Automotive HVAC Control System with LCD Interface for S12HY Family Devices Document Number: DRM159 Rev. 0 03/2015 Automotive HVAC Control System with LCD Interface 2 Freescale Semiconductor, Inc. CHAPTER 1 INTRODUCTION 1.1. 1.2. APPLICATION FEATURES AND COMPONENTS ....................................................................................................................... 5 MC9S12HY64 CONTROLLER ADVANTAGES AND FEATURES .................................................................................................. 6 CHAPTER 2 HARDWARE DESCRIPTION 2.1. INTRODUCTION ............................................................................................................................................................. 8 2.2. HARDWARE INTERFACE ................................................................................................................................................... 9 2.2.1. Power supply........................................................................................................................................................ 9 2.2.2. MC9S12HY64 MCU............................................................................................................................................. 10 2.2.3. Liquid Crystal Display (LCD) ................................................................................................................................ 16 2.2.4. Actuator motor driver ........................................................................................................................................ 17 2.2.5. Blower motor driver........................................................................................................................................... 17 2.2.6. MC9S08PT60 for touch sense ............................................................................................................................ 19 2.2.7. IR receiver .......................................................................................................................................................... 20 2.2.8. Temperature sensor........................................................................................................................................... 20 2.2.9. Controller Area Network (CAN) ......................................................................................................................... 21 2.2.10. Background debug mode (BDM) ................................................................................................................... 21 CHAPTER 3 SOFTWARE DESIGN 3.1. INTRODUCTION ........................................................................................................................................................... 23 3.2. SOFTWARE ARCHITECTURE ............................................................................................................................................ 23 3.2.1. LCD graphics display........................................................................................................................................... 25 3.2.2. User interface .................................................................................................................................................... 27 3.2.3. Motor control..................................................................................................................................................... 30 3.2.4. Temperature sensor........................................................................................................................................... 32 3.2.5. Real time clock ................................................................................................................................................... 32 CHAPTER 4 TESTING AND MEASUREMENTS 4.1. HARDWARE SETUP ....................................................................................................................................................... 33 4.2. DEBUGGING AND MEASUREMENT ................................................................................................................................... 34 4.2.1. LCD ..................................................................................................................................................................... 34 4.2.2. User interface .................................................................................................................................................... 35 4.2.3. Motor control..................................................................................................................................................... 37 4.3. TEMPERATURE SENSOR ................................................................................................................................................. 45 APPENDIX A A.1 SCHEMATIC ................................................................................................................................................................ 46 A.2 LAYOUT ..................................................................................................................................................................... 51 A.2.1 Silkscreen Top .................................................................................................................................................... 51 A.2.2 Silkscreen Bottom .............................................................................................................................................. 51 A.2.3 Top ..................................................................................................................................................................... 52 A.2.4 Bottom ............................................................................................................................................................... 52 APPENDIX B BILL OF MATERIAL Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 3 Chapter 1 Introduction This document describes the reference design of an automotive Heating, Ventilation, and Air Conditioning (HVAC) control system with LCD interface board based on MC9S12HY64. The purpose of the design is to replace the existing mechanical switches, which are prone to wear and tear, with interactive LCD based system for longevity and robustness of the system. Freescale has a full portfolio of HVAC design for the entire four-wheeler segments. The design described in this document is intended for lower and mid segment four-wheelers. Figure 1. Conventional HVAC The reference design replaces mechanical switches used for vent positions, blower speed, and temperature control. This HVAC control system offers a capacitive touch pad interface (controlled through proximity capacitive touch sensor), an IR remote control (provided for the ease of rear-seat passengers) and micro-switches. It drives the actuator and blower motor with the help of a robust Hbridge and intelligent high-current switch. The design provides safety features such as motor stall detection, motor jams/shorting, open load, etc. Automotive HVAC Control System with LCD Interface 4 Freescale Semiconductor, Inc. Introduction The design also features car cabin’s temperature (in degree Celsius) display, date and time displays, thus eliminating the need of separate date/time/temperature displays. Date/Time can be easily set through touch pads/remote control. Block diagram of MC9S12HY based HVAC system is shown in Figure 2. Figure 2. Block diagram 1.1. Application features and components The salient features of the reference design are as follows: • • LCD based Graphics Interface Control for airflow (Face, Foot, Defrost, Face & Defrost and Face & Foot) directions using actuator motors • Control for defogger using actuator motor • Control for recirculation using actuator motor • 5-level control for blower speed using PMDC motor • 9-level control for cooling/warming using actuator motor • Car cabin’s temperature display • Real Time Clock display and adjustment Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 5 Introduction • Date display and adjustment • IR remote interface • 8 Touch pad interface using PT60 MCU • Low Power Mode interfaced through Ignition The package that shall be supplied to the user for developing the HVAC system based on MC9S12HY64 MCU includes: • Hardware – Reference HVAC board • Documentation – DRM, BOM, Schematics 1.2. Advantages and features of MC9S12HY64 controller Advantage of using MC9S12HY64: • In-built LCD driver capable of driving 160 segments • Stepper Motor Controller • Low-voltage detect (LVD) with low-voltage interrupt (LVI) and Low-voltage reset (LVR) • MCU security mechanism that prevents unauthorized access to the Flash memory • Two static low-power modes Pseudo Stop and Stop mode to facilitate power saving when full system performance is not required The general features of MC9S12HY64 MCU are: • HCS12 CPU core, 32 MHz bus frequency (64 MHZ core frequency) • Up to 64 KB on-chip flash with ECC • 4 KB data flash with ECC • Up to 4 KB on-chip SRAM • LCD driver, configurable up to 40 x 4, all LCD pins are multiplexed with GPIOs • Stepper motor controller with up to four drivers • Phase locked loop (PLL) frequency multiplier with internal filter • 4–16 MHz amplitude controlled Pierce oscillator • 1 MHz internal RC oscillator • Two timer modules (TIM0 and TIM1) supporting input/output channels that provide a range of 16-bit input capture, output compare, counter, and pulse accumulator functions • Pulse width modulation (PWM) module with up to eight 8-bit channels • Autonomous periodic interrupt (API) • Up to 8-channel, 10-bit resolution successive approximation analog-to-digital converter (ATD) • One serial peripheral interface (SPI) module • One serial communication interface (SCI) module supporting LIN 2.0, 2.1, and SAE J2602 communications Automotive HVAC Control System with LCD Interface 6 Freescale Semiconductor, Inc. Introduction • • • • • On-chip voltage regulator (VREG) for regulation of input supply and all internal voltages One Inter-Integrated Circuit (I2C) module One multi-scalable controller area network (MSCAN) module (supporting CAN protocol 2.0A/B) Up to 22 key wakeup inputs Available in 64 LQFP and 100 LQFP packages Figure 3. Block diagram of S12HY family Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 7 Hardware Description Chapter 2 Hardware Description 2.1. Introduction The reference design consists of: • • • • • • • • • • Power supply section 100-pin LQFP packaged MC9S12HY64 MCU 132 segment (33X4) LCD Glass interface with backlight control Dual Intelligent High-current Self-protected Silicon High Side Switch, MC33984, capable of driving two blower motors of 15 A each Two Throttle Control H-Bridge, MC33932, for controlling four high current actuator motors, three of these are used for temperature, vent position, and re-circulation, while one of the motor control has been kept for future use 64-pin MC9S08PT60 which has Touch Sense Input (TSI) module for eight touch pad interface IR remote interface, provided especially for the ease of control for rear-seat passengers Temperature sensor, for measuring the car’s cabin temperature CAN interface for communication with various other units Ignition control section for low-power mode simulation Figure 4. S12HY based HVAC reference design PCB – MCU side Automotive HVAC Control System with LCD Interface 8 Freescale Semiconductor, Inc. Hardware Description Figure 5. S12HY based HVAC reference design PCB – LCD side 2.2. Hardware interface The following section details each hardware block with the corresponding schematic. 2.2.1. Power supply The reference design board is switched on from an automotive battery, 12 V, 32 AH. It is connected directly with • Blower motor driver, MC33984, as the blower motor is 12 V compatible • Actuator motor driver, MC33932, as the actuator motors are 12 V compatible Signal conditioning circuitry has been added on 12 V supply to avoid any negative spikes. Figure 6. Signal conditioning circuitry on input supply Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 9 Hardware Description A switching regulator LM2676S-5.0 is used to generate a 5 V power supply to the MCU and the connected peripherals, which include: • Temperature sensor • IR receiver • Digital interface of MC33984 • Digital interface of MC33932 • Controller Area Network transceiver • LCD Glass backlight Figure 7. Switching regulator section The design has a power grid controlled by the S12HY MCU to control power consumption during lowpower mode. Figure 8. MCU controlled peripheral power grid 2.2.2. MC9S12HY64 MCU MC9S12HY64 is an automotive, 16-bit microcontroller including error correction code (ECC) on flash memory, a separate data-flash module for diagnostic or data storage, a fast analog-to-digital converter (ADC) and a frequency modulated phase locked loop (IPLL) that improves the EMC performance. This family also services generic automotive applications requiring CAN, LCD, Motor driver control, or LIN/J2602. Typical examples of these applications include automotive HVAC system, entry level instrument clusters, automotive audio system, general purpose motor control, and body controllers. The MC9S12HY family delivers all the advantages and efficiencies of a 16-bit MCU while retaining the low cost, power consumption, EMC, and code-size efficiency advantages. Automotive HVAC Control System with LCD Interface 10 Freescale Semiconductor, Inc. Hardware Description The reference design utilizes the following modules of MC9S12HY64: 1. LCD controller to drive 33X4 LCD. 2. Motor Controller module to drive Actuator motors. 3. SPI and TIM module for controlling and driving the blower motor driver IC and PT60 for Touch sense application. 4. TIM module for interfacing IR remote control. 5. BKGD for programming. 6. CAN interface for communication. 7. ADC module for Temperature sensor and stall detection of blower and actuator motors. 8. IRQ/XIRQ as a wakeup source. 9. RTI module for time keeping. The design uses 8 MHz crystal for feeding the PLL and also acts as the source for time keeping. Figure 9. Crystal section The functional pin assignment for MC9S12HY64 is described in Table 1 and the schematic in Figure 10: Table 1. Pin# Pin Assignment Functional pin assignment Purpose Major Block 1 — — 2 — — 3 M0C0M Actuators (U10_IN1) (Fresh Air) Actuators 4 M0C0P Actuators (U10_IN2) (Fresh Air) Actuators 5 M0C1M Actuators (U11_IN3) (Temp) Actuators 6 M0C1P Actuators (U11_IN4) (Temp) Actuators Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 11 Hardware Description 7 Supply Supply 8 Supply Supply 9 M1C0M Actuators (U11_IN1) (Mode) Actuators 10 M1C0P Actuators (U11_IN2) (Mode) Actuators 11 M1C1M Actuators (U10_IN3) Actuators 12 M1C1P Actuators (U10_IN1) Actuators 13 MISO SPI (used for Blower motor/PT60) SPI 14 MOSI SPI (used for Blower motor/PT60) SPI 15 SCK SPI (used for Blower motor/PT60) SPI 16 SS SPI (used for Blower motor) SPI 17 Supply Supply 18 Supply Supply 19 IOC1_2 Used for Edge detect for checking the Stall on Blower Motor 20 PV5 Chip Select for PT60 Touch Sensor 21 PV6 IR data pin IR 22 PV7 Peripheral power control Power 23 — — — 24 — — — 25 RXD UART (RXD) UART 26 TXD UART (TXD) UART 27 RXCAN CAN (RX) CAN 28 TXCAN CAN (TX) CAN 29 — — — 30 PWM1 IN1 (MC33984) Blower Motor 31 PWM2 IN2 (MC33984) Blower Motor 32 — — — 33 PT60_IRQ IRQ for Touch Sensor Touch sensor 34 BLR_WK Blower Motor wake up Blower Motor 35 BLR_FAULT Blower Motor Fault Blower Motor 36 BLR_RST Blower Motor Reset Blower Motor Automotive HVAC Control System with LCD Interface 12 Freescale Semiconductor, Inc. Hardware Description 37 FP0 LCD (pin 11) LCD 38 FP1 LCD (pin 10) LCD 39 FP2 LCD (pin 9) LCD 40 FP3 LCD (pin 8) LCD 41 FP4 LCD (pin 7) LCD 42 FP5 LCD (pin 6) LCD 43 FP6 LCD (pin 5) LCD 44 FP7 LCD (pin 4) LCD 45 — — — 46 — — — 47 FP10 LCD (pin 3) LCD 48 FP11 LCD (pin 2) LCD 49 FP12 LCD (pin 1) LCD BDM Interface BDM Interface 50 51 — — — 52 — — — 53 FP15 LCD (pin 12) LCD 54 FP16 LCD (pin 13) LCD 55 FP17 LCD (pin 14) LCD 56 FP18 LCD (pin 15) LCD 57 FP19 LCD (pin 16) LCD 58 FP20 LCD (pin 17) LCD 59 FP21 LCD (pin 18) LCD 60 FP22 LCD (pin 19) LCD 61 Supply Supply 62 Supply Supply 63 PH4 Actuator Motor Control Actuator 64 FP24 LCD (pin 41) LCD 65 FP25 LCD (pin 36) LCD 66 FP26 LCD (pin 35) LCD Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 13 Hardware Description 67 FP27 LCD (pin 34) LCD 68 FP28 LCD (pin 33) LCD 69 Supply Supply 70 Supply Supply 71 Supply Supply 72 Crystal Crystal 73 Crystal Crystal 74 IRQ Ignition Ignition 75 PA1 Actuator Motor Control Actuator 76 FP31 LCD (pin 32) LCD 77 FP32 LCD (pin 31) LCD 78 FP33 LCD (pin 30) LCD 79 FP34 LCD (pin 29) LCD 80 FP35 LCD (pin 28) LCD 81 FP36 LCD (pin 27) LCD 82 FP37 LCD (pin 26) LCD 83 FP38 LCD (pin 25) LCD 84 FP39 LCD (pin 24) LCD 85 BP0 LCD (COM1) LCD 86 BP1 LCD (COM2) LCD 87 BP2 LCD (COM3) LCD 88 BP3 LCD (COM4) LCD 89 VLCD supply LCD Controller Supply LCD Controller Supply 90 BDM Interface BDM Interface 91 Supply Supply 92 Supply Supply 93 AN00 Temp Sensor I/p Data Temp Sensor 94 AN01 Feedback for Temp Actuator Feedbacks 95 AN02 Feedback for Mode Actuator Feedbacks 96 AN03 Feedback for Blower Motor Feedbacks 97 AN04 M0C0M(DNP) (Fresh Air Actuator) Feedbacks Automotive HVAC Control System with LCD Interface 14 Freescale Semiconductor, Inc. Hardware Description 98 AN05 M0C0P(DNP) (Fresh Air Actuator) Feedbacks 99 BLR_CSNS Blower Motor Sense Blower Motor 100 — — — Figure 10. MCU section Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 15 Hardware Description 2.2.3. Liquid Crystal Display (LCD) 132 segments (33X4) LCD Glass, GDC8799D, is interfaced with the MCU. The glass has four back planes and 33 front planes and is shown in Figure 11. Figure 11. LCD Glass The details of the LCD glass are as follows: 1. Viewing angle : 6 O’clock 2. LCD Type : TN, Positive, Transreflective 3. Multiplex level : ¼ Duty, 1/3 Bias 4. LCD driving voltage : 5.0 V As the LCD glass is transreflective, backlight has been added to improve its contrast, which is controlled through the MCU and is shown in Figure 12. Figure 12. LCD Glass backlight Automotive HVAC Control System with LCD Interface 16 Freescale Semiconductor, Inc. Hardware Description 2.2.4. Actuator motor driver MC33932 is an H-Bridge Power IC that has two independent monolithic H-Bridge Power ICs in the same package, which is used to drive the actuator motors. The present design uses two such ICs, capable of driving four motors. Three of these motor drivers have been utilized while one has been kept for future enhancements. Three actuator motors control include: • Cooling control • Air flow vent position control • Recirculation control Each actuator motor requires 200 mA @ 12 V of current, which is sourced through MC33932. SMC module of MCU is used to interface the H-Bridge. The schematic of one of the actuator motor interface is shown in Figure 13: Figure 13. Actuator motor section Two of the actuator motors (temperature and vent position) used in the design have feedback pins, which return the actuator motor position in the form of 0-5 V signal. It is interfaced with the ADC pin of the MCU for stall detection. Recirculation actuator motor is a two wire actuator motor without any feedback, so the stall detection has been implemented by a different mechanism. The total numbers of cycles, at fixed PWM duty cycle, required to move the motor from one position to the other (internal to external or vice-versa) is known (using the calibration process), after which the driving of the motor pin is stopped to implement the stall. 2.2.5. Blower motor driver Intelligent, high-current, self-protected, silicon, high side switch MC33984 is used to drive high current blower motor. It is capable of driving two blower motors of 15 A each. It provides many protections, few of which includes: • Over-voltage fault Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 17 Hardware Description • Over-temperature fault • Under-voltage shutdown • Open load fault • Over-current fault • Enhanced 16 V reverse polarity VPWR protection MC33984 is programmed and controlled via the Serial Peripheral Interface (SPI). It communicates various fault condition to the MCU via its fault status pin (𝐹𝑆) and the same can be read over SPI bus. The current driver is interfaced with the PWM channel of the MCU for controlling the blower motor speed. The output of the blower motor is interfaced to the ADC channel to implement stall so that motor drive could be stopped once the motor jams. The schematic of the blower motor section is shown in Figure 14. Figure 14. Blower motor section The reference design has the support for interfacing two blower motors, as there are HVAC units which requires two blower motors to be driven. The blower motor used in the design is of the following specifications: Table 2. Blower motor specifications S. No. Parameters Specifications 1 Motor Type PMDC 2 Motor Rating Continuous 3 Rated Voltage 12 V Automotive HVAC Control System with LCD Interface 18 Freescale Semiconductor, Inc. Hardware Description 4 No Load Current 1.7 A 5 No Load Speed 4500 rpm 6 Rate Torque 0.3 Nm 7 Rated Current 14.5 A 8 Rated Speed 3600 ± 5% 9 Direction of Rotation CCW 2.2.6. MC9S08PT60 for touch sense The 8-bit MCU S08PT60 has Touch Sense Interface (TSI) module which is utilized in the design for capacitive touch sensing. The touch sensing input (TSI) module provides capacitive touch sensing detection with high sensitivity and enhanced robustness. Each TSI pin implements the capacitive measurement by a current source scan, charging and discharging the electrode, once or several times. A reference oscillator ticks the scan time and stores the result in a 16-bit register when the scan completes. Meanwhile, an interrupt request is submitted to CPU (which is S12ZVH128 in this design) for postprocessing. After receiving the interrupt, S12ZVH128 communicates with PT60 on SPI bus and gets the information about which pad is touched. The schematic of the capacitive touch sensor is shown in Figure 15. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 19 Hardware Description Figure 15. Capacitive touch sensor section 2.2.7. IR receiver NEC based IR remote is used to provide the controllability to the user, especially the rear-seat passengers. IR sensor is interfaced to TIM module channel. The schematic of IR receiver is shown in Figure 16. Figure 16. IR receiver section 2.2.8. Temperature sensor Temperature sensor interfaced to the ADC channel of the MCU provides car cabin’s real time temperature, which in turn is displayed on the LCD. The sensor provides the voltage that is proportional to the temperature. The schematic is shown in Figure 17. Automotive HVAC Control System with LCD Interface 20 Freescale Semiconductor, Inc. Hardware Description Figure 17. Temperature sensor section 2.2.9. Controller Area Network (CAN) This design provides the CAN interface for communication with other system units and the schematic is shown in Figure 18. Figure 18. CAN section 2.2.10. Background debug mode (BDM) The BDM communication interface is used for programming and debugging the MCU. P&E’s USB multilink is a debug interface which allows a PC to access the BDM on MCU is shown in Figure 19. It connects between a USB port on a PC and the standard 6-pin berg debug connector on the target (MCU). The user can directly control the target’s execution, read/write registers and memory values, debug code on the controller and program internal or external FLASH memory devices. The schematic of BDM section is shown in Figure 20 Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 21 Figure 19. PE micro USB multilink Figure 20. Background debug section Automotive HVAC Control System with LCD Interface 22 Freescale Semiconductor, Inc. Software Design Chapter 3 Software Design 3.1. Introduction This chapter describes the embedded software design of the HVAC application based on MC9S12HY64. This application’s main purpose is to demonstrate MC9S12HY64’s capability to interface LCD, drive the motors, provide user interface, while maintaining the calendaring information at the same time. All embedded software of this project was written using CodeWarrior Development Studio for Freescale S12(X) Microcontrollers, V5.1 which is Windows supported and can be downloaded from freescale.com. Software design mainly consists of graphics display, user interface, motor control, real-time temperature sensing & display, and RTI for time keeping. The controller uses external crystal (8 MHz) and internal PLL to generate the core/bus clock of 40 MHz/20 MHz. The software has following main modules: • LCD graphics display • User interface — Capacitive touch pads — IR remote control • Motor control with stall detection — Blower Motor(s) — Actuator Motors • Real time temperature sensing • Real time clock 3.2. Software architecture MC9S12HY64 is based on a high-speed S12 CPU, 16-bit processing unit that has a programming model identical to that of the industry standard M68HC11 CPU. All the tasks are scheduled on round robin basis. Overall system flowchart is shown in Figure 21 and the system memory map in Table 3. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 23 Software Design Figure 21. System flowchart Automotive HVAC Control System with LCD Interface 24 Freescale Semiconductor, Inc. Software Design Table 3. Memory map Module Name Code Memory Data Memory ADC 65 1 Actuator Motors 1,812 122 Blower Motor 538 13 Clock 30 0 IR Remote 727 17 LCD 8,245 27 Push Buttons 129 0 RTC 351 11 Temperature Sensor 80 6 Touch 250 1 Data Page 185 0 Main 2,513 27 Total 14,925 225 The following subsection describes each of the modules and its design flow. 3.2.1. LCD graphics display Figure 22. LCD major blocks Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 25 Software Design The existing HVAC units use mechanical knobs, which in the present design have been shown on LCD. Major blocks of LCD are shown in Figure 22, which include • • Date display – shows the date in DD/MM/YY format. Time display – shows the Time in HH:MM format. User can select between 24H/12H display format. • Cabin temperature display – displays the car’s real time cabin temperature. • Fan position – A fan is made up of four spokes/blades, as is shown in Figure 23. L1 shows the position 1 of all the four spokes of the fan, L2 shows position 2, and L3 shows position 3. Rotation of the fan is a function of blower motor speed, higher the blower motor speed faster the fan will rotate. Figure 23. Fan positions • Blower speed – shows the speed of the blower motor at which it is currently running. • AC display – shows AC on/off position. • Defogger – it is shown when the defogger is switched on. • Cooling control display – it is a 9-level display for showing the level of cooling/heating. Any level indicates the mixing of hot/cold air through the vents using the flap control. The flap will be positioned to one extreme, for level 1 display, allowing only the cold air to flow, while it will be positioned on the other extreme, level 9 allowing only the hot air to flow. • Air flow position – shows the vent position for the air flow. There are total of five possible positions as per the HVAC units used — Face — Foot — Face & Foot — Defrost — Foot & defrost In each of the above case the corresponding text will be displayed • Recirculation display – shows the air circulation is fresh-air/recirculation-air. All the above displays, except temperature display can be controlled by user interface. The temperature display shows the cabin’s temperature which is not modifiable by any user interface. Automotive HVAC Control System with LCD Interface 26 Freescale Semiconductor, Inc. Software Design 3.2.2. User interface The reference design has two types of interfaces: 1. IR remote control 2. Capacitive touch pads These will be discussed in detail in the following section. 3.2.2.1. IR remote control Figure 24. IR remote control along with key descriptions NEC protocol based IR remote control is used for the reference design. Each key press updates its corresponding section on the LCD and is shown in Figure 24. Unmarked keys are kept for future enhancements. The functionality of each key block is as below: • AC ON/OFF – AC can be switched ON/OFF with this key, and the corresponding AC status will be display on LCD. • Air flow positions – AF +/- keys are used to change the vent positions. Each key press will drive the vent position actuator motor and the corresponding text and position on the LCD will be displayed. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 27 Software Design Figure 25. AF+/- key press control flow • Defogger – defogger can be switched ON/OFF with this key. If the defogger is switched on the icon will be displayed on LCD • Recirculation – CIRC is used to select between fresh-air and recirculation-air, which will drive the fresh air actuator motor and the corresponding arrow on the recirculation section of the LCD will be displayed. • Cooling Control – COLD/HOT key are used to change the degree of coldness/hotness in the vehicle. Pressing this key will drive the cooling actuator motor in the background, while the COLD/HOT level will be updated on the LCD. • Blower Speed Control – F+/- keys are used to update the blower speed by increasing the duty cycle of the PWM used to drive the PMDC blower motor. This will also update the blower speed on the LCD. • Date/Time display – Time Menu is used to select between the Date and Time display on the LCD. When date display is selected, then the Mode key is used to select between date/month/year, while in time display, it is used to select between hours/minutes/time-format (AM/PM/24H). Set key increments the selected digit, and once the limit is reached, digit is reset to zero. Automotive HVAC Control System with LCD Interface 28 Freescale Semiconductor, Inc. Software Design 3.2.2.2. Capacitive touch pads Figure 26. Touch pads Proximity Capacitive Touch Sensor Controller PT60 is interfaced to the MCU via SPI bus, through which it communicates the various touch pad pressed. Each touch pad updates its corresponding section on the LCD and is shown in Figure 26. ON/OFF, DEFG, CIRC, AF+/- have the same functionality as the corresponding IR remote key, which have already been explained in the above section. As the number of keys are limited, an innovative way of menu selection has been implemented using the three keys: • MENU SELECT • MODE / + • SET / ― When the AC is switched on, the MENU SELECT key, selects between four menu states as shown below in Figure 27, starting from Blower Motor Menu. Table 4 shows the functionality of touch pads MODE/+ and SET/ in each mode, which will emulate the functionality of IR remote keys. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 29 Software Design Figure 27. Menu Select control flow Functionality of Mode/Set keys when Menu key is active Table 4. 1. S. No. Menu Mode Mode Key Function1 Set Key Function1 1 Blower Speed F+ F― 2 Cooling Control HOT COLD 3 Date MODE SET 4 Time MODE SET The touch key function emulates the IR keys are listed here 3.2.3. Motor control The reference design has two types of motor control • Blower motor control • Actuator(s) motor control These will be discussed in detail in the following section 3.2.3.1. Blower motor control Blower Motor control is implemented using PWM channel of the MCU and is driven through the highcurrent switch MC33984. PWM duty cycle is varied as per the blower speed set through the user interface. The duty cycle and the blower speed are shown in Table 5. Automotive HVAC Control System with LCD Interface 30 Freescale Semiconductor, Inc. Software Design Blower Speed and Duty cycle Table 5. Blower Speed Levels Duty Cycle (%) 0 0 1 10 2 20 3 40 4 60 NOTE PWM’s frequency is 20 Hz (approx) Blower motor may develop fault due to mechanical or electrical reason because of which it may be jammed. Driving high current blower motor under such condition may lead to permanent damage of its coils. To avoid this, stall detection is implemented in the design, for which the output of the MC33984 is continuously monitored on the ADC channel of the MCU for generated back E.M.F. 3.2.3.2. Actuator motor(s) control Actuator motor(s) control is implemented using Motor Controller module of the MCU and is driven through the high-current H-Bridge MC33932. Actuator motor control consists of: • Cooling control actuator motor – controls the mixing of hot and cold air. It controls the flap position of the mixer unit as per the degree of coldness/hotness set through the user interface. • Air flow vent position control – controls the air direction flow. It controls the flap position of the actuator motor, having five possible positions, settable through user-interface. These are: — Face — Foot — Face & Foot — Defrost — Defrost & Foot • Recirculation control – controls the fresh air circulation in the vehicle. It controls the recirculation actuator motor, which open/closes the flap for inlet of the fresh air. This is controlled using the CIRC key/pad on IR remote/Touch pads. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 31 Software Design 3.2.4. Temperature sensor A temperature sensor has been interfaced with the MCU on the ADC channel, which is used to monitor the vehicle’s cabin temperature. The temperature is read continuously and the average temperature is shown on the LCD. 3.2.5. Real time clock The application integrates the Real time clock and calendaring information and displays it on the LCD; RTI is used for this purpose, which generates the interrupt periodically. In the reference design the periodicity of the interrupt is 250 ms. The application supports the setting of date and time through user interface. User can also select the time format as 24H/12H. Automotive HVAC Control System with LCD Interface 32 Freescale Semiconductor, Inc. Testing and Measurements Chapter 4 Testing and Measurements 4.1. Hardware setup The jumper and test point placement on the board are shown in Figure 28 and their settings in Table 6, which are useful for board bring up. Figure 28. Jumper settings Table 6. Jumper settings Jumper Functionality J1 Power connections on the board J2 VLCD 1-2 J3 SCI connector ― J4 S12 BDM Connector ― HVAC unit 18 pin connector ― J5 Connection 1: +12V 2: GND Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 33 Testing and Measurements MC33984 Sense back ― J8 HS0 Blower motor feedback connected to ADC channel J9 CAN termination connector ― J10 CAN connector ― J11 PT60 Reset Connector ― J12 GPIO Connector ― J13 PT60 BDM connector ― J14 PT60 Power Selection Pin 2-3 4.2. Debugging and measurement In this section, waveforms are shown for each section. 4.2.1. LCD For testing the LCD, probe any of the frontplane pin, on which there is one ON segment. The waveform on such a pin will be as shown below: Automotive HVAC Control System with LCD Interface 34 Freescale Semiconductor, Inc. Testing and Measurements Figure 29. Waveform - a front plane with exactly one ON segment 4.2.2. User interface For testing the IR receiver section, IR receiver data pin should be probed. The following waveform will be observed when a single key is pressed for a long time. Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 35 Testing and Measurements Figure 30. Waveform – when a single key is pressed for a long time Automotive HVAC Control System with LCD Interface 36 Freescale Semiconductor, Inc. Testing and Measurements Figure 31. Waveform – when multiple IR keys are pressed at a very fast pace 4.2.3. Motor control Waveforms for each of the interfaces are shown in following sections. 4.2.3.1. Blower motor Waveform for blower motor control at different levels (changed using the user interface) is probed at the MC33984 HS0 pin and is shown in figure below: Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 37 Testing and Measurements Figure 32. Waveform – Blower motor control at different speed levels 4.2.3.2. Actuators Motor Waveforms for recirculation actuator motor control in different position, with and without the actuator motor being interfaced to MC33932, are shown in Figure 33 to Figure 36. The major difference in the two waveforms when the actuator motor is connected/not connected is the flyback voltage (below the Gnd level) marked in Figure 33 and Figure 34. Automotive HVAC Control System with LCD Interface 38 Freescale Semiconductor, Inc. Testing and Measurements Figure 33. Recirculation motor control waveform for fresh air to internal circulation, when motor is connected Figure 34. Recirculation motor control waveform for internal to fresh air circulation, when motor is connected Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 39 Testing and Measurements Figure 35. Recirculation motor control waveform for fresh air to internal circulation, when motor is not connected Figure 36. Recirculation motor control waveform for internal to fresh air circulation, when motor is not connected Automotive HVAC Control System with LCD Interface 40 Freescale Semiconductor, Inc. Testing and Measurements Waveforms for air flow vent position actuator motor control in different positions are shown in Figure 37 to Figure 42. For each position change we have captured the initial phase, transition phase and the final phase of the waveforms. Figure 37. Air flow actuator motor control waveform for defrost position to face & foot position - initial phase Figure 38. Air flow actuator motor control waveform for defrost position to face & foot position – transition phase Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 41 Testing and Measurements Figure 39. Air flow actuator motor control waveform for defrost position to face & foot position – final phase Figure 40. Air flow actuator motor control waveform for face position to foot position – initial phase Automotive HVAC Control System with LCD Interface 42 Freescale Semiconductor, Inc. Testing and Measurements Figure 41. Air flow actuator motor control waveform for face position to foot position – transition phase Figure 42. Air flow actuator motor control waveform for face position to foot position – final phase Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 43 Testing and Measurements Waveforms for temperature actuator motor control at different degree of coldness/hotness levels are shown in Figure 43 and Figure 44. Figure 43. Waveform when the degree of coldness is decreased Figure 44. Waveform when the degree of coldness is increased Automotive HVAC Control System with LCD Interface 44 Freescale Semiconductor, Inc. Testing and Measurements 4.3. Temperature sensor Waveform for the temperature sensor is shown in Figure 45 when the temperature on the sensor is increased. The waveform is captured by bringing the solder rod @ 200°C close to the sensor for 2 seconds (approx). Figure 45. Waveform for temperature sensor output when temperature is increased drastically from the ambient temperature Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 45 Testing and Measurements Appendix A A.1 Schematic Automotive HVAC Control System with LCD Interface 46 Freescale Semiconductor, Inc. Testing and Measurements Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 47 Testing and Measurements Automotive HVAC Control System with LCD Interface 48 Freescale Semiconductor, Inc. Testing and Measurements Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 49 Testing and Measurements Automotive HVAC Control System with LCD Interface 50 Freescale Semiconductor, Inc. Testing and Measurements A.2 Layout A.2.1 Silkscreen Top A.2.2 Silkscreen Bottom Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 51 Testing and Measurements A.2.3 Top A.2.4 Bottom Automotive HVAC Control System with LCD Interface 52 Freescale Semiconductor, Inc. Testing and Measurements Appendix B Bill of Material Ite m Qu an tity 1 4 2 2 3 ASSY _OPT Reference Value Description Mfg Number BH1,BH2,BH3,B H4 MOUNTING HOLE MOUNTING HOLE DRILL 108 PAD 140 PLATED TH NO PART TO ORDER Mounting Hole - 108mil Drill PTH BH5,BH6 MH_180 MOUNTING HOLE DRILL 135 PAD 180 PLATED TH NO PART TO ORDER Mounting Hole - 135mil Drill PTH 2 BH7,BH8 MH_180 MOUNTING HOLE DRILL 135 PAD 180 PLATED TH NO PART TO ORDER Mounting Hole - 135mil Drill PTH 4 12 C1,C18,C20,C2 3,C24,C33,C34, C36,C37,C45,C 46,C51 0.01UF CAP CER 0.01UF 50V 10% X7R 0805 C0805X7R50 0-103KNE 5 15 0.1 UF CAP CER 0.1UF 50V 10% X7R 0805 C0805C104K 5RAC 6 1 C2,C6,C11,C13, C14,C15,C16,C 17,C19,C27,C29 ,C39,C41,C48,C 60 C3 1000PF CAP CER 1000PF 50V 5% C0G 0805 C0805C0G50 0-102JNE 7 1 C5 1000UF CAP ALEL 1000UF 50V 20% -RADIAL UVZ1H102M HD 8 1 C7 10UF CAP TANT ESR=.125 OHMS 10UF 35V 10% 7343-31 TPSD106K03 5R0125 9 1 C8 68UF CAP TANT ESR=0.045 OHMS 68UF 25V 10% -- 7343-43 TPME686K02 5R0045 10 2 C9,C10 47UF CAP TANT 47UF 16V 10% -7343-31 293D476X901 6D2TE3 11 1 C12 10uF CAP TANT 10uF 10V 10% -2013 T491R106K01 0AT 12 2 C21,C22 18PF CAP CER 18PF 50V 5% C0G 0805 08055A180JA T2A DNP Part Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 53 Testing and Measurements 13 4 C26,C28,C38,C 40 47UF CAP ALEL 6.3X6.3X5.3 SM MAL2153754 79E3 14 4 C30,C31,C42,C 43 0.033UF CAP CER 0.033UF 50V 10% X7R 0805 08055C333K AT2A 15 4 C32,C35,C44,C 47 1uF CAP CER 1uF 16V 10% X7R 0805 C0805C105K 4RAC 16 1 C49 10UF CAP CER 10UF 16V 10% X5R 1210 1210YD106K AT2A 17 1 C50 3.3 UF CAP CER 3.3UF 10V +80%/20% Y5V 0805 C0805C335Z 8VAC 18 1 C52 0.1uF CAP CER 0.10UF 50V 5% X7R 0805 MCCE104J2N RTF 19 1 C53 0.047UF CAP CER 0.047UF 50V 5% X7R 0603 GMC10X7R4 73J50NTLF 20 6 C54,C55,C56,C 57,C58,C59 0.1UF CAP CER 0.10UF 25V 10% X7R 0603 C0603C104K 3RAC 21 1 DS1 GDC8799 LCD DISPLAY 5V CUSTOM TH GDC8799 22 1 DS2 LX88461594 WS6 LCD BACK-LIGHT MODULE 3V TH LX88461594 WS6 23 2 D1,D2 B130LB-13 DIODE SCH RECT 1A 30V SMB B130LB-13-F 24 1 D3 LED GREEN LED GRN -- 25MA SMT 1206 APT3216SGC 25 1 D5 BAT54S DIODE DUAL SCH 200MA 30V SOT23 BAT54S 26 1 D6 BAT54S DIODE DUAL SCH 200MA 30V SOT23 BAT54S 27 8 D7,D8,D9,D10, D11,D12,D13,D 14 LED_GRN + ELECTROD E SUBASSEMBLY LED GRN SGL 20MA 1206 + RECTANGULAR ELECTRODE 590X270MIL 510-77640, 370-76519 28 1 F1 Fuse Holder FUSE CLIP,5X20 MOUNT HTC-15M 29 2 JP1,JP4 HDR 1X1 HDR 1X1 TH -- 330H AU 100L HTSW-10107-SM-S 30 3 JP2,JP3,JP5 HDR 1X1 HDR 1X1 TH -- 330H AU 100L HTSW-10107-SM-S 31 1 J1 CON TB 2 CON 1X2 TB TH 200MIL SP 709H - 197L 1711725 DNP DNP 47UF 50V FUSE,PC Automotive HVAC Control System with LCD Interface 54 Freescale Semiconductor, Inc. Testing and Measurements 32 2 J2,J8 HDR 1X2 HDR 1X2 TH 100MIL SP 330H SN 115L TSW-102-07T-S 33 1 J3 HDR_1X4 HDR 1X4 TH 100MIL SP 336H AU 100L TSW-104-07G-S 34 2 J4,J13 HDR 2X3 HDR 2X3 TH 2.54MM SP 340H AU 118L M20-9980345 35 1 J5 CON_2X8 CON 2X8 PLUG SHRD TH 4.2MM SP 516H SN 140L 39-28-8160 36 2 J6,J11 HDR TH HDR 1X2 TH 100MIL SP 339H AU 98L TSW-102-07G-S 37 1 J7 HDR_1X4 HDR 1X4 TH 100MIL SP 336H AU 100L TSW-104-07G-S 38 1 J9 HDR 2X2 HDR 2X2 TH 2.54MM CTR 330H AU TSW-102-07G-D 39 2 J10,J14 HDR 1X3 HDR 1X3 TH 100MIL SP 339H AU 100L TSW-103-07G-S 40 1 J12 HDR_2X5 HDR 2X5 TH 100MIL CTR 330H AU TSW-105-08G-D 41 1 L1 47UH IND PWR 47UH@100KHZ 1.65A 30% SMT SRU1038470Y 42 1 L2 68UH IND PWR 68UH@100KHZ 2.22A 20% SMT DR125-680-R 43 6 L3,L4,L5,L6,L7, L8 330 OHM IND FER BEAD 330OHM@100MHZ 2.5A -- SMT MPZ2012S33 1A 44 2 L9,L10 BLM31AJ60 1SN1L IND FER BEAD 600OHM@100MHZ 200MA 25% 1206 BLM31AJ601 SN1L 45 1 P1 CON_1_PW R CON 1 PWR PLUG RA TH 1A -430H NI RAPC722X 46 1 Q1 BC857BLT1 TRAN PNP GEN 100MA 45V SOT23 BC857BLT1G 47 4 Q2,Q3,Q5,Q6 BC847AL TRAN NPN GEN 45VDC BC847ALT1G 48 1 Q4 MGSF1N02 LT1G TRAN NMOS PWR 750MA 20V SOT-23 MGSF1N02LT 1G 49 1 R1 560 RES MF 560 OHM 1/8W 1% 0805 23227346560 1L 50 1 R2 0.01 OHM RES MF 0.01 OHM 1/2W 1% 2010 WSL2010R01 00FEA DNP DNP 2010 1/2W 1X2 TH Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 55 Testing and Measurements 51 16 R3,R6,R7,R12, R13,R18,R21,R 22,R35,R37,R51 ,R52,R54,R59,R 61,R74 R4,R14,R36,R5 3,R62 10.0K RES MF 10.0K 1/8W 1% 0805 CR0805-8W1002FT 52 5 100 RES MF 100 OHM 1/8W 5% 0805 RC73L2D101 JTF 53 8 R9,R10,R31,R3 2,R38,R39,R46, R47 R11,R19 1.0K RES MF 1.00K 1/8W 1% 0805 RK73H2ATTD 1001F 54 2 200 RES MF 200 OHM 1/8W 1% 0805 CR0805FX20 00ELF 55 3 R15,R16,R56 10.0K RES MF 10.0K 1/8W 1% 0805 CR0805-8W1002FT 56 3 R17,R65,R73 4.7K RES MF 4.7K 1/8W 5% 0805 CR0805-8W472JT 57 1 R20 1M RES MF 1M 1/10W 5% 0805 RC73L2A105 JTF 58 2 R23,R25 1.0K RES MF 1.00K 1/8W 1% 0805 RK73H2ATTD 1001F 59 10 0ohm RES 0.0 OHM 1/8W 5% 0805 SMD RC0805JR070RL 60 1 R24,R26,R27,R 28,R29,R40,R42 ,R43,R45,R58 R30 270 RES MF 270 OHM 1/8W 1% 0805 MCR10EZHF 2700 61 3 DNP R33,R41,R48 0ohm RES 0.0 OHM 1/8W 5% 0805 SMD RC0805JR070RL 62 3 DNP R34,R44,R49 270 RES MF 270 OHM 1/8W 1% 0805 MCR10EZHF 2700 63 1 R50 2.2K RES MF 2.2K 1/8W 5% 0805 CR0805-JW222ELF 64 1 R55 15.0K RES MF 15.0K 1/8W 1% 0805 RK73H2ATTD 1502F 65 9 1.0K RES MF 1.0K 1/8W 5% 0805 MCR10EZPJ1 02 66 1 R57,R66,R67,R 68,R69,R70,R71 ,R72,R75 R60 15.0K RES MF 15.0K 1/8W 1% 0805 RK73H2ATTD 1502F 67 2 R63,R64 60.4 RES MF 60.4 OHM 1/8W 1% 0805 23227346604 9L 68 1 SW1 EG1213 SW SPDT SLD RA 200MA 30V TH EG1213 69 1 U1 LM2676S5.0 IC VREG SWT 5V 3A 8.0-40V TO-263 LM2676S5.0/NOPB 70 1 U2 MC9S12HY/ HA IC MCU 16BIT 64K FLASH 4K RAM 4.5-5.5V LQFP100 P9S12HY64J 0MLL DNP DNP DNP Automotive HVAC Control System with LCD Interface 56 Freescale Semiconductor, Inc. Testing and Measurements 71 1 U3 LM94022 IC MULTI-GAIN ANALOG TEMPERATURE SENSOR 1.55.5V SC70-5 LM94022BIM GXNOPB 72 1 U4 TSOP34838 IC IR RCVR MODULE 38KHZ 2.5-5.5V TH TSOP34838 73 2 U5,U6 MC33932 IC THROTTLE CONTROL DUAL H-BRIDGE 8.0-28V HSOP44 MC33932VW 74 1 U7 MC33984CP NA IC LIN SW DUAL 4MILLIOHM 627V PQFN16 MC33984CPN A 75 1 U8 TJA1040T IC XCVR CAN HS 5V SO8 TJA1040T 76 1 U9 PC9S08PT6 0VLH IC MCU 8BIT 60KB FLASH 4KB RAM 20MHZ 2.7-5.5V LQFP64 PC9S08PT60 VLH 77 1 Y1 8MHz XTAL 8MHz -- SMT AT-51CD28.000M-STDPFE-2 Automotive HVAC Control System with LCD Interface Freescale Semiconductor, Inc. 57 How to Reach Us: Information in this document is provided solely to enable system and software implementers to use Freescale products. There are no express or implied copyright licenses granted hereunder to Home Page: freescale.com design or fabricate any integrated circuits based on the information in this document. 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