I 3-Phase BLDC Low-Voltage e m Power Stage e · User’s Manual 3-Phase BLDC Low-Voltage Power Stage 2 MOTOROLA Important Notice to Users While every effort has been made to ensure

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Motorola Embedded Motion Control

3-Phase BLDCLow-VoltagePower Stage

User’s Manual

For More Information On This Product,

Go to: www.freescale.com

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Important Notice to Users

While every effort has been made to ensure the accuracy of all information inthis document, Motorola assumes no liability to any party for any loss ordamage caused by errors or omissions or by statements of any kind in thisdocument, its updates, supplements, or special editions, whether such errors areomissions or statements resulting from negligence, accident, or any other cause.Motorola further assumes no liability arising out of the application or use of anyinformation, product, or system described herein: nor any liability for incidentalor consequential damages arising from the use of this document. Motoroladisclaims all warranties regarding the information contained herein, whetherexpressed, implied, or statutory, including implied warranties ofmerchantability or fitness for a particular purpose. Motorola makes norepresentation that the interconnection of products in the manner describedherein will not infringe on existing or future patent rights, nor do thedescriptions contained herein imply the granting or license to make, use or sellequipment constructed in accordance with this description.

Trademarks

This document includes these trademarks:

Motorola and the Motorola logo are registered trademarksof Motorola, Inc.

Motorola, Inc., is an Equal Opportunity / Affirmative Action Employer.

© Motorola, Inc., 2000; All Rights Reserved

User’s Manual 3-Phase BLDC Low-Voltage Power Stage

2 MOTOROLA For More Information On This Product,


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User’s Manual — 3-Phase BLDC Low-Voltage Power Stage

List of Sections

Section 1. Introduction and Setup. . . . . . . . . . . . . . . . . .11

Section 2. Operational Description . . . . . . . . . . . . . . . . .17

Section 3. Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . .21

Section 4. Schematics and Parts List . . . . . . . . . . . . . . .29

Section 5. Design Considerations . . . . . . . . . . . . . . . . . .43

3-Phase BLDC Low-Voltage Power Stage User’s Manual

MOTOROLA List of Sections 3 For More Information On This Product,


List of Sections

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4 List of Sections MOTOROLA For More Information On This Product,


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Table of Contents

Section 1. Introduction and Setup

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Section 2. Operational Description

2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4 Modification for 42 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Section 3. Pin Descriptions

3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3.1 40-Pin Ribbon Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3.2 Power Connectors J19 and J20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.3 Motor Connectors J16, J17, and J18 . . . . . . . . . . . . . . . . . . . . . . . 263.3.4 External Brake Connectors J14 and J15 . . . . . . . . . . . . . . . . . . . . 263.3.5 Bias Power Connectors J21 and J22 . . . . . . . . . . . . . . . . . . . . . . . 27


MOTOROLA Table of Contents 5 For More Information On This Product,


Table of Contents

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Section 4. Schematics and Parts List

4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Section 5. Design Considerations

5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3 Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


6 Table of Contents MOTOROLA For More Information On This Product,


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List of Figures

Figure Title Page

1-1 Systems’ Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-2 3D Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131-3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-1 40-Pin Ribbon Connector J13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4-1 3-Phase BLDC Low-Voltage Power Stage Overview . . . . . . . . . . . . 304-2 Gate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314-3 3-Phase H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324-4 Current and Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 334-5 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-6 dc Bus Voltage Sense and Brake Gate Drive . . . . . . . . . . . . . . . . . . . 354-7 Identification Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364-8 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5-1 Phase A Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445-2 Bus Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465-3 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485-4 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495-5 Phase A Back EMF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505-6 Phase A Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515-7 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53


MOTOROLA List of Figures 7 For More Information On This Product,


List of Figures

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8 List of Figures MOTOROLA For More Information On This Product,


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List of Tables

Table Title Page

2-1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192-2 Resistor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192-3 JP801 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-1 Connector J13 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4-1 Power Substrate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384-2 Printed Circuit Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


MOTOROLA List of Tables 9 For More Information On This Product,


List of Tables

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10 List of Tables MOTOROLA For More Information On This Product,


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Section 1. Introduction and Setup

1.1 Contents

1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.5 Setup Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2 Introduction

Motorola’s 3-phase, brushless dc (BLDC) low-voltage power stage (LV BLDCpower stage) is an integral part of Motorola’s embedded motion control seriesof development tools. It operates from a nominal 12-volt motor supply, anddelivers up to 30 amps of rms motor current from a dc bus that can deliver peakcurrents up to 46 amps. The LV BLDC power stage is supplied in kit numberECLOVACBLDC.

In combination with one of the Embedded Motion Control series Controlboards, it provides a ready made software development platform for fractionalhorsepower Brushless DC motors. Feedback signals are provided to facilitatecontrol with sensorless algorithms.

An illustration of the systems architecture is shown in Figure 1-1. A 3D modelappears in Figure 1-2.


MOTOROLA Introduction and Setup 11 For More Information On This Product,


Introduction and Setup

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The LV BLDC power stage’s features are:

• dc-bus brake MOSFET and brake current limiting resistors

• 3-phase bridge inverter (6-MOSFETs)

• Individual phase and dc bus current sensing shunts with Kelvinconnections

• Power stage temperature sensing diodes

• MOSFET gate drivers

• Current and temperature signal conditioning

• 3-phase back-EMF voltage sensing and zero cross detection circuitry

• Board identification processor (MC68HC705JJ7)

• Low-voltage on-board power supplies

• Cooling fans

Figure 1-1. Systems’ Configurations

CONTROL BOARD

MOTOR

WORKSTATION

EMULATOR DSP EVM BOARD

POWER STAGE

MOTOR

WORKSTATION

b) 56800 DSPa) MICROCONTROLLER

POWER STAGE


12 Introduction and Setup MOTOROLA For More Information On This Product,


Introduction and SetupAbout this Manual

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Figure 1-2. 3D Model

1.3 About this Manual

Key items can be found in the following locations in this manual:

• Setup instructions are found in 1.5 Setup Guide.

• Schematics are found in Section 4. Schematics and Parts List.

• Pin assignments are shown in Figure 3-1. 40-Pin Ribbon ConnectorJ13, and a pin-by-pin description is contained in 3.3.1 40-Pin RibbonConnector J13.

• For those interested in the reference design aspects of the board’scircuitry, a description is provided in Section 5. Design Considerations.





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1.4 Warnings

The LV BLDC Power Stage kit includes power components that can reachtemperatures hot enough to cause burns. The motor that it operates may alsoreach high temperatures.

The user should be aware that:

• To facilitate safe operation, input power should come from a DClaboratory power supply that is current limited to no more than 55 Amps.

• Before moving scope probes, making connections, etc., it is generallyadvisable to power down the motor supply.

• Operation in lab setups that have grounded tables and/or chairs should beavoided.

• Wearing safety glasses, avoiding ties and jewelry, and using shields arealso advisable.

1.5 Setup Guide

Setup and connections are very straightforward. The LV BLDC power stageconnects to an embedded motion control series control board via 40-pin ribboncable. The motor’s power leads plug into output connectors, J16 – J18, and itsHall sensors plug into the control board’s Hall sensor/encoder input connector.Figure 1-3 depicts a completed setup.

1. Mount four standoffs to the LV BLDC Power Stage at the locationsindicated in Figure 1-3. Standoffs, screws, and washers are included inthe kit.

NOTE: This step and step 3 are optional when making connections with DSP controlboards such as the DSP56F805EVM. The DSP boards may be placed flat on abench, next to the EVM motor board.

2. Plug one end of the 40-pin ribbon cable that is supplied with the kit intoinput connector J13, located on the right hand side of the top board. Theother end of this cable connects to the control board’s 40-pin outputconnector.




Introduction and SetupSetup Guide

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3. Mount the control board on top of the standoffs with screws and washersfrom the ECLOVACBLDC kit. This step is optional with DSP controlboards.

4. Plug the free end of the cable connected to input connector J13 into thecontrol board’s 40-pin output connector.

5. Connect a 12-Vdc power supply to fast-on connectors J19 and J20.Connector J19 is located on the back-left corner of the top board, andconnector J20 is in the front-left corner of the top board. The positivelead goes to J19, labeled +12V. The return is connected to J20, labeled0V. Voltage range for the power supply is 10 to 16 Vdc. The powersupply’s current limit should be set to less than 55 amps.

In the as-shipped configuration, jumper JP401 is set to INT. and a biassupply at connector J21 or power jack J22 is not needed. One powersupply connected to J19 and J20 is all that is required.

6. Connect motor phase A to fast-on connector J16, labeled phase A.Connector J16 is located along the back edge of the top board.

7. Connect motor phase B to fast-on connector J17, labeled phase B.Connector J17 is located along the back edge of the top board.

8. Connect motor phase C to fast-on connector J18, labeled phase C.Connector J18 is located along the back edge of the top board.

9. Apply power. The green power-on LED lights when power is present.





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Figure 1-3. Setup

MOTOR

56800 EVALUATION

LV BLDC 40-PINRIBBON CABLE

STANDOFFS

MOTOR SUPPLY

STANDOFFS

POWER STAGE

MODULE

OR

HC08 CONTROLBOARD




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Section 2. Operational Description

2.1 Contents

2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4 Modification for 42 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Description

Motorola’s embedded motion control series low-voltage (LV) brushless dc(BLDC) power stage operates from a nominal 12-volt motor supply, anddelivers up to 30 amps of rms motor current from a dc bus that can deliver peakcurrents up to 46 amps. In combination with one of Motorola’s embeddedmotion control series control boards, it provides a software developmentplatform that allows algorithms to be written and tested, without the need todesign and build a power stage. It supports a wide variety of algorithms forcontrolling BLDC motors.

Input connections are made via 40-pin ribbon cable connector J13. Pinassignments for the input connector are shown in Figure 3-1. 40-Pin RibbonConnector J13. Power connections to the motor are made with fast-onconnectors J16, J17, and J18. They are located along the back edge of the board,and are labeled Phase A, Phase B, and Phase C. Power requirements are metwith a 12-volt power supply that has a 10- to 16-volt tolerance. Fast-onconnectors J19 and J20 are used for the power supply. J19 is labeled +12V andis located on the back edge of the board. J20 is labeled 0V and is located alongthe front edge. Current measuring circuitry is set up for 50 amps full scale. Bothbus and phase leg currents are measured. A cycle by cycle overcurrent trip pointis set at 46 amps.


MOTOROLA Operational Description 17 For More Information On This Product,


Operational Description

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The LV BLDC power stage has both a printed circuit board and a powersubstrate. The printed circuit board contains MOSFET gate drive circuits,analog signal conditioning, low-voltage power supplies, and some of the largepassive power components. This board also has a 68HC705JJ7 microcontrollerused for board configuration and identification. All of the power electronics thatneed to dissipate heat are mounted on the power substrate. This substrateincludes the power MOSFETs, brake resistors, current-sensing resistors, buscapacitors, and temperature sensing diodes. Figure 2-1 shows a block diagram.

Figure 2-1. Block Diagram

POWERINPUT BIAS

POWERBRAKE

MOSFET

GATE

PHASE CURRENTPHASE VOLTAGE

BUS CURRENTBUS VOLTAGE

MONITOR

ZERO CROSSBACK-EMF SENSE

BOARDID BLOCK

SIGNALSTO/FROMCONTROL

BOARD

POWER MODULE

DRIVERS MOTORTO


18 Operational Description MOTOROLA For More Information On This Product,


Operational DescriptionElectrical Characteristics

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2.3 Electrical Characteristics

The electrical characteristics in Table 2-1 apply to operation at 25°C with a12-Vdc supply voltage.

2.4 Modification for 42 Volts

The LV BLDC power stage can be modified for operation with a 42-voltnominal motor supply. To change input voltage range:

1. Remove power and wait until the power-on LED is off.

2. Make the resistor value changes shown in Table 2-2. With the valuesshown for 42 volts, voltage-feedback signals are scaled at 60 mVper volt.

Table 2-1. Electrical Characteristics

Characteristic Symbol Min Typ Max Units

Motor Supply Voltage Vac 10 12 16 V

Quiescent current ICC — 175 — mA

Min logic 1 input voltage VIH 2.0 — — V

Max logic 0 input voltage VIL — — 0.8 V

Analog output range VOut 0 — 3.3 V

Bus current sense voltage ISense — 33 — mV/A

Bus voltage sense voltage VBus — 60 — mV/V

Peak output current(300 ms)

IPK — — 46 A

Continuous output current IRMS — — 30 A

Brake resistor dissipation(continuous)

PBK — — 50 W

Brake resistor dissipation(15 sec pk)

PBK(Pk) — — 100 W

Total power dissipation Pdiss — — 85 W

Table 2-2. Resistor Values

Resistors 12 Volts 42 Volts

R207, R522, R523, R524 0 Ω 39 kΩ


MOTOROLA Operational Description 19 For More Information On This Product,


Operational Description

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3. Configure identification coding jumper JP801 with the settings that areindicated in Table 2-3. This procedure allows software to interpret thenew analog values correctly.

4. Set jumper JP401 to the EXT. position. JP401 is located on left side ofthe top board adjacent to one of the bus capacitors. The EXT. settingallows bias circuitry to be powered from a 12-volt source that is separatefrom the motor supply.

5. Connect a 12-Vdc power supply either to connector J21, labeled - EXT.12V +, or power jack J22. Either one, but not both may be used. Polaritydoes not matter, since these inputs are connected to a full-wave bridge.Connectors J21 and J22 are located on the front left-hand corner of thetop board. The 12-volt power supply should have its current limit setbetween 500 mA and 1 amp. The input voltage range is 10 volts to16 volts.

Once these modifications have been made, the input voltage range for the motorsupply is 10 Vdc to 55 Vdc.

Table 2-3. JP801 Settings

Position 12 Volts 42 Volts

1-2 Open Open

3-4 Open Open

5-6 Open Open

7-8 Open Short


20 Operational Description MOTOROLA For More Information On This Product,


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Section 3. Pin Descriptions

3.1 Contents

3.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3.1 40-Pin Ribbon Connector J13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3.2 Power Connectors J19 and J20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.3.3 Motor Connectors J16, J17, and J18 . . . . . . . . . . . . . . . . . . . . . . . 263.3.4 External Brake Connectors J14 and J15 . . . . . . . . . . . . . . . . . . . . 263.3.5 Bias Power Connectors J21 and J22 . . . . . . . . . . . . . . . . . . . . . . . 27

3.2 Introduction

There are ten connectors on the top board for making input and outputconnections. They are listed as follows.

• J13 — 40-pin input and feedback connector

• J19 — Motor supply fast-on connector

• J20 — Motor supply fast-on connector

• J16 — Phase A fast-on connector

• J17 — Phase B fast-on connector

• J18 — Phase C fast-on connector

• J14 — Brake fast-on connector

• J15 — Brake fast-on connector

• J21 — Bias supply connector

• J22 — Bias supply power jack

• Pin assignments for input connector J13 are shown in Figure 3-1. Signaldescriptions for each of these connectors are identified in Table 3-1.


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Pin Descriptions

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3.3 Signal Descriptions

Control and feedback signals are grouped together on 40-pin ribbon connectorJ13. Motor outputs each have separate fast-on connectors that are designatedJ16 –J18. Power is supplied through fast-on connectors J19 and J20. The signalsassociated with each of these connectors, and the optional use of connectorsJ14, J15, J21, and J22 are discussed as follows.

3.3.1 40-Pin Ribbon Connector J13

40-pin ribbon cable connector J13 is located on the right side of the board. Pinassignments are shown in Figure 3-1. In this figure, a schematic representationappears on the left, and a physical layout of the connector appears on the right.The physical view assumes that the board is oriented such that its title is readfrom left to right. Signal descriptions are listed in Table 3-1.


22 Pin Descriptions MOTOROLA For More Information On This Product,


Pin DescriptionsSignal Descriptions

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Figure 3-1. 40-Pin Ribbon Connector J13

40393837363534333231302928272625242322212019181716151413121110987654321

BEMF_sense_CBEMF_sense_BBEMF_sense_A

ShieldingZero_cross_CZero_cross_BZero_cross_A

Serial_ConBrake_control

Shielding

Temp_senseI_sense_CI_sense_BI_sense_A

I_sense_DCBV_sense_DCB

–12V_A+12V_A

GNDAGNDA

+3.3V_A+5V_A+5V_A

GNDGND

PWM_CBShieldingPWM_CTShieldingPWM_BBShieldingPWM_BTShieldingPWM_ABShieldingPWM_AT

SCHEMATIC VIEW

J13

2468

10121416182022242628303234363840

13579111315171921232527293133353739

ShieldingShieldingShieldingShieldingShieldingGND+5V_D+3.3V_AGNDA–12V_AI_sense_DCBI_sense_BTemp_senseShieldingSerial_Con

Zero_cross_AZero_cross_CBEMF_sense_ABEMF_sense_C

PWM_ATPWM_ABPWM_BTPWM_BBPWM_CTPWM_CBGND_PS

+5V_DGNDA+12_A

V_sense_DCBI_sense_AI_sense_C

Brake_control

Zero_cross_BShielding

BEMF_sense_B

PHYSICAL VIEW




Pin Descriptions

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Table 3-1. Connector J13 Signal Descriptions

PinNo.

Signal Name Description

1 PWM_ATPWM_AT is the gate drive signal for the top half-bridge of phase A. A logic highturns phase A’s top switch on.

2 Shielding Pin 2 is connected to a shield wire in the ribbon cable and ground on the board.

3 PWM_ABPWM_AB is the gate drive signal for the bottom half-bridge of phase A. A logic highturns phase A’s bottom switch on.


5 PWM_BTPWM_BT is the gate drive signal for the top half-bridge of phase B. A logic highturns phase B’s top switch on.


7 PWM_BBPWM_BB is the gate drive signal for the bottom half-bridge of phase B. A logic highturns phase B’s bottom switch on.


9 PWM_CTPWM_CT is the gate drive signal for the top half-bridge of phase C. A logic highturns phase C’s top switch on.


11 PWM_CBPWM_CB is the gate drive signal for the bottom half-bridge of phase C. A logic highturns phase C’s bottom switch on.

12 GND Digital and power ground

13 GND Digital and power ground, redundant connection

14 +5V digital Digital +5-volt power supply

15 +5V digital Digital +5-volt power supply, redundant connection

16 +3.3V analog Analog +3.3-volt power supply

17 GNDA Analog power supply ground

18 GNDA Analog power supply ground, redundant connection

19 +15V_A Analog +12-volt power supply

20 –15V_A Analog –12-volt power supply

21 V_sense_DCBV_sense_DCB is an analog sense signal that measures dc bus voltage. It is scaledat 206 mV per volt of dc bus voltage.

22 I_sense_DCBI_sense_DCB is an analog sense signal that measures dc bus current. It is scaledat 33 mV per amp of dc bus current.





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23 I_sense_AI_sense_A is an analog sense signal that measures current in phase A. It is scaledat 33 mV per amp of dc bus current.

24 I_sense_BI_sense_B is an analog sense signal that measures current in phase B. It is scaledat 33 mV per amp of dc bus current.

25 I_sense_CI_sense_C is an analog sense signal that measures current in phase C. It is scaledat 33 mV per amp of dc bus current.

26 Temp_sense Temp_sense is an analog sense signal that measures power module temperature.

27 No connection

28 ShieldingPin 28 is connected to a shield wire in the ribbon cable and analog ground on theboard.

29 Brake_control Brake_control is the gate drive signal for the brake MOSFET.

30 Serial_ConSerial_Con is an identification signal that lets the controller know which powerstage is present.

31 No connection

32 No connection

33 No connection

34 Zero_cross_AZero_cross_A is a digital signal used for sensing phase A back-EMF zero crossingevents.

35 Zero_cross_BZero_cross_B is a digital signal used for sensing phase B back-EMF zero crossingevents.

36 Zero_cross_CZero_cross_C is a digital signal used for sensing phase C back-EMF zero crossingevents.

37 ShieldingPin 37 is connected to a shield wire in the ribbon cable and analog ground on theboard.

38 BEMF_sense_ABEMF_sense_A is an analog sense signal that measures phase A back EMF. It isscaled at 206 mV per volt of dc bus voltage.

39 BEMF_sense_BBEMF_sense_B is an analog sense signal that measures phase B back EMF. It isscaled at 206 mV per volt of dc bus voltage.

40 BEMF_sense_CBEMF_sense_C is an analog sense signal that measures phase C back EMF. It isscaled at 206 mV per volt of dc bus voltage.

Table 3-1. Connector J13 Signal Descriptions (Continued)

PinNo.

Signal Name Description




Pin Descriptions

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3.3.2 Power Connectors J19 and J20

Motor power is supplied through fast-on connectors J19 and J20. J19 is labeled+12V, and is located on the back left-hand corner of the top board. J20 is labeled0V, and is located on the front left-hand corner of the top board. Theseconnectors will accept a power supply voltage from 10 volts to 16 volts as theLV BLDC power stage is shipped. When the LV BLDC power stage has beenreconfigured for 42-volt nominal operation, this power supply input will acceptinputs from 10 volts to 55 volts. The power supply should be current limited toless than 55 amps.

3.3.3 Motor Connectors J16, J17, and J18

Power connections to the motor are made with fast-on connectors J16, J17, andJ18, located on the back edge of the top board. These connections are identifiedas follows.

• J16: Phase A — Connector J16, labeled Phase A, supplies power tomotor phase A. This is a 30-amp RMS fast-on connection.

• J17: Phase B — Connector J17, labeled Phase B, supplies power tomotor phase B. This is a 30-amp RMS fast-on connection.

• J18: Phase C — Connector J18, labeled Phase C, supplies power tomotor Phase C. This is a 30 amp RMS fast-on connection.

3.3.4 External Brake Connectors J14 and J15

An optional external brake resistor can be connected to external brake fast-onconnectors J14 and J15, labeled BRAKE 1 Ext. and BRAKE 2 Ext. Theseconnectors are located on the back left-hand corner of the top board. Theexternal resistor allows power dissipation to be increased beyond the 50 wattsthat brake resistors R1–R4 provide. Note that operation of the brake at100 percent duty cycle for more than 15 seconds at 12 volts will overdissipateR1–R4. For bus voltages higher than 12 volts, maximum duty cycle is restrictedto less than 100 percent. The total power dissipation limit for these fourresistors combined is 50 watts continuous and 100 watts for 15 seconds.





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3.3.5 Bias Power Connectors J21 and J22

Two connectors, labeled J21 and J22, are provided for an optional 12-volt biassupply. This input is only used when the LV BLDC power stage has beenreconfigured for operation with a 42-volt nominal motor supply. J21 and J22 arelocated on the front left-hand corner of the board. Connector J22 is a 2.1-mmpower jack for 12-volt plug-in type power supply connections. Connector J21has screw terminal inputs labeled + and – for accepting wire inputs. Power issupplied to one or the other, but not both. The power supply should becurrent-limited to at least 500 mA, and less than 1 amp.




Pin Descriptions

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F

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Section 4. Schematics and Parts List

4.1 Contents

4.2 Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.2 Mechanical CharacteristicsMechanically, the LV BLDC power stage consists of an FR-4 circuit board, a3.2-mm aluminum power substrate, two fans, a fan bracket, a heat sink,inter-board connectors, and standoffs. Construction is depicted in Figure 1-2.3D Model. The aluminum circuit board, fans, and heat sink provide the thermalcapability for D2PAK MOSFETs to drive fractional horsepower motors atcontinuous currents up to 30 amps. The FR-4 board contains most of the circuitcomplexity. The two boards plug together via 10 vertical connectors to, ineffect, form a discrete power module.

Four holes on the top board are spaced to allow mounting standoffs such that acontrol board can be placed on top of the power stage. This configuration allowsmounting control and power functions in one compact mechanical assembly.

4.3 SchematicsA set of schematics for the LV BLDC Power Stage appears in Figure 4-1through Figure 4-8. An overview appears in Figure 4-1. H-bridge gate drive isshown in Figure 4-2. The 3-phase H-Bridge appears in Figure 4-3. Current andtemperature feedback circuits are shown in Figure 4-4. Back EMF feedbackcircuitry appears in Figure 4-5. Brake gate drive is shown in Figure 4-6. Theidentification block is shown in Figure 4-7, and finally the power supply isshown in Figure 4-8. Unless otherwise specified, resistors are 1/8 watt, have a±5% tolerance, and have values shown in ohms. Interrupted lines coded with thesame letters are electrically connected. Parts lists for the printed circuit boardand power substrate appear in Table 4-1 and Table 4-2.


MOTOROLA Schematics and Parts List 29 For More Information On This Product,


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p_se

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1

+ -

U30

3A

LM39

3D

3 21

8 4

DC B

us C

urre

nt

Sen

sing

R31

33k

-1%

C30

110

0nF

R30

43k

-1%

R31

210

k

C30

468

0pF

R30

13k

-1%

+

C30

63.

3uF/

10V

R30

710

0k-1

%

GN

DA

R30

91.

2k

R31

410

0k-1

%

R32

13k

-1%

GN

DA

+12V

_D

+3.3

V_A

GN

D

I_se

nse_

DC

R31

510

0k-1

%

R31

810

0k-1

%

R30

510

0k-1

%

Tem

pera

ture

Se

nsin

g

+12V

_D

GN

DA

R32

210

0k-1

%

+3.3

V_A

GN

D

+-

U30

1BM

C33

502D

567

1.65V ref

GN

D

Tem

p_se

nse_

2

R31

63k

-1%

R32

533

.2k-

1%

1.65

V r

ef

+12V

_D

I_se

nse_

DC

B2

DA

I_se

nse_

DC

B

Ove

r-cur

rent

D

etec

tion

GN

DA

GN

DA

I_se

nse_

C

R30

81.

2kG

ND

R31

13k

-1%

Phas

e Cu

rren

t

Sen

sing +3.3

V_A

R31

910

0k-1

%

R30

668

0k

C30

210

0nF

R30

310

0k-1

%

+ -

U30

3B

LM39

3D

5 67

8 4G

ND

A

+-

U30

1AM

C33

502D

321

84

C30

310

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1.65V ref

+-

U30

2BM

C33

502D

567

GN

DA

R32

410

0k-1

%

+12V

_D

GN

DA

R32

339

0

GN

DA

R32

03k

-1%

U30

4LM

285M

8

5

4

I_se

nse_

B

+-

U30

2AM

C33

502D

321

84

+3.3

V_A

R30

22.

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I_se

nse_

A

C30

5

100n

F

I_se

nse_

DC

B1

Shut

_Dow

n_O

R31

047

0

GN

D

+3.3

V_A

I_se

nse_

B1

I_se

nse_

C1

I_se

nse_

B2

I_se

nse_

C2

C30

710

0nF

I_se

nse_

A1 GN

+12V

_D

+3.3

V_A

I_se

nse_

A2

GN

DA



Figu

re 4

-5.

Bac

k EM

F Si

gnal

s

+5V_

D

+12V

_D

1D 39D13G

ND

GN

DA

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R52

30

+ -U

501B

LM33

9D

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BEM

F_se

nse_

B

GN

D

+12V

_D

R51

43.

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1%

Zero

_cro

ss_C

R52

047

0k

+ -

U50

LM3

11 10

C50

210

0pF

BEM

F_se

nse_

A

GN

DA

Zero

_cro

ss_A

GN

DA

GN

DA

C50

410

0pF

GN

D

(3.3

0V @

Pha

se_C

= 1

6V)

R51

611

.5k-

1%

+ -U

501C

LM33

9D

9 814

R50

73.

32k-

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R52

13.

32k-

1%

R52

20

R50

41.

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1%

GN

DA

EMF_

sens

e_C

R52

40

+5V_

D

+5V_

D

C50

3

100n

FR

519

10k

R50

647

0k

C50

51.

8nF

GN

DA

GN

DR

518

1.18

k-1%

R50

210

k

Zero

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R50

310

M

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010

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510

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R50

910

k

R51

510

M

R51

710

k

Phas

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B

Phas

e_B

Phas

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Figu

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-6.

DC

Bus

Vol

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nd

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ke G

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GN

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= 1

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GN

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NC

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0

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bit #

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12345678910

20

1918 17161514131211

PB1/

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TCAP

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bit #

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R80

510

k

GN

D

+5V_

D GN

D

+C

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10uF

/6.3

V

DEFA

ULT

SE0

- PTB

0 =

H1

- PTB

1 =

L2

- PTB

2 =

H3

- PTB

3 =

H4

- PTB

4 =

H5

- PTB

5 =

H6

- PTA

6 =

H7

- PTA

7 =

H

X801

4MH

z

+5V_

D

+5V_

D

GN

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+5V_

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Figu

re 4

-8.

Pow

er S

uppl

y

-12V

_A

407

00nF

R40

21.

5k D40

1

LED

Gre

en

+12V

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+3.3

V_A

GN

D GN

D

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C41

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3uF/

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8V

12V

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mA

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mA

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O/T

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232223

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nect

ion

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408

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V

+5V_

D

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3

+12V

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k

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B_C

ap_P

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D40

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BRM

140T

3

U40

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3

1

6

Del

ay

Out

put

Res

etG

ND

Inpu

t

HS

C4

10

GN

D

R1

SG26

0

GN

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er_p

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1

+12V

_A

-12V

_A

+3.3

V_A

+5V_

D

GN

D

Pow

er_p

os_1

2V

J21

12



Schematics and Parts List

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

4.4 Parts Lists

The LV BLDC power stage’s parts content is described in Table 4-1 for thepower substrate and in Table 4-2 for the printed circuit board.

Table 4-1. Power Substrate Parts List

Designators Qty Description Manufacturer Part Number

C1, C2 2 4700 µF

D1 1 20 A/60 V SchottkyONSemiconductor

MBRB2060CT

D2, D3 2 Dual diode – temp sensingONSemiconductor

BAV99LT1

J1, J12 2 SM/CON/MCRD_SR_500_FFischerElektronik

SL 11 SMD 104 10 Z

J2, J3, J4,J5, J6, J7, J8

7 SM/CON/MCRD_SR_500_GFischerElektronik

SL 11 SMD 104 5 Z

J9 1 SM/CON/MCRD_SR_500_IFischerElektronik

SL 10 SMD 104 8 Z

J10 1 SM/CON/MCRD_SR_500_BFischerElektronik

SL 10 SMD 104 6 Z

J11 1 SM/CON/MCRD_SR_500_EFischerElektronik

SL 10 SMD 104 4 Z

Q1, Q2, Q3,Q4, Q5, Q6,Q7

7 75 A/60 V MOSFETONSemiconductor

MTB75N06HD

R1, R2, R3,R4

4 0.33 Ω/25 WCaddockElectronics

MP725-0.33-5.0%

R5, R6, R7,R8

4 0.001 Ω sense resistorIsabellenhütteHeusler

BVS-M-R001-1.0

1 Substrate CUBEcz 46615772


38 Schematics and Parts List MOTOROLA For More Information On This Product,


Schematics and Parts ListParts Lists

F

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sca

le S

em

ico

nd

uc

tor,

I


c..

.

Table 4-2. Printed Circuit Board Parts List (Sheet 1 of 3)


C1, C2, C102, C107, C112,C202, C301, C302, C303,C305, C307, C401, C403,C405, C407, C412, C503

17 100 nF/25 V Vitramon VJ0805U104MXXA_

C101, C106, C111 3 4.7 µF/16 V Sprague 293D475X_016B2_

C103, C104, C108, C109,C113, C114

6 470 nF/50 V Vitramon VJ1206U474MXAA_

C105, C110, C115 3 8.2 pF Vitramon VJ0805A8R2DXA_

C116, C117, C118, C119,C120, C121, C203

7 1 nF/50 V Vitramon VJ0805A102KXAA_

C122, C802 2 10 nF/25 V Vitramon VJ0805U103MXXA_

C123, C124, C125 3 33 µF/25 V AVX TPSE336K025R0200

C201 1 10 µF/35 V Sprague 293D106X0035D2_

C304 1 680 pF Vitramon VJ0805A681JXA_

C306, C402, C410 3 3.3 µF/10 V Sprague 293D335X0010A2_

C404, C406, C408, C409,C414

5 100 µF/16 V Sprague 293D107X0016D2_

C411 1 1 µF Siemens B32529-C105-K

C413 1 330 µF/16 V Vishay Roederstein EKA00PB333D00

C501, C502, C504 3 100 pF Vitramon VJ0805A101KXAA_

C505 1 1.8 nF Vitramon VJ0805A182KXAA_

C801 1 10 µF/6.3 V Sprague 293D106X06R3B2_

D101, D102, D103, D104,D105, D106, D107, D108,D109, D402, D405, D406,D407, D408

14 1 A/40 V Schottky ON Semiconductor MBRM140T3

D401 1 LED green Kingbright L-934GT

D403, D404 2 0.5 A/30 V Schottky ON Semiconductor MBR0530T1

JP401 1 Power jumper Fischer Elektronik SL 1/53 3 G

FLT401 1 EMI filter muRata DS306-55Y5S222M50

GC401 0 Ground connection N/A N/A

JP401 1 Power jumper Fischer Elektronik CAB 4 G

JP801 0 4x2 jumper pads N/A N/A

J1, J12 2 20-pin female header Fischer Elektronik BL 2 10 Z





F

ree

sca

le S

em

ico

nd

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tor,

I


c..

.

J2, J3, J4, J5, J6, J7, J8 7 10-pin female header Fischer Elektronik BL 2 5 Z

J9 1 8-pin female header Fischer Elektronik BL 1 8 Z

J10 1 6-Pin female header Fischer Elektronik BL 1 6 Z

J11 1 4-pin female header Fischer Elektronik BL 1 4 Z

J13 1 40-pin connector Fischer Elektronik ASLG40G

J14, J15, J16, J17, J18,J19, J20

7 Fast-on AMP 140814-2

J21 1 2-pole terminal block WAGO 237-132

J22 1 Power jack CUI Stack PJ-002A

L401 1 330 µH Pulse Engineering 53146

R1 1 30 A current limiterRhopointComponents

SG260

R101, R102, R107, R108,R111, R112

6 470 Ω Dale CRCW0805-471J

R103, R104, R105, R109,R110, R113, R114, R206,R312, R502, R505, R509,R512, R517, R519, R801,R802, R803, R804, R805

20 10 kΩ Dale CRCW0805-103J

R201, R106 2 100 Ω Dale CRCW0805-101J

R205, R507, R514, R521 4 3.32 kΩ–1% Dale CRCW0805-3321F

R202 1 3.4 kΩ–1% Dale CRCW0805-3401F

R203 1 4.75 kΩ–1% Dale CRCW0805-4751F

R204 1 4.53 kΩ–1% Dale CRCW0805-4531F

R207, R522, R523, R524 4 0 Dale CRCW0805-000

R301, R304, R311, R313,R316, R317, R320, R321

8 3 kΩ–1% Dale CRCW0805-3001F

R302 1 2.21 kΩ–1% Dale CRCW0805-2211F

R303, R305, R307, R314,R315, R318, R319, R322,R324

9 100 kΩ–1% Dale CRCW0805-1003F

R306 1 68 kΩ Dale CRCW0805-683J

R308, R309, R403 3 1.2 kΩ Dale CRCW0805-122J

R310 1 470 Ω Dale CRCW0805-221J






Schematics and Parts ListParts Lists

F

ree

sca

le S

em

ico

nd

uc

tor,

I


c..

.

R323 1 390 Ω Dale CRCW0805-391J

R325 1 33.2 kΩ–1% Dale CRCW0805-3322F

R401 1 4.7 kΩ Dale CRCW0805-473J

R402 1 1.5 kΩ Dale CRCW0805-152J

R501, R508, R516 3 11.5 kΩ–1% Dale CRCW0805-1152F

R503, R510, R515 3 10 MΩ Dale CRCW0805-106J

R504, R511, R518 3 1.18 kΩ–1% Dale CRCW0805-1181F

R506, R513, R520 3 470 kΩ Dale CRCW0805-474J

U101, U102, U 103 3 Gate driverInternationalRectifier

IR2112S

U104 1 Hex driver Fairchild DM74ALS1034M

U201 1 Gate driver ON Semiconductor MC33152D

U301, U302 2 Op amp On Semiconductor MC33502D

U303 1 Dual comparator On Semiconductor LM393D

U304 1 Voltage referenceNationalSemiconductor

LM285M

U401 1 DC/DC convertor Traco Power TEG1222

U402 1 Voltage regulator ON Semiconductor LM2575D2T-ADJ

U403 1 Voltage regulator ON Semiconductor

U404 1 Voltage regulator ON Semiconductor MC78PC33NTR

U501 1 Dual comparator ON Semiconductor LM339D

U801 1 Programmed MCU Motorola MC68HC705JJ7DW

X801 1 4-MHz resonator muRata CSTCC4.00MG

7 Tubular rivetINDUSTRIALRIVET

N/A







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F

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nc

...


Section 5. Design Considerations

5.1 Contents

5.2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3 Phase Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.4 Bus Voltage and Current Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5 Cycle-by-Cycle Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.6 Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.7 Back EMF Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.8 Phase Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.2 Overview

From a systems point of view, the LV BLDC power stage fits into anarchitecture that is designed for software development. In addition to thehardware that is needed to run a motor, a variety of feedback signals thatfacilitate control algorithm development are provided.

Circuit descriptions for the LV BLDC power stage appear in these subsections.

5.3 Phase Outputs

The output stage is configured as a 3 phase H-Bridge with 60-volt MOSFEToutput transistors. It is simplified considerably by integrated gate drivers thathave a cycle by cycle current limit feature. A schematic that shows one phase isillustrated in Figure 5-1.


MOTOROLA Design Considerations 43 For More Information On This Product,


4 TB75

N06

HD

1 TB75

N06

HD

01

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+C
123

33uF

/25V

Q MC

117

1nF

Q M

C10

58.

2pF

D10

1M

BRM

140T

3

+12V

_D

C10

347

0nF/

50V

R10

610

0

R10

147

0

GN

D

I_se

nse_

A2

R10

410

k

ND

D10

2M

BRM

140T

3

R10

247

0U

104B

DM

74AL

S103

4M

34

U10

1

IR21

12S

123456789 10 11 12 13 14 15 16

LOC

OM

VCCn/c

n/c

VSVBHO

n/c

n/c

VDD

HIN

SD LIN

VSS

n/c

+

C10

14.

7uF/

16V

D10

3M

BRM

140T

3

+5V_

D

C11

61n

F

C10

210

0nF

I_se

nse_

A1

I_Se

nse_

DC

B2

+5V_

Dsense

sense

R5

0.0

U10

4CD

M74

ALS1

034M

56

R10

510

k

R10

310

k

DC

B_C

ap_P

os

+5V_

D

C10

447

0nF/

50V

GN

D

Fi

gure

5-1

. Pha

se A

Out

put

PWM

_AT

G

Shut

_Dow

n

PWM

_AB



Design ConsiderationsBus Voltage and Current Feedback

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5.4 Bus Voltage and Current Feedback

Feedback signals proportional to bus voltage and bus current are provided bythe circuitry shown in Figure 5-2. Bus voltage is scaled down by a voltagedivider consisting of R202–R205.

The values are chosen such that a 16-volt maximum bus voltage corresponds to3.3 volts at output V_sense_DCB. An additional output, V_sense_DCB_half,provides a reference that is used in zero-crossing detection.

Bus current is sampled by resistor R8 in Figure 4-3. 3-Phase H-Bridge andamplified by the circuit in Figure 5-2. This circuit provides a voltage outputsuitable for sampling with A/D inputs. An MC33502 is used for the differentialamplifier. With R316 = R317 and R315 = R319, the gain is given by:

A = R315/R316

The output voltage is shifted up by 1.65 V to accommodate both positive andnegative current swings. A ±50 mV voltage drop across the sense resistorcorresponds to a measured current range of ±50 amps. In addition to providingan A/D input, this signal is also used for cycle-by-cycle current limiting. Adiscussion of cycle-by-cycle current limiting follows in 5.5 Cycle-by-CycleCurrent Limiting.




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+3.3V_A

GNDA

+C306

3.3uF/10V

R2044.53k-1%

V_sense_DCB_half

R324100k-1%

DCB_Cap_pos

I_sense_DCB2

GNDA

GNDA

R319100k-1%

DC Bus VoltageSensing

R202

3.4k-1%

R32533.2k-1%

1.65Vref

I_sense_DCB

R315 100k-1%

R316 3k-1%

R323 390

(+/- 50mV @ +/- Imax)

+

-

U301AMC33502D

3

21

84

DC Bus CurrentSensing

R203

4.75k-1%

(3.30V @ Vbus = 16V)

DCB_Cap_neg

+3.3V_A

C307100nF

R207

0

U304LM285M

8

5

4

V_sense_DCB

I_sense_DCB1

GNDA

I_sense_DCB

C305

100nF

R2053.32k-1%

R317 3k-1%

Figure 5-2. Bus Feedback

______________________________________________________________________ 35



Design ConsiderationsCycle-by-Cycle Current Limiting

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5.5 Cycle-by-Cycle Current Limiting

Cycle-by-cycle current limiting is provided by the circuitry illustrated inFigure 5-3. Bus current feedback signal I_sense_DCB is filtered with R308 andC304 to remove spikes, and then compared to a 3.15-volt reference in U303A.The open collector output of U303A is pulled up by R105. Additional filteringis provided by C105, C110, and C115. The resulting signal is fed into theIR2112 gate driver’s shutdown input on all three phases. Therefore, when buscurrent exceeds 46 amps, all six output transistors are switched off.

The IR2112’s shutdown input is buffered by RS latches for both top and bottomgate drives. Once a shutdown signal is received, the latches hold the gate driveoff for each output transistor, until that transistor’s gate drive signal is switchedlow, and then is turned on again. Hence, current limiting occurs on acycle-by-cycle basis.




Design Considerations

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Figure 5-3. Cycle-by-Cycle Current Limiting

I_sense_DCBR3081.2 kΩ

C304680 pF

GNDA

GNDA

GND

R3091.2 kΩ

R310470 Ω R312

10 kΩ

+3.3V_A

R306 680 kΩ

4

3

21

LM393D

U303A

+12V_D

PWM B TOP

PWM B BOTTOM

PWM A TOP

PWM A BOTTOM

PWM C TOP

PWM C BOTTOM

R10510 kΩ

100 Ω

R106

+5V_D

+5V_D

+5V_D

U101

U102

U103

B TOP OUT

A TOP OUT

C TOP OUT

A BOTTOM OUT

B BOTTOM OUT

C BOTTOM OUT

IR2112S

IR2112S

IR2112S

910111213141516

N/CN/CVDDHINSDLINVSSN/C

87654321

HOVBVS

N/CN/C

VCCCOM

LO

910111213141516


87654321

HOVBVS

N/CN/CVCCCOM

LO

910111213141516


87654321

C105 8.2 pF

C110 8.2 pF

+

–

8

HOVBVS

N/CN/CVCCCOM

LO

+5V_DC115 8.2 pF


48 Design Considerations MOTOROLA For More Information On This Product,


Design ConsiderationsTemperature Sensing

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5.6 Temperature Sensing

Cycle-by-cycle current limiting keeps average bus current within safe limits.Current limiting by itself, however, does not necessarily ensure that a powerstage is operating within safe thermal limits. For thermal protection, the circuitin Figure 5-4 is used. It consists of four diodes connected in series, a biasresistor, and a noise suppression capacitor. The four diodes have a combinedtemperature coefficient of –8.8 mV/°C. The resulting signal, Temp_sense, is fedback to an A/D input where software can be used to set safe operating limits.

Due to unit-to-unit variations in diode forward voltage, it is highly desirable tocalibrate this signal. To do so, a value for Temp_sense is read at a knowntemperature and then stored in nonvolatile memory. The measured value, ratherthan the nominal value, is then used as a reference point for further readings.

Figure 5-4. Temperature Sensing

R3022.2 kΩ –1%

C302100 nF

BAV99LT1

D2

PIN 26, CONNECTOR J13

+3.3V_A

BAV99LT1

D3

Temp_sense

GNDA





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5.7 Back EMF Signals

Back EMF and zero crossing signals are included to support sensorlessalgorithms. Referring to Figure 5-5, which shows circuitry for phase A, the rawphase voltage is scaled down by a voltage divider consisting of R501, R504,R507, and R522. One output from this divider produces back EMF sensevoltage BEMF_sense_A. Resistor values are chosen such that a 16-voltmaximum phase voltage corresponds to a 3.3-volt maximum A/D input. A zerocrossing signal is obtained by comparing motor phase voltage with one-half themotor bus voltage. Comparator U501C performs this function, producing zerocrossing signal Zero_cross_A.

Figure 5-5. Phase A Back EMF

+5V_D

U501CLM339D

Zero_cross_A

R50510 kΩ

149

8

C5051.8 nF

GNDA

V_sense_DCB_half

Phase_A

+

–

BEMF_sense_A3.30 V @ Phase_A = 16 V

R50111.5 kΩ –1%

R5041.18 kΩ –1%

GNDA

R5073.32 kΩ –1%

R50210 kΩ

GNDA

R506470 kΩ

R522

0 Ω

C501100 pF

R503

10 MΩ




Design ConsiderationsPhase Current Sensing

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5.8 Phase Current Sensing

Lower half-bridge sampling resistors provide phase current information for allthree phases. Since these resistors sample current in the lower phase legs, theydo not directly measure phase current. However, given phase voltages for allthree phases, phase current can be constructed mathematically from the lowerphase leg values. This information can be used in a variety of motor controlalgorithms. The measurement circuitry for one phase is shown in Figure 5-6.

Figure 5-6. Phase A Current Sensing

–

+

DCB_Cap_Pos

Gate_AB

Gate_AT

Phase_A

Source_AB

Q1MTB75N06HD

Q4MTB75N06HD

R50.01 Ω

sense

sense

R301 3 kΩ –1%

R304 3 kΩ –1%

R303 100 kΩ –1%

5

67

U301BMC33502D

R305100 kΩ –1%

I_Sense_DCB2

+3.3V_AR323 390 Ω 1.65 Vref

C307100 nF

C3063.3 µF

+

LM285MU304

GNDA

GNDA

R324100 kΩ –1%

R3253.23 kΩ –1%

I_sense_A

85

4





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Referencing the sampling resistors to the negative motor rail makes themeasurement circuitry straightforward and inexpensive. Current is sampled byresistor R5, and amplified by differential amplifier U301B. This circuitprovides a voltage output suitable for sampling with A/D inputs. An MC33502is again used for the differential amplifier. The gain is given by:

A = R303/R301

The output voltage is shifted up by 1.65 V to accommodate both positive andnegative current swings. A ±50-mV voltage drop across the shunt resistorcorresponds to a measured current range of ±50 amps.

5.9 Brake

A brake circuit is included to dissipate re-generative motor energy duringperiods of active deceleration or rapid reversal. Under these conditions, motorback EMF adds to the dc bus voltage. Without a means to dissipate excessenergy, an overvoltage condition could easily occur.

The circuit shown in Figure 5-7 connects R1–R4 across the dc bus to dissipateenergy. Q7 is turned on by software when the bus voltage sensing circuit inFigure 5-2 indicates that bus voltage could exceed safe levels. On-board powerresistors R1–R4 will safely dissipate up to 50 watts continuously or up to100 watts for 15 seconds. Additional power dissipation capability can be addedexternally via brake connectors J14 and J15.

Note that operation of the brake at 100% duty cycle for more than 15 secondsat 12 volts will over dissipate R1–R4. For bus voltages higher than 12 volts,maximum duty cycle is restricted to less than 100%.




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J14 1

Brake 2 EXT.

GND

R201

100

DCB_Cap_Pos

R20610k

Brake_control

GND

R30.33

Q7MTB75N06HD

D1

MBRB2060CT

GND

R10.33

+12V_D

OutBInB

GND

InA

NC NC

OutA

VCCU201

MC33152D

2

3

5

6

7

81

4

J151

+

C20110uF/35V

GND GND

C2031nF

Brake1 EXT.

R20.33

GND

R40.33

C202100nF

Figure 5-7. Brake




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MEMC3PBLDCLVUM/D

© Motorola, Inc., 2000

Motorola reserves the right to make changes without further notice to any products herein. Motorola makes no warranty, representation or guarantee regarding the suitability of itsproducts for any particular purpose, nor does Motorola assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability,including without limitation consequential or incidental damages. "Typical" parameters which may be provided in Motorola data sheets and/or specifications can and do vary in differentapplications and actual performance may vary over time. All operating parameters, including "Typicals" must be validated for each customer application by customer's technical experts.Motorola does not convey any license under its patent rights nor the rights of others. Motorola products are not designed, intended, or authorized for use as components in systemsintended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the Motorola product could create asituation where personal injury or death may occur. Should Buyer purchase or use Motorola products for any such unintended or unauthorized application, Buyer shall indemnify and holdMotorola and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of,directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that Motorola was negligent regarding thedesign or manufacture of the part. Motorola and are registered trademarks of Motorola, Inc. Motorola, Inc. is an Equal Opportunity/Affirmative Action Employer.

How to reach us:USA/EUROPE/Locations Not Listed: Motorola Literature Distribution, P.O. Box 5405, Denver, Colorado 80217. 1-303-675-2140

or 1-800-441-2447. Customer Focus Center, 1-800-521-6274JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu, Minato-ku, Tokyo 106-8573 Japan.

81-3-3440-8573ASIA/PACIFIC: Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, 2 Dai King Street, Tai Po Industrial Estate,

Tai Po, N.T., Hong Kong. 852-26668334HOME PAGE: http://motorola.com/semiconductors/

For More Information On This Product, Go to: www.freescale.com

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