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International Rectifier
233 Kansas Street, El Segundo, CA 90245 USA
1/3 HP- Phase Brushless DC (BLDC) Motor Controller Using IR3101/3/4
By Roger N. Khourey
TOPICS COVERED
Overview
Features
General Safety Note, Installation & Protection
System Description
Mechanical and Electrical Description
System connection and GUI Operation
Technical Data
Mode Operation
Circuit Description
Figure 1. IRADK31 Reference Design Kit
1. Overview
The IRADK31 Reference Design Kit (Figure 1) is an electronic controller for driving a 1/3HP
(see Table 1) 3-phase Motor from either a single phase 120VAC or 230VAC. The circuit
provides all the necessary functions, including software driven High performance Micro
Controller, for starting and operating the motor. It also includes an AC on/off switch, EMI
filter and the rectification stage with a buck-converter system that provides the auxiliary
+15V and +5V supply. This controller is software driven through a Graphical User Interface
(GUI) that enables the user to control the entire electrical system and motor parameters. In
addition, it allows the user to monitor the DC Bus current, motor speed, and detects fault
conditions.
2. Features
Fused 120/230VAC input.
AC input on/off switch and EMI filter.
NTC
inrush
current limiter
3-Phase, variable voltage output.
Opto-isolated RS-232 serial link interface to the Graphic User Interface software.
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Integral auxiliary power supply of +15V and +5V.
Fault protection for over current condition.
Stand-alone Mode and fully software driven (PC Mode) using Graphical User
Interface.
PIC18F2431 motor control MCU from Microchip Technology Inc. with Power PWM
module and Hi-speed 10-bit A/D converter.
RJ11 connector for MPLAB ICD2 that provides programming or In-Circuit debugger
interface.
3. General Safety Note
This controller operates at high voltage to control rotating machinery. Qualified, skilled
personnel conversant with all applicable safety standards must operate this equipment. Do
not connect any interface cables to the controller when power is present.
4. Installation
This controller must be placed on an insulated surface. Proper mating cables must be
used for the GUI and motor interfaces (refer to Figure 2). Do not make any alterations or
soldered connections to the printed wiring board. Verify that the input selector switch
matches the AC supply voltage.
5. Protection
Before handling the controller, check that the AC input voltage applied to J1 is turned off,
and the AC on/off switch, SW4 is set to position "0".
CAUTION: High voltage is present on the motor connector J6 during operation.
6. System Description
6.1 Power Modules
The IR3101/3/4 are FredFET Half-Bridge with integrated driver IC for motor drive
applications. The IR310X are developed for electronic motor control in appliance
applications, such as Dishwashing machine pumps and Fan Motors. These 500V power
modules (IR3101 and IR3103) contain 2 FredFETs with soft recovery commutation diodes,
and one Half-Bridge IC driver. Note that the IR3104 is a 600V module.
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IRADK31
6.2 Motor Controller
This motor controller is a single-phase 120V/230VAC input that can utilize 3 IR3101/03/04
modules that are used in a standard inverter configuration. The system is based on a high
computational performance, 8-Bit Micro controller with 10-bit A/D converter, used to
generate the PWM information and implement the motor control loop. The system
operates in an open loop mode, as defined by the firmware. However, this controller has
the provision to operate in closed loop mode.
This controller can be operated in Stand-alone Mode or PC Mode. It can be operated in
Stand-alone Mode even after connecting the RS-232 cable into J5 but prior to connecting
the GUI with the controller. Once the GUI is connected with the controller the system will
become operational in PC Mode and the user cannot operate in Stand-alone Mode, until
the system is reset again.
Refer to Section 7 and Appendix A for further explanation of Mode Operation.
Two LEDs (Green and Red) are used to monitor the status of the control board. Both LEDs
will blink on and off at initial power on, indicating normal board operation. These LEDs
have the following features:
Green: Indicates the Hall sensors level, 3 hall sensors combined. If the motor
shaft is rotated by hand, this LED will blink on and off. Once the motor ramps up at
higher rate, the blink rate of this LED will increase.
Red: In normal operation condition indicates the direction of rotation command.
On for forward, Off for reverse. It will blink on and off when over current fault
condition occurs.
When a Fault is detected the green light, below the Motor Speed Tachometer on the
Control Panel, will turn Red. A detected fault guarantees PWM drive shutdown and
complete protection for the power stage and the power modules. A fault condition is
detected when an over current condition occurs. The firmware current limit can be set in
the system limits from the setup parameters window (refer to Fault Condition and
Current Limit in section 8 for details).
6.3 Auxiliary Power Supply
The auxiliary power supply uses an IR2153 self-oscillating half-bridge driver in a buck
topology that delivers the +15V auxiliary supply. The 15V is fed through a linear regulator
(LM7805) that delivers the +5V to the remaining circuitry. Both the +15V and +5V are
referenced to the DC bus return. The auxiliary power supply operates with a constant on
time at variable frequency. Voltage regulation is maintained over a DC bus voltage
variation from 80V to 400V.
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6.4 Connection Diagram
WARNING
SW1 is an AC Input Voltage Selector switch. DO NOT apply 230VAC when this switch
is set to 115VAC this will result in sever damage to the system and personal injury
due to very high voltage produced by the voltage doubler circuit on the DC bus.
Figure 2 illustrates a typical connection block diagram. The printed wiring board has been
designed to minimize ground loop currents with particular attention to reducing EMI
generation.
Serial Communication
J4
J5
J1
U6
U7
U8
J6
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JP1
Power Modules
D1
0
D1
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Sw
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SW4
SW4
EMI Filter
Section
DC Rectifier
Section
Control
Section
ICD
Auxiliary
Supply Section
GUI
(Computer)
Led Feedback
Line
Motor
Hall Sensors
Neutral
Earth
Earth
Output Phase U
Output Phase V
Output Phase W
Flash Progmming
and debugging
RS-232
R28
SW3
SW2
PIC18F2431
J2
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234 6
Figure 2. IRADK31 Typical Connection Diagram
6.5 GUI and Micro Controller
The use of the GUI enables the user to control motor speed and direction, monitors the DC
Bus current and Fault conditions, and program motor parameters and other control factors.
The GUI also enables the users to set motor and system parameters such as motor type,
motor voltage and current, AC input voltage, and PWM frequency. In addition, it allows the
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user to set the system limits such as current and motor speed. All the setup parameters
are uploaded via serial link.
The PIC18F2431 MCU from Microchip Technology Inc. is responsible for all board
functions, including communication through the RS-232 interface. Moreover, the
Microcontroller introduces design enhancements that make it a logical choice for many high
performance, power and motor control applications.
Special peripherals include:
14-bit resolution Power Control PWM Module (PCPWM) with programmable dead
time insertion.
Motion Feedback Module (MFM), including a 3-channel Input Capture (IC) Module
and Quadrature Encoder Interface (QEI).
High-speed 10-bit A/D Converter (HSADC).
The MFM Quadrature Encoder Interface provides precise rotor position feedback and/or
velocity measurement. The MFM 3X input capture or external interrupts can be used to
detect the rotor state for electrically commutated motor applications using Hall Sensor
feedback, such as BLDC drives. The microcontroller also features Flash program memory
and an internal RC oscillator with built-in Low Power modes, fail-safe clock monitoring and
Enhanced USART module.
7. Mechanical and Electrical Description
The printed wiring board is a double-sided 122.7 x 127 mm board using a mixed
technology of SMT and through-hole components. The layout of the connectors, indicators
and user controls is shown in Figure 3.
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