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Motorola Embedded Motion Control

3-Phase ac BLDCHigh-VoltagePower Stage

User’s Manual

For More Information On This Product,

Go to: www.freescale.com

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Important Notice to Users

While every effort has been made to ensure the accuracy of all information inthis document, Motorola assumes no liability to any party for any loss ordamage caused by errors or omissions or by statements of any kind in thisdocument, its updates, supplements, or special editions, whether such errors areomissions or statements resulting from negligence, accident, or any other cause.Motorola further assumes no liability arising out of the application or use of anyinformation, product, or system described herein: nor any liability for incidentalor consequential damages arising from the use of this document. Motoroladisclaims all warranties regarding the information contained herein, whetherexpressed, implied, or statutory, including implied warranties ofmerchantability or fitness for a particular purpose. Motorola makes norepresentation that the interconnection of products in the manner describedherein will not infringe on existing or future patent rights, nor do thedescriptions contained herein imply the granting or license to make, use or sellequipment constructed in accordance with this description.

Trademarks

This document includes these trademarks:

Motorola and the Motorola logo are registered trademarksof Motorola, Inc.

Motorola, Inc., is an Equal Opportunity / Affirmative Action Employer.

© Motorola, Inc., 2000; All Rights Reserved

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

2 MOTOROLA For More Information On This Product,


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User’s Manual — 3-Phase ac BLDC High-Voltage Power Stage

List of Sections

Section 1. Introduction and Setup. . . . . . . . . . . . . . . . . .11

Section 2. Operational Description . . . . . . . . . . . . . . . . .19

Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . .25

Section 4. Schematics and Parts List . . . . . . . . . . . . . . .31

Section 5. Design Considerations . . . . . . . . . . . . . . . . . .47

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA List of Sections 3 For More Information On This Product,


List of Sections

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4 List of Sections MOTOROLA For More Information On This Product,


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Table of Contents

Section 1. Introduction and Setup

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Section 2. Operational Description

2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4 Modification for One-Half and Three-Fourths Horsepower. . . . . . . . 22

2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 3. Pin Descriptions

3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2 Pin-by-Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2.1 Power Input Connector J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2.2 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.3 External Brake Connector J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.4 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


MOTOROLA Table of Contents 5 For More Information On This Product,


Table of Contents

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Section 4. Schematics and Parts List

4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Section 5. Design Considerations

5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.10 Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


6 Table of Contents MOTOROLA For More Information On This Product,


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List of Figures

Figure Title Page

1-1 Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131-2 3-Phase ac BLDC High-Voltage Power Stage . . . . . . . . . . . . . . . . . . 141-3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-4 PFC Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-1 40-Pin Ribbon Connector J14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4-1 3-Phase ac BLDC High-Voltage Power Stage Overview. . . . . . . . . . 324-2 Gate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334-3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-4 Current and Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 354-5 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364-6 Power Factor Correction and Brake Gate Drives . . . . . . . . . . . . . . . . 374-7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384-8 Identification Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5-1 Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495-2 Bus Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515-3 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535-4 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545-5 Phase A Back EMF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555-6 Phase A Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565-7 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585-8 PFC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595-9 PFC Zero Crossing Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60


MOTOROLA List of Figures 7 For More Information On This Product,


List of Figures

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8 List of Figures MOTOROLA For More Information On This Product,


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List of Tables

Table Title Page

2-1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212-2 Resistor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222-3 JP801 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222-4 Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3-1 Connector J13 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 263-2 Connector J14 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4-1 Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404-2 Printed Circuit Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41


MOTOROLA List of Tables 9 For More Information On This Product,


List of Tables

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10 List of Tables MOTOROLA For More Information On This Product,


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Section 1. Introduction and Setup

1.1 Contents

1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2 Introduction

Motorola’s 3-Phase ac high-voltage brushless dc (BLDC) power stage (HV acpower stage) is a 115/230 volt, 180 watt (one-fourth horsepower), off-linepower stage that is an integral part of Motorola’s embedded motion controlseries of development tools. It is supplied in kit number ECPWRHiVACBLDC.

In combination with one of the embedded motion control series control boardsand an embedded motion control series optoisolation board, it provides aready-made software development platform for fractional horsepower off-linemotors. Feedback signals are provided that allow 3-phase ac induction andBLDC motors to be controlled with a wide variety of algorithms. In addition,the HV ac power stage includes an active power factor correction (PFC) circuitthat facilitates development of PFC algorithms.

An illustration of the systems’ architecture is shown in Figure 1-1. A linedrawing appears in Figure 1-2.


MOTOROLA Introduction and Setup 11 For More Information On This Product,


Introduction and Setup

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The HV ac power stage’s features are:

• 1-phase bridge rectifier

• Power factor switch and diode

• dc-bus brake IGBT and brake resistors

• 3-phase bridge inverter (6-IGBT’s)

• Individual phase and dc bus current sensing shunts with Kelvinconnections

• Power stage temperature sensing diodes

• IGBT gate drivers

• Current and temperature signal conditioning

• 3-phase back-EMF voltage sensing and zero cross detection circuitry

• Board identification processor (MC68HC705JJ7)

• Low-voltage on-board power supplies

• Cooling fans


12 Introduction and Setup MOTOROLA For More Information On This Product,


Introduction and SetupAbout this Manual

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Figure 1-1. Systems’ Configurations

1.3 About this Manual

Key items can be found in the following locations in this manual:

• Setup instructions are found in 1.5 Setup Guide.

• Schematics are found in Section 4. Schematics and Parts List.

• Pin assignments are shown in Figure 3-1. 40-Pin Ribbon ConnectorJ14, and a pin-by-pin description is contained in 3.2 Pin-by-PinDescriptions.

• For those interested in the reference design aspects of the board’scircuitry, a description is provided in Section 5. Design Considerations.

CONTROL BOARD

MOTOR

WORKSTATION

EMULATOR DSP EVM BOARD

HIGH-VOLTAGEPOWER STAGE

MOTOR

WORKSTATION

b) 56800 DSPa) MICROCONTROLLER

OPTOISOLATIONBOARD

HIGH-VOLTAGEPOWER STAGE

OPTOISOLATIONBOARD




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User’s Manual – 3 Phase AC BLDC High Voltage Power Stage

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



Introduction and SetupWarnings

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1.4 Warnings

This development tool set operates in an environment that includes dangerousvoltages and rotating machinery.

To facilitate safe operation, input power for the HV ac power stage should comefrom a current limited dc laboratory power supply, unless power factorcorrection is specifically being investigated.

An isolation transformer should be used when operating off an ac power line.

If an isolation transformer is not used, power stage grounds and oscilloscopegrounds are at different potentials, unless the oscilloscope is floating. Note thatprobe grounds and, therefore, the case of a floated oscilloscope are subjected todangerous voltages.

The user should be aware that:

• Before moving scope probes, making connections, etc., it is generallyadvisable to power down the high-voltage supply.

• When high voltage is applied, using only one hand for operating the testsetup minimizes the possibility of electrical shock.

• Operation in lab setups that have grounded tables and/or chairs should beavoided.

• Wearing safety glasses, avoiding ties and jewelry, using shields, andoperation by personnel trained in high-voltage lab techniques are alsoadvisable.

• Power transistors, the PFC coil, and the motor can reach temperatures hotenough to cause burns.

• When powering down; due to storage in the bus capacitors, dangerousvoltages are present until the power-on LED is off.





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1.5 Setup Guide

Setup and connections for the HV ac power stage are straightforward. Thepower stage connects to an embedded motion control optoisolation board via a40-pin ribbon cable and can be powered either by a 140- to 230-volt dc powersupply or with line voltage. For both safety reasons and ease of makingmeasurements, it is strongly recommended that a dc supply is used, unlesspower factor correction is specifically being investigated. The power supplyshould be current limited to under 4 amps. Figure 1-3 depicts a completedsetup. A step-by-step setup procedure is:

1. Plug one end of the 40-pin ribbon cable that comes with the optoisolatorkit into input connector J14. The other end of this cable goes to theoptoisolation board's 40-pin output connector.

2. Connect motor leads to output connector J13, located along the backedge of the top board. Phase A, phase B, and phase C are labeled Ph_A,Ph_B, and Ph_C.

For an ac induction motor, it does not matter which lead goes to whichphase. For BLDC motors, it is important to get the wire color coded forphase A into the connector terminal labeled Ph_A, and so on for phase Band phase C.

3. Connect earth ground to the earth ground terminals on the top board andon the heat sink. The top board’s ground terminal is located in the frontleft-hand corner and is marked with a ground symbol. The heat sink hasa screw on its front edge that is also marked with a ground symbol.

4. Connect a line isolated, current limited dc power supply to connectorJ11, located on the front edge of the top board. The input voltage rangeis 140 to 230 Vdc. Current limit should be set for less than 4 amps. Thedc supply’s polarity does not matter.

Either a 110-volt or 220-volt ac line that is coupled through an isolationtransformer may be used in place of a dc supply to provide input power.The connection is made on connector J11. Bias voltages are developedby internal power supplies. Only one power input is required.

WARNING: Operation off an ac power line is significantly more hazardous than operationfrom a line isolated and current limited dc power supply.

An isolation transformer should be used when operating off an ac power line.




Introduction and SetupSetup Guide

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5. Set up the optoisolation and control boards.

6. Optional PFC — The HV ac power stage is shipped with power factorcorrection (PFC) disabled. If power factor correction is desired, it isnecessary to remove and resolder power jumper JP201 from the no PFCposition to the PFC position. This jumper is found on the left side of thetop board between the dc bus capacitor and PFC inductor. Circuitconnections are illustrated in Figure 1-4. For first time setups, operationwithout power factor correction is recommended.

7. Apply power first to the optoisolator and then to the power stage. Thegreen power-on LED in the upper right-hand corner lights, and both fansrun when power is present. Note that the optoisolation board powers thecontrol board, and that the optoisolation board is not fully powered untilpower is applied to the power stage.

CAUTION: Hazardous voltages are present. Re-read all of 1.4 Warnings carefully.

Figure 1-3. Setup

MOTOR

CONTROL BOARD

OPTOISOLATOR

40-PINRIBBON CABLE

POWER STAGE 40-PINRIBBON CABLE

STANDOFFS

STANDOFFS

+12 Vdc

HIGH-VOLTAGEMOTOR SUPPLY

J2J1





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Figure 1-4. PFC Jumper

DCB_PFC_1

DCB_Cap_pos

Earth_GND

DCB_Cap_neg

PFC

NO PFC

1

2

3

JP201

PFC JUMPER

L201

4.9 mH/2.3 ADCB_PFC_2

C21310 nF/3000 V

C21410 nF/3000 V

C20822 nF/630 Vdc

C209470 µF/400 VC210

++

470 µF/400 V(OPTIONAL)




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Section 2. Operational Description

2.1 Contents

2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4 Modification for One-Half and Three-Fourths Horsepower. . . . . . . . 22

2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.2 Description

Motorola’s embedded motion control series high-voltage (HV) ac power stageis a 180 watt (one-fourth horsepower), 3-phase power stage that will operateoff of dc input voltages from 140 to 230 volts and ac line voltages from 100 to240 volts. In combination with one of the embedded motion control seriescontrol boards and an optoisolation board, it provides a software developmentplatform that allows algorithms to be written and tested without the need todesign and build a power stage. It supports a wide variety of algorithms for bothac induction and brushless dc (BLDC) motors.

Input connections are made via 40-pin ribbon cable connector J14. Pinassignments for the input connector are shown in Figure 3-1. 40-Pin RibbonConnector J14. Power connections to the motor are made on output connectorJ13. Phase A, phase B, and phase C are labeled PH_A, Ph_B, and Ph_C on theboard. Power requirements are met with a single external 140- to 230-volt dcpower supply or an ac line voltage. Either input is supplied through connectorJ11. Current measuring circuitry is set up for 2.93 amps full scale. Both bus andphase leg currents are measured. A cycle-by-cycle overcurrent trip point is setat 2.69 amps.


MOTOROLA Operational Description 19 For More Information On This Product,


Operational Description

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The high-voltage ac power stage has both a printed circuit board and a powersubstrate. The printed circuit board contains IGBT gate drive circuits, analogsignal conditioning, low-voltage power supplies, power factor control circuitry,and some of the large, passive, power components. This board also has anMC68HC705JJ7 microcontroller that is used for configuration andidentification. All of the power electronics which need to dissipate heat aremounted on the power substrate. This substrate includes the power IGBTs,brake resistors, current sensing resistors, a power factor correction MOSFET,and temperature sensing diodes. Figure 2-1 shows a block diagram.

Figure 2-1. Block Diagram

HV POWERINPUT SWITCH MODE

POWER SUPPLYPFC CONTROLdc BUS BRAKE

3-PHASE IGBT

GATE

PHASE CURRENTPHASE VOLTAGE

BUS CURRENTBUS VOLTAGE

MONITOR

ZERO CROSSBACK-EMF SENSE

BOARDID BLOCK

3-PHASE ACSIGNALSTO/FROMCONTROL

BOARD

POWER MODULE

DRIVERS MOTORTO


20 Operational Description MOTOROLA For More Information On This Product,


Operational DescriptionElectrical Characteristics

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2.3 Electrical Characteristics

The electrical characteristics in Table 2-1 apply to operation at 25°C with a160-Vdc power supply voltage.

Table 2-1. Electrical Characteristics

Characteristic Symbol Min Typ Max Units

dc input voltage Vdc 140 160 230 V

ac input voltage Vac 100 208 240 V

Quiescent current ICC — 70 — mA

Min logic 1 input voltage VIH 2.0 — — V

Max logic 0 input voltage VIL — — 0.8 V

Input resistance RIn — 10 kΩ —

Analog output range VOut 0 — 3.3 V

Bus current sense voltage ISense — 563 — mV/A

Bus voltage sense voltage VBus — 8.09 — mV/V

Peak output current IPK — — 2.8 A

Brake resistor dissipation(continuous)

PBK — — 50 W

Brake resistor dissipation(15 sec pk)

PBK(Pk) — — 100 W

Total power dissipation Pdiss — — 85 W





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2.4 Modification for One-Half and Three-Fourths Horsepower

The HV ac power stage can be modified for operation at either one-half orthree-fourths horsepower. To change maximum output power, follow thesesteps:.

1. Remove power and wait until the power-on LED is off.

2. If PFC jumper JP201 is in the PFC position, remove and resolder it intothe no PFC position.

3. Make the resistor value changes shown in Table 2-2. These resistors setcurrent amplifier gains. For one-half and three-fourths horsepower,lower gains allow for higher measured currents and higher overcurrenttrip points.

4. Configure identification coding jumper JP801 with the settings indicatedin Table 2-3. This proceedure allows software to interpret the newanalog values correctly.

Table 2-2. Resistor Values

Resistors1/4 HP

(180 W)

1/2 HP(370 W)

3/4 HP(550 W)

R303, R305, R307, R314, R315, R318,R319, R322

75 kΩ 62 kΩ 56 kΩ

R301, R304, R311, R313, R316, R317,R320, R321

10 kΩ 15 kΩ 16 kΩ

Table 2-3. JP801 Settings

Position1/4 HP

(180 W)

1/2 HP(370 W)

3/4 HP(550 W)

1-2 Open Short Open

3-4 Open Open Short

5-6 Open Open Open

7-8 Open Open Open




Operational DescriptionFuse Replacement

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5. For 550 watts (three-fourths horsepower), it is also necessary to add anaddional 470-µF/400-volt bus capacitor. To install the capacitor, it is firstnecessary to remove PFC inductor L201. Mounting holes for theadditional capacitor are located within L201’s footprint. Note that it isessential to orient the capacitor such that polarity is correct. Positive andnegative connections are indicated by + (plus) and – (minus)silk-screened labels on the board. In addition, the pad for the capacitor’spositive lead is square, and the pad for its negative lead is round.

6. Once these changes have been made, configuration for either one-half orthree-fourths horsepower is complete.

2.5 Fuse Replacement

A fast blow fuse is located on the front right-hand corner of the top board. If thisfuse has to be replaced, follow these steps:

1. Remove power and wait until the power-on LED is off.

2. Remove the fuse’s protective case.

3. Replace the fuse with one of the selections shown in Table 2-4.

4. Replace the protective case.

5. Set the controller’s speed control input to zero RPM.

6. Apply power and resume operation.

Table 2-4. Fuse Ratings

MotorHorsepower

RMS InputCurrent(Amps)

FuseCurrentRating(Amps)

FuseVoltageRating(Volts)

Fuse Type

1/4(180 W)

2.3 2.5 250 Fast blow

1/2(370 W)

4.8 6.3 250 Fast blow

3/4(550 W)

7.1 8 250 Fast blow





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Section 3. Pin Descriptions

3.1 Contents

3.2 Pin-by-Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2.1 Power Input Connector J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2.2 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.3 External Brake Connector J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.4 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2 Pin-by-Pin Descriptions

Inputs and outputs are located on four connectors. Pin descriptions for each ofthese connectors are included in this section.

3.2.1 Power Input Connector J11

The power input connector, labeled J11, is located on the front edge of theboard. It will accept dc voltages from 140 to 230 volts or an isolated ac lineinput from 100 to 240 volts. In either case, the power source should be capableof supplying at least 200 watts.


MOTOROLA Pin Descriptions 25 For More Information On This Product,


Pin Descriptions

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3.2.2 Motor Output Connector J13

Power outputs to the motor are located on connector J11. Phase outputs arelabeled Ph_A, Ph_B, and Ph_C. Pin assignments are described in Table 3-1.

3.2.3 External Brake Connector J12

An optional external brake resistor can be connected to external brake connectorJ12, labeled Ext. Brake. The external resistor allows power dissipation toincrease beyond the 50 watts that brake resistors R6–R9 provide.

Table 3-1. Connector J13 Signal Descriptions

PinNo.

Signal Name Description

1 Ph_A

Ph_A supplies power to motor phase A. On an induction motor, any one of thethree phase windings can be connected here. For brushless dc motors it isimportant to connect the wire color coded for phase A into the connector terminallabeled Ph_A, and so on for phase B and phase C.

2 Ph_B

Ph_B supplies power to motor phase B. On an induction motor, any one of thethree phase windings can be connected here. For brushless dc motors it isimportant to connect the wire color coded for phase B into the connector terminallabeled Ph_B, and so on for phase A and phase C.

3 Ph_C

Ph_C supplies power to motor phase C. On an induction motor, any one of thethree phase windings can be connected here. For brushless dc motors it isimportant to connect the wire color coded for phase C into the connector terminallabeled Ph_C, and so on for phase A and phase B.


26 Pin Descriptions MOTOROLA For More Information On This Product,


Pin DescriptionsPin-by-Pin Descriptions

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3.2.4 40-Pin Ribbon Connector J14

Signal inputs are grouped together on 40-pin ribbon cable connector J14,located on the right side of the board. Pin assignments are shown in Figure 3-1.In this figure, a schematic representation appears on the left, and a physicallayout of the connector appears on the right. The physical view assumes thatthe board is oriented such that its title is read from left to right. Signaldescriptions are listed in Table 3-2.

Figure 3-1. 40-Pin Ribbon Connector J14

40393837363534333231302928272625242322212019181716151413121110987654321

BEMF_sense_CBEMF_sense_BBEMF_sense_A

ShieldingZero_cross_CZero_cross_BZero_cross_A

PFC_z_cPFC_inhibitPFC_PWMSerial_Con

Brake_controlShielding

Temp_senseI_sense_CI_sense_BI_sense_A

I_sense_DCBV_sense_DCB

–15V_A+15V_A

GNDAGNDA

+3.3V_A+5V_D+5V_D

GNDGND

PWM_CBShieldingPWM_CTShieldingPWM_BBShieldingPWM_BTShieldingPWM_ABShieldingPWM_AT

SCHEMATIC VIEW

J14

2468

10121416182022242628303234363840

13579111315171921232527293133353739

ShieldingShieldingShieldingShieldingShieldingGND+5V_D+3.3V_AGNDA–15V_AI_sense_DCBI_sense_BTemp_senseShieldingSerial_ConPFC_inhibitZero_cross_AZero_cross_CBEMF_sense_ABEMF_sense_C

PWM_ATPWM_ABPWM_BTPWM_BBPWM_CTPWM_CBGND_PS

+5V_DGNDA

+15V_AV_sense_DCB

I_sense_AI_sense_C

Brake_controlPFC_PWM

PFC_z_cZero_cross_B

ShieldingBEMF_sense_B

PHYSICAL VIEW

CON40




Pin Descriptions

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Table 3-2. Connector J14 Signal Descriptions

PinNo.


1 PWM_ATPWM_AT is the gate drive signal for the top half-bridge of phase A. A logic highturns phase A’s top switch on.

2 Shielding Pin 2 is connected to a shield wire in the ribbon cable and ground on the board.

3 PWM_ABPWM_AB is the gate drive signal for the bottom half-bridge of phase A. A logic highturns phase A’s bottom switch on.


5 PWM_BTPWM_BT is the gate drive signal for the top half-bridge of phase B. A logic highturns phase B’s top switch on.


7 PWM_BBPWM_BB is the gate drive signal for the bottom half-bridge of phase B. A logic highturns phase B’s bottom switch on.


9 PWM_CTPWM_CT is the gate drive signal for the top half-bridge of phase C. A logic highturns phase C’s top switch on.


11 PWM_CBPWM_CB is the gate drive signal for the bottom half-bridge of phase C. A logic highturns phase C’s bottom switch on.

12 GND Digital and power ground

13 GND Digital and power ground, redundant connection

14 +5V digital Digital +5-volt power supply

15 +5V digital Digital +5-volt power supply, redundant connection

16 +3.3V analog Analog +3.3-volt power supply

17 GNDA Analog power supply ground

18 GNDA Analog power supply ground, redundant connection

19 +15V_A Analog +15-volt power supply

20 –15V_A Analog –15-volt power supply

21 V_sense_DCBV_sense_DCB is an analog sense signal that measures dc bus voltage. It is scaledat 8.09 mV per volt of dc bus voltage.

22 I_sense_DCBI_sense_DCB is an analog sense signal that measures dc bus current. It is scaledat 0.563 volts per amp of dc bus current.




Pin DescriptionsPin-by-Pin Descriptions

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23 I_sense_AI_sense_A is an analog sense signal that measures current in phase A. It is scaledat 0.563 volts per amp of dc bus current.

24 I_sense_BI_sense_B is an analog sense signal that measures current in phase B. It is scaledat 0.563 volts per amp of dc bus current.

25 I_sense_CI_sense_C is an analog sense signal that measures current in phase C. It is scaledat 0.563 volts per amp of dc bus current.

26 Temp_sense Temp_sense is an analog sense signal that measures power module temperature.

27 No connection

28 ShieldingPin 28 is connected to a shield wire in the ribbon cable and analog ground on theboard.

29 Brake_control Brake_control is the gate drive signal for the brake IGBT.

30 Serial_ConSerial_Con is an identification signal that lets the controller know which powerstage is present.

31 PFC_PWMPFC_PWM is a digital signal that controls the power factor correction circuit’sswitch.

32 PFC_inhibitPFC_inhibit is a digital output used to enable or disable the power factor correctioncircuit.

33 PFC_z_cPFC_z_c is a digital signal. Its edges represent power line voltage zero crossingevents.

34 Zero_cross_AZero_cross_A is a digital signal used for sensing phase A back-EMF zero crossingevents.

35 Zero_cross_BZero_cross_B is a digital signal used for sensing phase B back-EMF zero crossingevents.

36 Zero_cross_CZero_cross_C is a digital signal used for sensing phase C back-EMF zero crossingevents.

37 ShieldingPin 37 is connected to a shield wire in the ribbon cable and analog ground on theboard.

38 BEMF_sense_ABEMF_sense_A is an analog sense signal that measures phase A back EMF. It isscaled at 8.09 mV per volt of dc bus voltage.

39 BEMF_sense_BBEMF_sense_B is an analog sense signal that measures phase B back EMF. It isscaled at 8.09 mV per volt of dc bus voltage.

40 BEMF_sense_CBEMF_sense_A is an analog sense signal that measures phase C back EMF. It isscaled at 8.09 mV per volt of dc bus voltage.

Table 3-2. Connector J14 Signal Descriptions (Continued)

PinNo.





Pin Descriptions

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Section 4. Schematics and Parts List

4.1 Contents

4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2 Mechanical Characteristics

Mechanically, the high-voltage (HV) power stage consists of an FR-4 circuitboard, a 3.2-mm aluminum circuit board, two fans, a fan bracket, a heat sink,inter-board connectors, and standoffs. Construction is depicted in Figure 1-2.3-Phase ac BLDC High-Voltage Power Stage. The aluminum circuit board,fans, and heat sink provide thermal capability for surface-mounted powercomponents. The FR-4 board contains control circuitry and through-holemounted power components. The two boards plug together via 10 verticalconnectors to, in effect, form a discrete power module.

Four holes on the top board are spaced to allow mounting standoffs such that acontrol board can be placed on top of the power stage. This configuration allowsmounting control and power functions in one compact mechanical assembly.

4.3 Schematics

A set of schematics for the HV ac power stage appears in Figure 4-1 throughFigure 4-8. An overview of the board appears in Figure 4-1. H-bridge gatedrive is shown in Figure 4-2. The 3-phase H-bridge appears in Figure 4-3.Current and temperature feedback circuits are shown in Figure 4-4. Back EMFfeedback circuitry appears in Figure 4-5. Power factor correction and brakegate drives are shown in Figure 4-6. An on-board power supply appears inFigure 4-7, and finally the identification block is shown in Figure 4-8. Unlessotherwise specified, resistors are 1/8 watt, have a ±5% tolerance, and havevalues shown in ohms. Interrupted lines coded with the same letters areelectrically connected.


MOTOROLA Schematics and Parts List 31 For More Information On This Product,


Figu

re 4

-1.

3 Ph

ase

AC B

LDC

Hig

h Vo

ltage

Pow

er S

tage

Ove

rvie

w

Shielding

PWM_AB

I_sense_C

PWM_BB

I_sense_A

Serial_Con

I_sense_B

Shielding

BEMF_sense_A

PWM_BT

BEMF_sense_C

Brake_control

Shielding

PWM_CT

Sheilding

Shielding

Temp_sense

PWM_AT

Shielding

Shielding

Zero_cross_B

BEMF_sense_B

PFC_PWM

Zero_cross_C

+5V_

D

PWM_CB

I_sense_DCB

V_sense_DCB

GN

D

Zero_cross_A

PFC_enable

PFC_z_c

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e ut

GN

DA

Tem

p_se

nse_

2

+3.3

V_A

GN

D

J13

1 2 3

-15V

_A

+15V

_D

AN

AN2

2

Phas

e_C

Brak

e

+15V

_A

Tem

p_se

nse_

2

J9 CO

N/E 1

234

GN

DA

J7 CO

N/C

1

456

I_T_

Proc

essi

ng

I_sense_DCB1I_sense_DCB2

I_sense_A1I_sense_A2

I_sense_B1I_sense_B2

I_sense_C1I_sense_C2

GN

DA

I_se

nse_

DC

BI_

sens

e_A

I_se

nse_

BI_

sens

e_C

Tem

p_se

nse_

1Te

mp_

sens

e_2

Tem

p_se

nse

+3.3

V_A

Shut

_Dow

n_O

pen

C.

+15V

_D

GN

D

J3 CO

N/B

1

3456

2

+15V

_D

GN

D

J15

GN

DA

Back_EMF

V_sense_DCB_half_15

BEM

F_se

nse_

ABE

MF_

sens

e_B

BEM

F_se

nse_

C

Zero

_cro

s_A

Zero

_cro

s_B

Zero

_cro

s_C

Phase_APhase_BPhase_C

+15V_D

GNDGNDA

+5V_D

+15V

_D

GN

DA

J14 12345678910111213141516171819202122232425262728293031323334353637383940

GN

DA

Phas

e_B

-FAN

100n

F

+5V_

D

AN

AN1

2 +3.3

V_A

-FAN

J1 CO

N/A

1234

9101112

17181920

J5 CO

N/C 1

456

+5V_

D

J10

CO

N/B 1

3456

2

i

Mot

orTe

rmin

als

J6 CO

N/C

1

456

GN

D

GN

D

GN

DA

GN

D

J2 CO

N/A

1234

9101112

17181920

J8 CO

N/E

1234

SMPS

GND

GNDA

+5V_D

+15V_D

+3.3V_A

+15V_A-15V_A

Power_pos

Power_neg

-FAN+FAN

+5V_

D

+15V

_A

100n

F

+15V

_D

GN

D

Earth

Gro

und

Iden

tific

atio

n

+5V_

D

GN

D

Iden

tific

atio

n

GN

DA

12

Phas

e_A

PFC_DC_BUS_BRAKE

PFC_PWM

PFC_z_cPFC_enable

PFC_I_sense_1

DCB_PFC_1DCB_PFC_2

GND

+15V_D+5V_D

+15V_A

GNDA

PFC_Source

Brake_control

DCB_Cap_neg

Brake_gate

V_sense_DCB_5V_sense_DCB_half_15

DCB_Cap_pos

PFC_gate

Earth

_GN

D

+3.3

V_A

+15V

_D

HV_

Driv

ers

Gate_ATG

ate_

AB

Gate_BT

Gat

e_BB

Gate_CT

Gat

e_C

B

PWM

_AT

PWM

_AB

PWM

_BT

PWM

_BB

PWM

_CT

PWM

_CB

GND

+15V_D

Sour

ce_C

B

Sour

ce_B

B

Sour

ce_A

B

Source_BT+5V_D

Shut_DownSource_CT

Source_AT

POW

ERM

ODU

LE

+15V

_A

GN

DA

+5V_

D

J4 CO

N/C

1

456

-15V

_A+5

V_D

+FAN

J12

1 2

Lin

InpF F

1

D1

V14E

250C2

F F

1

+FAN R

1R

/ivar

SG

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J11

Fast

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F12.

5A/2

50V



Figu

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Gat

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rive

251B

T1

Sour

ce_B

B

Gat

e_C

B

251B

T1

Gat

e_BB

251B

T1

Sour

ce_C

B

Gat

e_C

T

Gat

e_AB

Sour

ce_C

T

251B

T1

251B

T1

Sour

ce_A

T

Gat

e_AT

Gat

e_BT

Sour

ce_B

T

251B

T1

Sour

ce_A

B

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GN

D

GN

D

GN

D

D

GN

D

D40

2M

BRS1

30LT

3

D41

5M

MSZ

5

+5V_

D

C42

31n

F

C41

147

0nF/

50V

U40

4ED

M74

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1110

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D40

5M

MSZ

5

GN

D

D40

3M

MSZ

5

R40

212

0

+15V

_D

+5V_

D

GN

D

+C

417

33uF

/25V

D40

1M

BRS1

30LT

3

R40

810

k

C42

11n

F

+15V

_D

C40

347

0nF/

50V

R41

110

k

C41

48.

2pF

+C

416

33uF

/25V

VCC

GN

D

+5V_

D

+C

418

33uF

/25V

R40

710

k

C40

447

0nF/

50V

C42

21n

F +5V_

D

+15V

_D

GN

DU

404B

DM

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S103

4M

34

R41

3

100

D40

7M

MSZ

5

C42

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F

D41

2M

MSZ

5

C40

110

0nF

+

C40

64.

7uF/

16V

+5V_

D

C41

247

0nF/

50V

_D

C41

38.

2pF

+

C41

04.

7uF/

16V

GN

D

+5V_

D

+

C40

24.

7uF/

16V

C42

41n

FC

415

8.2p

F

C42

510

nF

R40

410

k

U40

4FD

M74

ALS1

034M

1312

R40

912

0

C41

91n

F

R41

012

0

D40

9M

BRS1

30LT

3

R40

112

0

D40

4M

BRS1

30LT

3

GN

D

D41

3M

BRS1

30LT

3

C40

747

0nF/

50V

C40

510

0nF

U40

3

IR21

12S

123456789 10 11 12 13 14 15 16

LOC

OM

VCCn/c

n/c

VSVBHO

n/c

n/c

VDD

HIN

SD LIN

VSS

n/c

D40

6M

BRS1

30LT

3

R40

612

0

C40

847

0nF/

50V

U40

4AD

M74

ALS1

034M

12

_D

+5V_

D

R40

310

k

U40

4CD

M74

ALS1

034M

56

U40

2

IR21

12S

123456789 10 11 12 13 14 15 16

LOC

OM

VCCn/c

n/c

VSVBHO

n/c

n/c

VDD

HIN

SD LIN

VSS

n/c

VCC

+15V

_D

C40

910

0nF

GN

D

D40

8M

BRS1

30LT

3R

405

120

D41

0M

MSZ

5

U40

1

IR21

12S

123456789 10 11 12 13 14 15 16

LOC

OM

VCCn/c

n/c

VSVBHO

n/c

n/c

VDD

HIN

SD LIN

VSS

n/c

U40

4DD

M74

ALS1

034M

98

R41

410

k

+5V_

D

D41

4M

BRS1

30LT

3

D41

1M

BRS1

30LT

3

PWM

_BT

GN

PWM

_BB

PWM

_CT

PWM

_AB

+5V

+15V

PWM

_AT

PWM

_CB



Q5

SKB1

0N60

Q6

SKB1

0N60

_500

_C -

mal

e

6

R3

0.07

5 1

%

F

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Figu

re 4

-3.

3 Ph

ase

H-B

ridge

sense

sense

R5

0.07

5 1

%

sense

sense

R2

0.07

5 1

%

R8

250

DCB_PFC_2

I_sense_A2

Temp_sense2

DC

B_PF

C_1

Brake_Res

Gat

e_C

T

I_sense_B1

Gate_CT

J10

SM/C

ON

/MC

RD

_SR

_500

_B -

mal

e

1

3456

2

Phas

e_C

sense

sense

R4

0.07

5 1

%

Q3

SKB1

0N60

I_sense_C1

J8N

/MC

RD

_SR

_500

_E -

mal

e

1234

Sour

ce_P

FC

Brak

e_R

es

R9

250

I_sense_A1

J1R

D_S

R_5

00_A

- m

ale

9101112

17181920

I_se

nse_

C1

R7

250

Gate_CB

Tem

p_se

nse1

I_Sense_PFC1

D8

10ET

S08S

Gat

e_C

BG

ate_

PFC

I_Sense_DCB1

I_Se

nse_

PFC

1

Source_AB

Phase_C

D10

10ET

S08S

Phas

e_A

Gate_BB

I_se

nse_

B1

Phase_B

DC

B_C

ap_N

eg

Tem

p_se

nse2

sense

sense

R1

0.07

5 1

%

D12

HFA

08TB

60S

J4SM

/CO

N/M

CR

D_S

R_5

00_C

- m

ale

1

456

Gate_AT

J2SM

/CO

N/M

CR

D_S

R_5

00_A

- m

ale

1234

9101112

17181920

D11

HFA

08TB

60S

Q4

SKB1

0N60

D13 BA

V99L

T1Gate_PFC

I_se

nse_

C2

I_se

nse_

A2

J5SM

/CO

N/M

CR

D_S

R_5

00_C

- m

ale

1

456

DCB_Cap_Neg

Gate_Brake

Q8

MTB

8N50

E

Gat

e_AB

I_sense_C2

J6SM

/CO

N/M

CR

D_S

R_5

00_C

- m

ale

1

456

Gat

e_AT

Source_PFC

J3SM

/CO

N/M

CR

D_S

R_5

00_B

- m

ale

1

3456

2

Sour

ce_A

B

Temp_sense1

Phas

e_B

DC

B_C

ap_P

os

Phase_A

Q2

SKB1

0N60

Gate_BT

Source_BB

Gat

e_BT

Gat

e_BB

Gat

e_Br

ake

AC_IN_L1

I_Se

nse_

PFC

2

Q7

SGB1

0N60

I_Se

nse_

DC

B1

I_Sense_DCB2

Gate_AB

I_sense_B2

J9SM

/CO

N/M

CR

D_S

R_5

00_E

- m

ale

1234

Source_CB

I_se

nse_

B2

I_Sense_PFC2

I_se

nse_

A1

Q1

SKB1

0N60

J7SM

/CO

N/M

CR

D_S

R

1

45

Sour

ce_B

B

R6

250

DCB_Cap_Pos

sense

sense

Sour

ce_C

B

I_Se

nse_

DC

B2

D14 BA

V99L

T1

AC_IN_L2

DC

B_PF

C_2

D7

10ET

S08S

SM/C

O

SM/C

ON

/MC

1234DCB_PFC_1

AC_I

N_L

2

AC_I

N_L

1

D9

10ET

S08S



Figu

re 4

-4.

Cur

rent

& T

empe

ratu

re F

eedb

ack

Tem

p_se

nse

B I_se

nse_

DC

B

pen

C.

@ +

/- Im

ax)

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

R31

475

k-1%

R32

410

0k-1

%

Tem

p_se

nse_

2

R31

610

k-1%

R31

110

k-1%

A

GN

D

DC B

us C

urre

ntSe

nsin

g

C30

368

0pF

I_se

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DC

B2

I_se

nse_

A

R31

047

0

R30

81.

2k

I_se

nse_

C

C30

210

nF

R31

875

k-1%

R32

533

.2k-

1%

Phas

e Cu

rren

tSe

nsin

g

R31

210

k

+ -

U30

3A

LM39

3D

3 21

8 4

R30

668

0k

+3.3

V_A

(1.6

5V +

/- 1.

65V

@ +

/- Im

ax)

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2

2.21

k-1%

R30

91.

2k

+-

U30

1BM

C33

502D

567

U30

4LM

285M

8

5

4

1.65V ref

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510

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775

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+-

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1AM

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84

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p_se

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1

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nse_

DC

+-

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f

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R31

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R31

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375

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A (1.6

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/- 1.

65V

@ +

/- Im

ax)

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Ove

r-cur

rent

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ctio

n

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110

k-1%

R30

410

k-1%

GN

D

R31

710

k-1%

+15V

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I_se

nse_

DC

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Tem

pera

ture

Sens

ing

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D

1.65V ref

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GN

DA

GN

DA

GN

DA

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110

k-1%

C30

410

0nF(1

.65V

+/-

1.65

V @

+/-

Imax

)

+

C30

63.

3uF/

10V

GN

D

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GN

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Shut

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n_O

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3B

LM39

3D

5 67

8 4

GN

DA

(1.6

5V +

/- 1.

65V

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339

0

R31

310

k-1%

R30

575

k-1%

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502D

321

84

C30

110

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GN

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+15V

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nse_

B2

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nse_

A1

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710

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nse_

C1



Figu

re 4

-5.

Bac

k EM

F Si

gnal

s

GN

DA+1

5V_D

+5V_

D

U50

1DLM

339D

13

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D

F

ree

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le S

em

ico

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uc

tor,

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.

+ -U

501B

LM33

9D

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521

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6

0

R50

227

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421

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%

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210

pF

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81k-

1%

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221

5k-1

%

GN

D

R51

937

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%

R50

1

324k

-1%

BEM

F_se

nse_

B(3

.24V

@ P

hase

_B =

400

V)

GN

DA

C50

3

10nF

GN

D

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LM33

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3 12

V @

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Zero

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GN

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021

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0V @

Vbu

s =

400V

)

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Zero

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510

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7

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522

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11 10

GN

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410

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k

BEM

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721

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e_A

(3.2

4

Phas

e_C (400

V m

BEM

F_

(400

V m

ax)

Phas

e_B

(400

V m

ax)



Figu

re 4

-6.

Pow

er F

acto

r Cor

rect

ion

& B

rake

Gat

e D

rives

FC_g

ate

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e

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ree

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+

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210

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P

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470u

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5

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9

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C

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GN

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k

Zero

Cro

ssin

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etec

tion

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1

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527

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%

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35V

@ V

bus

= 40

0V)

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1

6.8n

F

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k

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F

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k

R21

72.

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510

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R21

627

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5251

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GN

D

DC

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84.

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712

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GN

D

L201

4.9m

H/2

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R20

210

k

GN

D

R20

368

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PFC

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ense

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Sw

itch

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utB

InB

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NC

NC

Out

A

VCC

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MC

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3

5

6

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P

PFC

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ion:

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410

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12 1311

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9

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0

33

+ -

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l

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ND

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os

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D

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DC

B_C

ap_n

eg

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M

GN

DA

DC

B_PF

C_1

GN

D

Earth

_GN

D

PFC

_ena

ble



Figu

re 4

-7.

Pow

er S

uppl

y

C11

410

0nF

-15V

_A

+3.3

V_A

+15V

_A GN

DA

GN

DA

+C

104

10uF

/6.3

V

0530

T1

C11

010

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F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

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2

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I

3

1

2

Dra

in

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trol

Sour

ce

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6M

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3

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C10

510

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86.

8

+ C12

933

uF/2

5V

R11

533

0

C11

210

0nF

+

C10

222

0uF/

10V

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C78

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CD

81

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VOU

T3

67

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107

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/25V

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410

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500V

GN

D

U10

1TL

431B

CD

1

8

23

76

FB

D10

8M

MSZ

5231

BT1

GN

D

U10

3TN

Y254

P

7

4

8

5

2

3

1

6

SEN SDra

in

S SBP

S

R10

1

1.0k

R11

41.

0k

U11

0M

C78

PC33

NTR

1

2

3

5Vi

n

GND

-CE

Vout

FB

U10

0SF

H61

06

14

23 C

125

1nF/

1kV

R10

427

0

+C

117

47uF

/16V

+15V

_D

GN

D

R10

62.

21k-

1%

D11

0M

BR05

30T1

-FAN

R10

92.

21k-

1%

+C

108

33uF

/25V

+5V_

D

T101

SM/T

rafo

_EFD

15/1

2PIN

1 2

10 89

53 4

76

1112

+

C10

122

0uF/

10V

+17V

_D

T100

SM/T

rafo

_EFD

20/1

2PIN

1 2

10 89

53 4

76

1112

-15V

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C12

610

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+15V

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06

14

23

R10

31.

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0

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B200

AT3

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4

MBR

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D10

5

MBR

S110

0T3

GN

D

D10

2

MU

RS1

60T3

D11

1M

BR05

30T1

GN

D

D10

3

MBR

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R11

227

R11

127

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T

3

4

1

GN

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GC

101

Gro

und_

Con

nect

ion

+

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333

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GN

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C78

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CD

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+

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322

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810

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D

GN

D

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010

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122

100u

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1.0k

Pow

er_p

os

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D

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610

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21.

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er_p

osD

109

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7M

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CD

5

21

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nd

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Vout

Vin

Vin

Vin

GN

D

pos

+

C11

133

uF/2

5V

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7M

MSZ

5242

BT1

R11

327

+FAN

R10

5

820

+17V

_D

R11

027

C10

9

100n

F

GN

DA

GN

D

D11

3

GR

EEN

LED

C12

310

0nF

+3.3

V_A

GN

DA

GN

D

+15V

_D

Pow

er_p

os

+5V_

D

-15V

_A Pow

er_

Pow

er_n

eg

+15V

_A +FAN

-FAN



Figu

re 4

-8.

Iden

tific

atio

n B

lock

#

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

U80

1M

C68

HC

705J

J7D

W_M

OD

12345678910

20

1918 17161514131211

PB1/

AN1

PB2/

AN2

PB3/

TCAP

PB4/

TCM

PPB

5PB

6PB

7

PA5

PA4

PA3

PB0

VCC

GN

D

OSC

1O

SC2

RES

ETIR

Q

PA0

PA1

PA2

+5V_

D

X801

4MH

z

0 Coding bit #

C80

210

nF

+5V_

D

ntifi

catio

n

+5V_

D

DEFA

ULT

SETT

ING

S:0

- PTB

0 =

H1

- PTB

1 =

H2

- PTB

2 =

H3

- PTB

3 =

H4

- PTB

4 =

H5

- PTB

5 =

H6

- PTA

6 =

H7

- PTA

7 =

H

R80

210

k

R80

110

k

R80

310

k

+C

801

10uF

/6.3

V

GN

D

JP80

1

SM/J

UM

PER

4x2

12

34

56

78

GN

D

Coding bit

7 6 5 4

+5V_

D

+5V_

D

R80

410

kR

805

10k

GN

D

GN

D

+5V_

D

+5V_

D

3 2 1 Coding bit #

GN

D

Ide



Schematics and Parts List

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

4.4 Parts Lists

The HV ac power stage’s parts content is described in Table 4-1 for the powersubstrate and in Table 4-2 for the printed circuit board.

Table 4-1. Power Substrate Parts List

Designators Qty Description Manufacturer Part Number

D7, D8, D9,D10

4 10 A/800 V rectifierInternationalRectifier

10ETS08S

D11, D12 2 8 A/600 V ultrafast rectifierInternationalRectifier

HFA08TB60S

D13, D14 2 Dual diode — temp sensingONSemiconductor

BAV99LT1

J1, J2 2 SM/CON/MCRD_SR_500_A - maleFisherElektronik

SL 11 SMD 104 20Z

J3, J10 2 SM/CON/MCRD_SR_500_B - maleFisherElektronik

SL 10 SMD 104 6Z

J4, J5, J6, J7 4 SM/CON/MCRD_SR_500_C - maleFisherElektronik

SL 10 SMD 104 6Z

J8, J9 2 SM/CON/MCRD_SR_500_E - maleFisherElektronik

SL 10 SMD 104 4Z

Q1, Q2, Q3,Q4, Q5, Q6

6 10 A/600 V co-packaged IGBT Infineon SKB10N60

Q7 1 10 A/600 V IGBT Infineon SGB10N60

Q8 1 8 A/500 V MOSFETONSemiconductor

MTB8N50E

R1, R2, R3,R4, R5

5 0.075 Ω 1% Isabellenhutte PMA-A-R075-1

R6, R7, R8,R9

4 250 Ω CaddockElectronics

MP725-250-5.0%

1 Power substrate CUBE 46615770


40 Schematics and Parts List MOTOROLA For More Information On This Product,


Schematics and Parts ListParts Lists

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

Table 4-2. Printed Circuit Board Parts List (Sheet 1 of 5)


C1, C2, C105, C109, C110,C112, C114, C116, C123,C126, C127, C203, C301,C304, C305, C307, C401,C405, C409

19 100 nF/25 V Vitramon VJ0805U104MXXA_

C100 1 10 pF/500 V Vishay Sprague Typ:5GAQ10, Serie: 562C

C101, C102, C103 3 220 µF/10 V AVX TPSE227K010R0100

C104,C128,C801 3 10 µF/6.3 V Sprague 293D106X_6R3B2_

C107, C108, C111, C113,C129, C416, C417, C418

8 33 µF/25 V AVX TPSE336K025R0200

C117 1 47 µF/16 V Any available

C122 1 100 µF/16 V AVX TPSE107K016R0100

C204, C206, C302, C425,C503, C506, C802

7 10 nF/25 V Vitramon VJ0805U103MXXA_

C124 3 100 pF/500 V Vishay Sprague Typ:5GAT10, Serie: 562C

C125 1 1 nF/1 kV muRata DE0505E102Z1K

C201 1 6.8 nF Vitramon VJ0805A682JXA_

C202 1 10 µF/35 V Sprague 293D106X_035D2_

C205, C207 2 22 nF Vitramon VJ0805A223JXA_

C208 1 22 nF/630 Vdc WIMA MKP10

C209 1 470 µF/400 VPhilipsComponents

15746471

C211, C212, C419, C420,C421, C422, C423, C424

8 1 nF Vitramon VJ0805A102JXA_

C213, C214 2 10 nF/ 3000 V Thomson 5ST410MCMCA

C303 1 680 pF Vitramon VJ0805A681JXA_

C306 1 3.3 µF/10 V Sprague 293D335X_010A2_

C402, C406, C410 3 4.7 µF/16 V Sprague 293D475X_016B2_

C403, C404, C407, C408,C411, C412

6 470 nF/50 V Vitramon VJ1206U474MXAA_

C413, C414, C415 3 8.2 pF Vitramon VJ0805A8R2DXA_

C505 1 22 pF Vitramon VJ0805A220DXA_





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D1 1 V14E250 EPCOS SOIV-S-10K250

D100 1 Transient suppressorONSemiconductor

P6SMB200AT3

D101 1 6 A/60 V SchottkyONSemiconductor

MBRD660CT

D102, D401, D408, D413 4 1 A/600 V ultrafastONSemiconductor

MURS160T3

D103, D104, D105, D106 4 1 A/100 V SchottkyONSemiconductor

MBRS1100T3

D107 1 12 V/.5 W zenerONSemiconductor

MMSZ5242BT1

D108 1 5.1 V/.5 W zenerONSemiconductor

MMSZ5231BT1

D109, D110, D111, D112 4 0.5 A/30 V SchottkyONSemiconductor

MBR0530T1

D113 1 Green LED Kingbright L-934GT

D201, D202, D403, D405,D407, D410, D412, D415

8 22 V/0.5 W zenerONSemiconductor

MMSZ5251BT1

D203 1 1N4148 Fairchild 1N4148LL-34

D402, D404, D406, D409,D411, D414

6 1 A/30 V SchottkyONSemiconductor

MBRS130LT3

F1 1 Fuse holder MULTICOMP MCHTE15M

JP201 1 Power jumper

JP801 1 4X2 jumper pads

J2, J1 2 20-pin connectorFisherElektronik

BL 2 20Z


BL 1 6Z

J4, J5, J6, J7 4 6-pin connectorFisherElektronik

BL 1 6Z


BL 1 4Z

J11, J12 2 Terminal block Weidmuller LP 7.62/2/90







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J13 1 Terminal block Weidmuller LP 7.62/3/90

J14 1 40-pin connectorFischerElektronik

ASLG40G

L201 1 4.9 mH/2.3 AThompsonTelevisionComponents

SMT4 ref G6982

R1 1 Inrush limiterRhopointComponents

SG190

R100, R101, R102, R103 4 1.0 kΩ Dale CRCW1206-102J

R104 1 270 Ω Dale CRCW0805-271J

R105 1 820 Ω Dale CRCW0805-821J

R106, R109 2 2.21 kΩ –1% Any available

R108 1 56 Ω Any available

R110, R111, R112, R113 4 27 Ω Dale CRCW1206-270J

R114 1 1.0 kΩ Dale CRCW0805-102J

R115 1 330 Ω Dale CRCW0805-331J

R201 1 3.92 kΩ –1% Any available

R202, 214 2 3.3 kΩ Dale CRCW0805-332J

R208, R211, R213, R215,R223, R312, R403, R404,R407, R408, R411, R412,R414, R505, R513, R521,R801, R802R803, R804, R805

21 10 kΩ Dale CRCW0805-103J

R203 1 68.1 –1% Any available

R204, R413 2 100 Ω Dale CRCW0805-101J

R206 1 100 kΩ Dale CRCW0805-104J


R210 1 33 Ω Dale CRCW0805-330J

R212 1 681 Ω –1% Any available

R216 1 270 Ω Dale CRCW0805-274J

R217 1 2.7 kΩ Dale CRCW0805-272J







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R218 1 4.7 kΩ Dale CRCW0805-472J

R219 1 33 kΩ Dale CRCW0805-333J

R220, R221 2 33 kΩ Dale CRCW0805-333J

R222 1 10 kΩ Dale CRCW0805-103J

R224, R225, R227, R502,R510, R519

6 274 kΩ –1% Any available


R228, R230, R508, R516,R524

5 6.81 kΩ–1% Any available

R229 1 255 Ω –1% Any available

R209, R301, R304, R311,R313, R316, R317, R320,R321

9 10 kΩ –1% Dale CRCW0805-103F


R205 1 1 kΩ –1% Dale CRCW0805-102F

R303, R305, R307, R314,R315, R318, R319, R322

8 75 kΩ –1% Dale CRCW0805-753F

R306 1 680 kΩ Dale CRCW0805-684J

R308, R309 2 1.2 kΩ Dale CRCW0805-122J

R310 1 220 Ω Dale CRCW0805-221J

R323 1 390 Ω Dale CRCW0805-391J

R324 1 100 kΩ –1% Dale CRCW0805-104F


R401, R402, R405, R406,R409, R410

6 120 Ω Dale CRCW0805-121J

R501, R509, R517 3 324 kΩ –1% Any available

R504, R512, R520 3 215 kΩ –1% Any available

R506, R514, R522 3 0 Any available

R507, R515, R523 3 21.0 kΩ –1% Any available

T100 1 SMPS transformerTronic Prahas.r.o

TRONIC 99 060 09







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T101 1 SMPS transformerTronic Prahas.r.o

TRONIC 00 003 73

U100, U104 2 Optocoupler Infineon SFH6106-2

U101 1 Voltage referenceONSemiconductor

TL431BCD

U102 1 SMPS controllerPowerIntegration

TOP202YAI

U103 1 SMPS controllerPowerIntegration

TNY254P

U108, U106 2 15 V/.1 A regulatorONSemiconductor

MC78L15ACD

U107 1 – 15 V/0.1 A regulatorONSemiconductor

MC79L15ACD

U110 1 3.3 V/.15 A regulatorONSemiconductor

MC78PC33NTR

U201 1 Quad 2-input NAND gateONSemiconductor

MC74VHCT00AD

U202 1 Dual gate driverONSemiconductor

MC33152D

U203, U303 2 Dual comparatorONSemiconductor

LM393D

U301, U302 2 Dual op ampONSemiconductor

MC33502D

U304 1 Voltage referenceNationalSemiconductor

LM285M

U401, U402, U403 3 Dual gate driverInternationalRectifier

IR2112S

U404 1 Hex non-inverting driver Fairchild DM74ALS1034M

U501 1 Quad comparatorONSemiconductor

LM339D

U801 1 Microcontroller Motorola MC68HC708JJ7CDW

X801 1 4-MHz resonator muRata CSTCC4.00MG







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...


Section 5. Design Considerations

5.1 Contents

5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.10 Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.2 Overview

From a systems point of view, the HV ac power stage fits into an architecturethat is designed for software development. In addition to the hardware that isneeded to run a motor, a variety of feedback signals that facilitate controlalgorithm development and a PFC circuit are provided.

Circuit descriptions for the HV ac power stage appear in 5.3 3-Phase H-Bridgethrough 5.10 Power Factor Correction. One phase leg of the 3-phase H-bridgeis looked at in 5.3 3-Phase H-Bridge. Bus voltage and bus current feedback arediscussed in 5.4 Bus Voltage and Current Feedback. Cycle-by-cycle currentlimiting is highlighted in 5.5 Cycle-by-Cycle Current Limiting. Temperaturesensing is discussed in 5.6 Temperature Sensing. Back-EMF signals appear in5.7 Back EMF Signals. Phase current sensing is discussed in 5.8 PhaseCurrent Sensing. The brake is highlighted in 5.9 Brake, and finally powerfactor correction is discussed in 5.10 Power Factor Correction.


MOTOROLA Design Considerations 47 For More Information On This Product,


Design Considerations

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5.3 3-Phase H-Bridge

The output stage is configured as a 3-phase H-bridge with IGBT outputtransistors. It is simplified considerably by high-voltage integrated gate driversthat have a cycle-by-cycle current limit feature. A schematic that shows onephase is illustrated in Figure 5-1.

At the input, pulldown resistors R403 and R404 set a logic low in the absenceof a signal. Open input pulldown is important, since it is desirable to keep thepower transistors off in case of either a broken connection or absence of poweron the control board. The drive signal is buffered by U404A and U404B. Thispart has a minimum logic 1 input voltage of 2.0 volts and a maximum logic 0input voltage of 0.8 volts, which allows for inputs from either 3.3- or 5-voltlogic. Gate drive is supplied by an international rectifier, IR2112. Undervoltagelockout and cycle-by-cycle current limiting are also provided by the IR2112.Undervoltage lockout is set nominally at 8.4 volts. Current limiting is discussedfurther in 5.5 Cycle-by-Cycle Current Limiting.

One of the more important design decisions in a motor drive is selection of gatedrive impedance for the output transistors. In Figure 5-1, resistor R402, diodeD404, and the IR2112’s nominal 500-mA current sinking capability determinegate drive impedance for the lower half-bridge transistor. A similar network isused on the upper half-bridge. These networks set turn-on gate drive impedanceat approximately 120 ohms and turn-off gate drive to approximately 500 mA.These values produce transition times of approximately 200 ns.

Transition times of this length represent a carefully weighed compromisebetween power dissipation and noise generation. Generally, transition timeslonger than 250 ns tend to get power hungry at non-audible PWM rates; andtransition times under 50 ns create di/dt’s so large that proper operation isdifficult to achieve. The HV ac power stage is designed with switching times atthe higher end of this range to minimize noise.

Anti-parallel diode softness is also a first order design consideration. If theanti-parallel diodes in an off-line motor drive are allowed to snap, the resultingdi/dt’s can cause noise management problems that are difficult to solve. Ingeneral, it is desirable to have peak to zero di/dt approximately equal the applieddi/dt that is used to turn the anti-parallel diodes off. The SKB10N60 IGBT’sthat are used in this design are targeted at this kind of reverse recoverycharacteristic.


48 Design Considerations MOTOROLA For More Information On This Product,


Q2

SKB1

0N60

R1

0.07

5 1

%

Q1

SKB1

0N60

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.

C42

01n

F

R40

112

0

GN

D

U40

4AD

M74

ALS1

034M

12

I_Se

nse_

DC

B2

+5V_

D

R41

410

k

R41

3

100

D40

2M

BRS1

30LT

3

I_se

nse_

A1

C41

38.

2pF

+5V_

D

I_se

nse_

A2

R40

410

k

D40

5M

MSZ

5251

BT1

C40

110

0nF

R40

212

0

R40

310

k

C40

447

0nF/

50VC

403

470n

F/50

V

D40

1M

BRS1

30LT

3

D40

4M

BRS1

30LT

3+

C41

633

uF/2

5V

sense

sense

+

C40

24.

7uF/

16V

+5V_

D

DC

B_C

ap_P

os

U40

1

IR21

12S

123456789 10 11 12 13 14 15 16

LOC

OM

VCCn/c

n/c

VSVBHO

n/c

n/c

VDD

HIN

SD LIN

VSS

n/c

GN

D

D40

3M

MSZ

5251

BT1

C41

91n

F

+15V

_D

GN

DU

404B

DM

74AL

S103

4M

34

Figu

re 5

-1. P

hase

A O

utpu

t

PWM

_AB

PWM

_AT

Shut

_Dow

n




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5.4 Bus Voltage and Current Feedback

Feedback signals proportional to bus voltage and bus current are provided bythe circuitry shown in Figure 5-2. Bus voltage is scaled down by a voltagedivider consisting of R224 –R230.

The values are chosen such that a 400-volt maximum bus voltage correspondsto 3.24 volts 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 R4 in Figure 4-3, and amplified by the circuitin Figure 5-2. This circuit provides a voltage output suitable for sampling withA/D (analog-to-digital) inputs. An MC33502 is used for the differentialamplifier. With R315 = R319 and R316 = R317, the gain is given by:

A = R315/R316

The output voltage is shifted up by 1.65 V to accommodate both positive andnegative current swings. A ±300-mV voltage drop across the sense resistorcorresponds to a measured current range of ±2.93 amps. In addition to providingan A/D input, this signal also is used for cycle-by-cycle current limiting. Adiscussion of cycle-by-cycle current limiting follows in 5.3 3-Phase H-Bridge.




+

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R32533.2k-1%

GNDA

DCB_Cap_pos

I_sense_DCB

GNDA

GNDA

C305100nF

R315 75k-1%

R2286.81k-1%

R324100k-1%

(3.24V @ DC-Bus = 400V)

R227274k-1%

U304LM285M

8

5

4

R229255-1%

(6.60V @ DC-Bus = 400V)

+3.3V_A

R2306.81k-1%

I_sense_DCB2

R316 10k-1%

R225274k-1%

R317 10k-1%

R2264.87k-1%

DC Bus CurrentSensing

GNDA

V_sense_DCB_half_15

GNDAI_sense_DCB

1.65V ref

+

C3063.3uF/10V

R31975k-1%

R224274k-1%

+

-

U302AMC33502D

3

21

84

R323 3903.3V_A

V_sense_DCB

DC Bus VoltageSensing

C307100nF

I_sense_DCB1

Figure 5-2. Bus Feedback




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5.5 Cycle-by-Cycle Current Limiting

Cycle-by-cycle current limiting is provided by the circuitry illustrated in

Figure 5-3. Bus current feedback signal, I_sense_DCB, is filtered with R308

and C303 to remove spikes, and then compared to a 3.15-volt reference with

U303B. The open collector output of U303B is pulled up by R414. Additional

filtering is provided by C413, C414, and C415. The resulting signal is fed into

the IR2112 gate driver’s shutdown input on all three phases. Therefore, when

bus current exceeds 2.69 amps, all six output transistors are switched off.

The IR2112’s shutdown input is buffered by RS latches for both top and bot-

tom gate drives. Once a shutdown signal is received, the latches hold the gate

drive off for each output transistor, until that transistor’s gate drive signal is

switched low, and then is turned on again. Hence, current limiting occurs on a

cycle-by-cycle basis.




Design ConsiderationsCycle-by-Cycle Current Limiting

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Figure 5-3. Cycle-by-Cycle Current Limiting

I_sense_DCBR3081.2 kΩ

C303680 pF

GNDA

GNDA

GND

R3091.2 kΩ

R310470 Ω R312

10 kΩ

+3.3V_A

R306 680 kΩ

4

5

67

LM393D

U303B

+15V_D

PWM B TOP

PWM B BOTTOM

PWM A TOP

PWM A BOTTOM

PWM C TOP

PWM C BOTTOM

R41410 kΩ

100 Ω

R413

+5V_D

+5V_D

+5V_D

+5V_D

U401

U402

U403

B TOP OUT

A TOP OUT

C TOP OUT

A BOTTOM OUT

B BOTTOM OUT

C BOTTOM OUT

IR2112S

IR2112S

IR2112S

910111213141516

N/CN/CVDDHINSDLINVSSN/C

87654321

HOVBVS

N/CN/C

VCCCOM

LO

910111213141516


87654321

HOVBVS

N/CN/C

VCCCOM

LO

910111213141516


87654321

C413 8.2 pF

C414 8.2 pF

C415 8.2 pF

+

–

8

HOVBVS

N/CN/C

VCCCOM

LO





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5.6 Temperature Sensing

Cycle-by-cycle current limiting keeps average bus current within safe limits.Current limiting by itself, however, does not necessarily ensure that a powerstage is operating within safe thermal limits. For thermal protection, the circuitin Figure 5-4 is used. It consists of four diodes connected in series, a biasresistor, and a noise suppression capacitor. The four diodes have a combinedtemperature coefficient of 8.8 mV/°C. The resulting signal, Temp_sense, is fedback to an A/D input where software can be used to set safe operating limits.

Due to unit-to-unit variations in diode forward voltage, it is highly desirable tocalibrate this signal. To do so, a value for Temp_sense is read at a knowntemperature and then stored in nonvolatile memory. The measured value, ratherthan the nominal value, is then used as a reference point for further readings.

Figure 5-4. Temperature Sensing

R3022.2 kΩ –1%

C301100 nF

BAV99LT1

D14

PIN 26, CONNECTOR J14

+3.3V_A

BAV99LT1

D13

Temp_sense

GNDA




Design ConsiderationsBack EMF Signals

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5.7 Back EMF Signals

Back EMF and zero crossing signals are included to support sensorlessalgorithms for brushless dc motors and dead time distortion correction for acinduction motors. Referring to Figure 5-5, which shows circuitry for phase A,the raw phase voltage is scaled down by a voltage divider consisting of R501,R502, R504, R507, and R508. One output from this divider produces back EMFsense voltage BEMF_sense_A. Resistor values are chosen such that a 400-voltmaximum phase voltage corresponds to a 3.24-volt maximum A/D input. Azero crossing signal is obtained by comparing motor phase voltage withone-half the motor bus voltage. Comparator U501C performs this function,producing zero crossing signal Zero_cross_A.

Figure 5-5. Phase A Back EMF

+5V_D

U501CLM339D

Zero_cross_A

R50510 kΩ

149

8

R5060 kΩ

C50522 pF

GNDA

R5086.81 kΩ –1%

V_sense_DCB_half_15

BEMF_sense_A3.24 V @ Phase_A = 400 V

R501324 kΩ –1%

R502274 kΩ –1%

R504215 kΩ –1%

Phase_A

+

–

GNDA

GNDA

C50110 pF

R50721 kΩ –1%





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5.8 Phase Current Sensing

Lower half-bridge sampling resistors provide phase current information for allthree phases. Since these resistors sample current in the lower phase legs, theydo not directly measure phase current. However, given phase voltages for allthree phases, phase current can be constructed mathematically from the lowerphase leg values. This information can be used in vector control algorithms forac induction motors. The measurement circuitry for one phase is shown inFigure 5-6.

Figure 5-6. Phase A Current Sensing

–

+

DCB_Cap_Pos

Gate_AB

Gate_AT

Phase_A

Source_AB

Q1SKB10N60

Q2SKB10N60

R10.075 Ω –1%

sense

sense

R301 10 kΩ –1%

R304 10 kΩ –1%

R303 75 kΩ –1%

5

67

U302BMC33502D

R30575 kΩ –1%

I_Sense_DCB2

+3.3V_AR323 390 Ω 1.65 Vref

C307100 nF

C3063.3 µF/10 V

+

LM285MU304

GNDA

GNDA

R324100 kΩ –1%

R32533 kΩ –1%

I_sense_A

85

4




Design ConsiderationsBrake

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Referencing the sampling resistors to the negative motor rail makes themeasurement circuitry straightforward and inexpensive. Current is sampled byresistor R1, and amplified by differential amplifier U302B. This circuitprovides a voltage output suitable for sampling with A/D inputs. An MC33502is again used for the differential amplifier. With R301 = R302 andR303 = R305, the gain is given by:

A = R303/R301

The output voltage is shifted up by 1.65 V to accommodate both positive andnegative current swings. A ±300-mV voltage drop across the shunt resistorcorresponds to a measured current range of ±2.69 amps.

5.9 Brake

A brake circuit is included to dissipate re-generative motor energy duringperiods of active deceleration or rapid reversal. Under these conditions, motorback EMF adds to the dc bus voltage. Without a means to dissipate excessenergy, an overvoltage condition could easily occur.

The circuit shown in Figure 5-7 connects R6–R9 across the dc bus to dissipateenergy. Q7 is turned on by software when the bus voltage sensing circuit inFigure 5-2 indicates that bus voltage could exceed safe levels. On-board powerresistors R6–R9 will safely dissipate up to 50 watts continuously or up to100 watts for 15 seconds. Additional power dissipation capability can be addedexternally via brake connector J12.





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Figure 5-7. Brake

5.10 Power Factor Correction

A power factor correction (PFC) circuit is included to facilitate development ofsoftware that includes PFC control features. The objective of the PFC hardwareand software is to draw sinusoidal current from the ac line, in an attempt toapproach as closely as possible a unity power factor. Without PFC, current isdrawn from the ac line at the peak of the sine wave, when the ac line voltageexceeds the dc bus voltage. PFC circuitry is illustrated in Figure 5-8.

DCB_Cap_Pos

R6250 Ω

R7250 Ω

R8250 Ω

R9250 Ω

Q7SGB10N60

D11HFA08TB60S

J12

12

R204

100 Ω

D201MMSZ5251BT1

NCNC

OutB

OutAInA

InB

U202VCC6

+15V_DC20210 µF/35 V

C203100 nF

MC33152D

GND GND GND GND

GNDC2121 nF

Brake_control

R20210 kΩ

1

2

4

+

7

8

5

3

GND




Design ConsiderationsPower Factor Correction

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Figure 5-8. PFC Circuitry

Looking toward the top of Figure 5-8, Q8, L201, D12, and the bus capacitorsform a boost power supply. This configuration allows current to be drawn fromthe ac line, when line voltage is lower than the dc bus voltage. Pulse-widthmodulation is controlled by software and augmented by the analog circuitry inthe lower half of Figure 5-8. Voltage feedback is provided by the bus voltagesensing circuit in Figure 5-2. A zero crossing feedback signal, PFC_z_c, is alsoused and is produced by the circuit in Figure 5-9.

+

–

D710ETS08S

D810ETS08S

PFC 4.9 mH/2.3 A

AC_IN_L1

AC_IN_L2

D910ETS08S

D1010ETS08S

I_Sense_PFC1

I_Sense_PFC2

NO PFC3

2

1

JP201PFC JUMPER L201

D12

R50.075 Ω – 1%

R21310 kΩ

D202MMSZ5251BT1

MTB8N50E Q8

HFA08TB60SC21310 nF/

Earth_GND

C21410 nF/

C20822 nF/

+ +C209470 µF/

GND

C210470 µF/

R21033 ΩNCNC VCC

6U202

+15V_D

R206 100 kΩ

GND

GNDGND

InA

InB

OutA

OutB

MC33152D

U201C

MC74VHCT00ADR21110 kΩ

MC74VHCT00AD

89

10

64

5

U201B

R20810 kΩ

+5V_D

C207

10 nF

+15V_D

LM393DU203A

4

2

3

8

7

1

2

4 5

+15V_AR205

R203

68.1 Ω – 1%

R207C201

1 kΩ –1%

22 nFC206

22 nF

GNDAGND

C205

R212680 Ω –1%

R209R201

3.92 kΩ 10 kΩ

12.1 kΩ

MC74VHCT00AD

U201A3

1

2

6.8 nF

R2143.3 kΩ

R21510 kΩ

PFC_I_sense_1

PFC_PWM

PFC_enable

400 V 400 V630 Vdc

3000 V

3000 V

– 1%

–1%

8

1GND

–1%

GND

GND

SEN

SE

SEN

SE

3

(OPTIONAL)





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Figure 5-9. PFC Zero Crossing Feedback

In this circuit, R219, R220, and R221 provide a relatively high impedanceconnection to the rectified line voltage, and form a .32:1 voltage divider withR222. D203 clamps the divided down voltage to approximately 15.7 volts.Comparator U203B then compares this signal to a 11.8-volt reference.Approximately fifty millivolts of hysteresis is added by R216. The result is alogic high at output PFC_z_c when the comparator’s input voltage falls below11.79 volts. This output remains high until 10.84 volts is reached on the nextcycle.

L201

+–

PFC_z_c

R2184.7 kΩ

+5V_D

LM393DU203B

GNDGNDAGNDA

4

6

58

7

33 kΩ 33 kΩ 33 kΩ

R22310 kΩ

R22247 kΩ

R216 270 kΩ

+15V_D

+15V_D+15V_D

R2172.7 kΩD203

SM/1N4148C2111 nF

R219 R220 R221

I_Sense_PFC1

D1010ETS08S

D810ETS08S

D710ETS08S

AC_IN_L1

AC_IN_L1

PFC

NO PFC

DCB_Cap_pos

DCB_PFC_24.9 mH/2.3 A

JP201PFC JUMPER

3

12

D910ETS08S




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MEMC3PBLDCPSUM/D

© Motorola, Inc., 2000

Motorola reserves the right to make changes without further notice to any products herein. Motorola makes no warranty, representation or guarantee regarding the suitability of itsproducts for any particular purpose, nor does Motorola assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability,including without limitation consequential or incidental damages. "Typical" parameters which may be provided in Motorola data sheets and/or specifications can and do vary in differentapplications and actual performance may vary over time. All operating parameters, including "Typicals" must be validated for each customer application by customer's technical experts.Motorola does not convey any license under its patent rights nor the rights of others. Motorola products are not designed, intended, or authorized for use as components in systemsintended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the Motorola product could create asituation where personal injury or death may occur. Should Buyer purchase or use Motorola products for any such unintended or unauthorized application, Buyer shall indemnify and holdMotorola and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of,directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that Motorola was negligent regarding thedesign or manufacture of the part. Motorola and are registered trademarks of Motorola, Inc. Motorola, Inc. is an Equal Opportunity/Affirmative Action Employer.

How to reach us:USA/EUROPE/Locations Not Listed: Motorola Literature Distribution, P.O. Box 5405, Denver, Colorado 80217. 1-303-675-2140

or 1-800-441-2447. Customer Focus Center, 1-800-521-6274JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu, Minato-ku, Tokyo 106-8573 Japan.

81-3-3440-8573ASIA/PACIFIC: Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, 2 Dai King Street, Tai Po Industrial Estate,

Tai Po, N.T., Hong Kong. 852-26668334HOME PAGE: http://motorola.com/semiconductors/

For More Information On This Product, Go to: www.freescale.com

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