Data Sheet No.

PD60305 revA

IRMCS3041
Sensorless Motor Drive Platform for Appliance
Based on iMOTIONTM Chipset
Features Product Summary
IRMCF341 - iMOTIONTM digital control IC - based Continuous output current 3.0 Arms*
system
Maximum overload output current 9.3 Apeak**
MCETM (Motion Control Engine) - Hardware based
computation engine for high efficiency sinusoidal
Maximum Internal clock (SYSCLK) 128 MHz
sensorless control of Permanent Magnet motors Sensorless control computation time 11 μsec typ.
Supports both interior and surface permanent RAM loaded from external EEPROM 48K bytes
magnet motor sensorless control
Data RAM 8K bytes
Single shunt current feedback reconstruction
A/D input channels 8
No external current or voltage sensing OP amp
circuit required A/D converter resolution 12 bits
230V/400W output power with IRAMS10UP60B, A/D converter conversion speed 2 μsec
TM
iMOTION Integrated Power Module 8051 instruction execution speed 2 SYSCLK
Bootstrap diode included in IRAMS10UP60B
Analog output (PWM) resolution 8 bits
Loss minimization Space Vector PWM
RS232C baud rate (typ.) 57.6K bps
Two-channel analog output (PWM)
Embedded 8-bit high speed microcontroller (8051) * Upgradeable to higher current with larger heat sink
for flexible I/O and man-machine control
** Limited by current feedback gain resistor values.
Isolated JTAG programming port for
emulation/debugger
I2C serial interface to EEPROM
MCE DesignerTM tool for easy operation
Flexible drive configuration
RS232 interface
Over-current fault protection
Over-voltage / Under-voltage protection
Zero Vector Braking control
EMI Filter included

Description
IRMCS3041 is a reference design for IRMCF341, which is a high performance RAM based motion control IC designed
primarily for appliance applications. It’s mainly aimed to achieve simple, low cost and high performance solutions for
advanced appliance motor control. The system contains an integrated power module, IRAMS10UP60B, which is also a part
of iMOTIONTM chipset. User can readily evaluate high performance sensorless control with MCEDesignerTM software without
spending development effort usually required in the traditional DSP or microcontroller based system. The complete B/Ms,
schematics and layout are provided so that the user can adapt and tailor the design per application needs.

This document is the property of International Rectifier and may not be copied or distributed without expressed consent.
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Table of Contents
1 Introduction............................................................................................................................................................... 3
1.1 Overview ........................................................................................................................................................... 3
1.2 Safety Precautions............................................................................................................................................. 4
1.3 Debris When Unpacking ................................................................................................................................... 6
2 Hardware Description ............................................................................................................................................... 7
2.1 PCB ................................................................................................................................................................... 7
2.2 Isolation Boundary ............................................................................................................................................ 7
2.3 IRMCF341 ........................................................................................................................................................ 8
2.3.1 Power......................................................................................................................................................... 8
2.3.2 Crystal ....................................................................................................................................................... 8
2.3.3 Reset Circuit.............................................................................................................................................. 8
2.3.4 EEPROM................................................................................................................................................... 8
2.3.5 Digital I/O ................................................................................................................................................. 8
2.3.6 Analog Input.............................................................................................................................................. 8
2.3.7 Single Shunt Current Feedback................................................................................................................. 8
2.4 IRAM ................................................................................................................................................................ 8
2.5 Power Supply .................................................................................................................................................... 8
2.6 EMI Filter.......................................................................................................................................................... 8
2.7 DC Bus Capacitor ............................................................................................................................................. 8
3 System Installation and Operation ............................................................................................................................ 9
4 Specifications .......................................................................................................................................................... 10

List of Figures
Figure 1. Typical Application Block Diagram Using IRMCF341 ................................................................................. 3
Figure 2. Top View of IRMCS3041 .............................................................................................................................. 7

List of Tables
Table 1. IRMCS3041 Electrical Specification ............................................................................................................. 10

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1 Introduction
1.1 Overview
IRMCS3041 is a reference design platform for inverter-controlled appliance motor drive applications based on
iMOTIONTM chipset. It contains IRMCF341 digital motion control IC, and IRAMS10UP60B, integrated power
module.

IRMCF341 is International Rectifier’s new integrated circuit device primarily designed as a one-chip solution for
sensorless permanent magnet motor control in appliance applications. Unlike a traditional microcontroller or DSP,
IRMCF341 provides a built-in closed loop sensorless control algorithm using a unique Motion Control Engine
(MCETM) for surface/interior permanent magnet motors with sinusoidal back EMF. IRMCF341 also employs a unique
single shunt current reconstruction circuit to eliminate additional analog/digital circuitry and enables a direct shunt
resistor interface to the IC. The MCETM consists of a collection of control elements, motion peripherals, a dedicated
motion control sequencer and dual port RAM to map internal signal nodes. Motion control programming is achieved
by using a dedicated graphical compiler integrated into the MATLAB/SimulinkTM development environment.
Sequencing, user interface, host communication, and upper layer control tasks can be implemented in the 8051 high-
speed 8-bit microcontroller. The 8051 microcontroller is equipped with a JTAG port to facilitate emulation and
debugging tools. Figure 1 shows a typical application schematic using the IRMCF341.

IRMCF341 contains 48K bytes of program RAM, which can be loaded from external EEPROM for 8051 program
execution. The IRMCF341 is intended for development purposes. For high volume production, IRMCK341 contains
OTP ROM in place of program RAM to reduce the cost. Both IRMCF341 and IRMCK341 come in the same 64-pin
QFP package with identical pin configuration to facilitate PC board layout and transition to mass production

IRAMS10UP60B is an integrated power module developed and optimized for appliance motor control. An internal
shunt resistor is included and offers easy current feedback through IRMCF341 single shunt current reconstruction
circuit. Built-in over-current protection and short-circuit rated IGBTs along with under-voltage lockout function and a
built-in temperature monitor deliver a high level of protection and fail-safe operation. The integration of bootstrap
diodes for the high-side driver section and the single polarity power supply required to drive internal circuitry simplify
the utilization of the module and deliver further cost reduction advantages.

Appliance Inverter

Passive HVIC
EMI Motor
Gate Drive
Filter (PMSM or IM)
&
Protection
Circuit
1.8
Multiple V IRMCF341
Output
Power 3.3
V
Supply

7 Analog Input

Upto 22 Digital
Input/Output

I2C Interface
to EEPROM

UART interface
to Front Panel

Figure 1. Typical Application Block Diagram Using IRMCF341

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 IRMCS3041

1.2 Safety Precautions

In addition to the precautions listed throughout this manual, please read and understand the following statements
regarding hazards associated with development system.

ATTENTION: The ground potential of the IRMCS3041 system is biased to a negative DC

bus voltage potential. When measuring voltage waveform by oscilloscope, the scope ground
needs to be isolated. Failure to do so may result in personal injury or death.

! Darkened display LEDs is not an indication that capacitors have discharged to safe voltage
levels.

ATTENTION: IRMCS3041 system contains dc bus capacitors which take time to discharge
after removal of main supply. Before working on drive system, wait three minutes for
capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or

!
death.
Darkened display LEDs is not an indication that capacitors have discharged to safe voltage
levels.

ATTENTION: Only personnel familiar with the drive and associated machinery should plan
or implement the installation, start-up, and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.

!
ATTENTION: The surface temperatures of the drive may become hot, which may cause
injury.

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 IRMCS3041

ATTENTION: IRMCS3041 system contains ESD (Electrostatic Discharge) sensitive parts

and assemblies. Static control precautions are required when installing, testing, servicing or

!
repairing this assembly. Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures, reference applicable ESD
protection handbook and guideline.

ATTENTION: An incorrectly applied or installed drive can result in component damage or

reduction in product life. Wiring or application errors such as undersizing the motor,
supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result

! in system malfunction.

ATTENTION: Remove and lock out power from the drive before you disconnect or
reconnect wires or perform service. Wait three minutes after removing power to discharge the
bus voltage. Do not attempt to service the drive until bus voltage has discharged to zero.

! Failure to do so may result in bodily injury or death.

ATTENTION: Do not connect power factor correction capacitors to drive output terminals U,
V, and W. Failure to do so may result in equipment damage or bodily injury.

!
ATTENTION: IRMCS3041 system includes a field-weakening control function. However, if
a drive trip occurs in field-weakening operation, excessive DC bus over-voltage will result.
Users should take the necessary precautions to protect against DC bus over-voltage. Failure to

! do so may result in equipment damage or bodily injury.

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 IRMCS3041

1.3 Debris When Unpacking

IRMCS3041 system is shipped with packing materials that need to be removed prior to installation.

ATTENTION: Failure to remove all debris and packing materials which are unnecessary for
system installation may result in overheating or abnormal operating condition.

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 IRMCS3041

2 Hardware Description
A top view of IRMCS3041 is shown in Figure 2.

Digital I/O RS232 Connector

Isolation Boundary

JTAG Connector

Power Supply
Magnetic Isolator

Isolation Boundary

Crystal

Reset Switch

Analog Channels
EEPROM

Diode Bridge
IRMCF341
Rectifier
Digital Control IC

IRAM
EMI Filter

NTC

Earth Ground DC Bus Capacitor

Connected to
Heat Sink

Power

Figure 2. Top View of IRMCS3041

2.1 PCB
The printed circuit board has two electrical layers and its size is 3.5 x 4.5 inches.

2.2 Isolation Boundary

Note that there are two different grounds on this system. The RS232 connector and JTAG connector are isolated by
magnetic isolators so that the user can connect their debugger and computer without isolating the computer. However,
the user should keep in mind that most parts of the hardware have negative DC bus ground and it is necessary to
isolate the scope when waveforms are measured.

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2.3 IRMCF341
2.3.1 Power
IRMCF341 requires 3.3V and 1.8V. VDD1 is 3.3V used for I/O and VDD2 is 1.8V for digital logic. AVDD is 1.8V
for analog and PLLVDD is1.8V for PLL. Only one source of 1.8V is shared in IRMCS3041 system. Typical current
value for 1.8V is less than 100mA.

2.3.2 Crystal
A 4 MHz crystal is used to generate the system clock. Actual system frequency is adjustable by changing Phase
Locked Loop configuration through Special Function Registers. For more information regarding the clock, please refer
to the IRMCx300 Reference Manual.

2.3.3 Reset Circuit

IRMCF341 doesn’t require external RC circuit for reset. The reset switch can be used to initialize the JTAG debugger.
For more information regarding reset, please refer to the IRMCx300 Reference Manual.

2.3.4 EEPROM
Boot load takes place at power-up to load 8051 code and MCE code from an external EEPROM to internal RAM of
IRMCF341. EEPROM can be written by MCEDesigner.

2.3.5 Digital I/O

Only some of the digital I/O’s are used in IRMCS3041. For example, ‘P1.5’ and ‘P1.6’ are used to drive the LED to
indicate the status of the system. The remainders are connected to headers (J3, J7) for the user’s convenience.

2.3.6 Analog Input

Analog channels are connected to header J5 for ease of use.

2.3.7 Single Shunt Current Feedback

IRMCF341 contains an Operational Amplifier for single shunt current reconstruction circuit. Resistors and capacitors
for amplifier circuit are placed very close to the pins. Note that there is a separate trace from shunt resistor instead of
sharing a plane with negative DC bus ground to get better current feedback.

2.4 IRAM
IRAMS10UP60B in mounted on a heat sink under the board. Voltage across 33.3 mΩ shunt is fed to ‘Itrip’ pin of
IR21363 high voltage gate driver IC through low pass filter with 2 μsec time constant to initiate the over-current
shutdown (Gatekill). For more information regarding IRAM, please refer to IRAM datasheet.

2.5 Power Supply

Switch mode power supply operates at about 80 kHz and generates 15V(VCC), 3.3V and isolated 5V. 1.8V is
generated from 3.3V by a linear regulator IRU1208.

2.6 EMI Filter

Passive EMI filter on the board consists of two 0.1 μF X-caps and two 2.2 nF Y-caps and a 1 mH common mode
inductor. Y-caps are connected to the heat sink through a metal bar and to J1 pin 1, which is assigned as earth ground.

2.7 DC Bus Capacitor

A 470 μF, 400 V, 85°C electrolytic capacitor is used to supply instantaneous power to IRAM. IRMCS3041 doesn’t
have a dynamic braking unit. In case of field weakening operation, it is recommended to use an external regenerative
unit or a braking unit for safety. Pin 4(GND) and Pin 5(DCP) of J1 can be used for connecting an external unit.

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 IRMCS3041

3 System Installation and Operation

For information regarding hardware/software installation and operation, please refer to the IRMCS3041 Quick Start
Guide.

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 IRMCS3041

4 Specifications
TC = 25°C unless specified
Parameters Values Conditions
Input Power
Voltage 115V-230Vrms, -20%, +10%
Frequency 50/60 Hz
Input current 4A rms @nominal output TA =40°C, RthSA=1.0 °C/W
Input line impedance 4%∼8% recommended
Output Power
Watts 400W continuous power Vin=230V AC, fPWM=10kHz, fO=60Hz,
TA=40°C, RthSA=1.0 °C/W,
Vertically mounted to help air flow
Current 3 Arms nominal, 9 Arms Overload RthSA limits ΔTC to 10°C during overload
Host interface (RS232C)
TXD, RXD 10V Typical 57.6 Kbps, single ended
JTAG interface
TMS, TDI, TCK, TDO 3.3V Interface with FS2 debugger
D/A
8- bit 3 Channel 0-3.3V output 8051 software needs modification to use it.
A/D
12-bit 0 – 1.2V DC bus, single shunt current, AIN1-AIN6
DC bus voltage
Maximum DC bus voltage 400V Should not exceed 400V more than 30 sec
Minimum DC bus voltage 120V
Current feedback
Current sensing device Single shunt reconstruction
Resolution 12-bit PCB design may reduce the resolution
Latency 1 pwm cycle
Protection
Output current trip level 14A peak, typical Detection from shunt on negative DC bus
Short circuit delay time Maximum 7 μsec line-to-line short, line-to-DC bus (-) short
Critical over voltage trip 380V Re-scalable
Over voltage trip 360V Re-scalable
Under voltage trip 120V Re-scalable
Power Device
IRAMS10UP60B 6 IGBT/FRED + IR2136 gate driver +3 Integrated over-current protection
bootstrap diode + shunt resistor + NTC
System environment
Ambient temperature 0 to 40°C 95% RH max. (Non-condensing)
Table 1. IRMCS3041 Electrical Specification

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IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105
http://www.irf.com Data and specifications subject to change without notice.

Sales Offices, Agents and Distributors in Major Cities Throughout the World.

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