Order this document
by AN1524/D
SEMICONDUCTOR APPLICATION NOTE
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.
INTEGRATED
POWER
STAGE
CAPACITORS
+
INTEGRATED
POWER
STAGE
AC DRIVE
+
THREE PHASE
AC OUTPUT
THREE PHASE
AC INPUT
PRECHARGE
CIRCUIT
POWER SUPPLY
VOLTAGE
DIVIDER
TEMPERATURE
AMPLIFIER
CURRENT
AMPLIFIER
GATE DRIVE
CONTROL
FUNCTIONS
+18 V
+18 V
+5 V
+12 V ISOLATED
+5 V
+12 V
MCU BOARD
Figure 1. System Block Diagram
REV 1
MOTOROLA
Motorola, Inc. 1996
1
AN1524
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.
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 VAC 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
P1
1
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.
P2
7
Q1
D8
R
S
T
D10
T+
G1
3
K1
24
23
22
21
2
D9
D11
Q5
Q3
D7
D12
D1
9
G3
8
K3
10
Q2
12
Q4
D2
G7
K5
D5
13
B
Q7
15
G5
20
19
18
T–
D13
D3
11
G2
16
Q6
D4
G4
17
U
V
W
D6
G6
14
R1
0.01 Ω
25
N1
6
N2
5
4
I–
I+
Figure 2. Integrated Power Stage Schematic
2
MOTOROLA
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Figure 3. Integrated Power Stage Module Illustration
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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
IC (Amps)
8
VCES
(Volts)
12
600
1200
MHPM7A8A120A
MHPM7A12A120A
15 – 16
20
30
MHPM7A15A60A
MHPM7A20A60A
MHPM7A30A60B
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 sufficient to
MOTOROLA
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.
3
AN1524
R
S
T
DB1
DB2
U
V
W
+VM
25
N1
U1
24
R
23
S
22
21
T
20
B
19
U
V
18
HEATSINK
W
INTEGRATED POWER STAGE
P1
1
2 3 4 5
N2
6
R1
1.0 Ω
P2
7
8 9
10 11
12 13
14 15 16 17
+VM
+
C1
0.033 µF
R2
1.0 Ω
J1
C2
470 µF
+
240
480
240
C3
470 µF
Figure 4. Power Electronics
Gate Drive
The gate drives for the high side IGBTs 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 VAC drives must operate with DC
link voltages as high as 850 volts under regeneration
+18 V
D4
U8
HCPL0453
UT
(FROM PLD)
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.
R46
2.2 Ω
R47
5.6 kΩ
C18
10 µF
U11
MC33151D
R52
100 Ω
R43
180 Ω
D5
C19
0.1 µF
D10
G1
(U1 PIN 9)
R53
22 Ω
E1
(U1 PIN 8)
Figure 5. High Side Gate Drive
4
MOTOROLA
AN1524
IO
(ANALOG OUTPUT)
+ 2.5 V
+5 V
+5 V
PlusI
(U1 PIN 4)
MinusI
(U1 PIN 5)
R26
1.10 kΩ
U4b
MC33272D
R25
13.0 kΩ
R28
3.01 kΩ
+
U3b
LM293AD
+
R27
1.10 kΩ
–
C9
120 pF
C10
120 pF
(4.0 V)
R30
13.0 kΩ
–
R31
2.2 kΩ
OC
(TO PLD)
R29
12.1 kΩ
C11
120 pF
Figure 6. Current Amplifier and Over–Current Comparator
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
MOTOROLA
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.
5
AN1524
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.
C7
1000 pF
R12
82.5 kΩ
VO
(ANALOG
OUTPUT)
+5 V
R21
137 kΩ
R22
10.0 kΩ
+5 V
R14
82.5 kΩ
R20
4.42 kΩ
+ 2.5 V
R11
82.5 kΩ
R13
82.5 kΩ
+5 V
PlusT
(U1 PIN 3)
+VM
R16
9.09 kΩ
U3a
LM293AD
R17
2.2 kΩ
+
–
+
U4a
MC33272D
TO
(ANALOG
OUTPUT)
R23
3.40 kΩ
R15
3.32 kΩ
OV
(TO PLD)
–
(4.25 V)
R18
51.1 kΩ
R19
150 kΩ
Figure 8. Voltage Divider and Over–voltage
Comparator
(0.69 V)
R24
1.30 kΩ
C8
0.1 µF
Figure 7. Temperature Amplifier
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 R11–14.
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.
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.
Complete Schematic & Bill of Materials
6
MOTOROLA
AN1524
+5 V
CN7
R10
4.7 kΩ
+5 V
+5 V 1
NC 2
GND 3
4
I/O1
I/O2 5
I/O3 6
7
Ut
8
Ub
9
Vt
Vb 10
Wt 11
Wb 12
BRK 13
Io 14
Vo 15
16
To
+5 V
S1
5
IO
VO
TO
I3
4
I2
R3–R9
4.7 kΩ
25
I/O6 24
UT
7 I5
I/O5 23
VT
22V10
NC 22
9 I6
I/O4 21
WT
10 I7
I/O3 20
UB
I/O2 19
VB
11 I8
J4
1
U2
2
28 27 26
I0 NC VCC I/O9 I/O8
I/O7
6 I4
8 NC
+5 V
3
I1
I9
I10 GND NC I11 I/O0 I/O1
12 13 14 15 16
17 18
WB
BRK
OV
OC
Figure 9. Input Logic
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.
2 µs
UT
UB
VT
VB
WT
WB
Figure 10. PWM Timing
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
MOTOROLA
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
7
AN1524
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.
AC CONTROL
MICROPROCESSOR
BOARD
ISOLATED THREE PHASE
AC POWER SUPPLY
(SEE TEXT)
IPS AC MOTOR DRIVE
DEMO BOARD
+18 V
100 mA
AC MOTOR
MOTOR
LOAD
+5 V
1 AMP
Figure 11. Laboratory Set–up Block Diagram
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,
8
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.
MOTOROLA
AN1524
MAINS INPUT
208 / 240 3∅
OR
380 / 480 3∅
L1
208 / 240 3∅
OR
380 / 480 V 3∅
480 V 3∅
L2
L3
EARTH
BREAKER
BOX
ISOLATION / STEP–UP
TRANSFORMER
MAINS OUTPUT
0–480 VAC 3∅
5 WIRE
ISOLATED
VARIAC
L1
L2
L3
N
EARTH
DISCONNECT
SWITCH BOX
Figure 12. Isolated Three Phase AC Supply
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.
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 Motor
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
SUMMARY
The Integrated Power Stage greatly simplifies the design
and assembly of an AC drive. A demo board has been
MOTOROLA
9
AN1524
Figure 13. Integrated Power Stage AC Motor Drive Board
10
MOTOROLA
AN1524
Appendix I
Board Schematic
IPS AC Motor Drive
Power I/O
CN1
CN3
1
1
1
R
2
CN6
2
U
S
1
1
V
T
2
2
W
CN2
+ VM
CN4
CN5
1
2
25
N1
24
R
23
S
22
T
21
B
20
19
U
V
1
2 3 4 5
N2
P2
6
7
8 9
10 11
DB2
18
W
U1
Integrated Power Stage
P1
DB1
12 13
14 15 16 17
R1
1.0 Ω
G7
G6
G4
G2
R2
1.0 Ω
+ VM
G5
E5
C1
0.033 µF
+ 1 C2
2 470 µF
J3
J1
J2
+ 1 C3
2 470 µF
G3
E3
G1
E1
Minusl
Plusl
PlusT
MOTOROLA
11
AN1524
IPS AC Motor Drive
Logic I/O
+5 V
+5 V
C4
(U2 DECOUPLING)
0.1 µF
R10
4.7 kΩ
CN7 + 5 V
+5 V
NC
GND
I/O1
I/O2
I/O3
Ut
Ub
Vt
Vb
Wt
Wb
BRK
lo
Vo
To
1
S1 3
1
2
2
+5 V
3
4
5
6
7
8
9
10
11
5
12
6
13
7
14
16
3
I1
10
11
+5 V
2
1
28
27
U2
26
I0 NC VCC I/O9 I/O8
I3
I/O7
I4
I/O6
25
24
23
I5
8
NC
9
I6
IO
VO
TO
15
4
I2
I/O5
22
NC
21
I/O4
22V10
I7
I/O3
I8
I/O2
20
19
UT
VT
WT
UB
VB
I9 I10 GND NC I11 I/O0 I/O1
12
1
J4
2
3
R3
4.7 kΩ
R4
4.7 kΩ
R5
4.7 kΩ
R6
4.7 kΩ
R7
4.7 kΩ
R8
4.7 kΩ
R9
4.7 kΩ
13
14
15
16
17
18
WB
BRK
OV
OC
CN8
+18 V
+5 V
GND
12
+18 V
1
+5 V
2
3
MOTOROLA
AN1524
IPS AC Motor Drive
Voltage and Temperature
+ VM
R11
82.5 kΩ
Temp Sensor Amp
R12
82.5 kΩ
C7
1000 pF
VO
R13
82.5 kΩ
+5 V
R16
9.09 kΩ
R14
82.5 kΩ
R15
3.32 kΩ
+5 V
+5 V
3
2
4.25 V
R18
51.1 kΩ
R20
4.42 kΩ
R17
2.2 kΩ
U3a
+
1
R21
137 kΩ
R22
10.0 kΩ
PlusT
OV
VREF
–
R23
3.40 kΩ
R19
150 kΩ
2
3
–
1
TO
+
U4a
MC33272D
0.69 V
+18 V
C5
(U3 DECOUPLING)
0.1 µF
MOTOROLA
+18 V
C6
(U4 DECOUPLING)
0.1 µF
R24
1.30 kΩ
C8
0.1 µF
13
AN1524
IPS AC Motor Drive
Current Limit
IO
VREF
Current Amp
+5 V
+5 V
R26
1.10 kΩ
R25
13.0 kΩ
U4b
5
Plusl
6
Minusl
R27
1.10 kΩ
C9
120 pF
C10
120 pF
+
–
R30
13.0 kΩ
C11
120 pF
R28
3.01 kΩ
7
U3b
5
R31
2.2 kΩ
+
7
4.0 V
6
OC
–
R29
12.1 kΩ
Over Current
Comparator
+18 V
Reference Voltage
C12
0.1 µF
14
R32
10 kΩ
VREF
8
LM285D–2.5
4 U5
MOTOROLA
AN1524
IPS AC Motor Drive
Low Side Gate Drive
+18 V
U6
C16
0.1 µF
R33
510 Ω
6
2
UB
C13
470 pF
4
R34
510 Ω
R36
100 Ω
7
G2
R38
100 Ω
5
G4
R39
22 Ω
3
3
VB
C14
470 pF
2
D1
1
3
2
R40
22 Ω
D2
1
+18 V
U7
C17
0.1 µF
R35
510 Ω
6
2
WB
R37
100 Ω
7
G6
C15
470 pF
4
R41
470 Ω
5
G7
3
BRK
3
2
R42
22 Ω
D3
1
MOTOROLA
15
AN1524
IPS AC Motor Drive
High Side Gate Drive
+18 V
2
D4
1
R46
2.2 Ω
U11
R47
5.6 kΩ
U8
R43
180 Ω
UT
3
8
6
2
7
4
5
R52
100 Ω
G1
2
3
6
1
3
D5
C18
10 µF
5
+18 V
2
D6
1
2
R53
22 Ω
D10
C19
0.1 µF
3
1
E1
R48
2.2 Ω
U12
R49
5.6 kΩ
U9
R44
180 Ω
VT
3
8
6
2
7
4
5
R54
100 Ω
G3
2
3
6
1
3
D7
C20
10 µF
5
+18 V
2
D8
1
2
R55
22 Ω
D11
C21
0.1 µF
3
1
E3
R50
2.2 Ω
U13
R51
5.6 kΩ
U10
R45
180 Ω
WT
3
8
2
7
4
5
R56
100 Ω
G5
3
6
3
5
16
6
2
1
D9
C22
10 µF
C23
0.1 µF
2
D12
3
1
R57
22 Ω
E5
MOTOROLA
AN1524
Appendix II
Bill of Materials
Item
#
Designators
Qty
Part Number
Value
Description
1
C1
1
FKP1 0,033 1000
0.033 µF Capacitor
2
C2,C3
2
LGQ2W471MHSC
470 µF
3
C4,C5,C6,C8,C12,
C16,C17,C19,C21,
C23
10
4
C7
5
C9,C10,C11
6
C13,C14,C15
3
7
C18,C20,C22
3
PCT5106–ND
8
CN1,CN2,CN3,
CN4,CN5
5
17 14 97 1
9
CN6
1
10
CN7
1
11
CN8
1
17 29 13 1
12
D1,D2,D3,D10,
D11,D12
6
13
D4,D6,D8
14
D5,D7,D9
15
J1,J2,J3
3
16
J4
1
17
R1,R2
2
18
R3,R4,R5,R6,R7,
R8,R9,R10
19
20
Package
Comp.
Manufacturer
Allow
Subs.
Rating
Tol.
1000 V
±10%
#WIM22p5
Poly.
Wima
no
Electrolytic Capacitor 450 V
± 20%
#SNAP35
Alum.
Nichicon
yes
0.1 µF
Capacitor
50 V
±10%
1206
X7R
Panasonic
yes
1
1000 pF
Capacitor
50 V
± 5%
805
NPO
Panasonic
yes
3
120 pF
Capacitor
50 V
± 5%
805
NPO
Panasonic
yes
470 pF
Capacitor
50 V
± 5%
805
NPO
Panasonic
yes
10 µF
Capacitor
25 V
± 20%
#PAND
Tant.
Panasonic
no
Phoenix Contact
no
Connector 2x0.375″
#PNX2x375
Screw hole
#SCRW440
Header 2x8 0.1″
#HDR8x2
Connector 3x0.2″
#PNX3x200
Phoenix Contact
no
MMBD6100LT1
Dual Diode
SOT23
Motorola
yes
3
MURS160T3
Diode
#SMB
Motorola
no
3
MMBD914LT1
Diode
SOT23
Motorola
yes
Jumper 18AWG
#J400
Jumper 3x0.1″
yes
yes
yes
#HDR3x1
yes
1.0 Ω
Thermistor
30 A
± 25%
#THRM310
Ketema
no
8
4.7 kΩ
Resistor
1/10 W
± 5%
805
Panasonic
yes
R11,R12,R13,R14
4
82.5 kΩ
Resistor
1/8 W
±1%
1206
Panasonic
yes
R15
1
3.32 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
21
R16
1
9.09 kΩ
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
51.1 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
24
R19
1
150 kΩ
Resistor
1/10 W
± 5%
805
Panasonic
yes
25
R20
1
4.42 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
26
R21
1
137 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
27
R22
1
10.0 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
28
R23
1
3.40 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
29
R24
1
1.30 kΩ
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
3.01 kΩ
Resistor
1/10 W
±1%
805
Panasonic
yes
33
R29
1
12.1 kΩ
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
470 Ω
Resistor
1/10 W
± 5%
805
Panasonic
yes
MOTOROLA
SG405
17
AN1524
Bill of Materials — continued
Item
#
Designators
Qty
39
R43,R44,R45
3
180 Ω
40
R46,R48,R50
3
41
R47,R49,R51
3
42
S1
1
SS–12SDP2
43
U1
1
44
U2
1
45
U3
46
U4
47
Part Number
Value
Description
Package
Comp.
Manufacturer
Allow
Subs.
Rating
Tol.
Resistor
1/10 W
± 5%
805
Panasonic
yes
2.2 Ω
Resistor
1/10 W
±10%
SG73
KOA
no
5.6 kΩ
Resistor
1/10 W
± 5%
805
Panasonic
yes
Subminiature Switch
#SW1
NKK
no
MHPM7A15A60A
Int. Power Stage
#HPM1
Motorola
no
22V10
PAL
PLCC20
TI
yes
1
LM293AD
Dual Comparator
SO8
Motorola
yes
1
MC33272D
Dual Op Amp
SO8
Motorola
no
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
SO8
3
MC33151D
Dual MOSFET Driver
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
18
MOTOROLA
AN1524
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
UT_in
UB_in
VT_in
VB_in
WT_in
WB_in
Brk_in
OC_in
OV_in
IO1
IO2
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
2;
5;
6;
7;
9;
10;
11;
12;
13;
16;
25;
26;
VCC
GND
NC
pin 28;”
pin 14;”
pin 1, 8, 15, 22;”
”outputs”
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
pin
pin
pin
pin
pin
pin
pin
pin
24;
20;
23;
19;
21;
18;
17;
27;
equations
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
=
=
=
=
=
=
=
=
UT_in
UB_in
VT_in
VB_in
WT_in
WB_in
0;
1;
& !UB_in & !OE;
&
!OE;
& !VB_in & !OE;
&
!OE;
& !WB_in & !OE;
&
!OE;
end IPS_PAL
MOTOROLA
19
AN1524
module IPS_PAL
title
’Inverted Inputs’
IPS_PAL device ’P22V10C’;
”This ABLE code provides inverted inputs. Configure J1 for pull up resistors.”
”inputs”
”
”
”
OE
UT_in
UB_in
VT_in
VB_in
WT_in
WB_in
Brk_in
OC_in
OV_in
IO1
IO2
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
2;
5;
6;
7;
9;
10;
11;
12;
13;
16;
25;
26;
VCC
GND
NC
pin 28;”
pin 14;”
pin 1, 8, 15, 22;”
”outputs”
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
pin
pin
pin
pin
pin
pin
pin
pin
24;
20;
23;
19;
21;
18;
17;
27;
equations
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
=
=
=
=
=
=
=
=
!UT_in
!UB_in
!VT_in
!VB_in
!WT_in
!WB_in
0;
1;
& UB_in & !OE;
&
!OE;
& VB_in & !OE;
&
!OE;
& WB_in & !OE;
&
!OE;
end IPS_PAL
20
MOTOROLA
AN1524
module IPS_PAL
title
’Auto Brake’
IPS_PAL device ’P22V10C’;
”This is the ABLE code with automatic braking under overvoltage”
”inputs”
”
”
”
OE
UT_in
UB_in
VT_in
VB_in
WT_in
WB_in
Brk_in
OC_in
OV_in
IO1
IO2
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
pin
2;
5;
6;
7;
9;
10;
11;
12;
13;
16;
25;
26;
VCC
GND
NC
pin 28;”
pin 14;”
pin 1, 8, 15, 22;”
”outputs”
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
pin
pin
pin
pin
pin
pin
pin
pin
24;
20;
23;
19;
21;
18;
17;
27;
equations
UT_out
UB_out
VT_out
VB_out
WT_out
WB_out
Brk_out
IO3
=
=
=
=
=
=
=
=
UT_in & !UB_in & !OE;
UB_in &
!OE;
VT_in & !VB_in & !OE;
VB_in &
!OE;
WT_in & !WB_in & !OE;
WB_in &
!OE;
OV_in;
1;
end IPS_PAL
MOTOROLA
21
AN1524
Motorola reserves the right to make changes without further notice to any products herein. Motorola makes no warranty, representation or guarantee regarding
the suitability of 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. “Typical” parameters can and do vary in different
applications. All operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. Motorola does
not convey any license under its patent rights nor the rights of others. Motorola products are not designed, intended, or authorized for use as components in
systems intended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of
the Motorola product could create a situation where personal injury or death may occur. Should Buyer purchase or use Motorola products for any such
unintended or unauthorized application, Buyer shall indemnify and hold Motorola and its officers, employees, subsidiaries, affiliates, and distributors harmless
against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death
associated with such unintended or unauthorized use, even if such claim alleges that Motorola was negligent regarding the design or manufacture of the part.
Motorola and
are registered trademarks of Motorola, Inc. Motorola, Inc. is an Equal Opportunity/Affirmative Action Employer.
How to reach us:
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P.O. Box 20912; Phoenix, Arizona 85036. 1–800–441–2447
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22
◊
*AN1524/D*
MOTOROLA
AN1524/D