ON Semiconductor EVBUM2775/D User Manual

EVBUM2775/D

Attention: The SECO−1kW−MCTRL−GEVB is powered by AC Mains, and exposed to high voltage. Only trained

Compact Intelligent Power Module (IPM) Motor Control Development Kit (MDK) 1 kW

This User Guides refer to revision 0.4 of the

SECO−1KW−MCTRL−GEVK evaluation board.

Description

This user guide provides practical guidelines for compact

Intelligent Power Module (IPM) evaluation board with interleaved power factor Correction (PFC) SECO−1KW−MCTRL−GEVB including its main features and key data. The board is fully compatible with the Universal Controller Board (UCB), based on the Xilinx Zynq−7000 SoC, which embeds FPGA logic and two ARM Cortex−A9 processors. As such, the system is fit for high−end control strategies and enables operation of a variety of motor technologies (AC induction motor, PMSM, BLDC, etc.). The board was developed to support customers during their first steps designing application with IPM and PFC. The design was tested as described in this document but not qualified regarding safety requirements or manufacturing and operation over the whole operating temperature range or lifetime. The board is intended for functional testing under laboratory conditions and by trained specialists only.

Collateral

• SECO−1KW−MCTRL−GEVB

• Universal Controller Board (UCB)

• NFAQ1060L36T

• NCP1632

• FCPF125N65S3

• NCP1063

• NCS2003

• NCS2250

Features

• 850 W complete motor control solution with AC mains

• Compatible with Universal Controller Board (UCB)

• User−friendly GUI with V/f and FOC control use cases

• Highly integrated power module NFAQ1060L36T

• PFC stage using NCP1632 controller, FCPF125N65S3

• DC/DC converter producing auxiliary power supply

• 3 phase current measurement using 3 x NCS2003

• Over current protection using NCS2250 comparator

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EVAL BOARD USER’S MANUAL

supply 230 Vrms ±15 %, EMI filter, 2−channel interleaved Power Factor Correction (PFC)

FPGA−controller based on Xilinx Zynq− 7000 SoC

for rapid evaluation

containing an inverter power stage for a high voltage 3−phase inverter in a DIP−S3 package

NMOS power transistors and FFSPF1065A diodes

15VDC – non−isolated buck converter using NCP1063

operational amplifier

personnel should manipulate and operate on the system. Ensure that all boards are properly connected before powering, and that power is off before disconnecting any boards. It is mandatory to read the Safety Precautions section before manipulating the board. Failure to comply with the described safety precautions may result in personal injury or death, or equipment damage.

March, 2021 − Rev. 1

1 Publication Order Number:

EVBUM2775/D

Overview

The block diagram of the whole system is represented in Figure 1. The picture of the real board is in the Figure 2 and Figure 3.

Figure 1. Block Diagram of the Evaluation Board

Figure 2. Picture of the Evaluation Board – Top Side

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EVBUM2775/D

Figure 3. Picture of the Evaluation Board – Bottom Side

(Top Side) (Bottom Side)

Figure 4. Picture of the UCB Adapter

PREREQUISITES

Hardware

• SECO−1 kW−MCTRL−GEVB (includes power board

and adapter for UCB)

• AC power cord one−phase

• Universal Controller Board (UCB) or pin−compatible

controller board

• USB isolator (5 kV optical isolation)

• HF ferrite clamp i.e. WE 7427154

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Software

• Downloadable GUI

• Binary file

SPECIFICATION

Table 1. EVALUATION BOARD SPECIFICATIONS

Parameters

Values

Conditions/comments

INPUT

Voltage

230 V

15%

OUTPUT

Power

850 W

Input 230 VAC, f

= 16 kHz, T

= 25°C

Current per IPM leg

5 A

= 100°C

DC BUS Voltage

390 V

Higher voltage value is created by interleaved PFC with

CURRENT FEEDBACK

Current sensing resistors

39 m

Op Amp power supply

3.3 V

Set Op Amp gain

Set output offset

1.65 V

Because of negative current measurement

Overcurrent protection

9 A

Configured by shunt resistors and comparator threshold

AUXILIARY POWER SUPPLY

15 V

4.6 W

Used NCP1063

CONTROL

Board with Microcontroller and 3V3 power supply

Arduino DUE headers

Type of control

V/f, Field Oriented Control (Sensor−less)

Supported type of motors

ACIM, PMSM, BLDC

APPLICATION

White goods (washers), Industrial fans, Industrial automation

The specification and main features can be seen in the Table 1.

EVBUM2775/D

rms

PWM

rms

NCP1632 working as a booster

peak

(voltage divider)

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SAFETY PRECAUTIONS

T able 2.

SECO−1KW−MCTRL−GEVB

The ground potential of the system is biased to a negative DC bus voltage potential. When measuring voltage

The ground potential of the system is NOT biased to an earth (PE) potential. When connecting the MCU board

SECO−1KW−MCTRL−GEVB system contains DC bus capacitors which take time to discharge after removal of

Only personnel familiar with the drive and associated machinery should plan or implement the installation,

The surfaces of the drive may become hot, which may cause injury.

SECO−1KW−MCTRL−GEVB system contains parts and assemblies sensitive to Electrostatic Discharge (ESD). A drive, incorrectly applied or installed, can result in component damage or reduction in product lifetime.

Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait

SECO−1KW−MCTRL−GEVB system is shipped with packing materials that need to be removed prior to

It is mandatory to read the following precautions before manipulating the SECO−1KW−MCTRL−GEVB.

waveform by oscilloscope, the scope’s ground needs to be isolated. Failure to do so may result in personal injury or death

via USB to the computer, the appropriate galvanically isolated USB isolator have to be used. The recommended isolation voltage of USB isolator is 5 kV

the main supply. Before working on the drive system, wait ten minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death.

start−up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

Electrostatic control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with electrostatic control procedures, refer to applicable ESD protection handbooks and guidelines.

EVBUM2775/D

Wiring or application errors such as under sizing the motor, supplying an incorrect or inadequate AC supply or excessive ambient temperatures may result in system malfunction.

ten 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.

installation. Failure to remove all packing materials which are unnecessary for system installation may result in overheating or abnormal operating condition.

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EVBUM2775/D

SCHEMATICS AND LAYOUT

To meet customer requirements and make the evaluation board a basis for development, all necessary technical data like schematics, layout and components are included in this chapter. Also simple measurements were done to show the functionality of individual stages.

4 A

L_IN

N_IN

AC_IN

PHASE_EMI_IN

2R2

AC_IN

10 A

PHASE _EMI_0 1

NEUTRAL_EMI_IN

AC_IN

R2 680k

R4 680k

R5 680k

NEUTRAL_IN

C16

1 mF

1−1

2−1

2 x 2.2 mH

Figure 5. Schematic of EMI filter

Input EMI Filter

Figure 5 depicts schematic from AC input to rectifier input. This circuitry include a passive EMI filter consisting of elements C16, L5, CY1, CY3, CY4, C51, L4 and C17.

AC_IN

1−2

2−2

CY3

CY4

4700 pF

CY1 4700 pF

iGND

G_PFC

C51 680 nF

150 mH

NEUTRAL_EMI_OUT

AC_IN

PHASE_EMI_OUT

C17 680 nF

NEUTRAL_IN

AC_L

AC_N

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EVBUM2775/D

Interleaved PFC Stage

In higher power applications to utilize full capacity power of mains and reduce harmonics is PFC−regulators generally required. This high power application use interleaved PFC stages, where may reduce inductor size, input and output capacitors ripple current. In overall, power components are smaller include capacitors. The NCP1632 as voltage mode IC for interleaved PFC applications used in conduction

PHASE_PFC_IN

AC_L

AC_N

15VDC

GBU6K

NEUTRAL_PFC_IN

15VDC

100 nF

100 mF

C4 1 mF

soldered pads

330 nF

R22 120k

R6 3M9

R12 3M9

R17 3M9

R21 3M9

R33 270k

DC_PFC_IN

R34 5k1

C15

1 nF

C13 68 pF

DC_IN

C11 C12

2m2

220 nF

R35 15k

R18 11k5

100 nF

TP24

VCC

OSC

REF5V

R32 22k

NCP1632

MMSD4148T1G

R36 22k

R37 143k

5 V reg

control blocks

FFOLD

C14

470 nF

critical mode. It drives two mosfets 180° phase shifted. The most important at design should be focused significant inductance value of selected PFC coils. It significantly specifies working range.

Figure 6 depicts schematic from rectifier input to DC link

output. Activation of stage (connection to 15 V DC power

supply) is via J2 (soldered pads).

SMF15AT1G

R26 1k8

ZCD1 DRV1 ZCD2 DRV2 Latch

OVP

GND

TP27

DCLINK_POS

R13 10k

R28 10k

1N5406RLG

TP23

i DC_IN

TR2

750314724

D2 FFSPF1065A

Q1 FCPF125N65S3

TR1

750314724

R10 22k

R11 22k

MMSD4148T1G

10R

TP25

R14

TP26

R29

10 2 8

R27 1k

C10 10 nF

MMBT589LT1G

MMSD4148T1G

MMBT589LT1G

R25

10R

TP28

G_PFC

i DC_IN

FFSPF1065A

Q3 FCPF125N65S3

TP1TP22

C42 470 mF

DCLINK_POS

R9 1M8

R16 1M8

R20 560k

R24

27k

1 nF

DC_LINK

R8 1M8

R15 1M8

R19 820k

1 nF

R23 27kC8

G_PFC

G_PFC G_PFC

G_PFC

G_PFC G_PFC G_PFC G_PFC G_PFC

R31

R30

0R075

NTSS3100

G_PFC

Figure 6. Schematic of interleaved PFC stage

G_PFC

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EVBUM2775/D

Basic tests and measurements were done. The results of efficiency, power factor, power losses, load transients and

Efficiency PFC stage

97.00%

96.80%

96.60%

96.40%

96.20%

96.00%

95.80%

Efficiency [%]

95.60%

95.40%

95.20%

95.00% 190 200 210 220 230 240 250 260 270

Input AC voltage [V]

Figure 7. Efficiency of PFC Stage for Various Value of Input AC Voltage and Load

startup can be seen in the Figures 7−13. The used load was Halogen light bulb.

930 W load 466 W load 155 W load

Efficiency [%]

Power factor PFC stage

0.998

0.978

0.958

0.938

0.918

0.898

0.878

0.858

0.838 190 200 210 220 230 240 250 260 270

Input AC voltage [V]

Figure 8. Power Factor of PFC Stage for Various Value of Input AC Voltage and Load

933 W load 466 W load 155 W load

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0.998

0.978

0.958

0.938

EVBUM2775/D

Power factor PFC stage

0.918

0.898

Efficiency [%]

0.878

0.858

0.838

190 200 210 220 230 240 250 260 270

Input AC voltage [V]

Figure 9. Power Losses of PFC Stage for Various Value of Input AC Voltage and Load

933 W load 466 W load 155 W load

Figure 10. Load Transient 155 W to 930 W at 230 V AC Input

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