Da 01 en LM - 393 - N - Motorola

MEMC3PBLDCPSUM/D
R E Q U I R E D
A G R E E M E N T
Motorola Embedded Motion Control
3-Phase ac BLDC
High-Voltage
Power Stage
N O N - D I S C L O S U R E
User’s Manual
Important Notice to Users
While every effort has been made to ensure the accuracy of all information in
this document, Motorola assumes no liability to any party for any loss or
damage caused by errors or omissions or by statements of any kind in this
document, its updates, supplements, or special editions, whether such errors are
omissions or statements resulting from negligence, accident, or any other cause.
Motorola further assumes no liability arising out of the application or use of any
information, product, or system described herein: nor any liability for incidental
or consequential damages arising from the use of this document. Motorola
disclaims all warranties regarding the information contained herein, whether
expressed, implied, or statutory, including implied warranties of
merchantability or fitness for a particular purpose. Motorola makes no
representation that the interconnection of products in the manner described
herein will not infringe on existing or future patent rights, nor do the
descriptions contained herein imply the granting or license to make, use or sell
equipment constructed in accordance with this description.
Trademarks
This document includes these trademarks:
Motorola and the Motorola logo are registered trademarks
of Motorola, Inc.
Motorola, Inc., is an Equal Opportunity / Affirmative Action Employer.
© Motorola, Inc., 2000; All Rights Reserved
User’s Manual 3-Phase ac BLDC High-Voltage Power Stage
2 MOTOROLA
User’s Manual — 3-Phase ac BLDC High-Voltage Power Stage
List of Sections
Section 1. Introduction and Setup . . . . . . . . . . . . . . . . . . 11
Section 2. Operational Description . . . . . . . . . . . . . . . . . 19
Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . 25
Section 4. Schematics and Parts List . . . . . . . . . . . . . . . 31
Section 5. Design Considerations . . . . . . . . . . . . . . . . . . 47
3-Phase ac BLDC High-Voltage Power Stage User’s Manual
MOTOROLA List of Sections 3

List of Sections
4 List of Sections MOTOROLA

Table of Contents
Section 1. Introduction and Setup

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 2. Operational Description

2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Modification for One-Half and Three-Fourths Horsepower. . . . . . . . 22
2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 3. Pin Descriptions

3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Pin-by-Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2.1 Power Input Connector J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.2 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.3 External Brake Connector J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.4 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MOTOROLA Table of Contents 5

Table of Contents
Section 4. Schematics and Parts List

4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 5. Design Considerations

5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.10 Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Table of Contents MOTOROLA

List of Figures
Figure Title Page
1-1 Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1-2 3-Phase ac BLDC High-Voltage Power Stage . . . . . . . . . . . . . . . . . . 14
1-3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-4 PFC Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-1 40-Pin Ribbon Connector J14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-1 3-Phase ac BLDC High-Voltage Power Stage Overview. . . . . . . . . . 32

4-2 Gate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4-3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-4 Current and Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4-5 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4-6 Power Factor Correction and Brake Gate Drives . . . . . . . . . . . . . . . . 37
4-7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4-8 Identification Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-1 Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5-2 Bus Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5-3 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5-4 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5-5 Phase A Back EMF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5-6 Phase A Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5-7 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5-8 PFC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5-9 PFC Zero Crossing Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
MOTOROLA List of Figures 7

List of Figures
8 List of Figures MOTOROLA

List of Tables
Table Title Page
2-1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2-2 Resistor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-3 JP801 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-4 Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-1 Connector J13 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3-2 Connector J14 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-1 Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4-2 Printed Circuit Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MOTOROLA List of Tables 9

List of Tables
10 List of Tables MOTOROLA

Section 1. Introduction and Setup
1.1 Contents
1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Introduction
Motorola’s 3-Phase ac high-voltage brushless dc (BLDC) power stage (HV ac
power stage) is a 115/230 volt, 180 watt (one-fourth horsepower), off-line
power stage that is an integral part of Motorola’s embedded motion control
series of development tools. It is supplied in kit number ECPWRHiVACBLDC.
In combination with one of the embedded motion control series control boards
and an embedded motion control series optoisolation board, it provides a
ready-made software development platform for fractional horsepower off-line
motors. Feedback signals are provided that allow 3-phase ac induction and
BLDC motors to be controlled with a wide variety of algorithms. In addition,
the HV ac power stage includes an active power factor correction (PFC) circuit
that facilitates development of PFC algorithms.
An illustration of the systems’ architecture is shown in Figure 1-1. A line

drawing appears in Figure 1-2.
MOTOROLA Introduction and Setup 11

Introduction and Setup
The HV ac power stage’s features are:

• 1-phase bridge rectifier
• Power factor switch and diode
• dc-bus brake IGBT and brake resistors
• 3-phase bridge inverter (6-IGBT’s)
• Individual phase and dc bus current sensing shunts with Kelvin
connections
• Power stage temperature sensing diodes
• IGBT gate drivers
• Current and temperature signal conditioning
• 3-phase back-EMF voltage sensing and zero cross detection circuitry
• Board identification processor (MC68HC705JJ7)
• Low-voltage on-board power supplies
• Cooling fans
12 Introduction and Setup MOTOROLA

About this Manual
EMULATOR CONTROL BOARD DSP EVM BOARD
WORKSTATION WORKSTATION
OPTOISOLATION HIGH-VOLTAGE OPTOISOLATION HIGH-VOLTAGE

BOARD POWER STAGE BOARD POWER STAGE
MOTOR MOTOR
a) MICROCONTROLLER b) 56800 DSP
Figure 1-1. Systems’ Configurations
1.3 About this Manual

Key items can be found in the following locations in this manual:
• Setup instructions are found in 1.5 Setup Guide.
• Schematics are found in Section 4. Schematics and Parts List.
• Pin assignments are shown in Figure 3-1. 40-Pin Ribbon Connector
J14, and a pin-by-pin description is contained in 3.2 Pin-by-Pin
Descriptions.
• For those interested in the reference design aspects of the board’s
circuitry, a description is provided in Section 5. Design Considerations.

User’s Manual – 3 Phase AC BLDC High Voltage Power Stage
C
N D I S
Figure 1-2. 3 Phase AC BLDC High Voltage Power Stage

O
N
Warnings
1.4 Warnings
This development tool set operates in an environment that includes dangerous
voltages and rotating machinery.
To facilitate safe operation, input power for the HV ac power stage should come
from a current limited dc laboratory power supply, unless power factor
correction is specifically being investigated.
An isolation transformer should be used when operating off an ac power line.
If an isolation transformer is not used, power stage grounds and oscilloscope

grounds are at different potentials, unless the oscilloscope is floating. Note that
probe grounds and, therefore, the case of a floated oscilloscope are subjected to
dangerous voltages.
The user should be aware that:

• Before moving scope probes, making connections, etc., it is generally
advisable to power down the high-voltage supply.
• When high voltage is applied, using only one hand for operating the test
setup minimizes the possibility of electrical shock.
• Operation in lab setups that have grounded tables and/or chairs should be
avoided.
• Wearing safety glasses, avoiding ties and jewelry, using shields, and
operation by personnel trained in high-voltage lab techniques are also
advisable.
• Power transistors, the PFC coil, and the motor can reach temperatures hot
enough to cause burns.
• When powering down; due to storage in the bus capacitors, dangerous
voltages are present until the power-on LED is off.

1.5 Setup Guide

Setup and connections for the HV ac power stage are straightforward. The
power stage connects to an embedded motion control optoisolation board via a
40-pin ribbon cable and can be powered either by a 140- to 230-volt dc power
supply or with line voltage. For both safety reasons and ease of making
measurements, it is strongly recommended that a dc supply is used, unless
power factor correction is specifically being investigated. The power supply
should be current limited to under 4 amps. Figure 1-3 depicts a completed
setup. A step-by-step setup procedure is:
1. Plug one end of the 40-pin ribbon cable that comes with the optoisolator
kit into input connector J14. The other end of this cable goes to the
optoisolation board's 40-pin output connector.
2. Connect motor leads to output connector J13, located along the back
edge of the top board. Phase A, phase B, and phase C are labeled Ph_A,
Ph_B, and Ph_C.
For an ac induction motor, it does not matter which lead goes to which
phase. For BLDC motors, it is important to get the wire color coded for
phase A into the connector terminal labeled Ph_A, and so on for phase B
and phase C.
3. Connect earth ground to the earth ground terminals on the top board and
on the heat sink. The top board’s ground terminal is located in the front
left-hand corner and is marked with a ground symbol. The heat sink has
a screw on its front edge that is also marked with a ground symbol.
4. Connect a line isolated, current limited dc power supply to connector
J11, located on the front edge of the top board. The input voltage range
is 140 to 230 Vdc. Current limit should be set for less than 4 amps. The
dc supply’s polarity does not matter.
Either a 110-volt or 220-volt ac line that is coupled through an isolation
transformer may be used in place of a dc supply to provide input power.
The connection is made on connector J11. Bias voltages are developed
by internal power supplies. Only one power input is required.
WARNING: Operation off an ac power line is significantly more hazardous than operation
from a line isolated and current limited dc power supply.
An isolation transformer should be used when operating off an ac power line.

Setup Guide
5. Set up the optoisolation and control boards.

6. Optional PFC — The HV ac power stage is shipped with power factor
correction (PFC) disabled. If power factor correction is desired, it is
necessary to remove and resolder power jumper JP201 from the no PFC
position to the PFC position. This jumper is found on the left side of the
top board between the dc bus capacitor and PFC inductor. Circuit
connections are illustrated in Figure 1-4. For first time setups, operation
without power factor correction is recommended.
7. Apply power first to the optoisolator and then to the power stage. The
green power-on LED in the upper right-hand corner lights, and both fans
run when power is present. Note that the optoisolation board powers the
control board, and that the optoisolation board is not fully powered until
power is applied to the power stage.
CAUTION: Hazardous voltages are present. Re-read all of 1.4 Warnings carefully.
MOTOR
STANDOFFS
40-PIN
CONTROL BOARD +12 Vdc
RIBBON CABLE
40-PIN
POWER STAGE OPTOISOLATOR
RIBBON CABLE
J1
J2
STANDOFFS
HIGH-VOLTAGE
MOTOR SUPPLY
Figure 1-3. Setup

PFC L201
1
DCB_PFC_2
4.9 mH/2.3 A
2 JP201
DCB_PFC_1
PFC JUMPER
3
NO PFC
DCB_Cap_pos
C213
10 nF/3000 V
C208 + +
Earth_GND C209 C210
22 nF/630 Vdc
470 µF/400 V 470 µF/400 V
(OPTIONAL)
C214
10 nF/3000 V
DCB_Cap_neg
Figure 1-4. PFC Jumper

Section 2. Operational Description
2.1 Contents
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Modification for One-Half and Three-Fourths Horsepower. . . . . . . . 22
2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Description
Motorola’s embedded motion control series high-voltage (HV) ac power stage
is a 180 watt (one-fourth horsepower), 3-phase power stage that will operate
off of dc input voltages from 140 to 230 volts and ac line voltages from 100 to
240 volts. In combination with one of the embedded motion control series
control boards and an optoisolation board, it provides a software development
platform that allows algorithms to be written and tested without the need to
design and build a power stage. It supports a wide variety of algorithms for both
ac induction and brushless dc (BLDC) motors.
Input connections are made via 40-pin ribbon cable connector J14. Pin
assignments for the input connector are shown in Figure 3-1. 40-Pin Ribbon
Connector J14. Power connections to the motor are made on output connector
J13. Phase A, phase B, and phase C are labeled PH_A, Ph_B, and Ph_C on the
board. Power requirements are met with a single external 140- to 230-volt dc
power supply or an ac line voltage. Either input is supplied through connector
J11. Current measuring circuitry is set up for 2.93 amps full scale. Both bus and
phase leg currents are measured. A cycle-by-cycle overcurrent trip point is set
at 2.69 amps.
MOTOROLA Operational Description 19

Operational Description
The high-voltage ac power stage has both a printed circuit board and a power
substrate. The printed circuit board contains IGBT gate drive circuits, analog
signal conditioning, low-voltage power supplies, power factor control circuitry,
and some of the large, passive, power components. This board also has an
MC68HC705JJ7 microcontroller that is used for configuration and
identification. All of the power electronics which need to dissipate heat are
mounted on the power substrate. This substrate includes the power IGBTs,
brake resistors, current sensing resistors, a power factor correction MOSFET,
and temperature sensing diodes. Figure 2-1 shows a block diagram.
HV POWER
INPUT SWITCH MODE PFC CONTROL
POWER SUPPLY dc BUS BRAKE
3-PHASE IGBT
POWER MODULE
SIGNALS
3-PHASE AC
TO/FROM GATE
TO
CONTROL DRIVERS MOTOR
BOARD PHASE CURRENT
PHASE VOLTAGE
BUS CURRENT
BUS VOLTAGE
MONITOR
BOARD
ID BLOCK
ZERO CROSS
BACK-EMF SENSE
Figure 2-1. Block Diagram
20 Operational Description MOTOROLA

Electrical Characteristics
2.3 Electrical Characteristics

The electrical characteristics in Table 2-1 apply to operation at 25°C with a
160-Vdc power supply voltage.
Table 2-1. Electrical Characteristics

Characteristic Symbol Min Typ Max Units
dc input voltage Vdc 140 160 230 V
ac input voltage Vac 100 208 240 V
Quiescent current ICC — 70 — mA
Min logic 1 input voltage VIH 2.0 — — V
Max logic 0 input voltage VIL — — 0.8 V
Input resistance RIn — 10 kΩ —
Analog output range VOut 0 — 3.3 V
Bus current sense voltage ISense — 563 — mV/A
Bus voltage sense voltage VBus — 8.09 — mV/V
Peak output current IPK — — 2.8 A
Brake resistor dissipation

PBK — — 50 W
(continuous)
Brake resistor dissipation

PBK(Pk) — — 100 W
(15 sec pk)
Total power dissipation Pdiss — — 85 W

2.4 Modification for One-Half and Three-Fourths Horsepower

The HV ac power stage can be modified for operation at either one-half or
three-fourths horsepower. To change maximum output power, follow these
steps:.
1. Remove power and wait until the power-on LED is off.

2. If PFC jumper JP201 is in the PFC position, remove and resolder it into
the no PFC position.
3. Make the resistor value changes shown in Table 2-2. These resistors set
current amplifier gains. For one-half and three-fourths horsepower,
lower gains allow for higher measured currents and higher overcurrent
trip points.
Table 2-2. Resistor Values

1/ HP 1/ HP 3/ HP
Resistors 4 2 4
(180 W) (370 W) (550 W)
R303, R305, R307, R314, R315, R318,

75 kΩ 62 kΩ 56 kΩ
R319, R322
R301, R304, R311, R313, R316, R317,

10 kΩ 15 kΩ 16 kΩ
R320, R321
4. Configure identification coding jumper JP801 with the settings indicated

in Table 2-3. This proceedure allows software to interpret the new
analog values correctly.
Table 2-3. JP801 Settings

1/ HP 1/ HP 3/ HP
Position 4 2 4
(180 W) (370 W) (550 W)
1-2 Open Short Open
3-4 Open Open Short
5-6 Open Open Open
7-8 Open Open Open

Fuse Replacement
5. For 550 watts (three-fourths horsepower), it is also necessary to add an

addional 470-µF/400-volt bus capacitor. To install the capacitor, it is first
necessary to remove PFC inductor L201. Mounting holes for the
additional capacitor are located within L201’s footprint. Note that it is
essential to orient the capacitor such that polarity is correct. Positive and
negative connections are indicated by + (plus) and – (minus)
silk-screened labels on the board. In addition, the pad for the capacitor’s
positive lead is square, and the pad for its negative lead is round.
6. Once these changes have been made, configuration for either one-half or
three-fourths horsepower is complete.
2.5 Fuse Replacement

A fast blow fuse is located on the front right-hand corner of the top board. If this
fuse has to be replaced, follow these steps:
1. Remove power and wait until the power-on LED is off.
2. Remove the fuse’s protective case.
3. Replace the fuse with one of the selections shown in Table 2-4.
Table 2-4. Fuse Ratings

Fuse Fuse
RMS Input
Motor Current Voltage
Current Fuse Type
Horsepower Rating Rating
(Amps)
(Amps) (Volts)
1/
4 2.3 2.5 250 Fast blow
(180 W)
1/
2 4.8 6.3 250 Fast blow
(370 W)
3/
4 7.1 8 250 Fast blow
(550 W)
4. Replace the protective case.

5. Set the controller’s speed control input to zero RPM.
6. Apply power and resume operation.


Section 3. Pin Descriptions
3.1 Contents
3.2 Pin-by-Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.1 Power Input Connector J11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.2 Motor Output Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.3 External Brake Connector J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.4 40-Pin Ribbon Connector J14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Pin-by-Pin Descriptions

Inputs and outputs are located on four connectors. Pin descriptions for each of
these connectors are included in this section.
3.2.1 Power Input Connector J11
The power input connector, labeled J11, is located on the front edge of the
board. It will accept dc voltages from 140 to 230 volts or an isolated ac line
input from 100 to 240 volts. In either case, the power source should be capable
of supplying at least 200 watts.
MOTOROLA Pin Descriptions 25

Pin Descriptions
3.2.2 Motor Output Connector J13
Power outputs to the motor are located on connector J11. Phase outputs are
labeled Ph_A, Ph_B, and Ph_C. Pin assignments are described in Table 3-1.
Table 3-1. Connector J13 Signal Descriptions

Pin
Signal Name Description
No.
Ph_A supplies power to motor phase A. On an induction motor, any one of the
three phase windings can be connected here. For brushless dc motors it is
1 Ph_A
important to connect the wire color coded for phase A into the connector terminal
labeled Ph_A, and so on for phase B and phase C.
Ph_B supplies power to motor phase B. On an induction motor, any one of the
2 Ph_B
important to connect the wire color coded for phase B into the connector terminal
labeled Ph_B, and so on for phase A and phase C.
Ph_C supplies power to motor phase C. On an induction motor, any one of the
3 Ph_C
important to connect the wire color coded for phase C into the connector terminal
labeled Ph_C, and so on for phase A and phase B.
3.2.3 External Brake Connector J12
An optional external brake resistor can be connected to external brake connector

J12, labeled Ext. Brake. The external resistor allows power dissipation to
increase beyond the 50 watts that brake resistors R6–R9 provide.
26 Pin Descriptions MOTOROLA

Pin Descriptions
Pin-by-Pin Descriptions
3.2.4 40-Pin Ribbon Connector J14

Signal inputs are grouped together on 40-pin ribbon cable connector J14,
located on the right side of the board. Pin assignments are shown in Figure 3-1.
In this figure, a schematic representation appears on the left, and a physical
layout of the connector appears on the right. The physical view assumes that
the board is oriented such that its title is read from left to right. Signal
descriptions are listed in Table 3-2.
J14
BEMF_sense_C 40
PWM_AT 1 2 Shielding
BEMF_sense_B 39
PWM_AB 3 4 Shielding
BEMF_sense_A 38
PWM_BT 5 6 Shielding
Shielding 37
PWM_BB 7 8 Shielding
Zero_cross_C 36
PWM_CT 9 10 Shielding
Zero_cross_B 35
PWM_CB 11 12 GND
Zero_cross_A 34
GND_PS 13 14 +5V_D
PFC_z_c 33
+5V_D 15 16 +3.3V_A
PFC_inhibit 32
GNDA 17 18 GNDA
PFC_PWM 31
+15V_A 19 20 –15V_A
Serial_Con 30
V_sense_DCB 21 22 I_sense_DCB
Brake_control 29
I_sense_A 23 24 I_sense_B
Shielding 28
I_sense_C 25 26 Temp_sense
27
27 28 Shielding
Temp_sense 26
Brake_control 29 30 Serial_Con
I_sense_C 25
PFC_PWM 31 32 PFC_inhibit
I_sense_B 24
PFC_z_c 33 34 Zero_cross_A
I_sense_A 23
Zero_cross_B 35 36 Zero_cross_C
I_sense_DCB 22
Shielding 37 38 BEMF_sense_A
V_sense_DCB 21
BEMF_sense_B 39 40 BEMF_sense_C
–15V_A 20
+15V_A 19 PHYSICAL VIEW
GNDA 18
GNDA 17
+3.3V_A 16
+5V_D 15
+5V_D 14
GND 13
GND 12
PWM_CB 11
Shielding 10
PWM_CT 9
Shielding 8
PWM_BB 7
Shielding 6
PWM_BT 5
Shielding 4
PWM_AB 3
Shielding 2 SCHEMATIC VIEW
PWM_AT 1
CON40
Figure 3-1. 40-Pin Ribbon Connector J14

Pin Descriptions
Table 3-2. Connector J14 Signal Descriptions

Pin
No.
PWM_AT is the gate drive signal for the top half-bridge of phase A. A logic high
1 PWM_AT
turns phase A’s top switch on.
2 Shielding Pin 2 is connected to a shield wire in the ribbon cable and ground on the board.
PWM_AB is the gate drive signal for the bottom half-bridge of phase A. A logic high
3 PWM_AB
turns phase A’s bottom switch on.
PWM_BT is the gate drive signal for the top half-bridge of phase B. A logic high
5 PWM_BT
turns phase B’s top switch on.
PWM_BB is the gate drive signal for the bottom half-bridge of phase B. A logic high
7 PWM_BB
turns phase B’s bottom switch on.
PWM_CT is the gate drive signal for the top half-bridge of phase C. A logic high
9 PWM_CT
turns phase C’s top switch on.
PWM_CB is the gate drive signal for the bottom half-bridge of phase C. A logic high
11 PWM_CB
turns phase C’s bottom switch on.
12 GND Digital and power ground
13 GND Digital and power ground, redundant connection
14 +5V digital Digital +5-volt power supply
15 +5V digital Digital +5-volt power supply, redundant connection
16 +3.3V analog Analog +3.3-volt power supply
17 GNDA Analog power supply ground
18 GNDA Analog power supply ground, redundant connection
19 +15V_A Analog +15-volt power supply
20 –15V_A Analog –15-volt power supply
V_sense_DCB is an analog sense signal that measures dc bus voltage. It is scaled

21 V_sense_DCB
at 8.09 mV per volt of dc bus voltage.
I_sense_DCB is an analog sense signal that measures dc bus current. It is scaled

22 I_sense_DCB
at 0.563 volts per amp of dc bus current.

Pin Descriptions
Pin-by-Pin Descriptions
Table 3-2. Connector J14 Signal Descriptions (Continued)

Pin
No.
I_sense_A is an analog sense signal that measures current in phase A. It is scaled

23 I_sense_A
I_sense_B is an analog sense signal that measures current in phase B. It is scaled

24 I_sense_B
I_sense_C is an analog sense signal that measures current in phase C. It is scaled

25 I_sense_C
26 Temp_sense Temp_sense is an analog sense signal that measures power module temperature.
27 No connection
Pin 28 is connected to a shield wire in the ribbon cable and analog ground on the
28 Shielding
board.
29 Brake_control Brake_control is the gate drive signal for the brake IGBT.
Serial_Con is an identification signal that lets the controller know which power
30 Serial_Con
stage is present.
PFC_PWM is a digital signal that controls the power factor correction circuit’s
31 PFC_PWM
switch.
PFC_inhibit is a digital output used to enable or disable the power factor correction
32 PFC_inhibit
circuit.
PFC_z_c is a digital signal. Its edges represent power line voltage zero crossing
33 PFC_z_c
events.
Zero_cross_A is a digital signal used for sensing phase A back-EMF zero crossing
34 Zero_cross_A
events.
Zero_cross_B is a digital signal used for sensing phase B back-EMF zero crossing
35 Zero_cross_B
events.
Zero_cross_C is a digital signal used for sensing phase C back-EMF zero crossing
36 Zero_cross_C
events.
Pin 37 is connected to a shield wire in the ribbon cable and analog ground on the
37 Shielding
board.
BEMF_sense_A is an analog sense signal that measures phase A back EMF. It is

38 BEMF_sense_A
scaled at 8.09 mV per volt of dc bus voltage.
BEMF_sense_B is an analog sense signal that measures phase B back EMF. It is

39 BEMF_sense_B
BEMF_sense_A is an analog sense signal that measures phase C back EMF. It is

40 BEMF_sense_C

Pin Descriptions

Section 4. Schematics and Parts List
4.1 Contents
4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Mechanical Characteristics

Mechanically, the high-voltage (HV) power stage consists of an FR-4 circuit
board, a 3.2-mm aluminum circuit board, two fans, a fan bracket, a heat sink,
inter-board connectors, and standoffs. Construction is depicted in Figure 1-2.
3-Phase ac BLDC High-Voltage Power Stage. The aluminum circuit board,
fans, and heat sink provide thermal capability for surface-mounted power
components. The FR-4 board contains control circuitry and through-hole
mounted power components. The two boards plug together via 10 vertical
connectors to, in effect, form a discrete power module.
Four holes on the top board are spaced to allow mounting standoffs such that a
control board can be placed on top of the power stage. This configuration allows
mounting control and power functions in one compact mechanical assembly.
4.3 Schematics
A set of schematics for the HV ac power stage appears in Figure 4-1 through
Figure 4-8. An overview of the board appears in Figure 4-1. H-bridge gate
drive is shown in Figure 4-2. The 3-phase H-bridge appears in Figure 4-3.
Current and temperature feedback circuits are shown in Figure 4-4. Back EMF
feedback circuitry appears in Figure 4-5. Power factor correction and brake
gate drives are shown in Figure 4-6. An on-board power supply appears in
Figure 4-7, and finally the identification block is shown in Figure 4-8. Unless
otherwise specified, resistors are 1/8 watt, have a ±5% tolerance, and have
values shown in ohms. Interrupted lines coded with the same letters are
electrically connected.
MOTOROLA Schematics and Parts List 31

+FAN -FAN
Identification
C1 100nF +5V_D
+5V_D
GND Identification
+15V_A -15V_A
+15V_A GND +3.3V_A +5V_D GND
1
FAN 2
+15V_D +15V_D +FAN GND
+5V_D +5V_D -FAN +15V_D
GNDA
GNDA
SMPS
PFC_DC_BUS_BRAKE
Back_EMF
GNDA J14
FAN1
-15V_A
+5V_D
+5V_D
+FAN
-FAN
+15V_D
+15V_D
+3.3V_A
PFC_enable
GND
GNDA
GND
+15V_A
+15V_A
+5V_D
V_sense_DCB_half_15
PFC_PWM
PFC_z_c
+15V_D
V_sense_DCB_5
GNDA
Brake_control
BEMF_sense_C 40 BEMF_sense_C
V_sense_DCB_half_15
BEMF_sense_B 39 BEMF_sense_B
BEMF_sense_A 38 BEMF_sense_A
37 Sheilding
C2 100nF Zero_cross_C
Zero_cros_C 36
PFC_I_sense_1
DCB_Cap_neg
Zero_cross_B
DCB_Cap_pos
Zero_cros_B 35
PFC_Source
DCB_PFC_1
DCB_PFC_2
Zero_cros_A 34 Zero_cross_A
Brake_gate
Power_neg
Earth
Power_pos
PFC_z_c
PFC_gate
Phase_C
33
Phase_A
Phase_B
Ground 32 PFC_enable
GNDA
GND
31 PFC_PWM
1
FAN 2 Earth_GND 30 Serial_Con
29 Brake_control
J15 Shielding
28
27
GND 26 Temp_sense
FAN2 GNDA Brake I_sense_C
Temp_sense_2 25
24 I_sense_B
1 23 I_sense_A
2 22 I_sense_DCB
GNDA V_sense_DCB
21
J12 -15V_A 20
+15V_A 19
9
4
3
2
1
1
2
3
4
5
6
4
5
6
1
2
3
4
9
20
19
18
17
12
11
10
10
11
12
17
18
19
20
18
J1 J3 J4 J2 17
POWER +3.3V_A 16
CON/A CON/B CON/C CON/A
+5V_D 15
J9 J8 J7 J6 J5
MODULE GNDA
14
D1 J10
13
V14E250 CON/B CON/E CON/E CON/C CON/C CON/C Motor 12
Terminals 11 PWM_CB
1
2
3
4
5
6
1
2
3
4
1
2
3
4
4
5
6
4
5
6
4
5
6
GND Shielding
J13 10
9 PWM_CT
1 Phase_A 8 Shielding
R1 2 Phase_B 7 PWM_BB
3 Phase_C 6 Shielding
R/ivar SG-190 i 5 PWM_BT
Shielding
4
3 PWM_AB
Source_AT
Gate_BT
Gate_AT
Source_CT
Source_BT
Gate_CT
Source_CB PWM_CB 2 Shielding

Gate_CB PWM_CT 1 PWM_AT
F1
Source_BB PWM_BB
2.5A/250V
Gate_BB PWM_BT
Fast-Blow
Source_AB PWM_AB
Gate_AB PWM_AT
Shut_Down
+15V_D
+5V_D
I_sense_C2
I_sense_C1
I_sense_A2
I_sense_B1
I_sense_DCB2
I_sense_A1
I_sense_B2
I_sense_DCB1
GND
2
1
J11
HV_Drivers
Line
Input Shut_Down_Open C.
+15V_D +5V_D GND
+15V_D +15V_D Temp_sense
I_sense_C
+3.3V_A +3.3V_A I_sense_B
I_sense_A
GNDA I_sense_DCB
GNDA GND Temp_sense_1

Temp_sense_2 Temp_sense_2
GND I_T_Processing GNDA
Figure 4-1. 3 Phase AC BLDC High Voltage Power Stage Overview

D402 MBRS130LT3
U404A
+5V_D Gate_AT
DM74ALS1034M
C402 D401
R401
4.7uF/16V C403 MBRS130LT3 120 D403
1 2 C401 U401 470nF/50V +15V_D MMSZ5251BT1
PWM_AT
100nF + 9 8
10 n/c HO 7
11 n/c VB 6
VDD VS Source_AT
12 5
13 HIN n/c 4
14 SD n/c 3 + D404 MBRS130LT3
LIN VCC C416
3 4 15 2 33uF/25V
PWM_AB VSS COM
16 1
n/c LO Gate_AB
+5V_D C404
GND IR2112S 470nF/50V R402 D405
C419 C420 U404B GND 120 MMSZ5251BT1
1nF 1nF DM74ALS1034M R414
10k
Source_AB
R413 C413 8.2pF
R403 R404 Shut_Down +5V_D
D406 MBRS130LT3
10k 10k
100
GND U404C
+5V_D Gate_BT
DM74ALS1034M D408
C406 R405
4.7uF/16V C407 MBRS130LT3 120 D407
5 6 C405 U402 470nF/50V +15V_D MMSZ5251BT1
PWM_BT
100nF + 9 8
10 n/c HO 7
11 n/c VB 6
VDD VS Source_BT
12 5
13 HIN n/c 4
14 SD n/c 3 + C417 D409 MBRS130LT3
9 8 15 LIN VCC 2 33uF/25V
PWM_BB VSS COM
16 1
n/c LO Gate_BB
C408
GND IR2112S 470nF/50V R406 D410
C421 C422 U404D GND 120 MMSZ5251BT1
1nF 1nF DM74ALS1034M
C414 8.2pF
Source_BB
+5V_D
R407 R408 D411 MBRS130LT3
10k 10k
GND U404E
+5V_D Gate_CT
DM74ALS1034M
C410 D413
C411 R409
4.7uF/16V MBRS130LT3 120 D412
470nF/50V
PWM_CT 11 10 C409 U403 +15V_D MMSZ5251BT1
100nF + 9 8
10 n/c HO 7
11 n/c VB 6
VDD VS Source_CT
12 5
13 HIN n/c 4
14 SD n/c 3 + D414 MBRS130LT3
LIN VCC C418
13 12 15 2 33uF/25V
PWM_CB VSS COM
16 1
n/c LO Gate_CB
C412
GND IR2112S 470nF/50V R410 D415
C423 C424 U404F GND 120 MMSZ5251BT1
C415 8.2pF
Source_CB
+5V_D
R411 R412
10k 10k
GND
+15V_D VCC +5V_D VCC

+15V_D
10nF
+5V_D
C425
GND
GND
GND
Figure 4-2. Gate Drive

DCB_PFC_1 DCB_Cap_Pos
D12
DCB_PFC_2
HFA08TB60S Q1 Q3 Q5
SKB10N60 SKB10N60 SKB10N60
D7 D8 R8
R6
10ETS08S 10ETS08S 250
250 Gate_AT Gate_BT Gate_CT
Phase_A Phase_B Phase_C

D11
R9
R7 250 HFA08TB60S
250 Q2 Q4 Q6
MTB8N50E Q8 SKB10N60 SKB10N60 SKB10N60
AC_IN_L1
AC_IN_L2 Brake_Res Gate_AB Gate_BB Gate_CB

Gate_PFC
Source_AB Source_BB Source_CB
Source_PFC
D9 D10 Q7 sense sense
I_sense_C1
sense
SGB10N60 I_sense_A1 I_sense_B1 R2 R3
10ETS08S 10ETS08S R1
Gate_Brake 0.075 1% 0.075 1% 0.075 1%
sense sense sense
R5 I_sense_A2 I_sense_B2 I_sense_C2
0.075 1% R4
0.075 1%
sense
sense
sense
sense
DCB_Cap_Neg
D13 D14
Temp_sense1
I_Sense_PFC1 I_Sense_PFC2 I_Sense_DCB1 I_Sense_DCB2 BAV99LT1 BAV99LT1
Temp_sense2
Temp_sense2
Temp_sense1
DCB_Cap_Neg
DCB_Cap_Pos
I_Sense_PFC2
I_Sense_PFC1
DCB_PFC_2
Gate_Brake
Source_PFC
Gate_PFC
Brake_Res
DCB_PFC_1
AC_IN_L1
AC_IN_L2
Gate_AT
Gate_BT
Phase_C
Phase_A
Phase_B
Gate_CT
1
2
3
4
9
10
11
12
17
18
19
20
1
2
3
4
9
10
11
12
17
18
19
20
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
J1 J2 J3 J4 J5 J6 J7
SM/CON/MCRD_SR_500_A - male SM/CON/MCRD_SR_500_A - male SM/CON/MCRD_SR_500_B - male SM/CON/MCRD_SR_500_C - male SM/CON/MCRD_SR_500_C - male SM/CON/MCRD_SR_500_C - male SM/CON/MCRD_SR_500_C - male
I_Sense_DCB2
I_Sense_DCB1
Source_BB
Source_AB
Source_CB
I_sense_C2
I_sense_C1
I_sense_B2
I_sense_B1
I_sense_A2
I_sense_A1
Gate_CB
Gate_BB
Gate_AB
1
2
3
4
1
2
3
4
1
2
3
4
5
6
J8 J9 J10
SM/CON/MCRD_SR_500_E - male SM/CON/MCRD_SR_500_E - male SM/CON/MCRD_SR_500_B - male
Figure 4-3. 3 Phase H-Bridge

+15V_D +15V_D
+3.3V_A
+3.3V_A +3.3V_A
C302 Temperature
GNDA
10nF Phase Current +15V_D R302
Sensing Sensing
GND
GNDA 2.21k-1%
8
U303A
GND GND R303 75k-1% 3 + Temp_sense_2 Temp_sense
1
2 -
R301 10k-1% C301
I_sense_A1 6 - LM393D 100nF
7 GNDA
4
I_sense_A Temp_sense_1
5
I_sense_A2
+
(1.65V +/- 1.65V @ +/- Imax)
R304 10k-1% GND
U302B
R305 MC33502D
75k-1%
1.65V ref
R306 680k
Over-current
R307 75k-1%
Detection +15V_D
R308 R309
8
1.2k 1.2k U303B
5 Shut_Down_Open C.
I_sense_DCB +
7
GNDA C303 6
+3.3V_A -
4
R311 10k-1% 680pF
2 R310 R312 LM393D
I_sense_B1
-
1 GNDA 470 10k
4
I_sense_B
3
I_sense_B2
+
(1.65V +/- 1.65V @ +/- Imax)
R313 10k-1% U301A
GND
R314 MC33502D GNDA
8
75k-1%
+3.3V_A
R315 75k-1%
1.65V ref
DC Bus Current
C304
100nF Sensing
I_sense_DCB
GNDA GNDA
4
R316 10k-1%
I_sense_DCB1 2 -
R318 75k-1% 1
I_sense_DCB
I_sense_DCB2 3 +
U302A (1.65V +/- 1.65V @ +/- Imax)
R320 10k-1% R317 10k-1% MC33502D
6
8
I_sense_C1
-
7
I_sense_C +3.3V_A
5 R319
I_sense_C2
+
(1.65V +/- 1.65V @ +/- Imax) 75k-1%
R321 10k-1%
R322 U301B
75k-1% MC33502D C305
R323 390 100nF
+3.3V_A 1.65V ref
GNDA
+
R324
8
C307 C306 100k-1%

100nF 3.3uF/10V 5
LM285M R325
U304 33.2k-1%
GNDA
4
GNDA
Figure 4-4. Current & Temperature Feedback

R501
Phase_A
(400V max) 324k-1%
R502 +15V_D
+15V_D
274k-1%
+5V_D
+5V_D +5V_D
R504
215k-1% R505
10k GND
R506
9 + GND
14
0 Zero_cross_A GNDA
R507 8 -
21.0k-1% U501C
C501 LM339D GNDA
10pF
BEMF_sense_A
(3.24V @ Phase_A = 400V) R508
6.81k-1%
GNDA
R509
Phase_B
GNDA
(400V max) 324k-1%
R510
374k-1% +15V_D
C503
+5V_D
R512 10nF
215k-1% R513
3
R514 GND 10k
5 +
2
0 Zero_cross_B
R515 4 -
21.0k-1% C502 U501A
10pF LM339D
12
BEMF_sense_B
(3.24V @ Phase_B = 400V) R516 +5V_D
6.81k-1% GND 11 +
GNDA 13
C506 10 -
R517 U501D
10nF LM339D
Phase_C
GNDA GND
(400V max) 324k-1% GND
R519
374k-1%
+5V_D
R520
215k-1% R521
R522 10k
7 +
1
0 Zero_cross_C
R523 6 -
21.0k-1% C504 U501B
10pF LM339D
BEMF_sense_C V_sense_DCB_half_15
(3.24V @ Phase_C = 400V) R524 (6.60V @ Vbus = 400V) C505
6.81k-1% 22pF
GNDA
GNDA
GNDA
Figure 4-5. Back EMF Signals

+5V_D VCC PFC_I_sense_1
+5V_D +15V_D
+15V_D C204 R203
+15V_D C202
10nF 68-1%
+15V_A 10uF/35V
+15V_A +15V_A +5V_D
+
R205 R206 100k
GNDA GND
1k-1%
GNDA 22nF +15V_D
C206 PFC Switch R210
C203
10nF R208 PFC_gate
GND C201 100nF GND 33
R207 C205 10k
6.8nF D202
12.1k-1%
6
GND C207 GND U202 R213 MMSZ5251BT1
U201A 22nF 3 U201B 1 NC VCC NC 8 10k
+
1 1 4 U201C
R201 R209
3 2 - 6 9
PFC_Source
PFC_PWM 2 10k-1% LM393D 5 8 2 InA OutA 7
3.92k-1%
U203A 10
4
MC74VHCT00AD R212 MC74VHCT00AD GND
MC74VHCT00AD R211
680-1% 10k 4 InB OutB 5 R204
R214 Brake_gate
3.3k 100
GND GND GND D201
GNDA Brake Switch MC33152D MMSZ5251BT1
3
GND Brake_control
PFC_enable GND
R202 C212 GND
10k 1nF
R215
10k
GND
+15V_D +15V_D
R216 270k
GND
+5V_D
+15V_D
Zero Crossing
D203
Detection SM/1N4148 R217 R218
C211 2.7k 4.7k
8
PFC Option: 1nF
L201 ref_l = 11.81V 5 +
PFC R219 R220 R221 ref_h = 11.86V 7
PFC_z_c
1 6 -
DCB_PFC_2
LM393D
2 JP201 4.9mH/2.3A 33k 33k 33k U203B
DCB_PFC_1 PFC Jumper R222 R223
4
3 10k 10k
no PFC GND
Bus Voltage Feedback
DCB_Cap_pos GNDA GNDA
V_sense_DCB_half_15
274k-1% 274k-1% 4.87k-1% 274k-1% R228
R224 R225 R226 R227 6.81k-1%
C213
10nF/3000V
+ R229
C208 C209 255-1%
Earth_GND
22nF/630VDC 470uF/400V
V_sense_DCB
U201D
C214 (3.235V @ Vbus = 400V) 12
10nF/3000V R230 11
6.81k-1% 13
DCB_Cap_neg
MC74VHCT00AD
GNDA GND
Figure 4-6. Power Factor Correction & Brake Gate Drives

D109 MBR0530T1
Power_pos Power_pos D101
MBRD660CT
Power_neg 1 U110
GND FB +5V_D C128 MC78PC33NTR
+3.3V_A +3.3V_A 10uF/6.3V +3.3V_A
4 1 5
Vin Vout
+5V_D +5V_D
3
GND
P6SMB200AT3 T100 + + + 3 + C104
+15V_D +15V_D -CE
1 12 +
Power_pos
+15V_A C101 D108 10uF/6.3V
+15V_A 220uF/10V
C100 D100 2 11 C105
2
MMSZ5231BT1
10pF/500V 100nF
-15V_A -15V_A
R100 3 10
1.0k D102 GC101
GNDA
4 9 Ground_Connection
C102 C103 GND
GNDA 5 8 220uF/10V 220uF/10V D110 MBR0530T1 GNDA
MURS160T3 GND
GND
R101 R102 R103 6 7
GND 1.0k 1.0k 1.0k D103 D104 +17V_D U106
SM/Trafo_EFD20/12PIN 100nF MC78L15ACD +15V_A
FB 2 3 33uF/25V 33uF/25V 8 1
+FAN +FAN VIN VOUT
R104 C107
MBRS1100T3 + + C108 C109 2 3 6 7 C110
-FAN -FAN 270 MBRS1100T3
1 4 + 100nF
U100 GNDA
SFH6106 C111 5
R105
33uF/25V GND
R106 D105 + + GNDA C112 7 C114
820 100nF 6 Vin Gnd 100nF
2.21k-1% GND
C113 C129 3 Vin 1
2 Vin Vout
33uF/25V 33uF/25V Vin -15V_A
C116 3 MBRS1100T3 U107
100nF MC79L15ACD
U102
R108 Drain
6.8
1
1 TOP202YAI
8 U101 Control D112 MBR0530T1
TL431BCD
R109 + C117 Source
2.21k-1%
47uF/16V 2
7
6
3
2
GND D111 MBR0530T1
D106
T101 MBRS1100T3 U108
SM/Trafo_EFD15/12PIN MC78L15ACD
+15V_D
1 12 8 1
Power_pos +FAN +17V_D VIN VOUT
2 11 C126 2 3 6 7 C127
100nF 100nF
3 10 C122
+ 100uF/16V
4 9
+5V_D
R110 R111 R112
5 8 GND GND
27 27 27
-FAN
6 7
TNY254P U103 D107 R115
R113 MMSZ5242BT1
1 5 330
27 C123 BP Drain
100nF U104
2 4 3 SFH6106 2
S EN R114 D113
C124 S S S S 1.0k
100pF/500V 4 1 GREEN LED
3 6 7 8
C125 1nF/1kV
GND
GND
Figure 4-7. Power Supply

+5V_D
C801 + C802 +5V_D +5V_D

10uF/6.3V 10nF U801
MC68HC705JJ7DW_MOD R802 R803 R804 R805
18 19 10k 10k 10k 10k
GND VCC
GND 11 10
12 PA2 PA3 9
13 PA1 PA4 8
Identification PA0 PA5
R801 10k JP801 Coding bit #
14 7 7
+5V_D IRQ PB7 8 7
15 6 6
16 RESET PB6 5 6 5
17 OSC2 PB5 4 4 3 5
X801 OSC1 PB4/TCMP 3 2 1 4
0 20 PB3/TCAP 2 3
PB0 PB2/AN2 SM/JUMPER4x2
1 2
4MHz PB1/AN1
1
GND
Coding bit #
Coding bit #
GND +5V_D
DEFAULT SETTINGS:
0 - PTB0 = H
+5V_D +5V_D
1 - PTB1 = H
2 - PTB2 = H
3 - PTB3 = H
GND 4 - PTB4 = H
5 - PTB5 = H
6 - PTA6 = H
GND 7 - PTA7 = H
Figure 4-8. Identification Block

Schematics and Parts List
4.4 Parts Lists

The HV ac power stage’s parts content is described in Table 4-1 for the power
substrate and in Table 4-2 for the printed circuit board.
Table 4-1. Power Substrate Parts List

Designators Qty Description Manufacturer Part Number
D7, D8, D9, International

4 10 A/800 V rectifier 10ETS08S
D10 Rectifier
International
D11, D12 2 8 A/600 V ultrafast rectifier HFA08TB60S
Rectifier
ON
D13, D14 2 Dual diode — temp sensing BAV99LT1
Semiconductor
Fisher
J1, J2 2 SM/CON/MCRD_SR_500_A - male SL 11 SMD 104 20Z
Elektronik
Fisher
J3, J10 2 SM/CON/MCRD_SR_500_B - male SL 10 SMD 104 6Z
Elektronik
Fisher
J4, J5, J6, J7 4 SM/CON/MCRD_SR_500_C - male SL 10 SMD 104 6Z
Elektronik
Fisher
J8, J9 2 SM/CON/MCRD_SR_500_E - male SL 10 SMD 104 4Z
Elektronik
Q1, Q2, Q3,

6 10 A/600 V co-packaged IGBT Infineon SKB10N60
Q4, Q5, Q6
Q7 1 10 A/600 V IGBT Infineon SGB10N60
ON
Q8 1 8 A/500 V MOSFET MTB8N50E
Semiconductor
R1, R2, R3,

5 0.075 Ω 1% Isabellenhutte PMA-A-R075-1
R4, R5
R6, R7, R8, Caddock

4 250 Ω MP725-250-5.0%
R9 Electronics
1 Power substrate CUBE 46615770
40 Schematics and Parts List MOTOROLA

Parts Lists
Table 4-2. Printed Circuit Board Parts List (Sheet 1 of 5)

C1, C2, C105, C109, C110,

C112, C114, C116, C123,
C126, C127, C203, C301, 19 100 nF/25 V Vitramon VJ0805U104MXXA_
C304, C305, C307, C401,
C405, C409
C100 1 10 pF/500 V Vishay Sprague Typ:5GAQ10, Serie: 562C
C101, C102, C103 3 220 µF/10 V AVX TPSE227K010R0100
C104,C128,C801 3 10 µF/6.3 V Sprague 293D106X_6R3B2_
C107, C108, C111, C113,

8 33 µF/25 V AVX TPSE336K025R0200
C129, C416, C417, C418
C117 1 47 µF/16 V Any available
C122 1 100 µF/16 V AVX TPSE107K016R0100
C204, C206, C302, C425,

7 10 nF/25 V Vitramon VJ0805U103MXXA_
C503, C506, C802
C124 3 100 pF/500 V Vishay Sprague Typ:5GAT10, Serie: 562C
C125 1 1 nF/1 kV muRata DE0505E102Z1K
C201 1 6.8 nF Vitramon VJ0805A682JXA_
C202 1 10 µF/35 V Sprague 293D106X_035D2_
C205, C207 2 22 nF Vitramon VJ0805A223JXA_
C208 1 22 nF/630 Vdc WIMA MKP10
Philips
C209 1 470 µF/400 V 15746471
Components
C211, C212, C419, C420,
8 1 nF Vitramon VJ0805A102JXA_
C421, C422, C423, C424
C213, C214 2 10 nF/ 3000 V Thomson 5ST410MCMCA
C303 1 680 pF Vitramon VJ0805A681JXA_
C306 1 3.3 µF/10 V Sprague 293D335X_010A2_
C402, C406, C410 3 4.7 µF/16 V Sprague 293D475X_016B2_
C403, C404, C407, C408,

6 470 nF/50 V Vitramon VJ1206U474MXAA_
C411, C412
C413, C414, C415 3 8.2 pF Vitramon VJ0805A8R2DXA_
C505 1 22 pF Vitramon VJ0805A220DXA_


D1 1 V14E250 EPCOS SOIV-S-10K250
ON
D100 1 Transient suppressor P6SMB200AT3
Semiconductor
ON
D101 1 6 A/60 V Schottky MBRD660CT
Semiconductor
ON
D102, D401, D408, D413 4 1 A/600 V ultrafast MURS160T3
Semiconductor
ON
D103, D104, D105, D106 4 1 A/100 V Schottky MBRS1100T3
Semiconductor
ON
D107 1 12 V/.5 W zener MMSZ5242BT1
Semiconductor
ON
D108 1 5.1 V/.5 W zener MMSZ5231BT1
Semiconductor
ON
D109, D110, D111, D112 4 0.5 A/30 V Schottky MBR0530T1
Semiconductor
D113 1 Green LED Kingbright L-934GT
D201, D202, D403, D405, ON

8 22 V/0.5 W zener MMSZ5251BT1
D407, D410, D412, D415 Semiconductor
D203 1 1N4148 Fairchild 1N4148LL-34
D402, D404, D406, D409, ON

6 1 A/30 V Schottky MBRS130LT3
D411, D414 Semiconductor
F1 1 Fuse holder MULTICOMP MCHTE15M
JP201 1 Power jumper
JP801 1 4X2 jumper pads
Fisher
J2, J1 2 20-pin connector BL 2 20Z
Elektronik
Fisher
Elektronik
Fisher
J4, J5, J6, J7 4 6-pin connector BL 1 6Z
Elektronik
Fisher
Elektronik
J11, J12 2 Terminal block Weidmuller LP 7.62/2/90

Parts Lists

J13 1 Terminal block Weidmuller LP 7.62/3/90
Fischer
J14 1 40-pin connector ASLG40G
Elektronik
Thompson
L201 1 4.9 mH/2.3 A Television SMT4 ref G6982
Components
Rhopoint
R1 1 Inrush limiter SG190
Components
R100, R101, R102, R103 4 1.0 kΩ Dale CRCW1206-102J
R104 1 270 Ω Dale CRCW0805-271J
R105 1 820 Ω Dale CRCW0805-821J
R106, R109 2 2.21 kΩ –1% Any available
R108 1 56 Ω Any available
R110, R111, R112, R113 4 27 Ω Dale CRCW1206-270J
R114 1 1.0 kΩ Dale CRCW0805-102J
R115 1 330 Ω Dale CRCW0805-331J
R201 1 3.92 kΩ –1% Any available
R202, 214 2 3.3 kΩ Dale CRCW0805-332J
R208, R211, R213, R215,

R223, R312, R403, R404,
R407, R408, R411, R412,
21 10 kΩ Dale CRCW0805-103J
R414, R505, R513, R521,
R801, R802
R803, R804, R805
R203 1 68.1 –1% Any available
R204, R413 2 100 Ω Dale CRCW0805-101J
R206 1 100 kΩ Dale CRCW0805-104J
R210 1 33 Ω Dale CRCW0805-330J
R212 1 681 Ω –1% Any available
R216 1 270 Ω Dale CRCW0805-274J
R217 1 2.7 kΩ Dale CRCW0805-272J


R218 1 4.7 kΩ Dale CRCW0805-472J
R219 1 33 kΩ Dale CRCW0805-333J
R220, R221 2 33 kΩ Dale CRCW0805-333J
R222 1 10 kΩ Dale CRCW0805-103J
R224, R225, R227, R502,

6 274 kΩ –1% Any available
R510, R519
R228, R230, R508, R516,

5 6.81 kΩ–1% Any available
R524
R229 1 255 Ω –1% Any available
R209, R301, R304, R311,

R313, R316, R317, R320, 9 10 kΩ –1% Dale CRCW0805-103F
R321
R205 1 1 kΩ –1% Dale CRCW0805-102F
R303, R305, R307, R314,

8 75 kΩ –1% Dale CRCW0805-753F
R315, R318, R319, R322
R306 1 680 kΩ Dale CRCW0805-684J
R308, R309 2 1.2 kΩ Dale CRCW0805-122J
R310 1 220 Ω Dale CRCW0805-221J
R323 1 390 Ω Dale CRCW0805-391J
R324 1 100 kΩ –1% Dale CRCW0805-104F
R401, R402, R405, R406,

6 120 Ω Dale CRCW0805-121J
R409, R410
R501, R509, R517 3 324 kΩ –1% Any available
R504, R512, R520 3 215 kΩ –1% Any available
R506, R514, R522 3 0 Any available
R507, R515, R523 3 21.0 kΩ –1% Any available
Tronic Praha
T100 1 SMPS transformer TRONIC 99 060 09
s.r.o

Parts Lists

Tronic Praha
T101 1 SMPS transformer TRONIC 00 003 73
s.r.o
U100, U104 2 Optocoupler Infineon SFH6106-2
ON
U101 1 Voltage reference TL431BCD
Semiconductor
Power
U102 1 SMPS controller TOP202YAI
Integration
Power
U103 1 SMPS controller TNY254P
Integration
ON
U108, U106 2 15 V/.1 A regulator MC78L15ACD
Semiconductor
ON
U107 1 – 15 V/0.1 A regulator MC79L15ACD
Semiconductor
ON
U110 1 3.3 V/.15 A regulator MC78PC33NTR
Semiconductor
ON
U201 1 Quad 2-input NAND gate MC74VHCT00AD
Semiconductor
ON
U202 1 Dual gate driver MC33152D
Semiconductor
ON
U203, U303 2 Dual comparator LM393D
Semiconductor
ON
U301, U302 2 Dual op amp MC33502D
Semiconductor
National
U304 1 Voltage reference LM285M
Semiconductor
International
U401, U402, U403 3 Dual gate driver IR2112S
Rectifier
U404 1 Hex non-inverting driver Fairchild DM74ALS1034M
ON
U501 1 Quad comparator LM339D
Semiconductor
U801 1 Microcontroller Motorola MC68HC708JJ7CDW
X801 1 4-MHz resonator muRata CSTCC4.00MG


Section 5. Design Considerations
5.1 Contents
5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.10 Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Overview
From a systems point of view, the HV ac power stage fits into an architecture
that is designed for software development. In addition to the hardware that is
needed to run a motor, a variety of feedback signals that facilitate control
algorithm development and a PFC circuit are provided.
Circuit descriptions for the HV ac power stage appear in 5.3 3-Phase H-Bridge
through 5.10 Power Factor Correction. One phase leg of the 3-phase H-bridge
is looked at in 5.3 3-Phase H-Bridge. Bus voltage and bus current feedback are
discussed in 5.4 Bus Voltage and Current Feedback. Cycle-by-cycle current
limiting is highlighted in 5.5 Cycle-by-Cycle Current Limiting. Temperature
sensing is discussed in 5.6 Temperature Sensing. Back-EMF signals appear in
5.7 Back EMF Signals. Phase current sensing is discussed in 5.8 Phase
Current Sensing. The brake is highlighted in 5.9 Brake, and finally power
factor correction is discussed in 5.10 Power Factor Correction.
MOTOROLA Design Considerations 47

Design Considerations
5.3 3-Phase H-Bridge

The output stage is configured as a 3-phase H-bridge with IGBT output
transistors. It is simplified considerably by high-voltage integrated gate drivers
that have a cycle-by-cycle current limit feature. A schematic that shows one
phase is illustrated in Figure 5-1.
At the input, pulldown resistors R403 and R404 set a logic low in the absence
of a signal. Open input pulldown is important, since it is desirable to keep the
power transistors off in case of either a broken connection or absence of power
on the control board. The drive signal is buffered by U404A and U404B. This
part has a minimum logic 1 input voltage of 2.0 volts and a maximum logic 0
input voltage of 0.8 volts, which allows for inputs from either 3.3- or 5-volt
logic. Gate drive is supplied by an international rectifier, IR2112. Undervoltage
lockout and cycle-by-cycle current limiting are also provided by the IR2112.
Undervoltage lockout is set nominally at 8.4 volts. Current limiting is discussed
further in 5.5 Cycle-by-Cycle Current Limiting.
One of the more important design decisions in a motor drive is selection of gate
drive impedance for the output transistors. In Figure 5-1, resistor R402, diode
D404, and the IR2112’s nominal 500-mA current sinking capability determine
gate drive impedance for the lower half-bridge transistor. A similar network is
used on the upper half-bridge. These networks set turn-on gate drive impedance
at approximately 120 ohms and turn-off gate drive to approximately 500 mA.
These values produce transition times of approximately 200 ns.
Transition times of this length represent a carefully weighed compromise

between power dissipation and noise generation. Generally, transition times
longer than 250 ns tend to get power hungry at non-audible PWM rates; and
transition times under 50 ns create di/dt’s so large that proper operation is
difficult to achieve. The HV ac power stage is designed with switching times at
the higher end of this range to minimize noise.
Anti-parallel diode softness is also a first order design consideration. If the

anti-parallel diodes in an off-line motor drive are allowed to snap, the resulting
di/dt’s can cause noise management problems that are difficult to solve. In
general, it is desirable to have peak to zero di/dt approximately equal the applied
di/dt that is used to turn the anti-parallel diodes off. The SKB10N60 IGBT’s
that are used in this design are targeted at this kind of reverse recovery
characteristic.
48 Design Considerations MOTOROLA

DCB_Cap_Pos
Q1
D402 MBRS130LT3 SKB10N60
U404A +5V_D
C402 D401
DM74ALS1034M R401
4.7uF/16V C403 MBRS130LT3 120 D403
C401 U401 470nF/50V +15V_D MMSZ5251BT1
PWM_AT 1 2 100nF + 9 8
10 n/c HO 7
11 n/c VB 6
12 VDD VS 5
13 HIN n/c 4 Q2
14 SD n/c 3 + D404 MBRS130LT3 SKB10N60
LIN VCC C416
15 2 33uF/25V
3 4 16 VSS COM 1
PWM_AB n/c LO C404
GND IR2112S 470nF/50V R402 D405
GND 120 MMSZ5251BT1
C419 C420 U404B +5V_D
R403 R404 R414 sense

I_sense_A1
10k 10k 10k R1
GND
sense 0.075 1%
I_sense_A2
R413 C413 8.2pF
Shut_Down +5V_D I_Sense_DCB2
100
Figure 5-1. Phase A Output

5.4 Bus Voltage and Current Feedback

Feedback signals proportional to bus voltage and bus current are provided by
the circuitry shown in Figure 5-2. Bus voltage is scaled down by a voltage
divider consisting of R224 –R230.
The values are chosen such that a 400-volt maximum bus voltage corresponds
to 3.24 volts at output V_sense_DCB. An additional output,
V_sense_DCB_half_15, provides a reference used in zero crossing detection.
Bus current is sampled by resistor R4 in Figure 4-3, and amplified by the circuit
in Figure 5-2. This circuit provides a voltage output suitable for sampling with
A/D (analog-to-digital) inputs. An MC33502 is used for the differential
amplifier. With R315 = R319 and R316 = R317, the gain is given by:
A = R315/R316
The output voltage is shifted up by 1.65 V to accommodate both positive and

negative current swings. A ±300-mV voltage drop across the sense resistor
corresponds to a measured current range of ±2.93 amps. In addition to providing
an A/D input, this signal also is used for cycle-by-cycle current limiting. A
discussion of cycle-by-cycle current limiting follows in 5.3 3-Phase H-Bridge.

DCB_Cap_pos V_sense_DCB_half_15
274k-1% 274k-1% 4.87k-1% 274k-1% R228 (6.60V @ DC-Bus = 400V)
R224 R225 R226 R227 6.81k-1%
DC Bus Voltage R229

255-1%
Sensing
V_sense_DCB
R230 (3.24V @ DC-Bus = 400V)
6.81k-1%
GNDA
R315 75k-1%
DC Bus Current
Sensing
I_sense_DCB
GNDA
R316 10k-1% 4
I_sense_DCB1 2 -
1
I_sense_DCB
I_sense_DCB2 3 +
U302A
R317 10k-1% MC33502D
8
R319
+3.3V_A
75k-1%
R323 390
1.65V ref C305
+3.3V_A
100nF
+
R324 GNDA
8
C307 C306 100k-1%

100nF 3.3uF/10V 5
LM285M R325
U304 33.2k-1%
GNDA
4
GNDA
Figure 5-2. Bus Feedback

5.5 Cycle-by-Cycle Current Limiting

Cycle-by-cycle current limiting is provided by the circuitry illustrated in
Figure 5-3. Bus current feedback signal, I_sense_DCB, is filtered with R308
and C303 to remove spikes, and then compared to a 3.15-volt reference with
U303B. The open collector output of U303B is pulled up by R414. Additional
filtering is provided by C413, C414, and C415. The resulting signal is fed into
the IR2112 gate driver’s shutdown input on all three phases. Therefore, when
bus current exceeds 2.69 amps, all six output transistors are switched off.
The IR2112’s shutdown input is buffered by RS latches for both top and bot-
tom gate drives. Once a shutdown signal is received, the latches hold the gate
drive off for each output transistor, until that transistor’s gate drive signal is
switched low, and then is turned on again. Hence, current limiting occurs on a
cycle-by-cycle basis.

Cycle-by-Cycle Current Limiting
U401
9 N/C 8 A TOP OUT
10 HO
N/C VB 7
11 VDD VS 6
12 HIN 5
PWM A TOP 13 N/C
SD N/C 4
PWM A BOTTOM 14 LIN 3
15 VCC
VSS COM 2
16 N/C 1 A BOTTOM OUT
LO
IR2112S
C413 8.2 pF
+5V_D
C414 8.2 pF
+5V_D
U402
9 N/C 8
10 HO B TOP OUT
N/C VB 7
11 VDD VS 6
12 HIN 5
R306 680 kΩ PWM B TOP 13 N/C
SD N/C 4
PWM B BOTTOM 14 LIN 3
+15V_D 15 VCC
VSS COM 2
+5V_D 16 N/C 1
LO B BOTTOM OUT
R308 R309 8 R414 IR2112S
I_sense_DCB 1.2 kΩ 1.2 kΩ U303B 10 kΩ
5 + R413
7
6
C303 +3.3V_A
– 100 Ω C415 8.2 pF
680 pF R310 LM393D +5V_D
470 Ω R312 4
10 kΩ
GNDA GND U403
GNDA 9 N/C 8
10 HO C TOP OUT
N/C VB 7
11 VDD VS 6
PWM C TOP 12 HIN 5
13 N/C
SD N/C 4
14 LIN 3
PWM C BOTTOM 15 VCC
VSS COM 2
16 N/C 1
LO C BOTTOM OUT
IR2112S
Figure 5-3. Cycle-by-Cycle Current Limiting

5.6 Temperature Sensing

Cycle-by-cycle current limiting keeps average bus current within safe limits.
Current limiting by itself, however, does not necessarily ensure that a power
stage is operating within safe thermal limits. For thermal protection, the circuit
in Figure 5-4 is used. It consists of four diodes connected in series, a bias
resistor, and a noise suppression capacitor. The four diodes have a combined
temperature coefficient of 8.8 mV/°C. The resulting signal, Temp_sense, is fed
back to an A/D input where software can be used to set safe operating limits.
Due to unit-to-unit variations in diode forward voltage, it is highly desirable to

calibrate this signal. To do so, a value for Temp_sense is read at a known
temperature and then stored in nonvolatile memory. The measured value, rather
than the nominal value, is then used as a reference point for further readings.
+3.3V_A
R302
2.2 kΩ –1%
D13 D14
BAV99LT1 BAV99LT1
Temp_sense
PIN 26, CONNECTOR J14

C301
100 nF
GNDA
Figure 5-4. Temperature Sensing

Back EMF Signals
5.7 Back EMF Signals

Back EMF and zero crossing signals are included to support sensorless
algorithms for brushless dc motors and dead time distortion correction for ac
induction motors. Referring to Figure 5-5, which shows circuitry for phase A,
the raw phase voltage is scaled down by a voltage divider consisting of R501,
R502, R504, R507, and R508. One output from this divider produces back EMF
sense voltage BEMF_sense_A. Resistor values are chosen such that a 400-volt
maximum phase voltage corresponds to a 3.24-volt maximum A/D input. A
zero crossing signal is obtained by comparing motor phase voltage with
one-half the motor bus voltage. Comparator U501C performs this function,
producing zero crossing signal Zero_cross_A.
Phase_A
R501
324 kΩ –1%
R502
274 kΩ –1%
+5V_D
R504
215 kΩ –1% R506 R505
0 kΩ 10 kΩ
9 +
14
R507 8
– U501C Zero_cross_A
21 kΩ –1%
C501 LM339D
BEMF_sense_A 10 pF
3.24 V @ Phase_A = 400 V
GNDA
R508
6.81 kΩ –1%
GNDA
V_sense_DCB_half_15 C505
22 pF
GNDA
Figure 5-5. Phase A Back EMF

5.8 Phase Current Sensing

Lower half-bridge sampling resistors provide phase current information for all
three phases. Since these resistors sample current in the lower phase legs, they
do not directly measure phase current. However, given phase voltages for all
three phases, phase current can be constructed mathematically from the lower
phase leg values. This information can be used in vector control algorithms for
ac induction motors. The measurement circuitry for one phase is shown in
Figure 5-6.
DCB_Cap_Pos
Q1
Gate_AT SKB10N60
Phase_A
Q2
Gate_AB SKB10N60
Source_AB R303 75 kΩ –1%
sense
R301 10 kΩ –1% 6
R1 –
0.075 Ω –1% 7
sense 5
+ I_sense_A
U302B
R304 10 kΩ –1% MC33502D
I_Sense_DCB2 R305
75 kΩ –1%
R323 390 Ω 1.65 Vref

+3.3V_A
C307 +
C306 R324
100 nF 3.3 µF/10 V 100 kΩ –1%
8
5
LM285M
U304
R325
GNDA 33 kΩ –1%
4
GNDA
Figure 5-6. Phase A Current Sensing

Brake
Referencing the sampling resistors to the negative motor rail makes the
measurement circuitry straightforward and inexpensive. Current is sampled by
resistor R1, and amplified by differential amplifier U302B. This circuit
provides a voltage output suitable for sampling with A/D inputs. An MC33502
is again used for the differential amplifier. With R301 = R302 and
R303 = R305, the gain is given by:
A = R303/R301
The output voltage is shifted up by 1.65 V to accommodate both positive and

negative current swings. A ±300-mV voltage drop across the shunt resistor
corresponds to a measured current range of ±2.69 amps.
5.9 Brake
A brake circuit is included to dissipate re-generative motor energy during
periods of active deceleration or rapid reversal. Under these conditions, motor
back EMF adds to the dc bus voltage. Without a means to dissipate excess
energy, an overvoltage condition could easily occur.
The circuit shown in Figure 5-7 connects R6–R9 across the dc bus to dissipate
energy. Q7 is turned on by software when the bus voltage sensing circuit in
Figure 5-2 indicates that bus voltage could exceed safe levels. On-board power
resistors R6–R9 will safely dissipate up to 50 watts continuously or up to
100 watts for 15 seconds. Additional power dissipation capability can be added
externally via brake connector J12.

+15V_D
C202 DCB_Cap_Pos
10 µF/35 V
+ R6 R8
250 Ω 250 Ω
J12 D11
1 HFA08TB60S
C203 2
R7 R9
100 nF 250 Ω
GND 250 Ω
U202 6
1 NC 8
VCC NC
2 InA OutA 7
Brake_control R204 Q7
4 InB OutB 5 SGB10N60
100 Ω
C212 GND D201
R202
10 kΩ 1 nF 3 MC33152D MMSZ5251BT1
GND GND GND GND
Figure 5-7. Brake
5.10 Power Factor Correction

A power factor correction (PFC) circuit is included to facilitate development of
software that includes PFC control features. The objective of the PFC hardware
and software is to draw sinusoidal current from the ac line, in an attempt to
approach as closely as possible a unity power factor. Without PFC, current is
drawn from the ac line at the peak of the sine wave, when the ac line voltage
exceeds the dc bus voltage. PFC circuitry is illustrated in Figure 5-8.

Power Factor Correction
NO PFC
3
2 JP201
PFC JUMPER L201
D12
1
PFC 4.9 mH/2.3 A HFA08TB60S
C213
D7 10 nF/
D8 3000 V
10ETS08S 10ETS08S
MTB8N50E Q8
AC_IN_L1 C208 + C209 + C210
22 nF/ 470 µF/ 470 µF/
AC_IN_L2 630 Vdc 400 V 400 V
Earth_GND
(OPTIONAL)
D9 D10 R213 D202 C214
10ETS08S 10ETS08S 10 nF/
10 kΩ MMSZ5251BT1
R5 3000 V
0.075 Ω – 1%
GND
SENSE
SENSE
I_Sense_PFC1 +15V_D
I_Sense_PFC2 U202 6 R210
R203 1 8 33 Ω
NC VCC NC
PFC_I_sense_1 68.1 Ω – 1% +15V_A 2 InA OutA 7
R205 R206 100 kΩ
1 kΩ –1% 4 InB OutB 5

+15V_D
22 nF +5V_D GND
C206
C201 R207 10 nF MC33152D 3
R208 GND
12.1 kΩ C205 8
6.8 nF – 1% GND 10 kΩ
C207 3 + U201B
U201A
1 R201 22 nF 1 4 U201C
3 R209 2 6 9
2
3.92 kΩ 10 kΩ
– 5 8
LM393D 10
PFC_PWM MC74VHCT00AD –1% –1% R212 U203A MC74VHCT00AD R211
680 Ω –1% MC74VHCT00AD 10 kΩ
R214 4
3.3 kΩ
GNDA GND GND
GND
PFC_enable R215
10 kΩ
GND
Figure 5-8. PFC Circuitry
Looking toward the top of Figure 5-8, Q8, L201, D12, and the bus capacitors
form a boost power supply. This configuration allows current to be drawn from
the ac line, when line voltage is lower than the dc bus voltage. Pulse-width
modulation is controlled by software and augmented by the analog circuitry in
the lower half of Figure 5-8. Voltage feedback is provided by the bus voltage
sensing circuit in Figure 5-2. A zero crossing feedback signal, PFC_z_c, is also
used and is produced by the circuit in Figure 5-9.

NO PFC
3
DCB_Cap_pos
2 JP201 L201
1 PFC JUMPER
DCB_PFC_2
PFC 4.9 mH/2.3 A
D7 D8
10ETS08S 10ETS08S
AC_IN_L1
AC_IN_L1
D9 D10
10ETS08S 10ETS08S
I_Sense_PFC1
+15V_D +15V_D +5V_D

R216 270 kΩ
+15V_D
R217 R218
2.7 kΩ 4.7 kΩ
C211 D203
1 nF SM/1N4148 8
5
+ 7
R219 R220 R221 6 PFC_z_c
– LM393D
33 kΩ 33 kΩ 33 kΩ U203B
R222 R223 4
47 kΩ 10 kΩ
GNDA GNDA GND
Figure 5-9. PFC Zero Crossing Feedback
In this circuit, R219, R220, and R221 provide a relatively high impedance
connection to the rectified line voltage, and form a .32:1 voltage divider with
R222. D203 clamps the divided down voltage to approximately 15.7 volts.
Comparator U203B then compares this signal to a 11.8-volt reference.
Approximately fifty millivolts of hysteresis is added by R216. The result is a
logic high at output PFC_z_c when the comparator’s input voltage falls below
11.79 volts. This output remains high until 10.84 volts is reached on the next
cycle.

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 which may be provided in Motorola data sheets and/or specifications can and do vary in different
applications and actual performance may vary over time. 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:

USA/EUROPE/Locations Not Listed: Motorola Literature Distribution, P.O. Box 5405, Denver, Colorado 80217. 1-303-675-2140
or 1-800-441-2447. Customer Focus Center, 1-800-521-6274
JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu, Minato-ku, Tokyo 106-8573 Japan.
81-3-3440-8573
ASIA/PACIFIC: Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, 2 Dai King Street, Tai Po Industrial Estate,
Tai Po, N.T., Hong Kong. 852-26668334
HOME PAGE: http://motorola.com/semiconductors/
© Motorola, Inc., 2000
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User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

Section 1. Introduction and Setup . . . . . . . . . . . . . . . . . . 11

Section 2. Operational Description . . . . . . . . . . . . . . . . . 19

Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . 25

Section 4. Schematics and Parts List . . . . . . . . . . . . . . . 31

Section 5. Design Considerations . . . . . . . . . . . . . . . . . . 47

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA List of Sections 3

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

4 List of Sections MOTOROLA

Section 1. Introduction and Setup

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Section 2. Operational Description

2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4 Modification for One-Half and Three-Fourths Horsepower. . . . . . . . 22

2.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 3. Pin Descriptions

3.2 Pin-by-Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA Table of Contents 5

Section 4. Schematics and Parts List

4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Section 5. Design Considerations

5.3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.10 Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

6 Table of Contents MOTOROLA

Figure Title Page

1-1 Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-1 40-Pin Ribbon Connector J14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4-1 3-Phase ac BLDC High-Voltage Power Stage Overview. . . . . . . . . . 32

5-1 Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA List of Figures 7

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

8 List of Figures MOTOROLA

Table Title Page

2-1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3-1 Connector J13 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4-1 Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA List of Tables 9

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage

10 List of Tables MOTOROLA

Section 1. Introduction and Setup

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

An illustration of the systems’ architecture is shown in Figure 1-1. A line

3-Phase ac BLDC High-Voltage Power Stage User’s Manual

MOTOROLA Introduction and Setup 11

The HV ac power stage’s features are:

User’s Manual 3-Phase ac BLDC High-Voltage Power Stage