Renesas YROTATE-IT-RX220 User manual

USER MANUAL
UM-YROTATE-IT-RX220 Rev.1.00 Page 1 of 50
Jan 15, 2014
YROTATE-IT-RX220
Low Cost Motor Control Kit based on RX220
Introduction
The Renesas Motor Control Kit, YROTATE-IT-RX220, is based on the RX220 device fro the powerful 32-bit RX
icrocontroller fa ily.
The kit enables engineers to easily test and evaluate the perfor ance of the RX220 in a laboratory
environ ent when driving any 3-phase Per anent Magnet Synchronous Motor (e.g. AC Brushless Motor)
using an advanced sensorless Field Oriented Control algorith . Typical applications for this type of solution
are co pressors, air conditioning, fans, air extractors, pu ps and industrial drives.
The phase current easure ent is done via three shunts which offers a low cost solution, avoiding the need
for an expensive current sensor. A single shunt current reading ethod is also available.
The powerful user-friendly PC Graphical User Interface (GUI) gives real ti e access to key otor perfor ance
para eters and provides a unique otor auto-tuning facility.
The hardware is designed for easy access to key syste test points and for the ability to hook up to an RX220
debugger. Although the board is nor ally powered directly fro the USB port of a Host PC, connectors are
provided to utilise external power supplies where required.
The YROTATE-IT-RX220 is an ideal tool to check out all the key perfor ance para eters of your selected
otor, before e barking on a final end application syste design.
Target Device: RX220
UM-YROTATE-IT-RX22
0
Rev.
1.00
Jan 15, 201
4

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Contents
1. Hardware overview ....................................................................................................................................................... 3
2. Connectors description ................................................................................................................................................. 4
3. Power supply selection ................................................................................................................................................. 5
4. LEDs function description ............................................................................................................................................. 6
5. Test points for debugging ............................................................................................................................................. 7
6. Internal power stage brief description ......................................................................................................................... 9
7. Interface with an external power stage ...................................................................................................................... 10
8. Single shunt current reading ....................................................................................................................................... 14
9. Current reading ti ing in three shunts and single shunt configurations ................................................................... 15
10. Control MCU overview .............................................................................................................................................. 16
11. Per anent agnets brushless otor odel ........................................................................................................... 17
12. Sensorless Field Oriented Control algorith ............................................................................................................ 23
13. Software description ................................................................................................................................................. 24
14. Start-up procedure .................................................................................................................................................... 28
15. Reference syste transfor ations in details ........................................................................................................... 30
16. Rotor position esti ation ......................................................................................................................................... 31
17. Internal representation of physical quantities.......................................................................................................... 33
18. EEPROM para eters list ........................................................................................................................................... 37
19. PC Graphical User Interface ...................................................................................................................................... 38
20. Motor Auto-calibration using the PC GUI ................................................................................................................. 40
21. List of otors tuned auto atically using the PC GUI ............................................................................................... 50

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1. Hardware overview
The inverter kit YROTATE-IT-RX220 is a single board inverter, based on the RX series icrocontroller RX220
and includes a low-voltage MOSFETs power stage and a co unication stage.
To obtain the axi u flexibility, the reference kit includes:
•A co plete 3-phase inverter on-board with a low voltage otor, so it beco es easy to test the
powerful sensorless algorith running on the RX220 icrocontroller.
•An insulated USB co unication with the PC.
•Connectors for hall sensors and encoder connections (both encoder and hall sensors are not
anaged in the sensorless software but they can be supported under request).
•Co patibility with the existing Motor Control Reference Platfor external power stage.
•USB supply possibility to avoid external power supplies (where galvanic insulation is lost).
To achieve these ai s, three different DC-DC converters are used:
1. A step-up DC-DC converter to increase the voltage fro the USB standard (5V) up to 13.5V
DC
2. A step-down converter fro the DC bus (which can reach up to 48V
DC
in case of external supply) to
the power switches drive voltage (12V).
3. A step-down converter fro the DC bus to the CPU supply voltage (5V).
COMMUNICATION
STEP
-
DOWN
STEP_UP
EXTERNAL POWER
STAGE INTERFACE
POWER STAGE
CONTROL STAGE
HALL, ENCODER
INSULATION
STEP
-
DOWN
OP
TIONAL ZIGBEE
MODULE

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2. Connectors description
As in the following figure, you can find the position and the description of the connectors present on the
board. Please refer to the board sche atics for the full description of the connectors.
The E1 connector is used for the progra ing and the debugging of the software running on the RX220.
The external power stage connector is co patible with the power stages, designed for Renesas inverter
kits, which are able to drive 230V
AC
otor up to 1.5KW.
EXTERNAL POWER SUPPLY
CONNECTORS
USB CONNECTOR
EXTERNAL POWER
STAGE CONNECTOR
MOTOR CONNECTOR
HALL
CONNECTOR
E1 CONNECTOR
ENCODER CONNECTOR

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3. Power supply selection
As stated before, there are two ways to supply power to the board.
1. The first possibility is to use directly the PC USB supply. In this case the current you can give to the
otor is li ited by the USB current capabilities.
2. The second possibility is to use an external voltage DC source to supply the board.
The reco ended voltage value is between 12V
DC
and 48V
DC
. In this case the co unication stage is
insulated fro the inverter.
The selection between the two possibilities is ade through two ju pers: JP1 and JP2. Please find below
the description:
1) The first ju per configuration connects the USB ground to the inverter ground and the output of
the step-up converter to the inverter DC link.
Please notice that in this case there is no galvanic insulation between the device connected to the
USB and the board.
2) The second ju per configuration connects the external power supply ground to the inverter ground
and the external + V
DC
to the inverter DC link.
7
7
7
7
7
7
7
7
JP2
JP
1
1
1
3
3
6
6
PC USB SUPPLY SELECTION
7
7
7
7
7
7
7
7
JP2
JP
1
1
1
3
3
6
6
EXTERNAL SUPPLY SELECTION

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. LEDs function description
So e of the LEDs available on the board are directly connected to the hardware and allow the user to
understand the status of the board. Please refer to the LED ap for the following indications:
•DL4 is connected to the output of the 12V step-down DC-DC converter and indicates the presence
of the switches drive supply;
•DL5 is connected to the output of the 5V step-down DC-DC converter and indicates the presence of
the logic power supply;
Other LEDs in the board are driven via software, in particular:
•DL1 is the USB co unication indicator and blinks when there are data exchanges between the PC
and the board.
•DL2 is free for the user (in the default software it is on when the ain interrupt is active).
•DL3 is blinking slowly if the control section MCU (RX220) is running nor ally. In case of hardware or
software alar s, the LED DL3 is blinking quickly.
DL5
DL1
DL3
DL4
DL2

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5. Test points for debugging
Several specific test points are available on the board to visualize with the oscilloscope the behavior of
so e internal analog signals. Further ore, it is possible to visualize internal variables as analog wavefor s
using filtered PWM outputs.
Finally, it is very useful during the tuning process for adapting the software to a new otor to use the test
points.
Please find below the description of the test points:
•TP13, TP1 : are connected to the two USB co unication signals, for debug purposes. Please refer
to the board sche atics for ore details.
•TP , TP5, and TP6: they are connected to the three output of the inverter (sources of the higher
switches).
•TP7, TP8, and TP9: they are connected to the sources of the lower switches of the inverter.
•TP10 is connected to the hardware over-current signal fro the power stage.
•TP11, TP12: they are connected to two digital ports of the icrocontroller (TP11 → Port3Bit5, TP12
→ Port1Bit7) and they can be used as digital outputs or digital inputs.
•TP15 is connected to the board ground.
TP7, TP8, TP9
TP4, TP5, TP6
TP10, TP11, TP12
TP1, TP2, TP3, TP15
TP13, TP14

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•TP1, TP2, TP3 are three filtered PWM outputs which can be used to visualize the behavior of
internal variables.
oIn the standard software TP1 is the output for the syste phase, e.g. esti ated rotor
position
oTP2 is used in the current PI tuning facility to show the nor alized response of the syste to
a current step request.
oTP3 is not used in the standard software.

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6. Internal power stage brief description
The power stage is a co plete 3-phase bridge co posed with discrete low voltage power MOSFETs.
The MOSFETs are the Renesas RJK065 DPB n-channel power MOSFETs. Please refer to the data-sheet for
the switches characteristics and to the board sche atics for the details on the driving circuit.
The axi u current is 30A, and the axi u voltage is 60V
The inverter has the classical sche a with the three shunts on the lower ar s:
CURRENT READING
SHUNTS
3 PHASES BRIDGE

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7. Interface with an external power stage
Since internal power stage allows only the anage ent of low voltage otors, an interface with an
external power stage has been developed.
The selection between the internal power stage and the external power stages is ensured by ju pers. It is
a safe way to ensure that the right voltage and current signals are active.
When the external power stage is connected to the kit, it is by default the active one. So the
icrocontroller pins are directly connected to the external power stage connector.
In this case the internal power stage should be disconnected, and this ust be done by disconnecting the
appropriate ju pers.
Please find below the ju pers description.
•JP7: if closed, then the internal power stage DC Bus voltage is connected to the opportune A/D
converter pin.
•JP8, JP9, and JP10: if closed, then the internal power stage currents easure ents (U, V, W) are
connected to the opportune A/D converter pins.
•JP11 to JP16: if closed then the inverter driving signals are connected to the internal power stage
drivers.
•JP5: if closed, the external power stage 5V is connected with the internal one.
•JP6: it allows the following selection:
POWER SUPPLY
SELECTION: JP5
AND JP6
INVERTER DRIVING
SIGNALS: JP11 TO 16
ANALOG MEASUREMENT
SIGNALS: JP7 TO 10

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o if pins 1 and 2 are shorted, then the external power stage low voltage supply (between 15V
to 24V) is connected to the internal DC Bus Voltage; in this case both the step-down
converters of the board will work;
oIf pins 2 and 3 are shorted, then the external power stage low voltage supply (between 15V
to 24V) is connected to the internal driving circuit supply; in this case only the step-down
converter which generates the internal logic supply will work.
Please be careful to take into account the following precautions:
1. Please avoid to connect both the external power stage connector (J6) and to close the ju pers JP5
to 16: this would produce short circuits between signals co ing fro different sources.
2. In JP6, chose the configuration with the pins 1 and 2 shorted, while pin 3 is open, in order to avoid
supplying so e internal circuits with a too high voltage.
Please find below the drawing of the interface connector.
For a co parison, find below the drawing of the corresponding connector in the MCRP07 external power
stage (E6108A).
If using a different external power stage, please keep present the following notes:

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a) The PWM drive signals are directly connected to the icrocontroller output pins, and there is no
pull-up or pull-down resistor connected, so the polarization has to be done in the power stage. In
case of alar , the icrocontroller output pins can be placed in high i pedance state, so the
external polarization is necessary. These output co ands are logic level signals, with li ited
current output capability, so an external driver is probably required. A further line is connected to
the icrocontroller: it is the external alar signal, connected to the POE input pin; this pin is
polarized with a 10K pull-up toward the logic supply.
b) The analog easure ent signals fro power stage, in particular the current readings and the DC
link voltage reading are cla ped (with diodes fro logic GND and to logic V
cc
) and weakly filtered,
then directly connected to the A/D converter input pins of the icrocontroller, so the external
power stage has to take care of the gain and the offset of these signals.
c) The ground connection is always active, and it represents the reference for all the interface signals.
In the next figure a si ple exa ple regarding how the power board connections have to be arranged is
presented. In this sche a it is supposed that the power board has its own supply for the power odule
(+15V); this supply is also used to supply the icrocontroller (thanks to ju per JP5 in icrocontroller
board); the 5V supply for current sensors and for the signal polarization is derived fro the icrocontroller
board (through JP5).
Please refer to the co plete sche atics for further details.

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+
VBUS
+5V
Intelligent
Power
Module
OUT V
OUT W
PWGND
UL
VL
WL
UH
VH
WH
ALRM
GND
VCC
VBUS
OUT U
+15V
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
MOTOR
1
2
3
+5V
Current
Sensor
+5V
Current
Sensor
+5V
Current
Sensor
+5V
THERMAL SENS
OR
+15V

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8. Single shunt current reading
While the nor al configuration of the board and the standard software are based on three shunts current
reading, we also offer the possibility to configure the board for single shunt current reading. So e
hardware odifications are required, and a different software version has to be loaded.
The required hardware odifications are the following (please refer to the board sche atics):
•Re ove fro the board R90 and R96 (they are the shunts related to the phases U and W).
•Close the soldering points PS1 and PS2 (those soldering points put the three inverter har s in
co on, below the lower switches and above the shunts).
•Change the value of R119 and R128 fro 3K3 to 1K (this will adapt the gain of the over-current
detection circuit).
•Re ove the capacitors C70, C72, C85 (it speeds up the current reading circuit).
The co ponents involved in the odifications are indicated in the figure below.
R90, R96
C70, C72, C85
R119, R128
PS1, PS2

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9. Current reading timing in three shunts and single shunt configurations
The figures below show the different situations related to the two configurations. The first figure is related
to three shunts current reading, the other are related to the single shunt current reading.
Three shunts
In the three shunts configuration the current in one shunt is equal to the corresponding phase current
when the corresponding lower switch is ON.
The ost suitable o ent to read the current in this configuration is at the trough of the PWM.
Single shunt
In the single shunt configuration, only when one or two of the lower switches are ON the current through
the shunt is related with the phase current.
When only one of the lower switches is ON, the current in the shunt is equal to the current of the
corresponding inverter phase.
When two of the lower switches are ON, the current in the shunt is equal to the su of the currents of the
corresponding phases that is it is inus the current of the third phase.
Important Note:
Software projects for each ethod are provided for both the High-perfor ance E bedded Workshop
(HEW) and e2studio develop ent environ ents.
The appropriate project for each are listed below.
Three shunts current for HEW: MCRP09_RX220_3_shunts_verXXX
Single shunt current for HEW: MCRP09_RX220_1_shunt_verXXX
Three shunts current for e2studio: YROTATE-IT-RX220_3_shunts_verXXX
Single shunt current for e2studio: YROTATE-IT-RX220_1_shunt_verXXX

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10. Control MCU overview
The RX220 Group is a low power entry-level 32-bit icrocontroller. The RX220 Group of products is the
sli ed-down version of the higher odel RX210 Group, and has very high co patibility in ter s of pin
arrange ent and on the software level.
The ain specifications of the RX220 icrocontrollers are as follows.
Please find below the block diagra of the RX220 icrocontroller:

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11. Permanent magnets brushless motor model
The synchronous per anent agnets otor (sinusoidal brushless otor) is widely used in the industry.
More and ore ho e appliance akers are now using such brushless otor, ainly because of the
intrinsic otor efficiency.
The per anent agnet otor is ade with few co ponents:
1. A stator for ed by stacking sheared etal plates where internally the copper wiring is wound,
constructing the stator winding
2. A rotor in which per anent agnets are fixed
3. Two covers with ball bearings that keep together the stator and the rotor; the rotor is free to rotate
inside the stator
The working principle is quite si ple: if we supply the otor with a three-phase syste of sinusoidal
voltages, at constant frequency, in the stator windings flow sinusoidal currents, which create a rotating
agnetic field.
The per anent agnets in the rotor tend to stay aligned with the rotating field, so the rotor rotates at
synchronous speed.
The ain challenge in driving this type of otor is to know the rotor position in real-ti e, so ainly
i ple entation are using a position sensor or a speed sensor.
In our i ple entation, the syste is using either one or three shunts to detect the rotor position in real-
ti e.
+
+
+
v
a
v
b
v
c
i
a
i
c
i
b
“a” winding
How current flows
into “a” winding
“a” winding
agnetic axis
“b” winding
“c” winding
Motor
axis
(shaft)

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Let’s analyse the otor fro a athe atic point of view.
If we apply three voltages v
a
(t), v
b
(t), v
c
(t) to the stator windings, the relations between phase voltages and
currents are:
dt
d
iRv
dt
d
iRv
dt
d
iRv
c
cSc
b
bSb
a
aSa
λ
λ
λ
+=
+=
+=
- λ
i
is the agnetic flux linkage with the i-th stator winding
- R
S
is the stator phase resistance (the resistance of one of the stator windings)
The agnetic flux linkages λ
i
are co posed by two ite s, one due to the stator currents, one to the
per anent agnets.
The per anent agnet creates a agnetic field that is constant in a plitude and fixed in position in
respect to the rotor. This agnetic field can be represented by vector Λ whose position in respect to the
stator is deter ined by the angle ϑ between the vector direction and the stator reference fra e.
The contribution of the per anent agnets in the flux linkages depends on the relative position of the
rotor and the stator represented by the echanical-electric angle ϑ.
ϑ
Λ
a
a’
b
c
c’
b’
a axis
b axis
c axis
Real axes (a, b, c) and equivalent ones (α, β); a fixed a plitude vector can be co pletely deter ined by its
position respect the (α, β) syste (angle ϑ)
α
α
’
α
axis
β
’
β
’
β
axis

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It is, in every axis, the projection of the constant flux vector Λ in the direction of the axis:
)
3
4
cos(
)
3
2
cos(
)cos(
π
ϑλ
π
ϑλ
ϑ
λ
−Λ+=
−Λ+=
Λ
+
=
mcc
mbb
maa
Li
Li
Li
Supposing that the rotor is rotating at constant speed ω (that is: ϑ(t) = ωt) the flux linkages derivatives can
be calculated, and we obtain:
)
3
4
sin(
)
3
2
sin(
)sin(
π
ϑω
π
ϑω
ϑω
−Λ−+=
−Λ−+=
Λ−+=
m
b
bSc
m
b
bSb
m
a
aSa
dt
di
LiRv
dt
di
LiRv
dt
di
LiRv
A “three phases syste ” ay be represented by an equivalent “two phases syste ”. So the by using
specific transfor ations, our three equations syste is equivalent to a two equations syste . It is basically
a athe atical representation in a new reference coordinates syste .
In the two phases (α,β) fixed syste the above equations beco e:
dt
d
iRv
dt
d
iRv
S
S
β
ββ
α
αα
λ
λ
+=
+=
For the agnetic field equations, we got:
)sin(
)cos(
ϑλλ
ϑ
λ
λ
ββββ
αααα
mm
mm
LiLi
LiLi Λ+=+=
Λ
+
=
+
=
After perfor ing the derivation:
mm
mm
dt
di
L
dt
di
L
dt
ddt
di
L
dt
di
L
dt
d
α
βββ
β
ααα
ωλϑω
λ
ωλϑω
λ
+=Λ+=
−=Λ−=
)cos(
)sin(
Finally, we obtain for the voltages in (α,β) syste :

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mS
mS
dt
di
LiRv
dt
di
LiRv
α
β
ββ
β
α
αα
ωλ
ωλ
++=
−+=
A second reference fra e is used to represent the equations as the fra e is turning at the rotor speed. So
the “d” axis is chosen in the direction of the agnetic vector Λ , and with the “q” axis orthogonal to the
“d” axis. The new reference syste is (d, q).
The reference fra e transfor ations fro the (α,β) syste to the (d, q) syste depends on the
instantaneous position angle ϑ
ϑϑ
ϑ
So we obtain two inter-dependant equations in the (d, q) syste :
md
q
qSq
q
d
dSd
Li
dt
di
LiRv
Li
dt
di
LiRv
Λ+++=
−+=
ωω
ω
These two equations represent the mathematical motor model.
A control algorith which wants to produce deter ined currents in the (d, q) syste ust i pose voltages
given fro the for ulas above.
This is ensured by closed loop PI control on both axis “d” & “q” (Proportional Integral).
Since there is a utual influence between the two axes, decoupling ter s can be used.
1/(R+sL)
1/(R+sL) (3/2)p
Λ
1/(B+sJ)
τ load
p Λ
pL
V d
V q
+
-
+
- -
+
ω mec
I d
I q τ
+
L ω e
Λω e