Infineon REF-AIRCON-C302A-IM564 User manual

User guide Please read the Important notice and the Safety precautions and the Warnings V 1.0.1
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REF-AIRCON-C302A-IM564 user guide
Air conditioner application reference design kits
About this document
Scope and purpose
This user guide provides an overview of the reference board REF-AIRCON-C302A-IM564 including its main
features, key test results and mechanical dimensions.
The REF-AIRCON-C302A-IM564 is a full-featured starter kit, turnkey motor drive designed for high-performance,
high-efficiency permanent magnet synchronous motor (PMSM) drive applications, including all of the required
elements for air conditioner applications, such as IMC302A iMOTIONTM controller, 1ED44175 PFC gate driver and
PFC-integrated CIPOSTM Mini IPM IM564-X6D.
The starter kit features and demonstrates Infineon’s CIPOSTM Mini IPM and advanced motion control engine
(MCE 2.0) technology for PMSM/BLDC motor and PFC driver up to a rating of 600 V and 20 A. It is optimized for
major home appliances like air conditioner compressors, fans, pumps and other motor drive applications.
Note: Please note that this product is not qualified according to the AEC Q100 or AEC Q101 documents of
the Automotive Electronics Council.
Intended audience
This application note is intended for all technical specialists who are familiar with air conditioner control and
electronics converters. The reference design is intended to be used under laboratory conditions only by trained
specialists.
Reference board
The Infineon products are embedded on this PCB with functions and form factor close to a commercial design.
PCB and auxiliary circuits are optimized for the final design.
Note: Boards do not necessarily meet safety, EMI, quality standards (for example UL, CE) requirements.

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Important notice
Important notice
“Evaluation Boards and Reference Boards” shall mean products embedded on a printed circuit board
(PCB) for demonstration and/or evaluation purposes, which include, without limitation, demonstration,
reference and evaluation boards, kits and design (collectively referred to as “Reference Board”).
Environmental conditions have been considered in the design of the Evaluation Boards and Reference
Boards provided by Infineon Technologies. The design of the Evaluation Boards and Reference Boards
has been tested by Infineon Technologies only as described in this document. The design is not qualified
in terms of safety requirements, manufacturing and operation over the entire operating temperature
range or lifetime.
The Evaluation Boards and Reference Boards provided by Infineon Technologies are subject to functional
testing only under typical load conditions. Evaluation Boards and Reference Boards are not subject to the
same procedures as regular products regarding returned material analysis (RMA), process change
notification (PCN) and product discontinuation (PD).
Evaluation Boards and Reference Boards are not commercialized products, and are solely intended for
evaluation and testing purposes. In particular, they shall not be used for reliability testing or production.
The Evaluation Boards and Reference Boards may therefore not comply with CE or similar standards
(including but not limited to the EMC Directive 2004/EC/108 and the EMC Act) and may not fulfill other
requirements of the country in which they are operated by the customer. The customer shall ensure that
all Evaluation Boards and Reference Boards will be handled in a way which is compliant with the relevant
requirements and standards of the country in which they are operated.
The Evaluation Boards and Reference Boards as well as the information provided in this document are
addressed only to qualified and skilled technical staff, for laboratory usage, and shall be used and
managed according to the terms and conditions set forth in this document and in other related
documentation supplied with the respective Evaluation Board or Reference Board.
It is the responsibility of the customer’s technical departments to evaluate the suitability of the
Evaluation Boards and Reference Boards for the intended application, and to evaluate the completeness
and correctness of the information provided in this document with respect to such application.
The customer is obliged to ensure that the use of the Evaluation Boards and Reference Boards does not
cause any harm to persons or third party property.
The Evaluation Boards and Reference Boards and any information in this document is provided "as is"
and Infineon Technologies disclaims any warranties, express or implied, including but not limited to
warranties of non-infringement of third party rights and implied warranties of fitness for any purpose, or
for merchantability.
Infineon Technologies shall not be responsible for any damages resulting from the use of the Evaluation
Boards and Reference Boards and/or from any information provided in this document. The customer is
obliged to defend, indemnify and hold Infineon Technologies harmless from and against any claims or
damages arising out of or resulting from any use thereof.
Infineon Technologies reserves the right to modify this document and/or any information provided
herein at any time without further notice.

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Safety precautions
Safety precautions
Please note the following warnings regarding the hazards associated with development systems.
Table 1 Safety precautions
Warning: The DC link potential of this board is up to 400 VDC. When measuring voltage
waveforms by oscilloscope, high voltage differential probes must be used. Failure to do
so may result in personal injury or death.
Warning: The reference board contains DC bus capacitors which take time to
discharge after removal of the main supply. Before working on the drive system, wait
five minutes for capacitors to discharge to safe voltage levels. Failure to do so may
result in personal injury or death. Darkened display LEDs are not an indication that
capacitors have discharged to safe voltage levels.
Warning: The reference board is connected to the grid input during testing. Hence,
high-voltage differential probes must be used when measuring voltage waveforms by
oscilloscope. Failure to do so may result in personal injury or death. Darkened display
LEDs are not an indication that capacitors have discharged to safe voltage levels.
Warning: Remove or disconnect power from the drive before you disconnect or
reconnect wires, or perform maintenance work. Wait five minutes after removing
power to discharge the bus capacitors. Do not attempt to service the drive until the bus
capacitors have discharged to zero. Failure to do so may result in personal injury or
death.
Caution: The heat sink and device surfaces of the reference board may become hot
during testing. Hence, necessary precautions are required while handling the board.
Failure to comply may cause injury.
Caution: Only personnel familiar with the drive, power electronics and associated
machinery should plan, install, commission and subsequently service the system.
Failure to comply may result in personal injury and/or equipment damage.
Caution: The reference board contains parts and assemblies sensitive to electrostatic
discharge (ESD). Electrostatic control precautions are required when installing, testing,
servicing or repairing the assembly. Component damage may result if ESD control
procedures are not followed. If you are not familiar with electrostatic control
procedures, refer to the applicable ESD protection handbooks and guidelines.
Caution: A drive that is incorrectly applied or installed can lead to component damage
or reduction in product lifetime. Wiring or application errors such as undersizing the
motor, supplying an incorrect or inadequate AC supply, or excessive ambient
temperatures may result in system malfunction.
Caution: The reference board is shipped with packing materials that need to be
removed prior to installation. Failure to remove all packing materials that are
unnecessary for system installation may result in overheating or abnormal operating
conditions.

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The board at a glance
Table of contents
About this document....................................................................................................................... 1
Important notice ............................................................................................................................ 2
Safety precautions.......................................................................................................................... 3
Table of contents............................................................................................................................ 4
1The board at a glance.............................................................................................................. 5
1.1 Delivery content ......................................................................................................................................5
1.2 Block diagram..........................................................................................................................................5
1.3 Main features...........................................................................................................................................7
1.4 Board parameters and technical data....................................................................................................7
2System and functional description........................................................................................... 9
2.1 Getting started with REF-AIRCON-C302A-IM564 ....................................................................................9
2.2 Description of the functional blocks.....................................................................................................15
2.2.1 Overview of IMC302A........................................................................................................................15
2.2.2 Overview of IM564-X6D ....................................................................................................................16
2.2.3 Overview of 1ED44175 .....................................................................................................................18
2.2.4 Overview of ICE5AR4770BZS............................................................................................................19
2.2.5 Design tips for direct motor current sensing ..................................................................................20
2.2.6 Design tips for PFC current sensing.................................................................................................22
3System design ......................................................................................................................24
3.1 Inverter section of REF-AIRCON-C302A-IM564 .....................................................................................24
3.2 PFC section of REF-AIRCON-C302A-IM564............................................................................................25
3.3 Auxiliary power supply..........................................................................................................................26
3.4 PCB Layout for REF-AIRCON-C302A-IM564...........................................................................................27
3.5 Bill of material .......................................................................................................................................29
3.6 Connector details..................................................................................................................................30
3.7 Test points.............................................................................................................................................31
4System performance .............................................................................................................32
4.1 Thermal characterization......................................................................................................................32
4.2 NTC thermistor characteristics and overheat protection....................................................................32
4.3 Motor overcurrent protection (OCP) test .............................................................................................35
4.4 PFC overcurrent protection test...........................................................................................................38
4.5 DC bus sensing and overvoltage protection ........................................................................................40
4.6 PFC performance test............................................................................................................................42
5References and appendices ....................................................................................................43
5.1 Abbreviations and definitions...............................................................................................................43
5.2 References .............................................................................................................................................43
5.3 Ordering details and other information...............................................................................................43
Revision history.............................................................................................................................44

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The board at a glance
1The board at a glance
The REF-AIRCON-C302A-IM564 is a part of Infineon’s CIPOSTM Mini IPM and iMOTION™ reference design kits. It is
designed to provide ready-to-use, air conditioner solutions based on Infineon’s PFC-integrated CIPOSTM Mini
IPM and advanced motion control engine (MCE 2.0) technology.
The REF-AIRCON-C302A-IM564 is an optimized design for 1400 ~ 2500 W power air conditioner applications. It
allows fast prototyping and fast time to market. It is available through regular Infineon distribution partners as
well as on Infineon's website. The main features of this board are described in this document, whereas the
remaining paragraphs provide information to enable the customers to copy and modify the design for
production according to their own specific requirements.
1.1 Delivery content
The board is equipped with all assembly groups for sensorless field-oriented control (FOC), and reserved
interface for BLDC/AC fan control, relays and 4-way valve control and 3-channel temperature sensing circuits,
so that it can be easily used for air conditioners and similar home applications.
It provides a single-phase AC connector, an EMI filter and soft power-up circuit, input rectifier, DC bus
capacitors, on-board PFC inductor emitter shunts for current sensing and overcurrent protection (OCP),
thermistor output and a voltage divider for DC-link voltage measurement.
The REF-AIRCON-C302A-IM564 reference design also contains a CoolSETTM based flyback auxiliary power supply
to provide 15 V, 12 V & 5 V.
1.2 Block diagram
The block diagram of the REF-AIRCON-C302A-IM564 is depicted in Figure 1.
M
HVIC
IMC302A
IM564-X6D Inverter Section
L
N
15V
PWM
VFO
Itrip
PWM
VTH
GK
DCBsense
5V
IM564-X6D
PFC Section
PFC
Current
sensing
VAC+
VAC-
Power
Supply
IFB
Gate
Driver
PFC_PWM
EMI Filter
& Soft
Power Up
Circuit
IPFC
PFC_Trip
Temperature
sensing EEPROM
IDU COM AC Fan/BLDC Fan
Debug Relays
Figure 1 Block diagram of the REF-AIRCON-C302A-IM564

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Figure 2 points out the functional groups on the top side of the REF-AIRCON-C302A-IM564 reference design:
Figure 2 Functional groups of the REF-AIRCON-C302A-IM564 reference design
2
1
10
7
9
1. 220 VAC & PE input connector
2. EMI filter
3. In-rush relay control
4. On-board PFC inductor
5. Heat sink (IM564 + 1ED44175 + input rectifier)
6. UVW motor phase connector
7. iMOTIONTM link connector, UART 0 & UART1
8. External BLDC fan VSP control
9. Auxiliary power supply
3
6
4
5
6
12
11
8
10. AC fan and 4-way valve relay control
11. Single-wire UART interface to IDU
12. EEV connector
13. UART tester connector
14. EEPROM
15. Temperature sensing
16. IMC302A
13
14
15
16

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The board at a glance
1.3 Main features
The REF-AIRCON-C302A-IM564 board is an optimized reference design for 220 V air conditioner applications,
which contains iMOTION™ controller IMC302A, 20 A, 600 V PFC-integrated CIPOS™Mini IPM and 1ED44175 PFC
gate driver.
Major REF-AIRCON-C302A-IM564 characteristics include:
•Input voltage 85~265 VAC
•Maximum 2500 W at 220 VAC power input with forced air cooling
•Maximum 1400 W at 220 VAC power input without forced air cooling
•20 A, 600 V PFC-integrated CIPOS™Mini IPM
•On-board 10 A, 400 µH PFC inductor for 40 kHz PFC operation
•VSP host interface for external BLDC fan
•AC fan and 4-way valve control relay
•Single-wire UART communication interface to IDU
•Overcurrent and over temperature protection, fault diagnostic LED output
•Auxiliary power supply with 15 V, 12 V and 5 V
•PCB is 250 mm ×157 mm, 2 layers, 1 oz. copper
•RoHS compliant
1.4 Board parameters and technical data
Table 2 depicts the key specifications of the reference design of REF-AIRCON-C302A-IM564.
Table 2 REF-AIRCON-C302A-IM564 board specifications
Parameter
Symbol
Conditions / comments
Value
Unit
Input voltage
Vac
Optimized design for 220 VAC applications
85 ~ 265
Vrms
Maximum input current
Iac(max1)
Input 220 VAC, Ta=25C, natural cooling mode
6
Arms
Iac(max2)
Input 220 VAC, Ta=25C, with 1 m/s wind cooling
12
Arms
Maximum output power
Pin(max1)
Input 220 VAC, Motor fPWM= 6 kHz, PFC fPWM=40 kHz,
Ta=25°C, IPM TC= 105 °C , Natural cooling mode
1400
W
Pin(max2)
Input 220 VAC, Motor fPWM= 6 kHz, PFC fPWM=40 kHz,
Ta=25°C, IPM TC= 105 °C , 1 m/s force cooling mode
2500
W
Maximum motor current
Imtr(max1)
Input 220 VAC, Motor fPWM= 6 kHz, PFC fPWM=40 kHz,
Ta=25°C, IPM TC= 105 °C , Natural cooling mode
6
Arms
Imtr(max2)
Input 220 VAC, Motor fPWM= 6 kHz, PFC fPWM=40 kHz,
Ta=25°C, IPM TC= 105 °C , 1 m/s force cooling mode
10
Arms
DC bus voltage
Maximum DC bus voltage
Vdc(max)
DC bus capacitors are 450 V, 470 µF x 2
450
V
Minimum DC bus voltage
Vdc(min)
Aux power supply brown-in voltage
80
V

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The board at a glance
Parameter
Symbol
Conditions / comments
Value
Unit
Current feedback
PFC shunt resistance
RS1
5 W shunt resistor with external OPA gain 14.7
15
mΩ
Motor shunt resistance
RS2
Direct AD sample (without external OPA)
20
mΩ
Protections
Motor current protection
trigger level 1
MtrItrip1
Wizard setup for OC trigger level, related to AD
range, shunt resistor RS2 and pull-up bias
16 1
Apeak
Motor current protection
trigger level 2
MtrItrip2
Hardware comparator overcurrent protection,
related to RS2 and IM564’s Itrip threshold
26.2
Apeak
PFC current protection
trigger level 1
PFCItrip1
IMC302A’s internal comparator for cycle-by-cycle
OCP, trip level can be adjusted by R50 & R55
20 2
Apeak
PFC current protection
trigger level 2
PFCItrip2
PFC driver local protection for 1ED44175 driver,
trip level can be adjusted by RS1, R66 & R71
33.3
Apeak
Thermal protection level
Tprotection
Temperature gap between junction and NTC
sensor needs to be considered
90
°C
Auxiliary power supply 1 –15 V
Output voltage
Vout1
Used for IPM driver
15 ±2%
V
Maximum output current
Iout1
150
mA
Auxiliary power supply 2 –12 V
Output voltage
Vout2
Used for relay control
12 ±10%
V
Maximum output current
Iout2
300
mA
Auxiliary power supply 3 –5 V
Output voltage
Vout2
Used for IMC controller and protection circuits
5 ±1%
V
Maximum output current
Iout2
200
mA
PCB characteristics
Dimension
Length ×width ×height
250×157
×65
mm
Material
FR4, 1.6 mm thickness, 1 oz. PCB
System environment
Ambient temperature
Ta
Non-condensing, maximum RH of 95%
0 ~ 50
°C
1
For iMOTION™ IC IMCxxx, there are three types of Gatekill input source options in MCEWizard setup: Gatekill-pin, Comparator and
both. If you select “comparator” mode, the external Gatekill signal will not be used, and the IFB will be compared by the internal
comparator with the “Device overcurrent trigger level setting” value set in MCEWizard.
2
For iMOTION™ IC IMC302 PFC overcurrent protection, there are two options in MCEWizard setup.
If you select “Enable cycle by cycle” mode, the PWM output immediately goes to logic LOW when the inductor current exceeds the
pre-determined OCP threshold, and re-starts at following PWM cycle.
For “Disable” mode, PFC state machine would shift from RUN state to FAULT state when inductor current exceeds the pre-
determined OCP threshold for a duration specified by parameter “PFC_GateKillTime”, only Fault_clear command can make it back
to STOP/RUN mode, which means latch–off OCP.

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System and functional description
2System and functional description
This chapter provides more function block details on setting up the system, and getting started with the
iMOTION™ development platform with the REF-AIRCON-C302A-IM564 reference design.
2.1 Getting started with REF-AIRCON-C302A-IM564
The REF-AIRCON-C302A-IM564 reference designs are shipped with embedded firmware and default
parameters.
A 6-pole, GK6063-6AC31 motor is used for the default DEMO functions, whose maximum speed is 2500 RPM and
maximum power is 3 KW. Please note that motor parameters need to be double-checked in MCEWizard for a
real air conditioner motor.
An iMOTIONTM Link or third party isolated USB-to-UART cable is needed to bridge the PC/debugger side and
motor drive system (the target iMOTION™ device, hot side) with 1 kV DC galvanic isolation.
The iMOTION™ software tools, MCEDesigner and MCEWizard, are required to initially set up the system, as well
as to control and fine-tune the system performance to match the user’s exact needs. These tools are available
for download via the Infineon website (https://www.infineon.com/cms/en/product/power/motor-control-
ics/digital-motor-controller-imotion/imc302a-f064/#!tools ). Please visit this page periodically to check for
tool/software updates.
After downloading and installing the iMOTION™ PC tools, MCEWizard and MCEDesigner, the following steps need
to be executed in order to run the motor. Refer to MCEWizard and MCEDesigner documentation for more
information.
Figure 3 shows the basic system connection using REF-AIRCON-C302A-IM564 to run motor with MCEDesigner:
Figure 3 System connection example
iMOTION Link Connector
(USB-to-UART)
AC
Power
Input
Motor Phase
Outputs

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System and functional description
Figure 4 shows the MCEWizard welcome page and interface of MCEDesigner.
Figure 4 MCEWizard welcome page and MCEDesigner interface

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Here are the steps needed to run the motor:
1. Connect iMOTIONTM Link’s 8-pin cable to J11 with default pin order (align connector orientation markings
with PCB silkscreen markings), and connect PC-USB connector to iMOTIONTM Link.
2. Use MCEWizard to enter the target motor’s system and operating parameters, as well as evaluation board’s
hardware parameters, which will then be used to calculate the digital parameter set of the controller
representing the complete motor drive system.
3. After system and operating parameters are set, go to the “Verify & Save Page” and click on “Calculate
Parameters” button. If no errors are reported, then save the drive parameter set into your project directory
by clicking “Export to MCEDesigner file (.txt)” (Figure 5); if an error is detected, double-click on the error
message (highlighted in RED) and adjust the related parameter. The saved drive system parameter file will
be later used by the MCEDesigner in step 9.
(Please refer to MCEWizard_V2.3.0.0 User Guide.pdf for more details, which is in MCEWizard’s install path)
Figure 5 MCEWizard Verify and Save page
4. Connect 220 V AC power supply and UVW outputs to the motor.
5. Turn on 220 V AC power supply, LED2 and LED5 ON.
6. Start MCEDesigner tool and open MCEDesigner default configuration file (.irc) for IMC302A device
(IMC302A_Vxxx.irc) by clicking “File” > “Open”.
(IMC302A_Vxxx.irc file is included in downloaded “IMC302A MCE Software Package”)
MCEDesigner should automatically connect to the REF-AIRCON-C302A-IM564 board using default COM port
(Indicated by green circle next to “COMx Up” status in the bottom frame of the MCEDesigner GUI).

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System and functional description
If it cannot establish the connection due to incorrect COM port, change COM port by doing the following:
Click on the “System Page” window and then click on “Preferences > Connection > Connect using” and choose
one of the other available COM ports from the drop-down list.
7. In case of blank IC: If the firmware has been erased from the IMC302A, a warning message will pop up saying
“Target device firmware and parameters file are not programmed! Please program firmware and parameters
file.”(Figure 6) See step 9 on how to obtain/program firmware and parameters.
Figure 6 MCEDesigner warning message
8. In case of blank IC: Do the following to program the firmware and the parameters’file into the internal Flash
memory of iMOTION™ Control IC: Click on system page, click “Tools” > “Programmer” and select “Program
Firmware and Parameters,” shown as Figure 7 below. The encrypted firmware is available in IMC302A MCE
Software Package, regarding the parameters file, browse and select the .txt file in step 3.
(If blank IMC302A IC, MCEDesigner will pop up information “Target device firmware and parameter files are not
programmed!”) Program the MCE firmware and system parameters into the internal Flash memory of iMOTION™ IC by
clicking “Tools > Programmer “in the pull-down menu, and then clicking on the “Program Firmware and Parameter”
check box. Select right Parameter file and firmware file. Finally click “Start” button to program firmware and parameter.
Then click YES and then the OK button to update IRC file with parameter file; finally “Save As” the IRC file to your own file
name that contains COM config, Parameters & firmware file path information. (Please refer to MCEDesigner User
Guide.pdf and MCEDesigner_V2.3.0.0 Application Guide.pdf for more details, which is in MCEDesigner’s install path)
Red LED4 will flash on after the program is done.
Figure 7 MCEDesigner program page

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System and functional description
9. Double click the “VF Diagnostic” function in Motor1 page, and monitor the motor current with oscilloscope.
If the motor current is not sinusoidal, change the target speed and Vd_Ext in VF Diagnostic sub-function,
then double-click “VF Diagnostic” until oscilloscope shows a steady sinusoidal current, with an amplitude of
30~50% motor rate current.
Double-click “Iu & Iv_Slow” in System page > Monitor Definitions; the motor current feedback should be
very clean and sinusoidal, as shown in Figure 8, otherwise please tune “Gating Propagation Delay & Phase
Shift Window Size” in MCEWizard. The sampled motor current amplitude should be over 300 cts ~500 cts
(corresponding to 30%~50% motor rate current); otherwise, the motor-current sample related hardware
and setup need tuning.
“VF Diagnostic” sub function can verify:
•If motor is correctly connected
•If MOS & gate driver work as expected
•If current sensing related parameters are correctly configured
•If PCB layout and DC bus decoupling have been done correctly
After “VF Diagnostic” is done, click STOP button (the red traffic light button) to stop PWM.
Figure 8 Trace waveform for Iu & Iv open loop diagnostic
10. Start the motor by clicking the green traffic light button in the control bar (or double-click Start Motor sub
function in Motor1 page, group of User Application Function Definitions); motor runs if above step goes well.
11. Check motor spin direction, adjust UVW connection order or set negative target speed in MCEDesigner if
direction is wrong.
12. Set target speed to about 50% of MAX speed, start “Iu & Flx_M” trace with “Auto Repeat on Level”. As Figure
9. Flx_M is better within the range of 2000~2500 cts (rated value is 2048), and MUST be steady and DC-like.
Some key tips for better motor-performance tuning:
•If Flx_M is not steady (swinging or oscillating), double-check motor parameters, speed loop PI gain, flux Estimator
time constant and PLL PI bandwidth (parameters PLLKp & PLLKi) related setup.
•If Flx_M is very noisy, double-check current feedback and Vdc-related hardware and parameters.
•If Flx_M is far from 2048, “Motor Back EMF Constant (Ke)” needs to be adjusted in MCEWizard.

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System and functional description
Figure 9 Trace waveform for Iu & Flx-M at 50% speed
13. Once the firmware has been programmed, in case a new parameters’ file has to be programmed, follow the
same instructions given in step 9. In this case, firmware programming is no longer needed and it is possible
to select the first option “Program Parameters.”
Note: For detailed information on controller programming, refer to AN2018-33 iMOTION™ 2.0 Device Programming,
MCEDesigner documentation and MCEWizard documentation.

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System and functional description
2.2 Description of the functional blocks
The motor inverter and PFC convertor of the REF-AIRCON-C302A-IM564 reference design are implemented by
the IM564-X6D IPM module, and the PFC MOSFET gate driver is 1ED44175.
The control functions of the air conditioning system, motor and PFC are implemented by IMC302A.
Motor current sensing is single shunt mode, with lowest cost configuration of direct AD sample.
An external 14.7 X gain operational amplifiers (OPA) SGM8968-1 is used for PFC current sensing.
The flyback auxiliary power supply is based on fixed-frequency CoolSETTM ICE5AR4770BZS.
2.2.1 Overview of IMC302A
The IMC302A combined dual core computation, Motion Control Engine (MCE) and ARM®Cortex®-M0 based user
application controller (MCU). The internal block and application diagram is shown in Figure 10.
Figure 10 IMC302A internal block and application schematics diagram
Main features of the iMOTION™ controller IMC302A include:
Motion control engine (MCE)
MCE as ready-to-use controller solution for sensorless motor drives
Field-oriented control (FOC) for permanent magnet synchronous motor (PMSM)
Integrated protection features (overvoltage /undervoltage, overcurrent and over-temperature, etc.)
Current sensing via single shunt or leg shunt

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System and functional description
Integrated analog comparators for overcurrent protection
Integrated scripting engine for application flexibility
Flexible host interface options for speed commands: UART, SPI, PWM or analog signal
Class B pre-certification (IEC60730) for MCE2.0 firmware
User application controller (MCU)
Arm®Cortex®-M0 based MCU with flexible peripherals and communication interfaces
48 / 96 MHz core / peripherals clock
8 Kbyte ROM, 16 Kbyte SRAM and 128 Kbyte FLASH memory (with ECC)
3.3 V or 5.0 V supply voltage options for controller
On-chip clock monitor
2.2.2 Overview of IM564-X6D
The IM564-X6D is a part of the CIPOS™Mini IPM series, with CoolMOSTM power MOSFET and a rapid switching
diode for PFC stage. The IM564-X6D main application-related data are as follows:
Inverter section continuous output ability is 20 A at Tc = 25℃, and 15 A at Tc = 80℃
Inverter IGBT short-circuit withstand time is 5 µs
Recommended minimum input pulse width is 1 µs
Recommended external dead time of motor PWM is 1.5 µs
Maximum motor PWM carrier frequency is 20 kHz
PFC continuous input ability is 20 A at Tc = 25℃, and 15 A at Tc = 80℃,
Maximum PFC peak current is 40 A at Tc = 25℃.
Maximum PFC PWM carrier frequency is 150 kHz
Figure 11 illustrates the internal block diagram of IM564-X6D. Its main features include:
Fully isolated dual in-line molded module
Very low thermal resistance due to DCB substrate
Lead-free terminal plating and RoHS compliant
3.3 V, 5 V and 15 V input logic compatible
TRENCHSTOP™ IGBTs for Inverter and CoolMOS™ Power MOSFET for PFC
Rugged SOI gate driver technology with stability against transient and negative voltage
Allowable negative VS potential up to -11 V for signal transmission at VBS = 15 V
Integrated bootstrap diode, cross-conduction prevention and rapid switching emitter-controlled diode
Built-in NTC thermistor for temperature monitor
All of 6 switches turn off during OCP and undervoltage lockout
Sleep function is activated after ITRIP or undervoltage lockout
Fast-track shutdown allows low-side outputs to be turned off faster than high-side outputs by about 200 ns

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Air conditioner application reference design kits
System and functional description
Figure 11 Block diagram of IM564-X6D
The IM564-X6D is in DIP 36x21D package; the pin definition and package outline are shown in Figure 12.
Figure 12 IM564-X6D lead assignments

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System and functional description
2.2.3 Overview of 1ED44175
A 1ED44175 is used for the PFC MOSFET drive and PFC OCP, its main functions and features are as follows:
2.6 A low-side driver with overcurrent protection and fault/enable pin
Overcurrent detection with negative input, -246 mV overcurrent threshold (with accurate ±5% tolerance)
Enable input and fault output
Output in phase with input, active-high input logic
Programmable fault clear time, OUT keeps “Low” during protection time
Undervoltage lockout
CMOS Schmitt-triggered inputs, 3.3 V, 5 V and 15 V input logic-compatible
3 kV ESD HBM
The 1ED44175 is in a SOT23-6 package; the pin definition and package outline are shown in Figure 13.
Figure 13 Package and block diagram of 1ED44175

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System and functional description
2.2.4 Overview of ICE5AR4770BZS
The ICE5AR4770BZS is Infineon’s latest (5th generation) fixed-frequency CoolSETTM offering high performance
and integration of the latest generation of 700 V CoolMOSTM superjunction MOSFETs in DIP-7 packages.
Figure 14 illustrates the internal block diagram and typical isolated flyback application.
Figure 14 ICE5AR4770BZS internal block and typical application in isolated flyback mode
Main features of ICE5AR4770BZS include:
100 kHz maximum switching frequency with 700 V integrated MOSFET
Power delivery of up to 15 W with universal wide input range (85 ~ 300 VAC) DCM design
Brown-in protection, fast and robust start-up operation with cascode configuration
3-level selectable entry/exit active-burst mode profile (optional)
Built-in digital soft-start
Cycle-by-cycle peak current limitation
Support both DCM and CCM operation with slope compensation
Integrated error amplifier to support direct feedback typical with non-isolated flyback topology
Digital frequency reduction with decreasing load for higher efficiency
Frequency jitter and soft gate driving for low EMI
Limited charging current for VCC pin short to ground
Comprehensive protection with VCC overvoltage, VCC undervoltage, overload/open loop, over-
temperature protection
Auto-restart for all protection features

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System and functional description
2.2.5 Design tips for direct motor current sensing
From the point view of the AD converter, the current input scaling value is the product of the voltage over shunt
resistor and the gain of the external current-sense amplifier, as shown in Figure 15.
Figure 15 Current feedback scaling outside IMC302A
Direct AD sample is used in the motor section of REF-AIRCON-C302A-IM564 reference design, i.e., motor current
sensing is done without an external OPA (Only C51, R83 & R77 used for operational gain, bias and low pass
filter), as shown in Figure 16.
The real AD input voltage is decided by the divider of R83 & R77, with bias of 49 mV and gain of 0.99:
  
  
  
       
R77 & C51 is a low pass filter (LPF) for switching noise suppression, whose time constant is about 0.1~0.5 µs
normally.
A 20 mOhm, 5 W single shunt resistor (50110 package), and 1 k & 10 Ohm pull-up net are the default
configuration for the motor section of the REF-AIRCON-C302A-IM564 reference design. In other words, a 1 A
motor current produces 19.8 mV voltage to the ADC input, so the MCEWizard’s “Motor1 Current Input Scaling”
needs input at 19.8 mV/A (20*0.99=19.8).
Please note that “Internal Current Feedback Amplifier Gain”(Question 84 for MCEWizard V2.3.0.0) is ADC’s
internal gain, which defines the MAX ADC input range at VCC/Gain. For a 5 V power supply, the ADC sensing range
is 0 ~ 833 mV if 6 times the internal gain is selected, and 0 ~ 416.6 mV if 12 times the internal gain is selected.
Figure 16 Direct AD sample (current feedback without external op-amp)