motor control 10-24v driver board (dual/single) user's...

2014 Microchip Technology Inc. DS50002261A

Motor Control 10-24V DriverBoard (Dual/Single)

User’s Guide

DS50002261A-page 2 2014 Microchip Technology Inc.

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Printed on recycled paper.

ISBN: 978-1-63276-149-1

Object of Declaration: Motor Control 10-24V Driver Board (Dual/Single)

2014 Microchip Technology Inc. DS50002261A-page 3

Motor Control 10-24V Driver Board (Dual/Single)

NOTES:


MOTOR CONTROL 10-24VDRIVER BOARD (DUAL/SINGLE)

USER’S GUIDE

Table of Contents

Preface ........................................................................................................................... 7

Chapter 1. Introduction1.1 Overview ...................................................................................................... 131.2 Motor Control 10-24V Driver Board (Dual/Single) Features ......................... 131.3 Block Diagram .............................................................................................. 15

Chapter 2. Board Interface Description2.1 Introduction ................................................................................................... 172.2 Highlights ...................................................................................................... 172.3 Board Connectors ........................................................................................ 172.4 User Interface Hardware .............................................................................. 35

Chapter 3. Hardware Description3.1 Introduction ................................................................................................... 413.2 Highlights ...................................................................................................... 413.3 Three-Phase Inverter Bridge and Gate Driver .............................................. 433.4 DC Bus Voltage Sensing .............................................................................. 433.5 Hall Sensor/Quadrature Encoder Interface .................................................. 443.6 Back-EMF and Recreated Neutral Signals ................................................... 453.7 Phase and Bus Current Sensing Circuits ..................................................... 463.8 Fault Generation Logic Circuit ...................................................................... 503.9 Brake Circuit ................................................................................................. 523.10 Power Supply ............................................................................................. 55

Appendix A. Board Schematics and LayoutA.1 Introduction .................................................................................................. 57A.2 Board Schematics and Layout ..................................................................... 57

Appendix B. Electrical SpecificationsB.1 Introduction .................................................................................................. 63

Appendix C. Component SelectionC.1 Introduction .................................................................................................. 65C.2 Highlights ..................................................................................................... 65C.3 Motor Current Amplifier Configuration ......................................................... 65C.4 Brake Current Amplifier Configuration ......................................................... 68C.5 Hardware Brake Enable Circuit Configuration ............................................. 70C.6 Hardware Brake Enable Circuit Configuration Resistors ............................. 73

Worldwide Sales and Service .................................................................................... 74



NOTES:



USER’S GUIDE

Preface

INTRODUCTION

This chapter contains general information that will be useful to know before using the Motor Control 10-24V Driver Board (Dual/Single). Items discussed in this chapter include:

• Document Layout• Conventions Used in this Guide• Warranty Registration

• Recommended Reading• The Microchip Web Site• Development Systems Customer Change Notification Service• Customer Support• Document Revision History

NOTICE TO CUSTOMERS

All documentation becomes dated, and this manual is no exception. Microchip tools and documentation are constantly evolving to meet customer needs, so some actual dialogs and/or tool descriptions may differ from those in this document. Please refer to our web site (www.microchip.com) to obtain the latest documentation available.

Documents are identified with a “DS” number. This number is located on the bottom of each page, in front of the page number. The numbering convention for the DS number is “DSXXXXXXXXA”, where “XXXXXXXX” is the document number and “A” is the revision level of the document.

For the most up-to-date information on development tools, see the MPLAB® IDE online help. Select the Help menu, and then Topics to open a list of available online help files.



DOCUMENT LAYOUT

This document describes how to use the Motor Control 10-24V Driver Board (Dual/Single). This user’s guide is composed of the following chapters:

• Chapter 1. “Introduction” provides a brief overview of the Motor Control 10-24V Driver Board (Dual/Single) and its features.

• Chapter 2. “Board Interface Description” summarizes the Motor Control 10-24V Driver Board (Dual/Single) input and output interfaces.

• Chapter 3. “Hardware Description” provides the hardware descriptions of the Motor Control 10-24V Driver Board (Dual/Single).

• Appendix A. “Board Schematics and Layout” provides a block diagram, board layouts and detailed schematics of the Motor Control 10-24V Driver Board (Dual/Single).

• Appendix B. “Electrical Specifications” provides the electrical specifications of the Motor Control 10-24V Driver Board (Dual/Single).

• Appendix C. “Component Selection” details the component selection of the motor current amplifier, brake current amplifier and the hardware brake enable circuit.


Preface

CONVENTIONS USED IN THIS GUIDE

This manual uses the following documentation conventions:

WARRANTY REGISTRATION

Please complete the enclosed Warranty Registration Card and mail it promptly. Sending in the Warranty Registration Card entitles users to receive new product updates. Interim software releases are available at the Microchip web site.

DOCUMENTATION CONVENTIONS

Description Represents Examples

Italic characters Referenced books MPLAB IDE User’s Guide

Emphasized text ...is the only compiler...

Initial caps A window the Output window

A dialog the Settings dialog

A menu selection select Enable Programmer

Quotes A field name in a window or dialog

“Save project before build”

Underlined, italic text with right angle bracket

A menu path File>Save

Bold characters A dialog button Click OK

A tab Click the Power tab

Text in angle brackets < > A key on the keyboard Press <Enter>, <F1>

Plain Courier New Sample source code #define START

Filenames autoexec.bat

File paths c:\mcc18\h

Keywords _asm, _endasm, static

Command-line options -Opa+, -Opa-

Bit values 0, 1

Constants 0xFF, ‘A’

Italic Courier New A variable argument file.o, where file can be any valid filename

Square brackets [ ] Optional arguments mcc18 [options] file [options]

Curly brackets and pipe character: { | }

Choice of mutually exclusive arguments; an OR selection

errorlevel {0|1}

Ellipses... Replaces repeated text var_name [, var_name...]

Represents code supplied by user

void main (void){ ...}

Notes A Note presents information that we want to re-emphasize, either to help you avoid a common pitfall or to make you aware of operating differences between some device family members. A Note can be in a box, or when used in a table or figure, it is located at the bottom of the table or figure. Note 1: This is a note used in a

table.

Note: This is a standard note box.

CAUTION

This is a Caution note.



RECOMMENDED READING

This user’s guide describes how to use the Motor Control 10-24V Driver Board (Dual/Single). The following Microchip documents are available and recommended as supplemental reference resources.

MPLAB® X IDE User’s Guide (DS50002027)

This user’s guide is a comprehensive guide that describes installation and features of Microchip’s MPLAB X Integrated Development Environment (IDE), as well as the editor and simulator functions in the MPLAB X IDE environment. Please visit www.microchip.com/mplabx for more information.

Readme Files

For the latest information on using other tools, read the tool-specific Readme files in the Readme subdirectory of the MPLAB X IDE installation directory. The Readme files contain updated information and known issues that may not be included in this user’s guide.

MPLAB® XC16 Assembler, Linker and Utilities User’s Guide (DS52106)

This user’s guide describes how to use GNU language tools to write code for 16-bit applications.

MPLAB® XC16 C Compiler User’s Guide (DS50002071)

This user’s guide describes how to use the 16-bit MPLAB XC16 C Compiler. Please visit www.microchip.com/compilers for more information.

dsPIC® DSC Signal Board User’s Guide (DS50002263)

This user’s guide describes how to use Microchip’s dsPIC DSC Signal Board.

dsPIC33EV256GM106 5V Motor Control Plug-In Module (PIM) Information Sheet (DS50002225)

This information sheet provides information specific to the dsPIC33EV256GM106 5V Motor Control Plug-In Module (PIM).

dsPIC33EP512GM710 Plug-In Module (PIM) Information Sheet for Single-Dual Motor Control (DS50002216)

This information sheet provides information specific to the dsPIC33EP512GM710 Plug-In Module (PIM) for Single-Dual Motor Control.

AN1299, Single-Shunt Three-Phase Current Reconstruction Algorithm for Sensorless FOC of a PMSM (DS01299)

AN1160, Sensorless BLDC Control with Back-EMF Filtering Using a Majority Function (DS01160)

AN1078, Sensorless Field Oriented Control of a PMSM (DS01078)

AN1292, “Sensorless Field Oriented Control (FOC) for a Permanent Magnet Synchronous Motor (PMSM) Using a PLL Estimator and Field Weakening (FW) (DS01292)

AN1017, Sinusoidal Control of PMSM Motors with dsPIC30F DSC (DS01017)


Preface

THE MICROCHIP WEB SITE

Microchip provides online support via our web site at http://www.microchip.com. This web site makes files and information easily available to customers. Accessible by most Internet browsers, the web site contains the following information:

• Product Support – Data sheets and errata, application notes and sample programs, design resources, user’s guides and hardware support documents, latest software releases and archived software

• General Technical Support – Frequently Asked Questions (FAQs), technical support requests, online discussion groups, Microchip consultant program member listings

• Business of Microchip – Product selector and ordering guides, latest Microchip press releases, listings of seminars and events; and listings of Microchip sales offices, distributors and factory representatives

DEVELOPMENT SYSTEMS CUSTOMER CHANGE NOTIFICATION SERVICE

Microchip’s customer notification service helps keep customers current on Microchip products. Subscribers will receive e-mail notification whenever there are changes, updates, revisions or errata related to a specified product family or development tool of interest.

To register, access the Microchip web site at www.microchip.com, click on Customer Change Notification and follow the registration instructions.

The Development Systems product group categories are:

• Compilers – The latest information on Microchip C compilers and other language tools

• Emulators – The latest information on the Microchip in-circuit emulator, MPLAB REAL ICE™

• In-Circuit Debuggers – The latest information on the Microchip in-circuit debugger, MPLAB ICD 3

• MPLAB X IDE – The latest information on Microchip MPLAB X IDE, the Windows® Integrated Development Environment for development systems tools

• Programmers – The latest information on Microchip programmers including the PICkit™ 3 development programmer

CUSTOMER SUPPORT

Users of Microchip products can receive assistance through several channels:

• Distributor or Representative

• Local Sales Office

• Field Application Engineer (FAE)

• Technical Support

Customers should contact their distributor, representative or field application engineer (FAE) for support. Local sales offices are also available to help customers. A listing of sales offices and locations is included in the back of this document.

Technical support is available through the web site at: http://support.microchip.com


http://www.microchip.com


DOCUMENT REVISION HISTORY

Revision A (April 2014)

This is the initial release of this document.



USER’S GUIDE

Chapter 1. Introduction

1.1 OVERVIEW

The Motor Control 10-24V Driver Board (Dual/Single) is a low-voltage, dual motor control power stage, targeted to drive two Brushless DC (BLDC) motors or Permanent Magnet Synchronous Motors (PMSMs) concurrently.

The Motor Control 10-24V Driver Board (Dual/Single), along with the compatible dsPIC® DSC Signal Board, provides a software development platform to build and evaluate embedded motor control application software using Microchip’s high-performance motor control Digital Signal Controllers (DSCs) and Microcontrollers (MCUs).

1.2 MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) FEATURES

The Motor Control 10-24V Driver Board (Dual/Single) is shown in Figure 1-1. The boardincludes these key features:

• Two PMSM/BLDC motor control power stages with electrical specifications:

- Input DC voltage: 10-24V DC ±10% (9V-26.4V DC)

- Output phase RMS current: 10A nominal @ +25ºC per phase

• MCP8024 gate drivers with undervoltage, overvoltage, overcurrent, shoot-throughand short-circuit protection

• Hall sensors/Quadrature Encoder Interface (QEI) in each motor control stage toenable sensor-based motor control algorithms

• Phase voltage and reconstructed neutral feedback signals in each motor controlstage to enable sensorless BLDC operation

• DC bus current sense resistor for overcurrent protection, torque control of theBLDC motor and single-shunt Field Oriented Control (FOC) of PMSMs

• Phase current sensing resistors for Field Oriented Control

• DC bus voltage sensing

• Dynamic braking chopper circuit with hardware and software brake control forboth the inverter stages

• Overcurrent protection

• LED indication for PWM signals and Power-on Status



FIGURE 1-1: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE)

The block diagram of the Motor Control 10-24V Driver Board (Dual/Single) is shown inFigure 1-2. For more information on electrical specifications, see Appendix B. “ElectricalSpecifications”.


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EncoderInterface

Three-PhaseBack-EMFs and

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URE 1-2: BLOCK DIAGRAM OF THE MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE

Inverte

SectInverter – A

Section

120-Pin Signal Board Interface Connector, J13


EncoderInterface

MotorConnector

I/P SupplyConnector

+12V LDO

Three-Phase Inverter Bridge

Phase and Bus Current Sensing

CoI/P SupplyConnector


Phase and Bus Current Sensing

Fault GenerationLogic

MCP8024

+5V LDO

+12V LDO

DE2Communication

Protection Circuit

Three Operational Amplifiers andOne Comparator

Three Half-Bridge Drivers

MCP8024

+5V LDO

+12V LDO

DE2Communication

Protection Circuit

Three Operational Amplifiers andOne Comparator

Three Half-Bridge Drivers

Dynamic BrakeCircuit – A


Circuit

Driver andBrake Switch


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C+

DVDD+5V

+12V

VDC_A (9V-26.4V) VDC_B (9V-26

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Three-PhaseBack-EMFs and

RecreatedNeutral

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NOTES:



USER’S GUIDE

Chapter 2. Board Interface Description

2.1 INTRODUCTION

This chapter provides a more detailed description of the input and output interfaces of the Motor Control 10-24V Driver Board (Dual/Single).

2.2 HIGHLIGHTS

This chapter covers the following topics:

• Board Connectors

• User Interface Hardware

The input power supply for powering the gate drivers, inverters and other control circuits on the board, must be in the range of 10-24V DC ±10%.

2.3 BOARD CONNECTORS

The Motor Control 10-24V Driver Board (Dual/Single) has various connectors, jumpers and LED indications. The on-board connectors are provided in Table 2-1 and are shown in Figure 2.3.

TABLE 2-1: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) CONNECTORS

Designator Description

J1 Input DC Power Supply Connector for Inverter A

J2 Hall Sensor/Quadrature Encoder Interface Connector for Motor A

J4 Hall Sensor/Quadrature Encoder Interface Connector for Motor B

J5,J8 Input DC Power Supply Connector

J6 Input DC Power Supply Connector for Inverter B

J7 Inverter A Three-Phase Output Connector

J9 Inverter B Three-Phase Output Connector

J10, J11, J12 MCP8024 (U8) Operational Amplifier Interface Connector

J13 dsPIC® DSC Signal Board Interface Connector

J15 Auxiliary Power Supply Output Connectors for +5V, DVDD, AVDD, AGND, DGND

J16 +12V LDO (U11) Output Connector

TP46-TP47 Terminals to Connect Brake Resistor on Inverter A Side

TP51-TP52 Terminals to Connect Brake Resistor on Inverter B Side



FIGURE 2-1: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) CONNECTORS

The following are the on-board connectors:

• Power Supply Connectors (J5, J8, J1 and J6)

• Inverter Output Connectors (J7, J9)

• Signal Board Interface Connector (J13)

• Hall Sensor/Quadrature Encoder Interface Connectors (J2, J4)

• Terminals for Brake Resistors (TP46-TP47, TP51-TP52)

• Auxiliary Power Supply Output Connectors (J15, J16)

• MCP8024 (U8) Operational Amplifier Interface Connectors (J10, J11, J12)

J2

J11

J10

J16

J15

J4

J7J1

J8J5

J6 J9

TP51-TP52TP46-TP47

J12

J13


Board Interface Description

2.3.1 Power Supply Connectors (J5, J8, J1 and J6)

The Motor Control 10-24V Driver Board (Dual/Single) is designed to operate in the DC voltage range of 9-26.4V. The possible input DC power supply connections are shown in Figure 2-2.

FIGURE 2-2: INPUT DC POWER SUPPLY CONNECTORS

If the wire jumpers between TP3-TP6 and TP7-TP8 are populated, Inverter A and Inverter B can be powered by a common voltage source, DC+, connected to either the coaxial plug, J5, or to the connector, J8. The voltage source, DC+, supplies power to the dsPIC DSC Signal Board through the signal board interface connector, J13. Connector, J5, can carry current up to 2.5A and connector, J8, can carry current up to 30A.

Both the Inverter A and Inverter B sections on the Motor Control 10-24V Driver Board (Dual/Single) can be powered independently by different voltage sources, such as VDC_A and VDC_B. Inverter A can be powered up by different voltage sources con-nected to connector, J1, if a wire jumper between TP3-TP6 is disconnected. Similarly, Inverter B can be powered up by different voltage sources connected to connector, J6, if a wire jumper between TP7-TP8 is disconnected. Connectors, J1 and J6, can carry the maximum current of 15A each. If both the jumpers, TP3-TP6 and TP7-TP8, are opened, then the dsPIC DSC Signal Board is powered from the connector, J5 or J8. Input power supply configuration is shown in Table 2-2.

J8

J5

J1

J13

J6

DC+

PGND

TP3 TP6

VDC_A

Populated By Default

Populated By Default

VDC_B

PGNDPGND

Jumper

DC+

PGND

PGND

TP7 TP8

Jumper

Signal BoardInterface Connector

Note: On the Motor Control 10-24V Driver Board (Dual/Single),TP3-TP6 andTP7-TP8 wire jumpers are populated by default.

TABLE 2-2: INPUT POWER SUPPLY CONFIGURATION

Wire Jumper Configuration Power Supply Connectors

TP3-TP6 TP7-TP8Inverter A Section

Inverter B Section

Signal Board

Connected Connected J5/J8 (DC+) J5/J8 (DC+)

J5/J8Disconnected Connected J1 (VDC_A) J5/J8

Connected Disconnected J5/J8 J6 (VDC_B)

Disconnected Disconnected J1 (VDC_A) J6 (VDC_B)



2.3.2 Inverter Output Connectors (J7, J9)

The Motor Control 10-24V Driver Board (Dual/Single) can drive two three-phase PMSM/BLDC motors. These motors are driven through Inverter A and Inverter B out-puts from connectors, J7 and J9. The pin assignments for connectors, J7 and J9, are provided in Table 2-3 and Table 2-4.

2.3.3 Signal Board Interface Connector (J13)

The signal board interface connector, J13, is used to interface the Motor Control 10-24V Driver Board (Dual/Single) to the dsPIC DSC Signal Board. The signal board interface connector, J13, has three rows and each row has 40 pins. The signals on the connector, J13, can be grouped into the following function sets:

• Control Signals to the Motor Control 10-24V Driver Board (Dual/Single) for eachInverter:

- Three pairs of PWMH/L signals

- Braking chopper circuit control signal

• Feedback Signals from the Motor Control 10-24V Driver Board (Dual/Single) foreach Inverter:

- Current shunt feedbacks

- DC bus voltage and current feedback

- Three-phase back-EMF signals and recreated neutral signals

- Hall Sensor/Quadrature Encoder Interface (QEI) sensor feedbacks

- Fault signals

• Power Supply Signals to Signal Board:

- Input DC power signal, DC+, and power ground

• Power Supply Signals from Signal Board:

- Auxiliary power supply signals, DVDD, +5V, DGND, AVDD and AGND

- DC bias voltage (VREF_EXT) signal to offset op amp outputs by a fixed DC voltage and this potential is referenced to AGND

• Signal Interface between Gate Driver and Microcontroller for each Inverter:

- Chip enable signal from microcontroller

- UART RX and TX to establish DE2 communication between controller and theMCP8024 gate driver

Connector, J13, pin function and pin mapping to the mate connector on the signal board are provided in Table 2-5 and Table 2-6. In Table 2-5, J13 pins are tabulated in order of their number, whereas in Table 2-6, signals on connector, J13, are grouped according to their functionality.

TABLE 2-3: INVERTER A OUTPUT CONNECTOR (J7)

Pin # Signal Name Pin Description

1 PHASE3_MA Phase 3 Output of Inverter A



TABLE 2-4: INVERTER B OUTPUT CONNECTOR (J9)


1 PHASE3_MB Phase 3 Output of Inverter B





TABLE 2-5: SIGNAL BOARD INTERFACE CONNECTOR (J13)

On-Board J13

Connector Pin #

Mating Connector

Pin #(1) Signal Name Pin Function Signal Type

A1 A40 DVDD +3.3V or +5V Digital Power Supply from dsPIC® DSC Signal Board(2)

Power Supply

B1 B40 DVDD +3.3V or +5VDigital Power Supply from dsPIC DSC Signal Board(2)

Power Supply

C1 C40 DVDD +3.3V or +5V Digital Power Supply from dsPIC DSC Signal Board(2)

Power Supply

A2 A39 DGND Digital Ground Ground

B2 B39 DGND Digital Ground Ground

C2 C39 DGND Digital Ground Ground

A3 A38 VPHASE1_MB Phase 1 BEMF Voltage Feedback of Motor B Analog Output

B3 B38 — — —


A4 A37 — — —

B4 B37 FAULT_AB Inverter A and Inverter B Combined Fault Output generated by Fault Generation Logic Circuit

Digital Output

C4 C37 VPHASE2_MB Phase 2 BEMF Voltage Feedback of Motor B Analog Output

A5 A36 VPHASE1_MA Phase 1 BEMF Voltage Feedback of Motor A Analog Output

B5 B36 VPHASE2_MA Phase 2 BEMF Voltage Feedback of Motor A Analog Output

C5 C36 VPHASE3_MA Phase 3 BEMF Voltage Feedback of Motor A Analog Output


B6 B35 RECN_MA,IPHASE3_MA,

IBRAKE_A

Recreated Neutral Feedback for Motor A orInverter A Phase 3 Current Feedback, or Braking Chopper Circuit – A Current Sense Output

Analog Output

C6 C35 — — —

A7 A34 VREF_EXT +1.65V/+2.5V Voltage Reference to Shift Op Amp Outputs(4)

Analog Output

B7 B34 — — —

C7 C34 — — —

A8 A33 — — —

B8 B33 — — —

C8 C33 — — —

A9 A32 — — —

B9 B32 VBUS_A DC Bus Feedback of Inverter A Analog Output

C9 C32 — — —

A10 A31 — — —

B10 B31 — — —

C10 C31 — — —

Note 1: The mating connector pin refers to the mating connector on the dedicated signal board interfaced to the Motor Control 10-24V Driver Board (Dual/Single).

2: On the dsPIC® DSC Signal Board, the DVDD voltage level is configured as either +3.3V or +5V by the PIM plugged into the board.

3: On the dsPIC DSC Signal Board, the AVDD voltage level is configured as either +3.3V or +5V by the PIM plugged into the board.

4: On the dsPIC DSC Signal Board, the VREF_EXT voltage level is configured as either +1.65 or +2.5V by the PIM plugged into the board.






A12 A29 RECN_MB,IPHASE3_MB,

IBRAKE_B

Recreated Neutral Feedback for Motor B orInverter B Phase 3 Current Feedback, or Braking Chopper Circuit – B Current Sense Output

Analog Output

B12 B29 DE2_RX_B UART RX from Microcontroller to establish DE2 Communication with MCP8024 (U9)

Digital Output

C12 C29 — — —

A13 A28 — — —

B13 B28 HALLC_MA Hall Sensor C/INDEX Feedback from Motor A Digital Output

C13 C28 HALLB_MA Hall Sensor B/QEB Feedback from Motor A Digital Output

A14 A27 — — —

B14 B27 — — —

C14 C27 — — —

A15 A26 IBUS_MB Bus Current Feedback of Inverter B Analog Output

B15 B26 DE2_TX_B UART TX from Microcontroller to establish DE2 Communication with MCP8024 (U9)

Digital Input

C15 C26 BRAKE_EN_B Software Brake Enable Signal for Braking Chopper Circuit – B

Digital Input

A16 A25 — — —

B16 B25 IPHASE2_MB Inverter B Phase 2 Current Feedback Analog Output

C16 C25 IPHASE1_MB Inverter B Phase 1 Current Feedback Analog Output

A17 A24 BRAKE_EN_A Software Brake Enable Signal for Braking Chopper Circuit – A

Digital Input

B17 B24 — — —

C17 C24 — — —

A18 A23 — — —

B18 B23 — — —

C18 C23 HOME_MA Quadrature Encoder Interface HOME Signal from Motor A

Digital Output

A19 A22 — — —

B19 B22 SHUNT_LOW_SUM_A Inverter A Bus Current Shunt (Rsh5) Negative Terminal

Analog Output

C19 C22 SHUNT_HIGH_SUM_A Inverter A Bus Current Shunt (Rsh5) Positive Terminal

Analog Output

TABLE 2-5: SIGNAL BOARD INTERFACE CONNECTOR (J13) (CONTINUED)

On-Board J13

Connector Pin #

Mating Connector








A20 A21 FAULT_MA Inverter A Bus Current Fault Output from Signal Board

Digital Output

B20 B21 DE2_RX_A UART RX from Microcontroller to establish DE2 Communication with MCP8024

Digital Output

C20 C19 — — —




A22 A19 — — —

B22 B19 SHUNT_HIGH_SUM_A Inverter A Phase 2 Current Shunt (Rsh1) Negative Terminal

Analog Output

C22 C21 — — —

A23 A18 — — —

B23 B18 SHUNT_HIGH_1_A Inverter A Phase 1 Current Shunt (Rsh7) Positive Terminal

Analog Output

C23 C18 SHUNT_HIGH_2_A Inverter A Phase 2 Current Shunt (Rsh1) Positive Terminal

Analog Output

A24 A17 — — —

B24 B17 DE2_TX_A UART TX from Microcontroller to establish DE2 Communication with MCP8024

Digital Input

C24 C17 — — —

A25 A16 HALLA_MA Hall Sensor A/QEA Feedback from Motor A Digital Output

B25 B16 VBUS_B DC Bus Feedback of Inverter B Analog Output

C25 C16 — — —

A26 A15 — — —

B26 B15 CE_A Chip Enable Signal to MCP8024 (U8) Digital Input

C26 C15 SHUNT_HIGH_SUM_A Inverter A Phase 1 Current Shunt (Rsh7) Negative Terminal

Analog Output

A27 A14 — — —

B27 B14 — — —

C27 C14 — — —

A28 A13 CE_B Chip Enable Signal to MCP8024 (U9) Digital Input

B28 B13 HOME_MB Quadrature Encoder Interface HOME Signal of Motor B

Digital Output

C28 C13 — — —


On-Board J13

Connector Pin #

Mating Connector








A29 A12 PWM1L_A PWM for Inverter A Phase 1 Bottom MOSFET Control

Digital Input

B29 B12 HALLC_MB Hall Sensor C/INDEX Feedback of Motor B Digital Output

C29 C12 — — —

A30 A11 HALLA_MB Hall Sensor A/QEA Feedback of Motor B Digital Output

B30 B11 HALLB_MB Hall Sensor B/QEB Feedback of Motor B Digital Output

C30 C11 PWM1H_A PWM for Inverter A Phase 1 Top MOSFET Control

Digital Input




A32 A9 PWM2H_A PWM for Inverter A Phase 2 Top MOSFET Control

Digital Input

B32 B9 PWM2L_A PWM for Inverter A Phase 2 Bottom MOSFET Control

Digital Input

C32 C9 — — —


Digital Input

B33 B8 — — —

C33 C8 PWM3L_A PWM for Inverter A Phase 3 Bottom MOSFET Control

Digital Input

A34 A7 PWM2L_B PWM for Inverter B Phase 2 Bottom MOSFET Control

Digital Input

B34 B7 PWM1L_B PWM for Inverter B Phase 1 Bottom MOSFET Control

Digital Input

C34 C7 PWM1H_B PWM for Inverter B Phase 1 Top MOSFET Control

Digital Input

A35 A6 PWM3H_B PWM for Inverter B Phase 3 Top MOSFET Control

Digital Input


Digital Input


Digital Input

A36 A5 — — —

B36 B5 — — —

C36 C5 FAULT_MB Inverter B Bus Current Fault Output to Microcontroller on Signal Board

Digital Input


On-Board J13

Connector Pin #

Mating Connector








A37 A4 AVDD +3.3V or +5V Analog Power Supply from Signal Board(3)

Power Supply

B37 B4 AVDD +3.3V or +5V Analog Power Supply from Signal Board(3)

Power Supply

C37 C4 AGND Analog Ground Ground

A38 A3 +5V +5V Digital Power Supply from Signal Board Power Supply

B38 B3 +5V +5V Digital Power Supply from Signal Board Power Supply


A39 A2 PGND Power Ground Ground

B39 B2 PGND Power Ground Ground

C39 C2 PGND Power Ground Ground

A40 A1 DC+ DC Supply (10-24V) from Power Board to Signal Board

Power Supply

B40 B1 DC+ DC Supply (10-24V) from Power Board to Signal board

Power Supply

C40 C1 DC+ DC Supply (10-24V) from Power Board to Signal Board

Power Supply


On-Board J13

Connector Pin #

Mating Connector








TABLE 2-6: SIGNAL BOARD INTERFACE CONNECTOR (J13), GROUPED BY FUNCTIONALITY

On-Board J13

Connector Pin #

Mating Connector

Pin #(1)Signal Name Pin Function Signal Type

A. Power Supply Signals

A1 A40 DVDD +3.3V or +5V Digital Power Supply from Signal Board(2)

Power Supply

B1 B40 DVDD +3.3V or 5V Digital Power Supply from Signal Board(2)

Power Supply

C1 C40 DVDD +3.3V or 5V Digital Power Supply from Signal Board

Power Supply














A37 A4 AVDD +3.3V or +5V Analog Power Supply from Signal Board(3)

Power Supply

B37 B4 AVDD +3.3V or +5V Analog Power Supply from Signal Board(3)

Power Supply


A38 A3 +5V +5V Digital Power Supply from Signal Board Power Supply

B38 B3 +5V +5V Digital Power Supply from Signal Board Power Supply


A39 A2 PGND Power Ground Ground

B39 B2 PGND Power Ground Ground

C39 C2 PGND Power Ground Ground

A40 A1 DC+ DC Supply (10-24V) from Power Board to Signal Board

Power Supply

B40 B1 DC+ DC Supply (10-24V) from Power Board to Signal Board

Power Supply

C40 C1 DC+ DC Supply (10-24V) from Power Board to Signal Board

Power Supply


2: On the dsPIC® DSC Signal Board, the DVDD voltage level can be configured as either +3.3V or +5V by the PIM plugged into the board.

3: On the dsPIC DSC Signal Board, the AVDD voltage level can be configured as either +3.3V or +5V by the PIM plugged into the board.




B. Signals to and from Inverter A Section

B.1 PWM Signals

C30 C11 PWM1H_A PWM for Inverter A Phase 1 Top MOSFET Control

Digital Input

A29 A12 PWM1L_A PWM for Inverter A Phase 1 Bottom MOSFET Control

Digital Input


Digital Input

B32 B9 PWM2L_A PWM for Inverter A Phase 2 Bottom MOSFET Control

Digital Input


Digital Input

C33 C8 PWM3L_A PWM for Inverter A Phase 3 Bottom MOSFET Control

Digital Input

A17 A24 BRAKE_EN_A Software Brake Enable Signal for Braking Chopper Circuit – A

Digital Input

B.2 Interface Signals between Microcontroller and Gate Driver, MCP8024 (U8)

B26 B15 CE_A Chip Enable Signal to MCP8024 (U8) Digital Input

B24 B17 DE2_TX_A UART TX from Microcontroller to establish DE2 Communication with MCP8024

Digital Input

B20 B21 DE2_RX_A UART RX from Microcontroller to establish DE2 Communication with MCP8024

Digital Output

B.3 Hall Sensor/Quadrature Encoder Interface Feedback Signals from Motor A

A25 A16 HALLA_MA Hall Sensor A/QEA Feedback from Motor A Digital Output

C13 C28 HALLB_MA Hall Sensor B/QEB Feedback from Motor A Digital Output

B13 B28 HALLC_MA Hall Sensor C/INDEX Feedback from Motor A Digital Output

C18 C23 HOME_MA Quadrature Encoder Interface HOME Signal from Motor A

Digital Output

TABLE 2-6: SIGNAL BOARD INTERFACE CONNECTOR (J13), GROUPED BY FUNCTIONALITY (CONTINUED)

On-Board J13

Connector Pin #

Mating Connector








B.4 Voltage and Current Feedback Signals

A5 A36 VPHASE1_MA Phase 1 Voltage Feedback of Motor A Analog Output

B5 B36 VPHASE2_MA Phase 2 Voltage Feedback of Motor A Analog output

C5 C36 VPHASE3_MA Phase 3 Voltage Feedback of Motor A Analog Output

B6 B35 RECN_MA,IPHASE3_MA,

IBRAKE_A

Recreated Neutral Feedback for Motor A or Inverter A Phase 3 Current Feedback, or Braking Chopper Circuit – A Current Sense Output

Analog Output

B23 B18 SHUNT_HIGH_1_A Inverter A Phase 1 Current Shunt (Rsh7) Positive Terminal

Analog Output

C26 C15 SHUNT_HIGH_SUM_A Inverter A Phase 1 Current Shunt (Rsh7) Negative Terminal

Analog Output

C23 C18 SHUNT_HIGH_2_A Inverter A Phase 2 Current Shunt (Rsh1) Positive Terminal

Analog Output

B22 B19 SHUNT_HIGH_SUM_A Inverter A Phase 2 Current Shunt (Rsh1) Negative Terminal

Analog Output

C19 C22 SHUNT_HIGH_SUM_A Inverter A bus Current Shunt (Rsh5) Positive Terminal

Analog Output

B19 B22 SHUNT_LOW_SUM_A Inverter A bus Current Shunt (Rsh5) Negative Terminal

Analog Output

B9 B32 VBUS_A DC Bus Feedback of Inverter A Analog Output

C. Signals to and from Inverter B Section

C.1 PWM Signals


Digital Input


Digital Input


Digital Input

A34 A7 PWM2L_B PWM for Inverter B Phase 2 Bottom MOSFET Control

Digital Input

A35 A6 PWM3H_B PWM for Inverter B Phase 3 Top MOSFET Control

Digital Input


Digital Input

C15 C26 BRAKE_EN_B Software Brake Enable Signal for Braking Chopper Circuit – B

Digital Input


On-Board J13

Connector Pin #

Mating Connector








C.2 Interface Signals between Microcontroller and Gate Driver, MCP8024 (U9)

A28 A13 CE_B Chip Enable Signal to MCP8024 (U9) Digital Input

B15 B26 DE2_TX_B UART TX from Microcontroller to establish DE2 Communication with MCP8024 (U9)

Digital Input

B12 B29 DE2_RX_B UART RX from Microcontroller to establish DE2 Communication with MCP8024 (U9)

Digital Output

C.3 Hall Sensor/Quadrature Encoder Interface Feedback Signals from Motor B

A30 A11 HALLA_MB Hall Sensor A/QEA Feedback of Motor B Digital Output

B30 B11 HALLB_MB Hall Sensor B/QEB Feedback of Motor B Digital Output

B29 B12 HALLC_MB Hall Sensor C/INDEX Feedback of Motor B Digital Output

B28 B13 HOME_MB Quadrature Encoder Interface HOME Signal of Motor B

Digital Output

C.4 Voltage and Current Feedback Signals


C4 C37 VPHASE2_MB Phase 2 BEMF Voltage Feedback of Motor B Analog Output


A12 A29 RECN_MB,IPHASE3_MB,

IBRAKE_B

Recreated Neutral Feedback for Motor B orInverter B Phase 3 Current Feedback, or Braking Chopper Circuit – B Current Sense Output

Analog Output

C16 C25 IPHASE1_MB Inverter B Phase 1 Current Feedback Analog Output

B16 B25 IPHASE2_MB Inverter B Phase 2 Current Feedback Analog Output

A15 A26 IBUS_MB Bus Current Feedback of Inverter B Analog Output

B25 B16 VBUS_B DC Bus Feedback of Inverter B Analog Output

D. Others

D.1 Fault Signals

A20 A21 FAULT_MA Inverter A Bus Current Fault Output from Signal Board

Digital Output

C36 C5 FAULT_MB Inverter B Bus Current Fault Output to Microcontroller on Signal Board

Digital Input

B4 B37 FAULT_AB Inverter A and Inverter B Combined Fault Output generated by Fault Generation Logic Circuit

Digital Input

D.2 Voltage Offset

A7 A34 VREF_EXT +1.65V/+2.5VVoltage Reference to Shift Op Amp Outputs(4)

Analog Input


On-Board J13

Connector Pin #

Mating Connector








E. Pins – Not Connected on Motor Control 10-24V Driver Board (Dual/Single)(2)

B3 B38 — — —

A4 A37 — — —

C6 C35 — — —

B7 B34 — — —

C7 C34 — — —

A8 A33 — — —

B8 B33 — — —

C8 C33 — — —

A9 A32 — — —

C9 C32 — — —

A10 A31 — — —

B10 B31 — — —

C10 C31 — — —

C12 C29 — — —

A13 A28 — — —

A14 A27 — — —

B14 B27 — — —

C14 C27 — — —

A16 A25 — — —

B17 B24 — — —

C17 C24 — — —

A18 A23 — — —

B18 B23 — — —

A19 A22 — — —

C20 C19 — — —

A22 A19 — — —

C22 C21 — — —

A23 A18 — — —

A24 A17 — — —

C24 C17 — — —

C25 C16 — — —

A26 A15 — — —


On-Board J13

Connector Pin #

Mating Connector








A27 A14 — — —

B27 B14 — — —

C27 C14 — — —

C28 C13 — — —

C29 C12 — — —

C32 C9 — — —

B33 B8 — — —

A36 A5 — — —

B36 B5 — — —


On-Board J13

Connector Pin #

Mating Connector








2.3.4 Hall Sensor/Quadrature Encoder Interface Connectors (J2, J4)

The Hall sensors or Quadrature Encoder Interfaces (QEIs) are used for determining the motor position. Connectors, J2 and J4, can be used to interface the Hall Sensor/Quadrature Encoder Interface of motors driven by Inverter A and Inverter B, respec-tively. The pin descriptions of connectors, J2 and J4, are shown in Table 2-7 and Table 2-8.

2.3.5 Terminals for Brake Resistors (TP46-TP47, TP51-TP52)

Brake resistors can be added to Braking Chopper Circuit of Inverter A and Inverter B through terminals provided on the Motor Control 10-24V Driver Board (Dual/Single). Table 2-7 and Table 2-10 provides the terminal pin-outs.

TABLE 2-7: HALL SENSOR/QUADRATURE ENCODER INTERFACE CONNECTOR (J2)


1 +5V Hall Sensors/QEI Power Supply

2 DGND Digital Ground

3 HALLA_MA Hall Sensor A/QEI Phase A Feedback for Motor A

4 HALLB_MA Hall Sensor B/QEI Phase B Feedback for Motor A

5 HALLC_MA Hall Sensor C/QEI INDEX Feedback for Motor A

6 HOME_MA QEI HOME Signal Feedback for Motor A

TABLE 2-8: HALL SENSOR/QUADRATURE ENCODER INTERFACE CONNECTOR (J4)


1 +5V Hall Sensors/QEI Power Supply


3 HALLA_MB Hall Sensor A/QEI Phase A Feedback for Motor B

4 HALLB_MB Hall Sensor B/QEI Phase B Feedback for Motor B

5 HALLC_MB Hall Sensor C/QEI INDEX Feedback for Motor B

6 HOME_MB QEI HOME Signal Feedback for Motor B

TABLE 2-9: TERMINALS FOR BRAKE RESISTOR ON INVERTER A SIDE

Terminal # Terminal Name Terminal Description

1 TP46 Inverter A Brake Resistor Positive Terminal

2 TP47 Inverter A Brake Resistor Negative Terminal

TABLE 2-10: TERMINALS FOR BRAKE RESISTOR ON INVERTER B SIDE

Terminal # Terminal Name Terminal Description

1 TP51 Inverter B Brake Resistor Positive Terminal

2 TP52 Inverter B Brake Resistor Negative Terminal



2.3.6 Auxiliary Power Supply Output Connectors (J15, J16)

Various auxiliary power supply outputs can be tapped through connectors, J15 and J16. The auxiliary power supply outputs on connector, J15, are provided in Table 2-11 and Table 2-12 provides the power supply outputs on connector, J16.

TABLE 2-11: AUXILIARY POWER SUPPLY OUTPUT CONNECTOR (J15)

Pin #Signal Name

Signal Description


2 +5V +5V Digital Power Output

3 DVDD +3.3V/+5V Digital Power Output

4 AGND Analog Ground

5 AVDD +3.3V/+5V Analog Power Output

TABLE 2-12: +12V LDO (U11) OUTPUT CONNECTOR (J16)

Pin #Signal Name

Signal Description

1 +12V +12V Output of LDO U11 (L7812CD2T-TR)

2 PGND Power Ground



2.3.7 MCP8024 (U8) Operational Amplifier Interface Connectors (J10, J11, J12)

The three-phase BLDC motor gate driver with the power module, MCP8024, has three internal operational amplifiers. These amplifiers can be configured as either inverting or non-inverting, and are labeled as U8-A, U8-B and U8-C. Each of these amplifier inputs and outputs are accessible through connectors, J10, J11 and J12 (see Figure A-1). The inputs and output of the gate driver amplifiers, U8-A, U8-B and U8-C, are provided in Table 2-13 through Table 2-15, respectively.

By default, the U8-A, U8-B and U8-C amplifiers are configured as non-inverting buffers with their non-inverting input connected to VREF_EXT (half of the amplifier supply voltage) for low-power consumption. For circuit details, see Figure A-1.

TABLE 2-13: AMPLIFIER U8-A INPUT AND OUTPUT CONNECTOR (J12)

Pin #Signal Name

Signal Description

1 IN3+ Positive Input of U8-A Amplifier Circuit

2 IN3- Negative Input of U8-A Amplifier Circuit

3 OUT3 U8-A Amplifier Output

TABLE 2-14: AMPLIFIER U8-B INPUT AND OUTPUT CONNECTOR (J11)

Pin #Signal Name

Signal Description

1 IN2+ Positive Input of U8-B Amplifier Circuit

2 IN2- Negative Input of U8-B Amplifier Circuit

3 OUT2 U8-B Amplifier Output

TABLE 2-15: AMPLIFIER U8-C INPUT AND OUTPUT CONNECTOR (J10)

Pin #Signal Name

Signal Description

1 IN1- Negative Input of U8-C Amplifier Circuit

2 IN1+ Positive Input of U8-C Amplifier Circuit

3 OUT1 U8-C Amplifier Output



2.4 USER INTERFACE HARDWARE

2.4.1 Board Jumpers

The Motor Control 10-24V Driver Board (Dual/Single) has three power jumpers and two signal jumpers. The on-board jumpers are provided in Table 2-16. Figure 2-3 shows the jumper positions.

FIGURE 2-3: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) JUMPERS

TABLE 2-16: BOARD JUMPERS

Jumper Designator

Jumper Description

JP2 Connects the chip enable signal of gate driver, IC U8, to +5 VLDO1(CE_A = High) enabling all device functions.

JP3 Connects the chip enable signal of gate driver, IC U9, to +5 VLDO2(CE_B = High) enabling all device functions.

TP3-TP6 Connects the power supply, DC+ signal, to Inverter A circuits which are populated by default and can carry 15A current.

TP7-TP8 Connects the power supply, DC+ signal, to Inverter B circuits which are populated by default and can carry 15A current.

TP54-TP55 If populated, +12V LDO (U11) input and output are shorted bypassing the low LDO.

JP2

TP54-TP55

TP3-TP6

JP3

TP7-TP8



2.4.2 Board LED Indications

The on-board LEDs are provided in Table 2-17 and Figure 2-4 shows the LED positions.

TABLE 2-17: BOARD LEDs

LED Designator

LED Indication

D1 Power-on status indication for Auxiliary Supply Output DVDD (+3.3V/+5V) from the Signal Board.

D2 Power-on status indication for Auxiliary Supply Output +5V from the Signal Board.

D3 Power-on status indication for the on-board +12V LDO (U11) output.

D25 Indicates PWM Pin status of Inverter A Phase 1 Top MOSFET control.

D26 Indicates PWM Pin status of Inverter A Phase 1 Bottom MOSFET control.





D31 Indicates PWM Pin status of Inverter B Phase 1 Top MOSFET control.

D32 Indicates PWM Pin status of Inverter B Phase 1 Bottom MOSFET control.







FIGURE 2-4: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) LEDs

D1

D3

D25-D30

D31-D36

D2



2.4.3 Board Test Points

There are several test points on the Motor Control 10-24V Driver Board (Dual/Single) to allow probing of voltages, currents and signals. Table 2-18 provides all the test points on the board.

TABLE 2-18: BOARD TEST POINTS

Test Point

Number

Test Point Name

Description

TP1 VBUS_A DC Bus Feedback of Inverter A

TP2 VBUS_B DC Bus Feedback of Inverter B

TP4 DGND Digital Ground

TP5 DGND Digital Ground

TP9 DE2_A DE2 Communication Link of MCP8024 U8

TP10 DE2_B DE2 Communication Link of MCP8024 U9

TP11 FAULT_MB Inverter B Bus Current Fault Output to Microcontroller on Signal Board

TP12 FAULT_AB Inverter A and Inverter B Combined Fault Output generated by Fault Generation Logic

TP13 IPHASE1_MB Inverter B Phase 1 Current Feedback


TP15 IBUS_MB Inverter B Bus Current Feedback

TP16 FAULT_MA Inverter A Bus Current Fault Output from Signal Board

TP17 5VLDO1 Output of Internal +5V LDO Regulator of Gate Driver, MCP8024 U8


TP19 VPHASE3_MA Phase 3 BEMF Voltage Feedback of Motor A

TP20 RECN_MA Recreated Neutral Feedback for Motor A



TP23 GT1H_A Gate Signal from Driver for Inverter A Phase 1 Top MOSFET Control



TP26 GT3L_A Gate Signal from Driver for Inverter A Phase 3 Bottom MOSFET Control



TP29 VDC_A DC Bus Voltage of Inverter A


TP31 RECN_MB Recreated Neutral Feedback for Motor B

TP32 VPHASE3_MB Phase 3 BEMF Voltage Feedback of Motor B

Note 1: On the dsPIC® DSC Signal Board, the DVDD voltage level is configured as either +3.3V or +5V by the PIM plugged into the board

2: On the dsPIC DSC Signal Board, the VREF_EXT voltage level is configured as either +1.65V or +2.5V by the PIM plugged into the board





TP35 GT1H_B Gate Signal from Driver for Inverter B Phase 1 Top MOSFET Control



TP38 GT3L_B Gate Signal from Driver for Inverter B Phase 3 Bottom MOSFET Control



TP41 VDC_B DC Bus Voltage of Inverter B



TP44 IPHASE3_MA Inverter A Phase 3 Current Feedback

TP45 — Reference Voltage Output of Comparator, U4

TP48 — Brake Enable Input to Brake Switch Driver, U5

TP49 IBRAKE_A Brake Circuit A Current Sensing Amplifier Output

TP50 — Reference Voltage Output of Comparator, U7

TP53 — Brake Enable Input to Brake Switch Driver, U10

TP54 DC+ DC Power Supply (10V-24V)

TP55 +12V On-board +12V LDO (U11) Regulator Output

TP56 IBRAKE_B Brake Circuit B Current Sensing Amplifier Output

TP58 PGND Power Ground


TP60 AGND Analog Ground

TP61 AGND Analog Ground

TP62 DVDD +3.3V or 5V Digital Power Supply from Signal Board(1)



TP68 VREF_EXT +1.65V/+2.5V Voltage Reference to shift Op Amp Outputs(2)

J3-1 PWM1H_A PWM Input to Driver for Inverter A Phase 1 Top MOSFET Control

J3-2 PWM1L_A PWM Input to Driver for Inverter A Phase 1 Bottom MOSFET Control



TABLE 2-18: BOARD TEST POINTS (CONTINUED)

Test Point

Number

Test Point Name

Description







J3-7 DGND Digital Ground

J14-1 PWM1H_B PWM Input to Driver for Inverter B Phase 1 Top MOSFET Control

J14-2 PWM1L_B PWM Input to Driver for Inverter B Phase 1 Bottom MOSFET Control





J14-7 DGND Digital Ground

HA_A HALLA_MA Hall Sensor A/QEA Feedback of Motor A

HB_A HALLB_MA Hall Sensor B/QEB Feedback of Motor A

HC_A HALLC_MA Hall Sensor C/INDEX Feedback of Motor A

HOME_A HOME_MA QEI HOME Signal of Motor A

HA_B HALLA_MB Hall Sensor A/QEA Feedback of Motor B

HB_B HALLB_MB Hall Sensor B/QEB Feedback of Motor B

HC_B HALLC_MB Hall Sensor C/INDEX Feedback of Motor B

HOME_B HOME_MB QEI HOME Signal of Motor B

TABLE 2-18: BOARD TEST POINTS (CONTINUED)

Test Point

Number

Test Point Name

Description





USER’S GUIDE

Chapter 3. Hardware Description

3.1 INTRODUCTION

This chapter provides a more detailed description of the hardware features of the Motor Control 10-24V Driver Board (Dual/Single).

The Motor Control 10-24V Driver Board (Dual/Single) is a power board with dual motor control and three-phase inverter stages that can be interfaced with the dsPIC® DSC Signal Board. The boards support PMSM/BLDC motor control application development using Microchip controllers. The Motor Control 10-24V Driver Board (Dual/Single) also features a three-phase Brushless DC (BLDC) motor gate driver with power module, MCP8024, from Microchip’s product portfolio. Motor control algorithms, position feedback interface, and current and voltage sensing circuits are built-in to facilitate development of various PMSM/BLDC motors. Two dynamic brake circuit stages are also integrated on the board.

Both Inverter A and Inverter B can be operated from an input voltage in the range of 10-24V, and are capable of delivering a continuous output phase current of 10A (RMS) in the specified operating range. The dynamic brake circuit can also handle continuous current of 10A, without exceeding the specified operating conditions.

3.2 HIGHLIGHTS

This chapter covers the following hardware sections:

• Three-Phase Inverter Bridge and Gate Driver

• DC Bus Voltage Sensing

• Hall Sensor/Quadrature Encoder Interface

• Back-EMF and Recreated Neutral Signals

• Phase and Bus Current Sensing Circuits

• Fault Generation Logic Circuit

• Brake Circuit

• Power Supply

The hardware section of the Motor Control 10-24V Driver Board (Dual/Single) is shown in Figure 3-1.

Note: Inverter A and Inverter B, and associated circuits are referred to using the symbols, A and B.



FIGURE 3-1: MOTOR CONTROL10-24V DRIVER BOARD HARDWARE SECTIONS

Legend:

1 dsPIC® DSC Signal Board Interface Connector 2 +12V LDO Circuit

3 Input Power Supply 4 Three-Phase Inverter Bridge A and B

5 Gate Driver Circuit 6 Current Sensing Shunts

7 Back-EMF Sensing Circuit 8 Hall Sensor/QE Interface Circuit

9 Motor Connector 10 Dynamic Brake Circuit

7-A

3

2

8-A

5-A

7-B

5-B

8-B

6-B6-A

4-B

3-B 9-B9-A 3-A

10-B10-A

4-A

Note: A and B indicates the inverter section to which each hardware block is associated.

1


Hardware Description

3.3 THREE-PHASE INVERTER BRIDGE AND GATE DRIVER

The three-phase motor power stage is implemented using six N-channel MOSFETs (IPB054N06N3 G), configured as three half-bridges. A resistor is connected across the gate and source of each MOSFET, to ensure soft turn-off of the MOSFET, if the gate signal is disconnected. Low-ESR ceramic capacitors are provided across each half-bridge for filtering high-frequency currents due to switching. Transient voltage sup-pressors are connected between each inverter supply and ground for protecting inverter and driver against voltage transients.

Microchip’s three-phase, BLDC motor gate driver along with the power module, MCP8024, are used for low and high side MOSFET gate drive. Gate driver inputs are 3.3V compatible. MCP8024 provides undervoltage, overvoltage, shoot-through and short-circuit protection of the inverter bridge. It also integrates three amplifiers and an overvoltage comparator. DE2 communication (half-duplex, 9600 baud, 8-bit, no parity, single line communication link) is provided for driver Fault status indication, driver con-figuration and setting parameters, such as dead time, blanking time, overcurrent threshold and so on.

The DE2 communication link that interfaces between the microcontroller and the MCP8024 can be established by the UART controller module, and by connecting the UART receive and transmit pins to a single line DE2 communication link of the gate driver, as shown in Figure 3-2.

FIGURE 3-2: DE2 COMMUNICATION LINK

The three-phase BLDC motor gate driver, with the power module MCP8024, also integrates +5V and +12V LDO voltage regulators, capable of delivering up to 20 mA of current. The +12V LDO output from MCP8024 supplies power to the bootstrap circuit on the same chip used for driving the high side MOSFETs. The +5V LDO output is used to supply power to the amplifier circuits on the board. Pull-down resistors are added to all driver inputs to turn off MOSFETs in the absence of PWM signals. For more information on MCP8024, refer to the “3-Phase Brushless DC (BLDC) Motor Gate Driver with Power Module” (DS20005228) data sheet.

3.4 DC BUS VOLTAGE SENSING

On the Motor Control 10-24V Driver Board (Dual/Single), the DC bus voltage sensing network is present in both the Inverter A and Inverter B sections. These inverters can be operated from different input voltage supplies.

Microcontroller

UART

TX

RX

MCP8024

DE2 DE2 Interface



3.5 HALL SENSOR/QUADRATURE ENCODER INTERFACE

The BLDC/PMSM motor control applications can read rotor position and speed infor-mation from Hall sensors or encoders. The Hall sensors can be powered by the +5V supply output available through the interface connector terminals. The Hall sensor/Quadrature Encoder Interface circuit supports either open-collector or push-pull output sensors. A capacitor is added to each signal output to reduce the noise. The Hall sensor outputs can be interfaced with a +3.3V or +5V microcontroller. By default, the voltage divider scales down the +5V output to +3.3V. If the sensor outputs are inter-faced with a +5V microcontroller, and the VIH of the controller input pins is less than 3.3V, the divider has to be modified to deliver a +5V output. Circuit configurations to set sensor output voltage are provided in Table 3-1 and Table 3-2.

TABLE 3-1: OUTPUT VOLTAGE LEVEL SETTING HALL SENSOR/QUADRATURE ENCODER INTERFACE CIRCUIT A

Signal Description

Resistor Value to Set Signal Output Voltage Level

3.3V (default setting)

5V

HALLA_MA(Hall Sensor A/QEA Feedback from Motor A)

R40 R40

HALLB_MA (Hall Sensor B/QEB Feedback from Motor A)

R41 R41

HALLC_MA(Hall Sensor C/INDEX Feedback from Motor A)

R42 R42

HOME_MA (QEI HOME Signal from Motor A)

R43 R43

TABLE 3-2: OUTPUT VOLTAGE LEVEL SETTING HALL SENSOR/QUADRATURE ENCODER INTERFACE CIRCUIT B

Signal Description

Resistor Value to Set Signal Output Voltage Level

3.3V (default setting)

5V

HALLA_MB (Hall Sensor A/QEA Feedback from Motor B)

R52 R52

HALLB_MB (Hall Sensor B/QEB Feedback from Motor B)

R53 R53

HALLC_MB (Hall Sensor C/INDEX Feedback from Motor B)

R54 R54

HOME_MB (QEI HOME Signal from Motor B)

R55 R55

47 k 0

47 k 0

47 k 0

47 k 0

47 k 0

47 k 0

47 k 0

47 k 0



3.6 BACK-EMF AND RECREATED NEUTRAL SIGNALS

The BLDC motors can be commutated by monitoring back-EMF signals. The motor back-EMF is scaled down by voltage dividers. The capacitors can be added at divider outputs to filter the noise. An additional resistor network is added to reconstruct motor neutral signals. The recreated neutral signals, RECN_MA and RECN_MB, are con-nected to the J13 connector pins through zero ohm resistors (board default setting). The back-EMF sensing circuits in both inverter sections are identical. Table 3-3 provides the resistor jumper setting for connecting the recreated neutral outputs to the J13 connector pins.

TABLE 3-3: RESISTOR JUMPER SETTING FOR RECREATED NEUTRAL OUTPUT SELECTION

Signal Description Zero Ohm Resistor Jumper Setting

RECN_MA to J13:B6

To connect RECN_MA (recreated neutraloutput) to the B6 pin of the signal boardinterface connector, J13.

RECN_MB to J13:A12

To connect RECN_MB (recreated neutraloutput) to the A12 pin of the signal boardinterface connector, J13.

47 k

R196

R197

R227

RECN_MA

IPHASE3_MA

IBRAKE_A

J13:B6

47 k

R194

R195

R228

RECN_MB

IPHASE3_MB

IBRAKE_B

J13:A12



3.7 PHASE AND BUS CURRENT SENSING CIRCUITS

In the Motor Control 10-24V Driver Board (Dual/Single), shunt resistors are provided in each inverter leg to determine the amount of current flowing through the motor phases that are required to implement the field-oriented control of the PMSMs.

An additional shunt resistor is provided for sensing bus current. DC bus current infor-mation is necessary for overcurrent protection and to implement torque control of the BLDC motors. Motor phase currents can also be reconstructed from the DC bus current information by sampling currents appropriately in the PWM switching period.

A non-inverting differential amplifier is used for amplifying voltage drop across shunt resistors. The amplifier output voltage is shifted by VREF_EXT to allow positive and negative current swings. The voltage offset can be modified by a resistor divider pro-vided in the non-inverting input of the bus current amplifiers. The Common mode and Differential mode filters are added to the op amp input pins for noise filtering. It is possible to add filters at the output of the amplifiers, if required. See Section C.3 “Motor Current Amplifier Configuration” for on-board amplifier gain setting and input filter details.

3.7.1 Inverter A Current Amplifiers

As shown in Figure 3-3, Phase 1, Phase 2 and the bus current shunt voltage drops are transferred to the dsPIC DSC Signal Board through connector, J13. On the dsPIC DSC Signal Board, amplifiers that are internal to the dsPIC DSC are used for amplification of Phase 1, Phase 2 and the bus current signals. The comparator that is internal to the dsPIC DSC is used for overcurrent detection. For more information, refer to the “dsPIC® DSC Signal Board User’s Guide” (DS50002263). For dsPIC DSC internal amplifier gain setting information, refer to the “dsPIC33EV256GM106 5V Motor Control Plug-In Module (PIM) Information Sheet” (DS50002225) and the “dsPIC33EP512GM710 Plug-In Module (PIM) Information Sheet for Single-Dual Motor Control” (DS50002216). Please check the Microchip web site (www.microchip.com) for future Plug-In Module (PIM) Information Sheets.

The Phase 3 current can be amplified using the operational amplifier, MCP6021, provided in the Inverter A section. This amplifier can also be configured to sense any phase current or bus current by populating the appropriate input resistors. The output of this amplifier can be connected to the J13 pin through the zero ohm jumper resistors. The resistor jumper setting is provided in Table 3-4.

3.7.2 Inverter B Current Amplifiers

As shown in Figure 3-4, operational amplifiers, U9-A, U9-B and U9-C that are internal to MCP8024, are used for Phase 1, Phase 2 and bus current amplification. IOUT1 of the MCP8024 is also connected to an internal overcurrent comparator and generates a Fault output at the ILIMIT_OUT pin of the driver. The Motor Control 10-24V Driver Board (Dual/Single) exploits this driver feature to generate the Inverter B overcurrent Fault, known as FAULT_MB. The MCP8024 amplifier, U9-C (see Figure A-1), can be configured to sense third phase current instead of DC bus current by populating the input resistors appropriately.

The operational amplifier, MCP6021, is added for Phase 3 current amplification. This amplifier can be configured to sense any phase current or bus current by populating the appropriate input resistors. The output of this amplifier can be connected to the J13 pins through zero ohm jumper resistors. The resistor jumper setting is provided in Table 3-5.

Note: On the dsPIC DSC Signal Board, the VREF_EXT voltage level is configured as +1.65V or +2.5V by the PIM plugged into the board.



TABLE 3-4: RESISTOR JUMPER FOR INVERTER A THIRD PHASE CURRENT OUTPUT SELECTION


IPHASE3_MA to J13:B6

To connect IPHASE3_MA (output of phasecurrent sensing amplifier, U3) to the B6 pinof the signal board interface connector,J13.

TABLE 3-5: RESISTOR JUMPER FOR INVERTER B THIRD PHASE CURRENT OUTPUT SELECTION


IPHASE3_MB to J13:A12

To connect IPHASE3_MB (output of phasecurrent sensing amplifier, U2) to the A12 pinof the signal board interface connector, J13.

47 k

R196

R197

R227

RECN_MA

IPHASE3_MA

IBRAKE_A

J13:B60

R194

R195

R228

RECN_MA

IPHASE3_MA

IBRAKE_A

J13:A120



FIGURE 3-3: INVERTER A CURRENT SENSING CIRCUIT ARCHITECTURE

R191

Bus Current (–) 0

Phase 3 Current (–)

R193

R190

Bus Current (+) 0

Phase 3 Current (+)

R192

J13 S

ign

al B

oa

rd I

nte

rfa

ce C

on

ne

cto

rPhase 2 Current (+)


Phase 1 Current (+)


C19

B19

B23

C23

B22

C26

R181

Phase 3 Current (–) R


R180


R178

Bus Current (–)

R177

U3

MCP6021

+

–

R184

Phase 3 Current (+) R

Phase 2 Current (+)

R186

Phase 1 Current (+)

R187

Bus Current (+)

R189

B6

R197

FAULT_MA

Power Board Signal Board

Phase 2 Current (+)


0.015

VDC_A

Phase 3 Current (+)


0.015

Phase 1 Current (+)


0.015

Bus Current (+)

Bus Current (–)

0.015

PGND

Rsh5

Rsh7 Rsh1 Rsh2

Inte

rfa

ce C

on

ne

cto

r

CMP–

+

+

–

+

–

+

–

dsPIC33EP

Three-Phase Inverter Bridge – A



FIGURE 3-4: INVERTER B CURRENT SENSING CIRCUIT ARCHITECTURE

IOUT1

ILIMIT_OUT

Phase 2 Current (+)


0.015

VDC_B

Phase 3 Current (+)


0.015

Phase 1 Current (+)


0.015

Bus Current (+)

Bus Current (–)

0.015

PGND

Rsh8 Rsh3 Rsh4

Rsh6

R35

Phase 3 Current (–) R


R19


R20

Bus Current (–)

R34

U2

MCP6021

+

–

R62

Phase 3 Current (+) R

Phase 2 Current (+)

R31

Phase 1 Current (+)

R22

Bus Current (+)

R64

R195

J13

Signal Board Interface Connector

B15A12 B16 B12

R161

Bus Current (–) R


R21

R164

Bus Current (+) R

Phase 3 Current (+)

R32

Phase 1 Current (+)


Phase 2 Current (+)B

+

– Phase 2 Current (–)

U9

MCP8024

A +

–

DAC REF

DE2 Interface

C +

–

18

17

16

15

14

13

12

11

10

9

44

DVDD

FAULT_MB

TX

RX

Three-Phase Inverter Bridge – B

CMP –

+

A15 C16 C36



3.8 FAULT GENERATION LOGIC CIRCUIT

This section describes the Fault outputs on the Motor Control 10-24V Driver Board (Dual/Single). There are three Fault outputs: Inverter A Overcurrent Fault (FAULT_MA), Inverter B Overcurrent Fault (FAULT_MB) and combined Fault (Fault_AB). All Faults are active-low outputs.

3.8.1 Inverter A Overcurrent Fault (FAULT_MA)

The Inverter A Overcurrent Fault output, FAULT_MA, is generated on the dsPIC DSC Signal Board and is transferred to the Motor Control 10-24V Driver Board (Dual/Single) through connector, J13. On the dsPIC DSC Signal Board, the comparator internal to the dsPIC DSC is used to generate the Overcurrent Fault FAULT_MA.

3.8.2 Inverter B Overcurrent Fault (FAULT_MB)

The Inverter B Overcurrent Fault, FAULT_MB, is generated by the comparator internal to the gate driver, MCP8024 (U9). The output of the operational amplifier (U9-C), configured to amplify bus current, is connected internally to the inverting input of the comparator. The non-inverting input of the comparator threshold may be set with a SET_ILIMIT command from the microcontroller to MCP8024 through the DE2 commu-nications link. For more information on DE2 communication and message protocol, refer to the “3-Phase Brushless DC (BLDC) Motor Gate Driver with Power Module” (DS20005228A) data sheet.

3.8.3 Combined Fault (FAULT_AB)

The Fault generation circuit performs logical and Overcurrent Faults, FAULT_MA and FAULT_MB, to generate a single Fault output called FAULT_AB. Table 3-6 provides the truth table of the Fault generation logic circuit.

Fault inputs, FAULT_MA or FAULT_MB, can be transferred to the Fault logic circuit out-put, FAULT_AB, by setting the other input at logic ‘1’. Figure 3-5 shows three possible configurations of Fault generation logic.

TABLE 3-6: FAULT GENERATION LOGIC TRUTH TABLE

FAULT_MA FAULT_MB FAULT_AB

0 0 0

0 1 0

0 1 0

1 1 1



FIGURE 3-5: FAULT GENERATION LOGIC CIRCUIT CONFIGURATIONS

Configuration 1:

0

R29

R30

FAULT_MA

FAULT_MB

R28

DVDD

R27

DVDD

0

FAULT_AB = ‘FAULT_MA’ and

Configuration 2:

0

R29

R30

FAULT_MA

FAULT_MB

R28

DVDD

R27

DVDD

FAULT_AB = ‘FAULT_MA’

04.7 k

LOGIC ‘1’

Configuration 3:

R29

R30

FAULT_MA

FAULT_MB

R28

DVDD

R27

DVDD

0

FAULT_AB = ‘FAULT_MB’

LOGIC ‘1’ 4.7 k

A

A

B

B

Y

Y

‘FAULT_MB’



3.9 BRAKE CIRCUIT

In motor control applications, during deceleration or periods of swift reversal, the motor can work as a generator, feeding energy back into the motor drive. When the motor drive does not provide four quadrant operation, and the braking power is not dissipated, the DC link voltage will increase and cause an overvoltage condition. During regener-ation or braking, a dynamic brake (brake switch in-series with a brake resistor connected across the DC bus) can be employed to absorb this excess energy, thereby ensuring that the DC link voltage is maintained at a safe operating level.

In the Motor Control 10-24V Driver Board (Dual/Single), dynamic brake circuits are provided for both the inverters. As per the application requirement, the user can add a brake resistor to the respective brake circuits using the on-board terminals. The diode is provided across the brake resistor terminals to free wheel current due to the inductance of the brake resistor.

The brake switches can handle 10A (RMS) @ +25ºC in the operating voltage range. The value of the resistor should be chosen such that the current is less than 10A at peak DC bus voltage.

By default, the Braking Chopper Circuits are disabled by pull-down resistors connected as inputs of the MOSFET driver, TC1412N. The brake switch can be controlled either through a hardware overvoltage detection comparator with hysteresis or through soft-ware brake enable. Figure 3-6 shows the brake circuit block diagram. Resistors to select the brake enable signal are provided in Table 3-7.

FIGURE 3-6: BRAKE CIRCUIT BLOCK DIAGRAM

VOUT

VOH

VOL

VTL VTHVIN-

OvervoltageComparator

VR

Load

Brake Switch

MOSFET DriverTC1412N

Brake Enablefrom dsPIC® DSC

VDC

VIN+



3.9.1 Firmware Brake Enable Signal (BRAKE_EN_A or BRAKE_EN_B):

The user firmware has to monitor the DC bus voltage and the brake enable signal to be made active if the voltage exceeds the predefined threshold level. The brake enable signal is turned off when the voltage reaches a safe inverter operating voltage. The firmware brake enable signal can be Pulse-Width Modulated at an appropriate frequency for brake switch control. The dsPIC DSC output compare module can be used for generating PWMs for controlling the brake switch.

3.9.2 Hardware Brake Enable Circuit

The non-inverting comparator circuit, MCP65R41, is provided on the board to generate a hardware brake enable signal and to control dynamic braking without firmware inter-vention. A voltage divider circuit is provided to monitor the bus voltage. The output of the DC bus voltage divider is fed to the non-inverting input of the comparator. The inverting input of the comparator is generated by dividing the Comparator Voltage Reference (VREF) output, 2.4V.

The hysteresis ensures that false triggering does not occur due to noise spikes and ripple voltage present on the DC bus voltage. The comparator hysteresis is configured externally by the resistors. There may be variation in the trip levels due to component tolerance and variation in comparator operating voltage. See Section C.5 “Hardware Brake Enable Circuit Configuration” for equations to calculate comparator hysteresis.

TABLE 3-7: BRAKE ENABLE SIGNAL CONFIGURATION RESISTORS

Brake Circuit

Brake Enable Signal

Hardware Brake Enable

Firmware Brake Enable

Disable Brake Circuit(default setting)

Brake Circuit – A

Brake Circuit – B

R232

R238

R239

0

R232

R238

R239

0

47 k

R232

R238

R239

10 k

0

R248

R254

R255

R248

R254

R255

0

R248

R254

R255

10 k



3.9.3 Brake Current Sensing Amplifier

An MCP6021 device-based, non-inverting differential amplifier is added to sense the current through the brake resistor. A shunt resistor is added in-series with the brake switch for sensing the current. The voltage across the shunt resistor is connected to the differential amplifier inputs. See Section C.4 “Brake Current Amplifier Configura-tion” for brake current amplifier gain setting. The brake current amplifier output can be connected to an analog pin of the controller through connector, J13, by configuring the resistor jumpers. The resistor jumper setting is shown in Table 3-8.

TABLE 3-8: RESISTOR JUMPER TO SELECT BRAKE CURRENT OUTPUT SIGNAL


IBRAKE_A to J13:B6

To connect IBRAKE_A (output of brake cur-rent sensing amplifier, U6) to the B6 pin of the signal board interface connector, J13.

IBRAKE_B to J13:A12

To connect IBRAKE_B (output of brake cur-rent sensing amplifier, U12) to the A12 pin of the signal board interface connector, J13.

R196

R197

R227

RECN_MA

IPHASE3_MA

IBRAKE_A

J13:B6

047 k0

R194

R195

R228

RECN_MB

IPHASE3_MB

IBRAKE_B

J13:A12

0 047 k0



3.10 POWER SUPPLY

The Motor Control 10-24V Driver Board (Dual/Single) receives power through the connectors, J5 or J8. The same voltage is transferred to the signal board through connector, J13.

Each inverter bridge and its associated circuits can be powered independently, allowing each power stage to operate at a different voltage level. Inverter A can be powered up by a voltage source connected to connector, J1, if a wire jumper between TP3-TP7 is disconnected. Similarly, Inverter B can be powered up by a different voltage source connected to connector, J6, if a wire jumper between TP7-TP8 is disconnected. See Section 2.3.1 “Power Supply Connectors (J5, J8, J1 and J6)” for configuration details.

Each MCP8024 gate driver is operated from the voltage supply that is powering the respective inverter bridge. The supply for biasing the low side gate drive and the boot-strap circuit for the high side gate drive is regulated by the +12V LDO, internal to MCP8024. The output of the +5V LDO, internal to the gate drivers, U8 and U9, supplies power to the operational amplifier, MCP6021, in the respective inverter sections. The low dropout voltage regulators, +5V and +12V, internal to MCP8024, are capable of delivering current up to 20 mA. For more information on the specifications of the +5V or +12V LDO that are internal to MCP8024 and the bootstrap circuit requirements, refer to the “3-Phase Brushless DC (BLDC) Motor Gate Driver with Power Module” (DS20005228) data sheet.

The signal board provides a +5V DC output for powering Hall sensors or encoders. The DVDD (+3.3V/+5V) for powering the Fault generation logic for the overvoltage detection comparator circuit and the hardware brake enable is provided through connector, J13. The voltage reference (VREF_EXT) for the operational amplifier output offset is also provided by the signal board through connector, J13.

The on-board +12V LDO (U11) supplies power to the MOSFET driver, TC1412N (U5 and U10), circuitry. The same +12V LDO output is also available through connector, J16, for powering the external circuits.

Figure 3-7 shows the Motor Control 10-24V Driver Board (Dual/Single) power supply architecture.


Mo

tor C

on

trol 10-2

4V D

river B

oa

rd (D

ua

l/Sin

gle

)

DS

50

00

22

61

A-p

ag

e 5

6

20

14

Micro

chip

Te

chn

olo

gy In

c.

HITECTURE

Dynamic BrakeCircuit B

AVDD

t

r

s

s


EncoderInterface

Amplifier – 3rd

Phase Current

+5V

5VLDO2

5VLDO2

DVDD

+12V

VDC_B


Circuit

DriverTC1412N


Brake Switch

+5V

Inverter B Section

VREF_EXT

To Sensors

FIGURE 3-7: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) POWER SUPPLY ARC

J13

+5V

Inverter A Section

120-Pin Signal Board Interface Connector


EncoderInterface

InputJack

I/P SupplyConnector

I/P SupplyConnector

Fault

Generation

Logic

VDC_A

Amplifier – 3rd

Phase Current

VDC_B

DC+ DVDD+5V


+5V

5VLDO1

Dynamic BrakeCircuit A


Circuit

DriverTC1412N


Brake Switch

Bootstrap Circuit

12VLDO1

5VLDO1

MCP8024

+5V LDO

+12V LDO

Three Op Amps anda Comparator

Low Side Drivers

High Side Drivers

VDC_A

5VLDO1

DVDD

+12V

VDC_A

DVDD

Input Supply 9-26.4V

TP3 TP6

I/P SupplyConnector


Bootstrap Circui

12VLDO2

MCP8024

+5V LDO

+12V LDO

Three Op Ampsand a Comparato

Low Side Driver

High Side Driver

VDC_B5VLDO2

+12V LDO +12VDC+

DC+

U8 U9

J1 J6 J8 J5

3 3

To Sensors

TP7 TP8


USER’S GUIDE

Appendix A. Board Schematics and Layout

A.1 INTRODUCTION

This chapter provides detailed technical information on the Motor Control 10-24V Driver Board (Dual/Single).

A.2 BOARD SCHEMATICS AND LAYOUT

The following are the Motor Control 10-24V Driver Board (Dual/Single) schematics:

• Figure A-1: Motor Control 10-24V Driver Board (Dual/Single) Schematics (Sheet 1 of 3)



• Figure A-4: Motor Control 10-24V Driver Board (Dual/Single) Layout


Mo

tor C

on

trol 10-2

4V D

river B

oa

rd (D

ua

l/Sin

gle

)

DS

50

00

22

61

A-p

ag

e 5

8

20

14

Micro

chip

Te

chn

olo

gy In

c.

1.0 (SHEET 1 OF 3)

DGND

HALLA_MA

HALLB_MA

HALLC_MA

HOME_MA

HA_A HB_A HC_A HOME_A

332k

0603

R2

IPB054N06N3 G D

G

S

Q2GT2H_A

332k0603

R8

IPB054N06N3 G D

G

S

Q8

PHASE2_MA

GT2L_A

4.7 μF50V1210

C4

SHUNT_HIGH_2_A

332k

0603

R3

IPB054N06N3 G D

G

S

Q3GT3H_A

332k0603

R9

IPB054N06N3 G D

G

S

Q9

PHASE3_MA

GT3L_A

4.7 μF50V1210

C5

SHUNT_HIGH_3_A

ERTER A VDC_A

SHUNT_HIGH_SUM_A

SHUNT_HIGH_SUM_A

k

k

k

k

100 pFC19

100 pFC20

100 pFC21

100 pFC2291k

R4491kR45

91kR46

91kR47

.015 ROARS-3

Rsh1.015 ROARS-3

Rsh2

DGND DGND DGND DGND DGND DGND DGND

1k

R181

1k

R184

1000 pF100V0603

C41 1k

R182

1k

R185

470 pFC40

470 pFC43

AGND

AGND

_SUM_A

H_3_A

47k

R179

47k

R188

0R0603

R183

AGND

TP44

VREF_EXT

IPHASE3_MA

DNPC42

DNP

R180

DNP

R178DNP

R177

DNP

R186

DNP

R187

DNP

R189

IGH_2_A

IGH_1_A

_SUM_A

_SUM_A

_SUM_A

_SUM_A

+A3

-A4

OUTA 1

VSS

VDD

25

MCP6021U3

AGND

5VLDO1

0.1 μF25V

C39

AGND

5VLDO1

PGND PGNDPGND PGND

DNPC59

DNPC60

DNP

R215

DNP

R224TP PAD PCB 1.2x0.7

TP68

DNP

R275

AGND

0R

R278

FIGURE A-1: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) SCHEMATIC REVISION

PHASE3_MAPHASE2_MAPHASE1_MA

+5V

MO

TOR

A

332k0603

R1

IPB054N06N3 G D

G

S

Q1GT1H_A

332k0603

R7

IPB054N06N3 G D

G

S

Q7

PHASE1_MA

GT1L_A

4.7 μF50V1210

C3

0R0603

R13

SHUNT_HIGH_SUM_A

PGND

SHUNT_LOW_SUM_A

INV

4.7kR36

4.7kR37

4.7kR38

4.7kR39

47R40

47R41

47R42

47R43

.015 ROARS-3

Rsh5

APWM2H_APWM1L_A

PWM1H_A PWM2L_A

PWM3H_A

PWM3L_A47k0603

R74

DGND 1 μF 25V

C44

12VLDO1

VB1_A

VB2_A

VB3_A

PHASE1_MA

PHASE2_MA

PHASE3_MA

PGNDPGND

47k0603

R73

DE2_A

DVDD

DNPD7 10R

R77

DNPD8 10R

R78

DNPD9 10R

R79

DNPD10

10R

R80

DNPD11 10R

R81

DNPD12

10R

R82

GT1H_A

GT2H_A

GT3H_A

GT3L_A

GT2L_A

GT1L_A

SSA24D19

3.3 μF25V0805

C46

12VLDO1

SSA24D20

3.3 μF25V0805

C47

SSA24D21

3.3 μF25V0805

C48

VB1_A

VB2_A

VB3_A

PHASE1_MA

PHASE2_MA

PHASE3_MA

12 JP2

10k0603

R167

CE_A

VDC_A

DNP

R66

DNP

R68

DNP

R70DNP

R69

DNPR67

DNP

R65

1kR113

GREEND25

DGND

1kR114

GREEND26

DGND

1kR115

GREEND27

DGND

1kR116

DGND

1kR117

GREEND29

DGND

1kR118

GREEND30

DGND

PWM2H_APWM1L_APWM1H_A PWM2L_A PWM3H_A PWM3L_A

TP1

18k0603

R15

1.8k0603

R160.1 μF16V0603

C9

VBUS_A

VDC_A

+5V

ED500/6DS

123456

J2

OSTVI030152

12

3

J7

TP9

2k0603

R23DE2_ADE2_TX_A

DE2_RX_A

PGND

4.7 μF25V

C11

MCP8024

PWM1L1 PWM2H 48

PWM1H2

CE3

PWM2L 47

PWM3H 46

LV_OUT24

HV_IN25

HV_IN16

PGND7

FB 40

LV_OUT18

IOUT39

LX 37

VDD38

+5V 41

CAP2 42

CAP1 43

DE2 44

PWM3L 45

HC 25

ISENSE3-10

ISENSE3+11

IOUT212

ISENSE2-13

ISENSE2+14

ILIMIT_OUT15

I_OUT116

I_SENSE1-17

I_SENSE1+18

PGND19

PGND20

LA21

LB22

LC23

PGND24

HB 26

HA 27

FC 28

FB 29

FA 30

VBC 31

VBB 32

VBA 33

+12V 34

PGND 35

PGND 36

VDD39

PAD49

U8

50V222010 μF C13

PGND

PGND

4.7 μF25V

C16

AGND AGND

DGND

1 2 3 4 5 6 7DNPJ3

PWM1H_A

PWM1L_A

PWM2H_A

PWM2L_A

PWM3H_A

PWM3L_A

DGND

TP24

TP26

TP28

TP23

TP25

TP27

TP29

TP30

TP17

.015 ROARS-3

Rsh7

SHUNT_HIGH_1_A

U8:ISENSE3+

U8:ISENSE3-

U8:IOUT3

U8:ISENSE1-

U8:ISENSE1+

U8:IOUT1

U8:IOUT2

U8:ISENSE2+

U8:ISENSE2-

10k0603

R72

DGND

DNP

R127

1k

R129

DNP

R128

0R0603

R130AGND

VREF_EXT

0R0603

R126

DNPC35

–

+U8-C

17

1816

AGND

OUT1U8:ISENSE1+

U8:ISENSE1-U8:IOUT1

IN1-

DNP

R131IN1+

DNP

R133

AGND

12

3

DNP

J10IN1-IN1+

OUT1

DNP

R135

1k

R137

DNP

R136

0R0603

R138AGND

VREF_EXT

0R0603

R134

DNPC36

–

+U8-B

13

1412

AGND

OUT2U8:ISENSE2+

U8:ISENSE2-U8:IOUT2

IN2-

DNP

R139IN2+

DNP

R140

AGND

12

3

DNP

J11

IN2-IN2+

OUT2

DNP

R142

1k

R144

DNP

R143

0R0603

R145AGND

VREF_EXT

0R0603

R141

DNPC37

-

+U8-A

10

119

AGND

OUT3U8:ISENSE3+

U8:ISENSE3-U8:IOUT3

IN3-

DNP

R175IN3+

DNP

R176

AGND

12

3

DNP

J12

IN3-IN3+

OUT3

DNP

12

34

5

J15

AGND

DVDD+5V

SHUNT_HIGH

SHUNT_HIG

SHUNT_H

SHUNT_H

SHUNT_HIGH

SHUNT_HIGH

SHUNT_HIGH

SHUNT_LOW

PGND

5VLDO1

DNPC58

PGND

Note:The operational amplifiers,U8-A, U8-B, U8-C shownin the schematic, areinternal to the MCP8024.

10k

0603

R198DVDD

47k0603

R20047k0603

R20147k0603

R20247k0603

R20347k0603

R20447k0603

R205

DGND DGND DGND DGND DGND DGND

PWM

1L_A

PWM

1H_A

PWM

2H_A

PWM

2L_A

PWM

3H_A

PWM

3L_A

DGND

AVDD

0R0603

R212

0R0603

R213

0R0603

R214

SHUNT_HIGH_SUM_A

GREEND28

0R1206

R2650R1206

R2660R1206

R267

5VLDO1

Tolerance of all resistors in the page must be 1%

RUBBER PAD 0.50x0.50x0.23

PAD1 PAD2 PAD3 PAD4

SJ-5518

PAD5

Bo

ard

Sc

he

matics

an

d L

ayo

ut

2

01

4 M

icroch

ip T

ech

no

log

y Inc.

DS

50

00

22

61

A-p

ag

e 5

9

FIG 0 (SHEET 2 OF 3)

DGND DGND DGND

HALLA_MB

HALLB_MB

HALLC_MB

HOME_MB

HB_B HC_B HOME_B

ND DGND DGND DGND

100 pFC23

100 pFC24

100 pFC25

100 pFC2691k

R5791kR58

91kR59

N06N3 G D

G

S

Q5

06N3 G D

G

S

Q11

4.7 μF50V1210

C7

_2_B

332k0603

R6

IPB054N06N3 G D

G

S

Q6GT3H_B

332k0603

R12

IPB054N06N3 G D

G

S

Q12

PHASE3_MB

GT3L_B

4.7 μF50V1210

C8

SHUNT_HIGH_3_B

VDC_B

_SUM_B

SHUNT_HIGH_SUM_B

.015 ROARS-3

Rsh3.015 ROARS-3

Rsh4

DNP

DNP

DNP

DNP

+A3

-A4

OUTA 1

VSS

VDD

25

MCP6021U2

AGND

5VLDO2

0.1 μF25V

C18

AGND

5VLDO2

0R0603

R61

AGND

TP43

IPHASE3_MB

DNPC29

1k

1k

1000 pF100V0603

C281k

R60

1k

R63

470pFC27

470 pFC34

AGND

AGNDDNP

DNP

47k

R71

47kR33

VREF_EXT

PGND PGNDPGND PGND

DNPC62

DNPC63

DNP

R226

DNPR225

DNP

R276

AGND

0R

R277

URE A-2: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) SCHEMATIC REVISION 1.

B

1k

R147

1k

R150

1000 pF100V0603

C711k

R148

1k

R151

470 pFC70

470 pFC73

AGND

AGND

SHUNT_HIGH_SUM_B

SHUNT_HIGH_1_B

47k

R146

47k

R152

0R0603

R149

DNPC72

–

+U9-A

10

119

AGND

IPHASE1_MB

TP13

VREF_EXT

1k

R154

1k

R157

1000 pF100V0603

C75 1k

R155

1k

R158

470 pFC74

470 pFC77

AGND

AGND

SHUNT_HIGH_SUM_B

SHUNT_HIGH_2_B

47k

R153

47k

R159

0R0603

R156

DNPC76

–

+U9-B

13

1412

AGND

IPHASE2_MB

TP14

VREF_EXT

1k

R161

1k

R164

1000 pF100V0603

C79 1k

R162

1k

R165

470 pFC78

470 pFC81

AGND

AGND

SHUNT_LOW_SUM_B

SHUNT_HIGH_SUM_B

47k

R160

47k

R166

0R0603

R163–

+U9-C

17

1816

AGND

TP15

VREF_EXT

U9:ISENSE3+

U9:ISENSE3-U9:IOUT3

U9:ISENSE1-

U9:ISENSE1+U9:IOUT1

U9:IOUT2U9:ISENSE2+

U9:ISENSE2-

IBUS_MB

PWM2H_BPWM1L_B

PWM1H_B PWM2L_B

PWM3H_B

PWM3L_B47k0603

R76

DGND 1 μF 25V

C45

12VLDO2

VB1_B

VB2_B

VB3_B

PHASE1_MB

PHASE2_MB

PHASE3_MB

PGNDPGND

DNPD13

47k0603

R75

DE2_B

DVDD

10R

R83

DNPD14

10R

R84

DNPD15 10R

R85

DNPD16 10R

R86

DNPD17 10R

R87

DNPD18

10R

R88

GT1H_B

GT2H_B

GT3H_B

GT3L_B

GT2L_B

GT1L_B

SSA24

D22

3.3 μF25V0805

C49

12VLDO2

SSA24

D23

3.3 μF25V0805

C50

SSA24

D24

3.3 μF25V0805

C51

VB1_B

VB2_B

VB3_B

PHASE1_MB

PHASE2_MB

PHASE3_MB

U9:ISENSE3+

U9:ISENSE3-

U9:IOUT3

U9:ISENSE1-

U9:ISENSE1+

U9:IOUT1

U9:IOUT2

U9:ISENSE2+

U9:ISENSE2-

12 JP3

10k0603

R168

CE_B

VDC_B

DNP

R170

DNP

R172

DNP

R174

DNPR169

DNPR171

DNP

R173

1kR119

GREEND31

DGND

1kR120

GREEND32

DGND

1kR121

GREEND33

DGND

1kR122

GREEND34

DGND

1kR123

GREEND35

DGND

1kR124

GREEND36

DGND

PWM2H_BPWM1L_BPWM1H_B PWM2L_B PWM3H_B PWM3L_B

DGND

PHASE3_MBPHASE2_MBPHASE1_MB

+5V

+5V

HA_B

MO

TOR

B

DG

4.7kR48

4.7kR49

4.7kR50

4.7kR51

47kR52

47kR53

47kR54

47kR55

91kR56

332k0603

R4

IPB054N06N3 G D

G

S

Q4GT1H_B

332k0603

R10

IPB054N06N3 G D

G

S

Q10

PHASE1_MB

GT1L_B

4.7 μF50V1210

C6

0R0603

R14

SHUNT_HIGH_SUM_B

SHUNT_LOW_SUM_B

332k0603

R5

IPB054GT2H_B

332k0603

R11

IPB054N

PHASE2_MB

GT2L_B

SHUNT_HIGH

INVERTER B

PGND

SHUNT_HIGH

.015 ROARS-3

Rsh6

TP2

18k0603

R17

1.8k0603

R180.1 μF16V0603

C10

VBUS_B

VDC_B

ED500/6DS

123456

J4

OSTVI030152

12

3

J9

TP10

2k0603

R24DE2_BDE2_TX_B

DE2_RX_B

4.7 μF25V

C12

PGND

MCP8024

PWM1L1 PWM2H 48

PWM1H2

CE3

PWM2L 47

PWM3H 46

LV_OUT24

HV_IN25

HV_IN16

PGND7

FB 40

LV_OUT18

IOUT39

LX 37

VDD38

+5V 41

CAP2 42

CAP1 43

DE2 44

PWM3L 45

HC 25

ISENSE3-10

ISENSE3+11

IOUT212

ISENSE2-13

ISENSE2+14

ILIMIT_OUT15

I_OUT116

I_SENSE1-17

I_SENSE1+18

PGND19

PGND20

LA21

LB22

LC23

PGND24

HB 26

HA 27

FC 28

FB 29

FA 30

VBC 31

VBB 32

VBA 33

+12V 34

PGND 35

PGND 36

VDD39

PAD49

U9

50V222010 μFC14

PGND

PGND

4.7 μF25V

C17

DGND

AGND AGND

1 2 3 4 5 6 7DNPJ14

PWM1H_B

PWM1L_B

PWM2H_B

PWM2L_B

PWM3H_B

PWM3L_B

DGND

TP36

TP38

TP40

TP35

TP37

TP39

TP41

TP42

Note:The operational amplifiers,U9-A, U9-B, U9-C shownin the schematic, areinternal to the MCP8024.

TP18

DNPC80

.015 ROARS-3

Rsh8

SHUNT_HIGH_1_B

ILIMIT_OUT_B

DNP

R21

R20

R19

R22

R31

DNP

R32

SHUNT_HIGH_1_B

SHUNT_HIGH_2_B

SHUNT_HIGH_3_B

SHUNT_HIGH_SUM_B

SHUNT_HIGH_SUM_B

SHUNT_HIGH_SUM_B

R35

R62

SHUNT_HIGH_SUM_B

SHUNT_HIGH_3_B

R34

R64SHUNT_HIGH_SUM_B

SHUNT_LOW_SUM_B

5VLDO210k0603

R125

DGND

PGND PGND

DNPC61

10k0603

R199DVDD

47k0603

R20647k0603

R20747k0603

R20847k0603

R20947k0603

R21047k0603

R211

DGND DGND DGND DGND DGND DGND

PWM

1L_B

PWM

1H_B

PWM

2H_B

PWM

2L_B

PWM

3H_B

PWM

3L_B

DNP

R216

DNP

R217

DNP

R218

DNP

R219

DNP

R221

DNP

R220

0R1206

R2680R1206

R2690R1206

R2705VLDO2

0R

R279

DNP

R280

AGND


Mo

tor C

on

trol 10-2

4V D

river B

oa

rd (D

ua

l/Sin

gle

)

DS

50

00

22

61

A-p

ag

e 6

0

20

14

Micro

chip

Te

chn

olo

gy In

c.

1.0 (SHEET 3 OF 3)

+12V

65R41/2.4V1

+A3

-A4

OUTA 1

VSS

VDD

25

MCP6021U6

TC1412N

IN2

VDD1

OUT 6

VDD8

NC3

GND 5GND4

OUT 7

U5

0.1 μF060325V

C66

DGND

DVDD

DNP

R232

DNP

R238

10k0603

R239

PGND

A

TP48

PGND PGND

0.1 μF060325V

C67

PGND

22R0603

R230

1 μF25V0603

C68

PGND

22R0603

R235DNP

D49

IPB054N06N3 G

D

G

S

Q13

332k0603

R237

.015 ROARS-3

Rsh9

PGND

BRAKE_SHUNT_HIGH_A

BRAKE_SHUNT_LOW_A

TAB .250

TP47

5 mm apartSS35D48

VDC_A

AGND

5VLDO1

0.1 μF060325V

C82

5VLDO1

AGND

47k0603

R241

1k0603

R2432k

R242

2k

R244

TP49

1000 pF50V0603

C83

AGND

IBRAKE_A

+12V

65R41/2.4V1

+A3

-A4

OUTA 1

VSS

VDD

25

MCP6021U12

TC1412N

IN2

VDD1

OUT 6

VDD8

NC3

GND 5GND4

OUT 7

U10

0.1 μF060325V

C84

DGND

DVDD

DNP

R248

DNP

R254

10k0603

R255

PGND

B

TP53

PGND PGND

0.1 μF060325V

C85

PGND

22R0603

R246

1 μF25V0603

C86

PGND

22R0603

R251DNP

D51

IPB054N06N3 G

D

G

S

Q14

332k0603

R253

.015 ROARS-3

Rsh10

PGND

BRAKE_SHUNT_HIGH_B

BRAKE_SHUNT_LOW_B

TAB .250

TP52

TAB .250

TP51

5 mm apartSS35D50

VDC_B

AGND

5VLDO2

0.1 μF060325V

C88

5VLDO2

AGND

47k0603

R257

1k0603

R2592k

R258

2k

R260

TP56

1000 pF50V0603

C93

AGND

IBRAKE_B

TAB .250

TP46

DNP

R271

47kR272

AGND

DNP

R273

47kR274

AGND

FIGURE A-3: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) SCHEMATIC REVISION

PGND

-24V Power Connector

470 μFP5D10H20

C11000 pF100V0603

C2

PGND

DGND AGND

JACK Power 2.1 mm Male231J5

Both

0R0603

R132ILIMIT_OUT_B

DNP

C38

FAULT_MB

TP11

OSTVI022152

12

J1

PGND

PGND

VDC_B

VDC_A

TP3

TP6

TP7

TP8

10 mm

10 mm

OSTT7022150

12

J8

PGND

DC+

DC+

5650874-4

B1C2

B2C3

B3C4

B4

C1

C5B5

C6B6

C7B7

C8B8

C9B9

C10B10

C11B11

C12B12

C13B13

C14B14

C15B15

C16B16

C17B17

C18B18

C19B19

C20B20

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

C21B21A21

C22B22A22

C23B23A23

C24B24A24

C25B25A25

C26B26A26

C27B27A27

C28B28A28

C29B29A29

C30B30A30

C31B31A31

C32B32A32

C33B33A33

C34B34A34

C35B35A35

C36B36A36

C37B37A37

C38B38A38

C39B39A39

C40B40A40

J13

Populateby default

Populateby default

SN74AHC1G09DBVR

A1

B2

3

Y 4

5

U1

DGND

DVDD

0.1 μF25V

C15

DGND

DVDD

4.7k0603

R25

DVDD

0R0603

R26

TP12

FAULT_ABFAULT_MB

FAULT_MA

TP16DNPR28

DNPR27

DVDD

DGND

0RR29

0RR30

470 μFP5D10H20

C321000 pF100V0603

C33

PGND

470 μFP5D10H20

C301000 pF100V0603

C31

PGND

PGND

PGND

PWM3H_A

PWM1H_BPWM1L_B

PWM2L_B

PWM2H_BPWM3L_B

PWM3H_B

FAULT_MB

VPHASE1_MB

VPHASE2_MBFAULT_AB

VPHASE3_MAVPHASE2_MA

VPHASE1_MA

RECN_MAVPHASE3_MB

VREF_EXT

VBUS_A

DE2_RX_BRECN_MB

HALLB_MAHALLC_MA

IBUS_MB

IPHASE1_MBIPHASE2_MB

BRAKE_EN_A

HOME_MA

SHUNT_HIGH_SUM_ASHUNT_LOW_SUM_A

DE2_RX_AFAULT_MA

SHUNT_HIGH_SUM_A

SHUNT_HIGH_SUM_ASHUNT_HIGH_2_A

SHUNT_HIGH_1_A

DE2_TX_A

VBUS_BHALLA_MA

CE_A

HOME_MBCE_B

HALLC_MBPWM1L_A

PWM1H_AHALLB_MB

HALLA_MB

PWM2L_APWM2H_A

PWM3L_A

AGND

DC+

AVDD

DGND

DGND

DGNDDGND

DGND

DGND

DGND

DC+

0RR190

DNPR192SHUNT_HIGH_3_A

0R

R191

DNP

R193SHUNT_HIGH_SUM_A

PGND

0R

R194

DNP

R195IPHASE3_MB

0R

R196

DNP

R197IPHASE3_MA

63V222010 μF

C64

PGND

63V222010 μF

C65

PGND

DVDD

DC+

PGNDPGND

0R1206

R222

0R1206

R223

5KP26A-E3/54D46

5KP26A-E3/54D47

PGND

PGND

DVDD

DGND

BRAKE_EN_B

DNP

R227

DNP

R228

IBRAKE_A

IBRAKE_B

L7812CD2T-TR

VIN1

GN

D2

VOUT 3U11

PGND

+12VDC+

0.1 μF060325V

C90

10 μF 50VC91 10 μF 50V

C9250V

0805.33 μFC89

PGNDPGND PGND PGND

TP54 TP55

For wire jumper

MCP

+A3

-A4

OUTAVSS

VDD

26

VREF5

U4

DVDD

DGND

2.2M

R234

280K0603

R233

1.8k0603

R236

180R0603

R240

PGND

0.1 μF060325V

C69

PGND

DGND

18k0603

R231

1.2k0603

R229

TP45

BRAKE_EN_

BRAKE_SHUNT_HIGH_A

BRAKE_SHUNT_LOW_A

MCP

+A3

-A4

OUTAVSS

VDD

26

VREF5

U7

DVDD

DGND

2.2M

R250

280K0603

R249

1.8k0603

R252

PGND

0.1 μF060325V

C87

PGND

DGND

1.2k0603

R245

TP50

BRAKE_EN_

BRAKE_SHUNT_HIGH_B

BRAKE_SHUNT_LOW_B

+5V

DGND PGND

0R1206

R261

VDC_A

VDC_B

OSTVI022152

12

J6

DE2_TX_B

TP PAD PCB 1.6x1.C24

30.1k

R106

301R

R107

2k0603

R111DNPC56

AGND AGND

PHASE1_MB VPHASE1_MB TP33

30.1k

R99

301R

R100

2k0603

R103DNPC54

AGND AGND


30.1k

R108

301R

R109

2k0603

R112DNPC57

AGND AGND


10k0603

R93

10k0603

R92

10k0603

R94

RECN_MB TP31

30.1k

R95

301R

R96

2k0603

R101DNPC52

AGND AGND

PHASE1_MA VPHASE1_MA TP22

30.1k

R104

301R

R105

2k0603

R110DNPC55

AGND AGND


30.1k

R97

301R

R98

2k0603

R102DNPC53

AGND AGND


10k0603

R90

10k0603

R89

10k0603

R91

RECN_MA TP20

1 μF25V0603

C94

AGND

TP LOOP Black

TP4

DGNDTP LOOP Black

TP5

DGND

TP LOOP Black

TP58

PGNDTP LOOP Black

TP59

PGND

TP LOOP Black

TP60

TP LOOP Black

TP61

AGND AGNDTP LOOP Red

TP62

DVDD

AGND

TP LOOP Black

TP63

PGNDTP LOOP Black

TP64

PGND

NUT #2-56 SS

2

Mounting hardware for J13

SCREW 2-56x.500

2Qty

Qty

GREEND1

DGND

GREEND2

DGND

GREEND3

PGND

+12VDVDD +5V

1k0603

R264470R0603

R262470R0603

R263

DNP

12 J16

PGND

+12V

TP PAD PCB 1.6x1.C12

TP PAD PCB 1.6x1A16

TP PAD PCB 1.6x1B27

VREF_EXT

VREF_EXT

180R0603

R256

18k0603

R247


Board Schematics and Layout

FIGURE A-4: MOTOR CONTROL 10-24V DRIVER BOARD (DUAL/SINGLE) LAYOUT



NOTES:



USER’S GUIDE

Appendix B. Electrical Specifications

B.1 INTRODUCTION

This chapter provides the electrical specifications for the Motor Control 10-24V Driver Board (Dual/Single) (see Table B-1).

At ambient temperature (+25ºC), the board remains within the thermal range when operating with continuous output currents of up to 10A (RMS) at the rated voltage.

TABLE B-1: ELECTRICAL SPECIFICATIONS

Parameter Operating Range

Input DC Voltage 10-24V ±10% (9-26.4V)

Maximum Input Current through Connector J5 2.5A

Maximum Input Current through Connector J8 30A

Maximum Input Current through Connector J1 or J6 15A

Continuous Output Current per Phase @ +25ºC 10A (RMS)

Brake Switch Continuous Current @ +25ºC 10A (RMS)



NOTES:



USER’S GUIDE

Appendix C. Component Selection

C.1 INTRODUCTION

This chapter provides detailed information on the component selection of the motor current amplifier, brake current amplifier and the hardware brake enable circuit.

C.2 HIGHLIGHTS

This chapter covers the following topics:

• Motor Current Amplifier Configuration

• Brake Current Amplifier Configuration

• Hardware Brake Enable Circuit Configuration

C.3 MOTOR CURRENT AMPLIFIER CONFIGURATION

An amplifier circuit for sensing the motor currents on the Motor Control 10-24V Driver Board (Dual/Single), Inverter A and Inverter B sections, is shown in Figure C-1.



FIGURE C-1: MOTOR CURRENT SENSING AMPLIFIER

C D

A

B E

F

11

10

9

U9VREF_EXT

IPHASE1_MB

SHUNT_HIGH_1_B

SHUNT_HIGH_SUM_B

Op Amp A+

–

C D

A

B E

F

14

13

12

VREF_EXT

IPHASE2_MB

SHUNT_HIGH_2_B

SHUNT_HIGH_SUM_B

Op Amp B

+

–

C

D

A

B E

F

3

4

1

VREF_EXT

IPHASE3_MB

SHUNT_HIGH_3_B +

–SHUNT_HIGH_SUM_B

VoltageDivider

C

D

A

B E

F

18

17

16

VREF_EXT

IBUS_MBSHUNT_HIGH_SUM_B

Op Amp C

+

–SHUNT_LOW_SUM_B

VoltageDivider

C

D

A

B E

F

3

4

1

VREF_EXT

IPHASE3_MA

+

–SHUNT_HIGH_SUM_A

VoltageDivider

SHUNT_HIGH_3_A

MCP6021

MCP6021

U2

U3

MCP8024

Filter,Feedbackand BiasCircuit






Component Selection

Figure C-2 shows the amplifier gain setting.

FIGURE C-2: AMPLIFIER GAIN SETTING

Equation C-1 provides the amplifier gain setting calculations. Equation C-2 and Equation C-3 show the cutoff frequency calculations using a differential-mode filter and a common-mode filter, respectively.

EQUATION C-1: AMPLIFIER GAIN

EQUATION C-2: CUTOFF FREQUENCY DIFFERENTIAL-MODE FILTER

EQUATION C-3: CUTOFF FREQUENCY COMMON-MODE FILTER

Filter, Feedback and Bias Circuit

B

A1k 1k

1k1kE

F

C D

47k47k

470 pF

1000 pF

470 pF

Differential Amplifier Gain 47 k2 1 k---------------------- 23.5= =

Differential mode f 3dB–1

2 2 1 k 470 pF2

------------------ 1000 pF+

------------------------------------------------------------------------------------- 65 kHz

Common mode f 3dB–1

2 1 k 470 pF ------------------------------------------------ 340 kHz



C.4 BRAKE CURRENT AMPLIFIER CONFIGURATION

Figure C-3 shows an amplifier circuit for sensing current flow through brake switches in the Motor Control 10-24V Driver Board (Dual/Single). Figure C-4 shows the brake current amplifier configuration.

FIGURE C-3: BRAKE CURRENT SENSING AMPLIFIER

C

D

A

B E

F

3

4

1

VREF_EXT

IBRAKE_A

BRAKE_SHUNT_HIGH_A +

–BRAKE_SHUNT_LOW_A

VoltageDivider

C

D

A

B E

F

3

4

1

VREF_EXT

+

–

VoltageDivider

MCP6021

MCP6021

U6

U12

IBRAKE_B

BRAKE_SHUNT_HIGH_B

BRAKE_SHUNT_LOW_B

Feedbackand BiasCircuit

Feedbackand BiasCircuit


Component Selection

FIGURE C-4: BRAKE CURRENT AMPLIFIER CONFIGURATION

EQUATION C-4: AMPLIFIER GAIN

Feedback and Bias Circuit

B

A

1k

1k

47k 47k

C D

E

F

Differential Amplifier Gain 47 k2 k--------------- 23.5= =



C.5 HARDWARE BRAKE ENABLE CIRCUIT CONFIGURATION

Figure C-5 shows the hardware brake enable circuit comparator with hysteresis in the Motor Control 10-24V Driver Board (Dual/Single).

FIGURE C-5: HARDWARE BRAKE ENABLE CIRCUIT COMPARATOR WITH HYSTERESIS

3

4

1

VR

HardwareBrake Enable B

+

–

ReferenceVoltageDivider

MCP65R41/2.4V

U7

5

VIN

VDC_BRIN RF

VREF (2.4V)

3

4

1

VR

HardwareBrake Enable A

+

–

ReferenceVoltageDivider

MCP65R41/2.4V

U4

5

VIN

VDC_ARIN RF

VREF (2.4V)

DC BusVoltageDivider

DC BusVoltageDivider


Component Selection

Figure C-6 shows the hysteresis diagram of the non-inverting comparator.

FIGURE C-6: HYSTERESIS DIAGRAM – NON-INVERTING COMPARATOR

Equation C-5 determines the input threshold voltages.

EQUATION C-5: INPUT THRESHOLD VOLTAGES

Equation C-6 determines RF, RIN and VR from the threshold voltage.

EQUATION C-6: DETERMINING RF, RIN AND VR FROM THRESHOLD VOLTAGE

VOUT

VDD

VOH

VOL

VSS

VSS

High-to-Low Low-to-High

VTHL VTLH VDD

VTLH VR 1RIN

RF--------+

VOL

RIN

RF-------- –=

VTHL VR 1RIN

RF--------+

VOL

RIN

RF-------- –=

Where:

VOL is the saturation voltage in the low state at the comparator output.

VOH is the saturation voltage in the high state at the comparator output.

VTLH is the threshold voltage from low-to-high.

VTHL is the threshold voltage from high-to-low.

VR is the comparator reference input voltage.

VTRIP

VTLH VTHL+

2-------------------------------=

RF

RIN--------

VOH VOL+

VTLH VTHL–-------------------------------=

VR

RIN VOH VOL+

2 RIN RF+ -------------------------------

RF

RIN RF+ -------------------------- VTRIP+=

Where:

VTRIP is the average trip voltage at the middle of the comparator hysteresis.



C.5.1 Setting Trip Voltage

The example calculations to set the DC bus upper and lower trip points, DC Bus Voltage Low-to-High (VDCLH) at 27.5V and DC Bus Voltage High-to-Low (VDCHL) at 23.5V for the hardware brake enable circuit in the Motor Control 10-24V Driver Board (Dual/Single) are shown in Equation C-7. The comparator supply voltage is 3.3V, the DC bus voltage divider circuit ratio is 11, VOH comparator is 3.1V and VOL comparator is 0.2V.

The trip voltages scaled by the DC bus voltage divider circuit ratio (VTLH and VTHL) can be calculated as shown in Equation C-8.

EQUATION C-7: THRESHOLD VOLTAGE CALCULATIONS

From VTLH and VTHL, the middle of the hysteresis or average Trip Voltage (VTRIP) is calculated as shown in Equation C-8.

EQUATION C-8: CALCULATION FOR AVERAGE TRIP VOLTAGE

From VOH, VOL, VTLH and VTHL, the hysteresis setting resistor ratio can be determined. By selecting one resistor value, the other resistor value can be calculated as in Equation C-9.

EQUATION C-9: HYSTERESIS SETTING RESISTOR RATIO VALUE

After calculating the hysteresis setting resistor values, the Comparator Reference Voltage (VR) input can be calculated as in Equation C-10.

EQUATION C-10: COMPARATOR REFERENCE (VR) INPUT CALCULATION

The Comparator Reference Voltage (VR) input is generated by the voltage divider circuit supplied by the Comparator Reference Voltage (VREF) output at 2.4V.

This voltage divider ratio can be calculated as, 2.4V/2.242V = 1.07.

Then, the voltage divider resistors can be determined:If R2 = 18 k, then R1 =18 k 1.07 = 1.2 k

VTLH27.511

---------- 2.5V==

VTHL23.511

---------- 2.136V==

VTRIP2.5V 2.136V+

2---------------------------------------- 2.318V= =

RF

RIN-------- 3.1V 0.2V–

2.5V 2.136V– --------------------------------------- 7.967= =

If RIN is 280 kRF 7.967 280 k 2230.76 k 2200 k==

VR280 k 3.1V 0.2V+

2 280 k 2200 k+ ---------------------------------------------------------- 2200 k

280 k 2200 k+ --------------------------------------------------- 2.318+=

0.186V 2.056V+= 2.24V=


Component Selection

C.6 HARDWARE BRAKE ENABLE CIRCUIT CONFIGURATION RESISTORS

Configuration resistors for setting the DC bus upper and lower trip points for comparator supply voltages of 3.3V and 5V are provided in Table C-1 and Table C-2.

TABLE C-1: CONFIGURATION RESISTORS IN HARDWARE BRAKE ENABLE CIRCUIT A

TABLE C-2: CONFIGURATION RESISTORS IN HARDWARE BRAKE ENABLE CIRCUIT B

Resistor Designator

Resistor Value to Set VDCHL @ 23.5V and VDCLH @ 27.5V,If the Comparator Supply Voltage is

3.3V 5V

R233 280 k 280 k

R234 2200 k 3600 k

R231 18 k 36 k

R229 1.2 k 1 k

Resistor Designator

Resistor Value to Set VDCHL @ 23.5V and VDCLH @ 27.5V, If the Comparator Supply Voltage is

3.3V 5V

R249 280 k 280 k

R250 2200 k 3600 k

R247 18 k 36 k

R245 1.2 k 1 k



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