Renesas YROTATE-IT-RX23T User manual

USER MANUAL
UM-YROTATE-IT-RX23T Rev. 1.0 Page 1 of 83
October 6, 2015
YROTATE-IT-RX23T
Rotate it! – Motor Control RX23T
Introduction
The Renesas Motor Control Kit called YROTATE-IT-RX23T, is based on the RX23T device fro the powerful 32-bit RX
icrocontrollers fa ily running at 40MHz and delivering up to 80DMIPs.
The kit enables engineers to easily test and evaluate the perfor ance of the RX23T 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, ho e appliances inverters 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 or hall sensor. A single shunt current reading ethod is also available to ensure an even ore
co pacter bill of aterial.
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. Further ore, it beco es also possible to select the best switching
frequency and control frequency (e.g. control loop) to adapt the control dyna ics suitable to the application
require ents.
The hardware is designed for easy access to key syste test points and for the ability to hook up to an RX23T debugger
known as E1. 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-RX23T 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: RX23T Microcontrollers Family
UM-YROTATE-IT-
RX23T
Rev. 1.0
October 6, 2015

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 2 of 83
October 6, 2015
Contents
1. Specifications & Hardware overview ....................................................................................................... 3
2. Connectors description ............................................................................................................................. 7
3. Power supply selection ............................................................................................................................. 8
4. L Ds functions description ...................................................................................................................... 10
5. Test points for debugging ...................................................................................................................... 11
6. Internal power stage description ........................................................................................................... 12
7. Current reading methods selection ........................................................................................................ 14
8. Interface to an external power stage ..................................................................................................... 16
9. Single shunt current reading .................................................................................................................. 20
10. Current reading timing in three shunts and single shunt configurations ............................................. 21
11. Website material: www.renesas.eu/motorcontrol .............................................................................. 24
12. Microcontroller RX23T short overview ................................................................................................. 25
13. Permanent Magnets Brushless Motor model ....................................................................................... 27
14. Sensorless Field Oriented Control algorithm ........................................................................................ 32
15. Software Tools used ............................................................................................................................. 33
16. Software description and Resources used ............................................................................................ 37
17. Start-up procedure – mbedded software ........................................................................................... 44
18. Reference system transformations in details ....................................................................................... 46
19. Rotor position estimation..................................................................................................................... 47
20. PC Graphical User Interface in details .................................................................................................. 50
21. PROM parameters: detailed description .......................................................................................... 56
22. Motor Auto-calibration using the PC GUI ............................................................................................. 57
23. Updating the RX23T Flash memory using the Renesas Programming Flash Tool ................................. 68
24. Integration of user code to the motor control algorithm ..................................................................... 73
25. Communication Protocol between the MCU and the PC GUI ............................................................... 74

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 3 of 83
October 6, 2015
1. Specifications & Hardware overview
ITEM
SPECIFICATIONS
TYPE OF MOTORS S PPORTED
3-phase Per anent Magnet Synchronous (PMSM, PMAC, BLAC)
3-phase Brushless DC (BLDC)
KIT MOTOR PARTNAME NANOTEC
DB42S03, 24V
DC
, 4000 RPM
KIT MAX INP T RANGE External power supply fro : 20V
DC
to 48V
DC,
6A
peak
TRANSISTOR SED Renesas Mosfets: RJK0654DPB, 60V, 30A
POWER S PPLY OPTION Either USB connection or external supply: up to 48V
DC
C RRENT DETECTION One or three shunts configuration (10 Ω)
SB IC SED ON THE BOARD FT232R - USB UART IC fro FDTI, 76.6KBd co unication speed
MICROCONTROLLER RX23T (R5F523T5ADFM), 64-pin LFQFP, 40MHz, 64KB Flash, 10KB RAM
MC PERFORMANCE 40MHz, 80DMIPs, 166 CoreMark
KEY FEAT RES Floating Point Unit, 3-phase inverter Ti er
12-bit A/D Converter, fast on-chip Co parators, Port Output Enable
MC EMBEDDED FIRMWARE Sensorless vector control algorith (Field Oriented Control)
SWITCHING FREQ ENCY 4KHz to 64KHz, 16KHz by default (PWM frequency)
CONTROL LOOP FREQ ENCY
(SAMPLING FREQ ENCY) 4KHz to 16KHz, 8KHz by default
CONTROL LOOP TIMING 50µs including debug features and auto-tuning/self-identification
40µs including only the sensorless vector control algorith
CODE SIZE IN FLASH / RAM 24KB / 3KB
TOOL SED, VERSION e²studio 4.0.2.008. , CS+ , RXC Toolchain, CC RX version v2.03.00
COMPILER OPTIMIZATION LEVEL Maxi u , opti ize for speed, little-endian data, RX V2 Core enable
ENVIRONMENT STANDARDS RoHS co pliant including China regulations
WEEE, RoHS

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 4 of 83
October 6, 2015
The inverter kit YROTATE-IT-RX23T is a single board inverter, based on the 32-bit RX series icrocontroller RX23T and
includes a low-voltage MOSFETs power stage and a co unication stage. The PCB is a four layers board and ensure
the anage ent of Per anent Magnet Motors up to 48V
DC
and up to 6A
ax
.
Please find below the content of the YROTATE-IT-RX23T kit:
To obtain the axi u flexibility, the inverter 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 Renesas 32-bit RX23T icrocontroller (e.g. MCU).
•An insulated USB co unication with the PC offering co unication speed up to 76.6KBd.
•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 stages, the first delivering
up to 1.5KW at 230V
AC
and the second up to 60V
DC
, 60A
DC
.
•USB power supply possibility to avoid external power supplies where galvanic insulation is lost.

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 5 of 83
October 6, 2015
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 and a low dropout linear converter, fro the DC bus first to 15V and then to the CPU
supply voltage: 5V, please find below the PCB overview.
The full sche atics and CAD design files (e.g. Gerber) of the inverter kit are available on the website:
www.renesas.eu/ otorcontrol , in the section related to the YROTATE-IT-RX23T develop ent kit.
In the YROTATE-IT-RX23T kit, the RX23T in a 64-pin package was selected to ensure the anage ent of inverter,
external co unications, three shunts, the EEPROM co unication, the E1 debugger, three voltages phases, the
over-current detection, the Bus voltage onitoring, etc.
The picture below is showing the detailed I/O pins assign ent of the RX23T to anage the co plete kit.
ZIGBEE/MCU progra ing or G I
communication selection
COMMUNICATION
STEP
-
DOWN
STEP_UP
EXTERNAL POWER
STAGE INTERFACE
LOW VOLTAGE
POWER STAGE
CONTROL
STAGE
HALL, ENCODER,
ANALOG INPUT
INSULATION
SUPPLY INPUT
OPTIONAL ZIGBEE
MODULE
LINEAR REGULATOR FOR 5V SUPPLY

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 6 of 83
October 6, 2015

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 7 of 83
October 6, 2015
EXTERNAL POWER SUPPLY
CONNECTORS
USB CONNECTOR
EXTERNAL POWER
STAGE CONNECTOR
MOTOR CONNECTOR
HALL
CONNECTOR
E1 CONNECTOR
ENCODER CONNECTOR
ANALOG INPUT CONNECTOR
PMODE
CONNECTOR
CONNECTOR FOR
ICS OSCILLOSCOPE
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 RX23T. It can be
connected either to the E2studio and the CS+ develop ent environ ents.
The external power stage connector is co patible with the power stages, designed for Renesas inverter kits, which
are able, the first one to drive 230V
AC
otor up to 1.5KW, and the second one up to 60V
DC
, 60A
DC
. The sche atics and
Gerber file of the power stage are available on the website: www.renesas.eu/ otorcontrol

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 8 of 83
October 6, 2015
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 power supply voltage is between 20V
DC
to 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:
7
7
7
7
7
7
7
7
JP2
JP
1
1
1
3
3
4
4
6
6
PC SB S PPLY SELECTION
7
7
7
7
7
7
7
7
JP2
JP
1
1
1
3
3
4
4
6
6
EXTERNAL S PPLY SELECTION
JP1, JP2

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 9 of 83
October 6, 2015
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.
Please find below the configuration of the RX23T kit using the internal MOSFETs power stage.
Please find below the configuration of the RX23T kit connected to the external 1.5KW, 230V
AC
power stage.
Power stage ju per JP1: correct
position
Microcontroller board + external power stage board:
Power supply +24V
DC
fro J4 or J5 of the power stage

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 10 of 83
October 6, 2015
4. LEDs functions 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 15V step-down DC-DC converter and indicates the presence of the
switches drive supply;
•DL5 is connected to the output of the 5V linear converter and indicates the presence of the 5V 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 blinking slowly if the control section of the RX23T icrocontroller is running nor ally. In case of
hardware or software alar s, the LED DL3 is blinking quickly.
•DL3 is free for the user and in the default software it is ON when the ain control interrupt is active. It give to
the user a quick and si ple way to easure the ti ing of the control loop of the algorith .
DL5
DL1
DL3
DL4
DL2

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 11 of 83
October 6, 2015
5. Test points for debugging
Several specific test points are available on the board to visualize with the oscilloscope the behaviour 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, TP14: are connected to the two USB co unication signals, for debug purposes. Please refer
to the board sche atics for ore details.
•TP4, TP5, and TP6: they are connected to the three inverter outputs (sources of the higher switches)
•TP7, TP8, and TP9: they are connected to the sources of the lower switches of the inverter
•TP1, TP3, TP12, TP15, TP16: they are connected to so e icrocontroller ports
•TP17, TP18, TP19 are connected to the board GND
•TP10, TP11 are two filtered PWM outputs which can be used to visualize the behaviour of internal
variables
•TP2 not used
TP9, TP8, TP7
TP6, TP5, TP4
TP2
TP18, TP17, TP12, TP1, TP3
TP19, TP10, TP11, TP15,
TP16
TP13, TP14

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 12 of 83
October 6, 2015
6. Internal power stage description
The power stage is a co plete 3-phase bridge co posed with discrete low voltage and high current MOSFETs. The
MOSFETs are the Renesas RJK0654DPB n-channel power MOSFETs. Please refer to the data-sheet available on the
Renesas website: www.renesas.eu 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
DC
.
The inverter has the classical sche a with the three shunts on the lower ar s, with the possibility to use a single shunt
by re oving two of the .
C RRENT READING
SH NTS
3 PHASES BRIDGE

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 13 of 83
October 6, 2015
Please find below the sche atics extract showing the draying in ode details.
Further ore, the three driving circuits for the six low voltage MOSFETS RJK0654DPB are described below.
Further ore, the signals fro the gate driver circuits called “PUL, PVL, PWL” are used to anage the risk of over-
current in the board. The signals are directly linked to the RX23T Microcontroller odule called the Port Output
Enable (e.g. POE) to stop the PWM signal in hardware and protect the 3-phase power stage.
In case of over-current, the POE odule will set in hardware the six PWM signals in high i pedance ode to ensure
safe-fail echanis . Please find below the extract of the sche atics regarding the over-current anage ent.

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 14 of 83
October 6, 2015
7. Current reading methods selection
As shown in the following figure, so e ju pers are placed on the board (see sche atics): JP7, JP17, JP18, JP8, JP19,
JP20, JP9, JP21 and JP22. The ju pers allows the reading of the otor current by using external operational
a plifiers or internal one as shown here below:
•Configuration 1: external op. amp.: JP7, JP8, JP8 closed, JP17, JP18, JP19, JP20, JP21, JP22 open
•Configuration 2: internal op. amp.: JP7, JP8, JP8 open, JP17, JP18, JP19, JP20, JP21, JP22 closed
NOTE: the RX23T microcontroller family is not equipped with internal operational amplifiers. But the RX24T family
is equipped with on-chip Op-amp, also called Programmable Gain Amplifier (PGA).
Please find below ore details about the circuit used to read the current flowing through the shunts.
MOTOR CURRENT
MEASUREMENT JUMPERS:
JP7, JP17, JP18
JP8, JP19, JP20
JP9, JP21, JP22

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 15 of 83
October 6, 2015
In case of 3-phase Brushless otors that need to be
driven in sensorless block co utation ode, the RX23T
kit integrates the possibility to anage the otor phases
voltage.
These are easured for the back EMF signals detection
using the A/D inputs: AN100 to AN102.
Please find on the right the detailed sche atics ade for
the phase voltages reading.

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 16 of 83
October 6, 2015
8. Interface to 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.
•JP10: if closed, then the internal power stage DC Bus voltage is connected to the opportune A/D converter pin.
•JP7, JP8, and JP9: 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.
•JP6: it allows the following selection:
POWER SUPPLY
SELECTION: JP6
INVERTER DRIVING
SIGNALS: JP11 TO 16
VBUS MEASUREMENT
SIGNALS: JP10

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 17 of 83
October 6, 2015
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 cannot be used to supply
the board.
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 JP6 to JP16: 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, when external power supply board is used.
Please find below the drawing of the interface connector.
For a co parison, find below the drawing of the corresponding connector in the 1.5KW, 230V
AC
external power stage
(E6108A).
If using a different external power stage, please keep present the following notes:
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.

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 18 of 83
October 6, 2015
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); +15 to +24V supply
fro power board is also used to supply the icrocontroller (thanks to ju per JP6 in icrocontroller board).
Please refer to the co plete sche atics for further details that are available on the website:
www.renesas.eu/ otorcontrol.
Two power stages are currently available under request, were successfully tested with the YROTATE-IT-RX23T kit.
On the left hand side, the power stage can anage 300V
DC
for 20A and the right hand side 60V
DC
for 100A.

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 19 of 83
October 6, 2015
+VB S
+5V
Intelligent
Power
Module O T V
O T W
PWGND
L
VL
WL
H
VH
WH
ALRM
GND
VCC VB S
O T
+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
THERMAL SENSOR
+15V

RX23T YROTATE-IT-RX23T Motor Control Kit
UM-YROTATE-IT-RX23T Rev. 1.0 Page 20 of 83
October 6, 2015
9. 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 progra into the RX23T flash
e ory.
The required hardware odifications are the following (please refer to the board sche atics):
•Re ove fro the board the shunts 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)
•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.
R96, R90
C72, C70, C85
PS2, PS1