EVBTPD410XInstruction Manual

Office NettetalRingstr. 88

D-41334 Nettetal-KaldenkirchenTel.: 0049 (0)2157-124-237Fax.: 0049 (0)2157-124-211

Support: harald.frank@glyn.de

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Contents

Topic Page

1.0 Introduction 31.1 Included in delivery 3

2.0 Hardware 32.1 Segmentation of the board 32.2 Section TPD4102K 4

2.2.1 Diagram 42.2.2 Connector pins 42.2.3 Jumper 52.2.4 Functionality 5

2.3 Section TPD4103(A)K 52.3.1 Diagram 62.3.2 Connector pins 62.3.3 Functionality 7

2.4 Section TB6551F 72.4.1 Diagram 72.4.2 Connector pins 72.4.3 Jumper 82.4.4 Functionality 8

2.5 Section 60° -> 120° 92.5.1 Diagram 92.5.2 Connector pins 92.5.3 Functionality 9

2.6 Section Dual-Comparator 102.6.1 Diagram 102.6.2 Connector pins 102.6.3 Functionality 11

Appendix

EVBTPD410X List of Components 11

© 2003 Glyn GmbH & Co. KG

Alle Rights reserved. No part of this document may be reproduced or with electronic sysytemsprocessed, duplicated or dispread in any form (print, copy, microfilm nor in any other way) without thewritten authorisation from Glyn GmbH & Co. KG, D-65510 Idstein.Microsoft and MS-DOS are registrated trademarks of Microsoft Corporation.

Regarding the contents of this document and the EVBTPD410X Data-CD-ROM Glyn GmbH & Co. KG,D-65510 Idstein assumes no liability nor warranty. The company Glyn GmbH & Co. KG, D-65510Idstein reserves the right of revision for this documentation and for the EVBTPD410X Data-CD-ROM.All programs and descriptions were developed to the best of the companys knowledge and tested withaccurateness. Nevertheless we can not exclude failures. For that reason Glyn GmbH & Co. KGassumes no waranty for failures or consequential losses in association with the preparation and theusage of the materials.

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1.0 IntroductionThe Evaluation-Board EVBTPD410X was developed due to the great demand for those new devices.

The following Toshiba-Components are testable with this board:

TPD4102K TPD4103K TPD4103AK TB6551F

The board should offer users a rapid prototype pcb for a working motion control system and could be areference design too. The pcb will be delivered full assembled.

1.1 Included in delivery

Contents of delivery:

1. printed Manual(german Version)2. Data-CD-ROM with all relevant Datasheets3. The assembled board

Contents of the CD:Acrobat_Reader........................... Version 5.0Datasheets................................... Datasheets of all Semiconductors of the boardBoard............................................ This Instruction-manual with Diagrams and scematicsReliability_report.......................... Toshiba Reliability_reportPresentation................................. A presentation about Single-Chip-Inverters from Toshiba

Important Link:Toshiba Product Guides Http://doc.semicon.toshiba.co.jp/noseek/us/buct/bcfm.htm

2.0 Hardware

2.1 Segmentation of the board

This board is devided into five separate sections. The sections could be used together orseparately.

This photo shows the segmentation of the five sections.

SectionTPD4102K

SectionTPD4103(A)K

SectionTB6551F

SectionDual-Comparator

Section60° to 120°

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2.2 Section TPD4102K

This section is suitable for the use of the TPD4102K. It contents all neccessary parts to drive abrushless DC-Motor with Hall-Sensors(arranged in 120° distance). Via a Jumper the directioncould be switched between clockwise or counter-clockwise and via potentiometer(R38) thePWM could be adjusted beteen 0 and 100%. (speed-control)

2.2.1 Diagram

2.2.2 Connector pins

This section is provided with several signal and supply-pins. There are 6 screw-clamps and 9 solderpins on this section. The screw-clamps are identified with thenumbers 1 to 6 and with a Label and have the following meaning:

Screwclamp 1: GND (0 Volts) SupplyScrewclamp 2: VCC (13,5 – 17,5 Volts) SupplyScrewclamp 3: VBB (50 – 400 Volts) SupplyScrewclamp 4: Motorwinding Phase WScrewclamp 5: Motorwinding Phase VScrewclamp 6: Motorwinding Phase U

The solderpins have labels and JPxx-Numbers. The following signals are related tothe solderpins:

Solderpin JP41, JP49 GND: GND-Ports for external signals. Connected toscrewclamp 1.

Solderpin JP42 V+: Output-power-supply 6 Volts for external Circuitsand Hall-Sensors-Supply.

Solderpin JP48 Vin: Input-level for PWM-generation(speed-control). Thisvalue is adjusted by the potentiometer. This pin isdesigned for the connection of a Volt-meter.

Solderpin JP40 Iout: At this pin the voltage over the 0,56 Ohms-resistorcould be measured. This voltage is proportional to thetotal current. At a voltage of 0,5 Volts at this pin, theinternal current-limitation starts to function. This pin isdesigned for the connection of a Volt-meter.

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Solderpin JP46 FG: This Output offers a PWM-sychronous Rectangular-signal. With this signal the rotating-field-frequencycould be measured.

Solderpin JP45 HW: Input for Hallsensor W.Solderpin JP44 HV: Input for Hallsensor V.Solderpin JP43 HU: Input for Hallsensor U.

2.2.3 Jumper

This section contents only one Jumper (JP47) for the switch of the motor-direction(cw/ ccw). The Jumper should be set to the wanted position before the motor starts toturn. A switch or a remove of this Jumper while the motor is in function can causedamages of some components !

2.2.4 Functionality

This section can drive a BLDC-motor stand alone, when the Hall-Sensors of the motorare arranged in 120° distance and the motorvoltage is leveled between 50 and 400Volts by a maximum current of 1A. If the Hall-Sensors are arranged in 60° distance,the section 60° to 120° must be circuited between the Sensors and the inputs(Have alook at Section 60° to 120°).

In case of correct circuited power supply, Hall-Sensors and motor, the potentiometershould be drawn to GND before switching on the power supplies. With turning thepotentiometer slowly the motor should start to turn from a certain point. At themaximum amplitude from the potentiometer 100 % of the speed should be reached.The components of this section are delivered uncooled and due to that fact a motorcan only be driven for a short time.

Attention ! Parts of this section could be heated up very high. Please attend theguidelines for the use of rectified high tension too.

2.3 Section TPD4103(A)K

This section is designed for the use of the TPD4103K(not included in delivery) or theTPD4103AK(mounted). All needed components are assembled. This section works as a 3Phase-IGBT-Power-Amplifier with 6 Inputs(U,V,W,X,Y,Z) (Low-aktive). It could be used todrive an AC- or a BLDC-motor.

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2.3.1 Diagram

2.3.2 Connector pins

This section is provided with several signal and supply-pins. There are 6 screw-clamps and 11 solderpins on this section. The screw-clamps are identified with thenumbers 1 to 6 and with a Label and have the following meaning:

Screwclamp 1: GND (0 Volts) SupplyScrewclamp 2: VCC (13,5 – 17,5 Volts) SupplyScrewclamp 3: VBB (50 – 400 Volts) SupplyScrewclamp 4: Motorwinding Phase WScrewclamp 5: Motorwinding Phase VScrewclamp 6: Motorwinding Phase U

The solderpins have labels and JPxx-Numbers. The following signals are related tothe solderpins:

Solderpin JP36 und JP35 GND: GND-Ports for external signals. Connected toscrewclamp 1.

Solderpin JP33 Vout: Outputvoltage 7 Volt for external circuits.Solderpin JP34 Diag: Diagnostic-Output to indicate malfunctions

due to overcurrent, undervoltage and thermal shutdown. This pin is designed for the connection of aVolt-meter.Solderpin JP32 Iout: At this pin the voltage overthe 0,56 Ohms-resistor could be measured. Thisvoltage is proportional to the total current. At a voltageof 0,5 Volts at this pin, the internal current-limitation ofthe TPD4103K starts to function. The TPD4103AKhas no internal current-limitation. This pin is designedfor the connection of a PWM-Generator-Chip or amicrocontroller. For the use of the TPD4103AK anexternal current-limitation must be provided.

Solderpin JP31 U: Input U (active LOW).Solderpin JP30 V: Input V (active LOW).Solderpin JP29 W: Input W (active LOW).Solderpin JP28 X: Input X (active LOW).Solderpin JP27 Y: Input Y (active LOW).Solderpin JP26 Z: Input Z (active LOW).

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2.3.3 Functionality

This section is not able to drive a motor on its own. It requires 6 Inputsignals(U,V,W,X,Y,Z), which must be generated from an external device. This could be aPWM-Generator-IC(look at section TB6551F) or a microcontroller, like theTMP88PS43F from Toshiba. The motor-voltage should be adjusted between 50 and400 Volts and the maximum current should not exceed 1 Ampere.

The components of this section are delivered uncooled and due to that fact a motorcan only be driven for a short time.

Attention ! Parts of this section could be heated up very high. Please attend theguidelines for the use of rectified high tension too.

2.4 Section TB6551F

This section contents the circuit for the PWM-Generator-IC TB6551F. This component isprovided for the signal-generation of BLDC-Motors with Hall-Sensors(arranged in 120°distance) and drive a sine-shaped PWM at its outputs(U,V,W,X,Y,Z). These outputs could bedirectly connected to the 3-Phase-IGBT-Power-Amplifier(section TPD4103(A)K).

2.4.1 Diagram

2.4.2 Connector pins

This section is provided with several signal and supply-pins. There are 17 solderpinsand 4 Jumper on this section. The solderpins are identified with labels and JPxx-numbers and have the following meaning:

Solderpin JP37,39 and 25 GND: GND-Ports for external signals.

Solderpin JP9 Vrefout: Output-voltage 5 Volt for external circuits and Hall-Sensors.

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Solderpin JP8 IDC: This is the current-feedback-input from the Power-Amplifier. Beginning from a voltage of 0,5 Volts at thispin the current-limitation of the TB6551F starts towork. The PWM-Outputs are shut off.

Solderpin JP17 REV: This output indicates the turning direction of themotor.

Solderpin JP7 FG: At this output a fixed number of pulses per electricalfield rotation could be measured. So the speed couldbe determined.

Solderpin JP24 VCC: Power-supply (6 – 10 Volts).

Solderpin JP16 HU: Input for Hall-Sensor HU.Solderpin JP15 HV: Input for Hall-Sensor HV.Solderpin JP10 HW: Input for Hall-Sensor HW.

Solderpin JP23 U: Output U (aktive LOW).Solderpin JP22 V: Output V (aktive LOW).Solderpin JP21 W: Output W (aktive LOW).Solderpin JP20 X: Output X (aktive LOW).Solderpin JP19 Y: Output Y (aktive LOW).Solderpin JP18 Z: Output Z (aktive LOW).

2.4.2 Jumper

This section contents of 4 jumper. All of the jumper connect the corresponding Inputsto +5V or GND.

Jumper JP11 TD: With this jumper the deadtime could be switchedbetween two fixed values. (default = +5V)

Jumper JP12 RES: With this jumper a RESET could be activated if theInput is switched to GND. In this case the componentstops to work. In normal use this jumper is set to +5V.(default = +5V)

Jumper JP13 OS: This input can switch the PWM-outputs between„Active-Low“ and „Active-High“.(default = GND)

Jumper JP14 CW: This input can switch the turn-direction of the motorbetween clockwise and counter-clockwise. (default =GND)

2.4.3 Functionality

The TB6551F is a stand alone PWM-Generator-IC for BLDC-Motors. This sectionmust be circuited to a power amplifier like section TPD4103(A)K to drive a motor. TheHall-Sensors could be connected directly or via section 60° -> 120°. With thePotentiometer R14 VE the speed could be controlled. With the Potentiometer R13 LAthe Lead-Angle could be adjusted between 0° and 30° . This is neccessary tocompensate the runtimes of the signal-feed-backlines. The ideal value will be reachedat the minimum current at a fixed speed. When slowly turning onwards thepotentiometer R14 VE the switch from rectangular- to sine-wave-modulation could bewatched electrically and audible.

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2.5 Section 60° -> 120°

This section changes the Hall-sensor-signals from arranged in 60° to arranged in 120°distance. Several sections have Hall-sensor-feedback-inputs and require them arranged in120° distance. For a motor is not so easy to be changed this section could be used.

2.5.1 Diagram

2.5.2 Connector pins

This section is provided with several signal and supply-pins. There are 10 solderpinson this section. The solderpins are identified with labels and have the followingmeaning:

Solderpin HALLGND: GND-Port for the connection of the Hall-Sensors.Solderpin HALL+: Output-voltage for the connection of the Hall-Sensors.Solderpin GND: GND-Port for the section supply.Solderpin V+: Power supply pin for positve voltage.

Solderpin HALL1IN: Hall-Sensor-Input 1.Solderpin HALL2IN: Hall-Sensor-Input 2.Solderpin HALL3IN: Hall-Sensor-Input 3.

Solderpin HU: Output Hall-Signal HU:Solderpin HV: Output Hall-Signal HV:Solderpin HW: Output Hall-Signal HW:

2.5.3 Functionality

The functionality of this section should be declared from the following diagram. Theinput-signals HALL1IN-HALL3IN are arranged in 60° distance and each are active for180°. The output-signals HU, HV and HW are virtual re-arranged in 120° distance andalso for 180° active.

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2.6 Section Dual-Comparator

This section offers two comparators with adjustable thresholds. These comparator-inputscould be connected with the current-feed-back-outputs(Iout) of the TPD4103(A)K or theTPD4102K. The LEDs indicate when the threshold is reached.

2.6.1 Diagram

2.6.2 Connector pins

This section is provided with several signal and supply-pins. There are 6 solderpins onthis section. The solderpins are identified with JPxx-numbers and have the followingmeaning:

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Solderpin JP3 Iin: Current-feed-back-input. The power-semiconductorsTPD410X may not used over 1A at 400 Volts. TheShunt-resistors (0,56 Ohms) cause a maximumvoltage of 0,56 Volts at this pin..

Solderpin JP4, JP6 GND: GND-port for supply and external circuits.

Solderpin JP5 Vcc: Positive supply-voltage.Solderpin JP1 CL: Threshold for a current-limitation-signal.(Low-active)Solderpin JP2 EMG: Threshold for an Emergency-Shut-Off-Function-

signal. (Low-active)

2.6.3 Functionality

The thresholds are adjustable via the potentiometers in the range between 0 and 1Volt and could be used as overcurrent-switch-off-signals. This is very helpful for theuse of the TPD4103(A)K in relation with a microcontroller. Especially for themicrocontrollers from Toshiba with a 3-Phase PWM-unit are two threshold-valuesneeded for Current-Limitation and Emergency-Shut-Off. So the separate Evaluation-Board EVBTMP88PS43 from Glyn for those microcontrollers could be easilyconnected with the TPD4103(A)K. The green LED corresponds with potentiometerR15 and the output JP1 CL. The red LED is connected to potentiometer R16 and theoutput JP2 EMG.

EVBTPD410X List of Components:

No. Comp. Typ Value Raster (mm) Reichelt Name*1 C1 1nF Capacitor 2,5 MKS-02 1,0N2 C2 1nF Capacitor 2,5 MKS-02 1,0N3 C3 1nF Capacitor 2,5 MKS-02 1,0N4 C4 10µF/16V Elko / Tantal 2,5 RAD 10/355 C5 1nF Capacitor 2,5 MKS-02 1,0N6 C6 1nF Capacitor 2,5 MKS-02 1,0N7 C7 10µF/16V Elko / Tantal 2,5 RAD 10/358 C8 1nF Capacitor 2,5 MKS-02 1,0N9 C9 1nF Capacitor 2,5 MKS-02 1,0N10 C10 1nF Capacitor 2,5 MKS-02 1,0N11 C11 33pF Keramik-Capacitor 2,5 NPO-G1206 33P12 C12 33pF Keramik-Capacitor 2,5 NPO-G1206 33P13 C13 1nF Capacitor 2,5 MKS-02 1,0N14 C14 1nF Capacitor 2,5 MKS-02 1,0N15 C15 1µF/16V Elko / Tantal 2,5 RAD 1/6316 C16 0,1µF/16V Elko / Tantal 2,5 RAD 0,1/10017 C17 10µF/25V Elko / Tantal 2,5 RAD 10/3518 C18 0,1µF/16V Elko / Tantal 2,5 RAD 4,7/3519 C19 470nF/630V Capacitor 27,5 MKS-4-630 470N20 C20 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6321 C21 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6322 C22 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6323 C23 10µF/25V Elko / Tantal 2,5 RAD 10/3524 C24 1nF Capacitor 2,5 MKS-02 1,0N25 C25 1nF Capacitor 2,5 MKS-02 1,0N26 C26 1µF/16V Elko / Tantal 2,5 RAD 1/6327 C30 470nF/630V Capacitor 27,5 MKS-4-630 470N28 C31 1µF/16V Elko / Tantal 2,5 RAD 1/6329 C32 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6330 C33 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6331 C34 2,2µF/25V bipolar Capacitor bipolar 15 TON 2,2/6332 D1 LED 3mm green LED 2,5 LED 3mm gn33 D2 LED 3mm red LED 2,5 LED 3mm rt

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34 HZIP TPD4103K Brushless Motor Driver 1,27 ---35 IC1 4093N Nand-Trigger DIP MOS 409336 IC2 LM393N Operationsvertärker DIP LM393DIP37 U$1 TB6551F 3-Phase Sine-Wave Gen. ---38 U$2 TPD4102K Brushless Motor Driver 1,27 ---39 JP11 Connector 1x3 + Jumper Jumper (TD) 2,54 Jumper bl40 JP12 Connector 1x3 + Jumper Jumper (RES) 2,54 Jumper bl41 JP13 Connector 1x3 + Jumper Jumper (OS) 2,54 Jumper bl42 JP14 Connector 1x3 + Jumper Jumper (CW) 2,54 Jumper bl.43 JP47 Connector 1x3 + Jumper Jumper (F/R) 2,54 Jumper bl44 Q1 Quarz 4,19MHz HC49/S 5 4,194304-HC49U-S45 R1 4,7KΩ Resistor 1/4W 10 1/4W 4K746 R2 4,7KΩ Resistor 1/4W 10 1/4W 4K747 R3 4,7KΩ Resistor 1/4W 10 1/4W 4K748 R4 4,7KΩ Resistor 1/4W 10 1/4W 4K749 R5 4,7KΩ Resistor 1/4W 10 1/4W 4K750 R6 4,7KΩ Resistor 1/4W 10 1/4W 4K751 R7 1KΩ Resistor 1/4W 10 1/4W 1K52 R8 1KΩ Resistor 1/4W 10 1/4W 1K53 R9 56KΩ Resistor 1/4W 10 1/4W 56K54 R10 56KΩ Resistor 1/4W 10 1/4W 56K55 R11 470Ω Resistor 1/4W 10 1/4W 47056 R12 470Ω Resistor 1/4W 10 1/4W 47057 R13 25K Potentiometer Potentiometer 25K 2,54 PT6-L 25K58 R14 25K Potentiometer Potentiometer 25K 2,54 PT6-L 25K59 R15 10K Potentiometer Potentiometer 10K 2,54 PT6-L 10K60 R16 10K Potentiometer Potentiometer 10K 2,54 PT6-L 10K61 R17 1KΩ Resistor 1/4W 10 1/4W 1K62 R18 4,7KΩ Resistor 1/4W 10 1/4W 4K763 R19 4,7KΩ Resistor 1/4W 10 1/4W 4K764 R20 4,7KΩ Resistor 1/4W 10 1/4W 4K765 R22 4,7KΩ Resistor 1/4W 10 1/4W 4K766 R23 0,56Ω / 0,5W Resistor 0,5W 15 2W DRAHT 0,5667 R24 4,7KΩ Resistor 1/4W 10 1/4W 4K768 R25 4,7KΩ Resistor 1/4W 10 1/4W 4K769 R26 4,7KΩ Resistor 1/4W 10 1/4W 4K770 R27 4,7KΩ Resistor 1/4W 10 1/4W 4K771 R28 1KΩ Resistor 1/4W 10 1/4W 1K72 R29 4,7KΩ Resistor 1/4W 10 1/4W 4K773 R30 25K Potentiometer Potentiometer 25K 2,54 PT6-L 25K74 R31 27KΩ Resistor 1/4W 10 1/4W 27K75 R32 1KΩ Resistor 1/4W 10 1/4W 1K76 R33 100KΩ Resistor 1/4W 10 1/4W 100K77 R34 0,56Ω / 0,5W Resistor 0,5W 15 2W DRAHT 0,5678 --- Jumper --- 2,54 Stiftl. 36G79 --- Socket 8-pol. Socket for LM393N 2,54 GS8P80 --- Socket 14-pol. Socket for 4093 2,54 GS14P81 --- Socket 23-Pol. IC70-2313MF-G4 1,27 ---82 --- Socket 23-Pol. IC70-2313MF-G4 1,27 ---

* Reichelt Elektronik; Elektronikring 1; D-26452 Sande; Germany Tel.: 04422-955-333 Fax.: -111