Infineon REF-AIRCON-C302A-IM564 User Manual

User guide Please read the Important notice and the Safety precautions and the Warnings V 1.0.1

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REF-AIRCON-C302A-IM564 user guide

Air conditioner application reference design kits

About this document

Scope and purpose

This user guide provides an overview of the reference board REF-AIRCON-C302A-IM564 including its main features, key test results and mechanical dimensions.

The REF-AIRCON-C302A-IM564 is a full-featured starter kit, turnkey motor drive designed for high-performance, high-efficiency permanent magnet synchronous motor (PMSM) drive applications, including all of the required elements for air conditioner applications, such as IMC302A iMOTIONTM controller, 1ED44175 PFC gate driver and PFC-integrated CIPOS

Mini IPM IM564-X6D.

The starter kit features and demonstrates Infineon’s CIPOS

Mini IPM and advanced motion control engine (MCE 2.0) technology for PMSM/BLDC motor and PFC driver up to a rating of 600 V and 20 A. It is optimized for major home appliances like air conditioner compressors, fans, pumps and other motor drive applications.

Note: Please note that this product is not qualified according to the AEC Q100 or AEC Q101 documents of

the Automotive Electronics Council.

Intended audience

This application note is intended for all technical specialists who are familiar with air conditioner control and electronics converters. The reference design is intended to be used under laboratory conditions only by trained specialists.

Reference board

The Infineon products are embedded on this PCB with functions and form factor close to a commercial design. PCB and auxiliary circuits are optimized for the final design.

Note: Boards do not necessarily meet safety, EMI, quality standards (for example UL, CE) requirements.

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Important notice

“Evaluation Boards and Reference Boards” shall mean products embedded on a printed circuit board

(PCB) for demonstration and/or evaluation purposes, which include, without limitation, demonstration, reference and evaluation boards, kits and design (collectively referred to as “Reference Board”).

Environmental conditions have been considered in the design of the Evaluation Boards and Reference Boards provided by Infineon Technologies. The design of the Evaluation Boards and Reference Boards has been tested by Infineon Technologies only as described in this document. The design is not qualified in terms of safety requirements, manufacturing and operation over the entire operating temperature range or lifetime.

The Evaluation Boards and Reference Boards provided by Infineon Technologies are subject to functional testing only under typical load conditions. Evaluation Boards and Reference Boards are not subject to the same procedures as regular products regarding returned material analysis (RMA), process change notification (PCN) and product discontinuation (PD).

Evaluation Boards and Reference Boards are not commercialized products, and are solely intended for evaluation and testing purposes. In particular, they shall not be used for reliability testing or production. The Evaluation Boards and Reference Boards may therefore not comply with CE or similar standards (including but not limited to the EMC Directive 2004/EC/108 and the EMC Act) and may not fulfill other requirements of the country in which they are operated by the customer. The customer shall ensure that all Evaluation Boards and Reference Boards will be handled in a way which is compliant with the relevant requirements and standards of the country in which they are operated.

The Evaluation Boards and Reference Boards as well as the information provided in this document are addressed only to qualified and skilled technical staff, for laboratory usage, and shall be used and managed according to the terms and conditions set forth in this document and in other related documentation supplied with the respective Evaluation Board or Reference Board.

It is the responsibility of the customer’s technical departments to evaluate the suitability of the

Evaluation Boards and Reference Boards for the intended application, and to evaluate the completeness and correctness of the information provided in this document with respect to such application.

The customer is obliged to ensure that the use of the Evaluation Boards and Reference Boards does not cause any harm to persons or third party property. The Evaluation Boards and Reference Boards and any information in this document is provided "as is" and Infineon Technologies disclaims any warranties, express or implied, including but not limited to warranties of non-infringement of third party rights and implied warranties of fitness for any purpose, or for merchantability.

Infineon Technologies shall not be responsible for any damages resulting from the use of the Evaluation Boards and Reference Boards and/or from any information provided in this document. The customer is obliged to defend, indemnify and hold Infineon Technologies harmless from and against any claims or damages arising out of or resulting from any use thereof.

Infineon Technologies reserves the right to modify this document and/or any information provided herein at any time without further notice.

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Safety precautions

Please note the following warnings regarding the hazards associated with development systems.

Table 1 Safety precautions

Warning: The DC link potential of this board is up to 400 VDC. When measuring voltage

waveforms by oscilloscope, high voltage differential probes must be used. Failure to do so may result in personal injury or death.

Warning: The reference board contains DC bus capacitors which take time to discharge after removal of the main supply. Before working on the drive system, wait five minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs are not an indication that capacitors have discharged to safe voltage levels.

Warning: The reference board is connected to the grid input during testing. Hence, high-voltage differential probes must be used when measuring voltage waveforms by oscilloscope. Failure to do so may result in personal injury or death. Darkened display LEDs are not an indication that capacitors have discharged to safe voltage levels.

Warning: Remove or disconnect power from the drive before you disconnect or reconnect wires, or perform maintenance work. Wait five minutes after removing power to discharge the bus capacitors. Do not attempt to service the drive until the bus capacitors have discharged to zero. Failure to do so may result in personal injury or death.

Caution: The heat sink and device surfaces of the reference board may become hot during testing. Hence, necessary precautions are required while handling the board. Failure to comply may cause injury.

Caution: Only personnel familiar with the drive, power electronics and associated machinery should plan, install, commission and subsequently service the system. Failure to comply may result in personal injury and/or equipment damage.

Caution: The reference board contains parts and assemblies sensitive to electrostatic discharge (ESD). Electrostatic control precautions are required when installing, testing, servicing or repairing the assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with electrostatic control procedures, refer to the applicable ESD protection handbooks and guidelines.

Caution: A drive that is incorrectly applied or installed can lead to component damage or reduction in product lifetime. Wiring or application errors such as undersizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction.

Caution: The reference board is shipped with packing materials that need to be removed prior to installation. Failure to remove all packing materials that are unnecessary for system installation may result in overheating or abnormal operating conditions.

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The board at a glance

Table of contents

About this document ....................................................................................................................... 1

Important notice ............................................................................................................................ 2

Safety precautions .......................................................................................................................... 3

Table of contents ............................................................................................................................ 4

1 The board at a glance .............................................................................................................. 5

1.1 Delivery content ...................................................................................................................................... 5

1.2 Block diagram .......................................................................................................................................... 5

1.3 Main features ........................................................................................................................................... 7

1.4 Board parameters and technical data .................................................................................................... 7

2 System and functional description ........................................................................................... 9

2.1 Getting started with REF-AIRCON-C302A-IM564 .................................................................................... 9

2.2 Description of the functional blocks ..................................................................................................... 15

2.2.1 Overview of IMC302A ........................................................................................................................ 15

2.2.2 Overview of IM564-X6D .................................................................................................................... 16

2.2.3 Overview of 1ED44175 ..................................................................................................................... 18

2.2.4 Overview of ICE5AR4770BZS ............................................................................................................ 19

2.2.5 Design tips for direct motor current sensing .................................................................................. 20

2.2.6 Design tips for PFC current sensing ................................................................................................. 22

3 System design ...................................................................................................................... 24

3.1 Inverter section of REF-AIRCON-C302A-IM564 ..................................................................................... 24

3.2 PFC section of REF-AIRCON-C302A-IM564 ............................................................................................ 25

3.3 Auxiliary power supply .......................................................................................................................... 26

3.4 PCB Layout for REF-AIRCON-C302A-IM564 ........................................................................................... 27

3.5 Bill of material ....................................................................................................................................... 29

3.6 Connector details .................................................................................................................................. 30

3.7 Test points ............................................................................................................................................. 31

4 System performance ............................................................................................................. 32

4.1 Thermal characterization...................................................................................................................... 32

4.2 NTC thermistor characteristics and overheat protection .................................................................... 32

4.3 Motor overcurrent protection (OCP) test ............................................................................................. 35

4.4 PFC overcurrent protection test ........................................................................................................... 38

4.5 DC bus sensing and overvoltage protection ........................................................................................ 40

4.6 PFC performance test ............................................................................................................................ 42

5 References and appendices .................................................................................................... 43

5.1 Abbreviations and definitions ............................................................................................................... 43

5.2 References ............................................................................................................................................. 43

5.3 Ordering details and other information ............................................................................................... 43

Revision history............................................................................................................................. 44

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The board at a glance

1 The board at a glance

The REF-AIRCON-C302A-IM564 is a part of Infineon’s CIPOS

Mini IPM and iMOTION™ reference design kits. It is

designed to provide ready-to-use, air conditioner solutions based on Infineon’s PFC-integrated CIPOS

Mini

IPM and advanced motion control engine (MCE 2.0) technology.

The REF-AIRCON-C302A-IM564 is an optimized design for 1400 ~ 2500 W power air conditioner applications. It allows fast prototyping and fast time to market. It is available through regular Infineon distribution partners as well as on Infineon's website. The main features of this board are described in this document, whereas the remaining paragraphs provide information to enable the customers to copy and modify the design for production according to their own specific requirements.

1.1 Delivery content

The board is equipped with all assembly groups for sensorless field-oriented control (FOC), and reserved interface for BLDC/AC fan control, relays and 4-way valve control and 3-channel temperature sensing circuits, so that it can be easily used for air conditioners and similar home applications.

It provides a single-phase AC connector, an EMI filter and soft power-up circuit, input rectifier, DC bus capacitors, on-board PFC inductor emitter shunts for current sensing and overcurrent protection (OCP), thermistor output and a voltage divider for DC-link voltage measurement.

The REF-AIRCON-C302A-IM564 reference design also contains a CoolSETTM based flyback auxiliary power supply to provide 15 V, 12 V & 5 V.

1.2 Block diagram

The block diagram of the REF-AIRCON-C302A-IM564 is depicted in Figure 1.

HVIC

IMC302A

IM564-X6D Inverter Section

15V

PWM

VFO

Itrip

PWM

VTH

DCBsense

IM564-X6D

PFC Section

PFC

Current

sensing

VAC+ VAC-

Power Supply

IFB

Gate

Driver

PFC_PWM

EMI Filter

& Soft

Power Up

Circuit

IPFC

PFC_Trip

Temperature

sensing

EEPROM

IDU COM

AC Fan/BLDC Fan

Debug Relays

Figure 1 Block diagram of the REF-AIRCON-C302A-IM564

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Figure 2 points out the functional groups on the top side of the REF-AIRCON-C302A-IM564 reference design:

Figure 2 Functional groups of the REF-AIRCON-C302A-IM564 reference design

10 7

1. 220 VAC & PE input connector

2. EMI filter

3. In-rush relay control

4. On-board PFC inductor

5. Heat sink (IM564 + 1ED44175 + input rectifier)

6. UVW motor phase connector

7. iMOTIONTM link connector, UART 0 & UART1

8. External BLDC fan VSP control

9. Auxiliary power supply

12 11

10. AC fan and 4-way valve relay control

11. Single-wire UART interface to IDU

12. EEV connector

13. UART tester connector

14. EEPROM

15. Temperature sensing

16. IMC302A

13 14 15

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1.3 Main features

The REF-AIRCON-C302A-IM564 board is an optimized reference design for 220 V air conditioner applications, which contains iMOTION™ controller IMC302A, 20 A, 600 V PFC-integrated CIPOS™ Mini IPM and 1ED44175 PFC gate driver.

Major REF-AIRCON-C302A-IM564 characteristics include:

• Input voltage 85~265 V

• Maximum 2500 W at 220 V

power input with forced air cooling

• Maximum 1400 W at 220 V

power input without forced air cooling

• 20 A, 600 V PFC-integrated CIPOS™ Mini IPM

• On-board 10 A, 400 µH PFC inductor for 40 kHz PFC operation

• VSP host interface for external BLDC fan

• AC fan and 4-way valve control relay

• Single-wire UART communication interface to IDU

• Overcurrent and over temperature protection, fault diagnostic LED output

• Auxiliary power supply with 15 V, 12 V and 5 V

• PCB is 250 mm × 157 mm, 2 layers, 1 oz. copper

• RoHS compliant

1.4 Board parameters and technical data

Table 2 depicts the key specifications of the reference design of REF-AIRCON-C302A-IM564.

Table 2 REF-AIRCON-C302A-IM564 board specifications

Parameter

Symbol

Conditions / comments

Value

Unit

Input voltage

Vac

Optimized design for 220 VAC applications

85 ~ 265

rms

Maximum input current

ac(max1)

Input 220 VAC, Ta=25C, natural cooling mode

rms

ac(max2)

Input 220 VAC, Ta=25C, with 1 m/s wind cooling

rms

Maximum output power

in(max1)

Input 220 VAC, Motor f

PWM

= 6 kHz, PFC f

PWM

=40 kHz,

Ta=25°C, IPM TC = 105 °C , Natural cooling mode

1400

in(max2)

Input 220 VAC, Motor f

PWM

= 6 kHz, PFC f

PWM

=40 kHz,

Ta=25°C, IPM TC = 105 °C , 1 m/s force cooling mode

2500

Maximum motor current

mtr(max1)

Input 220 VAC, Motor f

PWM

= 6 kHz, PFC f

PWM

=40 kHz,

Ta=25°C, IPM TC = 105 °C , Natural cooling mode

rms

mtr(max2)

Input 220 VAC, Motor f

PWM

= 6 kHz, PFC f

PWM

=40 kHz,

Ta=25°C, IPM TC = 105 °C , 1 m/s force cooling mode

rms

DC bus voltage

Maximum DC bus voltage

dc(max)

DC bus capacitors are 450 V, 470 µF x 2

450

Minimum DC bus voltage

dc(min)

Aux power supply brown-in voltage

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The board at a glance Parameter

Symbol

Conditions / comments

Value

Unit

Current feedback

PFC shunt resistance

RS1

5 W shunt resistor with external OPA gain 14.7

mΩ

Motor shunt resistance

RS2

Direct AD sample (without external OPA)

mΩ Protections

Motor current protection trigger level 1

MtrI

trip1

Wizard setup for OC trigger level, related to AD range, shunt resistor RS2 and pull-up bias

16 1

peak

Motor current protection trigger level 2

MtrI

trip2

Hardware comparator overcurrent protection, related to RS2 and IM564’s Itrip threshold

26.2

peak

PFC current protection trigger level 1

PFCI

trip1

IMC302A’s internal comparator for cycle-by-cycle OCP, trip level can be adjusted by R50 & R55

20 2

peak

PFC current protection trigger level 2

PFCI

trip2

PFC driver local protection for 1ED44175 driver, trip level can be adjusted by RS1, R66 & R71

33.3

peak

Thermal protection level

protection

Temperature gap between junction and NTC sensor needs to be considered

°C

Auxiliary power supply 1 – 15 V

Output voltage

out1

Used for IPM driver

15 ± 2%

Maximum output current

out1

150

Auxiliary power supply 2 – 12 V

Output voltage

out2

Used for relay control

12 ± 10%

Maximum output current

out2

300

Auxiliary power supply 3 – 5 V

Output voltage

out2

Used for IMC controller and protection circuits

5 ± 1%

Maximum output current

out2

200

mA PCB characteristics

Dimension

Length × width × height

250×157

×65

Material

FR4, 1.6 mm thickness, 1 oz. PCB

System environment

Ambient temperature

Non-condensing, maximum RH of 95%

0 ~ 50

°C

For iMOTION™ IC IMCxxx, there are three types of Gatekill input source options in MCEWizard setup: Gatekill-pin, Comparator and

both. If you select “comparator” mode, the external Gatekill signal will not be used, and the IFB will be compared by the internal comparator with the “Device overcurrent trigger level setting” value set in MCEWizard.

For iMOTION™ IC IMC302 PFC overcurrent protection, there are two options in MCEWizard setup.

If you select “Enable cycle by cycle” mode, the PWM output immediately goes to logic LOW when the inductor current exceeds the pre-determined OCP threshold, and re-starts at following PWM cycle.

For “Disable” mode, PFC state machine would shift from RUN state to FAULT state when inductor current exceeds the pre-

determined OCP threshold for a duration specified by parameter “PFC_GateKillTime”, only Fault_clear command can make it back to STOP/RUN mode, which means latch–off OCP.

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System and functional description

2 System and functional description

This chapter provides more function block details on setting up the system, and getting started with the iMOTION™ development platform with the REF-AIRCON-C302A-IM564 reference design.

2.1 Getting started with REF-AIRCON-C302A-IM564

The REF-AIRCON-C302A-IM564 reference designs are shipped with embedded firmware and default parameters.

A 6-pole, GK6063-6AC31 motor is used for the default DEMO functions, whose maximum speed is 2500 RPM and maximum power is 3 KW. Please note that motor parameters need to be double-checked in MCEWizard for a real air conditioner motor.

An iMOTIONTM Link or third party isolated USB-to-UART cable is needed to bridge the PC/debugger side and

motor drive system (the target iMOTION™ device, hot side) with 1 kV DC galvanic isolation.

The iMOTION™ software tools, MCEDesigner and MCEWizard, are required to initially set up the system, as well

as to control and fine-tune the system performance to match the user’s exact needs. These tools are available for download via the Infineon website (https://www.infineon.com/cms/en/product/power/motor-control-

ics/digital-motor-controller-imotion/imc302a-f064/#!tools ). Please visit this page periodically to check for

tool/software updates.

After downloading and installing the iMOTION™ PC tools, MCEWizard and MCEDesigner, the following steps need

to be executed in order to run the motor. Refer to MCEWizard and MCEDesigner documentation for more information.

Figure 3 shows the basic system connection using REF-AIRCON-C302A-IM564 to run motor with MCEDesigner:

Figure 3 System connection example

iMOTION Link Connector

(USB-to-UART)

Power

Input

Motor Phase

Outputs

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Figure 4 shows the MCEWizard welcome page and interface of MCEDesigner.

Figure 4 MCEWizard welcome page and MCEDesigner interface

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System and functional description

Here are the steps needed to run the motor:

1. Connect iMOTION

Link’s 8-pin cable to J11 with default pin order (align connector orientation markings

with PCB silkscreen markings), and connect PC-USB connector to iMOTIONTM Link.

2. Use MCEWizard to enter the target motor’s system and operating parameters, as well as evaluation board’s

hardware parameters, which will then be used to calculate the digital parameter set of the controller representing the complete motor drive system.

3. After system and operating parameters are set, go to the “Verify & Save Page” and click on “Calculate

Parameters” button. If no errors are reported, then save the drive parameter set into your project directory by clicking “Export to MCEDesigner file (.txt)” (Figure 5); if an error is detected, double-click on the error

message (highlighted in RED) and adjust the related parameter. The saved drive system parameter file will be later used by the MCEDesigner in step 9.

(Please refer to MCEWizard_V2.3.0.0 User Guide.pdf for more details, which is in MCEWizard’s install path)

Figure 5 MCEWizard Verify and Save page

4. Connect 220 V AC power supply and UVW outputs to the motor.

5. Turn on 220 V AC power supply, LED2 and LED5 ON.

6. Start MCEDesigner tool and open MCEDesigner default configuration file (.irc) for IMC302A device

(IMC302A_Vxxx.irc) by clicking “File” > “Open”.

(IMC302A_Vxxx.irc file is included in downloaded “IMC302A MCE Software Package”)

MCEDesigner should automatically connect to the REF-AIRCON-C302A-IM564 board using default COM port (Indicated by green circle next to “COMx Up” status in the bottom frame of the MCEDesigner GUI).

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System and functional description

If it cannot establish the connection due to incorrect COM port, change COM port by doing the following: Click on the “System Page” window and then click on “Preferences > Connection > Connect using” and choose

one of the other available COM ports from the drop-down list.

7. In case of blank IC: If the firmware has been erased from the IMC302A, a warning message will pop up saying

“Target device firmware and parameters file are not programmed! Please program firmware and parameters file.” (Figure 6) See step 9 on how to obtain/program firmware and parameters.

Figure 6 MCEDesigner warning message

8. In case of blank IC: Do the following to program the firmware and the parameters’ file into the internal Flash

memory of iMOTION™ Control IC: Click on system page, click “Tools” > “Programmer” and select “Program

Firmware and Parameters,” shown as Figure 7 below. The encrypted firmware is available in IMC302A MCE Software Package, regarding the parameters file, browse and select the .txt file in step 3.

(If blank IMC302A IC, MCEDesigner will pop up information “Target device firmware and parameter files are not

programmed!”) Program the MCE firmware and system parameters into the internal Flash memory of iMOTION™ IC by clicking “Tools > Programmer “in the pull-down menu, and then clicking on the “Program Firmware and Parameter”

check box. Select right Parameter file and firmware file. Finally click “Start” button to program firmware and parameter. Then click YES and then the OK button to update IRC file with parameter file; finally “Save As” the IRC file to your own file name that contains COM config, Parameters & firmware file path information. (Please refer to MCEDesigner User

Guide.pdf and MCEDesigner_V2.3.0.0 Application Guide.pdf for more details, which is in MCEDesigner’s install path)

Red LED4 will flash on after the program is done.

Figure 7 MCEDesigner program page

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System and functional description

9. Double click the “VF Diagnostic” function in Motor1 page, and monitor the motor current with oscilloscope.

If the motor current is not sinusoidal, change the target speed and Vd_Ext in VF Diagnostic sub-function, then double-click “VF Diagnostic” until oscilloscope shows a steady sinusoidal current, with an amplitude of 30~50% motor rate current.

Double-click “Iu & Iv_Slow” in System page > Monitor Definitions; the motor current feedback should be very clean and sinusoidal, as shown in Figure 8, otherwise please tune “Gating Propagation Delay & Phase

Shift Window Size” in MCEWizard. The sampled motor current amplitude should be over 300 cts ~500 cts

(corresponding to 30%~50% motor rate current); otherwise, the motor-current sample related hardware and setup need tuning.

“VF Diagnostic” sub function can verify:

• If motor is correctly connected

• If MOS & gate driver work as expected

• If current sensing related parameters are correctly configured

• If PCB layout and DC bus decoupling have been done correctly

After “VF Diagnostic” is done, click STOP button (the red traffic light button) to stop PWM.

Figure 8 Trace waveform for Iu & Iv open loop diagnostic

10. Start the motor by clicking the green traffic light button in the control bar (or double-click Start Motor sub

function in Motor1 page, group of User Application Function Definitions); motor runs if above step goes well.

11. Check motor spin direction, adjust UVW connection order or set negative target speed in MCEDesigner if

direction is wrong.

12. Set target speed to about 50% of MAX speed, start “Iu & Flx_M” trace with “Auto Repeat on Level”. As Figure

9. Flx_M is better within the range of 2000~2500 cts (rated value is 2048), and MUST be steady and DC-like.

Some key tips for better motor-performance tuning:

• If Flx_M is not steady (swinging or oscillating), double-check motor parameters, speed loop PI gain, flux Estimator

time constant and PLL PI bandwidth (parameters PLLKp & PLLKi) related setup.

• If Flx_M is very noisy, double-check current feedback and Vdc-related hardware and parameters.

• If Flx_M is far from 2048, “Motor Back EMF Constant (Ke)” needs to be adjusted in MCEWizard.

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System and functional description

Figure 9 Trace waveform for Iu & Flx-M at 50% speed

13. Once the firmware has been programmed, in case a new parameters’ file has to be programmed, follow the

same instructions given in step 9. In this case, firmware programming is no longer needed and it is possible to select the first option “Program Parameters.”

Note: For detailed information on controller programming, refer to AN2018-33 iMOTION™ 2.0 Device Programming, MCEDesigner documentation and MCEWizard documentation.

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