ZDB212 ZXBM2004 EVALUATION BOARD (ZDB212 REV3) Specification Input voltage (Vcc)...............................12V (Min 6V, Max 20V) Maximum Current …………………...3A PWM output frequency …………….. 200HZ to 100KHz ( 25KHZ nominal) PWM output duty cycle ……………. 0% to 100% PWM input frequency ……………… 200HZ to 100KHz ( 25KHZ nominal) PWM input voltage ………………… 3V to 5V PWM input duty cycle ……………... 0% to 100% Thermistor Input …………………….10kΩ NTC , 100KΩ NTC SPD input voltage …………………...1V to 3V Description The ZDB212 is a demonstration board for evaluating the ZXBM2004 Two Phase Brushless DC Motor Controller. PWM input control, thermistor input control or voltage input control can be selected simply by inserting a jumper. The Hall sensor can be either a four pin naked Hall sensor or a three pin digital (buffered) Hall sensor. Terminals Vcc ……………….+Supply input voltage GND……………... Supply 0V V+……………….. Motor supply voltage PH1_coil………… Motor coil connection PH2_coil………… Motor coil connection H+ ………………. Hall sensor positive input H- ……………….. Hall sensor negative input (four pin naked Hall only) Hall Bias ………... Hall sensor supply (four pin naked Hall only) Hall Vcc ………….Hall sensor supply (three pin digital Hall only) FG out ……………Motor speed output signal PWM INPUT …….External PWM control input Thref ……………..This terminal is used to monitor the internal IC voltage reference Lock Output ……...High when rotor is locked PH1, PH2 ………...Controller drive outputs G1, G2 …………..MOSFET gate drive terminals (or Bipolar Transistor base drive terminals) Jumpers J3 – This selects a resistor network for 10K thermistor input. Not required for 100K thermistor or voltage and PWM inputs. J4 – This selects the potential divider to the H- pin for three pin digital (buffered) Hall sensor. Leave open for 4 pin Naked Hall. J5 – This selects the pull-up resistor for open collector (or drain) digital (buffered) Hall. Leave open for 4 pin Naked Hall or for Hall sensors with internal pull-up. J6 – Pins 1 and 2 (PWM select and SPD_IC) select the external integrator network for PWM input. Leave open for voltage and thermistor inputs. Pins 3 and 4 (SPD_IC and SPD) connect pin 14 of connector J6 to the SPD control pin of the ZXBM2004. Select for voltage and thermistor input and leave open for PWM input. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 1 ZDB212 Terminals and Jumpers Positions Figure 1 below shows the positions on the PCB of the terminals and jumpers described above. Figure 1. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 2 ZDB212 Voltage Control For voltage control, connections to the PCB are illustrated in figure 2 below. A digital (buffered) Hall Sensor with open collector output is used in this example. Figure 2 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 3 ZDB212 The control voltage is varied from 3V (0% PWM ) to 1V (100% PWM). The ZXBM2004 has a linear voltage to PWM response. The speed response varies for different motor designs. The circuit for the above configuration is figure 3 below. VCC D2 D1 LL4148 V+ DIODE W1 PH1 PH2 PW1 15 4 R11 22k R13 5 R16 33k 6 7 8 1 2 J6 Pins 3 & 4 R12 33k C5 C2 C1 100pF 1uF NC1 Ph1 ThRef Ph2 SPD NC2 Cpwm FG Smin RD Gnd Clck 2 14 ZXBM2004 13 12 R2 100R R14 33k 10 R15 33k 9 1uF SPD 1V to 3V GND 0V Figure 3 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 4 G1 D4 C6 2.2uF 2 11 C3 0.1uF Q2 PW2 BAS216 2 Q1 2 1 1 1 R1 100R 1 V+OP ZD2 3 3 D3 3 DIGITAL HALL BAS216 Z XM N 6 A0 9 K H- 16 MMSZ5261B 47V 1 GND Vcc 2 2 1k H+ 47V Z X M N 6 A0 9 K U1 1 3 ZD1 1 2 RV+ 2 MMSZ5261B R17 33k 2 U3 J4 R18 33k V CC 1 2 Out W2 1 1 J5 G2 ZDB212 Thermistor Control For thermistor control, connections to the PCB are illustrated in figure 4 below. A digital (buffered) Hall Sensor with open collector output is used in this example. The thermistor is 10KΩ NTC and J3 selects the linearization resistor network.For 100KΩ thermistor J3 would be left open and all other connections would remain as below. Figure 4 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 5 ZDB212 The circuit for the above configuration is figure 5 below. VCC D2 V+ DIODE D1 LL4148 W1 PH1 PH2 16 15 R22 Therm Select R11 22k 1 4 R13 5 R16 33k 6 NC1 Ph1 ThRef Ph2 SPD NC2 Cpwm FG Smin RD Gnd Clck 2 2 14 13 1 1 1 Q1 3 3 D3 R1 100R Q2 2 V+OP 1 Vcc H- ZD2 R14 33k R15 33k 11 2 7 R21 33k J3 8 R12 33k C5 C2 C1 100pF 1uF ZXBM2004 1 2 T HERM 9 C3 1uF 0.1uF SPD RT1 GND 10 J6 Pins 3 & 4 0V Figure 5 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 6 G1 D4 C6 2.2uF 2 R2 100R 12 PW2 BAS216 3 H+ ZXMN6A09K GND 2 BAS216 MMSZ5261B 47V 1 1 3 1k 47V ZXM N6A09K U1 ZD1 1 1 MMSZ5261B RV+ 2 U3 R17 33k V CC 1 R18 33k 2 J4 2 DIG IT AL HALL PW1 2 Out W2 1 2 J5 R20 33k G2 ZDB212 PWM Control For PWM control, connections to the PCB are illustrated in figure 6 below. A Naked Hall Sensor is used in this example. Figure 6 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 7 ZDB212 The circuit for the above configuration is figure 7 below VCC D2 D1 LL4148 V+ DIODE W1 PH1 PH2 W2 PW1 3 4 47k 5 6 R4 Q3 S R8 G 2.2k C4 R11 22k 1uF ZXM61P02Z C4A R7 R9 0.1uF R5 1 2 R6 ZXM61N02Z 7 8 D R12 C5 33k 0.1uF C2 C1 100pF 1uF NC1 Ph1 ThRef Ph2 SP D NC2 Cpwm FG 16 15 Smin RD Gnd Clck ZXBM2004 13 12 R2 PW2 2 Q1 2 1 1 1 D3 R1 100R 14 1 V+OP 1 Vcc H- ZD2 Q2 BAS216 D4 C6 2.2uF 2 3 HALL_NAKED H+ ZXMN6A09K 2 3 1 BAS216 MMSZ5261B 47V ZXMN6A09K 2 4 1k 1 H- U1 47V 2 GND 1 V BB H+ 3 0% to 100% PWM Control PWM_I R3 U2 ZD1 2 MMSZ5261B RV+ 2 R10 2k 100R R14 33k R15 33k 11 10 G1 G2 9 C3 1uF J6 1&2 D Q4 G 2.2k S 0V GND Figure 7 Zetex application note AN42 details the adjustment of resistors R6, R7, R8 and R9 in order to get the required response. Resistors , R7, R8 and R9 have not been assembled. Sockets have been included to enable easy changing of the through-hole resistors. Surface mount pads have been included for those that prefer soldering and de-soldering surface mount devices. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 8 ZDB212 Test Point Waveforms Below are some waveforms taken at test points with a running motor connected. Trace 1 above is G1 and trace 2 is G2. These are the gate drives to MOSFETs Q1 and Q2. Motor is running at full speed. Trace 1 above is G1 and trace 2 is G2. These are the gate drives to MOSFETs Q1 and Q2 and the time base has been expanded to show the commutation delay. Motor is running at full speed. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 9 ZDB212 Trace 1 above is PH1 voltage and trace 2 is PH1 current. Motor is running at full speed. Trace 1 above is PH1_coil showing the voltage on the phase 1 coil and trace 2 is the current in Phase 1. Input voltage to the speed pin is 1.5V which is equivalent to 75% PWM. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 10 ZDB212 Trace 1 above is PH1_coil showing the voltage on the phase 1 coil and trace 2 is the current in Phase 1. Input voltage to the speed pin is 1.5V which is equivalent to 75% PWM. Time-base has been extended to show PWM switching. Trace 1 above is FG out, a signal representing twice motor rotational frequency, trace 2 is PH1 showing one of the two drive signals from the ZXBM2004. Motor is running at full speed. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 11 ZDB212 Trace 1 is FG out, a signal representing twice motor rotational frequency, trace 2 is PH1 showing one of the two drive signals from the ZXBM2004. Input to SPD is 1.5V which is equivalent to 75% PWM. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 12 20 19 18 SP D 17 16 14 15 13 T hRef 9 11 12 10 FG out PWM Input Lock Output H+ H- 8 7 Hal l V cc 6 3 4 2 5 Hal l GND 1 Hal l Bi as D2 DIODE D1 J5 Full PCB Circuit Diagram Below is the full PCB circuit diagram ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 J1 LL4148 1 2 W1 PH1' PH2' R10 2k R18 33k W2 1 1 16 BAS216 2 R16 H- V+OP Q1 15 R1 100R 3 NC1 Ph1 ThRef Ph2 14 3 33k 2 4 Q3 R8 S C4 G ZXM61P02F R20 56k 5 7 C2 R7 R12 C5 33k Cpwm FG Smin RD 12 Gnd Cl ck 11 G1 10 R15 33k G2 9 ZXBM2004 C3 1uF 0.1uF 0.1uF 1 R22 8 C1 C4A 2 4.7uF R14 33k 6 R6 3 NC2 BAS216 C6 2 R2 100R 22k 1uF D 4 SPD 13 D4 Q2 2 D3 1 Vcc 3 H+ 1 4 R11 R13 2.2k 1uF SMIN SPD 2 8.2k D J3 Q4 R5 ZXM61N02F G 2.2k S R21 GND VCC 40 39 38 Ph2_c oil 37 Ph1_c oil 35 36 V+ 32 31 33 Vcc 30 29 28 27 26 25 24 23 22 J2 V+ PH1 PH2 ZDB212 21 R9 GND 10k R3B 34 1 2 1 2 H- 47k R4 47V 47V 1 1 VBB 2 100pF 13 R3 U1 H+ ZXMN6A09K 2 GND J4 U2 3 DIGITAL HALL 1 J6 RV+ ZD2 MMSZ5261B D6 D5 MMSZ5261B HALL_NAKED 2 GND 3 ZD1 1 VCC 1 33k 2 R17 U3 Out ZDB212 Bill Of Materials Below is the Bill Of Materials for the complete board assembly: QUANTITY 2 1 2 1 3 2 4 1 1 1 IDENT R1,R2 R3 R4,R5 R10 R14,R15,R17 R16,R18 R20 R21 R22 RV+ 3 1 C1,C3,C4 C2 1 1 2 1 1 1 1 2 2 6 1 1 14 1 6 1 C6 U1 Q1,Q2 Q3 Q4 D1 D2 D3,D4 ZD1,ZD2 J3,J4,J5 V+-PW1-PW2 J6 R6,R7,R8,R9,R11,R12,R13 VCC, GND, V+, PW1, PW2 G1,G2,PH1,PH2,SPD,SMIN Box DESCRIPTION 100R 47k 2.2K 2K 33K 33K 56K 10K 8.2K 0R 1uF 25V GRM216R61E105KA12D 100pF 50V B3790K5101J60 4.7uF 100V GRM55ER72A475K ZXBM2004Q16 ZXMN6A09K ZXM61P02F ZXMN2A01F LL4148 30BQ100 BAS216 MMSZ5261B H3153-05 Test Terminal Test Terminal PK037 ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 14 SMD 1206 1% generic SMD 1206 1% generic SMD 1206 1% generic SMD 0805 1% generic SMD 1206 1% generic SMD 0805 1% generic SMD 0805 1% generic SMD 0805 1% generic SMD 0805 1% generic SMD 0805 1% generic 0805 X5R 0805 COG 2220 X7R 2 Phase Brushless Motor Controller DPAK N MOSFET SOT23 P MOSFET SOT23 N MOSFET MINIMELF Diode SMC Diode 100V BAS216 Diode 85V SOD123 Zener Diode 47V 2 Terminal Pin Header, 100thou 3 Terminal Pin Header, 100thou 4 Terminal Pin Header, 100thou Board Socket o.5mm Gold Presentation Box ZDB212 Zetex plc. 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The company reserves the right to alter without notice the specification, design, price or conditions of supply of any product or service. ZXBM2004 (ZDB212) ISSUE 2 – MARCH 2005 15