Low Power High Voltage Motor Control Board User's Guide: 2017 Microchip Technology Inc

Low Power High Voltage
Motor Control Board

User’s Guide
 2017 Microchip Technology Inc.

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ISBN:
page 2  2017 Microchip Technology Inc.

LOW POWER HIGH VOLTAGE
MOTOR CONTROL BOARD
USER’S GUIDE
Safety Notice
The safety notices and operating instructions provided should be adhered to, to avoid
a safety hazard. If in any doubt, consult your supplier.
WARNING – This system must be earthed (grounded) at all times.
WARNING – The output terminals are NOT isolated from the incoming AC mains
supply and may be at up to 410V with respect to earth ground, regardless of the input
mains supply voltage applied. These terminals are live during operation AND for five
minutes after disconnection from the supply. Do not attempt to access the terminals or
remove the cover during this time.
WARNING – The unit may obtain power through the output terminals if these are
connected to a rotating motor acting as a generator. If this is the case, then the previous
warning also applies (i.e., the output terminals are live when connected to the genera-
tor and for five minutes after the generator has been stopped). Note that this case can
arise even when the unit has been disconnected from the incoming AC mains supply.
CAUTION – The system should not be installed, operated, serviced or modified except
by qualified personnel who understand the danger of electric shock hazards and have
read and understood the user instructions. Any service or modification performed by
the user is done at the user’s own risk and voids all warranties.
CAUTION – If a motor is connected to the output of this unit, the frame should be
connected to the output protective ground terminal provided. Particular care should be
taken to mechanically guard such a motor, bearing in mind that unexpected behavior
is likely to result from the process of code development.
CAUTION – For continued protection against the risk of fire, replace the fuse with one
of the same type only (i.e., Fast Act Fuse 5A/250V).
• The system is intended for evaluation and development purposes and should only
be operated in a normal laboratory environment as defined by IEC 61010-1:2001
• Clean with a dry cloth only
• Operate flat on a bench, do not move during operation and do not block the
ventilation holes
• The system should not be operated without all the supplied covers fully secured in
place
• The system should not be connected or operated if there is any apparent damage
to the unit
• The unit is designed to be connected to the AC mains supply via a standard non-
locking plug. As the unit has no mains switch, this plug constitutes the means of
disconnection from the supply and thus the user must have unobstructed access
to this plug during operation.
 2017 Microchip Technology Inc. page 3

Low Power High Voltage Motor Control Board User’s Guide
NOTES:

MOTOR CONTROL BOARD
USER’S GUIDE
Table of Contents
Safety Notice ................................................................................................................. 3
Preface ........................................................................................................................... 3
Chapter 1. Introduction
1.1 Overview ........................................................................................................ 9
1.2 Features ....................................................................................................... 10
Chapter 2. Getting Started
2.1 Introduction ................................................................................................... 13
2.2 Board Layout ................................................................................................ 13
2.3 User Interface ............................................................................................... 14
Chapter 3. Hardware
3.1 Hardware Setup ........................................................................................... 19
Chapter 4. Running the Demonstration
4.1 Demonstration Requirements ....................................................................... 21
4.2 Software Setup and Run .............................................................................. 21
Appendix A. Board Schematics and Layout.............................................................. 25
A.1 Board Schematics and Layout ..................................................................... 25
Appendix B. Power Rating of Inverter or Integrated Power Module (IPM) ............. 33
B.1 Introduction .................................................................................................. 33
B.2 Power Loss .................................................................................................. 33
Worldwide Sales and Service .................................................................................... 35

DS00000A-page 2  2017 Microchip Technology Inc.

MOTOR CONTROL BOARD
USER’S GUIDE
Preface
INTRODUCTION
This preface contains general information that will be useful to know before using the
Low Power High Voltage Board. Topics discussed in this preface include:
• Document Layout
• Conventions Used in this Guide
• Recommended Reading
• The Microchip Web Site
• Development Systems Customer Change Notification Service
• Customer Support
• Document Revision History
DOCUMENT LAYOUT
This user’s guide describes how to use the Low Power High Voltage Board. The doc-
ument is organized as follows:
• Chapter 1. “Introduction” – This chapter introduces the Low Power High Volt-
age Board and provides a brief overview of its features.
• Chapter 2. “Getting Started” – This chapter provides information on getting
started with the Low Power High Voltage Board.
• Chapter 3. “Hardware” – This chapter describes the hardware on the Low Power
High Voltage Board.
• Chapter 4. “Running the Demonstration” – This chapter describes the
demonstration software that is intended for the Low Power High Voltage Board
and the procedure to run the board.
• Appendix A. “Board Schematics and Layout” – This appendix displays the
schematics and layout of the board.
• Appendix B. “Power Rating of Inverter or Integrated Power Module (IPM)” –
This appendix discusses the power rating/power loss related issues.

CONVENTIONS USED IN THIS GUIDE

This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS
Description Represents Examples
Arial font:
Italic characters Referenced books MPLAB® IDE User’s Guide
Emphasized text ...is the only compiler...
Initial caps A window the Output window
A dialog the Settings dialog
A menu selection select Enable Programmer
Quotes A field name in a window or “Save project before build”
dialog
Underlined, italic text with A menu path File>Save
right angle bracket
Bold characters A dialog button Click OK
A tab Click the Power tab
N‘Rnnnn A number in verilog format, 4‘b0010, 2‘hF1
where N is the total number of
digits, R is the radix and n is a
digit.
Text in angle brackets < > A key on the keyboard Press <Enter>, <F1>
Courier New font:
Plain Courier New Sample source code #define START
Filenames autoexec.bat
File paths c:\mcc18\h
Keywords _asm, _endasm, static
Command-line options -Opa+, -Opa-
Bit values 0, 1
Constants 0xFF, ‘A’
Italic Courier New A variable argument file.o, where file can be
any valid filename
Square brackets [ ] Optional arguments mcc18 [options] file
[options]
Curly braces and pipe Choice of mutually exclusive errorlevel {0|1}
character: { | } arguments; an OR selection
Ellipses... Replaces repeated text var_name [,
var_name...]
Represents code supplied by void main (void)
user { ...
}

Preface
RECOMMENDED READING
This user’s guide describes how to use the Low Power High Voltage Board. The device-
specific data sheets contain current information on programming the specific microcontrol-
ler or digital signal controller devices. Other useful documents are listed below. The follow-
ing Microchip documents are available and recommended as supplemental reference
resources:
MPLAB® XC16 C Compiler User’s Guide (DS50002071)

This user’s guide describes how to use the 16-bit MPLAB® XC16 C Compiler. Please
visit www.microchip.com/compilers for more information.
MPLAB® IDE User’s Guide (DS51519)

This user’s guide describes how to set up the MPLAB® IDE software and use it to cre-
ate projects and program devices.
MPLAB® X IDE User’s Guide (DS52027)

This document describes how to setup the MPLAB® X IDE software and use it to create
projects and program devices.
MPLAB® XC16 Assembler, Linker and Utilities User’s Guide

(DS50002106)
This user’s guide describes how to use GNU language tools to write code for 16-bit
applications.
Readme Files
For the latest information on using other tools, read the tool-specific Readme files in
the Readme subdirectory of the MPLAB® IDE installation directory. The Readme files
contain updated information and known issues that may not be included in this user’s
guide.
To obtain any of these documents, visit the Microchip web site at www.microchip.com.

THE MICROCHIP WEB SITE

Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser, the web site contains the following
information:
• Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents,
latest software releases and archived software
• General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program
member listing
• Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices,
distributors and factory representatives
DEVELOPMENT SYSTEMS CUSTOMER CHANGE NOTIFICATION SERVICE

Microchip’s customer notification service helps keep customers current on Microchip
products. Subscribers will receive e-mail notification whenever there are changes,
updates, revisions or errata related to a specified product family or development tool of
interest.
To register, access the Microchip web site at www.microchip.com, click on Customer
Change Notification and follow the registration instructions.
The Development Systems product group categories are:
• Compilers – The latest information on Microchip C compilers and other language
tools. These include the MPLAB® C compiler; MPASM™ and MPLAB® 16-bit
assemblers; MPLINK™ and MPLAB® 16-bit object linkers; and MPLIB™ and
MPLAB® 16-bit object librarians.
• Emulators – The latest information on the Microchip MPLAB® REAL ICE™
in-circuit emulator.
• In-Circuit Debuggers – The latest information on the Microchip in-circuit
debugger, MPLAB® ICD 3.
• MPLAB IDE – The latest information on Microchip MPLAB® IDE, the Windows®
Integrated Development Environment for development systems tools. This list is
focused on the MPLAB® IDE, MPLAB® SIM simulator, MPLAB® IDE Project Man-
ager and general editing and debugging features.
• Programmers – The latest information on Microchip programmers. These include
the MPLAB® PM3 device programmer and the PICkit™ 3 development
programmers.

Preface
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
• Distributor or Representative
• Local Sales Office
• Field Application Engineer (FAE)
• Technical Support
Customers should contact their distributor, representative or FAE for support. Local
sales offices are also available to help customers. A listing of sales offices and loca-
tions is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
DOCUMENT REVISION HISTORY

Revision A (April 2017)
This is the initial released version of the document.

NOTES:

MOTOR CONTROL BOARD
USER’S GUIDE
Chapter 1. Introduction
1.1 OVERVIEW
The Low Power High Voltage Motor Control Board is designed to help the user in rapid
evaluation of a wide variety of motor control applications using Microchip’s
dsPIC® DSC dsPIC33EP64MC206. This compact and cost-effective board has a 3-
phase power module with a built-in driver and is targeted to control various types of
high-voltage motors such as Brushless DC (BLDC) motors, Permanent Magnet Syn-
chronous Motors (PMSM) and AC Induction Motors (ACIM) in sensored or sensorless
mode of operation. Figure 1-1 displays a photograph of the Low Power High Voltage
Motor Control Board.
FIGURE 1-1: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD

Figure 1-2 shows a block diagram showing the main components of the Low Power
High Voltage Motor Control Board.
FIGURE 1-2: SYSTEM BLOCK DIAGRAM
RX/TX
Low Power High Voltage Motor Control Board
Communication
User Interface
Voltage Feedback Push Buttons

Non-Isolated
Circuitry (DC Bus
1.5V, 3.3V and Isolated
and Motor BEMFs)
Isolated 5V
dsPIC33EP64MC206 Hall Sensor/

FG Signal
QEI, FG Signal
Rectifier Current Feedback Hall Sensor/
Circuitry (DC Bus and QEI Circuitry
Phase Currents)
EMI Choke,
Inrush Current
Protection, Debug/Fault LEDs
Fuse Power Module
(3-Phase ICSP™ Connector
MOSFET Bridge) Non-Isolated
External Programmer/
90 VAC-230V AC
Debugger
Motor
1.2 FEATURES
Some of the key features of the Low Power High Voltage Motor Control Board are:
• 3-phase motor control evaluation board for driving Low Power High Voltage
BLDC/ PMSM motors.
• Current amplification and over-current protection through Op-Amps/comparators
internal to the dsPIC33EP64MC206.
• The motor drive stage uses an Integrated Power Module (IPM) with a built-in
temperature sensing circuit.
• Phase voltage feedback for sensorless BLDC operation and windmilling.
• DC bus and Phase current sensing for single/dual shunt sensorless FOC control.
• Non-isolated connector for Hall sensors/Quadrature Encoder Interface (QEI) for
sensored motor control algorithms.
• Isolated logic level (5V) UART interface.
• Four LEDs for debug/indication.
• Four user configurable push buttons.
For applications such as air conditioners (outdoor fan motor) where the main control
unit needs the information of the fan speed, the board features 15V level non-isolated
FG signal which can be used to generate a pulsed signal proportional to the motor
speed. There is also an isolated user-interface consisting of four push buttons and a
5V logic level communication interface. The push buttons can be programmed in the
firmware for various functions, such as command input and debugging. The tempera-
ture sensor of the IPM is connected to one of the analog inputs of
dsPIC33EP64MC206.

Introduction
The Low Power High Voltage Motor Control Board is capable of operating from 90 VAC
up to a maximum of 230 VAC. The power ratings of the board provided in Table 1-1.
TABLE 1-1: ELECTRICAL SPECIFICATIONS

Parameter Operating Range
Input AC Voltage 90 VAC-230 VAC, 50/60 Hz
Maximum input Current 1.5A (RMS)
Continuous Active Power at 230 VAC, 25°C 150W(1)
Active Power at 230 VAC, 25°C 150W for 8 min(2)
Auxiliary 15V Output Power 5W max
Auxiliary 3.3V Output Power 1.8W max
Auxiliary 5V (isolated) Output Power 0.8W max
Note 1: When the board is operated without enclosure in free air at 25°C with an
over-temperature trip limit of 80°C (IPM case temperature).
2: When the board is operated inside the enclosure with an over-temperature trip limit
of 80°C (IPM case temperature). Figure 1-3 shows a typical temperature rise for
the board at different power levels.
FIGURE 1-3: IPM’s CASE TEMPERATURE RISE AT DIFFERENT POWER

LEVELS
90
80
70
Temperature (°C)
60
50
100W
40
125W
30
150W
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Time in Minutes

NOTES:

MOTOR CONTROL BOARD
USER’S GUIDE
Chapter 2. Getting Started
2.1 INTRODUCTION
This chapter provides details of the input/output and other interfaces of the Low Power
High Voltage Motor Control Board. The input power for the board is passed through the
EMI filter section and then gets converted to DC using the rectifier. An auxiliary power
supply unit powers various integrated circuits of the board.
The outputs of the auxiliary power supply unit are:
• Non-isolated 15V - for the gate drive of the power module. 15V also decides the
level of the FG signal.
• Non-isolated 3.3V - to power logic level ICs and circuits including
dsPIC33EP64MC206.
• Isolated 5V - to power the external board interface circuitry.
2.2 BOARD LAYOUT

The Low Power High Voltage Motor Control Board has various sections which imple-
ment its salient features. They are marked in the Figure 2-1 and are detailed in
Table 2-1.
FIGURE 2-1: BOARD SECTIONS
12
4
3
5 11
1 10
7
13
6
9

Low Power High Voltage Motor Control Board User’s
TABLE 2-1: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD

SECTIONS
Section
Description
Number
1 MOV, fuse, EMI filter, inrush current limiter and bleeder resistor
2 Rectifier and DC bus capacitor
3 Flyback converter with 3 outputs: 15V (regulated), 4.2V (unregulated) and
5V (unregulated and isolated)
4 Bulk capacitors and EMI filter for 15V, 3.3V and 5V (isolated) output
LDO to convert 4.2V input to 3.3V output
5 3-phase power module (bottom side of the board)
6 Shunts for DC bus and 2-phase current measurement
7 Resistors for back EMF sensing and diodes for over voltage protection
8 3 green LED and 1 red LED for debug purpose
9 1.65V reference voltage generator
10 dsPIC33EP64MC206 with internal operational amplifier
11 Isolated user interface
12 Transistor to buffer the 15V - FG signal coming from the microcontroller output
13 Resistors for biasing current sensing internal OpAmp, capacitors for decoupling
2.3 USER INTERFACE

This section describes various interfaces of the Low Power High Voltage Motor Control
Board.
2.3.1 Power Supply Connector

The connector J1 provides the input power to the board. AC power input is specified
for 90 VAC-230 VAC, 3 Amps max. The connector is shown in Figure 2-2 and the
connection details are provided in Table 2-2.
FIGURE 2-2: POWER SUPPLY CONNECTOR
1 2 3
TABLE 2-2: CONNECTOR J1

Number Name
1 Live
2 Earth
3 Neutral

Getting Started
The user may consider the following guidelines in selecting the right cable for the
board.
• It is recommended that cables used for the power connections should be termi-
nated with insulated crimp terminals. If crimp terminals are not used, care should
be taken to ensure that stray strands of wire do not short to adjacent terminals. If
possible, all wires should be stripped and tinned with solder before connecting to
the Low Power High Voltage Motor Control Board terminals.
• For the AC mains supply input, standard double-insulated, 3-core flex cable
should be used with a minimum current rating of 3A.
• The recommended output cable size is 1.0 mm2 to 1.5 mm2 (18 AWG-16 AWG)
and it should have a rating of 600V. This cable should also be double insulated or
have a protective ground screen. Access to the terminal screws is provided via
holes in the lid of the enclosure. A slotted screwdriver should be used.
Note: The user should only access the power terminals when the system is fully
discharged (See “Safety Notice” on page 3.).
2.3.2 Motor Power Connectors

The output of 3-phase motor control power stage is available through the connector J2.
Connect the motor phase windings to the connector terminals U, V and W. Motor chas-
sis can be connected to the terminal E of the connector. Refer to Figure 2-3 and
Table 2-3 for details about the connectors.
FIGURE 2-3: MOTOR CONNECTOR
1 2 3 4

Number Name
1 Motor Earth
2 Phase W
3 Phase V
4 Phase U
2.3.3 Hall Sensor/Quadrature Encoder Interface (QEI)
Hall sensors or Quadrature encoder for sensored motor control algorithms can be inter-
faced using the connector J5. The connector provides 3.3V to power the motor sensor
circuitry, and also provides a 15V level pulse output which can be configured in the firm-
ware to output speed information. This is generally called FG Signal and is used in fan
applications.
CAUTION
All the terminals on this connector are non-isolated.

FIGURE 2-4: HALL/QEI
1 2 3 4 5 6

Number Name Port Pin
1 Ground NA
2 3.3V NA
3 Hall C/Index RP54/RC6
4 Hall B/QEB RP41/RB9
5 Hall A/QEA RP40/RB8
6 FG Signal RP55/RC7
2.3.4 Program/Debug Connector
The dsPIC33EP64MC206 microcontroller on the Low Power High Voltage Motor Con-
trol Board has a non-isolated ICSP™ programming/debugging connector J3 which can
be used to interface with a programmer/debugger available from Microchip.
FIGURE 2-5: PROGRAM/DEBUG CONNECTOR
The first pin MCLR (marked as “M”) can be used to correct the orientation of the pro-
grammer when interfacing with the board. For detailed information on how to program
the microcontroller, refer to Section 3.1.2 “Programming”.
CAUTION
Since the program/debug connector is non-isolated care should be taken while pro-
gramming/debugging the target. Following are some of the suggested ways to pro-
gram/debug the target.
1. Use an isolation transformer to power the board and operate the computer on
battery.
2. Use a USB-isolator (KXUSB-150) to isolate the programmer/debugger.
3. If there is no need for debugging, the user may use ICD3 or PICKIT3 to program the
target as described in Section 3.1.2.1 “Programming using MPLAB® ICD3 or PICkit 3”.
2.3.5 Debug LEDs

The board features four LEDs (three green and one red) for debug/indication. These
are user configurable in the firmware. The port pins of the dsPIC33EP64MC206
connecting to these LEDs are provided in the Table 2-5.
FIGURE 2-6: LEDS

Getting Started
TABLE 2-5: LEDS – PORT PIN MAPPING

LED Port Pin
LD2 RC5
LD3 RC4
LD4 RC3
LD5 RA9
2.3.6 Communication Interface
The Low Power High Voltage Motor Control Board provides an isolated communication
interface using the connector J4 to communicate with the host PC. The signals RX/TX
are 5V logic level.
FIGURE 2-7: COMMUNICATION INTERFACE
1 2345
TABLE 2-6: COMMUNICATION INTERFACE

1 5V (isolated) NA
2 RX (isolated data-in) RP56/RC8
3 TX (isolated data-out) RP57/RC9
4 GND (isolated) NA
5 Not Connected NA
2.3.6.1 COMMUNICATION USE CASE
This section describes how connector J4 can be used to establish UART-based com-
munication. Figure 2-8 shows usage of an MCP2200 breakout module (Part Number:
ADM00393) as a UART-USB bridge between the Low Power High Voltage Motor Con-
trol Board and the host PC through connector J4. The MCP2200 breakout module is a
development and evaluation platform for the MCP2200 USB-to-UART (Universal Serial
Bus-to-Universal Asynchronous Receiver/Transmitter) serial converter.
FIGURE 2-8: INTERFACING MCP2200 BREAKOUT MODULE

FIGURE 2-9: MCP2200 BREAKOUT MODULE
Note: Similarly, other serial communication adapters can be used with the Low
Power High Voltage Motor Control Board.
2.3.7 Push Buttons

The board has four isolated input push buttons, namely SW1 to SW4. The buttons are
reconfigurable in the firmware and can be used for various operations such as start,
stop, increase or decrease in speed and so on. For further details, refer to Figure 2-10
and Table 2-7.
FIGURE 2-10: PUSH BUTTONS
1 2 3 4
TABLE 2-7: PUSH BUTTON – PORT PIN MAPPING

1 SW1 RD8
2 SW2 RC10
3 SW3 RB7
4 SW4 RC13

MOTOR CONTROL BOARD
USER’S GUIDE
Chapter 3. Hardware
3.1 HARDWARE SETUP
In this chapter the procedures provided in the following sections enable a sensorless
FOC algorithm to run on the Low Power High Voltage Motor Control Board.
CAUTION
The user must be aware of the operating procedures outlined in this chapter and
ensure that they are executed accordingly. Failure to do so may result in damage to the
system.
3.1.1 Basic Evaluation

Execute the following procedure to ensure that the input power/auxiliary power supply
unit is working as expected.
1. Ensure that there is no power on the Low Power High Voltage Motor Control
Board and then setup the following connections:
a) Connector J1: Connect live, neutral and earth of AC mains, as marked on
the board.
b) Connector J2: Connect the 3-phase wires of motor.
2. Power the board with AC mains or an AC power supply (90 VAC-230 VAC,
50/60 Hz).
3. Ensure red LED LD1 (right-top corner) glows after the board is powered on.
4. Switch off the input power and wait till the LED LD1 goes off.
3.1.2 Programming
Execute the following steps to set up the programming tool:
1. Ensure that there is no power on the Low Power High Voltage Motor Control
Board and then remove the enclosure to access the programming interface.
2. Mount the RJ11 to ICSP™ adapter matching the MCLR (marked as “M”) pin.
Refer to Figure 3-1 for correct orientation.
FIGURE 3-1: ICSP™ ADAPTER ORIENTATION
The dsPIC33EP64MC206 on the Low Power High Voltage Motor Control Board can be
programmed in two ways which are explained in the following sections.

3.1.2.1 PROGRAMMING USING MPLAB® ICD3 OR PICKIT 3

The dsPIC33EP64MC206 on the Low Power High Voltage Motor Control Board can be
programmed using an MPLAB ICD3 or PICkit 3 without the need to power the board
from the mains supply.
Execute the following procedure to power the target circuit using the selected tool:
1. Open the Project Properties window
2. In the Categories panel on the left of the window, select the tool (ICD3 or PICkit
3)
3. In the Option categories drop-down menu, select Power
4. Check the box next to the Power target circuit from IDC3 field
5. For the Voltage Level drop-down menu, select 3.25
FIGURE 3-2: PROGRAMMING USING ICD3 OR PICKIT 3
6. Program the microcontroller with the given firmware as described in

Section 4.2 “Software Setup and Run”.
3.1.2.2 PROGRAMMING USING MPLAB REAL ICE™

As MPLAB REAL ICE does not have an option to power the target circuit, the Low
Power High Voltage Motor Control Board needs to be powered by AC mains. The
device, dsPIC33EP64MC206, can be programmed by executing the procedure given
in Section 4.2 “Software Setup and Run”.
CAUTION
Since the programming interface on Low Power High Voltage Motor Control Board is
non-isolated, care should be taken while programming.

MOTOR CONTROL BOARD
USER’S GUIDE
Chapter 4. Running the Demonstration

This chapter describes how to set up the Low Power High Voltage Motor Control Board
for 3-phase motor control using the application firmware “Sensorless Field Oriented
Control” from Microchip.
4.1 DEMONSTRATION REQUIREMENTS

The version of the MPLAB® IDE and MPLAB XC compiler used are:
• MPLAB X IDE v3.40 or later
• MPLAB XC16 v1.26 or later
The following are the hardware used:
• Low Power High Voltage Motor Control Board
• 220V PMSM/BLDC (Part # 80-252140-220, Beijing Eletechnic Ltd.)
• RJ11 to ICSP™ adapter (AC164110)
• MPLAB ICD 3 In-Circuit Debugger (DV164035) or PICkit 3 In-Circuit Debugger
(PG164130)
4.2 SOFTWARE SETUP AND RUN

4.2.1 Basic Demonstration
This section demonstrates a procedure to run the motor using the push buttons.
Note 1: The firmware supplied is already configured for enabling the basic
demonstration.
2: If both MPLAB X IDE and MPLAB IDE are used, ensure that the program-
mer/debugger is set to run on the MPLAB X IDE. To set this, the user
must run the MPLAB driver switcher, for Microsoft Windows the user
must run the driver switcher as Administrator.
Execute the following procedure to run the motor using a push button (SW1) and vary
the speed of the motor using another set of push buttons (SW2 and SW3):
1. Start MPLAB X IDE and open the LPHV_MTR80.X workspace.

Note: It is recommended to use MPLAB X v3.40 or later with compiler XC16 v1.26
or later.
2. Set LPHV_MTR80.X as main project and Build the project by selecting the Clean
and Build Main Project button available either on the toolbar or in the Run
menu.
3. After a successful build, download the code to dsPIC33EP64MC206 on the Low

Power High Voltage Motor Control Board by selecting the Make and Program
the device main project button on the toolbar.
Refer to Section 3.1.2 “Programming” for information to setup the program-
ming tool.
4. Disconnect the programmer from the board before proceeding to operate.
CAUTION
Failure to disconnect the programmer/debugger before proceeding to operate the
board cause potential damage to the programmer/debugger or the board or the user's
computer.
Ensure that the power to the board is turned on.

5. Press SW1 to start the motor (SW1 is configured to start and stop the motor).
The motor starts running (500 RPM) and the corresponding LEDs will glow as
described in the Table 4-1.

Running the Demo
6. Press SW2 to increase the speed or SW3 to decrease the speed. The increase
or decrease in speed is indicated by a series of LEDs as described in Table 4-1.
Ensure that the speed of the motor stabilizes before the next press of SW2 or
SW3.
TABLE 4-1: SPEED PATTERN

Speed (RPM) LD5 LD4 LD3
500 OFF OFF ON
1000 OFF ON OFF
1500 OFF ON ON
2000 ON OFF OFF
2300 ON OFF ON
2500 OFF ON ON
3000 ON ON ON
Note: If the temperature of the IPM increases due to continuous operation, the con-
troller shuts down the motor at 80°C (user configurable) and turns on the red
LED LD2 indicating a fault. The board can be restarted when the temperature
comes down to 30°C (user configurable) and the LED LD2 turns off indicating
that the board is ready for operation. Refer to Table 1-1 for the power rating
of the board.

NOTES:

MOTOR CONTROL BOARD
USER’S GUIDE
Appendix A. Board Schematics and Layout

A.1 BOARD SCHEMATICS AND LAYOUT
This appendix displays the following schematics and layout:
• Figure A-1: “Low Power High Voltage Motor Control Board Schematic
(Sheet 1 of 2)”
• Figure A-2: “Low Power High Voltage Motor Control Board Schematic
(Sheet 2 of 2)”
• Figure A-3: “Low Power High Voltage Motor Control Board Component Lay-
out - Top Layer”
• Figure A-4: “Low Power High Voltage Motor Control Board Component Lay-
out - Bottom Layer”
• Figure A-5: “Low Power High Voltage Motor Control Board Signal Layer -
Top”
• Figure A-6: “Low Power High Voltage Motor Control Board Signal Layer -
Bottom”

FIGURE A-1: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD SCHEMATIC (SHEET 1 of 2)
page 26

TP124
R4 18R C11
560pF ISO_5V
0215005.MXESPP NTC1 DC+
L1 3.3μH R96
750343319 D4
F1 0R
B57235S100M 1 TX1 13 C13
R2 D2 SB180 100μF TP25
2
L2 C5 D1 2.43M C12 D3.3V
TERMINAL 1x3
C1 470μF ISO_GND A3.3V D3.3V

J1 4700pF
͟͟
P6KE130A 15V
C8 C9 12
1 2 1 4700pF
C4 400V D5 R97
2 VR1 4 1 C7 10 SB1100-T TP26
C3 0.33μF 2200pF 2.2μF R3
3 350V R1 220μF
2.43M
D3 R5 27R C15 L3 3.3μH 0R
R98 R99
3 4 450V 1N4937 C14 390pF 0R 0R
0.33μF 2 330μF C16 4.2V
E_GND 744841330 470k
U2 TNY288PG D6 100μF U4 L4 R9
3
8 SB150-E3/73 1 3 2.2k
E_GND C6 8 1 Vin
C2 S EN
EN/UV
EN/UV Vout
L5 3.3μH 10μH
D
GND
GBJ1506-FDI-ND 7 2 9 R6 18R C17
4700pF
Tab
GN
4700pF S BP/M
/ 560pF C20
G
DC- C21 C22
680μF
6 C10 C19
S C18 10μF 10μF
5 4 100μF 1μF
L6
2
4
S D LD1
2200pF GREEN
TC1262-3.3VDB 10μH
D_GND C23 U3
0.10μF 4 1 R7 680R
3 2 R8 D_GND A_GND D_GND
1k D7
R43 LTV-817A
MCLR U1 13V
470R
D3.3V D3.3V D3.3V D3.3V A3.3V 7 13
MCLR MCLR AN0/OA2OUT/RA0 AN0/OA2OUT C71
D3.3V 14
AN1/C2IN1+/RA1 AN1/C2IN1+
R44 56 33
J3 VCAP CVREF2O/SDO1/RP20/T1CK/RA4 CVREF2O 15V C501uF
1
TDI/RA7 R33 470R
4.7k 10 34 3.3μF
1 2 3 4 5
C25 26 VDD SDI1/RPI25/RA9 64 LED3 TP13 PWM1H

C43 C72
VDD TDO/RA10
38 12 R95 1uF
C24 C26 C27 VDD AN9/RPI27/RA11 VA TP12
PGED 10uF 57 11 0.1uF
0.1uF VDD AN10/RPI28/RA12 VB
PGEC 19 4.7k C44 C51
C28 C29 AVDD R94 3.3μF
0.1uF 15
HDR-2.54 Male 1x5 0.1uF C30 PGED3/VREF-/AN2/C2IN1-/SS1/RPI32/CTED2/RB0 AN2/C2IN1- D_GND 1uF U5
9 16 C45
VSS PGEC3/VREF+/AN3/OA1OUT/RPI33/CTED1/RB1 AN3/OA1OUT 4.7k 1 17 V
0.1uF 0.1uF 25 17 COM P DC+
D_GND 0.1uF VSS PGEC1/AN4/C1IN1+/RPI34/RB2 AN4/C1IN1+ 2
41 18 PWM1L 10μF VB(U) U
VSS PGED1/AN5/C1IN1-/RP35/RB3 AN5/C1IN1- 3 DC-
D_GND 20 43 R34 470R VCC(U)
AVSS PGED2/ASDA2/RP37/RB5 PGED 4 18 J2
TERMINAL 1x4
D_GND 44 IN (UH) U, Vs(u)
PGEC2/ASCL2/RP38/RB6 PGEC 5
46 IN (UL)
1 2 3 4
D_GND RP39/INT0/RB7 Switch3 6
TP1 53 48 PWM2H C46 NC
A_GND 54 RD5 TCK/CVREF1O/ASCL1/RP40/T4CK/RB8 49 HA/QEA R93 R35 470R 7
VB(V) Nu
19
IA+
TP2 RD6 TMS/ASDA1/RP41/RB9(4) HB/QEB 1uF 8
42 60 VCC(V) 20
Switch1 RD8 RP42/PWM3H/RB10 PWM3H 9 Nv IB+
61
RP43/PWM3L/RB11 PWM3L R92 4.7k 10
IN (VH)
21 IBUS-
27 62 IN (VL) V, Vs(v)
Temp AN12/C2IN2-(3)/U2RTS/BCLK2/RE12 RPI44/PWM2H/RB12 PWM2H D_GND 11 R40 R41
C31 28 63 C47 VTS R42
VBus AN13/C3IN2-(3)/U2CTS/RE13 RPI45/PWM2L/CTPLS/RB13 PWM2L 4.7k R36 470R 12 0.1R 0.1R E_GND
29 2 V B(W) 0.1R
A_GND AN7/C3IN1- NEUT 30 AN14/RPI94/RE14 RPI46/PWM1H/T3CK/RB14 3 PWM1H PWM2L 0.1uF 13
V CC(W) 22
470pF TP3 AN15/RPI95/RE15 RPI47/PWM1L/T5CK/RB15 PWM1L 14 Nw IBUS+
PWM3H IN (WH)
R10 R12 R14 R37 470R 15 W
58 21 IN (WL)
IBUS+ AN6/OA3OUT TP4 RPI96/RF0 AN6/OA3OUT/C4IN1+/OCFB/RC0 AN6/OA3OUT R91 16 23
59 22 NC W, Vs(w)
1k 1k 20K TP5 RP97/RF1 AN7/C3IN1-/C4IN1-/RC1 AN7/C3IN1- C48
C32 TP20 31 23
TP6 SDA2/RPI24/RA8 AN8/C3IN1+/U1RTS/BCLK1/FLT3/RC2 AN8/C3IN1+ 4.7k FSB50660SF
1000pF TP7 32 36 R90 1uF
FLT32/SCL2/RP36/RB4 SDA1/RPI52/RC4 LED1
35 37 C49 C52
R11 R13 R15 LED2 SCK1/RPI51/RC3 SCL1/RPI53/RC5 Fault D_GND 3.3μF
50 4.7k
IB+ VREF RP54/RC6 HC/INDX
4 51 PWM3L 0.1uF
1k 1k 20K TP8 RP118/RG6 RP55/RC7 PULSE C73
C33 5 52 R38 470R
TP9 RPI119/RG7 RP56/RC8 TX
AN8/C3IN1+ 6 55 1uF
A_GND TP10 RP120/RG8 RP57/RC9 RX
8 45 Temp
470pF TP11 RPI121/RG9 RPI58/RC10 Switch2
24
AN11/C1IN2-(3)/U1CTS/FLT4/RC11 VC
39
OSC1/CLKI/RC12
47 C70
RC13 Switch4
40 0.1uF
OSC2/CLKO/RC15
Y1
C34 dsPIC33EP64MC206
A_GND D_GND D_GND

AN2/C2IN1- C37
8MHz (DNP)
470pF
R16 R18 R20 A_GND C68 C69
AN5/C1IN1-
IBUS+ AN0/OA2OUT 470pF 33pF (DNP) 33pF (DNP)
R22 R24 R26
1k 1k 20K
C35 TP21 IBUS- AN3/OA1OUT
1000pF 1k 1k 20K
C38 TP22
R17 R19 R21 1000pF
AN4/C1IN1+
IA+ VREF
R23 R25 R27 R28 D_GND PWM1H TP14
1k 1k 20K
C36 IBUS+ VREF
PWM1L TP15
AN1/C2IN1+ 1k 1k 560R 62k
A_GND C39 TP23 PWM2H TP16
470pF A_GND R29
56k PWM2L TP17
470pF
PWM3H TP18
PWM3L TP19
A_GND
FIGURE A-2: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD SCHEMATIC (SHEET 2 of 2)
15V
D3.3V ISO_5V
ISO_5V D3.3V
D3.3V ISO_5V
A3.3V
R62
10k R75 R77
R64 U6 R76 R78
J4 4.7k 4.7k
D8 FG 8 1 1k 1k
2 VDD2V
VDD2VDD1
V
R46 R47 R48 3 100R 7 2
1 2 3 4 5
3 R63 VIA VOA RX C63 U11 U8
DC+ VBUS 1 Q1 C62 6 3 4 1 4 1
1 PULSE VOB VIB TX 0.1uF Switch1 Switch2
150k 150k 300R MMBT2222A-7-F 0.1uF 5 4
1k GND2
G
GND2G
GND1
GN
G D1 3 2 3 2
BAR43S R65 2
FOD8012
C54 R49 100k LTV-817A LTV-817A
2.2k HDR-2.54 Male 1x5 D_GND D_GND
1 SW1 1 SW2
4700pF
4 4
D_GND 2 3 2 3
TACT SPST TACT SPST
D_GND
C64 C65
ISO_GND
A_GND
0.1uF 0.1uF
ISO_GND ISO_GND
A3.3V
ISO_5V
D3.3V D3.3V ISO_5V
D9
2
R50 R51 R52 R79
LED1
LED2
LED3
Fault
3 R80 R81
U
1
VA 4.7k R82
150k 150k 300R A3.3V 1k 4.7k
CVREF2O 1k
BAR43S A_GND U9
R53 4 1 U10
2
C55 4 U7 Switch3 4 1
2.2k R83 R84 R85 R86 R30 R31 Vin-
in- Switch4
4700pF MCP6001 3 2
2.2k 2.2k 2.2k 2.2k 0R (DNP) 10k VSS
S
1 3 2
VOUT
T VREF
VDD
V
VDD LTV-817A
3 D_GND LTV-817A
Vin+
in+ 1 SW3 D_GND
1 SW4
A3.3V 4
4
5
RED GREEN GREEN GREEN C40
A_GND
LD2 LD3 LD4 LD5 0.1uF R32 2 3
10k A3.3V TACT SPST 2 TACT SPST 3
C41
C66
0.1uF C67
A3.3V 0.1uF
0.1uF
A_GND
A_GND ISO_GND ISO_GND
D10 D_GND D_GND D_GND D_GND
2
R54 R55 R56
3
V VB
1
150k 150k 300R
BAR43S D3.3V
C56 R57
2.2k R87
4700pF
VA
R71 10k
R69 R70
FG R88
4.7k 4.7k 4.7k VB NEUT
D3.3V
R66 J5 10k
A_GND
HA/QEA 1
R89
47k R67 2 VC
3
HB/QEB 10k
A3.3V 4
47k
R68 5
HC/INDX 6
47k
D11 C61
Appendix A
2 0.1uF
R58 R59 R60
3
W VC
1
150k 150k 300R
R72 C58 R74 C60
BAR43S R73 C59
90.9k 90.9k
1000pF 90.9k 1000pF
C57 R61 1000pF D_GND
2.2k
4700pF
D_GND D_GND D_GND

A_GND
page 27
FIGURE A-3: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD

COMPONENT LAYOUT - TOP LAYER

Appendix A
COMPONENT LAYOUT - BOTTOM LAYER


SIGNAL LAYER - TOP

Appendix A
SIGNAL LAYER - BOTTOM

NOTES:

MOTOR CONTROL BOARD
USER’S GUIDE
Appendix B. Power Rating of Inverter or

Integrated Power Module (IPM)
B.1 INTRODUCTION
In this appendix the following topics in reference to the Low Power High Voltage Motor
Control Board are discussed:
• Causes for higher power loss in the inverter while delivering reactive power.
• Power rating when it is measured at the input (AC mains) to the board.
• A scenario when the de-rating of the inverter occurs.
B.2 POWER LOSS

The loss in the IPM (or inverter) are of two types:
a) Power loss due to switching
Since the demo software runs the PWM at 20 kHz, which is the optimum switch-
ing frequency recommended by the IPM manufacturer, the power loss due to
switching is insignificant when compared with power loss due to conduction.
b) Power loss during conduction
This is caused when:
- The current from DC bus to load generates heat in the MOSFET (I2R loss due
to RDS(on)).
- The recirculating current between IPM and load, due to reactive power, gener-
ates heat due to forward voltage drop (V x I loss) in the intrinsic diode of the
MOSFET. When MOSFETs are not turned on, recirculating current will cause
significant loss due to diode drop as compared to the loss due to RDS(on).
B.2.1 Power Loss Scenario

In a motor control application, field weakening is a typical case when there is significant recir-
culating current flowing between the motor and IPM. As a result, the temperature rise in the
IPM will be significantly faster. Even though the board draws low input power from AC mains,
there can be significant recirculating current between the motor and IPM and it will not be
seen in the input power.
Since the IPM (or inverter) can supply both active and reactive power, rating of the inverter
(similarly in transformers and alternators) is best specified in Volts-Amps (VA), instead of
Watts (W). But in case of motor drives, where both voltage and current varies, it can be cum-
bersome to measure the 3-phase output power of the inverter. Hence, for simplification, the
active power rating of the inverter is specified in W, when the inverter supplies active power
only (refer Table 1-1). If there is reactive power flow between the inverter and motor, de-rat-
ing of the inverter occurs, that is, the IPM heats up faster in the presence of reactive power.

NOTES:

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11/07/16
Low Power High Voltage Board User’s Guide

Low Power High Voltage Motor Control Board User's Guide: 2017 Microchip Technology Inc

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Low Power High Voltage

Motor Control Board

 2017 Microchip Technology Inc.

Information contained in this publication regarding device Trademarks

page 2  2017 Microchip Technology Inc.

WARNING – This system must be earthed (grounded) at all times.

 2017 Microchip Technology Inc. page 3

page 4  2017 Microchip Technology Inc.

 2017 Microchip Technology Inc. page 1

DS00000A-page 2  2017 Microchip Technology Inc.

 2017 Microchip Technology Inc. page 3

CONVENTIONS USED IN THIS GUIDE

page 4  2017 Microchip Technology Inc.

MPLAB® XC16 C Compiler User’s Guide (DS50002071)

MPLAB® IDE User’s Guide (DS51519)

MPLAB® X IDE User’s Guide (DS52027)

MPLAB® XC16 Assembler, Linker and Utilities User’s Guide

 2017 Microchip Technology Inc. page 5

THE MICROCHIP WEB SITE

DEVELOPMENT SYSTEMS CUSTOMER CHANGE NOTIFICATION SERVICE

page 6  2017 Microchip Technology Inc.

DOCUMENT REVISION HISTORY

 2017 Microchip Technology Inc. page 7

page 8  2017 Microchip Technology Inc.

FIGURE 1-1: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD

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FIGURE 1-2: SYSTEM BLOCK DIAGRAM

Voltage Feedback Push Buttons

dsPIC33EP64MC206 Hall Sensor/

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TABLE 1-1: ELECTRICAL SPECIFICATIONS

FIGURE 1-3: IPM’s CASE TEMPERATURE RISE AT DIFFERENT POWER

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2.2 BOARD LAYOUT

FIGURE 2-1: BOARD SECTIONS

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TABLE 2-1: LOW POWER HIGH VOLTAGE MOTOR CONTROL BOARD

2.3 USER INTERFACE

2.3.1 Power Supply Connector

FIGURE 2-2: POWER SUPPLY CONNECTOR

TABLE 2-2: CONNECTOR J1

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2.3.2 Motor Power Connectors

FIGURE 2-3: MOTOR CONNECTOR

TABLE 2-3: CONNECTOR J2

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TABLE 2-4: CONNECTOR J5

FIGURE 2-5: PROGRAM/DEBUG CONNECTOR

2.3.5 Debug LEDs

FIGURE 2-6: LEDS

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TABLE 2-5: LEDS – PORT PIN MAPPING

FIGURE 2-7: COMMUNICATION INTERFACE

TABLE 2-6: COMMUNICATION INTERFACE

FIGURE 2-8: INTERFACING MCP2200 BREAKOUT MODULE

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2.3.7 Push Buttons

FIGURE 2-10: PUSH BUTTONS

TABLE 2-7: PUSH BUTTON – PORT PIN MAPPING

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3.1.1 Basic Evaluation

FIGURE 3-1: ICSP™ ADAPTER ORIENTATION