Freescale Semiconductor User Guide Document Number: AHVACPUG Rev. 0, 10/2012 HVAC Platform V1.1 User Guide by: Shawn Shi, Albert Chen, Alex Liu Freescale AISG China Solution Center 1 Overview This document describes the basic steps for getting started with Freescale's HVAC Platform V1.1 demo, and the basic board function is explained. 2 Contents 1 2 3 4 5 6 Introduction Automotive heating, ventilation, and air conditioning (HVAC) systems are based on inputs from a variety of sensors, controlling different types of motors such as stepper/DC motors for flaps and DC/BLDC motors for blowers. Through the innovative combination of microcontroller (S12G family) and analog devices (MC33905, MC33932, MC33937), this Freescale automotive HVAC control platform reference design is able to drive three types of motors (sensorless BLDC, DC, and stepper) for automotive HVAC applications. © Freescale Semiconductor, Inc., 2012. All rights reserved. 7 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Demo board features. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Demo board application block diagram . . . . . . . . . . . . . . 3 Demo board views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 HVAC platform demo board . . . . . . . . . . . . . . . . . . . . . . 6 6.1 Getting started with HVAC central control board. . . 6 6.2 Getting started with the HVAC motor control board11 6.3 Getting started with the HVAC platform. . . . . . . . . 15 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Demo board features Leveraging the ultra low power of microcontrollers, and a scalable automatic climate control software algorithm, the reference design provides an ideal solution for saving energy, helping to make the world greener. The HVAC control platform reference design mainly consists of a central control board with a human-machine interface, motor control board, and motors. It implements all the basic functions of an automotive HVAC. The sensing functions for temperature, light, humidity, and air quality enable people to control the vehicle climate in a more efficient way. Moreover, the LCD in the reference design, controlled by a microcontroller (S08LG, optional), can display rich content including date, temperature, wind speed, etc., adding a significant level of convenience for the vehicle's occupants. This reference design aims at shortening time to market for customers and partners, and it can be tailored to a customer’s unique needs in an HVAC system, such as motor type and quantity, display (or lack of display), climate control algorithms, and so on. In addition, it is extensible by connecting an external touch-key or touch-screen board. 3 Demo board features The HVAC Platform V1.1 includes these features: • Three types of motor control — Sensorless BLDC — DC — Step motor • Automatic climate control • Multiple temperature zones supported • Ultra-low-power mode, with wakeup by human-machine-interface or LIN/CAN bus • CAN and LIN communication interfaces • 3 × 3 matrix keypad and two knob inputs • 4 × 37 segment LCD and adjustable backlight • Support of interface to sensors — Temperature — Light — Humidity — Air quality • Two logic relay interfaces to compressor and defrost • Real time clock and date display and adjustment for calendar • Extensible with touch-key board or touch-screen board • Suitable for both 12 V and 24 V HVAC systems HVAC Platform V1.1 User Guide, Rev. 0 2 Freescale Semiconductor Demo board application block diagram 4 Demo board application block diagram The block diagram of the design is found in Figure 1and Figure 2. 12V RESET MUXOUT 12V GPIOs INT CAN LIN SBC MC3390 5 VDD PWMs SPI0 CAN GPIOs MC9S12G240 Fault Relay Relays Driver Dead Contol Time Unit&Prot Feedback ection Unit SCI1 Debug Uart PWM Inputs SPI0 SCI1 Connector To Motor Control Board ADCs(BLDC Status Feedback) GPIOs(Motor Control Inputs ) Captures GPIO Interrupts (Fault Signals) ENV Inputs ADCs ADCs(Motor Position Feedback) Segment LCD SPI1 INT VAUX LCD Encoder Knob Inputs MC9S08LG32 Keypad Key Inputs GPIOs Figure 1. HVAC platform central control board block diagram 5V GPIOs INT Connector To Central Control Board H‐Bridge MC33932 LM2694 12V Flap Motor Drive Signals ADCs(Flap Motor Position Feedback) 12V LM5022 DCB Flap Motors (Step Motor or DC Motor) SPI Control Feedback Pre‐Driver MC33937 ADCs(Status Feedback) MOS CTL MOSFET Bridges U,V, W Current Sampling Circuit Blower Motor (BLDC Motor) U.V,W Figure 2. HVAC platform power board block diagram HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 3 Demo board views 5 Demo board views Figure 3. HVAC platform control board top view Figure 4. HVAC platform control board bottom view HVAC Platform V1.1 User Guide, Rev. 0 4 Freescale Semiconductor Demo board views Figure 5. HVAC platform power board top view Figure 6. HVAC platform demo HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 5 HVAC platform demo board 6 HVAC platform demo board 6.1 Getting started with HVAC central control board 6.1.1 Clocking The S12G240 system uses an external 8 MHz crystal. The LG32 system uses a 32.768 kHz crystal or an internal oscillator. 6.1.2 System power System power for the central control board can be an AC adaptor inserted from J38 or +12 V DC supplied from the motor control board through J4 on the central control board. HVAC Platform V1.1 User Guide, Rev. 0 6 Freescale Semiconductor HVAC platform demo board 6.1.3 Debug interface J5 is the BDM header used for debugging S12G240. J23 is the BDM header used for debugging LG32. 6.1.4 RS-232 interface UART signals can be wired out for transferring to RS-232 signals for debugging. If UART signals are not used, they can be used for LIN interface communciation. HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 7 HVAC platform demo board 6.1.5 CAN/LIN interface The CAN interface can be set in split mode. The LIN interface can select an internal or external 1 k pullup to VSUP. 6.1.6 Key matrix 33 Key matrix 33 can be input to MCU signals (3 GPIO with interrupt function, another 3 GPIO without interrupt function). HVAC Platform V1.1 User Guide, Rev. 0 8 Freescale Semiconductor HVAC platform demo board 6.1.7 Encoder There are two encoder inputs on the central control board. The encoder has two PWM outputs while switching. There is also one additional key on the encoder. 6.1.8 Segment LCD The segment LCD can be driven directly from LG32. 6.1.9 Backlight control The backlight is a 6 serial LED which can be driven from the CAT4238 output. The backlight intensity can be adjusted by changing the PWM ratio. HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 9 HVAC platform demo board 6.1.10 Jumper table Table 1. Jumper settings Jumper Option Setting Description J24 MC33905 Debug mode selection 1–2 Set MC33905 to Debug mode J21 MC33905 Safe mode selection 1–2 Set MC33905 to Safe mode J18 CAN bus mode selection 1–2 Set CAN bus to Split mode J12 CAN bus mode selection 1–2 Set CAN bus to Split mode J6 Lin bus pullup selection 1–2 Set LIN bus external pullup J7 Lin bus pullup selection 1–2 Set LIN bus internal pullup J26 VDD power supply 1–2 VDD supplied from MC33905 J13 Reset signal to MCU 1–2 MC33905 reset signal to MCU J3 VDD power supply 1–2 VDD supplied from motor control board J31 LG32 power supply option 1–2 Select 5 V Aux FROM MC33905 2–3 Select 5 V main from MC33905 J28 UART signal selection 1–2 Select MCU TXD output J29 UART signal selection 1–2 Select MCU RXD input J15 PWMA dead time unit selection 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Ignored hardware dead time 2–3 Set hardware dead time 1–2 Set protection output as RS trigger input 2–3 Set GND as RS trigger input J14 J17 J16 J20 J19 J8 PWMA dead time unit selection PWMB dead time unit selection PWMB dead time unit selection PWMC dead time unit selection PWMC dead time unit selection RS trigger input selection HVAC Platform V1.1 User Guide, Rev. 0 10 Freescale Semiconductor HVAC platform demo board Table 1. Jumper settings (continued) Jumper J10 6.2 6.2.1 Option MC33937 predriver enable selection Setting Description 1–2 Ignore RS trigger output as enable input 2–3 Set RS trigger output as enable input J9 Backlight driver enable 1–2 Backlight driver supply enabled or not J22 VLL3 supply selection 1–2 External voltage selected for VLL3 Getting started with the HVAC motor control board Motor control board power supply J23 and J24 are the motor control board power supply interface. Either of them can be used for the power supply. 6.2.2 MC33937 power supply MC33937 acts as an amplifier of the MCU PWM signal to drive the three-phase inverter of the BLDC. The MC33937 can be powered by a 12 V power supply which is configurable via J25. The charge pump supply can be powered via J26. By default, short J25 pin1 and pin 2, and do not short J26 pin1 and pin2. HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 11 HVAC platform demo board 6.2.3 DC-bus braking resistors J24 can be connected by dynamic braking resistors. If DC-bus voltage is very high, the brake gate supplies a high level to the Q2 MOSFET. The current bypasses the braking resistor and Q2 and DC-bus voltage are reduced. By default, dynamic braking resistors are not installed on J24. 6.2.4 BLDC three-phase drive port J32, J33, and J34 are the BLDC three-phase drive port: • J32 corresponds to phase C of the inverter. • J33 corresponds to phase B of the inverter. • J34 corresponds to phase A of the inverter. HVAC Platform V1.1 User Guide, Rev. 0 12 Freescale Semiconductor HVAC platform demo board 6.2.5 DC blower control port J29, J30, and J31 are the DC motor drive port. 6.2.6 Stepper control port The stepper motor is a two-phase, four-wire type. J11, J12, J16, J17, and J20 control the stepper motor: HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 13 HVAC platform demo board • • • • • 6.2.7 J11 corresponds to A phase. J12 corresponds to B phase. J16 corresponds to C phase. J17 corresponds to D phase. J20 is GND. Servo motor control port As pictured above, J1, J2, J3, J4, and J5 control one stepper motor. J6, J7, J8, J9, and J10 control another stepper motor. HVAC Platform V1.1 User Guide, Rev. 0 14 Freescale Semiconductor HVAC platform demo board 6.3 6.3.1 Getting started with the HVAC platform Connecting the central control board with the motor control board J1 of the central control board corresponds to J22 of the motor control board. J4 of the central control board corresponds to J27 of the motor control board. 6.3.2 Powering up the HVAC platform through the power supply of the motor control board J23 and J24 are the motor control board power supply interface. HVAC Platform V1.1 User Guide, Rev. 0 Freescale Semiconductor 15 Conclusions Powering up J23 or J24 will supply power to both motor control board and central control board. 7 Conclusions This document describes the basic steps for getting started with Freescale’s HVAC platform demo boards and the demo suitcase. For technical details about the board design and solution implemented, please go to www.freescale.com. HVAC Platform V1.1 User Guide, Rev. 0 16 Freescale Semiconductor How to Reach Us: Information in this document is provided solely to enable system and software Home Page: freescale.com implementers to use Freescale products. There are no express or implied copyright Web Support: freescale.com/support information in this document. licenses granted hereunder to design or fabricate any integrated circuits based on the Freescale reserves the right to make changes without further notice to any products herein. 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