UM1036 STMICROELECTRONICS | Alldatasheet
Document overview
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Technical content
Datasheet sections
- 1 System introduction
- 1.1 Main characteristics
- 1.2 Target application
- 1.3 Safety and operating instructions
- 1.3.1 General terms
- 1.3.2 Eevaluation board intended use
- 1.3.3 Evaluation board installation
- 1.3.4 Electrical connections
- 2 Board description
- 2.1 System architecture
- 2.2 Board schematic
- 2.3 Circuit description
- 2.3.1 Power supply
- 2.3.2 Inrush limitation
- 2.3.3 Power block based on IGBT module
- 2.3.4 Brake function
- 2.3.5 Overcurrent protection
- 2.3.6 Current sensing amplifying network
- 2.3.7 The tachometer and Hall/encoder inputs
- 2.3.8 Temperature feedback and overtemperature protection (OTP)
- 2.3.9 Active heatsink cooling
- 3 Hardware setting of the STEVAL-IHM028V2
- 3.1 Hardware settings for six-step (block commutation) current control in single-
- 3.2 Hardware settings for FOC in three-shunt configuration
- 3.3 Hardware settings for FOC in single-shunt configuration
- 4 Testing of the evaluation board
- 5 Description of jumpers, test pins, and connectors
- 6 Connector placement
and assembly costs, together with high reliability due to the design simplicity. 285 VAC or from 125 VDC up to 400 VDC for the DC voltage. Figure 1. STEVAL-IHM028V2
System introduction UM1036
1 System introduction
1.1 Main characteristics
The information listed below shows the converter specification data and the main parameters set for the STEVAL-IHM028V2 evaluation board.
- Minimum input voltage 125 VDC or 90 VAC
- Maximum input voltage 400 VDC or 285 VAC
- With applied input voltage doubler - the range from 65 VAC to 145 VAC
- Maximum output power for applied motor up to 2000 W
- Regenerative brake control feature
- Input inrush limitation with bypassing relay
- +15 V auxiliary power supply based on a buck converter with VIPer™26
- Using IGBT intelligent power module STGIPS20C60 in SDIP 25L molded package
- Fully populated board conception with test points and safety isolated plastic cover
- Motor control connector for interface with STM3210B-EVAL board, STM8/128-EVAL board, and other ST motor control dedicated kits
- Tachometer input
- Hall/encoder inputs
- Overheating protection
- Active fan cooling of heatsink with automatic temperature switch
- Possibility to connect MB843 BLDC daughterboard for sensor-less six-step control
- PCB type and size: – Material of PCB - FR-4 – Double-sided layout – Copper thickness: ~60 μm Total dimensions of evaluation board: 195 mm x 175 mm.
1.2 Target application
- Power fans for HVAC application
- Power tools
- Industrial drives
- High-power industry pumps
- Professional washing machines.
UM1036 System introduction
1.3 Safety and operating instructions
1.3.1 General terms
Warning: During assembly, testing, and normal operation, the evaluation board poses several inherent hazards, including bare wires, moving or rotating parts, and hot surfaces. There is a danger of serious personal injury and damage to property if the kit or components are improperly used or installed incorrectly. The kit is not electrically isolated from the AC/DC input. The evaluation board is directly linked to the mains voltage. No insulation is ensured between the accessible parts and the high voltage. All measuring equipment must be isolated from the mains before powering the board. When using an oscilloscope with the demo, it must be isolated from the AC line. This prevents shock from occurring as a result of touching any single point in the circuit, but does NOT prevent shock when touching two or more points in the circuit. Do not touch the evaluation board after disconnection from the voltage supply; several parts and power terminals, which contain energized capacitors, must be allowed to discharge. All operations involving transportation, installation and use, as well as maintenance, are to be carried out by skilled technical personnel (national accident prevention rules must be observed). For the purpose of these basic safety instructions, “skilled technical personnel” are considered as suitably qualified people who are familiar with the installation, use, and maintenance of power electronic systems.
1.3.2 Eevaluation board intended use
The STEVAL-IHM028V2 evaluation board is designed for evaluation purposes only and must not be used in final applications. The technical data, as well as information concerning the power supply conditions, must only be taken from the relevant documentation and must be strictly observed.
1.3.3 Evaluation board installation
The installation and cooling of the evaluation board must be done in accordance with the specifications and the targeted application.evaluation
- The motor drive converters are 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 must 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.
System introduction UM1036
1.3.4 Electrical connections
Applicable national accident prevention rules must be followed when working on the main power supply. The electrical installation must be carried out in accordance with the appropriate requirements. A system architecture which supplies power to the evaluation board must 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).
2 Board description
2.1 System architecture
- Control block - its main task is to accept user commands and motor drive configuration parameters. It provides all digital signals to implement the proper motor driving strategy. The STM3210B-EVAL evaluation board, based on the STM32 microcontroller can be used as the control block, thanks to the motor control connector equipped on the STEVAL-IHM028V2.
- Power block - it is based on 3-phase inverter topology. The heart of the power block is the STGIPS20C60 integrated intelligent power module which contains all the necessary active components. Please refer to the STGIPS20C60 datasheet for more information.
- Motor - the STEVAL-IHM028V2 evaluation board is able to properly drive any PMSM, but the FOC itself is mostly conceived for sinusoidal shaped back-EMF. The evaluation board is also convenient for driving any 3-phase asynchronous motor.
- Power supply block - able to work from 90 VAC to 285 VAC or from 125 VDC to 400 VDC. The power block is based on a buck converter with a VIPer26 controller. Please refer to Section 3 to properly set the jumpers according to the required application.
Figure 2. Motor control system architecture supply and the power block hardware blocks.
2.2 Board schematic
Figure 3. STEVAL- IHM028V2 schematic - part 1
Figure 4. STEVAL- IHM028V2 schematic - part 2
Figure 5. STEVAL- IHM028V2 schematic - part 3
Figure 6. STEVAL- IHM028V2 schematic - part 4
Figure 7. STEVAL- IHM028V2 schematic - part 5
Figure 8. STEVAL- IHM028V2 schematic - part 6
2.3 Circuit description
2.3.1 Power supply
with various single phases as well as the PFC input stage. a low level of input AC voltage. refer to the VIPer26LD datasheet for more information. The presence of +15 VDC on the board is indicated with the D5 green LED “Power ON”. Figure 9 describes the power supply section with a simplified block diagram. Figure 9. Power supply block diagram
2.3.2 Inrush limitation
The input stage of the evaluation board is provided with an NTC resistor to eliminate input inrush current peak during the charging of the bulk capacitors. To achieve a higher efficiency of the inverter it is possible to bypass the NTC after the start-up phase. The NTC bypass signal is provided from the MCU board through the J2 connector. The yellow D10 LED diode “Current limiter” is turned off when the inrush NTC is bypassed. A basic EMI filter based on X2 and Y2 capacitors was implemented on the board. The EMI filter is not able to absorb EMI distortion coming from the inverter for all ranges of the applications. The final EMI filter must be designed according to the motor and the design of the related EMI filter is up to the user according to the chosen motor and final target application. The heatsink itself is connected to the earth pin in the J1 connector. It is recommended to connect the heatsink to a negative voltage potential - common ground when a DC voltage is used to supply the evaluation board.
2.3.3 Power block based on IGBT module
The IGBT module STGIPS20C60 consists of high, rugged IGBT power switches and three smart drivers. STGIPS20C60 is provided with advanced gate smart drivers, many features are available, such as integrated comparators for overcurrent or short-circuit protection, and the “SMART SHUTDOWN” function. Please refer to the STGIPS20C60 datasheet for more information.
2.3.4 Brake function
A hardware brake feature is implemented on the STEVAL-IHM028V2 evaluationevaluation board. This feature connects the external resistive load, applied to the J7 connector, to the main supply bus to eliminate overvoltage generated while the motor acts as a generator. This connected load must be able to dissipate all motor generated energy. Almost any kind of high power resistor which may be used as dissipative load also has relative high parasitic inductance. Due to such inductance it is important to take care not to damage the brake Q8 IGBT switch with a freewheeling diode applied directly to the terminals of the dissipative power resistor used. Voltage on the bus is sensed through a voltage divider net, with resistors R40, R41, and R48, and is compared to the precise voltage reference U5. The brake dummy load is switched on when the voltage on the bus reaches approximately 435 VDC and is switched off when the voltage falls bellows 415 VDC. This voltage level has been chosen to be fully compliant with the possible use of front-end PFC stage. The brake function can also be activated by the microcontroller through the J2 motor-control connector (PWM_Brake signal). For this configuration, the user should set the W2 jumper to position “A”. The brake threshold levels can be modified by calculating R49 and R51 new values. D13 red LED diode “Brake” indicates the acting brake switch.
2.3.5 Overcurrent protection
Hardware overcurrent protection (OCP) is implemented on the board. This feature takes advantage of STGIPS20C60 intelligent module where an internal comparator is implemented. Thanks to the internal connection between the comparator output and shutdown block of the IPM, the intervention time of overcurrent protection is extremely low, ranging slightly above 200 ns. Please see Figure 10 for details.
Figure 10. Overcurrent protection protected against any overcurrent event.
2.3.6 Current sensing amplifying network
The STEVAL-IHM028V2 motor control evaluation board can be configured to run in various current reading configuration modes:
- Three-shunt configuration - suitable for field oriented control (FOC)
- Single-shunt configuration - suitable for FOC in a single-shunt configuration
- Single-shunt - six-step configuration - suitable for scalar control. Configuration with a shunt resistor, where voltage amplified with an operational amplifier is sensed, was chosen as current sensing networks. Single-shunt configuration requires a single op amp, three-shunt configuration requires three op amps. For compatibility purposes, one of them is common to both basic configurations. The configuration jumpers W11, W12, W13, and W14 allow to set the common op amp to achieve compatibility between single-shunt six-step configuration (suitable for scalar control) and three-shunt or single-shunt FOC current reading configuration. The operational amplifier TSV994 used on amplifying networks has a 20 MHz gain bandwidth and operates with just a single positive supply of +5 V. Three-shunt FOC or single-shunt FOC current reading configuration Details of the FOC current-sensing reading configuration are shown in Figure 11. In this configuration, the alternating signal on the shunt resistor, with positive and negative values, must be converted to be compatible with the single positive input of the microcontroller A-D converter used to read the current value. The op amp is used in symmetrical follower mode: its gain is set by resistors r and R: Equation 2 It is possible to calculate the voltage on the output of the op amp OP OUT - VOUT as a sum of a bias VBIAS and a signal VSIGN component equal to: Equation 3 Total gain of the circuit including the resistor divider is equal to: r r1 R+ LS() r2× G Rr+ VOUT VSIGN VBIAS+= VBIAS 3.3 R3× VSIGN IR HS× R1×
- VBIAS = 1.57 V
- Maximal voltage of VSIGN = 1.56 V
- G = 5.38
- GTOT = 3.90
- Maximum current amplifiable without distortion is 16 A.
Figure 11. Configuration for FOC Table 1 shows the mentioned setting of gain jumpers for both FOC configurations. must be measured, and in this case the amplifying network needs to be properly designed. for the op amp than the one set in three-shunt reading mode. Table 1. Gain settings for FOC current reading configuration
The op amp is used in follower mode with gain of the op amp set by resistors: Equation 5 It is possible to calculate the voltage on the op amp output OP OUT - VOUT as the sum of a bias VBIAS and a signal VSIGN component equal to: Equation 6 Total gain of the circuit with the resistor divider is equal to: Equation 7 With the default values this gives:
- VBIAS = 0.38 V
- Maximal voltage of VSIGN = 2.76 V
- G = 8.02
- GTOT = 6.90
- Maximum current amplifiable without distortion is 16 A. r r1 R LS+() r× 2 G Rr+ VOUT VSIGN VBIAS+= VBIAS 3.3 R3× VSIGN 1R HS× R1× GTOT VSIGN VIN VSIGN
Figure 12. Six-step current sensing configuration Table 2 shows the mentioned setting of gain jumpers for this configuration.
2.3.7 The tachometer and Hall/encoder inputs
using a tachometer, jumper W5 must be disconnected and jumper W4 connected. spectrum of various sensors.
2.3.8 Temperature feedback and overtemperature protection (OTP)
Table 2. Gain settings for six-step current reading configuration
the heatsink is somewhere between 85 °C and 90 °C.
2.3.9 Active heatsink cooling
Figure 13, the thermal resistance with active fan cooling is visible in Figure 14. Figure 13. Thermal resistance of the heatsink
Figure 14. Thermal resistance of the heatsink with continuous fan cooling
3 Hardware setting of the STEVAL-IHM028V2
unit for FOC-driving algorithms.
3.1 Hardware settings for six-st ep (block commutation) current
- The motor control evaluation board is driven by a control board which provides the six output signals required to drive the 3-phase power stage
- The motor is connected to the J4 motor output connector
- If using an encoder or Hall sensor connection, it is connected to connector J5
- If using a tachometer connection, it is connected to connector J6
- If using the brake control feature, connect a dissipative power load to connector J7. Table 3 shows the jumper settings for any motors. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC.
Table 3. Jumper settings for PMSM or generic AC motor - six-step
3.2 Hardware settings for FOC in three-shunt configuration
- The motor control evaluation board is driven by a control board which provides the six output signals required to drive the 3-phase power stage
- The motor is connected to the J4 motor output connector
- If using an encoder or Hall sensor connection, it is connected to connector J5
- If using a tachometer connection, it is connected to connector J6
- If using the brake control feature, connect a dissipative power load to connector J7. Table 4 shows the jumper settings for any motors. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC. W11 Not present W12 Not present W13 Not present W14 Not present W15 Present for voltage doubler (max. 145 VAC) Not present for normal supply range
Table 4. Jumper settings for PMSM or generic AC motor - FOC in three-shunt
3.3 Hardware settings for FOC in single-shunt configuration
- The motor control evaluation board is driven by a control board which provides the six output signals required to drive the 3-phase power stage
- The motor is connected to the J4 motor output connector
- If using an encoder or Hall sensor connection, it is connected to connector J5
- If using a tachometer connection, it is connected to connector J6
- If using the brake control feature, connect a dissipative power load to connector J7. Table 5 shows the jumper settings for any motors. Please confirm that the evaluation board input voltage is in the range of 125 VDC to 400 VDC or 90 VAC to 285 VAC. W11 Present W12 Present W13 Present W14 Present W15 Present for voltage doubler (max. 145 VAC) Not present for normal supply range
Table 5. Jumper settings for PMSM or ge neric AC motor - FOC in single-shunt
UM1036 Testing of the evaluation board
4 Testing of the evaluation board
The overall test of the evaluation board was performed on a motor bench with two kinds of applied PMAC motors. Test conditions are listed below. Parameters for 1st test Motor parameters:
- Manufacturer: Reel S.r.l.
- Type: IB100 F
- Nominal power: 10.7 kW
- 4-pole pairs
- Ls = 0.003465 H; Rs = 0.28 Ω
- Ke = 84 V
- Nominal speed: 3000 rpm Test conditions:
- Supply voltage 325 VAC; frequency 50 Hz
- Testing output power 1.8 kW; testing speed 1000 rpm
- Temperature of ambient 22 °C
- Active fan cooling disabled; plastic covers removed Parameters for 2nd test Motor parameters:
- Manufacturer: DOMEL
- Type: 748.3.292
- Nominal power: 1.6 kW
- 4-pole pairs
- Ls = 0.045 H; Rs = 1.03 Ω
- Ke = 84 V
- Nominal speed: 2250 rpm Test conditions:
- Supply voltage 325 VAC; frequency 50 Hz
- Testing output power 1.6 kW; testing speed 2250 rpm
- Ambient temperature 22 °C
- Active fan cooling disabled; plastic covers removed The STM3210B board was used as the control unit with STM32 FOC firmware library v2.0 loaded. The flux weakening strategy with no sensors was chosen for testing. Three-shunt resistors current sensing technique was selected. All related parameters of the motor were included in the source code via the FOCGUI 2.0.0 application. The duration of the tests was 45 minutes with the mentioned continuous output power measured on the load of the motor testing stand. For correct thermal measurements of the heatsink temperature, the assembled fan was removed together with the plastic covers. Measured parameters, visible in Figure 15, were taken with the type IB100 F motor.
Figure 15. Current signals
- Ch1 - Output phase current, current probe on phase C
Ch4 - voltage on TP22, phase current C.
5 Description of jumpers, test pins, and connectors
Table 6. Jumper description
Table 7. Connector pinout description
Table 8. Testing pins description Table 7. Connector pinout description (continued)
6 Connector placement
A basic description of the placement of all connectors on the board is visible in Figure 16. Figure 16. STEVAL-IHM028V2 connector placement
7 Bill of materials
the active components used are available from STMicroelectronics. Table 9. Bill of materials
1 C5 150 nF / X2 X2 cap; 6 x 15 x 26,5 EPCOS
2 C7, C72 10 nF Capacitor, SMD 0805 Any
1 C16 220 nF Capacitor, SMD 0805 Any
9 C31, C32, C33, C44, C45,
1 C39 470 pF Capacitor, SMD 0805 Any
5 C43, C60, C63, C69, C74 100 pF Capacitor, SMD 0805 Any
6 C46, C47, C48, C49, C50,
2 C57, C71 330 pF Capacitor, SMD 0805 Any
6 C58, C59, C61, C62, C67,
3 R1, R4, R7 100 k Ω Resistor, SMD 1206 Any
3 R53, R57, R61 100 k Ω Resistor, SMD 0805, 1% Any
4 R2, R5, R40, R41 470 k Ω Resistor, SMD 1206 Any
2 R6, R10 120 Ω Resistor, SMD 0805, 1% Any
3 R9, R91, R106 51 k Ω Resistor, SMD 0805, 1% Any
1 R13 160 Ω Resistor, SMD 1206 Any
1 KΩ Resistor, SMD 0805, 1% Any
7 R15, R27, R28, R29, R50,
9 R17, R18, R19, R20, R21,
1 R30 100 Ω Resistor, SMD 0805, 1% Any
8 R32, R98, R77, R83, R84,
4 R33, R49, R51, R114 15 k Ω Resistor, SMD 0805, 1% Any
2 R35, R109 910 Ω Resistor, SMD 0805, 1% Any
2 R47, R96 220 Ω Resistor, SMD 0805, 1% Any
1 R42 560 Ω Resistor, SMD 0805, 1% Any
1 R46 220 k Ω Resistor, SMD 0805, 1% Any
2 R48, R52 27 k Ω Resistor, SMD 0805, 1% Any
Table 9. Bill of materials (continued)
8 R66, R67, R68, R69, R70,
6 R81, R82, R88, R89, R99,
2 R102, R105 3 k Ω Resistor, SMD 0805, 1% Any
1 R107 180 Ω Resistor, SMD 0805, 1% Any
8 D2, D8, D11, D12, D15, D16,
3 D3, D9, D19 1N4148 Diode SMD, MINI-MELF Any
2 D4, D6 STTH1L06A Diode SMD, SMA STM
1 D13 LED Red LED 3 mm, 2 mA, universal Any
1 D7 BZV55C18SMD Zener diode 18 V, MINI-MELF Any
1 D10 LED yellow LED 3 mm, 2 mA, universal Any
1 D5 LED green LED 3 mm, 2 mA, universal Any
1 D14 BZX84B13V Zener diode, SOT23, 13 V; 2% Any
10 Q1, Q2, Q3, Q4, Q5, Q7, Q9,
1 Q6 BC857B PNP transistor, SOT23 Any
1 Q8 STGW35NB60SD TO-247 STM
1 Q13 BC807-25 SMD PNP transistor 45 V / 0,5 A,
1 U1 LF33ABDT-TR Linear regulator DPAK STM
1 U2 VIPer26LD PWM smart driver, SO-16 STM
1 U3 L78M05AB Linear regulator DPAK STM
1 U4 M74HC14R CMOS logic, SO-14 STM
2 U5, U10 TS3431BILT Voltage reference, SOT23 STM
1 U6 TS391ILT Op amp, SOT23-5 STM
1 U7 STGIPS20C60 IPM IGBT module STM
1 U8 TSV994IDT Op amp, SO-14 STM
1 U9 TS372ID Dual comparator, SO-8 STM
1 J2 MLW34G MLW connector 34-pins ARK
1 LS1 Finder 4061 Relay 12 V; 16 A / 250 VAC Finder
2 F1 PA-PZ1008 Fuse holder 10 x 38; 2 pc in one
1 Fuse 16 A, high
1 AIREN red wings
8 PCB layout
was selected. The PCB material is FR-4.
- Length: 195 mm
- Width: 175 mm
- PCB thickness: 1.55 mm
Figure 17. Copper tracks - top side
Figure 18. Copper tracks - bottom side
Figure 19. Silk screen - top side
Figure 20. Silk screen - bottom side
9 Ordering information
The evaluation board is available through the standard ordering system, the ordering code is: STEVAL-IHM028V2. The items delivered include the assembled application board, board documentation, PCB fabrication data, such as gerber files, assembly files (pick and place), and component documentation.
10 Using STEVAL-IHM028V2 with STM32 FOC firmware
STM32 FOC firmware library (UM1052) is a firmware library which allows performing of the FOC of a PMSM in configuration with and without sensors.
10.1 Environmental considerations
Warning: The STEVAL-IHM028V2 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: All measuring 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 to 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 shock 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 can be found in the AN438 application note. (Although this application note was written for a TRIAC, the isolation constraints still apply for switching semiconductor devices such as IGBT or MOSFET). Note: Isolating the application rather than the oscilloscope is highly recommended in any case.
Using STEVAL-IHM028V2 with STM32 FOC firmware library UM1036
10.2 Hardware requirements
To run the STEVAL-IHM028V2 together with the STM32 FOC firmware library, the following is required:
- The board: STEVAL-IHM028V2
- High voltage insulated AC power supply up to 230 VAC
- J-Link programmer - ST Link (not included in the package)
- J-Link insulating board (not included in the package)
- 3-phase brushless motor with permanent magnet rotor (not included in the package)
- Insulated oscilloscope (as required)
- Insulated multimeter (as required).
10.3 Software modifications
The most convenient way to edit the parameters header file is through the use of the ST MC Workbench (PC GUI configuration tool for the STM32 PMSM FOC SDK motor control firmware library.
11 Conclusion
This document describes the 2 kW 3-phase motor control STEVAL-IHM028V2 evaluation board based on IPM as a universal fully-evaluated and adaptable motor control platform.
12 References
- STGIPS20C60 datasheet 2. VIPer26 datasheet 3. STGW35NB60SD datasheet 4. UM0379 user manual 5. UM0580 user manual 6. UM0723 user manual 7. UM0900 user manual
Table 10. Document revision history 13-Jan-2011 1 Initial release. 13-Nov-2014 2 Add new reference product.