3-Phase BLDC/PMSM LowVoltage Motor Control Drive User Manual Rev. 0 04/2009 freescale.com 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive User Manual by:Petr Frgal Freescale Semiconductor Czech System Center To provide the most up-to-date information, the revision of our documents on the world-wide web will be the most current. Your printed copy may be an earlier revision. To verify that you have the latest information available, refer to www.freescale.com. The following revision history table summarizes the changes contained in this document. For your convenience, the page number designators have been linked to the appropriate location. Revision History Date Revision Level 10/2008 0 Description Initial release Page Number(s) N/A 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 3 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 4 Freescale Semiconductor List of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 2-1 Figure 3-1 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 Figure A-1 Figure A-2 Figure A-3 Figure A-4 Figure A-5 Figure A-6 Figure A-7 Figure A-8 Figure A-9 Figure A-10 Figure C-1 Figure C-2 Figure C-3 Figure C-4 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive. . . . . . . . . . . . . . . . . . . . . . . . . 13 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Setup . . . . . . . . . . . . . . . . . . . 15 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 J7 and J8 Connector Physical View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Phase Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Bus Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Back EMF Sensing — Phase A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PWM LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 DC-Bus Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 +5 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 +3.3 VA / +5 VA Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 +1.65 V Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Encoder/Hall-Effect Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 CAN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Control Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Board Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 Analog Sensing — Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 Analog Sensing — Back EMF Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 Micro Headers & Other Circuits — Encoder/Hall Sensor & CAN . . . . . . . . . . . . . . . . . . 1-47 Micro Headers & Other Circuits — Switches, User, and PWM LEDs. . . . . . . . . . . . . . . 1-48 Micro Headers & Other Circuits — Daughter Board Connectors & RESET . . . . . . . . . . 1-49 Micro Headers & Other Circuits — USB/SCI Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50 MOSFET Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 Board Top Layer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-60 Board Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61 Board Silkscreen Top Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-62 Board Silkscreen Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-63 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 5 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 6 Freescale Semiconductor Table of Contents Chapter 1 Introduction 1.1 1.2 1.3 1.4 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Outline . . . . . . . . . . . . . . . . . . . . . . . About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 13 13 Chapter 2 Operational Description 2.1 2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Chapter 3 Pin Description 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Connector J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Input Connectors J2 and J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN Header J4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder/Hall-Effect Interface J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daughter Board Connectors J7 and J8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB Controller BDM Header J9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB Connector J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 21 22 22 23 23 26 26 Chapter 4 Design Consideration 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Phase Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overcurrent, Undervoltage, and Other Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Points and LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supplies and Voltage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +5 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +3.3 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +3.3 VA Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +1.65 V Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 27 30 31 32 32 33 37 37 37 38 38 38 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 7 4.9 4.10 4.11 4.12 Encoder/Hall-Effect Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB/SCI Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 39 40 40 Appendix A. 3-Phase BLDC/PMSM Motor Control Drive Schematics Appendix B. Bill of Materials Appendix C. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Layouts 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 8 Freescale Semiconductor List of Tables Table 2-1 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table B-1 Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Connector J1 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN Header J4 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder/Hall-Effect Interface J6 — Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . Daughter Board Connector J7 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daughter Board Connector J8 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB Controller BDM Header J9 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . USB Connector J10 — Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 22 22 23 23 24 26 26 55 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 9 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 10 Freescale Semiconductor Chapter 1 Introduction 1.1 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Outline Freescale’s 3-Phase BLDC (Brushless DC) / PMSM (Permanent Magnet Synchronous Motor) LowVoltage Motor Control Drive is a 12–24 V DC, 4 A, off-line power stage that, as a main board together with a daughter board, creates a single unit for developing BLDC/PMSM motor control applications. With one of the available daughter boards, accommodating a selected microcontroller, it provides a readymade, software-development platform for one-third horsepower off-line motors. Feedback signals are provided that allow a variety of algorithms to control 3-phase PMSM and BLDC motors. Figure 1-1 shows an illustration of the system architecture. Figure 1-2 is a picture of the main board. The board features: • • • • • • • • • • • • • • • • • Power supply voltage input 12–24 V DC, extended up to 50 V (see chapter 2.2 Electrical Characteristics for details) Output current 4 A Power supply reverse polarity protection circuitry 3-phase bridge inverter (6 MOSFET’s) 3-phase MOSFET gate driver with overcurrent and undervoltage protection 3-phase and DC-bus-current-sensing shunts DC-bus voltage sensing 3-phase back-EMF voltage-sensing circuitry Low-voltage on-board power supplies Encoder/hall sensor sensing circuitry Motor power and signal connectors 2 connectors for daughter board connection CAN physical layer USB interface User LED, power-on LED, 6 PWM LED diodes, and SCI activity LED diodes Up, down, toggle switches Reset push-button 1.2 About This Manual Key items are in the following locations in this manual: • • • Setup instructions — 1.4 Setup Guide Schematics — Appendix A. 3-Phase BLDC/PMSM Motor Control Drive Schematics Pin assignments — Chapter 3 Pin Description 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 11 About This Manual • • Pin-by-pin description — 3.2 Signal Descriptions Description of reference design aspects of the board’s circuitry — Chapter 4 Design Consideration BDM or JTAG/EOnCE INTERFACE WORKSTATION CONTROLLER DAUGHTER BOARD BLDC/PMSM LOW-VOLTAGE MOTOR CONTROL DRIVE MOTOR Figure 1-1 System Configuration 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 12 Freescale Semiconductor Warnings Figure 1-2 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive 1.3 Warnings This development-tool set operates in an environment that includes rotating machinery. Be aware: • • Wear safety glasses, avoid ties and jewelry, use shields. Power devices and the motor can reach temperatures hot enough to cause burns. 1.4 Setup Guide Setup and connections for the 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive (main board) are straightforward. A controller daughter board connects to the main board via two 20-pin daughter board connectors. The system can be powered by a 12–24 V DC power supply. For safety reasons, and ease of making measurements, use a regulated DC power supply. Limit the power supply to under 5 A. Figure 13 depicts a complete setup. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor ‘ 13 Setup Guide The step-by-step setup procedure is as follows: 1. Plug a controller daughter board into the main board. 2. Connect the motor connector to the output connector J1, located along the back edge of the board. Phase A, phase B, and phase C are labelled on the bottom of the board. 3. For BLDC motors, it is important to put the wire color coded for phase A into the connector terminal labelled A, and so on for phase B and phase C. 4. Connect an encoder or hall sensor connector to the encoder/hall sensor interface J6. 5. Connect a current-limited DC power supply to connector J2 or J3, located on the left back edge of the board. The input voltage range is 12–24 V DC. Current limit should be set for less than 5 A. Only one power input is required. 6. Apply power to the main board. The green power-on LED D19 located on the front edge lights. The main board powers the controller daughter board. 7. Plug a standard AB-type USB cable into your PC and into the 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive. Then install the USB driver onto your PC to enable using FreeMASTER. Follow the instructions in the USB_driver_install.doc to properly install the USB driver. WARNING If an input voltage higher than 24 V is applied, the controller daughter board can be damaged. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 14 Freescale Semiconductor Setup Guide Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Optional Power J9 BDM Supply Connector for USB controller Controller Daughter board J10 J3 USB Power Connector Supply 12–24 V J2 Daughter board J7 J8 Connectors Daughter board Connectors BDM/JTAG Connector J1 J4 CAN Controller Daughter board is plugged into the 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Connector Phase_C 1 Phase_B 2 Phase_A 3 Motor J6 1 Hall/Encoder Connector 2 3 4 5 +5V GND HALL A / ENCODER PHASE A HALL B / ENCODER PHASE B HALL C / ENCODER INDEX Figure 1-3 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Setup 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor ‘ 15 Setup Guide 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 16 Freescale Semiconductor Chapter 2 Operational Description 2.1 Introduction Freescale’s 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive is a 3-phase power stage that will operate with DC input voltages in the range 12–24 V, 4 A. Together with the daughter boards, it provides a software-development platform that allows algorithms to be written and tested without designing and building any hardware. It supports a variety of algorithms for PMSM and brushless DC (BLDC) motors. The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains reverse-polarity protection circuitry, MOSFET-gate-drive circuits, analog-signal conditioning, low-voltage power supplies and bridge MOSFETs. The power devices do not need to be mounted on a heatsink. Figure 2-1 shows a block diagram. The daughter board is connected via two 20-pin rib-cage connectors, J7 and J8. Figure 3-1 shows pin assignments for the daughter board connectors. Power connections to the motor are made on output connector J1. Phase A, phase B, and phase C are labelled A, B, and C. Power requirements are met by a single external 12 V to 50 V DC power supply. Either input is supplied through connector J2 or J3. All connectors are marked on the bottom side of the board. Current-measuring circuitry is set up for 4 A full scale. Both bus and phase leg currents are measured. An overcurrent trip point is set at 3.75 A. There are controller daughter boards available with these controllers: • MC56F8013/23 — LQFP32 • MC9S08AC16 — LQFP44 • MCF51AC256 — LQFP80 • MC9S08MP16 — LQFP48 • MC56F8006 — LQFP32 More controller daughter boards are planned. Check the website www.freescale.com for more information. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 17 ENCODER/HALL-EFFECT MOTOR CAN J6 J1 J4 SWITCHES & LEDs 3-PH MOSFET BRIDGE USB/SCI BRIDGE J9 J10 INPUTS J2, J3 CAN PH. LAYER MOSFET DRIVERS J7, J8 DAUGHTER BOARD BDM for USB Controller USB Electrical Characteristics Legend: POWER SUPPLIES SIGNAL CONDITIONING DC BUS, PHASE voltages and currents, BEMF +5V, +3.3V, +3.3VA Module Connector Figure 2-1 Block Diagram 2.2 Electrical Characteristics The electrical characteristics in Table 2-1 apply to operations at 25 °C with a 24 V DC power supply voltage. Maximal value of the input voltage can be higher than 24 V. A 50 V maximal input voltage value is allowed, but the DC-bus and BEMF sensing circuits need to be modified. The divider resistors in these circuits need to be changed to change sensing range up to 50 V, if required. It prevents scaled quantities exceeding the maximum-allowed input voltage value on the controller input pins. WARNING If an input voltage higher than 24 V is applied, the controller daughter board can be damaged. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 18 Freescale Semiconductor Electrical Characteristics Table 2-1 Electrical Characteristics Characteristic Symbol Min Typ Max Units DC input voltage Vdc 12 — 24 V Quiescent Current* ICC — TBD — mA Logic 1 Input Voltage VIH 1.5 — 1.7 V Logic 0 Input Voltage VIL 0.9 — 1 V Input Resistance RIn — 10 — kΩ Analog Output Range VOut 0 — 3.3 V Bus Current Sense Voltage ISense — 413 — mV/A Bus Current Sense Offset Ioffset Bus Voltage Sense Voltage* VBus Bus Voltage Sense Offset Voffset +1.65 — 91 V — mV/V 0 V Bus Continuous Output Current ** IC — — 3.75 A Total Power Dissipation (per MOSFET) *** PD — — TBD W Dead Time (set by SW MC33927) **** toff 0 — 15 us * Full sensing range 3.3 V corresponds to 36.3 V. ** Overcurrent threshold is set at this level. *** The values were measured at 25 °C, for other temperatures the values may be different. **** Default dead time is 15 μs. Dead time depends on the timebase of the MC33927. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor ‘ 19 Electrical Characteristics 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 20 Freescale Semiconductor Chapter 3 Pin Description 3.1 Introduction Inputs and outputs are located on nine connectors and headers available on the board: • Three-pin motor connector J1 • Two power supply input connectors J2 and J3 • CAN header J4 • Encoder/hall-effect connector J6 • Two 20-pin daughter board connectors J7 and J8 • USB controller BDM (Background Debugger Monitor) tool header J9 • USB connector J10 Pin descriptions for each connector and header are identified in the following information. Figure 3-1 shows the pin assignments for the daughter board connectors J7 and J8. Table 3-4 and Table 3-5 show the signal descriptions. The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains several connectors and headers that serve for the connection of a power supply, for motor phases connection, and other functions. The input power supply, attached to the J2 or J3 input, must be in the range of 12–50 V DC. The output for the motor is done by the three-way connector J1. See 3.2.1 Motor Connector J1 for more details. Each connector and header is labelled from the bottom side of the board. 3.2 Signal Descriptions Pin descriptions are identified in this subsection. 3.2.1 Motor Connector J1 Power outputs to the motor are located on connector J1. Phase outputs are labelled A, B, and C. Table 31 contains pin assignments. Section 1.4 Setup Guide shows how to connect the motor. On a permanent magnet synchronous motor, any of the 3-phase windings can be connected here. For brushless DC motors, you must connect the wire color coded for phase A into the connector terminal labelled A, and so on for phase B and phase C. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 21 Signal Descriptions Table 3-1 Motor Connector J1 — Signal Descriptions Pin # Signal Name Description 1 C Supplies power to motor phase C. 2 B Supplies power to motor phase B. 3 A Supplies power to motor phase A. 3.2.2 Power Supply Input Connectors J2 and J3 The power supply input connectors, labelled J2 and J3, are located at the left back corner of the board. They accept DC voltages from 12 V to 50 V / 5 A maximum. The J2 connector is a two-wire connector, the J3 connector is a 2.1 mm power jack for plug-in type DC power supply connections. The power supply polarity label for connector J2 is located on the bottom side. The board has reverse polarity protection. Power applied to the board is indicated by a green color +5 V LED. This LED is the nearest one located to the reset switch. 3.2.3 CAN Header J4 This shows the CAN (Controller Area Network) bus header pin description. The CAN interface is located on the left edge of the board. Table 3-2 CAN Header J4 — Signal Descriptions Pin # Signal Name Description 1 No Connect 2 No Connect 3 CANL Low-level CAN voltage input/output 4 CANH High-level CAN voltage input/output 5 GND 6 No Connect 7 No Connect 8 No Connect 9 No Connect 10 No Connect Power supply ground 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 22 Freescale Semiconductor Signal Descriptions 3.2.4 Encoder/Hall-Effect Interface J6 The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains an encoder/hall-effect interface for position and speed sensing. The encoder/hall-effect interface is located on the right edge of the board. The circuit is designed to accept +3.3 V to +5 V encoder or hall-effect sensor inputs. Input noise filtering is supplied on the input path to the encoder/hall-effect interface. Table 3-4 shows the encoder/hall-effect interface pin description. Table 3-3 Encoder/Hall-Effect Interface J6 — Signal Descriptions Pin # Signal Name Description 1 +5V Supplies power from the board to either encoder or hall sensors. 2 GND Encoder or hall sensors’ ground. 3 PHASE A Encoder or hall sensors’ phase A input. 4 PHASE B Encoder or hall sensors’ phase B input. 5 INDEX Encoder, index, or hall sensors’ C input. 3.2.5 Daughter Board Connectors J7 and J8 Signal inputs and outputs for interconnection with different types of daughter boards are situated on two 20-pin connectors, located on the board’s front side. Figure 3-1 shows pin assignments. This figure shows the physical layout of the connectors. The physical view assumes that the board is oriented in such way that its title can be read from left to right. Table 3-4 and Table 3-5 contain lists of signal descriptions for connectors J7 and J8. Table 3-4 Daughter Board Connector J7 — Signal Descriptions Pin # Signal Name Description 1 GND Digital and power ground. 2 +3.3V Digital +3.3 V power supply. 3 CANTX CAN transmit-data input. 4 CANRX CAN receive-data output. 5 PWM_AT Gate-drive signal for the top half-bridge of phase A. A logic low turns on phase A’s top switch. 6 PWM_AB Gate-drive signal for the bottom half-bridge of phase A. A logic high turns phase A’s bottom switch on. 7 PWM_BT Gate-drive signal for the top half-bridge of phase B. A logic low turns on phase B’s top switch. 8 PWM_BB Gate-drive signal for the bottom half-bridge of phase B. A logic high turns phase B’s bottom switch on. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor ‘ 23 Signal Descriptions Table 3-4 Daughter Board Connector J7 — Signal Descriptions Pin # Signal Name Description 9 PWM_CT Gate-drive signal for the top half-bridge of phase C. A logic low turns on phase C’s top switch. 10 PWM_CB Gate-drive signal for the bottom half-bridge of phase C. A logic high turns phase C’s bottom switch on. 11 OC Overcurrent signal from 3-phase bridge driver. 12 INT Interrupt signal from 3-phase bridge driver. 13 TxD TxD signal between the JM60 and daughter board. 14 RxD RxD signal between the JM60 and daughter board. 15 TOGGLE_ SWITCH_ON1 Toggle-switch input (switch in position ON1). 16 TOGGLE_ SWITCH_ON2 Toggle-switch input (switch in position ON2). 17 UP_SWITCH 18 DOWN_SWITCH 19 USER_LED 20 /RESET Up switch input. Down switch input. User LED signal. RESET signal only for controller on daughter board and 3-phase bridge driver. * * JM60 reset signal is connected only on BDM connector J9. Table 3-5 Daughter Board Connector J8 — Signal Descriptions Pin # Signal Name Description 1 GNDA Analog power supply ground. 2 +3.3VA Analog +3.3 V power supply. 3 I_sense_A Analog sense signal that measures the current in phase A. It is scaled at 50 V per A of DC-bus current. 4 I_sense_B Analog sense that measures the current in phase B. It is scaled at 0.563 V per A of DC-bus current. 5 I_sense_C Analog sense signal that measures the current in phase C. It is scaled at 0.563 V per A of DC-bus current. 6 BEMF_sense_A Analog sense signal that measures phase A back EMF. It is scaled at 8.09 mV per V of DC-bus voltage. 7 BEMF_sense_B Analog sense signal that measures phase B back EMF. It is scaled at 8.09 mV per V of DC-bus voltage. 8 BEMF_sense_C Analog sense signal that measures phase C back EMF. It is scaled at 8.09 mV per V of DC-bus voltage. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 24 Freescale Semiconductor Signal Descriptions Table 3-5 Daughter Board Connector J8 — Signal Descriptions (Continued) Pin # Signal Name 9 V_sense_DCB Analog sense signal that measures bus voltage. It is scaled at 8.09 V per V of DCbus voltage. 10 V_sense_DCB/2 Analog sense signal that measures bus voltage. It is scaled at 8.09 V per V of DCbus voltage. 11 I_sense_DCB Analog sense signal that measures bus current. It is scaled at 8.09 V per A of DCbus current. 12 ENC_PhaseA Encoder or hall sensor phase A input pin logic. 13 ENC_PhaseB Encoder or hall sensor phase B input pin logic. 14 ENC_Index 15 DRV_EN 16 /SS 17 MOSI SPI pin master out slave in pin for 3-phase bridge driver. 18 SCLK SPI pin clock source pin input for 3-phase bridge driver. 19 MISO SPI pin master in slave out pin for 3-phase bridge driver. 20 GND Digital and power ground. GND CANTX PWM_AT PWM_BT PWM_CT OC TxD TOGGLE_SWITCH_ON1 UP_SWITCH USER_LED Description Encoder index or hall sensor phase C input pin logic. 3-phase bridge-gate driver enable signal. SPI pin chip select pin for 3-phase bridge driver. 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 +3.3V CANRX PWM_AB PWM_BB PWM_CB INT +RxD TOGGLE_SWITCH_ON2 DOWN_SWITCH /RESET GNDA I_sense_A I_sense_C BEMF_sense_B V_sense_DCB I_sense_DCB ENC_PhaseB DRV_EN MOSI MISO 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 +3.3VA I_sense_DCB BEMF_sense_A BEMF_sense_C V_sense_DCB/2 ENC_PhaseA ENC_Index /SS SCLK GND Figure 3-1 J7 and J8 Connector Physical View 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor ‘ 25 Signal Descriptions 3.2.6 USB Controller BDM Header J9 It serves for updating the software for JM60. Signals are described in Table 3-6. The BDM header J9 is not populated. Table 3-6 USB Controller BDM Header J9 — Signal Descriptions Pin # Signal Name 1 BKGD/MS 2 GND 3 No Connect 4 /RESET_JM 5 No Connect 6 +3.3V Description Background debug pin Digital ground RESET signal Digital +3.3 V power supply 3.2.7 USB Connector J10 USB connector J10 serves for connecting the controller to the host PC via a virtual serial port. Signals are described in Table 3-7. Table 3-7 USB Connector J10 — Signal Descriptions Pin # Signal Name Description 1 No Connect 2 UDSBDN Negative USB differential signal 3 UDSBDP Positive USB differential signal 4 GND Digital ground 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 26 Freescale Semiconductor Chapter 4 Design Consideration 4.1 Overview The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive is designed for software development. In addition to the hardware needed to run a motor, a variety of feedback signals that facilitate controlalgorithm development are provided. A set of schematics for the drive appears in the following section. Circuit descriptions for the drive appear in 4.2 3-Phase Bridge through 4.12 Control Switches. One phase leg of the 3-phase bridge is examined in 4.2 3-Phase Bridge. Bus voltage and bus current feedback are discussed in 4.3 Bus Voltage and Current Feedback. Safety functions are highlighted in 4.4 Overcurrent, Undervoltage, and Other Safety Functions. Back-EMF signals appear in 4.5 Back EMF Signals. Phase current sensing is discussed in 4.6 Phase Current Sensing. The test points description and LED description are in 4.7 Test Points and LED Indication, all power supplies and voltage reference are described in 4.8 Power Supplies and Voltage Reference. Encoder circuitry is described in 4.9 Encoder/Hall-Effect Interface. The CAN physical layer interface is discussed in 4.10 CAN Interface. The USB interface appears in section 4.11 USB/SCI Bridge and finally, push-buttons and the toggle switch are described in 4.12 Control Switches. 4.2 3-Phase Bridge The output stage is configured as a 3-phase bridge with MOSFET output transistors. It is simplified considerably by an integrated gate driver that has an overcurrent, undervoltage, and other safety features. Figure 4-1 shows a schematic of one phase. At the input, pull-down resistor R99 sets a logic low in the absence of a signal for the low side transistor. Open input pull-down is important, because the power transistors must stay off in the case of a broken connection or an absence of power on the daughter board. Gate-driver inputs are 3 V compatible. A Freescale device, the MC33927, supplies the gate drive. The MC33927 also provides undervoltage hold-off and overcurrent. Undervoltage hold-off threshold value is 8 V. The MC33927 has an implemented dead time insertion, which can be configured using SPI. The default dead time value is typically 15 μs. Current limiting and undervoltage hold-off are discussed further in 4.4 Overcurrent, Undervoltage, and Other Safety Functions. One important design decision in a motor drive is the selection of gate-drive impedance for the output transistors. In Figure 4-1, resistor R69, R70, diode D11, and the MC33927 nominal 100 mA current-sinking capability determine gate-drive impedance for the lower half-bridge transistor. A similar network is used on the upper half-bridge. These networks set the turn-on gate-drive impedance at approximately 100 Ω and the turn-off gate drive to approximately 100 mA. These values produce transition times of approximately 285 ns. Transition times of this length represent a carefully weighed compromise between power dissipation and noise generation. Generally, transition times longer than 250 ns tend to get power hungry at non-audible 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 27 3-Phase Bridge PWM rates; transition times under 50 ns create di/dts so large that proper operation is difficult to achieve. The BLDC Motor Control Drive is designed with switching times at the higher end of this range to minimize noise. Anti-parallel diode softness is also a primary design consideration. If the anti-parallel diodes in an off-line motor drive are allowed to snap, the resulting di/dts can cause noise management problems, difficult to solve. In general, the peak to zero di/dt should be approximately equal to the di/dt applied to turning off the anti-parallel diodes. The FDS3672 MOSFETs used in this design are targeted at this kind of reverse recovery. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 28 Freescale Semiconductor PWM_AB PWM_AT R99 10K PWM_AT TP25 GND PWM_AB TP26 28 25 26 18 19 20 21 13 16 22 12 15 23 5 3 4 OC_TH AMP_N AMP_P CS SI SCLK SO PA_LS PB_LS PC_LS PA_HS PB_HS PC_HS RST EN1 EN2 U6 VSS 29 7 8 9 GND0 GND1 PGND for QPUMP PGNDA PGNDB PGNDC 30 31 2 44 39 34 PUMP VPUMP(12V) VBAT(42V) 14 32 51 54 INT MC33927 AMP_OUT OC_OUT NC6 NC5 NC4 NC3 NC2 NC1 PHASEC PHASEB PHASEA PC_BOOT PC_HS_G PC_HS_S PC_LS_G PB_BOOT PB_HS_G PB_HS_S PB_LS_G PA_BOOT PA_HS_G PA_HS_S PA_LS_G VDD VLS_CAP VLS VPWR EP 55 24 27 53 52 50 49 33 6 11 10 1 38 37 36 35 43 42 41 40 48 47 46 45 17 D11 C20 1UF D10 51R 51R 51R R67 R69 I_sense_A2 I_sense_A1 51R R70 MBR0520LT1G R66 MBR0520LT1G 4 4 5 6 7 8 3 2 1 5 6 7 8 Freescale Semiconductor R85 0.1R FDS3672 Q6 FDS3672 Q3 GND_LSFET 3 2 1 DCB_pos Phase_A 3-Phase Bridge Figure 4-1 Phase Output 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 29 Bus Voltage and Current Feedback 4.3 Bus Voltage and Current Feedback Figure 4-2 shows the circuitry that provides feedback signals proportional to bus voltage and bus current. Bus voltage is scaled down by a voltage divider consisting of R23, R27, and R104. The values are chosen in such way that a 36.3 V bus voltage corresponds to 3.3 V at output V_sense_DCB. The V_dcb is scaled at 91 mV per V of the DC-bus voltage, and is connected to the daughter board connector J8 pin 9 V_sense_DCB. An additional output, V_sense_DCB/2, provides a reference used in zero-crossing detection. The V_dcb/2 is scaled at 45.5 mV per V of the DC-bus voltage, and is connected to the daughter board connector J8 pin 10 V_sense_DCB/2. Bus current is sampled by resistor R88 in Figure A-9, and amplified in the MC33927’s operational amplifier (Figure 4-2). This circuit provides a voltage output suitable for sampling on A/D (analog-todigital) inputs. The MC33927’s operational amplifier is used as a differential amplifier for bus-current sensing. With R82 = R83, R102 = R103, and R81 = R84, the gain is given by: A = R81 / (R82 + R102) (EQ 4-1) The output voltage is shifted up by +1.65 V_REF to accommodate positive and negative current swings. A ±400 mV voltage drop across the sense resistor corresponds to a measured current range of ±4 A. The AMP_OUT signal is internally connected to the overcurrent comparator of the MC33927, and provides an overcurrent triggering function. A discussion about overcurrent limiting follows in chapter 4.4 Overcurrent, Undervoltage, and Other Safety Functions. In addition, the AMP_OUT is connected to the daughter board connector J8 pin 11 I_sense_DCB. The shunt resistor is represented by a 0.1 Ω resistance Welwyn SMD precision resistor, the same as the phase-current measurement resistors. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 30 Freescale Semiconductor Overcurrent, Undervoltage, and Other Safety Functions VLS_CAP DCB_pos R65 EN1 EN2 R98 10K PA_HS PB_HS PC_HS 13 16 22 PA_LS PB_LS PC_LS 18 19 20 21 CS SI SCLK SO 25 26 AMP_N AMP_P OC_TH R78 1.0K C23 0.1UF GND 14 32 51 54 0 OHM R68 INT 17 PA_BOOT PA_HS_G PA_HS_S PA_LS_G 48 47 46 45 PB_BOOT PB_HS_G PB_HS_S PB_LS_G 43 42 41 40 PC_BOOT PC_HS_G PC_HS_S PC_LS_G 38 37 36 35 PHASEC PHASEB PHASEA 11 10 1 NC6 NC5 NC4 NC3 NC2 NC1 53 52 50 49 33 6 AMP_OUT OC_OUT 24 27 10K INT V_dcb TP13 DCB_pos 3.3V @ R27 1.5K V_dcb/2_s TP45 1.65V @ DC-Bus/2 = 18.15V V_sense_DCB/2 R104 1.5K AMP_OUT OC MC33927 GNDA GND +3.3VA DC Bus Current Sensing GNDA D16 MBR0520LT1G R82 AMP_P I_Sense_DCB2 2 R83 AMP_N I_Sense_DCB1 R84 MC33502DG 1 AMP_OUT 1.6K C45 47PF 4 R102 Idcb_s TP1 3 OpAmp is within 3PP-A 8 R81 7.5K I_sense_DCB + GND GND_LSFET 220 OHM DC-Bus = 36.3V V_sense_DCB GND +1.65V_REF 220 OHM R103 R23 30K V_dcb_s TP15 - OC_TH @ 3.09V @ 3.75A 15.0K 29 VSS +3.3V DCB_pos EP 12 15 23 28 R77 RST 55 AMP_N AMP_P 5 30 31 2 44 39 34 GND /RESET GND0 GND1 PGND for QPUMP PGNDA PGNDB PGNDC 3 4 DRV_EN PUMP VPUMP(12V) VBAT(42V) U6 VDD VLS_CAP VLS VPWR 7 8 9 VDD VLS U1A 1.65V +/- 1.65V Imax = 4A @ +/- Imax 1.6K 7.5K +3.3VA Figure 4-2 Bus Feedback 4.4 Overcurrent, Undervoltage, and Other Safety Functions The MC33927 provides overcurrent and undervoltage functions (Figure 4-2). Bus current feedback is filtered to remove spikes, and this signal is fed into the MC33927 current comparator. Therefore, when bus current exceeds 3.75 A, all six output transistors are switched off. Once a fault state has been detected, all six gate drivers are off, until the fault state is cleared by the low-level on/RESET pin, or by switching the board off. Then you can switch the power stage on. The undervoltage function is implemented internally. The MC33927’s supply voltage is sensed internally. If this voltage is lower than 8 V, the hold-off circuit is evaluated, and an interrupt is generated if set. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 31 Back EMF Signals The MC33927 safety functions keep the driver operating properly and within safe limits. Current limiting by itself, however, does not necessarily ensure that a board is operating within safe thermal limits. The MC33927 has a thermal warning feature. If the temperature rises above 170 °C on one of the three detectors, then an interrupt is generated if set. The MC33927 driver has also other safety features such as desaturation detection, phase error, framing error, write error after the lock, and exiting RESET. All these features can be configured through SPI to trigger interrupts. Detailed information is available in the driver datasheet. 4.5 Back EMF Signals Back EMF signals are included to support sensorless algorithms for BLDC motors, and dead time distortion correction for sinusoidal motors. Referring to Figure 4-3, which shows circuitry for phase A, the raw phase voltage is scaled down by a voltage divider consisting of R20 and R22. Output from this divider produces back EMF sense voltage BEMF_sense_A. Resistor values are chosen such that a 36.3 V of phase voltage corresponds to a 3.3 V A/D input. The BEMF_sense_A is led directly to the daughter board connector J8 pin 6, without any offset correction (see Figure A-6). The V_sense_DCB and V_sense_DCB/2 are provided by the R23, R27, and R104 resistor divider from the bus voltage (see Figure 4-2). BEMF_A TP11 Phase_A BEMF_A_s TP12 R20 30K 3.3V @ Phase_A = 36.3V BEMF_sense_A R22 3.0K GNDA Figure 4-3 Back EMF Sensing — Phase A 4.6 Phase Current Sensing Sampling resistors provide phase current information for all three phases. Because these resistors sample the current in the lower phase legs, they do not directly measure the phase current. However, given phase voltages for all three phases, phase current can be constructed mathematically from the lower phase leg values. The measurement circuitry for one phase is shown in Figure 4-4. Referencing the sampling resistors to the negative motor rail makes the measurement circuitry straightforward and inexpensive. Current is sampled by resistor R85 and amplified by the differential amplifier U1B. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 32 Freescale Semiconductor Test Points and LED Indication This circuit provides a voltage output suitable for sampling on A/D inputs. The MC33502DG is used as a differential amplifier. With R2 = R7,R3 = R5, and R4 = R6, the gain is given by: A = R2 / (R3 + R4) (EQ 4-2) The input voltage is shifted up by +1.65 V_REF to accommodate both positive and negative current swings. A ±400 mV voltage drop across the shunt resistor corresponds to a measured current range of ±4 A. As a source for +1.65 V_REF, we use the voltage divider described in chapter 4.8.5 +1.65 V Reference. The gain of this operational amplifier is 4.12 with the +1.65 V offset, in other words the output ±1.65 V corresponds to ±4 A. The output is connected to the daughter board connector J8. R2 IaTP2 7.5K R3 R4 I_sense_A1 6 5 I_sense_A2 220 OHM 1.6K 1.65V +/- 1.65V Imax = 4A MC33502DG 7 @ +/- Imax I_sense_A + 220 OHM R5 Ia_s TP4 1.6K C1 47PF R6 - Ia+ TP3 U1B R7 7.5K +3.3VA R90 68R +1.65V_REF TP38 R93 68R GNDA C44 0.1UF GNDA Figure 4-4 Phase Current Sensing 4.7 Test Points and LED Indication Some voltages and currents of the 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive can be sensed, whilst some are connected to the daughter board connector pins. Those are: back-EMF voltage, phase current, bus-power voltage, half of bus-power voltage, bus current, PWM signal for all six switches of the 3-phase power bridge, and other control signals. The four test points are located near the corners of the board and provide a GND signal (digital ground) for easy oscilloscope attachment. As mentioned in previous chapters, the board contains more grounds — analog and digital. The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains 45 round-shape test points to allow the user to easily check the voltage of all important points: 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 33 Test Points and LED Indication • TP1 Idcb_s — Bus-current output test point, scaled at 0.413 V per A of bus current B, and shifted by 1.65 V. • TP2 Ia– — Phase A current sense resistor test point for node I_sense_A1. • TP3 Ia+ — Phase A current sense resistor test point for node I_sense_A2. • TP4 Ia_s — Phase A current output test point for node I_sense_A, scaled at 0.413 V per A of phase current A, and shifted by 1.65 V. • TP5 Ib– — Phase B current sense resistor test point for node I_sense_B1. • TP6 Ib+ — Phase B current sense resistor test point for node I_sense_B2. • TP7 Ib_s — Phase B current output test point of node I_sense_B, scaled at 0.413 V per A of phase current B, and shifted by 1.65 V. • TP8 Ic– — Phase C current sense resistor test point for node I_sense_C1. • TP9 Ic+ — Phase C current sense resistor test point for node I_sense_C2. • TP10 Ic_s — Phase C current output test point of node I_sense_C, scaled at 0.413 V per A of phase current C, and shifted by 1.65 V. • TP11 BEMF_A — Back EMF phase A test point. • TP12 BEMF_A_s — Back EMF phase A test point, scaled at 91 mV per V of phase voltage A. • TP13 V_dcb — Bus voltage test point. • TP14 BEMF_B — Back EMF phase B test point. • TP15 V_dcb_s — Bus voltage test point, scaled at 91 mV per V. • TP16 BEMF_B_s — Back EMF phase B test point, scaled at 91 mV per V of phase voltage B. • TP17 BEMF_C — Back EMF phase C test point. • TP18 BEMF_C_s — Back EMF phase C test point, scaled at 91 mV per V of phase voltage C. • TP19 CANTX — TX signal for CAN physical layer. • TP20 CANRX — RX signal for CAN physical layer. • TP21 TxD — TxD signal for SCI communication between JM60 and daughter board controller. • TP22 RxD — RxD signal for SCI communication between JM60 and daughter board controller. • TP23 — signal activity on TxD signal. • TP24 — signal activity on RxD signal. • TP25 PWM_AT — PWM control signal for top transistor gate of phase A, test point on connector J7 pin. • TP26 PWM_AB — PWM control signal for bottom transistor gate of phase A, test point on connector J7 pin. • TP27 PWM_BB — PWM control signal for bottom transistor gate of phase B, test point on connector J7 pin. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 34 Freescale Semiconductor Test Points and LED Indication • TP28 PWM_CT — PWM control signal for top transistor gate of phase C, test point on connector J7 pin. • TP29 PWM_BT — PWM control signal for top transistor gate of phase B, test point on connector J7 pin. • TP30 PWM_CB — PWM control signal for bottom transistor gate of phase C, test point on connector J7 pin. • TP31 /SS — Chip-select signal for SPI communication. • TP32 MOSI — MOSI signal for SPI communication. • TP33 SCLK — Clock signal for SPI communication. • TP32 MISO — MISO signal for SPI communication. • TP35 V_dcb — Bus-voltage test point. • TP36 +5V — This point is the output of the U7 switching step-down inverter. It serves as the power supply for the on-board encoder and CAN physical layer interface. • TP37 +3.3V — This point is the output of the U8 linear voltage regulator. It serves as the power supply for the on-board logic inverter and JM60 controller, and as the source for generating +3.3 VA. It is connected to the daughter board connector J7. • TP38 +1.65V_REF — Reference-voltage test point. • TP39 GND — Ground test point. • TP40 GND — Ground test point. • TP41 GND — Ground test point. • TP42 GND — Ground test point. • TP43 GNDA — Analog ground test point. • TP44 GNDA — Analog ground test point. • TP45 V_dcb/2_s — Half of bus voltage test point, scaled at 45.5 mV per V. This board also contains ten LEDs as indicators: • D1 — PWM_AT indication LED, activated on low level. • D2 — PWM_AB indication LED, activated on high level. • D3 — PWM_BT indication LED, activated on low level. • D4 — PWM_BB indication LED, activated on high level. • D5 — PWM_CT indication LED, activated on low level. • D6 — PWM_CB indication LED, activated on high level. • D7 — User LED diode for user-defined purposes, activated on high level. • D8 — Indicated communication activity on TxD pin. • D9 — Indicated communication activity on RxD pin. • D19 — Indicates that the +5 V level is properly generated. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 35 Test Points and LED Indication For more details, see Figure 4-5. +3.3V +5V R55 270 OHM TP23 D8 2 D7 HSMG-C170 LED Green D19 HSMG-C170 LED Green R63 2 +3.3V 2 R91 820 OHM PTB0 1 HSMG-C170 270 OHM USER LED 3 1 TP24 GND Q2 MMBT2369ALT1G 1 USER LED 4.7K R64 2 +3.3V PTB1 1 HSMY-C170 2 1 R57 D9 270 OHM GND Figure 4-5 LED Indication For more details see Figure 4-6. 14 +3.3V PWM_AT 1 U4A 74AC14 PWM0 R44 2 D1 2 GND PWM_AB 3 GND 2 +3.3V HSMY-C170 7 270 OHM 1 LED Yellow U4B 74AC14 PWM1 R47 4 D2 1 270 OHM HSMY-C170 LED Yellow U4C 74AC14 PWM_BT 5 PWM2 R49 6 D3 2 270 OHM 1 GND 2 +3.3V HSMY-C170 LED Yellow U4D 74AC14 PWM_BB 9 PWM3 R51 8 D4 1 270 OHM HSMY-C170 LED Yellow U4E 74AC14 PWM_CT 11 PWM4 R54 10 D5 2 270 OHM 1 GND 2 +3.3V HSMY-C170 LED Yellow U4F 74AC14 PWM_CB 13 PWM5 R56 12 D6 1 270 OHM HSMY-C170 LED Yellow Figure 4-6 PWM LED Indication 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 36 Freescale Semiconductor Power Supplies and Voltage Reference 4.8 Power Supplies and Voltage Reference The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains devices that require various voltage levels of +5 V or +3.3 V. 4.8.1 Input Power Supply The bus can be supplied from two input connectors, J2 and the J3 power jack. The power source should be able to deliver at least 4 A. The DC-bus has reverse polarity protection. The MC33927 driver is supplied directly from the DC-bus. The +5 V power supply is served from bus voltage. Q1 CON_2_TB 2 A 1 3 J2 J3 DCB_pos 2 1 B FQD11P06 R1 1M + + 1 2 3 C33 100uF C32 100uF C34 0.1UF POWER_JACK 12-50V/5A GND GND GND Figure 4-7 DC-Bus Input Circuitry 4.8.2 +5 V Power Supply The +5 V level is generated by means of the LM2594HVM switching step-down regulator (see Figure 48), which generates this level from bus voltage. This converter can supply up to 500 mA. This voltage level serves the MC33269D linear regulator, encoder, and CAN physical layer interface. If the LM2594HVM converter operates properly, the D19 green LED is lit. V_dcb TP35 U7 L2 8 1 1 NC1 NC2 NC3 ON/OFF OUT 100UH 2 D18 MURS120T3 + C37 100UF C38 0.1UF 2 1 2 3 GND + 6 C35 68.0UF LM2594HVM-5.0 FB 4 VIN 5 7 DCB_pos +5V TP36 +5V GND GNDGND GND GND GND Figure 4-8 +5 V Power Supply 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 37 Encoder/Hall-Effect Interface 4.8.3 +3.3 V Power Supply An important voltage level for this board is +3.3 V. This voltage level is obtained from the MC33269D linear voltage regulator, and can supply up to 800 mA (Figure 4-9). The +3.3 V level is used to supply the on-board logic inverter and JM60 controller. It is connected to the daughter board connector J7. D17 +5V TP36 U8 R89 1 4 5 8 +5V 0 OHM +3.3V TP37 MBR0520LT1G GND/ADJVOUT1 VIN VOUT2 NC1 VOUT3 NC2 VOUT4 +3.3V 2 3 6 7 1 2 1uH MC33269D_3.3 + C38 0.1UF C39 47UF C40 0.1UF GND GND GND GND + C41 0.1UF L3 1 GND +3.3VA L1 C42 0.1UF C43 100PF C36 47UF 2 1uH GNDA Figure 4-9 +3.3 VA / +5 VA Power Supply 4.8.4 +3.3 VA Power Supply The +3.3 VA power supply is drawn from the +3.3 V level by passive filtering through L1and L3 (see Figure 4-9). Maximum current load should not exceed 200 mA. This voltage level serves the on-board operational amplifiers and voltage reference. It is also connected to the daughter board connector J8. 4.8.5 +1.65 V Reference The +1.65 V reference is generated from the +3.3 VA level simply by the voltage divider (see Figure 410). This reference serves to shift the DC-bus and phase-current-sensing values. It can sink up to 30 mA. +3.3VA R90 68R +1.65V_REF TP38 +1.65V_REF R93 68R GNDA C44 0.1UF GNDA Figure 4-10 +1.65 V Reference Source 4.9 Encoder/Hall-Effect Interface 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 38 Freescale Semiconductor CAN Interface The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive contains an encoder/hall-effect interface. The circuit is designed to accept +3.3 V to +5.0 V encoder or hall-effect sensor inputs. Input noise filtering is supplied on the input path for the encoder/hall-effect interface. Filtered signals are then connected to the controller daughter board connector J8. Figure 4-11 contains the encoder interface. +5V R32 1.0 K R33 R34 24 OHM 1.8K C6 470PF ENC_PhaseA +5V GND R36 1.0 K R37 R38 24 OHM 1.8K C7 470PF ENC_PhaseB +5V J6 1 2 3 4 5 GND +5V HDR_1X5_M GND R41 1.0 K R42 R43 24 OHM 1.8K C8 470PF ENC_Index GND Figure 4-11 Encoder/Hall-Effect Circuitry 4.10 CAN Interface The board contains a CAN interface. The main part of the interface is CAN controller PCA82C250. The PCA82C250 is the interface between the CAN communication controller and the physical bus. The device provides differential transmit capability to the bus and differential receive capability to the CAN controller. The CAN interface is compatible with ISO 11898, and allows a maximum data transfer rate of 1 Mbit/s. The CAN transceiver is short-circuit protected, transient-bus protected, thermal protected, RFI and EMI immunized. The CAN transceiver is connected via CANTX and CANRX signals to the daughter board connector J7. Bus signals CANL and CANH are connected to the CAN bus header J4. Shorten the jumper terminal J5 to attach the bus’ end termination resistor. This resistor ensures that data will not be reflected at the bus’ end. The schematic diagram of the CAN is in Figure 4-12. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 39 USB/SCI Bridge J4 1 3 5 7 9 CANL GND 2 4 6 8 10 CANH HDR 2X5 2 1 R35 120 OHM HEADER/CAN bus termination J5 HDR_1X2_M R39 CANTX TP19 R40 CANRX TP20 +5V 1.0 K U3 CANTX 1 8 TXD RS CANRX 4 5 RXD VREF 2 GND GND 0 OHM VCC 3 CANH CANL 7 6 CANH CANL PCA82C250TD Figure 4-12 CAN Interface 4.11 USB/SCI Bridge The 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive provides a USB interface by the use of USB level converter circuitry, referred to in the USB/SCI bridge schematic diagram in Figure A-7. The core of the USB interface is the MC9S08JM60 controller and it’s universal serial bus (USB) device controller. The USB device controller module is based on the Universal Serial Bus Specification Rev 2.0, and provides a single-chip solution for full-speed (12 Mbps) USB device applications. The USB level converter transitions the SCI UART’s +3.3 V signal levels to USB compatible signal levels, and connects to the host’s serial port via the standard USB connector J10. The pinout of the USB connector is listed in Table 3-7. To enable proper working of the serial interface, code for the USB/SCI bridge should be loaded in the JM60 controller. LED diodes D8 and D9 indicate communication activity. 4.12 Control Switches Three on-board push-button switches and one toggle switch are provided for the user’s program control (see Figure 4-13). Two push-buttons (up, down) are directly connected to the daughter board connector J7. One push-button (RESET) is provided for setting the daughter board controller RESET input pin to logic level low. The RESET signal is connected to the 3-phase driver and to the daughter board connector J7. A toggle switch is connected to the daughter board connector J7 too. This toggle switch has 3 stable positions — two on states in edge positions, and one off state in the middle position. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 40 Freescale Semiconductor Control Switches +3.3V R45 4.7K R46 SW1 1 3 2 4 UP_SWITCH 1.8K KSC621J +3.3V GND R48 4.7K R50 SW2 1 3 2 4 DOWN_SWITCH 1.8K KSC621J +3.3V GND +3.3V SW3 TL39P0050 R96 4.7K R52 4.7K R97 R53 1 TOGGLE_SWITCH_ON1 2 3 TOGGLE_SWITCH_ON2 1.8K 1.8K GND RESET +3.3V SW4 A A1 GND R65 4.7K GND B B1 /RESET /RESET C20 0.1UF LIGHT TOUCH PUSH BUTTON GND Figure 4-13 Control Switches 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 41 Control Switches 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 42 Freescale Semiconductor Appendix A. 3-Phase BLDC/PMSM Motor Control Drive Schematics 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 43 44 J1 HDR1x3 +3.3V +3.3V DCB_Pos GND +3.3VA +3.3VA +3.3VA +1.65V_REF GND Gate_AT Gate_AB Source_AT Phase_A Phase_B Phase_C Gate_AT Gate_AB PWM_AT PWM_AB PWM_CT PWM_CB Gate_BT Gate_BB Source_BT Gate_BT Gate_BB Gate_CT Gate_CB Source_CT Gate_CT Gate_CB Phase_A Phase_B Phase_C I_sense_A1 I_sense_A2 I_sense_A1 I_sense_A2 I_sense_B1 I_sense_B2 I_sense_B1 I_sense_B2 I_sense_C1 I_sense_C2 I_sense_C1 I_sense_C2 DCB_pos DCB_pos /RESET DRV_EN I_Sense_DCB1 I_Sense_DCB2 GND_LSFET GND Power Circuit GND_LSFET INT OC GND_LSFET INT OC /SS MISO MOSI SCLK /RESET DRV_EN MOSFET Drivers BEMF_sense_C BEMF_sense_B BEMF_sense_A I_sense_C I_sense_B I_sense_A V_sense_DCB/2 V_sense_DCB I_sense_DCB GND +3.3V +5V GNDA +3.3VA PWM_CT PWM_CB MicroHeaders&others_circuits +3.3VA +3.3V +5V GND GNDA Q1 CON_2_TB B 2 A 1 3 J2 J3 DCB_pos 2 FQD11P06 DCB_pos R1 1M +5V +3.3V +3.3VA +1.65V_REF 1 2 3 +5V +3.3V +3.3VA +1.65V_REF GND GNDA POWER_JACK Power Supplies 12-50V/5A GNDA GND GNDA BEMF_sense_C BEMF_sense_B BEMF_sense_A I_sense_C I_sense_B I_sense_A V_sense_DCB/2 V_sense_DCB I_sense_DCB I_sense_DCB_out Analog sensing GND_LSFET PWM_BT PWM_BB GNDA DCB_pos DCB_neg I_sense_DCB1 /SS I_sense_DCB2 MISO MOSI SCLK I_sense_DCB_out 1 Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 PWM_BT PWM_BB PWM_AT PWM_AB +1.65V_REF +1.65V_REF +1.65V_REF +3.3VA Motor 1 2 3 DCB_Pos GND Figure A-1 Board Overview GND Freescale Semiconductor R2 Idcb_s TP1 GNDA 6 5 I_sense_A2 1.6K 2 MC33502DG 1 I_sense_A I_sense_DCB_out 3 U1B I_sense_DCB U1A 1.65V +/- 1.65V Imax = 4A R7 7.5K 1.65V ref +3.3VA IbTP5 R10 7.5K R8 R9 I_sense_B1 I_sense_B2 2 3 1.6K R13 7.5K 1.65V ref 220 OHM GNDA 4 1.6K C2 47PF R12 8 220 OHM R11 + Ib+ TP6 - Ib_s TP7 MC33502DG 1 1.65V +/- 1.65V Imax = 4A @ +/- Imax I_sense_B U2A GNDA GNDA +3.3VA +3.3VA +3.3VA +1.65V_REF +1.65V_REF R14 IcTP8 R15 7.5K R16 I_sense_C1 220 OHM R18 Ic_s TP10 1.6K C3 47PF R17 6 5 I_sense_C2 220 OHM 1.6K MC33502DG 7 1.65V +/- 1.65V Imax = 4A @ +/- Imax I_sense_C + Ic+ TP9 - 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 220 OHM MC33502DG 7 @ +/- Imax 8 1.6K C1 47PF R6 1.65V +/- 1.65V Imax = 4A + 220 OHM R5 - Ia+ TP3 Ia_s TP4 4 R4 I_sense_A1 + R3 7.5K - IaTP2 U2B +3.3VA +3.3VA R19 7.5K C4 0.1UF GNDA +1.65V_REF 45 Figure A-2 Analog Sensing — Phase Current Sensing C5 0.1UF GNDA @ +/- Imax 46 BEMF_A TP11 Phase_A BEMF_A_s TP12 R20 30K 3.3V @ Phase_A = 36.3V BEMF_sense_A Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 R22 3.0K V_dcb TP13 GNDA DCB_pos V_dcb_s TP15 BEMF_B TP14 R23 30K 3.3V @ Phase_B DC-Bus = 36.3V V_sense_DCB BEMF_B_s TP16 R25 30K V_dcb/2_s TP45 R27 1.5K 3.3V @ Phase_B = 36.3V 1.65V @ BEMF_sense_B DC-Bus/2 = 18.15V V_sense_DCB/2 R28 3.0K R104 1.5K GNDA GNDA BEMF_C TP17 Phase_C GNDA BEMF_C_s TP18 R29 30K GNDA 3.3V @ Phase_C = 36.3V BEMF_sense_C R31 3.0K GNDA Figure A-3 Analog Sensing — Back EMF Sensing Freescale Semiconductor +5V R32 1.0 K R33 R34 24 OHM 1.8K C6 470PF J4 ENC_PhaseA GND +5V GND 2 4 6 8 10 HDR 2X5 R35 R36 1.0 K 120 OHM R37 HEADER/CAN bus termination R38 J5 HDR_1X2_M ENC_PhaseB +5V J6 1.8K C7 470PF 24 OHM 1 2 3 4 5 GND R39 +5V CANTX TP19 HDR_1X5_M R41 1.0 K +5V 1 8 CANTX R42 R43 CANRX ENC_Index 1.8K C8 470PF 24 OHM R40 CANRX TP20 1.0 K U3 GND CANH 2 1 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 1 3 5 7 9 CANL GND TXD RS 4 5 RXD VREF 2 GND 0 OHM VCC 3 CANH CANL 7 6 CANH CANL PCA82C250TD GND +5V +5V +5V GND C9 0.1UF GND C11 2.2UF C10 0.1UF GND GND 47 Figure A-4 Micro Headers & Other Circuits — Encoder/Hall Sensor & CAN GND +5V +5V 48 14 +3.3V +3.3V 1 PWM_AT 4 GND UP_SWITCH KSC621J 3 PWM_AB U4B 74AC14 1 GND 2 +3.3V HSMY-C170 PWM1 R47 4 +3.3V GND D1 2 LED Yellow 1.8K D2 1 270 OHM HSMY-C170 LED Yellow U4C 74AC14 R48 4.7K 1 3 2 5 PWM_BT R50 SW2 +3.3V +3.3V SW3 TL39P0050 9 2 1.8K R51 3 TOGGLE_SWITCH_ON2 11 PWM_CT PWM4 R54 10 1.8K D5 2 270 OHM U4F 74AC14 R55 270 OHM GND 13 PWM_CB 2 +3.3V PWM5 R56 12 D6 1 270 OHM USER LED R57 Q2 MMBT2369ALT1G 1 USER LED 4.7K +3.3V 3 1 GND GND HSMY-C170 LED Yellow 2 D7 HSMG-C170 LED Green +3.3V 1 HSMY-C170 LED Yellow +3.3V GND +3.3V HSMY-C170 LED Yellow U4E 74AC14 GND +3.3V 2 D4 1 270 OHM R53 1 GND PWM3 8 R52 4.7K R97 1 HSMY-C170 LED Yellow U4D 74AC14 PWM_BB TOGGLE_SWITCH_ON1 D3 2 1.8K 4 R96 4.7K R49 270 OHM KSC621J GND PWM2 6 DOWN_SWITCH C12 0.1UF 2 Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 3 2 2 7 R46 1 PWM0 R44 270 OHM R45 4.7K SW1 U4A 74AC14 GND Figure A-5 Micro Headers & Other Circuits — Switches, User, and PWM LEDs Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 J7 CANTX PWM_AT GND PWM_BT PWM_CT OC TxD TOGGLE_SWITCH_ON1 UP_SWITCH USER LED 1 3 5 7 9 11 13 15 17 19 J8 2 4 6 8 10 12 14 16 18 20 +3.3V CANRX PWM_AB PWM_BB PWM_CB INT RxD TOGGLE_SWITCH_ON2 DOWN_SWITCH /RESET I_sense_A I_sense_C GNDA BEMF_sense_B V_sense_DCB I_sense_DCB ENC_PhaseB DRV_EN MOSI MISO 87407-110LF 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 +3.3VA I_sense_B BEMF_sense_A BEMF_sense_C V_sense_DCB/2 ENC_PhaseA ENC_Index /SS SCLK 87407-110LF GND RESET +3.3V SW4 A A1 GND +3.3V R58 4.7K GND B B1 /RESET C13 0.1UF LIGHT TOUCH PUSH BUTTON GND +3.3VA /RESET +3.3V +3.3VA GND GND GNDA GNDA 49 Figure A-6 Micro Headers & Other Circuits — Daughter Board Connectors & RESET 50 3 2 4 1 S2 2 3 4 1 S1 -D +D G V 31 16 40 41 42 43 1 44 PTC0/SCL PTC1/SDA PTC2 PTC3/TxD2 PTC4 PTC5/RxD2 29 30 33 PTD0/ADP8/ACMP+ PTD1/ADP9/ACMPPTD2/KBIP2/ACMPO 2 3 36 IRQ/TPMCLK RESET BKGD/MS SHIELD DD+ GND SHIELD R95 TxD RxD 10K TP21 TP22 R94 10K PTE0/TxD1 PTE1/RxD1 PTE2/TPM1CH0 PTE3/TPM1CH1 PTE4/MISO1 PTE5/MOSI1 PTE6/SPSCK1 PTE7/SS1 8 9 10 11 12 13 14 15 PTF0/TPM1CH2 PTF1/TPM1CH3 PTF4/TPM2CH0 PTF5/TPM2CH1 4 5 6 7 J9 BKGD/MS RxD TxD TP23 D8 +3.3V 2 MC9S08JM60CFGE R63 20 18 19 R60 XTAL EXTAL 1M X1 +3.3V DR61 33 OHM R62 33 OHM 1 2 8MHz D+ C14 22PF GND 270 OHM /RESET_JM +3.3V R59 0 OHM PTB0 1 HSMG-C170 VUSB33 USBDN USBDP VSSAD/VREFL VSS1 VSSOSC /RESET_JM BKGD/MS 32 17 39 GND 21 22 34 35 37 38 2 4 6 HDR 2X3 CON USB PTG0/KBIP0 PTG1/KBIP1 PTG2/KBIP6 PTG3/KBIP7 PTG4/XTAL PTG5/EXTAL 1 3 5 EXTAL PTB0/MISO2/ADP0 PTB1/MOSI2/ADP1 PTB2/SPSCK2/ADP2 PTB3/SS2/ADP3 PTB4/KBIP4/ADP4 PTB5/KBIP5/ADP5 +3.3V XTAL Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 J10 23 24 25 26 27 28 VDDAD/VREFH VDD1 U5 PTB0 PTB1 +3.3V GND +3.3V C15 22PF GND GND TP24 D9 +3.3V 2 R64 HSMY-C170 +3.3V +3.3V +3.3V +3.3V PTB1 1 +3.3V 270 OHM C16 10.0uF C17 0.1UF C18 4.7UF C19 0.47UF +3.3V GND GND GND GND GND GND Figure A-7 Micro Headers & Other Circuits — USB/SCI Bridge Freescale Semiconductor VLS_CAP DCB_pos R65 VDD VLS DCB_pos D10 MBR0520LT1G R66 R67 R99 10K R100 10K GND AMP_N AMP_P R101 10K R77 PA_LS PB_LS PC_LS 18 19 20 21 CS SI SCLK SO 25 26 AMP_N AMP_P 28 OC_TH R78 +3.3V 1.0K C23 0.1UF OC_TH @ 3.09V @ 3.75A 15.0K GND 14 32 51 54 17 PA_BOOT PA_HS_G PA_HS_S PA_LS_G 48 47 46 45 PB_BOOT PB_HS_G PB_HS_S PB_LS_G 43 42 41 40 PC_BOOT PC_HS_G PC_HS_S PC_LS_G 38 37 36 35 PHASEC PHASEB PHASEA 11 10 1 NC6 NC5 NC4 NC3 NC2 NC1 53 52 50 49 33 6 AMP_OUT OC_OUT 24 27 INT MBR0520LT1G R69 R70 Gate_AB 10R D12 10R MBR0520LT1G R71 R72 Gate_BT C21 1UF 10R 10R Source_BT D13 MBR0520LT1G R73 R74 Gate_BB 10R 10R D14 MBR0520LT1G R75 R76 AMP_OUT Gate_CT OC C22 1UF MC33927 10R 10R Source_CT D15 MBR0520LT1G R80 Gate_CB GND 10R GND R102 DC Bus Current Sensing D16 MBR0520LT1G R82 AMP_P I_Sense_DCB2 AMP_OUT 1.6K C45 47PF R83 OpAmp is within 3PP-A 1.6K 220 OHM VLS_CAP VLS VLS DCB_pos +3.3V +3.3V +3.3VA +3.3VA +1.65V_REF 7.5K VLS_CAP DCB_pos I_sense_DCB_out R84 AMP_N I_Sense_DCB1 10R +3.3VA GND_LSFET DCB_pos Source_AT D11 R79 R81 7.5K DCB_pos 10R GND +1.65V_REF 220 OHM R103 10R 10K EP /SS MOSI SCLK MISO 13 16 22 55 PWM_AB PWM_BB PWM_CB PA_HS PB_HS PC_HS C20 1UF R68 INT RST GND0 GND1 PGND for QPUMP PGNDA PGNDB PGNDC 5 12 15 23 VSS 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 GND /RESET 0 OHM VDD VLS_CAP VLS VPWR R98 10K PWM_CB TP30 PWM_AT PWM_BT PWM_CT /SS MOSI SCLK MISO TP31 TP32 TP33 TP34 EN1 EN2 30 31 2 44 39 34 PWM_CT TP28 3 4 DRV_EN 29 PWM_BB TP27 PUMP VPUMP(12V) VBAT(42V) U6 PWM_AB TP26 PWM_BT TP29 7 8 9 Gate_AT PWM_AT TP25 VDD +1.65V_REF GND VDD GND C24 2.2uF GND C25 0.1UF GND C26 2.2UF C27 0.1UF GND_LSFET GND_LSFET C28 2.2UF C29 0.1UF GND_LSFET GND_LSFET C30 2.2UF GND C31 0.1UF GND 51 Figure A-8 MOSFET Drivers GND_LSFET GND_LSFET 52 Freescale Semiconductor Q4 4 Gate_BT Phase_A Phase_B Phase_C Q6 4 Gate_AB 5 6 7 8 Q7 4 Gate_BB Q8 4 Gate_CB FDS3672 FDS3672 3 2 1 FDS3672 I_sense_A1 3 2 1 C34 0.1UF 5 6 7 8 C33 100uF 5 6 7 8 + FDS3672 3 2 1 FDS3672 3 2 1 C32 100uF 4 Gate_CT FDS3672 + Q5 3 2 1 4 Gate_AT 5 6 7 8 5 6 7 8 Q3 3 2 1 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 5 6 7 8 DCB_pos I_sense_C1 I_sense_B1 R85 0.1R I_sense_A2 R86 0.1R I_sense_B2 R87 0.1R I_sense_C2 DCB_neg R88 0.1R I_Sense_DCB1 GND_LSFET I_Sense_DCB2 Figure A-9 Power Circuit GND_LSFET GND_LSFET Freescale Semiconductor D17 V_dcb TP35 U8 R89 1 4 5 8 L2 8 1 1 NC1 NC2 NC3 ON/OFF + OUT 100UH 2 0 OHM +3.3V TP37 MBR0520LT1G GND/ADJVOUT1 VIN VOUT2 NC1 VOUT3 NC2 VOUT4 + C37 100UF +3.3V 2 3 6 7 +3.3VA L1 1 2 1uH MC33269D_3.3 D18 MURS120T3 1 2 3 VIN GND + C38 0.1UF C39 47UF C40 0.1UF + C41 0.1UF L3 1 C42 0.1UF C43 100PF C36 47UF 2 2 GND GND GNDGND GND GND GND GND GND 1uH GND GNDA Grounds Connection GND GND GND GND TP39 TP40 TP41 TP42 +3.3VA +5V +1.65V_REF TP38 R91 820 OHM GND +1.65V_REF +1.65V_REF GNDA +3.3V +3.3V 2 R90 68R GNDA GNDA TP43 TP44 +1.65V_REF R93 68R C44 0.1UF +3.3VA D19 HSMG-C170 LED Green +5V +5V GND GND GNDA +3.3VA 1 C35 68.0UF LM2594HVM-5.0 FB 4 5 DCB_pos 6 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 7 +5V TP36 +5V U7 GND GNDA GNDA GNDA 53 Figure A-10 Power Supplies 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 54 Freescale Semiconductor Appendix B. Bill of Materials Table B-1 Parts List DESIGNATORS C1-3,C5 C4,C5,C9,C10,C12,C13 ,C17,C23,C27,C29,C31, C38,C40-C42,C44 C6-C8 C11,C26,C28,C30 C14,C15 C16 C18 C19 C20-C22 C24 C25,C34 C32,C33 C35 C36,C39 C37 C43 QUANTITY 4 DESCRIPTION 47 pF / 100 V size 0805 MANUFACTURER ANY ACCEPTABLE PART NUMBER — 16 100 nF / 100 V size 0805 ANY ACCEPTABLE — 3 4 2 1 1 1 3 1 2 2 1 2 1 1 470 pF / 100 V size 0805 2.2 μF / 25 V size 0805 22 pF / 100 V size 0805 10 μF / 16 V size 0805 4.7 μF / 16 V size 0805 470 nF / 25 V size 0805 1 μF / 25 V size 0805 2.2 μF / 50 V size 1210 100 nF / 100 V size 1206 100 μF / 80 V size H13 68 μF / 100 V size H13 47 μF / 6.3 V size C 100 μF / 16 V size E 100 pF / 100 V size 0805 — — — — — — — — — — — — — — D1-D6,D9 7 D7,D8,D19 8 D10-D17 8 D18 1 J1 J2 J3 1 1 1 J4 1 J5 1 J6 J7,J8 1 2 J9 1 J10 1 L1,L3 L2 2 1 Q1 1 ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE ANY ACCEPTABLE AVAGO Yellow Display LED size 0805 TECHNOLOGIES AVAGO Green Display LED size 0805 TECHNOLOGIES 0.5 A / 20 V Schottky Rectifier ON size SOD-123 SEMICONDUCTOR ON 1 A / 200 V Ultrafast Rectifier size B SEMICONDUCTOR HDR 1x3 MOLEX CON_2_TB LUMBERG INC Power Jack SWITCHCRAFT TYCO HDR 2x5 ELECTRONICS TYCO HDR 1X2 ELECTRONICS HDR 1X5 MOLEX 87407-110 FCI TYCO HDR 2X3 ELECTRONICS TYCO CON USB ELECTRONICS 1 μH size 2012 TDK 100 μH Wurth Elektronik FAIRCHILD 9.4 A / 60 V MOSFET size D-PAK SEMICONDUCTOR HSMY-C170 HSMG-C170 MBR0520LT1G MURS120T3G 09-65-2038 KRM 02 RAPC712X 4-103322-2 4-103321-8 22-27-2051 87407-110LF 4-103322-2 292304-1 MLZ2012A1R0P 744778920 FQD11P06TF 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 55 Table B-1 Parts List DESIGNATORS QUANTITY DESCRIPTION Q2 1 200 mA / 40 V NPN size SOT-23 Q3-Q8 6 R1,R60 2 MANUFACTURER ON SEMICONDUCTOR FAIRCHILD SEMICONDUCTOR PART NUMBER MMBT2369ALT1G R20,R23,R25,R29 4 R22,R28,R31 3 R27,R104 21 R32,R36,R39,R41 R33,R37,R42 R34,R38,R43,R46,R50, R53,R97 R35 R40,R59,R65,R89 R44,R47,R49,R51,R54R56,R63,R64 R45,R48,R52,R57, R58,R96 R61,R62 R66,R67,R69-R76,R79, R80 R68,R94,R95,R98-R10 1 41 3 7.5 A / 100 V MOSFET size SOIC-8 1 MΩ Resistor 1/8 W 1 % size 0805 7.5 kΩ Resistor 1/8 W 1 % size 0805 220 Ω Resistor 1/8 W 1 % size 0805 1.6 kΩ Resistor 1/8 W 1 % size 0805 30 kΩ Resistor 1/8 W 1 % size 0805 3 kΩ Resistor 1/8 W 1 % size 0805 1.5 kΩ Resistor 1/8 W 1 % size 0805 1 kΩ Resistor 1/8 W size 0805 24 Ω Resistor 1/80 W size 0805 7 1.8 kΩ Resistor 1/8 W size 0805 ANY ACCEPTABLE — 1 4 120 Ω Resistor 1/8 W size 0805 0 Ω Resistor 1/8 W size 0805 ANY ACCEPTABLE ANY ACCEPTABLE — — 9 270 Ω Resistor 1/80 W size 0805 ANY ACCEPTABLE — 6 4.7 kΩ Resistor 1/8 W size 0805 ANY ACCEPTABLE — 2 33 Ω Resistor 1/8 W size 0805 ANY ACCEPTABLE — 12 10 Ω Resistor 1/8 W size 0805 ANY ACCEPTABLE — 7 10 kΩ Resistor 1/8 W size 0805 ANY ACCEPTABLE — R77 1 ANY ACCEPTABLE — R78 1 ANY ACCEPTABLE — R85-R88 4 WELWYN COMPONENTS LIMITED LR2512-R10FW R90,R93 2 ANY ACCEPTABLE — R91 SW1,SW2 1 2 SW3 1 SW4 TP1-TP45 1 45 U1,U2 2 R2,R7,R10,R13,R14,R1 9,R81,R84 R3,R5,R8,R11,R15,R18 ,R102,R103 R4,R6,R9,R12,R16,R17 ,R82,R83 8 8 8 1 kΩ Resistor 1/8 W 1 % size 0805 15 kΩ Resistor 1/8 W 1 % size 0805 100 mΩ Resistor 1 % size 2512 68 Ω Resistor 1/8 W 1 % size 0805 820 Ω Resistor 1/8 W size 0805 20 mA / 32 V Touch Key FDS3672 ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE — ANY ACCEPTABLE ANY ACCEPTABLE — — ANY ACCEPTABLE C&K COMPONENTS APEM 20 mA / 20 V Toggle Switch/3-state COMPONENTS 20 mA / 32 V Touch Key C&K COMPONENTS N/P — ON Operational Amplifier / SOIC-8 SEMICONDUCTOR — KSC621J LFS TL39P0050 KSC341J LFS — MC33502DR2G 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 56 Freescale Semiconductor Table B-1 Parts List DESIGNATORS QUANTITY DESCRIPTION U3 1 CAN INTERFACE / SOIC-8 U4 1 Schmitt Inverter / SOIC-14 U5 1 8-bit HCS08 Controller / LQFP-44 U6 1 3-Phase Bridge Driver / 54 SOICW-EP U7 1 Step-Down Regulator / SOIC-8 U8 1 Voltage Regulator / SOIC-8 X1 1 8 MHz Crystal / HC49 MANUFACTURER PART NUMBER PHILIPS PCA82C250TD SEMICONDUCTOR ON MC74AC14DG SEMICONDUCTOR FREESCALE MC9S08JM60CFGE SEMICONDUCTOR FREESCALE MCZ33927EK SEMICONDUCTOR NATIONAL LM2594HVM-5.0/NO SEMICONDUCTOR PB ON MC33269D-3.3G SEMICONDUCTOR RAKON LF A140E 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 57 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 58 Freescale Semiconductor Appendix C. 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive Layouts 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor 59 60 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor Figure C-1 Board Top Layer Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Figure C-2 Board Bottom Layer 61 62 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Freescale Semiconductor Figure C-3 Board Silkscreen Top Layer Freescale Semiconductor 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 Figure C-4 Board Silkscreen Bottom Layer 63 3-Phase BLDC/PMSM Low-Voltage Motor Control Drive, Rev. 0 64 Freescale Semiconductor How to Reach Us: Home Page: www.freescale.com E-mail: [email protected] USA/Europe or Locations Not Listed: Freescale Semiconductor Technical Information Center, CH370 1300 N. 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