Getting Started with the EV-INVERTERGEN3 EV Traction Inverter Control Reference Design Gen 3

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2.1 Get S32 Design Studio

Download and Install S32 Design Studio for S32 Platform v.3.6.1

S32 Design Studio Download and Installation Pt. 1

S32 Design Studio Download and Installation Pt. 1

S32 Design Studio Download and Installation Pt. 2

S32 Design Studio Download and Installation Pt. 2

NOTE: Since version 3.6.1, the S32DS installer doesn't require an activation code, but you may still found it under the License Keys tab.

2.2 Downloading the Real-Time Drivers

Download S32K3_S32M27x Real-Time Drivers ASR R21-11 Version 5.0.0

Selecting S32K3_S32M27x Real-Time Drivers Version 5.0.0

Selecting S32K3_S32M27x Real-Time Drivers Version 5.0.0

Downloading S32K3_S32M27x Real-Time Drivers Version 5.0.0

Downloading S32K3_S32M27x Real-Time Drivers Version 5.0.0

2.3 Install the RTD Drivers

In S32DS, go to Help → S32DS Extensions and Updates from the top menu to open the S32DS Extensions and Updates dialogue.

Click on Add Update Sites and browse for the downloaded RTD *.zip file.

Installing the RTD Drivers Pt. 1

Installing the RTD Drivers Pt. 1

Find, select and install S32K39X Real-Time Drivers ASR R21-11 Version 5.0.0.

Installing the RTD Drivers Pt. 2

Installing the RTD Drivers Pt. 2

2.4 Download GD3162 Driver

Download S32K396 GD3162 R21-11 Version 2.0.2 CD01 driver from Automotive SW - S32K3/S32M27x - Real-Time Drivers for Cortex-M package.

Selecting S32K396 GD3162 R21-11 Version 2.0.2 CD01

Selecting S32K396 GD3162 R21-11 Version 2.0.2 CD01

Downloading S32K396 GD3162 R21-11 Version 2.0.2 CD01

Downloading S32K396 GD3162 R21-11 Version 2.0.2 CD01

2.5 Install GD3162 Driver

In S32DS, go to Help → S32DS Extensions and Updates from the top menu to open the S32DS Extensions and Updates dialogue.

Click on Add Update Sites and browse for the downloaded GD3162 update site file.

2.6 Download FS26 Driver

Download S32K396 FS26 Version 2.0.1

Selecting S32K396 FS26 Version 2.0.1

Selecting S32K396 FS26 Version 2.0.1

Downloading S32K396 FS26 Version 2.0.1

Downloading S32K396 FS26 Version 2.0.1

2.7 Install FS26 Driver

In S32DS, go to Help → S32DS Extensions and Updates from the top menu to open the S32DS Extensions and Updates dialogue.

Click on Add Update Sites and browse for the downloaded S32K396 FS26 Driver update site file.

Select and install FS26 drivers.

2.8 Download eTPU SW

Download S32K3 ETPU SW RTM 2.0.0 Code Drop 4.

Selecting S32K3 ETPU SW RTM 2.0.0 Code Drop 4.

Selecting S32K3 ETPU SW RTM 2.0.0 Code Drop 4.

Downloading S32K3 ETPU SW RTM 2.0.0 Code Drop 4.

Downloading S32K3 ETPU SW RTM 2.0.0 Code Drop 4.

2.9 Install eTPU SW

In S32DS, go to Help → S32DS Extensions and Updates from the top menu to open the S32DS Extensions and Updates dialogue.

Click on Add Update Sites and browse for downloaded eTPU SW update site file.

Select and install eTPU SW.

2.10 Get FreeMASTER Comm. Driver

In S32DS, go to Help → S32DS Extensions and Updates from the top menu to open the S32DS Extensions and Updates dialogue.

Select and install the S32K3 FreeMASTER Communication driver.

2.11 Get FreeMASTER Application Tool

Download and install FreeMASTER tool 3.2 for real-time debugging.

2.12 Get AMMCLib for S32K3

Download and install the latest Automotive Math and Motor Control Library set for S32K3 (version 1.1.39 or newer).

Selecting the Automotive Math and Motor Control Library

Selecting the Automotive Math and Motor Control Library

Downloading the Automotive Math and Motor Control Library

Downloading the Automotive Math and Motor Control Library

TIP: If possible, install AMMCLib in their default path location to make future path modifications easier.

2.13 Get the Motor Control App. Software

Download and install the EV-INVERTERGEN3 motor control application software.

NOTE: The application checks the version and whether the appropriate AMMCLib was correctly installed or not. If not (red note), install AMMCLib and reinstall the EV-INVERTERGEN3 motor control application software. That will simplify the next project import (paths to the latest AMMCLib will be already updated).

2.14 Get the CAN Node Driver (Optional)

Optionally, download and install drivers for your CAN interface. For example, if you use the PCAN interface, select your interface at the PEAK System  webpage, and then download the Windows device driver and PCAN-View application from the download section. Install the downloaded driver and GUI tool.

3.1 Default Jumper Positions

Check The Default Jumper Positions at the S32K396-HPWR-MC MCU Control Board.

S32K396-HPWR-MC Jumpers

S32K396-HPWR-MC Jumpers

Table 1. S32K396-HPWR-MC Default Jumper Settings

3.2 Assembly the Inverter

The NXP partner Vepco may provide a hardware component setup that will help with building the inverter, or you may build your own traction inverter based on the NXP EV-INVERTERGEN3 components. The next chapter (3.3) contains the steps for building an inverter without the Vepco platform. If you use the Vepco platform, please skip chapter 3.3 and continue on chapter 3.4 from step 8.

3.3 Custom Hardware Setup

The instructions below cover electrical connectivity only. It is the customer's responsibility to assemble the physical structures (busbar, mounting hardware, and so on) required to support and connect the components in their platform.

EV-INVERTERGEN3-NON-VEPCO Assembly

EV-INVERTERGEN3-NON-VEPCO Assembly

1. Attach the Six-Pack (three-phase) SiC power module (Wolfspeed ECB2R1M12YM3LlSiC) to the cooling plate.
2. Attach the DC link capacitors to the busbar.
3. Connect the three positive DC power connectors on the power module to the corresponding connectors on the busbar. Connect the three negative DC power connectors on the power module to the corresponding connectors on the DC link busbar.
4. Connect the high-voltage cables to the 3-phase output connectors on the power module. Then route each wire through the one of the three motor phase current sensors (U13, U14, U15) on the S32K396-HPWR-MC board.
5. Prepare the three high-voltage cables that were routed through the current sensors in the previous step to be connected with the motor. Make sure that the A, B and C connections match.
6. Connect the two enablement kit boards. The connection can be made using two different methods:
   • Method A: Mount the S32K396-HPWR-MC board on top of the EV-POWEREVBHD2 board by directly connecting the 46-pin connectors (P3 and P4) and the +12 supply connectors (P4 and P2). Make sure that the pins on the lower board are completely inserted into the connectors on the upper board. Use stand-offs to provide structural support between the two boards. Notice that connecting the boards in this fashion blocks access to the test points and components on the top of the EV-POWEREVBHD2 board.
   • Method B: Connect the two boards with cables. To do so, connect a 46-pin ribbon cable between the connector P3 on the S32K396-HPWR-MC board and connector P1 on the EV-POWEREVBHD2 board. In this configuration, the EV-POWEREVBHD2 board must be powered independently from the S32K396- HPWR-MC board. See step 8.
7. Connect the EV-POWEREVBHD2 board to the power module. Aligning the power module is best done by aligning the pins on the surface of the power module with the power module connectors on the bottom of the EV-POWEREVBHD2 board and mounting the two units together.

3.4 Inverter Hardware Setup

Inverter Hardware Setup Assembly

Inverter Hardware Setup Assembly

8. Connect the motor to the power inverter by high-voltage cables
9. Connect the motor resolver to the 23-pin P1 connector on the S32K396-HPWR-MC board. The connections are made as follows:
   • Using the two-wire high-power shielded cable, connect pin 14 and pin 21 (resolver excitation signals) on the 23-pin P1 connector to the corresponding connections on the motor. Connect the shield ground to pin 6 on the 23-pin connector
   • Using the low-power cable, connect pins 8, 15, 22, and 23 (resolver sense signals) on the 23-pin connector to the corresponding connections on the motor. Connect the shield ground to pin 9 on the 23- pin connector. The signal table for the 23-pin connector is in next chapter 3.5
10. Connect the low-voltage DC power supply (12 V) to the connector P4 on the S32K396-HPWR-MC board. If Method B in step 6 was used to connect the S32K396-HPWR-MC board to the EV-POWEREVBHD2 board, an additional connection must be made from the low-voltage DC power supply to the +12 supply connector (P2) on the EV-POWEREVBHD2 board. (When the two boards are mounted, as in Method A, step 6, the EV-POWEREVBHD2 draws power directly through the +12 supply connector on the S32K396-HPWR-MC board)
11. Using the two-wire high-voltage cable, connect the positive connector on the high-voltage/high-current DC supply to the positive DC link capacitor connectors on the busbar. Then connect the negative connector on the high-voltage/high current DC supply to the negative DC link capacitor connectors on the busbar.
    Warning:

    HIGH DC VOLTAGES CAN BE FATAL. Use extreme caution

    Important note: Before applying high voltage (>300 V) to the DC connection, use a current limited (1 A) power supply and apply 15 V to 30 V to the DC connection to make sure that there is no excessive leakage current.

12. Connect the 20-pin Arm JTAG debugger (for example, PEmicro Multilink) header to connector J6 on the S32K396-HPWR-MC with the pin 1 marks aligned. Connect a USB cable from the PEmicro multilink to the host PC. Both LED lights on the PEmicro multilink should be on, indicating that the JTAG bus is live and ready to communicate
13. Attach the USB-CAN Interface Adapter (PEAK System) to the 23-pin connector on the bottom of the S32K396-HPWR-MC board and a USB port on the Windows PC

3.5 23-pin Connector Description

23-pin Connector Position

23-pin Connector Position

Table 2. S32K396-HPWR-MC1 bottom interface connections

TE Connectivity Ltd. AMPSEAL (PN 770680-1), 4 mm, 23 plug

Let's take your EV-INVERTERGEN3 motor control board for a test drive.

4.1 Select Application and Project Import

Select the appropriate PMSM motor control application from the installed directory.

To import the installed application software project in the S32 Design Studio IDE for S32 Platform:

1. Launch S32DS for S32 Platform
2. Go to File → Import, then select General → Existing Projects into Workspace
3. Navigate to the installed application directory: NXP\MC_DevKits\EV-INVERTERGEN3, click Select Folder. Next, check the box for the option Copy projects into workspace. Then, click Finish

   Note: EV-INVERTERGEN3 is a multicore application. Make sure that both projects are selected for import.

4. Afterward, a new window will appear. First for the M7_0_0 project, then for the M7_0_2 project. Click on Yes To All to overwrite '.settings' folder in both project directories

4.2 Use Configuration Tool

1. Unfold the structure of the first project and double-click on *.mex file to open the project configuration in S32 Configuration Tool
2. Ensure that you are configuring the M7_0_0 project, and click on the Update Code button for generating configuration files. Next, in the S32 Configuration Tool, click on the pop down button next to the project name and choose *.mex file for the M7_0_2 project. Click on Update Code accordingly

   Configuring the M7_0_0 Project

   

   Configuring the M7_0_0 Project

   

4.3 Upload Software and Debug

In S32DS, return back to the C/C++ perspective by clicking the button located in the upper-right corner.

Selecting the C/C++ Perspective

Selecting the C/C++ Perspective

Click on Debug As menu and select Debug Configurations.

Next, expand Launch Group and click on the first launch configuration. This configuration will upload both the M7_0_0 and M7_0_2 projects to the MCU. Click on Debug for building and uploading software into the MCU.

Afterward, a new window will appear. Check the box for the option Remember my decision, and click on Switch.

The S32DS will switch to Debug Perspective. First, press Ctrl + click on both project main() files to highlight them. Next, let both projects run by clicking on Resume (or press F8).

Click on Disconnect to avoid interference between the S32DS IDE debugger and the FreeMASTER tool.

4.4 Setup the Debugging Tool

Launch the FreeMASTER application.

To open the *.pmp FreeMASTER project <selected project>\FreeMASTER_control, click File → Open Project.

Note: You can also start it by double-clicking directly in the S32DS project folder.

To enable communication, in the FreeMASTER toolbar, click Go (or press Ctrl + G).

Successful communication displays in the status bar at the bottom as: CAN;drv=peak;port=1;bitrate=500000;cmdid=0x7aa;rspid=0x7aa;tmo=1000.

Note: You can check or modify the communication settings by clicking Project → Options.

5.1 Spin the Motor

Motor Parameters (Optional Step)

If you do not use Vepco motor, you may need to edit the motor parameters according to the used PMSM motor. In the Motor Control Application Tuning (MCAT) tool, switch to the Parameters tab and edit the values on the left side.

Once you finish editing the motor parameters, click on Store Data, switch to the Output File tab and click on Generate Configuration File.

The motor parameters cannot be updated at runtime, therefore, repeat step 4.3 to build the project and upload the code into MCU.

Note: MCU will go to reset and the FreeMASTER reconnecting might require (Ctrl + K, Ctrl + G).

Spin the Motor in Open Loop

1. In the Project Tree, select the Position view via Sensors/Actuators → Position/Speed → OpenLoop - Scalar Control
2. Switch to the Control Struct tab in the MCAT tool and select the Scalar Control
3. Optionally, click on the FAULT button in MCAT to clear any pending faults
4. When the state READY appears, make sure that Scalar Control is ENABLED, and switch the application to ON either in MCAT or in the Variable Watch window by selecting the variable On/Off to Run
5. Set the Speed_Req value in the MCAT to initiate motor rotation with a maximum up to 20 rpm, due to any missing feedback in the control loop. For evaluation, 10 rpm is ideal. Optionally, increase the V/rpm_factor to spin the motor
6. The Scalar Control strategy (open-loop) in the EV-INVERTERGEN3 might be used to debug feedback position signals from the resolver. Check and compare the open loop and feedback from Resolver motor positions. If the position signals are phase-reversed, any of the two motor phase wires should be swapped to synchronize the spin rotation of motor and Resolver. Waveforms with synchronized spin rotation:

Spin the Motor in Closed Speed Loop (FOC)

1. In the Project Tree, select the Speed view via Sensors/Actuators → Position/Speed → Speed Control
2. Switch to the Control Struct tab in the Motor Control Application Tuning (MCAT) tool
3. Optionally click on the FAULT button (Application State) in MCAT to clear any of pending faults
4. When the state READY appears, make sure that Speed FOC is ENABLED, and switch the application to ON either in MCAT or in the Variable Watch window by selecting the variable On/Off to Run
5. Set the Speed_Req value in MCAT to initiate motor rotation

For an in-depth description of motor control application tuning using MCAT, see AN4642: Motor Control Application Tuning (MCAT) Tool for 3-Phase PMSM.

Board Documents

• EV-INVERTERGEN3 Design Files
• EV-POWEREVBHD2 Schematics
• S32K396-HPWR-MC Schematics

Chip Documents

• S32K39/37/36 Electrification MCUs Data Sheet
• S32K39/37/36 Electrification MCUs Reference Manual
• S32K39/37/36 Errata

Application Documents

• AN14504: EV Traction Inverter Control Reference Design Gen 3 SW Application Note
• AN14505: EV Traction Inverter Reference Design Gen 3 System Application Note
• AN14552: Safety Concept Overview Of High-Voltage EV Traction Inverter Gen3 Reference Design

Software

• EV-INVERTERGEN3-SW Application Software
• S32K3 Standard Software Package
• S32K3 Reference Software Package
• S32 Design Studio for S32 Platform
• Real-Time Drivers (RTD)
• Automotive Math and Motor Control Library (AMMCLib)
• FreeMASTER Run-Time Debugging Tool
• Motor Control Application Tuning (MCAT) Tool
• Model-Based Design Toolbox (MBDT)

Trainings

• EV Efficiency and System Optimization Using GD3162
• Next Generation of NXP EV Traction Inverter with S32K39 MCU and FS26 SBC
• Electrification: Functional Safety Concept and Collaterals for EV Traction Inverter
• EV Traction Inverter System
• S32K39/37/36 Software Overview Training

Forums

• S32 Design Studio
• Model-Based Design Toolbox (MBDT)
• FreeMASTER
• S32K3 Motor control SW examples