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www.irf.com 1 i i r r a a d d k k 3 3 1 1 international rectifier ? 233 kansas street, el segundo, ca 90245 ? usa 1/3 hp- phase brus hless dc (bldc) motor cont roller using ir3101/3/4 by roger n. khourey topics covered overview features general safety note, installation & protection system description mechanical and electrical description system connection and gui operation technical data mode operation circuit description figure 1. IRADK31 reference design kit 1. overview the IRADK31 reference design kit (figure 1) is an electronic controller for driving a 1/3hp (see table 1) 3-phase motor from either a single phase 120vac or 230vac. the circuit provides all the necessary functions, includ ing software driven high performance micro controller, for starting and operating the motor. it also includes an ac on/off switch, emi filter and the rectification stage with a buck-co nverter system that provides the auxiliary +15v and +5v supply. this co ntroller is software driven th rough a graphical user interface (gui) that enables the user to control the entire electrical syst em and motor parameters. in addition, it allows the user to monitor the dc bu s current, motor speed, and detects fault conditions. 2. features ? fused 120/230vac input. ? ac input on/off switch and emi filter. ? ntc inrush cu rrent limiter ? 3-phase, variable voltage output. ? opto-isolated rs-232 serial link interf ace to the graphic user interface software.
www.irf.com 2 i i r r a a d d k k 3 3 1 1 ? integral auxiliary power supply of +15v and +5v. ? fault protection for over current condition. ? stand-alone mode and fully software driv en (pc mode) using graphical user interface. ? pic18f2431 motor control mcu from mi crochip technology inc. with power pwm module and hi-speed 10-bit a/d converter. ? rj11 connector for mplab icd2 that prov ides programming or in-circuit debugger interface. 3. general safety note this controller operates at high voltage to control rota ting machinery. qualified, skilled personnel conversant with all applicable safety standards mu st operate this equipment. do not connect any interface cables to th e controller when power is present. 4. installation this controller must be placed on an insulat ed surface. proper ma ting cables must be used for the gui and motor interf aces (refer to figure 2). do not make any alterations or soldered connections to the printed wiring board . verify that the input selector switch matches the ac supply voltage. 5. protection before handling the controller, check that the ac input voltage applied to j1 is turned off, and the ac on/off switch, sw4 is set to position ?0?. caution: high voltage is present on th e motor connector j6 during operation. 6. system description 6.1 power modules the ir3101/3/4 are fredfet half-bridge with integrated driver ic for motor drive applications. the ir310x are developed fo r electronic motor control in appliance applications, such as dishwashing machine pumps and fan motors. these 500v power modules (ir3101 and ir3103) contain 2 fredfe ts with soft recovery commutation diodes, and one half-bridge ic driver. note that the ir3104 is a 600v module.
www.irf.com 3 IRADK31 6.2 motor controller this motor controller is a si ngle-phase 120v/230vac input t hat can utilize 3 ir3101/03/04 modules that are used in a standa rd inverter configuration. the system is based on a high computational performance, 8-bit micro controll er with 10-bit a/d converter, used to generate the pwm information and implement the motor control loop. the system operates in an open loop mode, as defined by the firmware. however, this controller has the provision to operate in closed loop mode. this controller can be operated in stand-alo ne mode or pc mode. it can be operated in stand-alone mode even after connecting the rs -232 cable into j5 but prior to connecting the gui with the controller. once the gui is connected with the controller the system will become operational in pc mode and the user cannot operate in stand-alone mode, until the system is reset again. refer to section 7 and appendix a for fu rther explanation of mode operation. two leds (green and red) are used to monitor the status of t he control board. both leds will blink on and off at initial power on, indicating normal board operation. these leds have the following features: ? green: indicates the hall sensors level, 3 hall sensors combined. if the motor shaft is rotated by hand, this led will blink on and off. once the motor ramps up at higher rate, the blink rate of this led will increase. ? red: in normal operation condition indica tes the direction of rotation command. on for forward, off for reverse. it will blink on and off wh en over current fault condition occurs. when a fault is detected th e green light, below the moto r speed tachometer on the control panel, will turn re d. a detected fault guarantees pwm drive shutdown and complete protection for the power stage and the power modules. a fault condition is detected when an over current condition occurs . the firmware current limit can be set in the system limits from th e setup parameters window (refer to fault condition and current limit in section 8 for details). 6.3 auxiliary power supply the auxiliary power supply uses an ir2153 self -oscillating half-bridge driver in a buck topology that delivers the +15v auxiliary supply. the 15v is fed through a linear regulator (lm7805) that delivers the +5v to the remain ing circuitry. both the +15v and +5v are referenced to the dc bus return . the auxiliary power supply operates with a constant on time at variable frequency. voltage regulation is main tained over a dc bus voltage variation from 80v to 400v.
www.irf.com 4 i i r r a a d d k k 3 3 1 1 6.4 connection diagram warning sw1 is an ac input voltage selector switch . do not apply 230vac when this switch is set to 115vac ? this will result in sever damage to the system and personal injury due to very high voltage produced by the voltage doubler circuit on the dc bus. figure 2 illustrates a typical co nnection block diagram. the pr inted wiring board has been designed to minimize ground lo op currents with particular attention to reducing emi generation. serial communication j4 j5 j1 u6 u7 u8 j6 1 1 1 jp1 power modules d10 d11 on/off switch sw4 sw4 emi filter section dc rectifier section control section icd auxiliary supply section gui (computer) led feedback line motor hall sensors neutral earth earth output phase u output phase v output phase w flash progmming and debugging rs-232 r28 sw3 sw2 pic18f2431 j2 15 2 3 46 figure 2. IRADK31 typical connection diagram 6.5 gui and micro controller the use of the gui enables the user to control motor speed and direction, monitors the dc bus current and fault conditions , and program motor parameters and other control factors. the gui also enables the users to set motor and system parameters such as motor type, motor voltage and current, ac input voltage, and pwm frequency. in addition, it allows the
www.irf.com 5 i i r r a a d d k k 3 3 1 1 user to set the system limits such as current and motor speed. all the setup parameters are uploaded via serial link. the pic18f2431 mcu from microchip technol ogy inc. is respon sible for all board functions, including communication throug h the rs-232 interfac e. moreover, the microcontroller introduces design enhancements that make it a lo gical choice for many high performance, power and moto r control applications. special peripherals include: ? 14-bit resolution power co ntrol pwm module (pcpwm) with programmable dead time insertion. ? motion feedback module (mfm), includi ng a 3-channel input capture (ic) module and quadrature encode r interface (qei). ? high-speed 10-bit a/d converter (hsadc). the mfm quadrature encoder interface provid es precise rotor posit ion feedback and/or velocity measurement. the mfm 3x input c apture or external in terrupts can be used to detect the rotor state for elec trically commutated motor appl ications using hall sensor feedback, such as bldc drives. the microcont roller also features flash program memory and an internal rc oscillator with built-in low power modes, fail-safe clock monitoring and enhanced usart module. 7. mechanical and electrical description the printed wiring board is a doubl e-sided 122.7 x 127 mm board using a mixed technology of smt and through-hole components. the layout of the co nnectors, indicators and user controls is shown in figure 3.
www.irf.com 6 i i r r a a d d k k 3 3 1 1 j4 j5 j1 u6 u7 u8 j6 1 1 1 jp1 power modules d10 d11 sw4 sw4 icd output phases 1 o 120/230vac input hall sensor tp1 tp3 tp2 tp4 tp5 leds 230v 115v sw1 j2 j3 rs-232 sw3 sw2 r28 pic18f2431 15 2 3 46 l n e figure 3. IRADK31 connectors and indicators layout power switch (sw4) this is the ac on/off power switch. when set to position ?0? power is disconnected from the board. when set to posit ion ?1? ac power will be applied to the board. 120/230vac input terminal (j1) this is the main connector for the ac 120/230vac i nput power with earth ground connection. main ac input pow er (line, neutral and earth ground) is to be connected as shown in figure 2. line terminal: input ac vo ltage (120v or 230v) phase. neutral terminal: input ac voltage (120v or 230v) neutral. earth: ground connection (recommended connection to reduce the emi noise). 115v/230v selector switch (sw1) warning: sw1 must be operated only wh en the ac power is disconnected from terminal j1. ignoring this warning will r esult in damage to the board and/or severe personal injury.
www.irf.com 7 i i r r a a d d k k 3 3 1 1 this is the voltage selector swit ch to set the correct rectifier configuration to the ac input. prior to connection the system to the ac i nput, carefully check the position of sw1. set to 115v when applying power from 110/120vac source, or set to 230v when applying power from a 220/230vac source. output phases terminal (j6) this is the terminal for motor connection, out put from 3-phase invert er circuit driven by pwm signals to the motor (i.e . motor voltages). these si gnals are referenced to the negative dc power rail, which is not a ground potential. caution: beware of electric shock haza rd. do not connect any grounded test equipment such as an oscillo scope to these test terminals. always isolate your equipment from earth ground. connect the motor phase inputs (u, v, and w) fr om this terminal as depicted in figure 2. hall sensor connector (jp1) this is motor?s hall sensors f eedback connector that allows for detecting the rotor state and position. rs-232 port (j5) a standard 9-pin d-shell female type connector (db9f) that provides an opto-isolated rs- 232 serial link with the pc to contro l and monitor the development board. rs-232 serial link: a standard 9-pin d female connector is used for the rs-232 serial link. the pins used on this connector are the rxd, txd, gnd, rts, and dtr. the rts and dtr signals provide sufficient current to drive the opto-couplers. the current dr awn from these pins is far below permissible limits fo r the rs-232 drivers. the gui should work with any of the ava ilable com ports on t he pc. there is no restriction on com port. co m1 is the gui?s default por t. the serial cable may be connected or disconnected at any time wi thout having to rest art your computer. mplab icd2 connector (j4) a 6-wire rj-11 jack is provided as a programming or in-circuit debugger interface. this will also allow users to use development tool s, such as mplab i cd2, while the board is under power. note that this connector is referenced to the ?dc bus.
www.irf.com 8 i i r r a a d d k k 3 3 1 1 leds d10, d11, and sw2, sw3, r28 at initial power on, leds d10 (red) and d 11 (green) blink on and off at a fixed rate. rotating potentiometer r28 c an change the blinking rate. clockwise (cw) slows the blinking rate and counterclockwise (ccw) incr eases the blinking rate . when r28 is near the end position on ccw, both leds may look like they are on all the time because they are blinking at a faster rate. the functions of d10, d11, sw2, sw3, and r28 are as follows: stand-alone mode (also referred as manual mode): - green led: indicates the hall sensors le vel, 3 hall sensors co mbined when the motor rotates. if the motor shaft is rotated by hand, this led will blink on and off. - red led: in normal operat ion indicates the direction of rotation command. on for forward, off for reverse. it will blink on and off, if hardware over current fault condition occurs (using the last downloaded parameters). - sw2: this switch is used to toggle between run and stop. - sw3: this switch is used to toggle between forward and reverse. - r28: used to cont rol the motor speed. pc mode (also referred as gui mode): - green led: indicates the hall sensors le vel, 3 hall sensors co mbined when the motor rotates. if the motor shaft is rotated by hand, this led will blink on and off. - red led: in normal operat ion indicates the direction of rotation command. on for forward, off for reverse. it will blink on and off if an over current fault condition occurs. - sw2, sw3: they are not used in pc mode. gui command is used instead. - r28: not used with this mode. test points (tp1 ? tp5) these test points are used for volt age and signal monitoring purposes. tp1, tp2: for monitoring the +d c bus and ?dc bus, respectively ? tp3: current feedback signal. ? tp4: +15v aux iliary power supply. ? tp5: +5v auxiliary power supply. jumper (j2) this is the reset jumper to t he microcontroller. when short ed, it resets the microcontroller and starts the firmware from beginning. this jumper is default to open. jumper (j3) this jumper is connected across the diode of opto-isolator, op 3. it allows the user to externally apply an opto-isolated pwm si gnal into the microcontroller for debugging purposes.
www.irf.com 9 i i r r a a d d k k 3 3 1 1 jumpers jx1 ? jx3 these jumpers are used to conn ect or disconnect the sensor less feedback circuit. their defaults are in the open positi on and not used with the curr ent firmware version provided with this kit. connecting the inverter to the motor warning sw1 is an ac input voltage selector switch . do not apply 230vac when this switch is set to 115vac ? this will result in sever damage to the system and personal injury due to very high voltage produced by the voltage doubler circuit on the dc bus. use a 3-phase connected bldc motor, rated at 1/3 hp or less. provide a 3-wire, 2a minimum rated cable for the mo tor connection, and a 3-wire 2a minimum rated cable for the ac mains connections. ensure that t he ground connection is also connected to the earth terminal of j1. the motor phases can be connected in any sequence, only the rotation direction will be affected. make all nec essary connections, including the serial link with the pc before a pplying ac power. note: connecting both the rs-2 32 serial cable into j5 an d the rj-11 cable into j4 simultaneously will disable communicat ion between the gu i and the system. when operating the motor, only connect th e serial link cable into j5 and when programming or debugging the microcontroller, only connect the rj-11 cable into j4. 8. system connection and gui operation warning when energized, the power produced by th e IRADK31 board ? particularly from the 3-phase inverter ? can cause severe equipment damage or personal injury. always use the proper precautions when working around the board, or power electronic equipment. whenever possible, use the IRADK31 board with the safety shield installed. connect the IRADK31 board to the motor as illustra ted in figure 2. en sure that the voltage select switch, sw1, is set to the appropriate voltage being su pplied to the board. set sw4 switch to position ?1? to supply ac power to the board. verify that the red and green leds are flashing, indicating that pow er to the board has been established. launch the microchip motor control gui (mot orcontrolir2.exe). the first screen will appear is the control panel as illustrated in figure 4.
www.irf.com 10 i i r r a a d d k k 3 3 1 1 figure 4. IRADK31 gui control pane l this the main display for t he application. us er can control moto r speed and rotation direction in a way that is similar to stand- alone mode. the user can also monitor motor speed and dc bus current. the control panel also allows users to access to the setup and pattern programming displays. main features: ? motor speed: this displays the actual speed of the motor in rpm, as determined by hall sensors, in both tachometer and digital (text) formats. the rpm speed is relative to the hall sensor frequency and the number of pole pairs in the motor. it can be determined from the following equation: pairs pole f rpm hall _ ) 60 ).( ( = the full-scale value is determined by the speed limit defined in the setup window plus an additional margin. the upper boundary of th e green range represents the motor?s rated speed. the upper blue boundary is set to scale the maximum safe speed well into the red area. this boundary is half way between the rated and full- scale speeds. the values may be changed in the setup display to reflect the actual performance limitations of the motor. ? fault display: a scrolling text indica tes the state of the fault conditions monitored by the board. under normal conditions, it will displa y a scrolling ?no fault? message and a green
www.irf.com 11 i i r r a a d d k k 3 3 1 1 indicator. if an over current fault condition occurs, the indicator will change to blinking red; the text will also change to red, and the me ssage will indicate ?over current fault?. ? fault condition and current limit: hardware ? the trip level is determi ned by the threshold voltage (1.66v) at the input of comparator u5:b, set by resist ors r30 and r35. with a gain of 4, set by u5:a, this becomes 0.415v (1.66v /4). when this vo ltage is across shunt resistor r2, the corresponding current is 0.415v/0.2 ? , or 2.075a at output ?f aulta?. therefore, the maximum safe current limit fo r the hardware is 2.1a. firmware ? this current feedback limit at output u5:a (idc) is co nverted to voltage, filtered and fed into the microcontroller?s a/d port. the microcontroller detect s when this limit is exceeded and determines when to shutdown the pwm signals if an actual over current condition occurs. ? set speed: the user can set the target run speed fo r the motor with this spin box by either direct entry or using the up /down controls. the motor s peed can be changed while the motor is rotating. since the algorithm is an open loop type, ac tual speed may vary depending on motor parameters and actual load. ? direction: the direction indicator is shown with a left and right arrows , and text of the motor revolution to the default direction. the motor direction can be changed from either clockwise or counterclockwise while the motor is rotating. doing so , the motor will ramp down and then ramp back up in the opposite direction. ? dc bus current: this displays the current drawn fo r the dc bus in amperes. information is given in analog gauge and digita l (text) format. as with t he speed display, the different color zones represent average safe and hazardo us operating ranges, based on the current limit defined in the setup window. the actual safe operating range should be determined from the motor?s nameplate and maximum curr ent rating of the power module being used. the maximum current rating of the modules used with this re ference design kit are as follows: ? ir3101: 1.6a ? ir3103: 0.8a ? ir3104: 0.5a ? run/stop: allows the user to star t and stop the motor. enteri ng the desired speed value in the set speed display and pressing the key will also start the motor. to start the motor, click on the run button an d observe that the motor skips twice before it starts rotating in full speed. this is to a llow the hall sensors to be aligned in the proper position before the motor fully accelerates.
www.irf.com 12 i i r r a a d d k k 3 3 1 1 ? connect/abort: this button can establis h or break a serial link c onnection with the board. when a link is established, the connect label changes to abort , and com setup becomes unavailable. when the lin k is broken; by clicking on abort, com select becomes available for configuration. press the com setup and verify that the co m port and baud rate ar e set as shown in figure 5. note that the com port can be set to either com1 or com2 depending on where the serial link cable is connected on your pc. figure 5. com port and baud rate settings dialog selecting the auto connect button can e nable the auto connect feature. once communication is established, the message ?connected to pic18f2431 on comx at xxxxbps (default value is 9600 bps). firmware version: 1. 0? will appear in the message window at the bottom of the co ntrol panel. (?x? represents t he com port actually selected; the actual baud rate depends on the setting used). also, the message ?brushless dc motor-open loop control on ir31xx demo boa rd? will appear on the top of the control panel. the connection indicator in the lower le ft corner of the contro l panel window should change to solid green. you are now read y to work with the motor control gui. from the control panel, press the setup button and verify that the motor parameters window is displayed as shown in figure 6.
www.irf.com 13 i i r r a a d d k k 3 3 1 1 figure 6. typical motor parameters setup window users can define the individual settings for the motor being us ed. if the appropriate information is included in the fi rmware, most of the values will auto-populate, or at least be limited to a smaller subset of c hoices. features or parameters that are not used will be masked or grayed out. there are three categories t hat the user can modify: ? motor parameters, which define the actual motor and sensor hard ware that are used. ? system (control) parameters, wh ich define the control variables. ? system limits, which define the hardware maximum ratings. controls are also provided to save or load parameters for later use, or restore default settings. note: users have to download the set tings to the connected board after any changes to see the effect of the new parameters. the following parameter s are masked out: ? motor parameter 9a.
www.irf.com 14 i i r r a a d d k k 3 3 1 1 ? system parameters 1 through 6. ? v/f curve button (not available for the IRADK31 motor controller board). motor parameters these are generally self-explanat ory. information on the mo tor hardware itself (items 1 through 6) can be found on the motor?s nameplate or in its data shee t. the ?motor type? filed is auto-populated with the mo tor type identified upon connection. selecting the appropriate check boxes in ?f eed back devices? sele ctively enables the configuration for motion feedback sensors. wh en only ?hall sensor? check box is selected the sensor angle and motion filter prescaler (mfm) may be configured; the other options are disabled. when optical encoders ar e enabled, the encode r ppr (pulses per revolution), and mfm filter may be configured; hall sensors configurat ion is unavailable. qei update mode is default to x4 and cann ot be changed. the recommended setting for the mfm filter prescaler to be used wi th the IRADK31 is ?filter disabled?. note that the hall sensor s and optical sensor s are not mutually exclusive. it is possible for some control methods to us e both types at once. for the IRADK31, on ly the hall sensor option is available. selecting the ?none? option in ?feed back devices? disables all sensor configuration options. informatio n on the sensor type and arrangement can be found in the motor data sheet. system parameters the system parameters options c an only be used with bldc motors with the firmware provided with th is demo kit. acceleration and deceleration rate are defined as rps/sec for most applications. input voltage is the ac input vo ltage applied to the board. t he input voltage should be kept at 220vac, regardless of actual ac input applied. because the board has a voltage doubler on the input rectifier side, when 115/120v ac is supplied, the dc bus volrage would be 320v with volt age doubler circuit. when the in put voltage is 220/230v ac, the dc bus volrage would also be 320v wi thout voltage doubler circuit. the calculated dc bus voltage supplied to the buck converter is given as 2 times the ac input (when 120vac is applied) times 1.414, with the on-board vo ltage doubler enabled. when the on-board voltage doubler is not us ed and 230vac is applied to the board the dc bus voltage would be 230v times 1.414. the pwm frequency determines the resolution of the control firmware. the drop-down combo box presents a fixed range of values.
www.irf.com 15 i i r r a a d d k k 3 3 1 1 system limits the system limits reflect the maximums of both the motor and the board being used. voltage limit: not used by the fi rmware provided with this kit. current limit: refer to the fault conditi on and current limit discussion in section 8. speed limit: is set at the va lue given in the motor?s data sheet, or at a predetermined speed set by the particular motor data file. caution not all motors may be able to run at th e maximum speed defined by the speed limit parameter. it should be re garded as an upper limit an d not the motor?s expected maximum speed. storing and using setting profiles once the parameters for a particular motor ar e established, it woul d be nice to preserve them for future use. users have several options from t he setup display to do just that. clicking on the save button allows the current settings to be stored in a file, while clicking on the load button selects and loads a file with saved settings. both comman ds used the conventional windows dialogs fo r opening and saving files. setting profiles are saved as motor data files (.mcd extension). neither of these affects the par ameters currently in effect in the on-board firmware. the default button replaces all of the current setti ngs with the default settings associated with the current motor type. this may be useful for quickl y starting over when a set of parameters has been extensivel y modified and isn?t working. the download button transfers the currently disp layed parameters to the on-board firmware. it only changes the parameters, and not the control firmware itself. note 1: attempting to load a motor data file that does not match the currently loaded motor and/or control method type w ill generate an error message. 2: remember that downloading a profile to the IRADK31 controller board only downloads variable values. it does not do wnload new firmware. similarly, loading and saving profiles only loads or saves the motor data file to the computer, but does not load or save the file on the on-board firmware.
www.irf.com 16 i i r r a a d d k k 3 3 1 1 9. technical data table 1 indicates the electrical specificat ion of the IRADK31 reference design kit. table 1. IRADK31 electrical specifications input voltage: 120vac / 60hz and 230vac / 50hz. output phases: 3-phase, 1/3 hp, 250w bldc motor (when 120vac input is applied). 3-phase, 2/3 hp, 520w bldc motor (when 230vac input is applied. protection: fused ac line with on/off power switch, ntc, and transient suppression varistor. motor over current shutdown filtering: x and y capacitors with common mode choke. indicator and status monitor: two leds for system communication and normal operation status, as well as fault condition indicator (red led) and gui for sett ing and monitoring system parameters. rs-232 interface: opto-isolated rs-232 serial interface.
www.irf.com 17 i i r r a a d d k k 3 3 1 1 10. appendix a ? mode operation 10.1 which mode to use? before setting up the developmen t board, it is necessary to decide which operation mode is appropriate for what you want to do. there are two choices: ? stand-alone mode: the IRADK31 board is conne cted to a power supply and a motor, but not to a computer. motor ope ration is controlled through the two push buttons, sw2 and sw3 (start/stop and di rection) and the po tentiometer, r28 (speed). this is a simple demonstration of the board?s capability, and is useful for verifying the board?s oper ation. it can also work as fast ?sanity check? of newly programmed control firmware. ? pc mode: the IRADK31 board is also connected to a ho st computer through a serial interface. in this configuration, motor operation is c ontrolled through a gui application on the computer; speed cannot be controlled from the potentiometer on the board. the gui allows more sophisticated motor operation, with controllable speed, and real-tim e monitoring of motor operation. since both modes start with the same set-up procedure, we will start by describing the set-up for the stand-alone mode. setti ng up the pc mode involves adding the serial interface to the stand-alone mode, and is covered later in this discussion. 10.2 setting up the IRADK31 board: stand-alone mode for evaluating the IRADK31 board, the simple st configuration is to use the board by itself, with no computer connection. this setup involves the following: 1. connecting power to the board 2. connecting the motor to the board (see figure 2). 3. verifying operation for the sake of simplicity, we will assume that we are us ing the development board in its default configuration for bldc. this m eans that board jumpers are not installed and the pic18f2431 device has been programm ed with bldc control firmware. this also assumes the use of a motor with bu ilt-in sensors for comm utation, spaced at 60. some motors have hall sensors spaced at 120. correct hall sensor spacing can be found in the data sheet for the motor being used.
www.irf.com 18 i i r r a a d d k k 3 3 1 1 10.3 setting up the IRADK31 board: pc mode while the stand-alone mode is useful for si mple testing, the pc mode allows more robust motor control. configuring the IRADK31 board for pc mode requires very little additional effort beyond the set up for stand-alone mode. 10.3.1 host computer requirements to use the IRADK31 board in pc mode, the computer being used must meet the following hardware and software requirements: ? pc-compatible system with an intel pentium ? class or higher processor, or equivalent, with a minimu m clock speed of 133 mhz. ? a minimum of 16 mb ram. ? a minimum of 16 mb available hard disk space. ? cd-rom drive (for use with the accompanying cd). ? one available standard serial port, with a matching com por t available through the operation system. ? any 32-bit version of microsoft windows ? (windows 98, windows nt ? , windows 2000 or windows xp). 10.3.2 installing the motor control gui the installation of the host software pack age is completely aut omated and does not require any user intervention or configur ation once the process is started. the process is identical for al l 32-bit windows operating s ystems. users with windows nt-based desktops (nt 4.0, 2000 and xp) should not need administrative rights to their systems for this installation. cl osing all background applications before proceeding is helpful, but not required. note: it is possible that some organizat ions may implement a desktop computer policy sufficiently rest rictive to prevent the user from loading any software at all. in theory, this can be done with any 32-bit windows operati ng system on a network ? including windows 95. if this describes your situation, c ontact your local information services provider for assistance installing this software. to install the host software, insert the so ftware and documentat ion cd into the cd- rom drive. open the cd in explorer view, a nd locate the ?gui? fol der. unzip the file ?microchip mc_rev2.zip? and copy its conten ts in to the folder ?microchip irad31 mc? that you create on your system.
www.irf.com 19 i i r r a a d d k k 3 3 1 1 the microchip mc_rev2 zip file contains the following files: 9 motorcontrolir2.exe 9 pic18_bldc_ol.ini 9 mcdemo.ini you may wish to create other folders and copy valuable files from the cd such as the motor parameter data, the pic18f2431 hex f ile, and data sheets for future reference. create a short cut on your desktop for the motorcontroir2 file. double-click on that file to launch the gui control panel as shown in figure 4. now you are ready to proceed with the operation of the gui and controller as described in section 8 of this document.
1 2 3 4 5 6 a b c d 6 5 4 3 2 1 d c b a rv2 mov 1 2 3 j1 con3 f1 2a 250v 1 4 2 3 d1 kbpc608 cx1 0.1uf 250vac d4 murs160 r4 1k r15 27k r16 2.4k rv1 ntc 2 1 4 3 emi1 1.8mh 2a cx2 0.1uf 250vac c1 470uf 250v c2 470uf 250v 2 4 6 5 3 1 sw1 v80212m +dc r2 0.2r 1w if cy3 10nf 275vac vin 1 gnd 2 vout 3 u2 lm7805c c16 47uf 25v r17 0r l1 1mh 0.53a q1 irfr420a vs 6 vb 8 com 4 rt 2 ct 3 ho 7 vcc 1 lo 5 u1 ir2153 r14 22 ohm c3 0.1uf r3 11k c18 470pf c4 0.1uf c17 4.7uf 25v r1 470k d3 murs160 d5 ll4148 vdd +15v +dc agnd -dc +dc -dc egnd d2 zener 18v r66 82k r67 82k c28 10uf 450v sw4 ac power r68 56r tp1 tp2 tp3 tp4 tp5 1 3 2 u3 iru431 a power supply 20
1 2 3 4 5 6 a b c d 6 5 4 3 2 1 d c b a r28 2k 1 2 3 4 5 6 jp1 5header r5 1k r7 1k r8 1k r6 1k r9 1k r10 1k jx1 jumper jx2 jumper jx3 jumper vdd vdd hall1 hall2 hall3 be3 be2 be1 mclr/vpp 1 ra0/an0 2 ra1/an1 3 ra2/an2/vref- 4 ra3/an3/vref+ 5 ra4/an4 6 avdd 7 avss 8 osc1/clki/ra7 9 osc2/clko/ra6 10 rc0/t1oso/t1cki 11 rc1/t1osi/ccp2 12 rc2/ccp1 13 rc3/int0 14 rc4/int1 15 rc5/int2 16 rc6/tx/ck 17 rc7/rx/dt 18 vss 19 vdd 20 rb0/pwm0 21 rb1/pwm1 22 rb2/pwm2 23 rb3/pwm3 24 rb4/pwm5 25 rb5/pwm4 26 rb6/pgc 27 rb7/pgd 28 u4 pic18f2431 r23 470 r18 10k r22 470 c5 0.1uf c6 0.1uf c7 0.1uf j2 jumper y1 20mhz c19 33pf c20 33pf 2 3 1 8 4 u5a mcp6002 6 5 7 u5b mcp6002 c8 0.1uf c9 0.1uf r12 1k r11 1k r24 1k r29 3k r25 470 r30 4.7k r35 2.2k mclr vdd vss rb7 rb6 rb3 1 2 3 4 5 6 j4 rj11 vdd vdd avdd vdd pgd pgc pwm4 pwm5 pwm3 pwm2 pwm1 pwm0 rx tx rc5 rc4 mclr idc hall1 hall2 hall3 rc0 faulta rc2 rc3 mclr pgd pgc vdd faulta vdd vdd if idc manual speed adj. shield a microcontroller and current sensing 21
1 2 3 4 5 6 a b c d 6 5 4 3 2 1 d c b a 1 6 2 7 3 8 4 9 5 j5 db9 d6 ll4148 r39 8.2k r38 8.2k r40 470 r41 1.5k d8 ll4148 d7 ll4148 d9 zener 30v 1 2 4 3 op1 hmha2801 1 2 4 3 op2 hmha2801 r42 2.2k r36 470 c21 680pf vdd vdd vdd tx rx 1 2 4 3 op3 hmha2801 r13 1k vdd rc2 r37 470 j3 jumper d10 red r26 470 r34 4.7k r33 4.7k d11 green r27 470 rc0 rc3 sw3 pts645sl50 rc5 vdd r32 4.7k r31 4.7k sw2 pts645sl50 rc4 vdd start fwd/rvs a rs-232 interface 22
1 2 3 4 5 6 a b c d 6 5 4 3 2 1 d c b a vcc 1 hin 2 lin 3 nc 4 vss 5 com 6 vb 8 vo 9 nc 10 vdd 11 u6 ir3101 1 2 3 4 j6 con4 c22 2.2uf 25v pwm1 pwm0 if +dc +15v +15v m1 vcc 1 hin 2 lin 3 nc 4 vss 5 com 6 vb 8 vo 9 nc 10 vdd 11 u7 ir3101 c23 2.2uf 25v pwm3 pwm2 +15v m2 vcc 1 hin 2 lin 3 nc 4 vss 5 com 6 vb 8 vo 9 nc 10 vdd 11 u8 ir3101 c24 2.2uf 25v pwm5 pwm4 +15v m3 c25 2.2uf 25v c26 2.2uf 25v c27 2.2uf 25v a power modules / pwm outputs 23
1 2 3 4 5 6 a b c d 6 5 4 3 2 1 d c b a sensorless feedback circuit 3 2 1 4 11 u9a mcp6544 12 13 14 u9d mcp6544 r19 10k r58 27k r57 27k r50 560k r48 560k r46 560k c12 0.1uf c11 0.1uf vdd vdd m1 r55 27k r56 27k r45 560k r44 560k r43 560k c10 0.1uf +dc r63 1m be1 5 6 7 u9b mcp6544 r20 10k r60 27k r59 27k r51 560k r49 560k r47 560k c13 0.1uf m2 r64 1m be2 10 9 8 u9c mcp6544 r21 10k r62 27k r61 27k r54 560k r53 560k r52 560k c14 0.1uf m3 r65 1m be3 24

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