M TC64X/TC64XB Fan Control Evaluation Board User’s Guide 2003 Microchip Technology Inc. DS21403C Note the following details of the code protection feature on Microchip devices: • Microchip products meet the specification contained in their particular Microchip Data Sheet. • Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the intended manner and under normal conditions. • There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our knowledge, require using the Microchip products in a manner outside the operating specifications contained in Microchip's Data Sheets. Most likely, the person doing so is engaged in theft of intellectual property. • Microchip is willing to work with the customer who is concerned about the integrity of their code. • Neither Microchip nor any other semiconductor manufacturer can guarantee the security of their code. Code protection does not mean that we are guaranteeing the product as “unbreakable.” Code protection is constantly evolving. We at Microchip are committed to continuously improving the code protection features of our products. Attempts to break microchip’s code protection feature may be a violation of the Digital Millennium Copyright Act. If such acts allow unauthorized access to your software or other copyrighted work, you may have a right to sue for relief under that Act. Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo, Accuron, dsPIC, KEELOQ, MPLAB, PIC, PICmicro, PICSTART, PRO MATE and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. AmpLab, FilterLab, microID, MXDEV, MXLAB, PICMASTER, SEEVAL and The Embedded Control Solutions Company are registered trademarks of Microchip Technology Incorporated in the U.S.A. Application Maestro, dsPICDEM, dsPICDEM.net, ECAN, ECONOMONITOR, FanSense, FlexROM, fuzzyLAB, In-Circuit Serial Programming, ICSP, ICEPIC, microPort, Migratable Memory, MPASM, MPLIB, MPLINK, MPSIM, PICkit, PICDEM, PICDEM.net, PowerCal, PowerInfo, PowerMate, PowerTool, rfLAB, rfPIC, Select Mode, SmartSensor, SmartShunt, SmartTel and Total Endurance are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. Serialized Quick Turn Programming (SQTP) is a service mark of Microchip Technology Incorporated in the U.S.A. All other trademarks mentioned herein are property of their respective companies. © 2003, Microchip Technology Incorporated, Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. Microchip received QS-9000 quality system certification for its worldwide headquarters, design and wafer fabrication facilities in Chandler and Tempe, Arizona in July 1999 and Mountain View, California in March 2002. The Company’s quality system processes and procedures are QS-9000 compliant for its PICmicro® 8-bit MCUs, KEELOQ® code hopping devices, Serial EEPROMs, microperipherals, non-volatile memory and analog products. In addition, Microchip’s quality system for the design and manufacture of development systems is ISO 9001 certified. DS21403C-page ii 2003 Microchip Technology Inc. M TC64X/TC64XB FAN CONTROL EVALUATION BOARD USER’S GUIDE Table of Contents Chapter 1. General Information 1.1 Introduction ..................................................................................................... 1 1.2 The TC64X/TC64XB Fan Control Evaluation Board ...................................... 2 1.3 Reference Documents .................................................................................... 4 Chapter 2. Getting Started 2.1 TC64X/TC64XB Fan Control Evaluation Board Functional Description ......... 5 2.2 Implementing The TC64X/TC64XB Fan Control Evaluation Board ................ 7 2.3 Operation In The Adjustable Output Voltage Mode ........................................ 8 Appendix A. Board Layout and Schematic A.1 Introduction .................................................................................................... 9 A.2 Board Layout and Schematics ....................................................................... 9 Appendix B. Bill-of-Materials (BOM) B.1 TC64X/TC64XB Fan Control Evaluation Board Components ...................... 11 Worldwide Sales and Service ...................................................................................................... 12 2003 Microchip Technology Inc. DS21403C-page iii TC64X/TC64XB Fan Control Evaluation Board User’s Guide NOTES: DS21403C-page iv 2003 Microchip Technology Inc. M TC64X/TC64XB FAN CONTROL EVALUATION BOARD USER’S GUIDE Chapter 1. General Information 1.1 INTRODUCTION Thank you for purchasing the TC64X/TC64XB Fan Control Evaluation Board from Microchip Technology Inc. The TC64X/TC64XB Fan Control Evaluation Board allows the user to evaluate and prototype brushless DC fan control circuits using one of the following Microchip BDC fan controllers. These devices will be referred to as “TC64X” in this document: • • • • • TC642 TC646 TC647 TC648 TC649 These devices will be referred to as TC64XB in this document: • • • • • TC642B TC646B TC647B TC648B TC649B The fan speed control signal can be provided by an external sensor or voltage signal, or from the on-board control voltage potentiometer. Minimum speed setting devices are: • TC642/2B • TC647/7B Auto-shutdown threshold devices are: • TC646/6B • TC648/8B • TC649/9B The minimum speed setting and auto-shutdown threshold devices are conveniently set by an on-board potentiometer. The TC64X/TC64XB Fan Control Evaluation Board has the following features: 1. Capacity for complete evaluation and prototyping for TC64X and TC64XB BDC fan controllers. 2. Works with any BDC fan. 3. User prototyping area is provided for dedicated circuity and other user-specific circuits. 4. Jumper blocks allow users to quickly configure output stage and input signal source. 5. External or internal control voltage. 6. Convenient user test points provide easy access for instrument readings at critical nodes. 2003 Microchip Technology Inc. DS21403C-page 1 TC64X/TC64XB Fan Control Evaluation Board User’s Guide 1.2 THE TC64X/TC64XB FAN CONTROL EVALUATION BOARD The TC64X/TC64XB Fan Control Evaluation Board (Figure 1-1) measures 4” x 6”. The circuit board is populated with an 8-pin PDIP socket that can accommodate any of the TC64X and TC64XB devices. While the evaluation kit is pre-configured for a 100 mA, 12V fan, it can be custom-configured for a user-specific combination of control and fan requirements. A LED status indicator is also provided to give a visual indication of a fan fault condition. The TC64X/TC64XB Fan Control Evaluation Board is powered from an external power supply (5V, 50 mA). The fan speed control signal can be provided by an external sensor, an external voltage signal or the on-board potentiometer. Minimum speed setting and auto-shutdown thresholds are conveniently set by a second potentiometer. Also included are jumper-configurable options for setting the output stage configuration, the modulation frequency and the input signal source. A SHDN/RESET switch is also available for manually shutting down the fan or resetting the system. FIGURE 1-1: DS21403C-page 2 TC64X/TC64XB Fan Control Evaluation Board Kit 2003 Microchip Technology Inc. General Information The TC64X/TC64XB Evaluation Kit includes the following: 1. 4” x 6” printed circuit board with components installed. 2. TC64X/TC64XB Fan Control Evaluation Board User’s Guide (DS21403). 3. Sample Devices: Device Part Number PDIP SOIC TC642B TC642BEPA TC642BEOA TC646B TC646BEPA TC646BEOA TC647VPA TC647VOA TC647BEPA TC647BEOA TC648VPA TC648VOA TC648BEPA TC648BEOA TC649VPA TC649VOA TC649BEPA TC649BEOA TC647 TC647B TC648 TC648B TC649 TC649B If any of these items are damaged or missing, please contact your nearest Microchip sales office, listed on the back of this publication. Certain items must be provided by the user to implement the TC64X/TC64XB Evaluation Kit: 1. A 5.0V, 50 mA regulated power supply 2. A 12.0V regulated power supply capable of supplying the required fan current 3. Small, flat-bladed screwdriver for adjusting the speed control and minimum speed/auto-shutdown potentiometers 4. Digital volt meter 5. General-purpose oscilloscope 6. Clip leads for power supply and fan connections 7. 12V, 75 mA to 100 mA brushless DC fan Note: 2003 Microchip Technology Inc. The TC64X and TC64XB will work with any BDC fan. A 12V, 75 mA to 100 mA fan is recommended for initial start-up since the evaluation board is preconfigured for this fan rating. If a 12V, 75 mA to 100 mA BDC fan is not available, the configuration settings of the TC64X/TC64XB Fan Control Evaluation Board must be modified accordingly. DS21403C-page 3 TC64X/TC64XB Fan Control Evaluation Board User’s Guide 1.3 REFERENCE DOCUMENTS Other Reference Documents may be obtained by contacting your nearest Microchip sales office or by visiting the Microchip web site at www.microchip.com. • Technical Library CD-ROM, DS00161 • Analog & Interface Families Data Book 2002, DS00207 • 2002 Technical Documentation Analog & Interface Product Families CD-ROM, DS51205 • AN768, “Redundant Fan Systems Using the TC642 Fan Manager”, DS00768, Microchip Technology Inc., 2002 • AN770, “Linear Voltage Fan Speed Control Using Microchip’s TC64x Family”, DS00770, Microchip Technology Inc., 2003 • AN771, “Suppressing Acoustic Noise in Pulse Width Modulation (PWM) Fan Speed Control Systems”, DS00771, Microchip Technology Inc., 2003 • AN772, “Speed Error in Pulse Width Modulation (PWM) Fan Control Systems”, DS00772, Microchip Technology Inc., 2003 • TC642 Fan Speed Control Module for TC64X Family Sell Sheet, DS51251 • TC642EV, Evaluation Kit for Brushless DC Fan Controllers, DS21403 • TC64X, TC64XB Sell Sheet, DS51252 Other reference documents may be obtained by contacting your nearest Microchip sales office (listed on the back of this document). The Microchip web site (www.microchip.com) also contains a wealth of documentation. Individual data sheets, application notes, tutorials and user’s guides are all available for easy download. DS21403C-page 4 2003 Microchip Technology Inc. M TC64X/TC64XB FAN CONTROL EVALUATION BOARD USER’S GUIDE Chapter 2. Getting Started This Chapter describes how the TC64X/TC64XB Fan Control Evaluation Board functions and how to use the various features. The development system demonstrates the ability of the TC64X and TC64XB families to interface with virtually any brushless DC fan, control the speed of the fan according to external temperature input, indicate overtemperature conditions, and detect fan failure. A variety of test points and a user prototyping area are provided for easy and complete design evaluation. The TC64X/TC64XB Evaluation Kit’s versatility and ease-of-use helps speed up prototyping and development. 2.1 TC64X/TC64XB FAN CONTROL EVALUATION BOARD FUNCTIONAL DESCRIPTION 2.1.1 Hardware Description Various jumper options and sites for user-installed components allow the TC64X/TC64XB Fan Control Evaluation Board to operate with virtually any BDC fan. As shown in Figure A-1 of Appendix A. “Board Layout and Schematic”, the TC64X/TC64XB Fan Control Evaluation Board operates with any of the TC64X and TC64XB devices installed in the 8-pin DIP socket. The TC646/646B/648/648B/649/649B devices have an auto-shutdown mode, whereby the fan is shut off when measured temperature is below a prescribed minimum. The TC642/2B/647/7B devices operate the fan continuously at a minimum speed when the measured temperature is low. For details, please refer to the data sheets for these devices. Shipped from the factory, the TC64X/TC64XB Fan Control Evaluation Board is configured to operate as a TC642/2B/647/7B that drives a 12V BDC fan having a 100 mA maximum operating current. The TC64X and TC64XB devices modulate fan speed in direct proportion to the control signal applied to pin 1 (VIN). This input can be supplied by an off-board sensor, or from the on-board speed control (Potentiometer 1), depending on the setting of the INT/EXT switch. The minimum fan operating speed (TC642/2B/647/7B) or auto-shutdown temperature setting (TC646/6B/648/8B/649/9B) is determined by the setting of Potentiometer 2. Additionally, the TC64X and TC64XB devices can be manually shut down (or reset) by pushing the SHDN/RESET switch or by applying a short between the two terminals of TB4. Be sure JB4 is set to match the TC64X and TC64XB devices currently in service. The BDC fan modulation frequency should be between 15 Hz to 30 Hz. This frequency is determined either by capacitor C 1, or the user-installed capacitor C 2, and the setting of JB1. The default operating frequency is 30 Hz (see the TC64X and TC64XB data sheets for details). 2003 Microchip Technology Inc. DS21403C-page 5 TC64X/TC64XB Fan Control Evaluation Board User’s Guide The output drive device can be either a SOT-23, TO-92 or a TO-220 transistor/ MOSFET, depending on the fan operating current and application. Resistor R2 sets the base drive current for this transistor. The configuration, as shipped from the factory, consists of a 2N2222A transistor and a 1.1 kΩ base resistor, which will drive a BDC fan with an operating current of 100 mA or less. Larger fans can be driven with a different combination of base resistor and output transistor. Fan commutation pulses are sensed by pin 5 of the TC64X and TC64XB devices through R3 and C5. Table 2-2 shows suggested values for R3 for various fan current ratings. The TC64X/TC64XB Evaluation Kit is shipped from the factory with a 4.7Ω resistor installed for R3 and a 0.1 µF capacitor installed for C5. A fault visual indicator is also provided to facilitate experimentation. The FAULT LED is driven active by Q4 whenever the FAULT output of the TC64X/TC64XB device goes low. The various jumper blocks and options are summarized in Table 2-1. TABLE 2-1: TC64X/TC64XB EVALUATION BOARD JUMPER OPTIONS Jumper Shorting Block Block Installed JB1 JB2 JB3 JB4 DS21403C-page 6 Factory Setting Function 1 to 2 TC64X/TC64XB, 30 Hz timebase enabled. 3 to 4 TC64X/TC64XB timebase determined by user-installed capacitor C 2. 1 to 2 4.7Ω sense resistor selected. Shorted Open Shorted 3 to 4 User-installed sense resistor R4 selected. 1 to 2 0.1 µF sense capacitor selected (adequate for nearly all BDC fans). 3 to 4 User-installed sense capacitor C4 selected. Open Shorted 2 to TC642 TC64X/TC64XB Fan Control Evaluation Board configured for TC642/2B, TC647/7B. 2 to TC646 TC64X/TC64XB Fan Control Evaluation Board configured for TC646/6B, TC648/8B, TC649/9B. Open Shorted Open 2003 Microchip Technology Inc. Getting Started 2.2 IMPLEMENTING THE TC64X/TC64XB FAN CONTROL EVALUATION BOARD Initial start-up of the TC64X/TC64XB Fan Control Evaluation Board is simplified by using a 12V BDC fan with an operating current between 75 mA to 100 mA. The TC64X/TC64XB Fan Control Evaluation Board is shipped pre-configured for such a fan. If such a fan is available, please proceed to Step 1 below. If such a fan is unavailable, the TC64X/TC64XB Fan Control Evaluation Board will require modification to certain component values and jumper settings. Proceed to Section 2.3, “Operation in the Adjustable Output Voltage”. 1. The TC64X/TC64XB Fan Control Evaluation Board is shipped from the factory configured as outlined in Table 2-1. Inspect the jumper settings on the board to ensure they match those listed in Table 2-1. Also be sure that a 4.7Ω resistor is installed for R 3, a 1.1 kΩ resistor is installed for R 2, a 0.1 µF capacitor is installed for C 5 and a 2N2222A transistor is installed for Q2. 2. Connect the positive side of a 5V DC supply to VDD (BP1) and the negative side of the supply to GND (BP2). 3. Connect the positive lead of a 12V, 100 mA (max) BDC fan to the FAN + terminal. Connect the negative lead of the fan to the FAN - terminal. 4. Connect the positive lead of a 12V DC supply to VFAN (BP3). Connect the negative lead from the 12V DC supply to ground (BP2). 5. Set the INT/EXT switch to INT (Internal Control Voltage). Turn Potentiometer 1 (Speed Control) fully clockwise. Turn Potentiometer 2 (min speed/auto-shutdown level) fully clockwise. 6. Turn both DC supplies on. The fan should immediately run to full speed and the FAULT LED should be lit. If this is not the case, check the configuration settings and repeat steps 1 through 5. 7. Connect the positive lead of a DC voltmeter to test point TP1 and the negative voltmeter lead to ground. This is the minimum speed setting voltage. Adjust Potentiometer 2 until a reading of 1.9V is achieved. This voltage corresponds to a minimum speed setting of approximately 40 percent of full speed. 8. Verify proper operation of the TC642/2B/647/7B by rotating Potentiometer 1 counterclockwise. The fan speed decreases and the FAULT LED goes off. Fan speed will decrease as Potentiometer 1 is rotated counterclockwise until the voltage on the wiper of Potentiometer 1 is less than the voltage on the wiper of Potentiometer 2, at which time the fan will operate continuously at 40 percent of full speed. Verify the minimum speed circuit is operating by adjusting Potentiometer 2 clockwise, while Potentiometer 1 is fully counterclockwise. 9. Verify open fan detection by disconnecting one lead of the fan while it is running. The FAULT LED will light after a disconnect time of about two seconds. 10. Verify locked rotor detection by stopping the fan blades during operation. The FAULT LED will light approximately two seconds after the fan blades are stopped. The TC64X/TC64XB circuit board may now be custom-configured for your particular combination of control and fan requirements. 2003 Microchip Technology Inc. DS21403C-page 7 TC64X/TC64XB Fan Control Evaluation Board User’s Guide 2.3 OPERATION IN THE ADJUSTABLE OUTPUT VOLTAGE MODE 2.3.1 Output Driver Transistors such as 2N2222A are recommended for use as the output driver. These transistors are low cost, multiple sourced and have a high enough Beta for BDC fan applications of 200 mA or less operating current. If a single transistor is used, care must be taken to select a transistor having a minimum hFE of 50 to ensure that the minimum output current specification (5 mA) of the TC64X and TC64XB devices are not exceeded. For large BDC fans, a logic level MOSFET is a good choice for the drive device. All component selections should be made based on information in the “Applications” section of the TC64X and TC64XB data sheets. Table 2-2 provides a list of typical fan module operating configurations for 12V fan applications. The values in Table 2-2 assume the use of low-cost, bipolar transistors (such as the 2N2222A). Substituting a logic level MOSFET, such as a BS170, for Q2, results in lower system voltage losses and significantly reduces output loading on the TC64X and TC64XB devices. The low R DSON of the MOSFET (1Ω in the case of the BS170) enables it to be used in place of the Darlington in high current fan applications (See the TC64X and TC64XB individual data sheets’ “Applications” section for details). The pinout of many logic level MOSFETs is reversed from that of bipolar junction transistors, so care must be taken to properly orient the MOSFET. TABLE 2-2: Full Speed Fan Motor Current OUTPUT DRIVE DEVICE CONFIGURATIONS Darlington Pair/MOSFET* Single Transistor R2 (Ω) R3 ( Ω) 50 mA — X 2.4 k 9.1 100 mA — X 1.1 k 4.7 150 mA — X 750 3.0 200 mA — X 620 2.4 200 mA X — 5.6 k 2.4 250 mA X — 4.7 k 2.0 300 mA X — 3.9 k 1.8 350 mA X — 3.3 k 1.5 400 mA X — 3.0 k 1.3 450 mA X — 2.4 k 1.2 *R2 is not necessary when using a MOSFET as the drive device. 2.3.2 Sensor Interface Circuit The TC64X and TC64XB data sheets provide detailed information relating to the design of a temperature sensor based on a low cost thermistor. DS21403C-page 8 2003 Microchip Technology Inc. M TC64X/TC64XB FAN CONTROL EVALUATION BOARD USER’S GUIDE Appendix A. Board Layout and Schematic A.1 INTRODUCTION This appendix contains general information concerning the layout, schematic and components associated with the TC64X/TC64XB Fan Control Evaluation Board. A.2 BOARD LAYOUT AND SCHEMATICS TC55 C3 TP7 GND VIN TP5 BP2 Pot 1 FIGURE A-1: TC64X TC64XB C8 Q1 R2 SOT-23 JB3 Csense VOUT TP4 /FAULT TP6 Q4 SENSE R5 VMIN /VAS TP3 C4 JB4 TC642 TC646 + Pot 2 C5 R1 R4 SHDN/RESET RSENSE R3 + TB4 GND VDD TC642EV U1 C6 JB1 Cpwm BP1 Q2 TP 2 TO-92 EXT C1 VMIN TP1 VDD INT C7 C2 FAN Q3 VIN REF1 + BP3 TO-220 FAN _ + VDD VIN GND VDD GND Figure A-1 depicts the layout for the TC64X/TC64XB Fan Control Evaluation Board. Figure A-2 shows the schematic for the Fan Control Module. GND VMIN FAULT JB 2 RSENSE TC64X/TC64XB Fan Control Evaluation Board Layout 2003 Microchip Technology Inc. DS21403C-page 9 TC64X/TC64XB Fan Control Evaluation Board User’s Guide VDD TP7 Reg1 2 IN OUT 3 TC55 C3 1 µF GND 1 Pot 1 (Speed Control) Int Potentiometer 2 (Min Speed/ Shutdown Level) Ref1 SHDN/ RESET External Sensor Input Ext VDD C7 0.01 µF FAN + TP5 2 TC646 C1* JB 4 1 1 µF 2 JB1 3 4 1 C6 0.01 µF VIN VDD 8 TP2 FAULT GND SENSE VDD 6 TP6 3 5 TP4 R5 30 kΩ E SOT-23 4 C4 TP3 JB 3 1 2 3 4 C5*,0.1 µF R4 JB2 R1 620Ω * Indicates normal value. Dashed line = factory setting. C R2 * 1.1 kΩ TC64X/TC64XB 3 VMIN (VAS) E B C8 4.7 µF VOUT 7 Q4 2N3906 DS21403C-page 10 TO-92 B 2N2222A* VDD 2 C F TP1 4 FIGURE A-2: C TO-220 TC642 Ext SHDN/ RESET TB4 BP1 BP2 BP3 VDD GNDVFan VDD 1 FAULT 2 R3 * 4.7Ω Fan Control Module Schematic 2003 Microchip Technology Inc. M TC64X/TC64XB FAN CONTROL EVALUATION BOARD USER’S GUIDE Appendix B. Bill-of-Materials (BOM) B.1 TC64X/TC64XB FAN CONTROL EVALUATION BOARD COMPONENTS Table B-1 lists typical components and associated values that comprise the TC64X/TC64XB Fan Control Evaluation Board. TABLE B-1: FAN CONTROL MODULE COMPONENTS Component Typical Value BP1 – BP3 Banana receptacle C1 1 µF tantalum capacitor. C2 Not installed C3 1 µF tantalum capacitor C4 Not installed C5 0.1 µF ceramic capacitor C6, C7 0.01 µF ceramic capacitor C8 4.7 µF tantalum capacitor JB1 – JB4 SIP header terminal strips LED -1 Miniature LED Pot 1, Pot 2 1 kΩ, on-board potentiometer Q1 Not installed (SOT-23 site) Q2 2N2222A NPN bipolar transistor Q3 Not installed (TO-220 site) Q4 2N3906 PNP bipolar transistor R1 620Ω, 1/4 watt, 5% carbon resistor R2 1.1 kΩ, 1/4 watt, 5% carbon resistor R3 4.7Ω, 1/4 watt, 5% carbon resistor R4 Not installed R5 30 kΩ, 1/4 watt, 5% carbon resistor REF-1 LM385, 1.2V reference REG-1 TC55RP3002EZB 3.0V, 2% regulator SW-1 Miniature SPDT toggle switch (INT/EXT Switch) SW-2 Miniature SPDT push button switch (SHDN/RESET switch) U1 TC642B, TC646B, TC647/7B, TC648/8B, TC649/9B (Two, each provided as samples) 2003 Microchip Technology Inc. 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