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DMC1500 Technical Reference
2000
DSP Development Systems
DMC1500 Technical Reference
504915-0001 Rev. A September 2000
SPECTRUM DIGITAL, INC. 12502 Exchange Drive, Suite 440 Stafford, TX. 77477 Tel: 281.494.4505 Fax: 281.494.5310 www.spectrumdigital.com sales@spectrumdigital.com
IMPORTANT NOTICE Spectrum Digital, Inc. reserves the right to make changes to its products or to discontinue any product or service without notice, and advises its customers to obtain the latest version of relevant information to verify, before placing orders, that the information being relied on is current. Spectrum Digital, Inc. warrants performance of its products and related software to current specifications in accordance with Spectrum Digital's standard warranty. Testing and other quality control techniques are utilized to the extent deemed necessary to support this warranty. Please be aware that the products described herein are not intended for use in life-support appliances, devices, or systems. Spectrum Digital does not warrant nor is liable for the product described herein to be used in other than a development environment. Spectrum Digital, Inc. assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or services described herein. Nor does Spectrum Digital warrant or represent any license, either express or implied, is granted under any patent right, copyright, or other intellectual property right of Spectrum Digital, Inc. covering or relating to any combination, machine, or process in which such Digital Signal Processing development products or services might be or are used. WARNING This equipment is intended for use in a laboratory test environment only. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to subpart J of part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. TRADEMARKS eZdsp is a trademark of Spectrum Digital, Inc.
Copyright (c) 2000 Spectrum Digital, Inc.
Contents
Introduction to the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provides you with a description of the DMC1500 module, key features, and board outline. 1.1 Overview of the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Key Features of the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation of the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provides you with a technical description of the DMC1500 module, along with key features, and a description of the connectors. 2.1 Overview of the DMC1500 with a DSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Installation of the DSK on the Digital Motor Controller ......................... 2.2.1 Installation of the DSK using the Serial Interface on the DMC1500 ............. 2.2.2 Installation of the DSK Using the XDS510PP and SPI110 Opto POD . . . . . . . . . . . . 2.3 Connecting Motors to the Digital Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 WARNINGS .......................................................... 2.3.2 Connecting a DC Brushless Motor to the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Connecting an AC Induction Motor to the DMC1500 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Connecting a Switched Reluctance Motor to the DMC 1000 .................. 2.4 DMC1500 Connectors ................................................. 2.4.1 P1-P2, Phase U Hookup ............................................... 2.4.2 P3-P4, Phase V Hookup ............................................... 2.4.3 P5-P6, Phase W Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4 P7, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.5 P8, Phase U External Driver Power ...................................... 2.4.6 P9, Phase V External Driver Power ...................................... 2.4.7 P10, Phase W External Driver Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.8 P11-P12, PFC Inductor Terminals ....................................... 2.4.9 P13, Power Ground ................................................... 2.4.10 P14, Motor Center Tap Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.11 P15-P17, P21-P22, Motor Power Selection .............................. 2.4.12 P18, DSK Analog Connector .......................................... 2.4.13 P19, DSK I/O Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.14 P20, Line Input ..................................................... 2.4.15 P23, Sensor Expansion .............................................. 2.4.16 P24, SPI Port ....................................................... 2.4.17 P25, Neutral Input ................................................... 2.4.18 P26, External 24VDC Power Input ...................................... 2.4.19 P27, Digital I/O (Optically Coupled) ..................................... 2.4.20 P28, RS-232 I/O (Optically Coupled) ................................... 2.4.21 P29, CAN Interface (Optically Coupled) ................................. 2.4.22 P30, Hall Sensor/Encoder Inputs (Non-isolated) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.5.1 JP1, Phase U Leg Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2 JP2, Phase V Leg Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3 JP3, Phase W Leg Tie ........................................... 2.5.4 JP4, Bus Sense Resistor Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.5 JP5, Frame to Ground Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6 JP6, Cap CT Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7 JP7, Bus Current Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.8 JP8, PFC Voltage Calibration ..................................... 2.5.9 JP9, Phase U Bus Voltage Calibration ............................. 2.5.10 JP10, Phase U Voltage Calibration ................................ 2.5.11 JP11, Phase U Current, Offset Enable ............................. 2.5.12 JP12, Phase V Bus Current Calibration ........................... 2.5.13 JP13, Phase V Voltage Calibration ............................... 2.5.14 JP14, Phase V Current, Offset Enable ............................. 2.5.15 JP15, Phase W Voltage Calibration ................................ 2.5.16 JP16, Phase W Current, Offset Enable ............................. 2.5.17 JP17, PFC Enable ............................................. 2.5.18 JP18, Vcca Select ............................................. 2.5.19 JP19, V Sense Cap Amplifier .................................... 2.5.20 JP20, V Sense Bus Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.21 JP21, V Sense PFC Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.22 JP22, V Sense U Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.23 JP23, V Sense V Amplifier .. .................................... 2.5.24 JP24, A/D Channel Configuration ................................ 2.5.25 JP25, V Sense W Amplifier ..................................... 2.5.26 JP26, Opt1 .................................................. 2.5.27 JP27, PWM Watchdog Mode .................................... 2.5.28 JP28, CAN Regulator Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.29 JP29, CAN Termination Resistor Enable ........................... 2.5.30 JP30, 110/220 VAC Selection .................................... 2.6 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 LEDs ......................................................... 2.9 Fusing ........................................................ 2.10 Motor Power Input Options ........................................ 2.11 Power Factor Correction .......................................... 2.12 Emulation Logic ................................................ 2.13 External Driver Power ............................................ 2.14 Power Stage ................................................... 2.15 Phase Current ................................................. 2.16 Phase Voltage ................................................. 2.17 Bus/PFC Current ............................................... 2.18 Bus/PFC/Cap Voltage ........................................... 2.19 Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A DMC1500 Schematics ............................................... Contains the schematics for the DMC1500
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About This Manual This document describes the board level operations of the DMC1500. This Digital Motor Controller module is designed to be used with the F240, F243, or LF2407 DSP Starter Kit (DSK), or eZdspTM LF2407 supplied by Spectrum Digital. The DSKs or eZdspTM LF2407 and the DMC1500 make up a table top motor development system which allows engineers and software developers to evaluate certain characteristics of the TMS320F240, TMS320F243, and TMS320LF2407 DSPs to determine if the processor meets the designers application requirements. Evaluators can create software to execute onboard or expand the system in a variety of ways. Notational Conventions
This document uses the following conventions. The F240, F243, and LF2407 DSK will sometimes be referred to as the DSK. The eZdspTM LF2407 will sometimes be referred to the eZdsp. The DSK and eZdsp can be used interchangeably with the DMC 1500. The DMC1500 will sometimes be referred to as the DMC. Program listings, program examples, and interactive displays are shown is a special italic typeface. Here is a sample program listing.
equations !rd = rw &!strobe;
Information About Cautions This book may contain cautions. This is an example of a caution statement. A caution statement describes a situation that could potentially damage your software, or hardware, or other equipment. The information in a caution is provided for your protection. Please read each caution carefully. Related Documents Texas Instruments TMS320F240 Users Guide Texas Instruments TMS320 Fixed Point Assembly Language Users Guide Texas Instruments TMS320 Fixed Point C Language Users Guide Texas Instruments TMS320 Fixed Point C Source Debugger Users Guide Spectrum Digital F240 and F243 Technical Reference
DANGER !
IMPORTANT WARNING !
Please read this entire manual before making any connections to the Digital Motor Controller. Because of the voltages and currents involved any mistakes will be very noticeable and could be deadly. If you are not sure of how to make connections to the unit please call Spectrum Digital "BEFORE" applying power to the unit.
Chapter 1 Introduction to the DMC1500
This chapter provides you with a description of the DMC1500 for use with the F240, F243, and LF2407 DSKs, and the eZdspTM LF2407 along with the key features and a block diagram of the circuit board.
Topic
1.0 1.1 Overview of the DMC1500 Key Features of the DMC1500
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1.0 Overview of the DMC1500 The DMC1500 is versatile digital motor controller that allows motor controller designers examine certain characteristics of the TMS320F240, TMS320F243, and TMS320LF2407 Digital Signal Processors (DSPs) to determine if one of these DSPs meets their application requirements. Furthermore, the module is an excellent platform to develop and run motor control software for the TMS320F240, TMS320F243, or TMS320LF2407 processor. The DMC1500 uses a F240, F243, LF2407 DSP Starter Kit (DSK) or eZdspTM LF2407 board as the computer engine to run algorithms. The DMC1500 along with a DSK or eZdsp allows full speed verification of F24xx code. Code development for the DMC can be done in two ways; * Use the serial interface on the DMC with the symbolic assembler and debugger that comes with the DSK, or JTAG Port on the eZdspTM LF2407. * Use the XDS510PP PLUS JTAG emulator from Spectrum Digital, with the compiler/assembler/linker and Code Composer from Texas Instruments. Note: It is recommended to use the SPI110 Opto Pod during development for safety from high voltages 1.1 Key Features of the DMC1500 The DMC1500 has the following features: * Compatible with the F240, F243, LF2407 DSKs, or eZdsp LF2407 from Spectrum Digital * Allows development of algorithms for AC Induction, DC Brushless (-0001), or Switched Reluctance Motors (-0002) * Rated for Bus voltages of 350VDC * Rated current is 5 amps continuous and 10 amps peak * Onboard control power supply (115-230 VAC) * Onboard bus supply (Bridge + Capacitors + Voltage Doubler) * Optically isolated digital I/O * Optically isolated RS-232 port * Optically isolated CAN interface * Onboard Power Factor Correction Logic 1-2
DMC1500 Technical Reference
Chapter 2 Operation of the DMC1500
This chapter provides you with a technical description of the DMC1500 along with the key features, and a description of the connectors.
Topic
2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15 2.4.16 2.4.17 2.4.18 2.4.19 2.4.20 Overview of the DMC1500 with a DSK Installation of the DSK on the Digital Motor Controller Installation of the DSK using the Serial Interface on the DMC1500 Installation of the DSK Using the XDS510PP and SPI110 Opto POD Connecting Motors to the Digital Motor Controller WARNINGS Connecting a DC Brushless Motor to the DMC1500 Connecting an AC Induction Motor to the DMC1500 Connecting a Switched Reluctance Motor to the DMC1500 DMC1500 Connectors P1-P2, Phase U Hookup P3-P4, Phase V Hookup P5-P6, Phase W Hookup P7, Ground P8, Phase U External Driver Power P9, Phase V External Driver Power P10, Phase W External Driver Power P11-P12, PFC Inductor Terminals P13, Frame Ground P14, Motor Center Tap Connection P15-P17, P21-P22, Motor Power Selection P18, DSK Analog Connector P19, DSK I/O Connector P20, Line Input P23, Sensor Expansion P24, SPI Port P25, Neutral Input P26, External 24VDC Power Input P27, Digital I/O (Optically Coupled) P28, RS-232 (Optically Coupled)
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Spectrum Digital, Inc
Topic 2.4.21 2.4.22 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9 2.5.10 2.5.11 2.5.12 2.5.13 2.5.14 2.5.15 2.5.16 2.5.17 2.5.18 2.5.19 2.5.20 2.5.21 2.5.22 2.5.23 2.5.24 2.5.25 2.5.26 2.5.27 2.5.28 2.5.29 2.5.30 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2-2 P29, CAN Interface (Optically Coupled) P30, Hall Sensor/Encoder Inputs (Non-isolated) Jumpers JP1, Phase U Leg Tie JP2, Phase V Leg Tie JP3, Phase W Leg Tie JP4, Bus Sense Resistor Disable JP5, Frame to Ground Tie JP6, Cap CT Voltage Calibration JP7, Bus Current Calibration JP8, PFC Voltage Calibration JP9, Bus Voltage Calibration JP10, Phase U Voltage Calibration JP11, Phase U Current, Offset Enable JP12, Phase V Bus Current Calibration JP13, Phase V Voltage Calibration JP14, Phase V Current, Offset Enable JP15, Phase W Voltage Calibration JP16, Phase W Current, Offset Enable JP17, PFC Enable JP18, Vcca Select JP19, V Sense Cap Amplifier JP20, V Sense Bus Amplifier JP21, V Sense PFC Amplifier JP22, V Sense U Amplifier JP23, V Sense V Amplifier JP24, A/D Channel Selection JP25, V Sense W Amplifier JP26, Opt1 JP27, PWM Watchdog Mode JP28, CAN Regulator Disable JP29, CAN Termination Resistor Enable JP30, 110/220 VAC Selection Test Points Potentiometers LEDs Fusing Motor Power Input Options Power Factor Correction Emulation Logic External Driver Power Power Stage Phase Current Phase Voltage Bus/PFC Current Bus/PFC/Cap Voltage Overcurrent Page 2-17 2-18 2-19 2-21 2-21 2-21 2-22 2-22 2-22 2-23 2-23 2-23 2-24 2-24 2-24 2-25 2-25 2-25 2-26 2-26 2-26 2-27 2-27 2-27 2-28 2-28 2-28 2-29 2-30 2-30 2-30 2-31 2-31 2-32 2-34 2-36 2-36 2-37 2-38 2-38 2-39 2-39 2-40 2-41 2-42 2-43 2-43
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2.1 Overview of the DMC1500 with a DSK The DMC1500 is the power stage of a Digital Motor Controller development system. The computing engine for the DMC1500 is either a F240 DSK (#701023), F243 DSK (#701024), or LF2407 DSK (#701025) from Spectrum Digital. The DMC1500 allows development to be done with AC Induction, DC Brushless, and Switched Reluctance motors. To accommodate these 3 types of motors, the DMC1500 has many jumper options and connections. Please be sure to read this entire manual before powering up a motor. A board outline of the DMC1500 is shown below.
Figure 2-1, Board Outline of DMC1500
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The DMC1500 is a stand alone module that is not enclosed. It is intended to be used in a development environment only. High voltages are present on the DMC1500 along with components dissipating heat. The user is advised to use extreme caution.
DANGER !
2.2 Installation of the DSK on the Digital Motor Controller The F240, F243, or LF2407 DSK is the computing engine of the DMC1500 system. The DSK must be installed on the DMC1500 by plugging the DSK into mating connectors. There are two ways to develop and debug algorithms for the DMC1500: * Use the serial interface on the DMC1500 with the symbolic assembler and debugger that comes with the DSK * Use the XDS510PP JTAG emulator and SPI110 Opto POD from Spectrum Digital, with the compiler/assembler/linker and Code Composer from Texas Instruments. Software can be developed using the symbolic assembler and debugger included with the DSK. This allows the engineer to generate algorithms and load them into the RAM memory on the DSK. The DSK communicates to the debugger on the host PC via the serial port on the DMC1500. The serial port on the DMC1500 is optically isolated because the DMC1500 is operating at a floating voltage level. NOTE: Do NOT use the serial port on the DSK because it is not optically isolated ! Using the XDS510PP JTAG emulator with the SPI110 allows the engineer to debug algorithms with the JTAG interface on the DSK. The SPI110 optically isolates the JTAG interface and is required because the DMC1500 is operating at a floating voltage level. NOTE: The SPI110 MUST be used with a JTAG emulator !
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2.2.1 Installation of the DSK using the Serial Interface on the DMC1500 To install the DSK on the DMC1500 for serial debug, perform the following procedure: 1. Remove all power from the DMC1500 2. Remove all power from the DSK. 3. If installed, unplug the serial cable from the DMC1500 4. Put masking/electrical tape over the DSK serial connector, P4 5. Install connectors on the bottom of the DSK by soldering double row headers into connectors P1 (analog) and P2 (I/O). 6. Configure the on chip UART to use the serial connector on the DMC1500. 7. Plug the DSK on to the DMC1500 by aligning DSK connectors P1 and P2 with DMC1500 connectors P18 and P19 respectively and pushing downward. 2.2.2 Installation of the DSK Using the XDS510PP and SPI110 Opto POD To install the DSK on the DMC1500 for JTAG debug, perform the following procedure: 1. Remove all power from the DMC1500 2. Remove all power from the DSK. 3. If installed, unplug the serial cable from the DMC1500 4. Install connectors on the bottom of the DSK by soldering double row headers into connectors P1 (analog) and P2 (I/O). 5. Plug the DSK on to the DMC1500 by aligning DSK connectors P1 and P2 with DMC1500 connectors P18 and P19 respectively and pushing downward. 6. Remove power from the SPI110 and attach the SPI110 Opto POD to the JTAG header on the DSK. 7. Remove power from the XDS510PP emulator and attach the JTAG tail to the connector on the top of the XDS510PP.
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2.3 Connecting Motors to the Digital Motor Controller The DMC1500 will support the development of algorithms for a variety of motors. Each type of motor requires a specific type of connection. These connections are discussed in the following sections. 2.3.1 WARNINGS The DMC1500 is capable of driving high voltage medium current motors. It is designed for bus voltages of up to 350 volts with currents up to 10 amps. There is an onboard diode bridge and capacitor. The bus current can be derived from AC, or DC can be directly driven in. There are many warnings that should be observed when operating with high energy devices.
DANGER !
The user is reminded to remove all power to the unit, motors, and associated electronics when connecting/disconnecting wires or connectors.
Warnings:
1. Make sure the bus is discharged before operating on or connecting probes to the equipment. There is an LED that indicates the bus is charged. It should not be used to guarantee that the unit is safe to touch. You should verify that the bus is discharged by using a voltmeter across the bus connections. 2. The input power must be fused externally for safe operation. The fuse should be sized to the voltage and current requirements of the load. You must also guarantee that the unit will not be fused above the safe operating range of the inverter module. 3. If the motor is being used for regenerative braking it will source current back into the supply. This will raise the bus voltage. If this is the case then the user must put a voltage regulator across the Bus terminals to absorb this energy. If this is not done then the bus voltage may rise above the maximum voltage and destroy the inverter board.
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2.3.2 Connecting a DC Brushless Motor to the DMC1500 ( -0001) To connect a DC brushless motor to the DMC1500 perform the following steps: 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove all power from the DMC1500 Attach Phase U from the motor to lug P1. Attach Phase V from the motor to lug P3. Attach Phase W from the motor to lug P5. Attach +5 volts from the motor to connector P30, pin 1. (+5V is available on P30 pin 6 if external supply is not used) Attach Phase A from the motor to connector P30, pin 2. Attach Phase B from the motor to connector P30, pin 3. Attach Phase C from the motor to connector P30, pin 4. Attach the ground from the motor to connector P30, pin 5.
These connections are shown in the figure below. P30-1 P30-2 P30-3 P30-4 P30-5 GND U V W B C A
Encoder
+5
P1 P3 P5 Figure 2-2, DC Brushless Motor connections for the DMC1500 The jumper settings for using a DC Brushless motor are shown in the table below. Table 1: DC Brushless Jumper Settings Jumper # JP1 JP2 JP3 Size 1x2 1x2 1x2 Setting In In In Function Phase U Leg Tie Phase V Leg Tie Phase W Leg Tie
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2.3.3 Connecting an AC Induction Motor to the DMC1500 ( -0001) To connect an AC Induction motor to the DMC1500 perform the following steps: 1. 2. 3. 4. Remove all power from the DMC1500 Attach Phase U from the motor to lug P1. Attach Phase V from the motor to lug P3. Attach Phase W from the motor to lug P5.
These connections are shown in the figure below.
U
V
W
P1 P3 P5 Figure 2-3, AC Induction Motor connections for the DMC1500 The jumper settings for using a AC Induction motor are shown in the table below. Table 2: AC Induction Jumper Settings Jumper # JP1 JP2 JP3 Size 1x2 1x2 1x2 Setting In In In Function Phase U Leg Tie Phase V Leg Tie Phase W Leg Tie
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2.3.4 Connecting a Switched Reluctance Motor to the DMC1500 ( -0002) To connect a Switched Reluctance motor to the DMC1500 perform the following steps: 1. 2. 3. 4. 5. 6. 7. Remove all power from the DMC1500 Attach Phase U+ from the motor to lug P1. Attach Phase U- from the motor to lug P2. Attach Phase V+ from the motor to lug P3. Attach Phase V- from the motor to lug P4. Attach Phase W+ from the motor to lug P5. Attach Phase W- from the motor to lug P6.
These connections are shown in the figure below.
U+ U-
V+
W+ V-
WP1 P2 P3 P4 P5 P6 Figure 2-4, Switched Reluctance Motor connections for the DMC1500 The jumper settings for using a Switched Reluctance motor are shown in the table below. Table 3: Switched Relucatance Jumper Settings Jumper # JP1 JP2 JP3 Size 1x2 1x2 1x2 Setting Cut/Open Cut/Open Cut/Open Function Phase U Leg Tie Phase V Leg Tie Phase W Leg Tie
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2.4 DMC1500 Connectors The DMC1500 has 30 connectors. These connectors are used to bring power to the DMC1500, signals to/from the DSK, and power to the motor. These connectors are shown in the table below and discussed in the following sections. Table 4: DMC1500 Connectors Connector P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11,P12 P13 P14 P15-P17 P18 P19 P20 P21-P22 P23 P24 P25 P26 P27 P28 P29 P30 # Pins 1 1 1 1 1 1 1 2 2 2 1 1 1 1 20 40 1 1 16 10 1 2 8 9 4 6 Function Phase U+ Phase UPhase V+ Phase VPhase W+ Phase WGround Phase U External Driver Power Phase V External Driver Power Phase W External Driver Power PFC Inductor Terminals Frame Ground Motor Center Tap Connection Motor Power Selection DSK Analog Connector DSK I/O Connector Line Input Motor Power Selection Sensor Expansion SPI Port Neutral Input External 24VDC Power Input Digital I/O ( Opto ) RS232 ( Opto ) CAN Interface ( Opto ) Hall Sensor/ Encoder Inputs
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The position of each connector on the DMC1500 is shown in the figure below.
P7
P1,P2
P3,P4
P5,P6
P8 P11 P10 P14 P12 P13 P9 P18 P19 P15-P17 P21-P22 P24 P25 P30 P23
P26
P27
P28
P29
Figure 2-5, DMC1500 Connector Positions
2.4.1 P1-P2, Phase U Hookup Connectors P1 and P2 are for the Phase U+ and U- signals respectively. These are tab terminals. These lines should be connected directly to your motor. For BLDC and ACI motors connect Phase U to P1. For SR motors connect Phase U between P1 and P2. Make sure JP1 is cut or open for SR motors. 2.4.2 P3-P4, Phase V Hookup Connectors P3 and P4 are for the Phase V+ and V- signals respectively. These are tab terminals. These lines should be connected directly to your motor. For BLDC and ACI motors connect Phase V to P3. For SR motors connect Phase V between P3 and P4. Make sure JP2 is cut or open for SR motors.
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2.4.3 P5-P6, Phase W Hookup Connectors P5 and P6 are for the Phase W+ and W- signals respectively. These are tab terminals. These lines should be connected directly to your motor. For BLDC and ACI motors connect Phase W to P1. For SR motors connect Phase W between P1 and P2. Make sure JP3 is cut or open for SR motors. 2.4.4 P7, Ground Connector P7 is for motor ground. These is a male Tab terminal. This line should be connected directly to your motor. 2.4.5 P8, Phase U External Driver Power The high side driver in U2 is normally powered by the boot strap method. If you want to have continuous gate drive voltage then you can apply 12-15VDC to connectors P8. This voltage supply must be isolated from P9, P10, and from ground. Separate isolated supplies must be used for each driver. 2.4.6 P9, Phase V External Driver Power The high side driver in U3 is normally powered by the boot strap method. If you want to have continuous gate drive voltage then you can apply 12-15VDC to connectors P9. This voltage supply must be isolated from P8, P10, and from ground. Separate isolated supplies must be used for each driver. 2.4.7 P10, Phase W External Driver Power The high side driver in U4 is normally powered by the boot strap method. If you want to have continuous gate drive voltage then you can apply 12-15VDC to connectors P10. This voltage supply must be isolated from P8, P9, and from ground. Separate isolated supplies must be used for each driver. 2.4.8 P11-P12, PFC Inductor Terminals These terminals are not used in standard configurations. 2.4.9 P13, Frame Ground The terminal should be connected to Earth ground. 2.4.10 P14, Motor Center Tap Connection The terminal is used for the center tap connection for PSC motors.
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2.4.11 P15-P17, P21-22, Motor Power Selection Connectors P15 and P16 bring in AC power through the AC line filter. Connectors P17 and P18 are the internal power connections. Normally P21 is connected to P22. Connecting P15 to P16 uses the voltage doubler while P15-P17 does not.
WARNING !
Make sure you do not exceed the maximum DC bus when using the voltage doubler, i.e. don't use the doubler with 220 VAC input.
It is also possible to connect input power to P16-P22 through another source such as a Variac or isolation transformer. Remember to place a fuse in the high side power.
2.4.12 P18, DSK Analog Connector Connector P18 provides the analog signal interface to the DSK which plugs onto the DMC1500. The signals on this connector are defined in the table below: Table 5: P18, DSK Analog Connector Pin # 1 3 5 7 9 11 13 15 17 19 Signal Gnd Gnd Gnd Gnd Gnd Gnd Gnd Gnd Gnd Gnd Pin # 2 4 6 8 10 12 14 16 18 20 Signal Ad0 Ad1 Ad2 Ad3 Ad4 Ad5 Ad6 Ad7 NC NC
NC = Not Connected
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2.4.13 P19, DSK I/O Connector Connector P19 mates with connector P2 on the DSKs. The signals present on P2 of the DSK are present on P19. Table 6: P19, DSK I/O Connector Pin # 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Signal +5V Tx In1 Cap2 Pwm1 Pwm3 Pwm5 StrobeEnableGnd Opt1 SpiSiMo SpiClk CanTx Out1 Reserved Reserved Reserved OverCurrentGnd Pin # 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Signal +5V Rx Cap1 Cap3 Pwm2 Pwm4 Pwm6 Pwm7 LedGnd In2 SpiSoMi SpiSte CanRx Out2 Reserved Reserved Reserved Reserved Gnd
2.4.14 P20, Line Input Connector P20 is a Tab terminal which attached to the line side from an AC power source (110-220 VAC).
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2.4.15 P23, Sensor Expansion Connector P23 is a 2 x 8 double row header which allows the user to expand their phase current sensors or Hall effect current sensors. The signals on connector P23 are shown in the table below. Table 7: P23, Sensor Expansion Pin # 1 3 5 7 9 11 13 15 Signal +5V GND GND GND GND GND GND GND Pin # 2 4 6 8 10 12 14 16 Signal +5V Option1 Option2 Option3 Option4 Option5 Option6 GND
Jumper JP24 allows the user to connect these option pins to the analog input channels. 2.4.16 P24, SPI Port Connector P24 is a 2 x 5 double row header which brings out the four SPI signals from the DSK and Vcc. This allows the user to easily have access to the signals. The SPI signals and their pin positions are shown in the table below. Table 8: P24, SPI Port Pin # 1 3 5 7 9 Signal Gnd Gnd Gnd Gnd Gnd Pin # 2 4 6 8 10 Signal +5V SpiSiMo SpiSoMi SpiClk SpiSte
2.4.17 P25, Neutral Input Connector P25 is a Tab terminal which attached to the neutral side from an AC power source (110-220 VAC).
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2.4.18 P26, External 24VDC Power Input An external power supply can be connected to this input to supply control power. This supply must be isolated and capable of sustaining the maximum bus voltage.
2.4.19 P27, Digital I/O (Optically Coupled) Connector P27 is an 8 pin connector that provides two input and two outputs. The inputs and outputs are optically coupled with NEC PS2501 series devices. The outputs are capable of sourcing and sinking 20Ma. The inputs are setup with 750 Ohm .25 WATT series resistors. You can drive these inputs with 5-12Vdc. These are general purpose I/O signals which are controlled by the DSP. The signals present on this connector and their pin number are shown in the table below: Table 9: P27, Digital I/O (Optically Coupled) Pin # 1 2 3 4 5 6 7 8 Signal Out2Out2+ Out1Out1+ In1+ In1INT2+ INT2-
2.4.20 P28, RS-232 (Optically Coupled) Connector P28 is a DB9 female connector. This connector can be used to debug algorithms through if the DSK debugger is used, or it can be used as general purpose serial communication. The signals present on P28 are optically coupled. Power must be supplied by the Device connected to P28. This is done by driving either pin 4 ( DTR ) or pin 7 ( RTS ) or both high. This supplies power to the interface. Make sure that DTR or RTS is high or the serial interface will not work. P28 is configured for a straight through cable to a PC.
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The pin positions for the P28 connector as viewed from the edge of the DMC1500 are shown below.
5
4
3
2
1
9
8
7
6
Figure 2-6, P29, DB9 Female Connector
Table 10: P28, RS-232 (Optically Coupled) Pin # 1 2 3 4 5 6 7 8 9 Signal N/C TX RX DTR RTN N/C RTS N/C N/C In( Power ) Out In In( Power ) DMC1500 Direction
2.4.21 P29, CAN Interface (Optically Coupled) Connector P29 is a 4 pin female mini-DIN connector which provides a CAN interface to the DMC1500. The CAN feature is only available when using the F243 or LF2407 DSK. The TMS320F240 DSP on the F240 DSK does not have a CAN controller. Because this interface is optically isolated power must be provided by the interface plugged into P29. If JP28 is installed, then a regulated +5 volts must be provided between pins 4 and 3. If JP28 is not installed then unregulated power up to 12 volts can be applied. JP29 is the 120 ohm termination for devices on the end of the CAN bus. Note: Because of the optocouplers the full bus speed might not be possible. Start with lower baud rates to verify operation.
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The signals on this connector and their pin numbers are shown in the table below. Table 11: P29, CAN Interface (Optically Coupled) Pin # 1 2 3 4 Signal Name CAN+ CANCAN-RTN CAN-Vcc (Power Input)
2.4.22 P30, Hall Sensor/ Encoder Inputs (Non-isolated) Connector P30 is a 1 x 6 header which supports 3 non-isolated channels. The three channels can either be Hall Effect sensors or a quardrature encoder. The Sensor power on pin 1 can be adjusted from 0-15Vdc by resistor R20. The signals present on this connector and their pin number are shown in the table below. Table 12: P30, Hall Sensor/Encoder Inputs Pin # 1 2 3 4 5 6 Signal Vsensor( 0-15Vdc ) Capture1( Hall U, Channel A ) Capture2( Hall V, Channel B ) Capture3( Hall W, Index ) Gnd +5V
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2.5 Jumpers The DMC1500 has 30 jumpers. Their designator, size, and function are shown in the table below: Table 13: DMC1500 Jumpers Jumper # JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 JP9 JP10 JP11 JP12 JP13 JP14 JP15 JP16 JP17 JP18 JP19 JP20 JP21 JP22 JP23 JP24 JP25 JP26 JP27 JP28 JP29 JP30 Size 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x2 1x3 1x3 1x3 1x3 1x3 1x3 1x3 2 x 10 1x3 1x3 1x3 1x2 1x2 1x4 Function Phase U Leg Tie Phase V Leg Tie Phase W Leg Tie Bus Sense Resistor Disable Frame to Ground Tie Cap CT Voltage Calibration Bus Current Calibration PFC Voltage Calibration Bus Voltage Calibration Phase U Voltage Calibration Phase U Current, Offset Enable Bus Current Calibration Phase V Voltage Calibration Phase V Current, Offset Enable Phase W Voltage Calibration Phase W Current, Offset Enable PFC Enable Vcca Select (3.3/5.0 Volts) V Sense Cap Amplifier V Sense Bus Amplifier V Sense PFC Amplifier V Sense U Amplifier V Sense V Amplifier A/D Channel Selection V Sense W Amplifier Opt1 PWM Watchdog Mode CAN Regulator Disable CAN Termination Resistor Enable 110/220 VAC Selection 2-19
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The position of each jumper on the DMC1500 is shown in the figure below.
JP9 JP10 JP11 JP2
JP7 JP8 JP1
JP3 JP12 JP13
JP4 JP14 JP6 JP15 JP16 JP5 JP19 JP26 JP25 JP24 JP23
JP17 JP18
JP30
JP27
JP20-22
JP28
JP29
Figure 2-7, DMC1500 Jumper Positions
DANGER !
The user is reminded to remove all power to the unit, motors, and associated electronics when connecting/disconnecting jumpers, wires, or connectors.
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2.5.1 JP1, Phase U Leg Tie Jumper JP1 is used to connect the phase U transistors in a totem-pole configuration. The open position is used for SR motors. The shorted selection is used to drive BLDC and ACI motors. The settings are shown in the table below. Table 14: JP1, Phase U Leg Tie Position Open Shorted Function SR BLDC, ACI
2.5.2 JP2, Phase V Leg Tie Jumper JP2 is used to connect the phase V transistors in a totem-pole configuration. The open position is used for SR motors. The shorted selection is used to drive BLDC and ACI motors. The settings are shown in the table below.. Table 15: JP2, Phase V Leg Tie Position Open Shorted Function SR BLDC, ACI
2.5.3 JP3, Phase W Leg Tie Jumper JP3 is used to connect the phase W transistors in a totem-pole configuration. The open position is used for SR motors. The shorted selection is used to drive BLDC and ACI motors. The settings are shown in the table below.. Table 16: JP3, Phase W Leg Tie Position Open Shorted Function SR BLDC, ACI
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2.5.4 JP4, Bus Sense Resistor Disable Jumper JP4 is used to disable the Bus Sense resistor. In the open position Bus Current Sense is disabled. When the shorted selection is used Phase Current Sense is disabled. The settings are shown in the table below. Table 17: JP4, Bus Sense Resistor Disable Position Open Shorted Function Bus Current Sense disabled Phase Current Sense disabled
2.5.5 JP5, Frame to Ground Tie Jumper JP5 is used to connect the DMC1500 chassis to the earth ground. In the open position the DMC1500 is not connected to earth ground. When the shorted selection is used earth ground is connected to the DMC1500 chassis. The setting are shown in the table below. Table 18: JP5, Frame to Ground Tie Position Open Shorted Function Not grounded DMC1500 chassis to Earth Ground
2.5.6 JP6, Cap CT Voltage Calibration Jumper JP6 is used to calibrate the V Sense Cap amplifier. When the shorted selection is used the V cap sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 19: JP6, Cap CT Voltage Calibration Position Open Shorted Function Normal Mode Calibrate Mode
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2.5.7 JP7, Bus Current Calibration Jumper JP7 is used to calibrate the Bus Current Sense amplifier. When the shorted selection is used the Bus Current sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 20: JP7, Bus Current Calibration Position Open Shorted Function Normal Mode Calibrate Mode
2.5.8 JP8, PFC Voltage Calibration Jumper JP8 is used to calibrate the Power Factor Correction Voltage Sense amplifier. When the shorted selection is used the Power Factor Correction sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 21: JP8, PFC Voltage Calibration Position Open Shorted Function Normal Mode Calibrate Mode
2.5.9 JP9, Phase U Bus Voltage Calibration Jumper JP9 is used to calibrate the Phase U Bus Voltage Sense amplifier. When the shorted selection is used the Bus Voltage sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 22: JP9, Bus Voltage Calibration Position Open Shorted Function Normal Mode Calibrate Mode
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2.5.10 JP10, Phase U Voltage Calibration Jumper JP10 is used to calibrate the Phase U Voltage Sense amplifier. When the shorted selection is used the Phase U Voltage sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 23: JP10, Phase U Voltage Calibration Position Open Shorted Function Normal Mode Calibrate mode
2.5.11 JP11, Phase U Current, Offset Enable Jumper JP11 is used to select the sensing of the Bi-polar phase U current. In the open position Uni-polar current is selected for sensing. When the shorted selection is used Bi-polar current is selected. The settings are shown in the table below. Table 24: JP11, Phase U Current, Offset Enable Position Open Shorted Function Uni-polar Current Bi-polar Current
2.5.12 JP12, Phase V Bus Current Calibration Jumper JP12 is used to calibrate the Phase V Bus Voltage Sense amplifier. When the shorted selection is used the Bus Voltage sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 25: JP12, Bus Current Calibration Position Open Shorted Function Normal Mode Calibrate Mode
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2.5.13 P13, Phase V Voltage Calibration Jumper JP13 is used to calibrate the Phase V Voltage Sense amplifier. When the shorted selection is used the Phase V Voltage sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 26: P13, Phase V Voltage Calibration Position Open Shorted Function Normal Mode Calibrate Mode
2.5.14 JP14, Phase V Current, Offset Enable Jumper JP14 is used to select the sensing of the Bi-polar phase V current. In the open position Uni-polar current is selected for sensing. When the shorted selection is used Bi-polar current is selected. The settings are shown in the table below.. Table 27: JP14, Phase V Current, Offset Enable Position Open Shorted Function Uni-polar Current Bi-polar Current
2.5.15 JP15, Phase W Voltage Calibration Jumper JP15 is used to calibrate the Phase W Bus Voltage Sense amplifier. When the shorted selection is used the Bus Voltage sense amplifier can be calibrated. After calibration, the open position is used for normal operation. The settings are shown in the table below. Table 28: JP15, Phase W Voltage Calibration Position Open Shorted Function Normal Mode Calibrate Mode
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2.5.16 JP16, Phase W Current, Offset Enable Jumper JP16 is used to select the sensing of the bi-polar phase W current. In the open position Uni-polar current is selected for sensing. When the shorted selection is used Bi-polar current is selected. The settings are shown in the table below. Table 29: JP16, Phase W Current, Offset Enable Position Open Shorted Function Uni-polar Current Bi-polar current
2.5.17 JP17, PFC Enable Jumper JP17 is used to enable the Power Factor Correction driver. If the 1-2 position is selected the PFC driver is disabled. When the 2-3 selection is used the PFC driver is enabled. The setting are shown in the table below. Table 30: JP17, PFC Enable Position 1-2 2-3 Function Disable PFC driver Enable PFC driver
2.5.18 JP18, Vcca Select Jumper JP18 is used to select 3.3 volts or 5.0 volts for analog inputs. If the 1-2 selection is used 3.3 volts is used for analog inputs. The 2-3 selection will allow 5.0 volts to be used. The settings are shown in the table below. Table 31: JP18, Vcca Select Position 1-2 2-3 Function 3.3 Volts 5.0 Volts Processor TMS320LF2407 TMS320F240/243
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2.5.19 JP19, V Sense Cap Amplifier Jumper JP19 is used to allow the V Sense capacitor input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 32: JP19, V Sense Cap Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R8
2.5.20 JP20, V Sense Bus Amplifier Jumper JP20 is used to allow the V Sense bus input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 33: JP20, V Sense Bus Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R10 2.5.21 JP21, V Sense PFC Amplifier Jumper JP21 is used to allow the V Sense PFC input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 34: JP21, V Sense PFC Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R13
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2.5.22 JP22, V Sense U Amplifier Jumper JP22 is used to allow the V Sense U input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 35: JP22, V Sense U Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R11
2.5.23 JP23, V Sense V Amplifier Jumper JP23 is used to allow the V Sense V input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 36: JP23, V Sense V Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R15
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2.5.24 JP24, A/D Channel Configuration JP24 allows selecting 8 out of 17 analog signals. The standard configuration is shown in the below. Table 37: JP24 A/D Channel Configuration JP18 Position 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16 17-18 19-20 21-22 23-24 25-26 27-28 29-30 31-32 33-34 Signal Selection Option 1 to AD0 Option 2 to AD2 Option 3 to AD3 Option 4 to AD4 Option 5 to AD5 Option 6 to AD6 I Sense U to AD0 I Sense V to AD1 I Sense U to AD0 V Sense U to AD3 V Sense V to AD4 V Sense W to AD5 I Sense Bus to AD6 V Sense Bus to AD7 I Sense PFC to AD4 V Sense PFC to AD3 V Sense Cap to AD5
2.5.25 JP25, V Sense W Amplifier Jumper JP25 is used to allow the V Sense W input to be amplified or not amplified. The 1-2 position is used to select amplification. When the jumper is in the 2-3 position there will be no amplification. These settings are shown in the table below. Table 38: JP23, V Sense W Amplifier Position 1-2 2-3 Function Amplified Not Amplified
The gain for this amplifier is set by resistor, R18 2-29
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2.5.26 JP26, Opt1 Jumper JP26 is a used definable jumper that can be read by reading I/O port XF/IOPC0 pin on the F243 or the XF/IOPC2 on the F240. If the 1-2 position is selected a zero (0) is read. When the 2-3 selection is used a one (1) is read. The setting are shown in the table below. Table 39: JP26, Opt1 Position 1-2 2-3 Function Read 0 Read 1
2.5.27 JP27, PWM Watchdog Mode Jumper JP27 is used to enable the PWM drivers regardless of the watch dog timer. If the 1-2 position is selected the PWM is enabled from I/O. When the 2-3 selection is used the PWM is always enabled. The setting are shown in the table below. Table 40: JP27, PWM Watchdog Mode Position 1-2 2-3 Function PWM Enabled From I/O PWM Always Enabled
2.5.28 JP28, CAN Regulator Disable Jumper JP28 is used to select the 5 volt input for the CAN driver. If the open selection is used a value greater than 5 volts can be used as the input for the CAN driver. When the shorted selection is used 5 volts is used as the input. The setting are shown in the table below. Table 41: JP28, CAN Regulator Disable Position Open Shorted Function Greater than 5 volts 5 volts
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2.5.29 JP29, CAN Termination Resistor Enable Jumper JP29 is used to enable the CAN termination resistor. If the open position is selected the use of a CAN termination resistor is disabled. When the shorted selection is used the use of a termination resistor is enabled. The setting are shown in the table below. Table 42: JP29, CAN Termination Resistor Enable Position Open Shorted Termination Resistor Disabled Enabled
2.5.30 JP30, 110-220 VAC Selection Jumper JP30 is used to what voltage is being brought in on connectors P24 and P25. If the 1-2, 3-4 position is selected this indicates that 110 VAC is being brought in on P24 and P25. When the 2-3 selection is used it indicates 220 VAC is present on connectors P24 and P25. The settings are shown in the table below. Table 43: JP30, 110-220 Selection Position 1-2, 3-4 2-3 Function 110 VAC in P24, P25 220 VAC in P24, P25
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2.6 Test Points The DMC1500 has 12 test points. The user should not tie a scope to ground unless an isolation transformer is used for Bus power.
DANGER !
The user is reminded to remove all power to the unit, motors, and associated electronics when connecting/disconnecting probes, jumpers, wires or connectors.
Warning:
1. Remove all input power to the DMC1500 and DSK prior to connecting any probes. LED DS1 should not be illuminated. The table below shows the test points and the signal present on each. Table 44: DMC1500 Test Points Test Point # TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 Signal Name Bus+ BusGround Vcca Ground Driver Vee 3.3 Volts Vcc Control Power (24VDC) Ground V Sensor Ground
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The position of each test point on the DMC1500 is shown in the figure below.
TP1 TP4
TP3
TP2
TP5 TP6 TP8 TP11 TP12
TP10
TP9
TP7
DS1,DS2,DS3
Figure 2-8, DMC1500 Test Point and Led Positions
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2.7 Potentiometers The DMC1500 has 13 potentiometers. The table below shows the potentiometer designator, its function, and range of adjustment: Table 45: DMC1500 Potentiometers Potentiometer # R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Function Cap CT Voltage Gain Bus Current Gain Bus Voltage Gain Phase U Voltage Gain Phase U Current Gain PFC Voltage Gain PFC Current Gain Phase V Voltage Gain Phase V Current Gain Phase Current Offset Phase W Voltage Gain Phase W Current Gain Sensor Voltage Trim Adjustment Range 40.5 - 405.5 V 1.5 - 16.6 A 40.5 - 405.5 V 40.5 - 405.5 V 1.1 - 12.5 A 40.5 - 405.5 V 1.1 - 12.5 A 40.5 - 405.5 V 1.1 - 12.5 A 0 - 0.45 V 40.5 - 405.5 V 1.1 - 12.5 A 0 - 15 V
DANGER !
The user is reminded to use extreme caution when adjusting the potentiometers. It is suggested that you use a non-conducting screw driver.
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The position of each potentiometer on the DMC1500 is shown in the figure below.
R8 R9
R10 R11
R12 R13
R14
R15 R16 R17
R19 R18
R20
Figure 2-9, DMC1500 Potentiometer Positions
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2.8 LEDs The DMC1500 has 3 light emitting diodes (LEDs). The position of these LEDs are shown in figure 2-x above. Their function and color are shown in the table below. Table 46: DMC1500 LEDs Led # DS1 DS2 DS3 Function Power ( Green ) User Progammable ( Yellow ) Drive Enabled ( Red )
2.9 Fusing The DMC1500 has a replacable fuse, F1. This fuse is rated for 6 amps at 250 volts. If this fuse needs to be replaced it must be replace with a fuse with the same rating.
DANGER !
The user is reminded to remove all power to the unit, motors, and associated electronics when connecting/disconnecting wires or connectors.
Warning:
1. Remove all input power to the DMC1500 and DSK prior to connecting any probes. LED DS! should not be illuminated.
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2.10 Motor Power Input Options There are several input options. You can bring power in through P20 and P25 which also powers the onboard logic. You can also bring power in through P16 or P17 and P22. There is also a voltage doubled input option. If you use P17 and P22, the Input voltage is rectifed and fed to BUS+. If you use P16 and P22, then the input voltage is rectfied and doubled and fed to BUS+. This allows you to generate 220 bus voltages from 110 mains.
NOTE !
If applying 220 volts to P20 and P25 make sure that jumper JP30 is set correctly or the control logic will be destroyed. If 110 VAC is on P20, P25 and JP30 is jumpered pins 1-2 and 3-4 you can have the following configurations: A. P20 Line(110) P15-P17 Bus(110) P25 Neutral P21-P22 P20 Line(110) P15-P16 Bus(220) P25 Neutral P21-P22
B.
If 220 VAC is on P20, P25 and JP30 is jumpered pins 2-3 you can have the following configurations: A. P20 Line(220) P15-P17 Bus(220) P25 Neutral P21-P22 No Voltage Doubler Option.
B.
If using separate motor power you can have the following configurations: A. P17 Line(110) Bus(110) P22 Neutral P16 Line(110) Bus(220) P22 Neutral
B.
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2.11 Power Factor Correction The Power Factor Correction Logic consists of Inductor L1, Diode D1 transistor Q1, and driver U2. The PFC supports a boost configuration. Without PFC power caps C1 and C2 charge only when the voltage of the mains is greater than the voltage on the caps. This causes high main current for short periods of time. The PFC logic stores energy in the inductor all though the 60Hz cycle and transfers it to the Caps. The input current is more uniform and matches the input waveform. Transistor Q1 is turned on which creates a current path from the bridge through the inductor, transistor and back to the mains. The control algorithm then turns the transistor off. The energy in the inductor then travels through diode D1 and charges the caps C1, and C2. The control algorithm uses one pwm channel to drive the transistor and uses input voltage, inductor current, and capacitor voltage to control the PWM duty cycle. Note: The DMC1500 is specified for half output power rating when using the power factor correction.
2.12 Emulation Logic The DMC1500 contains an additional watchdog timer that disables the drivers if it is not strobed every 225mS. The software to strobe the watchdog should be placed in an Interrupt Service Routine (ISR) or in the main loop if timeout can be guaranteed. This logic is useful for emulation. If the emulator stops, the commutation will stop and the rotor will lock. Stopping the emulator will also stop the watchdog which will disable the drivers preventing continuous rotor current. There are also two other modes. With jumper JP27 in position 2-3 the watchdog logic is disabled. When jumper JP27 is in position 1-2 then an I/O pin can be used to enable the drivers and disable the watchdog. The watchdog strobe is on T1CMP/IOPB6 of the C242. The Enable signal is on TDIR/IOPB6. Refer to the signal mapping when using the F240, F243, or LF2407 DSK. Table 47: On Board Watchdog Timer, JP22 JP27 1-2 1-2 1-2 2-3 none Enable TDIR/IOPB6 Low High High Don't Care Don't Care Strobe T1CMP/IOPB6 Don't Care Don't Care Yes Don't Care Yes Watchdog Drivers Enabled Disabled Enabled Enabled Enabled
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DMC1500 Technical Reference
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2.13 External Driver Power The high side drivers in U3-U5 are normally powered by the boot strap method. If you want to have continuous gate drive voltage then you can apply 12-15VDC to connectors P8-P10. Each of these three supplies must be isolated from each other and ground.
2.14 Power Stage The power stage is either configured for ACI/BLDC or SR from the factory. Spectrum Digital does not support making a conversion in the field and this would void the warranty. Both configurations use 20Amp 400V high speed IGBT's. The ACI/BLDC configuration uses jumpers JP1-JP3 to tie the high side transistor to the low side transistor. The motor phases are then connected to P1,P3,P5. The SR configuration uses six 8 amp steering diodes across the IGBT's. In this configuration the motor phases are connected between the upper and lower transistors.
Table 48: ACI/BLDC Configuration Pin # P1 P3 P5 Phase Signal Phase U Phase V Phase W
Table 49: SR Configuration Pin # P1 P2 P3 P4 P5 P6 Phase Signal Phase U+ Phase UPhase V+ Phase VPhase W+ Phase W-
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2.15 Phase Current The DMC1500 supports reading the phase current in the lower transistor leg. This is the most common configuration. The currents are measured across three .04 ohm resistors. These sense signal are then filtered for a 40Khz cutoff frequency, clamped to the rails and applied to the non inverting input to an opamp. For each input there is also a jumper to apply an offset voltage. This allows unipolar or bipolar current measurements. The gain of each amplifier can be adjusted from 10 to 111. The example below shows how to calibrate the gain and offset for the U channel. First determine your maximum current. In our example we will allow plus and minus 5 amps. The maximum voltage across the sense resistor would then be: V=IxR V = 5.00 Amps x .04 Ohms V = .20 Volts The next step is to calculate the gain. Because we are measuring a bipolar current, 0 A/D volts corresponds to -5 Amps, 2.5 Volts for 0 Amps, and 5.0 Volts for +5 Amps. This example assumes 5 volts input on the A/D (on the LF2407 the max A/D voltage is 3.3 volts) Gain = Vout/Vin Gain = 2.5V/0.20V Gain = 12.5 The next step is to adjust the gain for the channels. Install jumpers JP11, JP14, JP16 for bipolar operation. Pick a reference voltage such that it will not be greater than 5 volts when multiplied by the gain. We will pick a reference voltage of .1 which when multiplied by 12.5 meets our criteria. Measure the voltage at JP11 and adjust R17 for 0.1 Volts. Next measure the output voltages at JP24 pin 1 and adjust R12 for 1.25 volts. Repeat this procedure for the remaining two phases. The final step is to adjust the offset voltage. This is done by measuring the output voltage on one of the channels at JP11 and adjusting R17 until the voltage is 2.5 Volts.
Table 50: Phase Current Gain Adjust Phase U V W Adjust R12 R16 R19 Measure on J24 Pin 13 Pin 15 Pin 17
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DMC1500 Technical Reference
Spectrum Digital, Inc
2.16 Phase Voltage The phase voltages are measured from the top transistor with respect to Bus-. Each phase is divided by a resistive divider consisting of 400K and 4.99k. This gives a division of 81. Each channel also contains a filter with a cutoff frequency of 3.2Khz. The gain of each channel can be adjusted between 1 and 10. In our example we will assume a maximum voltage of 160 volts. Op-amp voltage = Phase Voltage / 81 Op-amp voltage = 160V / 81 Op-amp voltage = 1.97 Volts The next step is to calculate the gain. In our case we want the 1.97 volts to correspond to 5.0 volts to the A/D. The gain would be: Gain = A/D Volts / Op-amp Volts Gain = 5.0 volts / 1.97 Volts Gain = 2.6 To set the gain make sure there is 0 phase volts. To set phase U volts install jumper JP10. Next measure the voltage on JP10 and adjust R17 for .5 volts. This sets a reference voltage we will use to set the gain. The output voltage will be: Vout = Ref x gain Vout = .5v x 2.6 Vout = 1.3V Now measure the voltage on JP24 pin 17 and adjust R11 for 1.3 volts. Repeat this procedure for each of the phases.
Table 51: Phase Current Gain Adjust Phase U V W Jumper JP10 JP13 JP15 Adjust R11 R15 R18 Measure on JP24 Pin 17 Pin 19 Pin 21
Note: Make sure the jumper is removed after each adjustment
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2.17 Bus/PFC Current The currents are measured across .04 ohm resistors. The Bus current resistor R6 is shunted with a jumper JP4 from the factory. You can either have bus current measurements or phase current measurements but not both at the same time. To enable the bus current measurement cut out jumper JP4. These sense signal are then filtered for a 40Khz cutoff frequency, clamped to the rails and applied to the non inverting input to an opamp. The gain of each amplifier can be adjusted from 10 to 111. The example below shows how to calibrate the gain for the bus current. First determine your maximum current. In our example we will allow 5 amps. The maximum voltage across the sense resistor would then be: V=IxR V = 5.00 Amps x .04 Ohms V = .20 Volts The next step is to calculate the gain. Gain = Vout/Vin Gain = 5.0V/0.20V Gain = 25 The next step to adjust the gain is to install jumper JP7. Pick a reference voltage such that the A/D voltage will not be greater than 5 volts when multiplied by the gain. We will pick a reference voltage of .1 volts which when multiplied by 25 meets our criteria. Measure the voltage at JP7 and adjust R17 for 0.1 Volts. Next measure the output voltages at JP24 pin 25 and adjust R9 for 2.5 Volts.
Table 52: Ibus and IPFC Current Adjust IAdj Ibus IPFC Jumper JP7 JP12 Adjust R9 R14 Measure on JP24 Pin 25 Pin 29
Note: Make sure the jumper is removed after each adjustment
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DMC1500 Technical Reference
Spectrum Digital, Inc
2.18 Bus/PFC/Cap Voltage The Bus, PFC and Cap center tap voltage are adjusted the same as the phase voltages.
Table 53: Bus, PFC, and Cap Center Tap Voltage Adjust Vadj Bus PFC Cap Jumper JP9 JP8 JP6 Adjust R10 R13 R8 Measure on JP24 Pin 29 Pin 31 Pin 33
Note: Make sure the jumper is removed after each adjustment.
2.19 Overcurrent Failure The overcurrent trip logic is made from the bus current resistor R1, resistor R21, and Opto Isolator U1. When the Bus current exceeds the maximum value opto U1 conducts causing a PPINT to the DSK.
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Appendix A DMC1500 Schematics
This appendix contains the schematics for the DMC1500. The schematics were drawn on ORCAD.
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DMC1500 Technical Reference
Printed in U.S.A., September 2000 504915-0001 Rev. A

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