MOTOROLA AN1524 User Manual

1

MOTOROLA



      

Prepared by: Ken Berringer
Motorola Inc., Hybrid Power Module Operation, Phoenix, Arizona

Abstract

The AC induction motor is the workhorse of modern
industry. Worldwide about 50 million motors are installed
every year that have greater than 1/2 hp. Today only a small
percentage of these motors utilize variable speed drives.
Almost half of the variable speed AC drives sold today are in
the 1 to 5 hp range. Companies producing this range of drives
are under a great deal of pressure to reduce costs. Lower
system cost will result in higher volumes as more applications
use variable speed. The power semiconductors are a
significant portion of the cost of these drives. A new module
called an Integrated Power Stage may be used to reduce the

cost and complexity of the power semiconductors. A
functional demo board has been developed using this module
for a 1 to 2 hp AC motor drive.

INDUCTION MOTOR SYSTEM

A systems approach can be taken to reduce the overall cost
of an AC drive in the 1 to 3 hp power range. The system can
be partitioned by semiconductor technologies and power
dissipation requirements. A block diagram of a basic AC drive
system is shown in Figure 1.

Figure 1. System Block Diagram

THREE PHASE

AC INPUT

INTEGRATED
POWER
STAGE

INTEGRATED
POWER
STAGE
AC DRIVE

THREE PHASE

AC OUTPUT

PRECHARGE

CIRCUIT

+ +

CAPACITORS

VOLTAGE

DIVIDER

TEMPERATURE

AMPLIFIER

CURRENT

AMPLIFIER

GATE DRIVE

POWER SUPPLY

+18 V

+5 V

+12 V ISOLATED

CONTROL

FUNCTIONS

+18 V

+5 V +12 V

MCU BOARD

Order this document

by AN1524/D



SEMICONDUCTOR APPLICATION NOTE

 Motorola, Inc. 1996

REV 1

AN1524

2

MOTOROLA

The power semiconductors for an AC drive consist of a
three phase rectifier and a three phase inverter. The three
phase rectifier converts a three phase AC power source into
a DC supply. A single phase power source may also be
connected to any two of the three inputs. Electrolytic
capacitors are used to provide energy storage for the DC
supply.

A three phase inverter consisting of six IGBTs and six soft
recovery diodes is used to drive the motor. Three phase AC
is then generated by using sine wave pulse width modulation.
The voltage and frequency of the AC output can be easily
controlled using an embedded microcontroller unit. The most
common constant V/F (volts per hertz) drives provide sine
frequencies of 1 to 120 Hz and voltages of 0 to 240 V AC or 480
VAC. The three phase inverter is very flexible and can also be
used for most three phase motors and modulation or
commutation schemes. This includes brushless DC motors.

Because AC motors under sine wave excitation are also
capable of generating, a dynamic brake circuit is often used.
When the speed command is reduced in an AC drive, the
motor will regenerate. The real part of the three phase power
flows from the motor to the inverter. This results in current
flowing from the inverter into the DC buss capacitors. Because
this energy cannot flow back into the AC supply it must be
stored in the capacitors or dissipated. If too much energy is

pumped into the capacitors the voltage will rise to
unacceptable levels. A dynamic brake resistor and a seventh
IGBT are often used to dissipate this energy. Because large
resistors used for dynamic braking are inductive, a clamp
diode is used to limit the transistor voltage during turnoff.

INTEGRATED POWER STAGE MODULE

There are a total of 20 power semiconductor devices in this
AC drive system. Using single transistor discrete packages is
very cumbersome. Often a rectifier module and IGBT six pack
is used with a discrete transistor for the brake. This simplifies
matters a little, reducing the number of components that must
be mounted to a heatsink and soldered to three.

The “Integrated Power Stage” Module is a comprehensive
solution for small motor drives. A schematic of the Integrated
Power Stage is shown in

Figure 2 and the module is illustrated

in

Figure 3. These modules contain all the power electronics
for an AC drive. By combining all the power devices into a
single package mounting use is greatly simplified. A single
module is fewer parts than two modules. This should reduce
manufacturing cost and improve reliability. The Integrated
Power Stage also contains a 1% sense resistor and a
temperature sense diode. These components can be used to
provide status and control functions as well as protection
features.

Figure 2. Integrated Power Stage Schematic

D1

Q3

D8 D10 D12

D9 D11 D13

R1

0.01

Ω

I+

3

T+

2

T–

21

B

18

W

19

V

20

U

9

G1

8

K1

6

N2

25

N1

7

P2

1

P1

22

T

23

S

24

R

I–

Q1 Q5

Q4Q2 Q6

D3 D5

D2 D4 D6

G3

K3

G5

K5

G2 G4 G6

11

10

13

12

16 17 14

G7

Q7

D7

45

15

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MOTOROLA

Figure 3. Integrated Power Stage Module Illustration

There is a family of six modules for 1, 2 and 3 hp motor
drives for both low voltage (up to 240 VAC) and high voltage
(up to 480 VAC). Table 1 contains the part numbers and the

voltage and current ratings for the Integrated Power Stage
modules.

Table 1. Integrated Power Stage Ratings

ББББББББББББББББББББББББББ

ББББББББББББББББББББББББББ

ББББББББББББББББББББББББББ

IC (Amps)

ББББББ

ББББББ

ББББББ

8

12

15–16

20

30

CES

600

MHPM7A15A60A

MHPM7A20A60A

MHPM7A30A60B

V

CES

(Volts)

1200

MHPM7A8A120A

MHPM7A12A120A

MHPM7A16A120B

IPS AC MOTOR DRIVE DEMO BOARD CIRCUITRY

A demo board has been developed for the Integrated Power
Stage family of modules. A photograph of this demo board is
included at the end of the text as shown in Figure 13.

The
purpose of this demo board is to provide a vehicle for
evaluating the performance of these modules and to enable
customers to rapidly develop proof of concept systems. The
board contains the integrated power stage module, passive
power components and gate drive. It also contains a current
amplifier, temperature amplifier and voltage divider for
monitoring drive status. Over–current, over–voltage
comparators and a programmable logic device provide
instantaneous fault protection.

Power Circuit

The power electronics for the demo board is shown in
Figure 4. Three phase or single phase AC power is connected
to the input terminals R, S, and T. The order of the input
connections makes absolutely no difference. The Integrated
Power Stage (U1) rectifies the AC and provides a DC output
at P1 (1) and N1 (25). Negative temperature coefficient
thermistors (R1 and R2) are used to limit the inrush current
and protect the rectifier diodes from excessive surge current.
Two thermistors with a cold resistance of 1 Ω are suf ficient to

protect the low voltage systems. Alternatively, a relay and
precharge resistor could be used to limit inrush current. Both
upper and lower branches of the DC buss are split between
the rectifier and brake for flexibility.

Capacitor C1 is a polypropylene capacitor for high
frequency performance. Capacitors C2 and C3 are the DC
buss capacitors. Jumpers are provided to configure these
capacitors in series or parallel. The PC board is designed for
both high voltage and low voltage systems. All the values
shown are for the low voltage configuration.

The output terminals U, V, and W are connected to the
motor. Exchanging the order of the connections will reverse
the direction of the motor rotation. The motor rotation can also
be reversed by software control. A connector is also provided
for dynamic brake connection.

The heatsink of U1 is earth grounded using a small screw
through one of the module standoffs. The heatsink should be
earth grounded for safety reasons. The clearance and
creepage distances for the printed circuit board are designed
to meet the spacing requirements of UL 840 and IEC 335 for
480 VAC drives. The AC drive standards UL 508, UL 508C,
VDE 0110, and VDE 0160 refer to these standards or use
similar clearance tables.

V

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MOTOROLA

Figure 4. Power Electronics

HEATSINK

R1

1.0

Ω

R2

1.0

Ω

+V

M

INTEGRATED POWER STAGE

N1 R S T U V WB

P1 N2 P2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1819202122232425

U1

R S T U V WDB1 DB2

C3
470

µ

F

C1

0.033

µ

F

240

240

480

J1

+V

M

C2
470 µF

+

+

Gate Drive

The gate drives for the high side IGBT s use optocouplers for

level shifting. The circuit is shown in

Figure 5. The HCPL0453
optocoupler (U8) was chosen for its high dv/dt capability and
speed of operation. The 480 V AC drives must operate with DC
link voltages as high as 850 volts under regeneration

conditions. Thus, a 600 volt HVIC solution is not suitable for
480 VAC drives. It is estimated that high voltage drives
account for more than 1/3 of 1 hp drives and about
three–fourths of the 5 hp drives. Optocouplers provide a
universal solution for both voltage ranges.

Figure 5. High Side Gate Drive

C18
10

µ

F

U8

HCPL0453

C19

0.1

µ

F

D5

G1
(U1 PIN 9)

E1
(U1 PIN 8)

UT

(FROM PLD)

U11
MC33151D

D10

D4

+18 V

R43

180

Ω

R46

2.2

Ω

R53

22

Ω

R52

100

Ω

R47

5.6 k

Ω

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MOTOROLA

PlusI

(ANALOG OUTPUT)

U4b

MC33272D

R31

2.2 k

Ω

R29

12.1 k

Ω

R28

3.01 k

Ω

R30

13.0 k

Ω

R25

13.0 k

Ω

R27

1.10 k

Ω

R26

1.10 k

Ω

U3b

LM293AD

+5 V

+5 V

C10
120 pF

+2.5 V

+

–

+

–

(4.0 V)

Power is supplied by a bootstrap circuit consisting of a high
voltage diode (D4), a small resistor (R46), and capacitor
(C18). When the lower IGBT is turned on, the capacitor
charges through the diode and resistor. The lower transistor
is then turned off and the upper transistor is turned on. The
charge stored in the capacitor supplies the gate drive energy .
Actually, the bias current of the IC and optocoupler pull–up
resistor are the primary current drains on the bootstrap
capacitor. The 10 µF capacitor can provide a holdup time of
several milliseconds. An 18 volt supply is recommended
because about 3 volts are lost in the lower transistor on
voltage and the bootstrap diode. The small resistor limits the
peak current under transient conditions.

The gate drive current is supplied by an MC33151D (U11)
high current MOSFET driver. This is an economical LVIC with

1.5 amps of source and sink capability . Separate resistors are
used for turn–on and turn–off. A low turn–off impedance is
essential to minimize turn–off losses and shoot–through
current. The turn–on resistor is selected to limit the turn–on
dv/dt to an acceptable level. The values for R52 and R53 thus
vary according to the specified power module/development
system.

The dv/dt limitations necessitate some additional power
losses in the IGBTs, particularly for the high voltage drives.
The dv/dt applied to the motor is also a consideration as this
stresses the motor insulation. The typical dv/dt measured on
the demo board is 5 to 10 V/ns during IGBT turn–on. This
value can be lowered by adding output filter inductors or using

larger gate drive resistors. However, using larger gate drive
resistors will greatly increase power dissipation in the IGBTs.

The low side gate drive uses a similar circuit without the
optocoupler. Two non–inverting MC33152Ds are used for the
three low side transistors and the brake transistor.

Status Circuitry

The sense resistor in the integrated power stage is placed
between the brake and inverter. This allows the resistor to
sense both positive motor current and dynamic braking
currents. A resistor placed between the rectifier and brake
transistor would not sense the regenerative current when the
brake is turned on. The DC link current may be used in many
different control and protection schemes. The DC current in
this resistor multiplied by the DC voltage gives the real power
output of the inverter. The real power divided by 3 and divided
by the output phase voltage gives the real output phase
current. Unfortunately, the output power factor is not known.
However, the peak current in the resistor is indicative of the
peak phase current. Thus, a DC measurement and a peak
over current detect provides a cost effective means of control
and protection.

The current amplifier and over–current comparator are
shown in

Figure 6. A differential amplifier senses current in
both directions. A 2.5 volt reference provides an offset for the
differential amplifier. The conditioned output varies from 0 to
5 volts with 2.5 volts representing zero current. The
over–current comparator trips at 12.7 amps.

(U1 PIN 4)

MinusI

(U1 PIN 5)

IO

OC
(TO PLD)

C9
120 pF

C11

120 pF

Figure 6. Current Amplifier and Over–Current Comparator

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MOTOROLA

The temperature amplifier is shown in Figure 7. The circuit
consists of an inverting amplifier with a 0.69 volt offset. The
output provides a temperature signal of approximately

26.5 mV/°C. The compensation capacitor is essential to avoid
oscillations with such a large feedback resistor. Resistor R20
biases the temperature sense diode at 1 mA. The bias current
can be increased if necessary to minimize noise problems.
However, the gain will have to be readjusted.

(ANALOG
OUTPUT)

R20

4.42 k

Ω

R24

1.30 k

Ω

R23

3.40 k

Ω

R22

10.0 k

Ω

R21

137 k

Ω

C7

1000 pF

U4a

MC33272D

PlusT

(U1 PIN 3)

+5 V

C8

0.1

µ

F

+2.5 V

+

–

(0.69 V)

The voltage divider and over–voltage comparator are
shown in

Figure 8. The voltage divider provides a 0 to 5 volt
signal, 1 volt per 100 volts on the DC buss. Four resistors in
series are used to ensure the voltage rating of the resistors is
not exceeded for the high voltage system. The over–current
comparator trips at 4.25 volts. Some hysteresis is also
provided to prevent the brake from oscillating between the on
and off states. The resistive divider also serves as a bleeder
resistor to slowly discharge the buss capacitors. The high
voltage drive uses resistors twice the value shown for R1 1–14.

Logic Circuit

The input logic of the demo board uses a programmable

logic device for flexibility, see

Figure 9. The 22V10 PLD has
12 input pins and 10 I/O pins. Seven of the outputs are
dedicated to the seven IGBT gate drives. Seven of the inputs
are configured for use with the seven transistor inputs. Seven
resistors are connected to the inputs and may be configured
as pull–up or pull–down resistors. The polarity of the input
signals may be changed by modifying the device equations
and setting the polarity jumper. One of the inputs is dedicated
as a hardware enable. The three remaining I/O pins are
available as programmable I/O signals to the ribbon
connector.

Complete Schematic & Bill of Materials

(ANALOG
OUTPUT)

R17

2.2 k

Ω

R18

51.1 k

Ω

R16

9.09 k

Ω

OV

(TO PLD)

R19

150 k

Ω

+V

M

+5 V

+5 V

U3a

LM293AD
+

–

(4.25 V)

Appendix I contains a complete board level schematic of the
demo board. All of the component values listed in the
schematic are for the 1 hp 240 VAC configuration. Appendix
II is a bill of materials for the demo board. Again the values
listed are for the 1 hp 240 VAC configuration. The 2 hp 240
VAC configuration requires changing several resistor
component values. The 1 & 2 hp 480 VAC configurations
require changing J1 and using 1000 volt bootstrap diodes, in
addition to changing several resistor values. Alternate bill of
materials are available on special request.

USING THE IPS AC MOTOR DRIVE DEMO BOARD

PWM Signals

The demo board requires a PWM signal source. The PWM
signals can be generated by a microcontroller. Two
microcontrollers suitable for this purpose are the MC68332
and the MC68HC16Y1. Basic code for PWM AC motor control
has been written for the MC683321 and the MC68HC16Y12.
Both of these microcontrollers include a Time Processor unit.
The Time Processor unit is an autonomous timer which may
be micro–programmed for various time functions. A special
microcode primitive has been written called Multi–Channel
PWM3 that can generate center aligned PWM signals with
dead time. A motor control development system has been
developed for the ’HC16Y1. The integrated power stage demo
board was designed specifically to interface directly to the
’HC16Y1 motor control development system. However, the
PLD provides added flexibility for use with different
microcontrollers.

R11

82.5 k

R12

82.5 k

R13

82.5 k

R14

82.5 k

Ω

Ω

Ω

Ω

VO

Figure 7. Temperature Amplifier

TO

R15

3.32 k

Ω

Figure 8. Voltage Divider and Over–voltage

Comparator

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MOTOROLA

Figure 9. Input Logic

BRK

VO
TO

IO

VT

WT

UT

UB

VB

WB

OC

OV

I4

I5

I6

I7

I8

I9 I10

I3

I2 I1 I0 VCCI/O9 I/O8

I/O7

I/O6

I/O5

NC

I/O4

I/O3

I/O2

I/O1I/O0

NC

GND I11

22V10 NC

NC

14

28234

5

6

7

9

10

11

12 13 16 17 18

19

20

21

23

24

25

26271

8

15

22

U2

J4

To

Vo

Io

BRK

Wb

Wt

Vb

Vt

Ub

Ut

I/O3

I/O2

I/O1

GND

NC

+5 V

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

CN7

S1

R10

4.7 k

Ω

+5 V

+5 V

+5 V

+5 V

R3–R9

4.7 k

Ω

The PWM signals should be center aligned with dead time.
The demo board does not provide any dead time. The
microcontroller can provide accurate digitally generated dead
time far better than an analog circuit. Appropriate PWM
signals are illustrated in Figure 10.

Figure 10. PWM Timing

2 µs

UT

UB

VT

VB

WT

WB

The recommended dead time for the demo board is at least
2 µs. Less than 2 µs of dead time will allow some shoot
through current during switching, resulting in higher switching

losses. Inadequate dead time may also result in damage to the
power transistors.

PLD Programming

The demo board is shipped with a preprogrammed PLD.
This PLD provides only two basic essential functions,
half–bridge lockout and a master enable. A half–bridge
lockout ensures that both upper and lower transistors are not
simultaneously turned on. The master enable function
enables or disables all six PWM signals according to the
position of SW1 (U2 pin I0).

The standard PLD is programmed for active high logic
signals. Therefore jumper J1 should be positioned to
configure the input resistors as pull downs. The three general
purpose I/O pins are programmed for compatibility with the
HC16Y1 development system. Connector CN7 pin 6 (I/O3) is
connected to the active low fault pin of the development
system. It is set high to enable the PWM signals. The other two
I/O pins are tri–stated. The logic equations for the standard
PLD were compiled using ABLE. The PLDs were

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MOTOROLA

programmed using a Data I/O 2900 programmer. The actual
ABLE code is included in Appendix III.

Additional functions may be implemented by changing the
logic equations, recompiling the ABLE code and programming
a new PLD. In an AC motor drive system many of the functions
are a combination of hardware and microprocessor software.
The PLD provides the flexibility of being able to easily change
the hardware to implement new functions.

The standard PLD does not directly disable the PWM
signals under overcurrent conditions. This was intentionally
done to enable easy setup and testing of the drive system.
Once the system is setup and running, an overcurrent latch
may be added by changing the PLD. An overcurrent latch is
very sensitive to noise and may result in too many false trips
in some systems.

The brake transistor can be configured to turn on
automatically when the over voltage comparator detects an
over voltage. The micro should monitor the regeneration
current to protect the inverter, brake transistor and brake
resistor.

When used with a different microprocessor, it may be
desirable to invert the PWM polarities. This can easily be
accomplished by simply changing the logic equations and
moving jumper J1. Also included in Appendix III are ABLE
examples of using the brake for overvoltage and inverted
inputs.

Laboratory Setup

The demo board is intended to be used only in a power
laboratory. The high voltage levels present in any AC drive
system represent a serious shock hazard. The demo board
should only be used by engineers and technicians who are
experienced in power electronics.

A complete laboratory setup consists of an isolated AC
supply, the IPS AC Motor Drive demo board, an AC induction
motor, a dynamometer or motor load, a microprocessor board
and isolated lab supplies for +18 V and +5 V . A block diagram
of the lab setup is shown in Figure 11.

Figure 11. Laboratory Set–up Block Diagram

IPS AC MOTOR DRIVE

DEMO BOARD

ISOLATED THREE PHASE

AC POWER SUPPLY

(SEE TEXT)

+5 V

1 AMP

+18 V

100 mA

AC CONTROL

MICROPROCESSOR

BOARD

MOTOR

LOAD

AC MOTOR

The motor drive demo is not electrically isolated from the AC
mains. This topology is very common in low cost AC drives.
The microprocessor is grounded on the negative supply of the
high voltage DC buss. Thus, the micro and associated
circuitry are hot and must be isolated from user controls and
serial interfaces in final product form.

In the laboratory it is safest to isolate the AC supply , auxiliary
power supplies and oscilloscopes. This prevents a shock from
touching any single point in the circuit. This does not, however,
prevent shocks when touching two or more points in the
circuit. If absolutely necessary, one point in the circuit (the
micro ground for example) may be earth grounded. However,

this establishes all high voltage nodes at dangerously high
voltages.

An isolated AC power supply can be constructed using an
isolation transformer and a variable transformer (variac). A
schematic of the recommended AC power source is shown in
Figure 12. Fast semiconductor grade fuses should be used
directly up line of the AC drive. The transformer should be
fused with slower fuses to prevent blowing a fuse when
energizing the transformer. The demo board contains
thermistors to prevent excessive inrush current. However, it is
advisable to use a variac when first powering up the system.

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MOTOROLA

Figure 12. Isolated Three Phase AC Supply

L1
L2
L3

L1
L2
L3
N

EARTH

EARTH

MAINS INPUT

208/240 3

∅

OR

380/480 3

∅

208/240 3

∅

OR

380/480 V 3

∅

480 V 3

∅

BREAKER

BOX

MAINS OUTPUT

0–480 VAC 3

∅

5 WIRE

ISOLATED

DISCONNECT

SWITCH BOX

VARIAC

ISOLATION/ STEP–UP

TRANSFORMER

Use the following procedure the first time the system is
powered up. Check all connections twice. First turn on the +5
and +18 volt supplies. Then check all the gate drive signals
with an oscilloscope. Once you are confident the micro and
gate drives are functioning properly , proceed to power up the
AC line. Set the inverter output frequency to about 15 Hz. Set
the load torque to zero or disconnect the motor load. First turn
down the variac all the way. Then energize the isolation
transformer. Monitor the DC link voltage. Slowly increase
variac output voltage. The motor should start turning before
the DC buss reaches 100 volts. Once the motor is turning, it
should be safe to turn up the variac to full voltage.

SUMMARY

The Integrated Power Stage greatly simplifies the design
and assembly of an AC drive. A demo board has been

developed for the integrated power stage module. The demo
board has been tested and is fully operational. This board may
be used to evaluate module performance and facilitate rapid
product development.

REFERENCES

1.

Using the MC68332 Microcontroller for AC M otor
Control,

J. Baum and K. Berringer, Motorola Application

Note AN1310

2.

M68MCD16Y1 Motion Control Development Board
Users Manual,

M68MCD16Y1/D

3. Multi–Channel PWM TPU Function, TPUPN05/D

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MOTOROLA

Figure 13. Integrated Power Stage AC Motor Drive Board

AN1524

11

MOTOROLA

Appendix I

Board Schematic

CN1 CN3

CN6

R
S
T

CN2 CN4

U
V

W

1

N1 R S T B U V W

U1

P1 N2 P2

R1

1.0

Ω

R2

1.0

Ω

+V

M

+V

M

CN5

DB1
DB2

C1

0.033

µ

F

C2
470

µ

F

C3
470 µF

J2

J1

J3

G7
G6

G4
G2

G5
E5

G3
E3

G1
E1

Minusl
Plusl
PlusT

Integrated Power Stage

IPS AC Motor Drive

Power I/O

1

2

1

2

1

2

1

2

25 24 23 22 21 20 19 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1

2

1
2

+

1
2

+

AN1524

12

MOTOROLA

IPS AC Motor Drive

Logic I/O

CN7

+5 V

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

+5 V

NC

I/O1
I/O2
I/O3

Ut

Ub

Vt
Vb
Wt

Wb

BRK

lo

Vo

To

GND

TO

VO

IO

+5 V

J4

1

2

3

CN8

+18 V

+5 V

+18 V

+5 V

GND

1

2

3

R3

4.7k

Ω

BRK

OC

OV

WB

VB

UB

WT

VT

UT

R4

4.7 k

Ω

R5

4.7 k

Ω

R6

4.7 k

Ω

R7

4.7 k

Ω

R8

4.7 k

Ω

R9

4.7 k

Ω

4 3 2 1 28 27 26

10
11

9

8

7

6

5

12 13 14 15 16 17 18

25
24

23
22
21
20
19

+5 V

+5 V

R10

4.7 k

Ω

C4
(U2 DECOUPLING)

0.1µF

+5 V

S1

1
3

2

NC

I3
I4
I5

I6
I7
I8

GNDI9 I10 NC I11 I/O0 I/O1

I2 I1 I0 NC VCCI/O9 I/O8

I/O7
I/O6
I/O5

NC

I/O4
I/O3
I/O2

22V10

U2

AN1524

13

MOTOROLA

IPS AC Motor Drive

Voltage and Temperature

+V

M

R11

82.5 k

Ω

R12

82.5 k

Ω

R13

82.5 k

Ω

R14

82.5 k

Ω

R15

3.32 k

Ω

+5 V

R16

9.09 k

Ω

R18

51.1 k

Ω

R19

150 k

Ω

4.25 V

+5 V

VO

OV

R17

2.2 k

Ω

U3a

+18 V +18 V

C5
(U3 DECOUPLING)

0.1

µ

F

C6
(U4 DECOUPLING)

0.1 µF

R24

1.30 k

Ω

R23

3.40 k

Ω

0.69 V
C8

0.1

µ

F

V

REF

+5 V

R20

4.42 k

Ω

R22

10.0 k

Ω

C7

1000 pF

R21

137 k

Ω

TO

U4a
MC33272D

+
–

–
+

1

2

3

Temp Sensor Amp

3

2

PlusT

1

AN1524

14

MOTOROLA

IPS AC Motor Drive

Current Limit

Plusl

Minusl

R26

1.10 k

Ω

R27

1.10 k

Ω

C9
120 pF

C10
120 pF

R25

13.0 k

Ω

U4b

+

–

R30

13.0 k

Ω

C11

120 pF

+5 V

+5 V

R28

3.01 k

Ω

R29

12.1 k

Ω

R31

2.2 k

Ω

IO

OC

7

5

6

7

5

6

+18 V

V

REF

R32
10 k

Ω

C12

0.1

µ

F

LM285D–2.5
U5

8

4

Current Amp

Reference Voltage

Over Current

Comparator

+

–

V

REF

4.0 V

U3b

AN1524

15

MOTOROLA

IPS AC Motor Drive

Low Side Gate Drive

UB

VB

R33

510

Ω

R34

510

Ω

C13
470 pF

C14
470 pF

C16

0.1

µ

F

+18 V

U6

R36

100

Ω

R38

100

Ω

R39

22

Ω

R40

22

Ω

G2

G4

D1

D2

WB

BRK

R35

510

Ω

C15
470 pF

C17

0.1

µ

F

+18 V

U7

R37

100

Ω

R41

470

Ω

R42

22

Ω

D3

G6

G7

6

2

4

7

5

3

3

2

1

3

2

1

6

2

4

7

5

3

3

2

1

AN1524

16

MOTOROLA

IPS AC Motor Drive

High Side Gate Drive

+18 V

R46

2.2

Ω

UT

G1

E1

R43

180

Ω

D5

U8

D4

R47

5.6 k

Ω

C18
10

µ

F

C19

0.1

µ

F

U11

R52

100

Ω

R53

22

Ω

D10

2

3

3 1

8

6

5

6

7

54

2

3 1

3

2

+18 V

R48

2.2

Ω

VT

G3

E3

R44

180

Ω

D7

U9

D6

R49

5.6 k

Ω

C20
10

µ

F

C21

0.1

µ

F

U12

R54

100

Ω

R55

22

Ω

D11

2

3

3 1

8

6

5

6

7

54

2

3 1

3

2

+18 V

R50

2.2

Ω

WT

G5

E5

R45

180

Ω

D9

U10

D8

R51

5.6 k

Ω

C22
10

µ

F

C23

0.1

µ

F

U13

R56

100

Ω

R57

22

Ω

D12

2

3

3 1

8

6

5

6

7

54

2

3 1

3

2

2 1

2 1

2 1

AN1524

17

MOTOROLA

Appendix II

Bill of Materials

Item

#

Designators Qty Part Number Value Description Rating Tol. Package Comp. Manufacturer

Allow
Subs.

1 C1 1 FKP1 0,033 1000 0.033 µF Capacitor 1000 V ±10% #WIM22p5 Poly. Wima no
2 C2,C3 2 LGQ2W471MHSC 470 µF Electrolytic Capacitor 450 V ±20% #SNAP35 Alum. Nichicon yes
3 C4,C5,C6,C8,C12,

C16,C17,C19,C21,
C23

10 0.1 µF Capacitor 50 V ±10% 1206 X7R Panasonic yes

4 C7 1 1000 pF Capacitor 50V ±5% 805 NPO Panasonic yes
5 C9,C10,C11 3 120pF Capacitor 50 V ±5% 805 NPO Panasonic yes
6 C13,C14,C15 3 470 pF Capacitor 50 V ± 5% 805 NPO Panasonic yes
7 C18,C20,C22 3 PCT5106–ND 10 µF Capacitor 25 V ±20% #PAND Tant. Panasonic no
8 CN1,CN2,CN3,

CN4,CN5

5 17 14 97 1 Connector 2x0.375″ #PNX2x375 Phoenix Contact no

9 CN6 1 Screw hole #SCRW440 yes
10 CN7 1 Header 2x8 0.1″ #HDR8x2 yes
11 CN8 1 17 29 13 1 Connector 3x0.2″ #PNX3x200 Phoenix Contact no
12 D1,D2,D3,D10,

D11,D12

6 MMBD6100LT1 Dual Diode SOT23 Motorola yes

13 D4,D6,D8 3 MURS160T3 Diode #SMB Motorola no
14 D5,D7,D9 3 MMBD914LT1 Diode SOT23 Motorola yes
15 J1,J2,J3 3 Jumper 18AWG #J400 yes
16 J4 1 Jumper 3x0.1″ #HDR3x1 yes
17 R1,R2 2 SG405 1.0 Ω Thermistor 30 A ±25% #THRM310 Ketema no
18 R3,R4,R5,R6,R7,

R8,R9,R10

8 4.7 kΩ Resistor 1/10 W ±5% 805 Panasonic yes

19 R11,R12,R13,R14 4 82.5 kΩ Resistor 1/8 W ±1% 1206 Panasonic yes
20 R15 1 3.32kΩ Resistor 1/10 W ±1% 805 Panasonic yes
21 R16 1 9.09kΩ Resistor 1/10 W ±1% 805 Panasonic yes
22 R17,R31 2 2.2 kΩ Resistor 1/10 W ±5% 805 Panasonic yes
23 R18 1 51.1kΩ Resistor 1/10 W ±1% 805 Panasonic yes
24 R19 1 150kΩ Resistor 1/10 W ±5% 805 Panasonic yes
25 R20 1 4.42kΩ Resistor 1/10 W ±1% 805 Panasonic yes
26 R21 1 137kΩ Resistor 1/10 W ±1% 805 Panasonic yes
27 R22 1 10.0kΩ Resistor 1/10 W ±1% 805 Panasonic yes
28 R23 1 3.40kΩ Resistor 1/10 W ±1% 805 Panasonic yes
29 R24 1 1.30kΩ Resistor 1/10 W ±1% 805 Panasonic yes
30 R25,R30 2 13.0 kΩ Resistor 1/10 W ±1% 805 Panasonic yes
31 R26,R27 2 1.10 kΩ Resistor 1/10 W ±1% 805 Panasonic yes
32 R28 1 3.01kΩ Resistor 1/10 W ±1% 805 Panasonic yes
33 R29 1 12.1kΩ Resistor 1/10 W ±1% 805 Panasonic yes
34 R32 1 10 kΩ Resistor 1/10 W ±5% 805 Panasonic yes
35 R33,R34,R35 3 510 Ω Resistor 1/10 W ±5% 805 Panasonic yes
36 R36,R37,R38,

R52,R54,R56

6 100 Ω Resistor 1/10 W ±5% 805 Panasonic yes

37 R39,R40,R42,

R53,R55,R57

6 22 Ω Resistor 1/10 W ±5% 805 Panasonic yes

38 R41 1 470Ω Resistor 1/10 W ±5% 805 Panasonic yes

AN1524

18

MOTOROLA

Bill of Materials — continued

Item

#

Designators Qty Part Number Value Description Rating Tol. Package Comp. Manufacturer

Allow
Subs.

39 R43,R44,R45 3 180 Ω Resistor 1/10 W ±5% 805 Panasonic yes
40 R46,R48,R50 3 2.2 Ω Resistor 1/10 W ±10% SG73 KOA no
41 R47,R49,R51 3 5.6 kΩ Resistor 1/10 W ±5% 805 Panasonic yes
42 S1 1 SS–12SDP2 Subminiature Switch #SW1 NKK no
43 U1 1 MHPM7A15A60A Int. Power Stage #HPM1 Motorola no
44 U2 1 22V10 PAL PLCC20 TI yes
45 U3 1 LM293AD Dual Comparator SO8 Motorola yes
46 U4 1 MC33272D Dual Op Amp SO8 Motorola no
47 U5 1 LM285D–2.5 Voltage Reference SO8 Motorola no
48 U6,U7 2 MC33152D MOSFET Driver SO8 Motorola no
49 U8,U9,U10 3 HCPL0453 High Speed Opto SO8 HP no
50 U11,U12,U13 3 MC33151D Dual MOSFET Driver SO8 Motorola no
51 1 4200 02 U 2 0450 Heatsink Aavid no
52 1 FS24B3 2 1/2″ Box Fan

(opt.)

ComAir yes

53 4 1/2″ 4–40 Metal Standoffs yes
54 4 1/4″ 4–40 Screws yes
55 4 7/8″ 4–40 Screws yes
56 2 3/8″ 6–32 Screws yes
57 2 6–32 Lock Washer yes

AN1524

19

MOTOROLA

Appendix III

ABLE Code Listing

module IPS_PAL

title ’IPS demo board PAL’

IPS_PAL device ’P22V10C’;

”This is the ABLE code for the preprogrammed PLD which comes in the demo”

”inputs”

OE pin 2;
UT_in pin 5;
UB_in pin 6;
VT_in pin 7;
VB_in pin 9;
WT_in pin 10;
WB_in pin 11;
Brk_in pin 12;
OC_in pin 13;
OV_in pin 16;
IO1 pin 25;
IO2 pin 26;

” VCC pin 28;”
” GND pin 14;”
” NC pin 1, 8, 15, 22;”

”outputs”

UT_out pin 24;
UB_out pin 20;
VT_out pin 23;
VB_out pin 19;
WT_out pin 21;
WB_out pin 18;
Brk_out pin 17;
IO3 pin 27;

equations

UT_out = UT_in & !UB_in & !OE;
UB_out = UB_in & !OE;
VT_out = VT_in & !VB_in & !OE;
VB_out = VB_in & !OE;
WT_out = WT_in & !WB_in & !OE;
WB_out = WB_in & !OE;
Brk_out = 0;
IO3 = 1;

end IPS_PAL

AN1524

20

MOTOROLA

module IPS_PAL

title ’Inverted Inputs’

IPS_PAL device ’P22V10C’;

”This ABLE code provides inverted inputs. Configure J1 for pull up resistors.”

”inputs”

OE pin 2;
UT_in pin 5;
UB_in pin 6;
VT_in pin 7;
VB_in pin 9;
WT_in pin 10;
WB_in pin 11;
Brk_in pin 12;
OC_in pin 13;
OV_in pin 16;
IO1 pin 25;
IO2 pin 26;

” VCC pin 28;”
” GND pin 14;”
” NC pin 1, 8, 15, 22;”

”outputs”

UT_out pin 24;
UB_out pin 20;
VT_out pin 23;
VB_out pin 19;
WT_out pin 21;
WB_out pin 18;
Brk_out pin 17;
IO3 pin 27;

equations

UT_out = !UT_in & UB_in & !OE;
UB_out = !UB_in & !OE;
VT_out = !VT_in & VB_in & !OE;
VB_out = !VB_in & !OE;
WT_out = !WT_in & WB_in & !OE;
WB_out = !WB_in & !OE;
Brk_out = 0;
IO3 = 1;

end IPS_PAL

AN1524

21

MOTOROLA

module IPS_PAL

title ’Auto Brake’

IPS_PAL device ’P22V10C’;

”This is the ABLE code with automatic braking under overvoltage”

”inputs”

OE pin 2;
UT_in pin 5;
UB_in pin 6;
VT_in pin 7;
VB_in pin 9;
WT_in pin 10;
WB_in pin 11;
Brk_in pin 12;
OC_in pin 13;
OV_in pin 16;
IO1 pin 25;
IO2 pin 26;

” VCC pin 28;”
” GND pin 14;”
” NC pin 1, 8, 15, 22;”

”outputs”

UT_out pin 24;
UB_out pin 20;
VT_out pin 23;
VB_out pin 19;
WT_out pin 21;
WB_out pin 18;
Brk_out pin 17;
IO3 pin 27;

equations

UT_out = UT_in & !UB_in & !OE;
UB_out = UB_in & !OE;
VT_out = VT_in & !VB_in & !OE;
VB_out = VB_in & !OE;
WT_out = WT_in & !WB_in & !OE;
WB_out = WB_in & !OE;
Brk_out = OV_in;
IO3 = 1;

end IPS_PAL

AN1524

22

MOTOROLA

How to reach us:
USA / EUROPE: Motorola Literature Distribution; JAPAN: Nippon Motorola Ltd.; Tatsumi–SPD–JLDC, Toshikatsu Otsuki,

P.O. Box 20912; Phoenix, Arizona 85036. 1–800–441–2447 6F Seibu–Butsuryu–Center, 3–14–2 Tatsumi Koto–Ku, Tokyo 135, Japan. 03–3521–8315

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INTERNET: http://Design–NET.com 51 Ting Kok Road, Tai Po, N.T., Hong Kong. 852–26629298

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the suitability of its products 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. “T ypical” parameters can and do vary in different
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Motorola and are registered trademarks of Motorola, Inc. Motorola, Inc. is an Equal Opportunity/Affirmative Action Employer.

AN1524/D

*AN1524/D*

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