TOSHIBA TPD4204F DC 300V Input BLDC Motor Sensorless Control Circuit User Guide
- June 4, 2024
- Toshiba
Table of Contents
TPD4204F DC 300V Input BLDC Motor Sensorless Control Circuit
User Guide
Introduction
This reference guide (hereinafter referred to as “this guide”) explains the
specifications and steps of operation of the DC 300 V Input BLDC Motor
Sensorless Control Circuit (hereinafter referred to as “this reference
design”).
The fan of the indoor unit of air conditioners is run using a brushless motor
generally driven at a DC 300 V level. Previously, motors were driven mainly by
square-wave energization using Hall sensors, etc., but in recent years, in
response to demands for lower system costs, higher efficiency, and quieter
motors, motors have been driven by sinusoidal energization without the use of
Hall sensors and with vector control.
In this reference design, a microcontroller TMPM374FWUG is used for
controlling the motor, and for implementing sensorless vector control.
An intelligent power device consisting of a switch for a three-phase inverter
and a gate driver in a compact package is used for driving the motor. This
reference design (RD180- 3) uses a TPD4204F (MOSFET built-in type,
withstanding voltage of 600 V, the maximum output current of 2.5 A, and SSOP30
package). This device helps in achieving a high-efficiency motor drive with a
compact board mounting area.
Specifications
Table 2.1 lists the main specifications of this reference design.
Table 2.1 DC 300 V Input BLDC Motor Sensorless Control Circuit Specifications
| Item | Specifications |
|---|---|
| Motor Power Input | DC 120 V to 340 V |
| Control Power Input | DC 15 V, DC 5 V |
| Motor Drive Maximum Current (per Phase) | 2.5 A |
| Motor Drive System | Sensorless Vector Control (Speed Control) |
| Switching Frequency | 15.625 kHz (changeable by software) |
| MC() Control Method | Single MCU Control or External MCU Control |
| Cooling System | Natural Air Cooling |
| Protective Function | Overcurrent of Motor Power Input (10 A by Fuse) |
Overcurrent of Motor Output (Approx. 2.9A each phase)
Board Size
(Including the Accessory Board Part)| 130 x 85 x 53.4 mm
I/O Interface
(Mounted on Accessory Board)| Red LED for Status Display x 3
DIP Switches for Status Setting x 4
Potentiometer for Speed Setting x 1
SWD Input/Output x 1
2.1. Circuit Block Diagrams
Fig. 2.1 shows the block diagram of this reference design.
Fig. 2.1 DC 300 V Input BLDC Motor Sensorless Control Circuit Block Diagram
2.2. External View and Component Layout
Fig. 2.2 and Fig. 2.3 show the external appearance of this reference design,
and Fig. 2.4 shows the layout of the main components.
Fig. 2.2 DC
300 V Input BLDC Motor Sensorless Control Circuit Board Front View (For
RD179-3)
Fig. 2.3 DC 300 V Input BLDC Motor Sensorless Control Circuit External view of PCB (for RD179-3)
Circuit Diagram, Bills of Material, and PCB Pattern Diagram
3.1. Circuit Diagram
Refer to the following file:
RD179-3 (equipped with TPD4204F): RD179-SCHEMATIC3-xx.pdf
(xx is the revision number)
3.2. Component List
Refer to the following file:
RD179-3(equipped with TPD4204F): RD179-BOM3-xx.pdf
(xx is the revision number)
3.3. PCB Pattern Diagram
Fig. 3.1 shows the PCB pattern diagrams of this reference design.
Also, refer to the following file:
RD179-3(equipped with TPD4204F): RD179-LAYER3-xx.pdf
(xx is the revision number)
Description of Circuit Operation
4.1. Name and Function of Components
4.1.1. Shunt Method Setting Solder Jumper (SJP1, SJP2, SJP3, SJP4)
To switch the current detection method, set four solder jumpers as described
below.
Table 4.1 Solder Jumper Settings
| Current Detection System | SJP1 | SJP2 | SJP3 | SJP4 |
|---|---|---|---|---|
| 3-shunt system | Open | Open | Short | Short |
| 1-shunt system | Short | Short | Open | Open |
4.1.2. Motor Power Input Connector (J1)
Used for input DC power to drive the motor.
Fig. 4.2 Motor Power Input Connector on Board (J1)
4.1.3. Motor Connector (J2)
Used for connecting a 3-phase BLDC motor.
Fig. 4.3 Motor Connector on Board (J2)
4.1.4. Control Power Input Connectors (J3, J10)
Used for supplying Input power for control. The connector is a jack-type
connector (inner positive polarity) so it can be supplied using an AC adapter,
etc. J3 is for 15 V input and is used to operate Intelligent Power Device
(TPD4204F). And, J10 is for 5 V input and is used as a power supply for MCU,
peripheral IC, etc. Since both Connectors are of same type, be careful not to
connect them incorrectly.
Fig. 4.4
Control Power Input Connectors (J3, J10) on the Board
4.1.5. Switches and LEDs (S_SW1～4, LED1～3, LEDP1～2)
Switches and LEDs operate as follows.
S_SW1, S_SW2, S_SW3, S_SW4, LED1, LED2, and LED3 are connected to the GPIO
pins of the MCU and are controlled by software.
Fig. 4.5
Switches and LEDs on the Board
Table 4.2 Switch and LED Specifications
| Component | Function | Remark |
|---|---|---|
| S SW1 | (not used) | |
| S SW2 | MCU Control Method | On: External MCU control, Off Single MCU control |
(It should be set to Off in this reference design.)
S SW3| Motor Rotation Direction| On: CW (clockwise), Off: CCW
(counterclockwise)
S SW4| (Not used)|
LED1| Error Indicator| No
Er Error: Off
Error: On or Blink
LED2| Vector Engine Indicator| VE Interrupt in progress: On
LED3| Communication Indicator| Communicating: On
Communication stopped due to error: Blinks every 0.5 seconds
LEDP1| Motor Power ON Indicator| When motor power is ON: On (yellow)
LEDP1 also On while the capacitor is charged. Be careful not to touch the
board while it is On.
LEDP2| Control Power
Supply Energization Indicator| Control power (5 V) energized: On (green)
4.1.6. Potentiometer (VR1)
The potentiometer can be used to set the motor speed (cHZ_MIN to 60 Hz range).
Fig. 4.6
Potentiometer on Board (VR1)
Electric angular rotation
Fig. 4.7
Relationship between potentiometer setting value and rotational speed
4.1.7. External MCU Connector (J7)
Connector for connecting to an external (host) MCU. Not used in this reference
design.
Fig. 4.8 External MCU Connector (J7)
Table 4.3 External MCU Connector Specifications
| Pin | Function | Remark | |
|---|---|---|---|
| 1 | DVDD | Digital power supply (5 V) | |
| 2 | DVS | Digital power supply (GND) | |
| 3 | UART RX | UART Reception | |
| 4 | UART_TX | UART Transmission | |
| 5 | GPIO connection | Reserved (not used) | Same as S SW1 |
| 6 | GPIO connection | Control mode | Same as S SW2 |
| 7 | RESET# | Reset input | To MCU reset |
| 8 | GPIO connection | Reserved (not used) | GPIO connection |
4.1.8. External DAC Connector (J4)
The data to be processed inside the MCU is output as serial data. By
connecting an external DAC, the processing data can be checked as a waveform
using an oscilloscope, etc.
Fig. 4-9 External DAC Connector (J4)
Table 4.4 External DAC Connector Specifications
| Pin | Function | Remarks | |
|---|---|---|---|
| 1 | DVDD | 5 V power output | |
| GND | GND | ||
| 3 | SYNC | DAC sync signal | Uses GPIO |
| 4 | SDO | DAC data | Uses SIO |
| 5 | SCLK | DAC clock | Uses SIO |
4.1.9. Debugger Connector (J5)
20-pin connector for connecting to the emulator/debugger probe. It conforms to
the MIPI-20 connector standard and supports only the SWD interface.
Fig. 4.10. Debugger Connector (J5)
Table 4.5 Debugger Connector Specifications
| Pin | Function | Pin | Function |
|---|---|---|---|
| 1 | VDD(5 V) | 2 | SWDIO |
| 3 | GND | 4 | SWCLK |
| 5 | GND | 6 | SWV |
| 7 | (n.c.) | 8 | (n.c.) |
| 9 | GND | 10 | RESET |
| 11 | (n.c.) | 12 | (n.c.) |
| 13 | (n.c.) | 14 | (n.c.) |
| 15 | GND | 16 | (n.c.) |
| 17 | GND | 18 | (n.c.) |
| 19 | GND | 20 | (n.c.) |
4.2. Operation Check
4.2.1. Preparation
Connect a 3-phase BLDC motor to the motor connector (J2). Connect the DC power
supply to the motor power input connector (J1). Set switch S_SW2 (MCU control
method) on the board to Off (single MCU control). Turn on the power in the
following order: control power (5 V) input connector (J10) → control power (15
V) input connector (J13) → motor power input connector (J1).
4.2.2. Operation Method
The motor is in the stopped state when the potentiometer (VR1) is in Min-
position (0 Hz). The motor can be started by raising the potentiometer (VR1)
setting from the Min- position (0 Hz). If the motor is stopped when the
potentiometer is not in the MIN position, change VR1 to the Min position once.
While in a stopped state, LED1, LED2, and LED3 are turned off.
After motor operation starts, the speed can be varied by using VR1. The closer
VR1 is to the Max position (60 Hz), the faster the rotational speed. The
closer it is to the Min position, the slower the rotational speed. When S_SW3
(rotation direction) is On, the motor rotates in CW (clockwise) direction and
when it is Off, the motor rotates in CCW (counterclockwise) direction.
4.2.3. Operation when Abnormality is Detected
If the following error is detected, the system enters an EMG (Emergency)
state, the motor stops, and the LED1 either blinks or turns on.
- Abnormal voltage detection: When abnormal voltage is detected, LED1 blinks in 250 ms cycles.
- Abnormal current detection: When abnormal current is detected, LED1 blinks in 500 ms cycle.
- Software overcurrent detection: When overcurrent is detected using software processing, LED1 blinks in 1 s cycles.
- Hardware overcurrent detection: When overcurrent is detected using the MCU hardware function, LED1 turns on.
The EMG status is canceled by lowering VR1 to the MIN position.
4.3. Precautions for Use
Pay special attention to the following when operating.
- Jumper setting before energizing must be confirmed. Especially the 3-shunt/1-shunt solder jumper setting must be checked.
- The polarity of connectors and terminals must be correct.
- The smoothing capacitor on the motor power supply takes approximately 10 minutes to get fully discharged. Even after the power is turned off, the board must not be touched until LEDP1 turns off.
- During the operation, the BOARD must be covered with an acrylic case for safety.
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