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Inputs on my first PCB for AC motor driver.

KlausST

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Hi,

The IEC 61010 is not free for download. About 200€ as print version.
****

Some free online informations:
https://docs.broadcom.com/doc/AV02-2041EN
https://www.ieee.li/pdf/essay/safety_considerations_in_power_supply_design.pdf
https://training.ti.com/pcb-layout-smps-part-2?context=1135942-1135946

I just did an internet seacrch to find them. Feel free to do your own search ;-)

Klaus

I agree with your safety assessment of the AN1660 board. Isolation is flawed by connecting one transformer secondary winding to the mains side and the other to the "isolated" low voltage side. The board layout is just continuing the fault.
Yes. Horrible. What is the clearance? Maybe less than 0.2mm!
 

ghoetic

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Hi,

The IEC 61010 is not free for download. About 200€ as print version.
****

Some free online informations:
https://docs.broadcom.com/doc/AV02-2041EN
https://www.ieee.li/pdf/essay/safety_considerations_in_power_supply_design.pdf
https://training.ti.com/pcb-layout-smps-part-2?context=1135942-1135946

I just did an internet seacrch to find them. Feel free to do your own search ;-)

Klaus


Yes. Horrible. What is the clearance? Maybe less than 0.2mm!
Hello again!

Yeah i should check what is regulatory for my country, but as you said i will let no one else touch it.

This might not be microchips first wiff at circuit APP notes actually.

Anyways i have now atleast 2mm clerance between all the ac/dc & pe connections. i measured 5.08 straight between the non isolated to the isolated pin of the DC/DC.

take a last check and if you want and comment what you think. I will await the shunt resistors arrival before i order the board.

*EDIT* And for laughs, here is my first crude build 4 years ago haha
https://www.youtube.com/watch?v=A1Ip2bk8uy8
https://www.youtube.com/watch?v=0gZrBgXn4NI
 

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KlausST

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Hi,

well done. You really learn fast. (and it´s clear: you want to learn) :thumbsup:

I didn´t go through the PCB in detail, but it looks much better now.


I hope it´s working as expected. Good luck.


Klaus
 

ghoetic

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Hi,

well done. You really learn fast. (and it´s clear: you want to learn) :thumbsup:

I didn´t go through the PCB in detail, but it looks much better now.


I hope it´s working as expected. Good luck.


Klaus
Thanks for your input and encourgement, it really helped me!

I will check back on how it works and try to get some measurments but might take a week or two.

Take care!
 

ghoetic

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Board arrived. excited to start soldering and and not hope it explodes when i power it up.

looks very good.
some text ended up on the backside. i must have missed when fiddling around.

i forgot a pulldown resistor on the mosfet relay. might hack one in from the pad tho!

https://ibb.co/qCqXhg9
https://ibb.co/5snwn22
 

KlausST

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Hi,

looks good.
Good luck.

Keep us informed.

Klaus
 

ghoetic

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Ok. the driver is tripping for overcurrent with no load. for which i assume is shoottrough. I took lowside and highside scope pics with phone.


high side seems to have problems.
ideas? gate driver deadtime is built in 420ns so we are clearly needing more with that gate waveform
 

KlausST

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Hi,

do we have a schematic?
I can´t validate shoot through. Maybe there is maybe not.
420ns dead time is huge. I doubt you need more.
Don´t know what your 4 scope pictures show...

Klaus
 

ghoetic

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Hi,

do we have a schematic?
I can´t validate shoot through. Maybe there is maybe not.
420ns dead time is huge. I doubt you need more.
Don´t know what your 4 scope pictures show...

Klaus

took the driver section schematic, do you need more?
2 first pictures are one of the LOW side waveform rise and fall.
2 last pictures are one of the TOP side waveform rise and fall.
I just noticed i swapped low and highside ON PWM4 cause i mistakenly read it the same as the other.
gotta switch that in firmware and try again i guess.
 

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ghoetic

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Success so far!

So i tried somethings on the board.
I replaced the IRS2334 with a new one.
replaced the 10uF bulk with a 47uF.
replaced the bootstrap caps from 2.2uF to 1.0uF
replaced the gate resistors from 20 to 150ohm **lowest i had in lab*

***i replaced gate resistors after i tried the new driver and bulk cap, because it tripped, but in my haste i forgot to check for what it tripped,
and afterwards noticed it was undervoltage (had set lab supply to low) so doh. might have just been a bad driver, maby i should resolder the 20ohm gate resistors and try again.

but this seems to work! measured with fliir and nothing is abnormaly hot.
hottest parts are the bleeder resistors and the bypass relay.

worked without and with load.

oh and noticed a bug, forgot to " LED_MOTOR_SetLOW() after brakeing ^^ "
driving the motor and injection brakeing:
 

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