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Fairchild Reference Design RD-401

This reference design (RD-401) supports inclusion of 3-phase PMSM / BLDC controller
FCM8531QY, Smart Power Module FSB50550A, Boundary Mode PFC Controller
FAN6961SY, and Green Mode Fairchild Buck Switch FSL306LRN in design of a
PMSM motor-drive solution up to 200 W. It should be used in conjunction with the
FCM8531QY, FSB50550A, FAN6961SY, and FSL306LRN datasheets as well as
Fairchilds application notes and technical support team. Please visit Fairchilds website
at http://www.fairchildsemi.com.
Input Voltage Maximum Rating Voltage of
Application Fairchild Device
Range Motor Power Motor
FCM8531QY,
PSMS Motor FSB50550A,
90-265 VAC 200 W 400 VDC
Drive System FAN6961SY,
FSL306LRN

Key Features
Total Solution for PMSM Motor Drive
High Power Factor, Low Total Harmonic Discharge
Wide VIN Range: 90-265 VAC
PFC On/Off Selectable
Independent Evaluation on each Functional Block
Evaluation Program Pre-Programmed
Rich Protection on each Circuit Block

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1. Schematics
PFC Aux Power
D2
1N5406

D3
FFPF08H60S PFC_OUT +15V
U30
1

D1 FSB50550A

4
GBU8J C3 T1 + C14 R67 Power-SPM 1 C31 C32 C33
COM
+

474/400V PQ2620 220uF 330K C30 105 105 105

215uH 450V 1206 100uF 2 PFC_OUT

7
+
2 3 27:3T 2
1 25V VBU 17

7
3 P

Vcomp

D
R68 TP-UH1 VccU
U15 330K 4 TP-U
-

R5 FSL306LR 1206 TP-UL1 InUH 18

Power PFC 39K R10 5 U

GND
Ilimit
4

InUL

Vcc
Vfb
+15V 1M
1206 R69 6
330K NC 19
2
1

1
NU
1 5 + C10 C11 D15 D16 1206 7
22uF D4 R11 1N4148WS ES1J VBV
104 OVS
L2 25V 1N4148WS Q1 1M C15 8
9mH FDPF12N50NZ 1206 103 TP-VH1 VccV 20 CON30
4 8 U1 9 NV To Motor
FAN6961 R7 TP-VL1 InVH
C2 1 8 R6 24K R12 R16 10 TP-V 1
0.47uF/250VAC INV VCC 1M 10K R18 TP-TS1 InVL 21 2
22 C17 V
2 7 1206 24K 11 3
Comp Gate 105 Vts
3 6 R8 R9 R15 + C16 L15 12
C4 C5 MOT GND 0.33 0.33 22uF 1mH VBW 22
4.7K NW
222/250VAC222/250VAC R3 R4 4 5 1206 1206 25V +15V 13
10K 39K CS ZCD TP-WH1 VccW
14 TP-W
InWH
R17 + C18 TP-WL1 23
NC D17 220uF 15 W
InWL IA
1 5 C7 C8 +15V ES1J 25V
105 104 C9 C12 C13 R13 TP-15V J30 J31 J32 J33 J34 J35 JTS 16
NC IB
L1 100pF NC NC 18.7KF
9mH R20 U16
IC
4 8 220/1206 LM78L05ACZX +5V TP-5V
1 3
C1 VIN VOUT 2
1 2
1 2
1 2
1 2
1 2
1 2
1 R30 R31 R32
0.47uF/250VAC + C19 1 1 1
D18 100uF 1206 1206 1206
MMSZ5248B 10V

TP-TS
TP-WL

TP-VL

TP-UL
TP-WH

TP-VH

TP-UH
R1 R2
NC NC
1206 1206
Vts
JP1 CN3
JUMPER2 Communication
RV1 2 1 R80 100 1
7D-561 4 3 R81 100 2
3
4

RT1
2R/13D
Vpp

C50
+5V Vpp 104
F1 +5V
R50 R51

32

31

30

29

28

27

26

25
7A/250VAC C51 C52
CN1 3.3 3.3 105 104
MCDs Kit Bus JP2 Power 8531

P07

P06

P05

P04

P03

P02

VPP

DVss
1 2 R72 100 JUMPER2 TP-V25
3 4 1 2 1 24
5 6 R73 100 3 4 P10 V25 DVdd L50 1
2
DVdd 7 8 2 23 Bead/0805
1
2
3

9 10 P11 DVdd L51

11 12 R74 100 3 22 Bead/0805
C68 P12 AVdd
104 13 14 TP-VIA
CN6 R75 100 4 U50 21 R53 39K
P13 IA IA
AC in FCM8531 TP-VIB
R76 100 5 20 R54 39K
P14 IB IB
TP-VIC
R77 100 6 19 R55 39K
P15 IC IC
R78 100 7 18
P16 ADC0
R79 100 8 17
P17 AVss

ADC3
DVdd

RST
P24

P25

P26
D50

VC

VB

VA
C53 C54 C55 C56
DVdd Status 105 22 22 22
R70 1K R56
9

10

11

12

13

14

15

16
DVdd TP-AO 10K
R52 TP-VSP
100 TP-R/S TP-OVS
R61 R62 R63
OVS
4.7K 4.7K 4.7K TP-HA TP-HB TP-HC C57 VR1
CN2 DVdd TP-SPMT C58 R57 104 47K
Hall Port 102 8.45K Speed control
Vts
1 R64 1K TP-DIR C61
2 R65 1K D51 DVdd DVdd DVdd 102 C59
3 R66 1K PWR 104
4 R82
5 C64 100 +15V C65 C66 C67 R60 R59 TP-VC-ADC
104 102 102 102 SW1 10K SW2 10K SW3
Run/Stop CW/CCW Reset
R71 1 2 1 2 C60
1K C63 C62 102
R58 39K
104 104

Figure 1. Schematic

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2. PFC Inductor

2.1. Inductor Schematic Diagram

Figure 2. Inductor Schematic Diagram

2.2. Winding Specification

Pins (SF) Wire Turns Winding Method
NBoost 7, 811, 12 0.1 80 27 Solenoid Winding
NAux 21 0.1 1 3 Center Winding

Core: PQ2625 (Ae=118 mm2)

Bobbin: PQ2625 12 Pins THT Vertical. Pin 3, 5, 6, 9, 10 cut.

2.3. Electrical Characteristics

Pin Specification Remark
Inductance 7, 811, 12 210 H 1 kHz, 1 V

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3. Bill of Materials
Part Number Description Qty. Designator Manufacturer
IC 0.5 A 650 V FPS FSL306LRN DIP-7 1 U15 Fairchild Semiconductor
IC CRM PFC Controller FAN6961SY SO-8 1 U1 Fairchild Semiconductor
IC 500 V 1.4 SPM FSB50550A DIP-23 1 U30 Fairchild Semiconductor
IC BLDC Controller FCM8531QY LQFP-32 1 U50 Fairchild Semiconductor
IC 5 V 0.1 A LDO LM78L05ACZX TO-92 1 U16 Fairchild Semiconductor
MOSFET FDPF12N50NZ TO220F 1 Q1 Fairchild Semiconductor
Bridge Diode GBU4J 4 A 600 V GBU-4L 1 D1 Fairchild Semiconductor
Diode 1N5406 3 A 600 V DO201AD 1 D2 Fairchild Semiconductor
Diode FFPF08H60S 3 A 600 V TO220F-2L 1 D3 Fairchild Semiconductor
Diode ES1J 1 A 600 V 35 ns SMA 2 D16, D17 Fairchild Semiconductor
Diode 1N4148WS 0.3 A 70 V SOD323 2 D4, D15 Fairchild Semiconductor
Zener Diode MMSZ5248B 18 V 0.5 W SOD123 1 D18 Fairchild Semiconductor
LED 5 mm Green 1 Power Any
LED 5 mm Red 1 Status Any
SMD Resistor 0805 3.3 5% REEL 2 R50, R51 Any
SMD Resistor 0805 22 5% REEL 1 R6 Any
SMD Resistor 0805 100 5% REEL 12 R52, R72-R82 Any
SMD Resistor 0805 1 k 5% REEL 5 R64-R66, R70, R71 Any
SMD Resistor 0805 4.7 k 5% REEL 4 R15, R61-R63 Any
SMD Resistor 0805 8.45 k 1% REEL 1 R57 Any
R3, R16, R56, R59,
SMD Resistor 0805 10 k 5% REEL 5 Any
R60
SMD Resistor 0805 18.7 k 1% REEL 1 R13 Any
SMD Resistor 0805 24 k 5% REEL 2 R7, R18 Any
R4, R5, R53-R55,
SMD Resistor 0805 39 k 5% REEL 6 Any
R58
SMD Resistor 1206 0.33 5% REEL 2 R8, R9 Any
SMD Resistor 1206 1 5% REEL 3 R30-R32 Any
SMD Resistor 1206 220 5% REEL 1 R20 Any
SMD Resistor 1206 330 k 5% REEL 3 R67-R69 Any
SMD Resistor 1206 1 M 5% REEL 5 R1, R2, R10-R12 Any
NTC B57237S0229M000 2.2 D15 1 RT1 EPCOS
MOV B72214-S0321-K101 320 V D14 1 RV1 EPCOS
MLCC 0805 NP0 50 V 22 pF-M REEL 3 C54-C56 Any
MLCC 0805 NP0 50 V 100 pF-M REEL 1 C9 Any
C58, C60, C61, C65-
MLCC 0805 X7R 50 V 1 nF-M REEL 6 Any
C67
MLCC 0805 X7R 50 V 10 nF-M REEL 1 C15 Any
C8, C11, C50, C52,
MLCC 0805 Y5V 25 V 100 nF-M REEL 10 C57, C59, C62-C64, Any
C68
C7, C17, C31-C33,
MLCC 0805 Y5V 25 V 1 F-M REEL 7 Any
C51, C53

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Part Number Description Qty. Designator Manufacturer

E-Capacitor 22 F 35 V 5x11 mm Radial 2 C10, C16 Any
E-Capacitor 100 F 10 V 5x11 mm Radial 1 C19 Any
E-Capacitor 100 F 25 V 6x12 mm Radial 1 C30 Any
E-Capacitor 220 F 25 V D=8 mm Radial 1 C18 Any
E-Capacitor 22 0F 450 V 30x30 mm Snap in 1 C14 Any
Film Capacitor 470 nF 630 V 1 C3 Any
X-Capacitor 470 nF 300 VAC 2 C1, C2 Any
Y-Capacitor 2.2 nF 300 VAC 2 C4, C5 Any
Common Choke 8 mH 2.5 A D=25 mm 2 L1, L2 Any
SMD Power Inductor 7337714102 1 mH 0.43 A 1 L15 WURTH
SMD Chip Inductor 7447905 0805 1 H 2 L50, L51 WURTH
210 H
PFC Inductor 751341751 1 T1 Midcom
PQ2625
Connector 691101710003 5 mm 3Pin 2 CN6, Motor WURTH

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4. Performance

4.1. VOUT of Auxiliary Power

Output PFC State No Load Full Load Variance Ratio (%)
Off 15.16 14.77
15 V 1.6
On 15.06 14.68
Off 5.007 5.002
5V 0.13
On 5.015 5.013

4.2. VOUT of PFC

VIN VOUT (V) (No Load) VOUT (V) (Full Load) Variance Ratio (%)
90 V 398.55 398.32 (0.3 A)
110 V 398.37 398.36 (0.3 A)
0.05
220 V 398.36 398.16 (0.5 A)
265 V 398.39 398.15 (0.5 A)

4.3. Efficiency of PFC

VIN (VAC) 90 110 220 265
25% Load 94.58% 94.58% 96.28% 97.02%
50% Load 94.05% 95.78% 97.25% 97.37%
75% Load 91.40% 94.89% 97.36% 97.93%
100% Load 92.53% 97.46% 97.94%

4.4. Efficiency of PFC

VIN (VAC) 90 110 220 265
Load (%) PF THD PF THD PF THD PF THD
10 0.972 16.640% 0.964 10.580% 0.534 51.89% 0.389 58.08
20 0.985 13.090% 0.978 15.680% 0.825 33.52% 0.588 57.63
30 0.995 8.000% 0.990 9.260% 0.924 19.410% 0.749 44.51
40 0.989 13.370% 0.983 9.610% 0.952 14.35% 0.910 21.81
50 0.993 10.580% 0.986 13.520% 0.968 9.34% 0.937 16.64
60 0.993 10.360% 0.987 13.940% 0.978 7.26% 0.954 12.59
70 0.993 10.700% 0.988 13.030% 0.982 7.17% 0.967 8.33
80 0.974 21.920% 0.991 12.170% 0.983 8.51% 0.973 6.53
90 0.991 12.630% 0.981 11.2% 0.977 6.37
100 0.977 20.65% 0.982 13.63% 0.979 7.90
Note:
1. Red color highlights that, in light-load and high-VIN condition, the PF and THD performance degrades.

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5. Related Resources

FCM8531 MCU Embedded and Configurable 3-Phase PMSM / BLDC Motor Controller
FSB50550A Motion SPM
FAN6961 Boundary Mode PFC Controller
FSL306LRN Green Mode Fairchild Buck Switch

Reference Design Disclaimer

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faith attempt to build for the specifications provided or needed by the customer. Fairchild provides this product as is and without recourse and
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All solutions, designs, schematics, drawings, boards or other information provided by Fairchild to Customer are confidential and provided for
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2013 Fairchild Semiconductor Corporation 7 RD-401 Rev. 1.0.1