on the RPM button Delay coefficient from RV2 RV3 If the check box Delay coefficient from RV2 RV3 is checked then the Rising Falling delay are set by R62 and R63 Otherwise if the check box is unchecked these two parameters Rising Falling delay can be set by the user in the following control boxes B emf rising falling edge in this case the two parameters are fixed and cannot be modified during the run time B emf rising edge The B EMF Rising delay coefficient value from 0 to 255 B emf falling edge The B EMF Falling delay coefficient value from 0 to 255
35. n driving the brushless permanent magnet motor sensorless so at this point please check that the board has been set up for sensorless driving See Section 8 8 3 phase BLAC DC trapezoidal settings on page 22 To drive the motor also in closed loop mode it is not required that the motor include any position or speed sensor LED behavior after power on Turn on the power supply For this demonstration the power supply output voltage should be set to 230 Vac and the current limitation of the power supply should be set to 2 A After power on the control board LED behavior should be the following LED D12 blinks signaling that the firmware has started to run e Aftera while LED D13 stays on to indicate idle state Potentiometers functionality If enabled during the configuration the three potentiometers R61 R62 R63 can be used to set run time parameters See Table 7 to understand their functionality Table 7 Potentiometer functionality based on open closed loop driving strategy Voltage mode Open loop Closed loop Sets the target rotor frequency value from minimum value to maximum value R61 seb hs d Pide aes _ ee configured see Section 8 8 3 phase 2 BLAC DC trapezoidal settings on page 22 R62 Sets the value of rising delay coefficient from 0 to 255 R63 Sets the value of falling delay coefficient from 0 to 255 Current mode Open loop Closed loop Sets the target rotor frequency value fro
36. pezoidal settings Figure 13 3 BLAC DC trapezoidal settings basic parameters window STEVAL IHMO17V1 GUI 3 Phase BLAC DC Motor trapezoidal Poles Pairs Speed Regulation Driving Mode Detection Mode E Open Loop Current Sensorless C Sensor 60 Closed Loop Voltage Current Bus Limitation 3 C s 120 ensor Alignment Phase Acceleration Phase Electrical Frequency 30 Mechanical Acceleration Rate 1000 s Duty Cycle 30 Alignment Duration 1250 ms Duty Cycle Number of Z events before auto switched mode 2 Run Settings Delay Coefficient From RV1 From RV2 RV3 B emf rising edge 20 m B emf falling edge 7 io yl Change Motor Type Advanced Settings Generate Source files Save Load Motor control operations Table 5 3 phase BLAC DC trapezoidal basic parameters Parameter name Poles pairs Description The number of pole north south pairs in the motor Speed regulation The manner in which to run the motor either open loop without speed regulation or closed loop with speed regulation Driving mode The motor driving mode current mode or voltage mode Current bus limitation The software current limitation value only in voltage mode if the current flowing inside one of three phases of the motor reaches this value overcurrent is not generated but the pwm is manage
37. pply with a motor drive The electrical installation shall be completed in accordance with the appropriate requirements e g cross sectional areas of conductors fusing PE connections for further information see Section 8 Motor control operations on page 19 1574 UM0522 Safety and operating instructions 3 5 Evaluation board operation A system architecture which supplies power to the STEVAL IHMO17V1 evaluation board shall be equipped with additional control and protective devices in accordance with the applicable safety requirements e g compliance with technical equipment and accident prevention rules Warning not touch the board after disconnection from the voltage supply as several parts and power terminals which contain possibly energized capacitors need to be allowed to discharge 174 9 39 ST7FMC2S4T6 microcontroller functions UM0522 4 4 1 10 39 ST7FMC2S4T6 microcontroller functions Main features TQFP44 package 16 Kbyte dual voltage Flash program memory with read out protection capability 768 bytes RAM 256 stack bytes Clock reset and supply management with enhanced reset system enhanced low voltage supervisor LVD for mains supply and auxiliary voltage detector AVD with interrupt capability clock sources crystal ceramic resonator oscillators and bypass for external clock clock security system four power saving modes halt active halt wait and slow Conf
38. t and is shown on the left side of the window below the opened stw file 4 Make sure that Release is set as the active project configuration see Figure 15 Figure 15 ST7VD active project configuration a SofTec STVD7 3PH SR stw config h File Edit View Project Build Debug Debug instrument Tools Wind r 5 act AC 3PH SR Q Release vz Workspace AC_3PH_SR stw AC_3PH_SR 5 Use the build pull down menu to display and select the rebuild all command The project will be compiled and built and an executable file lt firmware name gt s19 will be generated inside release folder under the workspace Make sure that the following string lt firmware name gt elf 0 error s 0 warning s is displayed inside the output pane after the building of the executable After the building of the executable please ensure that the file lt firmware name gt s19 generated inside the release folder under the workspace has been created To do this show the properties and check the creation date Programming firmware Before programming the firmware the board must be supplied and connected to the PC using the inDART board We suggest setting up the system as described in Figure 16 27 39 Motor control operations UM0522 Note 28 39 Figure 16 System setup for programming phase Flat Cable B 1 Use the USB cable to connect the inDART STX
39. utton near name box and select the binary code S19 to download into the microcontroller and press OK to know which binary code to select see Section 8 11 Compiling the firmware on page 26 8 13 Setup option byte 10 Press the option byte button in the toolbar and select the value as shown in the option configuration window see Figure 17 and press Figure 17 Option byte settings Edit Option Bytes FMP_R Read Out Protection Read ut Protection Disabled DIV2 Divider by 2 2 divider enabled Cancel RSTC RESET Clock Cycle Selection Reset phase with 4096 CPU cycles gt VD Voltage Detection Selection and On X CKSEL Clock Source Selection PLL clock selected X wDG Sw Watchdog Activation Software Y WDG_HALT Watchdog and Halt Mode No Reset in HALT M Motor Control Output Options Low PKG Package Selection TOFP44 11 Press the auto button in the toolbar and select the programming options as shown in Figure 18 Ti 29 39 Motor control operations UM0522 8 14 30 39 Figure 18 Programming option auto window Steps Erase Options Erase Code Blank Check Code Program Code Verify Code Erase Prog Options Verify Options iv Run 12 Press start to program the device If an error window appears make sure that the inDART STX board is
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