Application Note

Vector Control of a 3-Phase

AC Induction Motor Using
FMC16100 MCU

AN024702-1006

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applications, or technology described is intended to suggest possible uses and may be superseded.
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Application Notes are tested with the version of ZDS II available at the time of release. Subsequent
releases of ZDS II may require you to modify Application Note code to restore its function.

AN024702-1006
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

iii

Revision History
Each instance in the Revision History reflects a change to this document from its
previous revision. For more details, refer to the corresponding pages or appropri-
ate links given in the table below.

Date Revision Level Section\Description Page No

October 02 eZ80®
Table 6, replaced CPU with 29
2006 Z8 Encore!® and eZ80® CPU User
Manual (UM0077) with eZ8 CPU User
Manual (UM0128).
July 2006 01 All Initial Release All

AN024702-1006 Revision History

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

iv

Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Z8 Encore!® MC Flash Microcontrollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Software Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Variables and Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Event Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Subfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Software Metrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendix A—References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix B—Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix C—Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Appendix D—Flowcharts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

AN024702-1006 Table of Contents

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

List of Figures
Figure 1. Washing Machine Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2. Washing Machine Motor with Tachogenerator . . . . . . . . . . . . . . . . . . . 5
Figure 3. Modular Controller and XP Command Module . . . . . . . . . . . . . . . . . . 5
Figure 4. Hardware Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5. Current Sense Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6. Overcurrent Sense Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7. Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 8. Sampling Space Vector PWM Current (State = 3) . . . . . . . . . . . . . . . 15
Figure 9. Space Vector PWM States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 10. Phase Current Reconstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 11. Park Transform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 12. Inverse Park Transform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 13. Inverse Clarke Transform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 14. PWM Space Vector Modulation (Ground Reference) . . . . . . . . . . . 23
Figure 15. PWM Space Vector Modulation (Neutral Reference) . . . . . . . . . . . . 24
Figure 16. High-Voltage Main Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 17. FMC16 Control Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 18. HV Gate Drive Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 19. HV Power Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 20. Washing Machine Interface Module Schematic . . . . . . . . . . . . . . . . 35
Figure 21. DAC Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 22. XP Command Module Schematic (Connects to Washing
Machine Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 23. Flowchart for the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 24. Flowchart for the PWM ISR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

AN024702-1006 List of Figures

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

vi

List of Tables
Table 1. Sample Interpretation by PWM State . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 2. PWM Duty Cycle by State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 3. Initialization Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 4. Main Loop (ISR) Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 5. Subfunction Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 6. List of References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 7. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

AN024702-1006 List of Tables

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

Abstract
The 3-phase alternating current (AC) induction motors are mechanically simple,
rugged, highly reliable, lower in cost per horsepower than DC motors, and
capable of more torque and efficiency than single-phase AC motors. A 3-phase
AC induction motor can be controlled by varying its inputs according to a
mathematical model of the rotor flux field in a complex vector space (Vector
Control). Vector Control provides efficient and accurate control of the motor’s
speed and torque.
Until now, Vector Control has been the domain of digital signal processors
(DSPs), digital signal controllers (DSCs), and a few 32-bit and 16-bit
microcontrollers. Constant cost pressure and increased consumer expectations
have driven design engineers to seek minimal hardware solutions that extract
maximum performance from motors used in consumer goods.
This application note demonstrates how ZiLOG's Z8 Encore!® MC 8-bit
microcontroller is used to implement Vector Control of an AC induction motor.

Z8 Encore!® MC Flash Microcontrollers

ZiLOG’s Z8FMC16100 Series Flash MCU is based on ZiLOG’s advanced eZ8
8-bit CPU core and is optimized for motor control applications. It supports control
of single and multiphase variable speed motors. Target applications are consumer
appliances, HVAC, factory automation, refrigeration, and automotive applications,
among others.
To rotate a 3-phase motor three AC voltage signals must be supplied, phase-
shifted 120° from each other. To control a 3-phase motor the MCU must provide 6
Pulse Width Modulation (PWM) outputs. The Z8FMC16100 Series Flash MCU
features a flexible PWM module with three complementary pairs or six
independent PWM outputs supporting deadband operation and fault protection
trip input. These features provide multiphase control capability for various motor
types and ensure safe operation of the motor by providing immediate shutdown of
the PWM pins during a fault condition.

Discussion
An electric motor consists of a stationary frame (stator) in which a rotating
component (rotor) is mounted on a shaft and bearings. In a 3-phase AC induction
motor, the stator is laced with three sets of inductor windings energized by three
AC voltage inputs that are phase-offset 120° from each other, producing a rotating
field of magnetic flux inside the motor. This field creates an induced magnetic flux
in short passive windings on the rotor. The stator field exerts magnetic force on
the rotor flux field, resulting in torque on the output shaft.

AN024702-1006 Abstract
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

In a 3-phase motor control application, the input to the motor is produced by a

3-phase inverter bridge. A bridge contains three complimentary source/drain
transistor pairs which connect either ground or high-voltage DC to each of its
three outputs in response to digital control signals from the microcontroller. The
microcontroller uses PWM on the bridge control signals to generate three
approximately sinusoidal AC waveforms on the bridge outputs, with the required
120° phase offset.
The duty cycle of each microcontroller PWM output is varied to control the period
and amplitude of the generated AC signal, which in turn determines the speed
and torque of the motor. The microcontroller senses the resulting AC current and
motor speed and periodically adjusts the AC signal waveform, increasing or
decreasing torque to maintain the appropriate motor speed. For more information
on motor control, see documents listed in Appendix A—References on page 29.

Theory of Operation
In this application, the FMC16100 microcontroller’s PWM module is configured as
three complementary output pairs. Each output pair controls one complementary
source/drain transistor pair in the inverter bridge. The PWM module is configured
to insert a 0.6 µS deadband between ON states to prevent leakage that might
occur if one transistor in a pair turns on before the other is fully off.
Each PWM output pair produces a stream of complementary on/off pulses to
activate the corresponding source or drain transistor in the inverter bridge. The
voltage of each bridge output varies with the source/drain pulse duty cycle.
The period of each PWM cycle is configured to be 50 µS and the PWM module
generates an interrupt request at the end of each cycle. The PWM interrupt
service routine (ISR) leaves the PWM interrupt disabled while it executes, and is
tuned to execute within 200 µS to 250 µS. Therefore, the PWM ISR is executed
every five PWM cycles or 250 µS.
The PWM ISR controls all of the ongoing application program functions after
initialization. The primary goal of the ISR is to update the duty cycle value for each
PWM channel as needed to produce the appropriate AC waveforms at the inverter
bridge outputs.
The PWM duty cycle values are derived from a feedback loop based on rotor
speed and rotor flux position. The stator current waveform is determined by
sampling two phases of the inverter output current and reconstructing the third
phase.
The rotor speed is sampled by a counter/timer configured to measure the period
of a magnetic position sensor on the motor. The measured speed is periodically
compared to the requested speed received through UART from an external
controller. The resulting speed command value is used to create a rotation
reference frame expressed as a two-phase direct/quadrature (DQ) vector.

AN024702-1006 Discussion
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

The resulting vector is regulated to produce the necessary flux and torque
amplitude in the output vector.
An inverse Park transform is used to rotate the reference frame relative to the
rotor position. Then an inverse Clarke transform is used to convert the rotated
two-phase reference frame back into a 3-phase expression. At the same time, the
vector’s position is classified into one of six states, each corresponding to one
sixth of the vector circle.
When the ISR calculates duty cycles for the three PWM channels, one phase is
left unmodulated (ON or OFF for the whole PWM cycle), and the flux vector is
encoded by modulating the other two phases. This reduces switching losses by
one third. The two phases to be modulated depend on the flux vector’s state
position. After the PWM space vector calculation is complete, the corresponding
PWM registers are updated. For more details on the software implementation, see
Software Implementation on page 11.

Description of Components
In addition to the Z8 Encore!® MC microcontroller, this design uses the following
major components:
• Z8 Encore! XP® microcontroller
• Insulated-gate bipolar transistors (IGBTs)
• I2C interfaced 8-bit digital-to-analog converter (DAC)
• Washing Machine Motor

Z8 Encore! XP® Microcontroller

This application employs the Z8 Encore! XP® 8-pin MCUs internal precision
oscillator, 10-bit analog-to-digital converter (ADC), I/O, and UART features to
demonstrate the washing machine application user interface. User commands are
transmitted to the Z8 Encore!® MC MPU as serial data. In theory, this allows very
complex control commands to be transmitted. The demonstrated user interface
consists of a potentiometer for speed control, a pushbutton command input, and a
pushbutton to reset the Z8 Encore! XP® MCU.
Two 6N137 single-channel optocouplers transmit UART command signals while
electrically isolating the user command module from the high-voltage modules.

Insulated-Gate Bipolar Transistors

Six 6SGS5N60RUFD IGBTs are used under PWM control to generate the
required 3-phase AC motor drive current from a high-voltage DC supply. Although
these IGBTs are rated for momentary short-circuit operation, the Z8 Encore!® MC
PWM deadband feature is used to reduce leakage when the IGBTs are switched.

AN024702-1006 Discussion
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

Three IR21064S high-side and low-side gate drivers are used to convert the
Z8 Encore!® MC microcontroller’s CMOS PWM outputs into signals with the
voltage needed to drive the IGBT gate inputs.

Digital-to-Analog Converter
The Z8 Encore!® MC microcontroller’s I2C interface is used with a DAC5574
digital-to-analog-converter to generate up to 4 analog test outputs based on
internal program values. This allows the internal values to be directly compared to
the motor controller’s output waveform on an oscilloscope.

Motor
The motor is a 3-phase AC Induction motor used in washing machine applications
as illustrated in Figure 1.

Figure 1. Washing Machine Application

The application motor is illustrated in Figure 2 on page 5. The motor has the
following specifications:
• Rated Power: 500 W
• RPM max: 15,000 rpm
• Max current: 2.8 Arms
• Continuous current: 1.5 Arms
• DC Bus Voltage: 350 Vdc
The motor windings are connected in the Wye configuration for this application.
The back side of the motor has an integrated Tachogenerator, which consists of
an 16-pole magnet mounted on the shaft and a single-phase winding mounted on
the housing. This produces a sine wave signal whose voltage and frequency are
proportional to the motor speed. The interface to the Z8FMC16100 is a simple
transistor circuit that squares off the sine wave into 3.3 V digital pulses going to
Timer 0 in Capture Restart mode. This gives 8 pulses per revolution.

AN024702-1006 Discussion
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

Figure 2. Washing Machine Motor with Tachogenerator

Application Hardware
The application electronic components and circuitry are divided among several
printed circuit modules that attach to a main board mounted on a heat sink and a
separate user command module, as illustrated in Figure 3.

Figure 3. Modular Controller and XP Command Module

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

Figure 4 is a block diagram of the application hardware design, showing the

logical position of each module in the controller.

HV Main Board

AC 3 Phase AC
Power Stage Induction
Power
Motor

HV HV
Power Drive
Module Module

FMC16
Control
Module
User Interface

XP Washing
Command Machine DAC
Module Interface Module
Module

Figure 4. Hardware Block Diagram

The following sections briefly describe each module of the application hardware.
The schematics are shown in Appendix C—Schematic Diagrams on page 31.

High-Voltage Main Board and Power Stage

The main board serves as the connector backplane for all the other controller
modules. It also provides the high-voltage power stage that converts the single-
phase AC supply to the 3-phase motor control output under PWM control. The
schematic for the main board module is illustrated in Figure 16 on page 31.

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

The power stage section rectifies and filters the single-phase AC supply to provide
a high-voltage DC bus supply. This section also contains the six IGBTs used
under PWM control to generate the 3-phase AC motor drive current.
The MPU is powered after the AC supply is connected, but a normally-open relay
withholds DC power from the IGBTs until the MPU has started and the application
software has completed its necessary startup functions. The application then uses
an I/O port output to enable a simple transistor driver that closes the relay,
powering the IGBTs.

High-Voltage Power Supply Module

The schematic for the power supply module is shown in Figure 19 on page 34.
This module uses an LNK304G IC to convert rectified AC from the power stage to
generate the application’s 120 mA, 12 V supply. This 12 V supply is then regulated
by a UA78M33 IC to provide the 3.3 V supply.

High-Voltage Gate Drive Module

The schematic for the gate drive module is shown in Figure 18 on page 33.This
module contains three IR21064S high-side and low-side gate drivers that convert
the Z8 Encore!® MC microcontroller PWM outputs into the voltage needed to drive
the IGBT gate inputs.

FMC16100 MPU Control Module

The schematic for the MPU module is shown in Figure 17 on page 32. This
module contains the Z8 Encore!® MC microcontroller, a 20 MHz ceramic
resonator, ZiLOG 6-pin DBG interface, and the off-chip components of the high-
voltage current sense and overcurrent detection circuits.

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

Figure 5 illustrates the overall current sense circuit, including some power stage
components and components internal to the MPU. Vref is the internal reference
voltage of the MPU analog-to-digital converter and the full scale input range. At
zero current (zero voltage across Rsense) the output of the Op Amp is at 1/2Vref,
this centers the current waveform at one half of the full input range of the ADC.

Figure 5. Current Sense Circuit

R1 = 10 KΩ
R2 = 100 KΩ
Gain = 10
Vref = 2 V
C1 = unused
C2 = 120 pF

Vref 2V
Rsense = = 10 kΩ × = 0.0125 Ω (0.020 used)
2 × Gain × I_max 2 × 10 × 8A

The Resistive Divider also forms a Low Pass Filter (LPF) to take out the diode
reverse recovery current spike in the current sense signal. Since this is usually in
the MHz frequency range a single pole LPF is sufficient set at a couple of hundred
kHz. As the Operational Amplifier circuit already has a LPF this is more important
for the following comparator circuit.

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

The Cutoff Frequency is calculated as follows:

1 1
ƒc = = = 256 kHz
2π × R1 || R2 × C2 2π × 5 kΩ × 120 pF

Figure 6 illustrates the overall schematic for the overcurrent sense circuit, likewise
including some power stage components and components internal to the MPU.

Figure 6. Overcurrent Sense Circuit

R3 and R4 set the overcurrent trip threshold. Since this is a DC value, a bypass
capacitor (C3) of 0.1 μF is used.
For R4 = 10, R3 is selected as:

(Vref + I_max × Rsense) (2V + 10A × 0.02 Ω)

R3 = R4 × = 10 kΩ × = 12.2 kΩ ≈12.4 kΩ
(Vref – I_max × Rsense) (2V – 10A × 0.02 Ω)

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

10

Washing Machine Interface Module

This module provides the speed control interface between the modular controller
and the washing machine. It consists of the following parts:
• Optoisolated UART command interface
• Motor tachometer/turn sensor
The optoisolator section ensures the electrical isolation of the user command
module from the high-voltage module, and also serves to multiplex the FMC16100
RXD and TXD signals onto a single isolated DATA signal that connects to the
remote Z8 Encore! XP® user command module. Power and ground for the user
side of the optoisolator section are provided by the user command module.
The tachometer/turn sensor section converts the analog rotor-sense signal from
the AC motor to a logic-level DC pulse stream suitable for the Z8 Encore!® MC
timer/counter input.

DAC Test Output Module

This module contains a DAC5574IDGS DAC whose I2C serial interface is driven
by the Z8 Encore!® MC microcontroller. The controller software transmits selected
internal values to the DAC, which converts those digital values to one of four
analog outputs. This allows, for example, the internal reconstructed waveform to
be compared on an oscilloscope to the actual AC output from the power stage.

Z8 Encore! XP® Command Module (External)

The Z8 Encore! XP® user command module is separate and remote from the
modular controller. It requires a separate 12 V power supply, which it regulates to
5 V and 3.3 V for its own use. The module’s clock source is the Z8 Encore! XP®
MPU’s internal precision oscillator. The module includes a 6-pin DBG header, a
reset pushbutton switch, an input pushbutton, and an input potentiometer for
speed control. Command values derived from the input are transmitted to the
controller main board through a single data line connected to both the TXD and
RXD pin of the Z8 Encore! XP® UART. The main board connector also supplies
5 V and GND signals to power the user side of the optoisolator section of the
washing machine interface module.

AN024702-1006 Application Hardware

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

11

Software Implementation
Figure 7 illustrates the functional block diagram of the Vector Control application.

Figure 7. Functional Block Diagram

Variables and Declarations

Declarations set the PWM frequency, the Timer 0 scaling for the Tachogenerator,
and the modulation values. All variables are declared as global for speed of
execution and simplicity of code.
All variables are unsigned. All signed values have separate variables of the form
Name for positive and nName for negative contents. One of these variables is
always zero. Using unsigned math speeds up execution but makes the algorithms
longer in code.
The ADC inputs are treated as 8 bits and the PWM output is 8 bits. Internal
computations generally have 4 extra bits of precision especially in the control
loops that use PI (Proportional Integral) compensators, this prevents rounding
from affecting integrator precision. For Inverse Park Transform (vector rotation)
the concept of a quadrant is used to determine calculations on the unsigned
values.

AN024702-1006 Software Implementation

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

12

The program uses a 128-value sine lookup table, Sine_Table[128]. This table
represents sine values from 0 to 90 Degrees, or approximately 0.7 Degree steps.
Stepping through the table in the forward direction gives sine values from 0 to 90
Degrees and stepping through the table in the reverse direction gives cosine val-
ues from 0 to 90 Degrees. This along with knowledge of the quadrant of the angle
of interest (Theta) allows full reconstruction of sine and cosine values for any
angle between 0 and 360 Degrees.
The polarity table, Polarity_table[8], contains bit masks used to set the polar-
ity bits in the PWMCTL1 register. A 1 bit causes the corresponding channel to
start the next PWM cycle in the ON state. A 0 bit causes the channel to start in the
OFF state.
The ripple compensation table, ripple_table[256], contains pre-calculated bus
voltage ripple compensation factors. See Bus Ripple Compensation on page 20.

Initialization
The following initializations are performed when main() is executed:

Option Bits
The options bits set the PWM Polarity and the WDT default mode.

Oscillator
Oscillator initialization consists of sending an unlock sequence to the oscillator
control register then enabling the external oscillator circuit. After allowing a setting
time of 50 ms the oscillator control register is unlocked again 20 MHz External
Ceramic Resonator

Digital Output
PB7 is used as a digital test pin for code development. This allows testing of the
speed of routines and to check out conditional branching of routines.

Comparator
Used for Overcurrent shutdown.

Op Amp
For current sensing using a single current sense resistor. The op Amp is used to
offset the ground referenced current sense signal to 1 V (half of the 2 V reference)
and the voltage is gained up by a factor of 10. For a sense resistor value of
20 mOhms and a current of +/-4A gained up by 10 this represents a 1 V signal
that can swing +/- 0.8 V.

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

13

ADC
Used for sampling current and DC Bus Voltage.

Relay
The main relay is normally open so the high-voltage power supply is disabled
while the microcontroller starts up. The relay initialization pauses for three
seconds before closing the relay to make sure the high-voltage bus capacitors can
precharge through a resistor. After closing the relay, the program waits another
second to allow the relay contacts to settle.

Current Calibration
Once the peripherals are enabled and have settled out 8 samples of the current
sense channel are taken with zero current. The average of these samples are
used to zero out any offsets in the circuit.

UART
The UART is configured for 9600 baud, 1 start bit, 8 data bits, and 1 stop bit.
UART transmit and receive are tied together for single wire communication. The
3 wires are ground, data, and 5 V. The UART service routine updates every 2 ms.
The service routine is set up for just receiving data in this application. A more
elaborate communication link could be implemented with this hardware.

I2C
I2C is used for an external EEPROM for logging product data. For testing
purposes the I2C interface is used to send data to a 4 Channel DAC. In this
implementation a single channel of the DAC is updated every 250 μs so that one
parameter can be monitored in real time. This provides a method for
troubleshooting and code development, and field orientation tuning using an
oscilloscope. To control the DAC the Z8FMC16100 is set up as the I2C Master at
384 kbps, 2.6 μs per bit. All data is sent to DAC channel A.

Timer0
Timer 0 is used in Capture Restart Mode, the encoder input rising edge is used to
trigger the Capture. If the timer rolls over then the maximum timer count of
0xFFFF is used setting it to the minimum speed.

PWM Module
The 3-phase PWM module is set up in Edge Aligned PWM and the PWM polarity
is controlled to Allow Space Vector Modulation and current sampling and
reconstruction. Each PWM pair is set up in complementary mode with 12 clock

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14

cycles of deadband (0.6 μs). The PWM reload event triggers an ADC conversion.
This is used for current reconstruction.

PWM Interrupt
The PWM reload interrupt is enabled. The PWM ISR constitutes the program
control loop. PWM interrupts are disabled during the ISR until the ISR is complete.

Main Event Loop

After initializations are complete, program control drops into an infinite ‘do nothing’
loop. All subsequent program functions are performed by the PWM interrupt
service routine (ISR), so this ISR is in effect the main event loop. The PWM ISR is
executed on every fifth PWM cycle.

Current Sample
The PWM interrupt is configured to automatically start an ADC conversion that
samples the high-voltage current, so the PWM ISR begins with an ADC
conversion already in progress. The PWM interrupt is edge-aligned, and the
sample takes place before the PWM state change propagates to the inverter
bridge gates. Thus, this first sample captures the current at the end of the just-
completed PWM cycle.
After reading the first sample, the ISR immediately begins another ADC
conversion. This second sample captures the current at the beginning of the new
PWM cycle. This is illustrated in Figure 8 on page 15. Phase currents are then
reconstructed from these samples.

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15

PWM PERIOD PWM PERIOD

1
A
0
1
B
0
1
C
0

Current Sample 1 Current Sample 2

Figure 8. Sampling Space Vector PWM Current (State = 3)

I2C Send Address and Start Bit

Sends the address byte used by the DAC to establish communication. This action
begins a side-process of the PWM ISR. I2C-related instructions are inserted at
intervals to set up and transmit one test value per ISR loop to an external DAC.

Phase Current Reconstruction

Phase current reconstruction is based on the two current samples previously
obtained plus the PWM space vector State. The State value is updated at the end
of each ISR pass to reflect the stator flux vector angle arrived at in that pass. State
positions are shown in Figure 9 on page 16. The State determines how each
current sample is interpreted, as shown in Table 1 on page 16. In this table, the
variables I_a, nI_a, I_b, nI_b, I_c, and nI_c represent the positive and negative
current variables for phases A, B, and C.

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

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180°
STATE 2 STATE 1

240° VB -VC 120°

STATE 3 -VA VA STATE 0

300° VC -VB 60°

STATE 4 STATE 5
360°

Figure 9. Space Vector PWM States

Table 1. Sample Interpretation by PWM State

Current Sample 1 Current Sample 2

PWM State Variable Variable
0 nI_c nI_b
1 I_b I_a
2 nI_a nI_c
3 I_c I_b
4 nI_b nI_a
5 I_a I_c
6 (Not Used)
7 (Not Used)

Using Kirchoff’s current Law and assuming no zero sequence currents (zero
sequence currents are only possible in an imbalanced Delta wound motor not in a

AN024702-1006 Software Implementation

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

17

Wye winding), the sum of three phase currents equals zero. The third current can
be derived from the other two samples using the following equation:
I_a + I_b + I_c = 0
The oscillograph in Figure 10 compares a reconstructed waveform as output to
the DAC at 1 A/330 mV (top trace) to the original waveform as read by a current
probe at 1 A/10 mV.

Figure 10. Phase Current Reconstruction

Test for End of PWM Period

This action begins another side-process of the PWM ISR. PWM interrupts remain
disabled until the main loop ISR returns. However, at several times during the
main loop, the program polls the IRQ0 register to see if a PWM request is
pending. If so, the program clears the request and increments a counter. Near the
end of the main loop, this event counter is used to delay completion of the process
until four PWM request events have occurred, in addition to the one that began
the loop. This process ensures a five-event main loop cycle (250 μs total) without
the need for precise timing of each main loop routine.

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

18

Clarke Transform
A Clarke transform produces a 2-phase (direct and quadrature) representation of
the reconstructed 3-phase stator flux vector. Then a quadrant test is applied to the
reference currents I_ds and I_qs to determine which quadrant the currents are
in. This result is used later in the Park Transform to rotate the 2-phase vector. The
equation for the Clarke Transform is:

1
I_ds = I_a – 2 (I_b + I_c)

2
I_qs = √3 (I_b + I_c)

Angle Update
The angle Theta is updated through the following equation:
Theta = Theta + Speed + Slip
Where:
Theta = rotor flux angle relative to the stator phase A winding
Speed = speed (frequency) of the rotor in terms of the update rate of the control
loop
Slip = slip speed (frequency) required to produce the proper rotor flux

Sine and Cosine Lookup

Sine and Cosine values are generated from an unsigned table of sine values from
0 to 90 degrees contained in a 128 value table (90 Degrees/128steps = 0.7
Degrees/step) Two values are taken from the table one at angle stored in the
variable Sin_1 and one at 128-angle stored in the variable Sin_2.

I2C Send Control Byte to DAC

Sends the control byte used by the DAC to select the DAC output channel.

Park Transform—Vector Rotation

The Park transform rotates the two phase currents referred to the stationary
reference frame of the stator to the rotating reference frame of the rotor flux. This
is illustrated by Figure 11 on page 19. The equation for the Park Transform is:
I_dr = I_ds × cos(Theta) + I_qs × sin(Theta)
I_qr = –I_ds × sin(Theta) + I_qs × cos(Theta)

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

19

I_qs

I_qr

I_dr

Theta
I_ds

Figure 11. Park Transform

I2C Send MSB to DAC

Sends the 8 bit data used by the DAC. This is the internal value that is sent to the
DAC board to allow display of internal values as voltages on the oscilloscope. The
implemented routine sends data to one channel of the DAC updated at the loop
rate. This allows real time display of reference or feedback values.

I_d Regulator
Regulator that controls the direct component of the current vector. This is
regulated by a simple PI regulator.

I_q Regulator
Regulator that controls the quadrature component of the current vector. This is
regulated by a simple PI regulator.

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

20

Quadrant Test
A quadrant test is applied to the reference currents I_dr and I_qr to determine
which quadrant the currents are in. This result is used later in the Inverse Park
Transform to rotate the 2-phase vector. Reference currents I_dr and I_qr are
calculated in the Speed_reg() subroutine.

I2C Send LS Byte to DAC

The DAC is only 8-bits resolution so this is a don’t care byte required by the DAC.

Read Bus Voltage

The bus voltage is sampled through the microcontroller’s ADC. Currently this is
used for ripple compensation, but it could also be included in field weakening
calculations or used for over-voltage shutdown protection.

Bus Ripple Compensation

This routine tracks changes in the bus voltage and looks up a precalculated ripple
compensation factor which is inversely proportional to the ADC sample of the bus
voltage. The PWM duty cycle is scaled by this factor to compensate for variations
in the DC bus voltage, so that a smaller factor value corresponds to a reduced
PWM duty cycle. This clamps the output waveform to a nominal voltage.
This application uses a nominal bus voltage of 225 VDC. At this voltage, the
output factor is 255 (full scale, no compensation). The factor scales down to 0 at
375 VDC or higher, providing an overvoltage shutdown. Between 225 VDC and
375 VDC, the lookup table values are calculated using the following equation:

ADC_vbus_nom
pwm_correction = × 255
ADC_vbus

Inverse Park Transform—Vector Rotation

The Inverse Park transform rotates the two phase voltages referred to the rotating
reference frame of the rotor flux to the stationary reference frame of the stator.
This is illustrated by Figure 12 on page 21. The equation for the Inverse Park
Transform is:
V_ds = V_dr × cos(Theta) – V_qr × sin(Theta)
V_qs = V_dr × sin(Theta) + V_qr × cos(Theta)

AN024702-1006 Software Implementation

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

21

V_qs

V_qr

V_dr

Theta
V_ds

Figure 12. Inverse Park Transform

I2C Send Stop Bit to DAC

A stop bit is sent to terminate the I2C communication.

Inverse Clarke Transform

The Inverse Clarke Transform converts the two phase voltages of the rotated DQ
reference frame to the ABC reference frame of the stator windings. This is
illustrated by Figure 13 on page 22. The equation for the Inverse Clarke
Transform is:

V_a = V_ds
1 2
V_b = 2 (V_ds) + √3 (V_qs)
1 2
V_c = 2 (V_ds) – √3 (V_qs)

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

22

I_q

I_b

I_a=I_d

I_c

Figure 13. Inverse Clarke Transform

PWM Space Vector Modulation

Space Vector Modulation starts with the 6 states that represent the 6 voltage
vectors VA, –VC, VB, –VA, VC, and –VB. Table 2 shows the PWM duty cycle
calculation used for each state. States 6 and 7 represent the unmodulated phase
(OFF or ON).

Table 2. PWM Duty Cycle by State

PWM Duty Cycle

PWM State Phase A Phase B Phase C

0 100% 100%– V_b 100%– V_c
1 V_a V_b 0%
2 100%– V_a 100% 100%– V_c

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Table 2. PWM Duty Cycle by State (Continued)

PWM Duty Cycle

PWM State Phase A Phase B Phase C

3 0% V_b V_c
4 100%– V_a 100%– V_b 100%
5 V_a 0% V_c
6 0 0 0
7 100% 100% 100%

Figure 14 illustrates an example of PWM space vector modulation at a PWM

magnitude of 75 out of 125, referenced to DC Ground.

Figure 14. PWM Space Vector Modulation (Ground Reference)

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 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

24

Figure 15 illustrates an example of PWM space vector modulation at a PWM

magnitude of 75 out of 125, referenced to Neutral.

Figure 15. PWM Space Vector Modulation (Neutral Reference)

Watchdog Timer Refresh

Refreshes the Watchdog Timer once every loop update (250 μs). A reset occurs if
the oscillator or a fault in the code disrupts operation for more than 200 ms.

Subfunction Service Routine

The subfunctions are subroutines that don’t need to be updated every time the
PWM ISR executes. There are ten subroutine calls arranged in a round-robin
sequence so that only one call is executed per ISR loop. Therefore, each call is
executed once every 2 ms. Not all round robin slots are needed for the currently
implemented subfunctions. The remaining slots are available for future expansion.

Subfunctions
Tachometer Update
The Tachometer update routine looks at the latest Capture Value from Timer 0.
The routine checks for a roll-over, if it detects a roll-over then the maximum
counter value of 0xFFFF is used to calculate speed. Also a rate limit is put on the
variable Speed_step to make sure noise doesn’t cause erratic speed readings. In
case of an optical encoder you can have the phenomena of edge jitter, when and
encoder line is on the edge of the optical pick-up and the motor is at stand still,
and movement in the motor can cause fast edges that can be interpreted as

AN024702-1006 Software Implementation

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

25

sensing high speed. This is filtered out by not allowing a jump in speed. The
Tachometer update function is divided into three subfunction calls to limit the
execution time for each call.

Field Weakening
Currently not developed for this application.

Slip Update (Current Model)

Currently not developed for this application

Speed Regulator
The speed regulator is a standard Proportional Integral (PI) regulator. The
command comes from the UART and the speed feedback comes from the
Tachometer.

UART Communication
The UART communicates with the Z8 Encore! XP® module that simulates a
washing machine control panel. The control module has a potentiometer and two
momentary switches. The potentiometer setting determines the transmitted speed
command. Switch 1 stops/starts communication (stopping the communication
stops motor).
The control module sends a single command byte that is read at each UART
update. Bits 7:1 of the command byte are the speed command (MSB of the
control module’s ADC sample). Bit 0 reflects the controller module Switch 2
status, which is used to control the motor direction.
Acknowledge byte from motor controller: AAh
The UART baud rate is 9600 Baud.

Software Metrics
Table 3 illustrates the execution time for each program initialization routine,
executed once at startup.

Table 3. Initialization Execution Times

Routine Time
init_osc 50 ms
init_out 1 µs
init_comp 1 µs
init_amp 2 µs

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26

Table 3. Initialization Execution Times (Continued)

Routine Time
init_adc 2 µs
init_relay 4s
init_current 32 µs
init_uart 2 µs
init_i2c 3 µs
init_timer0 3 µs
init_pwm 5 µs
init_pwmint 1 µs

Table 4 illustrates the execution time for each routine in the PWM ISR, executed
every 250 μs (4 kHz loop).

Table 4. Main Loop (ISR) Execution Times

Routine Time (µs)

Current Sample 5
I2C Send Address and Start Bit 1
Current Reconstruction 14
Clarke Transform (3=>2 Conversion) 18
PWM Period Test 1
Theta Update 6
Sine and Cosine Lookup 3
I2C Send Control Byte 1
Park Transform (Vector Rotation) 28
PWM Period Test 1
I2C Send MSB 1
I_d Regulator 13
I_q Regulator 13
Quadrant Test 5
I2C Send LSB 1
Bus Voltage Sample 1

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

27

Table 4. Main Loop (ISR) Execution Times (Continued)

Routine Time (µs)

Bus Ripple Compensation 3
PWM Period Test 1
Inverse Park Transform (Vector 28
Rotation)
PWM Period Test 1
I2C Send Stop Bit 1
Inverse Clarke Transform (2=>3 18
Conversion)
PWM Period Test 1
PWM Space Vector Modulation 33
PWM Period Test 1
WDT refresh 1
Sub Function (stepped through list) 26

Subtotal 224
End of PWM Period Test Variable

Total 250

Table 5 illustrates the execution time for each subfunction routine,

executed every 2 ms.

Table 5. Subfunction Execution Times

Subroutine Time (µs)

Tachometer Update 1 of 3 7
Tachometer Update 2 of 3 26
Tachometer Update 3 of 3 2
Field Weakening Unused
Slip Update Unused
Speed Regulator 26
UART Communication 4

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Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

28

Summary
The purpose of this application is to demonstrate how a Z8 Encore!® MC
microcontroller is used for efficient rotor flux field oriented vector control of a
3-phase AC induction motor. The following microcontroller features make this part
particularly suited to motor control applications:
• The eZ8 processor core runs at up to 10 MIPS with a 20 MHz clock.
• The integrated PWM interface module provides the necessary timing and logic
outputs for synthesizing 3-phase voltage in motor control applications.
• The 2.5 μs successive approximation register (SAR) ADC can be triggered by
PWM events for sampling and reconstructing phase currents. The integrated
Op Amp amplifies and provides offset adjustment of a single ground-
referenced sense resistor, centered to one-half of the built-in ADC reference.
The integrated comparator provides for fast overcurrent shutdown.
• The integrated communication peripherals (UART, I2C, and SPI) provide for
system level communication. For example, the UART in this application
provides a highly capable user command interface, yet simple enough to be
optically coupled for electrical isolation.
In addition to the Z8 Encore!® MC microcontroller’s native advantages, the
software design uses the following techniques to manage the processing task:
• To make time for the waveform calculations, the main loop operates at one
fifth of the 20 kHz PWM chop rate (five 50 μs cycles, 250 μs per loop). This
preserves most of the advantages of a high-frequency PWM rate, while still
producing a good approximation of the appropriate output waveform.
• To free up additional time for main loop calculations, low-priority subfunctions
are called in a 10-position round-robin schedule, so that each subfunction is
executed only once every 2.5 ms. The lengthy tachometer update operation is
further divided into three subfunction calls to limit execution time per call.
• Converting current measurements to a 2-phase vector for the rotation
transform reduces calculation time compared to rotating a 3-phase vector.
• All signed values are expressed as pairs of unsigned variables. This requires
extra code to perform an if-then-else for each calculation, but the eZ8
processor’s short-range branch instructions are efficient enough so the
unsigned calculations can execute faster than the equivalent library routines,
which are written for general-case signed arithmetic.
The example application and techniques described in this document should prove
helpful for anyone who intend to develop motor control applications based on the
Z8 Encore!® MC family of microcontrollers.

AN024702-1006 Summary
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

29

Appendix A—References
Further details on this topic and the eZ80® family of products is available in the
references listed in Table 6.

Table 6. List of References

Topic Document Name

Z8 Encore!® CPU eZ8 CPU User Manual (UM0128)
Z8FMC16100 MCU Z8FMC16100 Series Product Specification (PS0246)
Motor Control Hsu, P.,. “A Short Course on Vector Control”. San Jose State University, pp.
49-54, 1996.
Garcia, G., Stephan R. & Watanabe E. “Comparing the Indirect Field-Oriented
Control with a Scalar Method”. IEEE Trans. Ind. Electronics, vol. 41 Nº2, pp.
201-207, April 1994.
Trzynadlowski, M., Andrzej “Control of Induction Motors”. Academic Press, pp.
102-105, 2001.
Ned Mohan, “Short Course on Electric Drives: Understanding Basics to
Advanced Control & Encoder-Less Operation.” University of Minnesota, 2005
(A recording of the internet-based short course presented on May 12, 2005 by
Professor Ned Mohan, edited to fit on one Video DVD.)

AN024702-1006 Appendix A—References

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

30

Appendix B—Glossary
Definitions for terms and abbreviations used in this application note that are not
commonly known are listed in Table 7.

Table 7. Glossary

Term/Abbreviation Definition
ADC Analog-to-Digital Converter
DAC Digital-to-Analog Converter
IGBT Insulated-gate bipolar transistor
ISR Interrupt Service Routine
PI Proportional plus Integral
PWM Pulse Width Modulation
Rotor Rotating cage and windings of AC motor
Stator Stationary windings of AC motor

AN024702-1006 Appendix B—Glossary

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
31
Appendix C—Schematic Diagrams
Figure 16 through Figure 22 are the schematic diagrams for the Vector Control application modules.

1 2 3 4 5 6

MTHOLE1
HIGH VOLTAGE POWER STAGE HEATSINK

M_FGND
M_4_DC_IN M_R4 MTHOLE
M_5_VBUS TEMP SENSOR
4

CL-140
M_TEMP MTHOLE2
MTHOLE
M_R7 M_Q1 M_Q3 M_Q5

1
1.00M M_6_AH SGS5N60RUFD M_7_BH SGS5N60RUFD M_8_CH SGS5N60RUFD
M_R17 MTHOLE3
D + M_C2 10k NTC MTHOLE D
3 M_3_DIV 2322 640 66103
M_1_AC 2 M_6_PH_A A M_7_PH_B B M_8_PH_C C
1000uF 200V MTHOLE4
ESMQ201VSN102MR30S M_R6 M_C3 M_C4 MTHOLE
2 5 1.00M 22nF 400V 22nF 400V M_GND
Rectifier B32529B6223J B32529B6223J M_12V
GBU6J M_K1 M_Q2 M_Q4 M_Q6
RELAY_JS1A-12V

3
M_D1 M_GATE_AL SGS5N60RUFD M_GATE_BL SGS5N60RUFD M_GATE_CL SGS5N60RUFD
M_3_CENTER_TAP M_V+
M_RELAY
M_12V

2 M_D2
BAS16
M_2_AC 3

1
+
M_C1 M_R5 M_RELAY
1000uF 200V 10.0k M_R1 M_RSENSE M_R2 10.0k M_CS+
ESMQ201VSN102MR30S 0.020 OHM
ERJ-M1WSF20MU M_R18
M_GND M_R3 10.0k M_CS- M_ENABLE M_BASE
2K
M_Q7
MMBT2N2222A

M_GATE_AL

M_GATE_BL

M_GATE_CL
1

M_6_PH_A

M_7_PH_B

M_8_PH_C
M_6_AH

M_7_BH

M_8_CH
M_GND

M_GND

M_GND

M_GND
C C

BEMF DIVIDERS
AC POWER

1
2

1
2

1
2

1
2

1
2

1
2
M_6_PH_A M_7_PH_B M_8_PH_C
pad 2 pad 2 pad 2 pad 2 pad 2 pad 2 M_P1
MG_J5 MG_J4 MG_J9 MG_J8 MG_J13 MG_J12 M_1_AC
1
M_R10 M_R13 M_R16 M_2_AC
2
UNUSED UNUSED UNUSED M_12V HV GATE DRIVE MODULE M_3_CENTER_TAP
1 3
M_GND MG_J1 M_FGND
2 4
pad 2
EDGE 4 HV
M_9_DIV M_10_DIV M_11_DIV MG_J2 MG_J3 MG_J6 MG_J7 MG_J10 MG_J11
pad 2 pad 2 pad 2 pad 2 pad 2 pad 2

1
2

1
2

1
2

1
2

1
2

1
2
M_R9 M_R12 M_R15
UNUSED UNUSED UNUSED ME_J1
DAC MODULE MOTOR
M_GND

M_GND

M_GND

M_GND

M_GND

M_GND
M_AH

M_AL

M_BH

M_BL

M_CH

M_CL
M_P2
M_VA M_VB M_VC
1
4
3
2
1

M_6_PH_A
1
2

1
2

1
2

1
2

1
2

1
2
2
B MW_J1 M_7_PH_B B
3
pad 2 pad 2 pad 2 pad 2 pad 2 pad 2 M_3_3V MW_J4 M_8_PH_C
1 4
M_R8 M_R11 M_R14 M_3_3V MC_J3 MC_J4 MC_J5 MC_J6 MC_J7 MC_J8 M_GND
1 2 1 5
UNUSED UNUSED UNUSED M_SCL M_T2
2 WASHING 2 6
M_SDA MC_J17 Pad2 M_T1
3
M_GND pad 4 pad 2 HV EDGE 6 HV
4 MACHINE
MW_J2
M_GND M_VC
1 INTERFACE
M_GND
2
M_ENABLE FMC16 CONTROL MODULE
1 MODULE
M_GND MC_J2 Pad2 OPTO UART
2
pad 2
M_4_DC_IN

MC_J10 MW_J3 MW_J5 M_P3

M_RXD M_ISO_VCC
M_GND

1 1 1 1
M_3_3V M_TXD M_ISO_DATA
1 2 2 2 2
M_GND MC_J1 M_GND M_ISO_GND
2 3 3 3 3
M_5_VBUS pad 2
MC_J16 MC_J15 MC_J14 MC_J13 MC_J12 MC_11 Pad3 Pad3 pad 3 EDGE3
pad 2 pad 2 pad 2 pad 2 pad 2 pad 2
M_GND AUX POWER
1
2

1
2

1
2

1
2

1
2

1
2

1
2

1
2

1
2

M_P4
M_C5 M_C6 pad 2 HV pad 2 pad 2 M_12V
1
4700pF 4700pF MP_J1 MP_J2 MP_J3 M_GND
2
M_TEMP

A EDGE2 A
M_GND

M_GND

M_GND

M_GND

M_GND

M_CS+
M_CS-
M_V+

M_VA

M_VB

M_VC

HV POWER SUPPLY MODULE

M_FGND Title
HV MAIN BOARD
TP1 M_GND Size Number Revision
GND
B 96C1024-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes\
Drawn By:
1 2 3 4 5 6

Figure 16. High-Voltage Main Board Schematic

AN024702-1006 Appendix C—Schematic Diagrams
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
32
1 2 3 4 5 6

C_P8
C_VREF
1
C_GND
2
con 2
C_R1 C_R3 C_R4 C_P16
C_P7 10.0K 10.0K 10.0K C_V+
1
C_GND
1 2
D C_GND D
2
con 2
con 2
C_P15
C_P6 C_C1 C_3_3V C_R15 C_VA
1
C_C2 UNUSED
1 2
C_GND 0.1uF C_R2 C_GND
2
12.4K 100pF con 2
con 2
C_P14
C_P5 C_3_3V C_R14 C_VB

C_NRESET
C_GND
1

C_ENABLE
UNUSED

C_CINP
1 2

C_DBG
C_GND C_GND

C_CH
C_BL
2

C_CL
con 2
con 2
C_U1 C_P13
C_P4 Z8FMC16_32LQFP C_3_3V C_R13 C_VC

16
15
14
13
12
11
10
1

9
1 10K 2
C_GND C_GND
2
con 2

PA7/FAULT1/T0OUT/COUT
PA2/CINP
DBG
RESET/FAULT0
PC0/T0OUT
PWM2H
PWM1L

PWM2L
con 2
C_P12
C_P3 C_VREF C_R10 C_TEMP
1
C 1 10.0K 2 C
C_GND C_GND
2
con 2
con 2
C_BH 17 8 C_CS+ C_P11
PWM1H PA1/OPINP/CINN
C_AL 18 7 C_CS- C_CS+
PWM0L PA0/OPINN 1
C_AH 19 6 C_VREF C_CS-
PWM0H VREF 2
C_GND 20 5 C_GND
GND AGND
C_XOUT 21 4 C_3_3V con 2
XOUT AVDD
C_XIN 22 3 C_VA
XIN PB0/ANA0/T0IN0
C_3_3V 23 2 C_VB
VDD PB1/ANA1/T0IN1
C_SCL 24 1 C_VC
PA3/TXDE/SCK/SCL PB2/ANA2/T0IN0
C_Y1

PB3/ANA3/OPOUT
C_C5 C_C6 C_C12 C_C13
PA6/CTS/SS/SDA

PB4/ANA4/CINN
PA4/RXD/MISO

1 3
PA5/TXD/MOSI

C_C7 C_C8 C_C9 C_C10 C_C11

1 3
0.1uF 0.01uF 0.1uF 10uF 6.3V
CCR20.0MXC7T 2200pF UNUSED UNUSED 0.01uF 0.1uF 0805
PB7/ANA7
PB6/ANA6
PB5/ANA5
2

20MHz C_GND
2

C_GND
25
26
27
28
29
30
31
32

C_C14
C_CURRENT

B B
C_P2
C_ENABLE
C_TEMP

1 TP1
C_GND UNUSED
C_CMD

2 CURRENT
C_V+

CON2 C_R9

C_P1 49.9K
C_3_3V
1
C_GND C_3_3V
2
DBG
con 2 INTERFACE

C_R11 C_P18
C_P17 10.0K C_R12
1 2
C_3_3V 10.0K
1 3 4
C_SCL
2 5 6
C_SDA
3 C_GND C_NRESET HEADER 3X2
4 TP2
C_DBG
con 4 TEMP C_C19
C_GND
C_C18 2200pF
A A
CP10 C_C17 UNUSED
C_RXD Title
1 FMC16 CONTROL MODULE
C_TXD UNUSED
2
C_GND C_GND
3
Size Number Revision
CON3
B
96C1020-001 A
Date: 12-Jul-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes\
Drawn By:
1 2 3 4 5 6

Figure 17. FMC16 Control Module Schematic

AN024702-1006 Appendix C—Schematic Diagrams

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
33
1 2 3 4 5 6

GATE DRIVE MODULE

G_12V
G_12V G_D1
2 US1J1 G_6_VB

G_P2
G_AH
1
G_GND G_U1 G_R1 49.9 G_P5
2
1 G_6_AH G_C3 + G_C4
VCC 1
+ G_C1 G_C2 con 2
D 2 D
2 13 0.1uF 10uF 16V
HIN VB
10uF 16V 0.1uF G_P3 con 2
UWX1C100MCL2GB 3 12 UWX1C100MCL2GB
G_AL G_6_HO
1 LIN HO
G_GND
2
11 G_6_PH_A
VS
con 2
G_GND 5
VSS
6
COM
7
LO
IR21064S
G_R2 49.9 G_P4
G_LO_A G_GATE_AL
1
2
con 2

C G_12V
G_12V G_D2
2 US1J1 G_7_VB C

G_P6
G_BH
1
G_GND G_U2 G_R3 49.9 G_P9
2
G_P1 1 G_7_BH G_C7 + G_C8
VCC 1
G_12V + G_C5 G_C6 con 2
1 2
G_GND 2 13 0.1uF 10uF 16V
2 HIN VB
10uF 16V 0.1uF G_P7 con 2
UWX1C100MCL2GB 3 12 UWX1C100MCL2GB
con 2 1 G_BL
LIN HO
G_7_HO
G_GND
2
11 G_7_PH_B
VS
con 2
G_GND 5
VSS
6
COM
7
LO
IR21064S
G_R4 49.9 G_P8
G_LO_B G_GATE_BL
1
2
con 2
B B

G_12V
G_12V G_D3
2 US1J1 G_8_VB

G_P10
G_CH
1
G_GND G_U3 G_R5 49.9 G_P13
2
1 G_8_CH G_C11 + G_C12
VCC 1
+ G_C9 G_C10 con 2 2
2 13 0.1uF 10uF 16V
HIN VB
10uF 16V 0.1uF G_P11 con 2
UWX1C100MCL2GB 3 12 UWX1C100MCL2GB
G_CL G_8_HO
1 LIN HO
G_GND
2
11 G_8_PH_C
VS
con 2
G_GND 5
VSS
6
COM
7
LO
A IR21064S A
G_R6 49.9 G_P12
G_LO_C G_GATE_CL Title
1
2 HV GATE DRIVE MODULE
con 2 Size Number Revision
Orcad B 96C1017-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes
Drawn By:
1 2 3 4 5 6

Figure 18. HV Gate Drive Module Schematic

AN024702-1006 Appendix C—Schematic Diagrams
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
34
1 2 3 4 5 6

D D

15V POWER SUPPLY

P_R2 16.5k
P_2_FB P_2_OUT

1
P_U1 P_R1 UWX1C100MCL2GB P_D2
P_2_BP 3.3V POWER SUPPLY
P_1_VBUS 5 4 P_C1 2.00k + P_C2
D FB US1J
C 3 C
BP
0.01uF 10uF P_L1 UA78M33CSCYR

2
P_P1 7 2 P_12V 1 3 P_3_3V
S7 S2 VI VO

GND
1
8 1 1mH P_C4
2 S8 S1 B82477G4105M
P_D1 + P_C3 P_P2 P_C5 + P_C6 P_P3
con 2 HV LNK304G 0.1uF P_U2
0.2" Spacing 1 1
US1J 100uF 16V 0.1uF 100uF 16V

2
UWX1C101MCL1GB 2 UWX1C101MCL1GB 2
P_2_S
con 2 con 2
2

0.1" Spacing 0.1" Spacing

P_GND

REFERENCE DESIGNATORS AND NET NAMES: "P_" FOR POWER SUPPLY MODULE

B B

A A

Title
HV POWER MODULE
Size Number Revision
Orcad B 96C1016-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes
Drawn By:
1 2 3 4 5 6

Figure 19. HV Power Module Schematic

AN024702-1006 Appendix C—Schematic Diagrams
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
35
1 2 3 4 5 6

D D

TACH/TURN SENSOR

W_C3 W_P1
W_GND W_3_3V
1
W_GND
0.1uF 2
CON2

W_R5
OPTOISOLATED UART 10.0K
C W_P4 W_P2 C
W_C1 200mil spacing from rest of circuitry W_T1 W_VC
1 1
W_GND W_3_3V W_T2 W_GND
2 2
0.1uF con 2 CON2

3
W_R1 W_Q1
220 W_C2 W_BASE 1 MMBT2N2222A
W_R3
0.1uF W_R2 390 W_3_3V W_R6 10.0K

3
4.99K

2
W_U1 W_U2 C_EMITTER
W_C4 2 W_C5
1 8 1 8 2
W_R4 0.1uF W_D1 W_D2 0.1uF W_R7
W_ANODE 2 7 W_ISO_ANODE2 7 4.99K BAS16 BAS16 100
W_P3

1
3 6 3 6 W_RXD
1
W_TXD W_GND
2
4 5 4 5 W_GND
3
CON3
6N137 6N137
B B
W_P5
W_ISO_5V
1
W_ISO_DATA
2
W_ISO_GND
3
con 3

A A

Title
Washing Machine Interface Module
Size Number Revision
B 96C1021-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes\
Drawn By:
1 2 3 4 5 6

Figure 20. Washing Machine Interface Module Schematic

AN024702-1006 Appendix C—Schematic Diagrams

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
36

1 2 3 4

D D

J1 J2 J3 J4 J5 J6
CON1 CON1 CON1 CON1 CON1 CON1

1
3.3V

C C
R1 R2
U1 10K 10K
1 10
VOUTA A1
2 9
VOUTB A0
3 8
GND VDD
4 7
VOUTC SDA
5 6 C1
VOUTD SCL
.1uF

DAC5574IDGS

1
2
3
4
B B
J7
CON4

Title
A DAC MODULE A

Size Number Revision

A
96C1022-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes
Drawn By:
1 2 3 4

Figure 21. DAC Module Schematic

AN024702-1006 Appendix C—Schematic Diagrams
 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU
37
1 2 3 4

12V U1 5V
VREG_LM78M05CDT
1 3
D V_IN V_OUT D

GND
C1 C2
.1uF .1uF

2
J1 J2
CON2 CON3

1
2

1
2
3
12V 3.3V 12V 5V
U2
2 1
IN V_OUT

C3 GND C4
.1uF VREG_LM3480 .1uF
3.3V
3

DATA
C 3.3V R3 C
220

R1 R2
10K 10K LED1
3.3V U3 GRN
1 8
VCC GND
2 7
PA0/DBG PA5/TXD0
3 6
PA1/VREF PA4/RXD0
4 5
PA2/RESET PA3/CTS0
Z8F04XP_8PIN
S2

DEBUG R4 R5
2.49K 2.49K C5
.1uF
B 3.3V B
JP1 S1
1 2
3 4
RESET
5 6 R6
HEADER 3X2 5K

Title
A A
XP COMMAND MODULE
Size Number Revision
A 96C1023-001 A
Date: 26-Jun-2006 Sheet of
File: C:\Program Files\Design Explorer 99 SE\PROJECTS\APPLICATIONS\Rex\HiVoltRefDes
Drawn By:
1 2 3 4

Figure 22. XP Command Module Schematic (Connects to Washing Machine Module)

AN024702-1006 Appendix C—Schematic Diagrams

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

38

Appendix D—Flowcharts
Figure 23 illustrates the overall program flow. After main() initializes the
application, it drops into an infinite loop. Meanwhile, the PWM timer generates an
event every 50 μs. The PWM ISR is timed to execute on every fifth PWM event,
once every 250 μs. The ISR calls one of ten low-priority subfunctions on every
loop cycle, so each subfunction is called once every 2.5 ms.

main()

Initialization
PWM Timer
Events (50 μs)

Infinite Loop
PWM Interrupt
Service Routine
Tach Update 1
Calculate/Update
PWM Values Tach Update 2

Tach Update 3
Refresh
WDT Timer Field Weakening

Slip Update

0–9 Step Speed Regulator

Round-Robin
UART
Communication

Unused

Wait for Fifth Unused

PWM Period
(250 μs Loop) Unused

Return

Figure 23. Flowchart for the Application

AN024702-1006 Appendix D—Flowcharts

 Application Note
Vector Control of a 3-Phase AC Induction Motor Using FMC16100 MCU

39

Figure 24 illustrates the PWM ISR main loop.

PWM Interrupt
Service Routine

Current Sample Bus Voltage

Ripple Compensation
I2C Send Address
and Start Bit Inverse Park Transform
(Rotation)
Current
Reconstruction I2C Send
Stop Bit
Clark Transform
(3 to 2 Phase)
Inverse Clarke
Transform
(3 to 2 Phase)
Theta Update

I2C Send PWM Space

Control Byte Vector Modulation

Park Transform Refresh

(Rotation) WDT Timer

I2C Send MSB

0–9 Step Call Subfunction
Round-Robin for Current Step
PI Regulator

I2C Send LSB

Wait for 5th PWM
Period (250 μs Loop)

Return

Figure 24. Flowchart for the PWM ISR

AN024702-1006 Appendix D—Flowcharts