STMicroelectronics UM1036 User manual

January 2011 Doc ID 18293 Rev 1 1/48

UM1036

User manual

2 kW 3-phase motor control STEVAL-IHM028V1 demonstration board

featuring the IGBT intelligent power module STGIPS20K60

1 Introduction

This document describes the 2 kW 3-phase motor control demonstration board featuring the

IGBT intelligent power module STGIPS20K60. The demonstration board is an AC-DC

inverter that generates a 3-phase waveform for driving 3-phase motors such as induction

motors or permanent magnet synchronous motors (PMSM) up to maximal 2000 W with or

without sensors.

The main device presented in this user manual is a universal, fully evaluated and populated

design consisting of a 3-phase inverter bridge based on the 600 V IGBT power module in

the SDIP 25L package mounted on a heatsink. The IGBT power module integrates all power

IGBT switches with freewheeling diodes together with high voltage gate drivers. Thanks to

this integrated module, the system has been specifically designed to achieve power

inversion in a reliable and compact design. Such integration saves PCB space occupation

and assembly costs, together with high reliability due to the design simplicity.

The board is designed to be compatible with single-phase mains, supplying from 90 VAC to

285 VAC or from 125 VDC up to 400 VDC for the DC voltage.

This document is associated with the release of the STEVAL-IHM028V1 demonstration

board (see Figure 1).

Figure 1. STEVAL- IHM028V1

www.st.com

Contents UM1036

2/48 Doc ID 18293 Rev 1

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 System introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Target application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Safety and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3.1 General terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3.2 Demonstration board intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3.3 Demonstration board installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Board schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.2 Inrush limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.3 Power block based on IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.4 Brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.5 Overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.6 Current sensing amplifying network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3.7 The tachometer and Hall/encoder inputs . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3.8 Temperature feedback and overtemperature protection (OTP) . . . . . . . 22

3.3.9 Active heatsink cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4 Hardware setting of the STEVAL-IHM028V1 . . . . . . . . . . . . . . . . . . . . . 25

4.1 Hardware settings for six-step (block commutation) current control in single-

shunt configuration 25

4.2 Hardware settings for FOC in three-shunt configuration . . . . . . . . . . . . . 26

4.3 Hardware settings for FOC in single-shunt configuration . . . . . . . . . . . . . 27

5 Testing of the demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Description of jumpers, test pins, and connectors . . . . . . . . . . . . . . . 31

UM1036 Contents

Doc ID 18293 Rev 1 3/48

7 Connector placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

11 Using STEVAL-IHM028V1 with STM32 FOC firmware library . . . . . . . 44

11.1 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

11.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.3 Software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.4 Software modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

12 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

13 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

14 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

List of tables UM1036

4/48 Doc ID 18293 Rev 1

List of tables

Table 1. Gain settings for FOC current reading configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 2. Gain settings for six-step current reading configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 3. Jumper settings for PMSM or generic AC motor - six-step. . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 4. Jumper settings for PMSM or generic AC motor - FOC in three-shunt. . . . . . . . . . . . . . . . 27

Table 5. Jumper settings for PMSM or generic AC motor - FOC in single-shunt . . . . . . . . . . . . . . . 28

Table 6. Jumper description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table 7. Connector pinout description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 8. Testing pins description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 9. Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table 10. Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

UM1036 List of figures

Doc ID 18293 Rev 1 5/48

List of figures

Figure 1. STEVAL- IHM028V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 2. Motor control system architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 3. STEVAL- IHM028V1 schematic - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 4. STEVAL- IHM028V1 schematic - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 5. STEVAL- IHM028V1 schematic - part 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 6. STEVAL- IHM028V1 schematic - part 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 7. STEVAL- IHM028V1 schematic - part 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 8. STEVAL- IHM028V1 schematic - part 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 9. Power supply block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 10. Overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 11. Configuration for FOC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 12. Six-step current sensing configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 13. Thermal resistance of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 14. Thermal resistance of the heatsink with continuous fan cooling. . . . . . . . . . . . . . . . . . . . . 24

Figure 15. Current signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 16. STEVAL-IHM028V1 connector placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 17. Copper tracks - top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 18. Copper tracks - bottom side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 19. Silk screen - top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 20. Silk screen - bottom side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

System introduction UM1036

6/48 Doc ID 18293 Rev 1

2 System introduction

2.1 Main characteristics

The information listed below shows the converter specification data and the main

parameters set for the STEVAL-IHM028V1 demonstration board.

●Minimum input voltage 125 VDC or 90 VAC

●Maximum input voltage 400 VDC or 285 VAC

●With applied input voltage doubler - the range from 65 VAC to 145 VAC

●Maximum output power for applied motor up to 2000 W

●Regenerative brake control feature

●Input inrush limitation with bypassing relay

●+15 V auxiliary power supply based on a buck converter with VIPer™26

●Using IGBT intelligent power module STGIPS20K60 in SDIP 25L molded package

●Fully populated board conception with test points and safety isolated plastic cover

●Motor control connector for interface with STM3210B-EVAL board, STM8/128-EVAL

board, and other ST motor control dedicated kits

●Tachometer input

●Hall/encoder inputs

●Overheating protection

●Active fan cooling of heatsink with automatic temperature switch

●Possibility to connect MB843 BLDC daughterboard for sensor-less six-step control

●PCB type and size:

– Material of PCB - FR-4

– Double-sided layout

– Copper thickness: ~60 μm

– Total dimensions of demonstration board: 195 mm x 175 mm.

2.2 Target application

●Power fans for HVAC application

●Power tools

●Industrial drives

●High-power industry pumps

●Professional washing machines.

UM1036 System introduction

Doc ID 18293 Rev 1 7/48

2.3 Safety and operating instructions

2.3.1 General terms

Warning: During assembly, testing, and normal operation, the

demonstration board poses several inherent hazards,

including bare wires, moving or rotating parts, and hot

surfaces. There is a danger of serious personal injury and

damage to property if the kit or components are improperly

used or installed incorrectly. The kit is not electrically

isolated from the AC/DC input. The demonstration board is

directly linked to the mains voltage. No insulation is ensured

between the accessible parts and the high voltage. All

measuring equipment must be isolated from the mains before

powering the board. When using an oscilloscope with the

demo, it must be isolated from the AC line. This prevents

shock from occurring as a result of touching any single point

in the circuit, but does NOT prevent shock when touching two

or more points in the circuit. Do not touch the demonstration

board after disconnection from the voltage supply; several

parts and power terminals, which contain energized

capacitors, must be allowed to discharge.

All operations involving transportation, installation and use, as well as maintenance, are to

be carried out by skilled technical personnel (national accident prevention rules must be

observed). For the purpose of these basic safety instructions, “skilled technical personnel”

are considered as suitably qualified people who are familiar with the installation, use, and

maintenance of power electronic systems.

2.3.2 Demonstration board intended use

The STEVAL-IHM028V1 demonstration board is designed for demonstration purposes only

and must not be used in final applications. The technical data, as well as information

concerning the power supply conditions, must only be taken from the relevant

documentation and must be strictly observed.

2.3.3 Demonstration board installation

The installation and cooling of the demonstration board must be done in accordance with

the specifications and the targeted application.

●The motor drive converters are protected against excessive strain. In particular, no

components are to be bent or isolating distances altered during the course of

transportation or handling.

●No contact must be made with other electronic components and contacts.

●The boards contain electrostatically sensitive components that are prone to damage

through improper use. Electrical components must not be mechanically damaged or

destroyed.

System introduction UM1036

8/48 Doc ID 18293 Rev 1

2.3.4 Electrical connections

Applicable national accident prevention rules must be followed when working on the main

power supply. The electrical installation must be carried out in accordance with the

appropriate requirements.

A system architecture which supplies power to the demonstration board must be equipped

with additional control and protective devices in accordance with the applicable safety

requirements (e. g. compliance with technical equipment and accident prevention rules).

UM1036 Board description

Doc ID 18293 Rev 1 9/48

3 Board description

3.1 System architecture

A generic motor control system can be basically schematized as the arrangement of four

main blocks (see Figure 2).

●Control block - its main task is to accept user commands and motor drive

configuration parameters. It provides all digital signals to implement the proper motor

driving strategy. The STM3210B-EVAL demonstration board, based on the STM32

microcontroller can be used as the control block, thanks to the motor control connector

equipped on the STEVAL-IHM028V1.

●Power block - it is based on 3-phase inverter topology. The heart of the power block is

the STGIPS20K60 integrated intelligent power module which contains all the

necessary active components. Please refer to the STGIPS20K60 datasheet for more

information.

●Motor - the STEVAL-IHM028V1 demonstration board is able to properly drive any

PMSM, but the FOC itself is mostly conceived for sinusoidal shaped back-EMF. The

demonstration board is also convenient for driving any 3-phase asynchronous motor.

●Power supply block - able to work from 90 VAC to 285 VAC or from 125 VDC to 400

VDC. The power block is based on a buck converter with a VIPer26 controller. Please

refer to Section 4 to properly set the jumpers according to the required application.

Figure 2. Motor control system architecture

Of the above motor control system architecture, the STEVAL-IHM028V1 includes the power

supply and the power block hardware blocks.

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Board description UM1036

10/48 Doc ID 18293 Rev 1

3.2 Board schematic

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