User's Manual, V 1.0, June 2003 Motor Control Development Kit A reference design for low voltage 3-phase AC induction and brushless DC motor control. Microcontrollers N e v e r s t o p t h i n k i n g . Motor Control Development Kit Revision History:2003-06 V 1.0 Previous Version:Page 1.0 Subjects (major changes since last revision) June 2003: First Release References Infineon C868 User's Manual http://www.infineon.com/cmc_upload/documents/048/247/ UM_c868_BA_singlepage_v1.0.pdf Infineon TLE6280GP Datasheet http://www.infineon.com/cmc_upload/documents/014/220/TLE6280GP_P6_1.pdf We Listen to Your Comments Any information within this document that you feel is wrong, unclear or missing at all? Your feedback will help us to continuously improve the quality of this document. Please send your proposal (including a reference to this document) to: ipdoc@infineon.com Motor Control Development Kit Introduction 1 Introduction This user manual describes the MCDK, Motor Control Development Kit reference design board and its functions. The MCDK reference design provides a turnkey solution for driving 3-phase low voltage brushless DC and AC induction motors, which are usually powered by batteries. The hardware design applies a broad range of Infineon IC products including microcontroller, bridge driver, power transistor, temperature sensor and voltage regulator. Infineon also makes Hall Effect sensors which often are placed inside Brushless DC motors for position sensing. Also included in the kit is reference software. This reference solution allows engineers to shorten the development cycle, reduce the design cost and cut the time from concept to market significantly. The reference software provided with the MCDK release demonstrates a variable speed drive for a high speed brushless DC motor with hall sensors, the motor has the following features: * * * * 24V DC Supply 3-phase, 4-pole, trapezoidal 3/4 Horse Power Speed up to 30,000 RPM The software can be trivially changed to adopt different type of 3-phase brushless DC motors. User's Manual 3 V 1.0, 2003-06 Motor Control Development Kit MCDK Overview 2 MCDK Overview 2.1 Parameters The MCDK reference design meets the following specifications: Low Voltage: 12V ~ 24V DC High Current: 50A, continuous DC Output Power: Up to 1.2KW Power Efficiency: > 95% 2.2 Features * 8-bit MCU: C868 with on-chip 8kB SRAM, 5 channel 8-bit ADC and powerful PWM module CAPCOM6E * 3-Phase Bridge Driver: TLE6280G * 6 OptiMOS MOSFETs: SPB80N06S2-05, TO263 package, 55V / 80A / 4.8 m RDS(on) * EEPROM: 8kB to store program + stand alone boot option * RS232: Interface to PC for SW development + boot from PC option * Protection: shut down protection for over current and over temperature * Board can be used for current/torque or speed control * Supports Hall-Effect sensors or sensor-less control * Extension for alternative MCU like XC164 * Small foot print: 51/4" x 3" dimension (133.4mm x 76.2mm) * SW development tools: Keil Compiler + Debugger or Mini Debugger http://www.keil.com + free reference software User's Manual 4 V 1.0, 2003-06 Motor Control Development Kit MCDK Overview 2.3 Assembly Power Transistors Current Sensor Bridge Driver Motor Wires DC Supply Hall Signals Pot for speed setting EEPROM Expansion I/Os for Alternate MCU C868 MCU RS232 Figure 1 User's Manual Assembly of the MCDK Board 5 V 1.0, 2003-06 Motor Control Development Kit Hardware Design 3 Hardware Design The hardware is designed with maximum versatility and flexibility to meet fluctuating motor drive needs: * * * * * * CPU selections between C868 and alternatives like C164, XC164 and TriCore. Power Transistor Packages compatible in both DPAK and D2PAK Bridge Driver selection between TLE6280 or TLE6287 Motor rotor position detection through hall sensors or sensor-less calculation. Booting sequences via EEPROM, RS232 or on-chip ROM. Circuit protections for over current and over temperature conditions The following block diagram illustrates the basic idea to drive a 3-phase AC induction or BLDC motor. Intelligence C868 Bridge driver Power Stage VD Position Feedback: Sensor or Sensor-less Figure 2 Block Diagram of 3-phase Motor Control Circuit The Infineon C868 microcontroller implements a powerful PWM unit CAPCOM6E, which is able to generate optimized PWM waveform for all kind of motor controls with minimal CPU load. The following diagram illustrates how the CAPCOM6E can generate 6-channels of PWM signals according to the 3 hall sensor position signals, to drive a 3-phase BLDC motor. The CAPCOM6E is very flexible and can generate practically any pattern that is desired. User's Manual 6 V 1.0, 2003-06 Motor Control Development Kit Hardware Design Period Reg. CT1P Mod Offset Reg. CT1OF Input FCP Control Compare Timer Timer 16-bit 16-bit Compare Compare Co Timer Input Control Speed 0 CC0 CC Channel Port CC0 COUT0 CCPhase Channel 1 CC1 Delay* Control CC1 COUT1 Time (Stall2Detect) CC Out Channel CC2 Hall Effect* deadtime Noise Filter Control FCP CTRAP PWM Signals CC2 COUT2 Burst Mode Comp Reg. CMP2 Block Commutation Control Period Reg. COUT3 INT0 INT1 INT2 Hall Pattern Signals Figure 3 User's Manual Block Diagram of the CAPCOM6E PWM Unit (with C868) 7 V 1.0, 2003-06 Motor Control Development Kit Board Configurations 4 Board Configurations The MCDK board is pre-configured during production. The following table shows the factory setting for circuit breaks and jumpers: - - - - - - - - - - - - - CB1: Close CB2: Close CB3: Open CB4: Open CB5: Close CB6: Open JP1: 1+2 JP2: 2+3 JP3: Close JP4: 1+2 JP5: 1+2 JP6: 1+2 JP7: 1+2 4.1 Circuit Break Settings The circuit breaks are pre-set in the assembly process, a solder drop between the gap makes the circuit break `Close', otherwise the circuit break is `Open'. The circuit breaks CB4, CB5 and CB6 are used to select two types of Infineon bridge drivers, the factory setting is choosing the TLE6280. To choose the TLE6287, the configuration for CB4, CB5 and CB6 will be: Table 1 TLE6287 Configurations for using TLE6287 bridge driver CB4 CB5 CB6 Close Open Close The circuit breaks CB1 and CB2 make the board flexible for users who want to use the A/D ports of the microcontroller for alternate purpose. In this case, they need to be `Open'. While CB3 is closed, the board can supply a DC voltage to the external RS232 connections where opto-isolation can be applied. User's Manual 8 V 1.0, 2003-06 Motor Control Development Kit Board Configurations 4.2 Jumper Settings Jumper setting is more flexible, users can change "on-the-fly" to meet specific applications. Table 2 Jumper setting for bootstrap mode JP1: Bootstrap Mode Selection 1-2 Bootstrap Mode 2-3 Normal ModeTable Table 3 Jumper setting for logic power supply voltage JP2: Logical Power Supply Voltage Selection 1-2 Vcc = + 5V 2-3 Vcc = + 3.3V Table 4 Jumper setting for boot enable and disable JP3: Boot Enable/Disable Open Boot from PC via RS232 Close Boot from EEPROM Table 5 Jumper setting for position detection methods JP4, JP5 and JP6: Position Detection 1-2 Hall Sensor 2-3 Sensor-less Table 6 Jumper setting for A2D input selection JP7: A/D Input selection 1-2 Temperature Input 2-3 Current Input User's Manual 9 V 1.0, 2003-06 Motor Control Development Kit Get Started 5 Get Started 5.1 Run the Demo The EEPROM on the board has been pre-programmed with a BLDC motor control reference demo, the microcontroller C868 will boot from the EEPROM and automatically fetch then execute the code after power-up. The potentiometer for speed setting is preset at zero RPM. To run the demo, follow these steps: * Hook up the motor wires and hall sensor signals of the brushless DC motor to the board. * Connect a 12~24V battery with at least 1A output current to the board, the board is powered up then. * Turn on the knob of the potentiometer, the motor will starts to spin. Since the reference code is designed for a demo motor, the code has to be fine tuned for the right type of motor applied. 5.2 Re-program the EEPROM Users can re-program the EEPROM with their own code, to do this, follow these steps: * * * * * * Switch off the power supply by disconnecting the battery. Open the jumper JP3. Connect a RS232 cable to the host PC, and execute the Loader program on the PC. Connect the battery back so the board will be powered up again. Close the jumper JP3. Download your code into the EEPROM. User's Manual 10 V 1.0, 2003-06 Motor Control Development Kit Utilize an Alternative Microcontroller 6 Utilize an Alternative Microcontroller The expansion I/O connector, JP9, allows users to apply an alternative microcontroller to drive the motor, for example, the Infineon C166 series microcontrollers with integrated CAPCOM6(E) PWM units such as the XC164. The signals of the expansion I/O JP9 are described in the following table: Table 7 Description of Expansion I/Os of JP9 Pin # Name Description 1 CC0 First phase high side PWM signal 2 COUT0 First phase low side PWM signal 3 CC1 Second phase high side PWM signal 4 COUT1 Second phase low side PWM signal 5 CC2 Third phase high side PWM signal 6 COUT2 Third phase low side PWM signal 7 CTRAP Over current trap signal 8 POS0 Rotor position signal 9 POS1 Rotor position signal 10 POS2 Rotor position signal 11 Temp/ Current Temperature or Current amplitude 12 SPEED Motor speed setting 13 MFP Multifunction control signal for bridge drive 14 ERR Error signal from bridge drive 15 TX Transmitting signal of RS232 16 RX Receiving signal of RS232 17 CS Chip select signal for EEPROM 18 SIO Serial I/O pin of EEPROM 19 SCK Serial Clock signal of EEPROM 20 GND Ground 21 RST Reset signal for CPU 22 +3.3V Logic voltage supply when C868 used 23 +5V Logic voltage supply when alternate MCU used, i.e., C164xx 24 GND Ground 25 +24V_IN DC power supply (filtered) User's Manual 11 V 1.0, 2003-06 Motor Control Development Kit Utilize an Alternative Microcontroller The expansion I/Os provide all the necessary signals for external microcontroller to access the EEPROM, RS232 interface and motor drive circuits. There are two ways to utilize an alternate microcontroller: One is to design a mezzanine board that can plug on top of the MCDK board through the JP9 connector, the other way is to connect a 25pin flat cable to an existing microcontroller board (e.g., a starter kit). For the MCDK board, some changes have to be done: the on-board C868 device must be un-populated to avoid signal conflicts, also the jumper JP2 should be re-positioned if the alternate microcontroller uses a different I/O logic voltage supply, i.e., +5V. User's Manual 12 V 1.0, 2003-06 Motor Control Development Kit Appendix 1: Layout 7 Appendix 1: Layout Figure 4 Assembly Bottom Figure 5 Assembly Top User's Manual 13 V 1.0, 2003-06 Motor Control Development Kit Appendix 1: Layout Figure 6 Bottom Figure 7 Top User's Manual 14 V 1.0, 2003-06 Motor Control Development Kit Appendix 1: Layout Figure 8 Mask bottom Figure 9 Mask top User's Manual 15 V 1.0, 2003-06 Motor Control Development Kit Appendix 1: Layout Figure 10 Silk Bottom Figure 11 Silk Top User's Manual 16 V 1.0, 2003-06 Motor Control Development Kit Appendix 2: BOM 8 Appendix 2: BOM Table 8 Bill of Material for MCDK Reference Design Designator Quantity Part Type Footprint CB1->CB6 6 Solder drop custom footprint C1->C3 3 2.2F _0805 C4->C6 3 0.22F _0805 C7 1 15uF / 25V D-PACK C8, C19 2 1F _1206 C9 1 12nF _0805 C10, C11 2 10F-100v Radial/Bulk C16 1 10nF _0603 C17, C18 2 22pF _0603 C20, C21, C23, C25, C26, C27, C29, C31, C32, C33, C35, C36 12 100nF _0603 C22, C24 2 10F _1206 C28 1 10nF _0603 D1 1 1N4148 SOD-123 D2 1 1201:red/ orang, 1202:red _1206 D3 1 404-1059-1- _1206 ND JP1,JP2,JP4->JP7 6 HEADER 3 SIL3 JP3 1 JUMPER SIL2 JP9 1 HEADER 25 SIL25 JP10 1 HEADER 2 J1 1 Motor Wires Conn Hdr Vert Mini Fit SR 3Pos J2 1 Hall Sensor Signals SIL5 J3 1 DC Power Supply Conn Hdr Vert Mini Fit SR 2Pos User's Manual 17 SIL2 V 1.0, 2003-06 Motor Control Development Kit Appendix 2: BOM Table 8 Bill of Material for MCDK Reference Design Designator Quantity Part Type Footprint M1->M6 6 SPB80N06 S2-05 P- TO263 -7-3 OZ1 1 CSTLA10M SIL3 6T55002-B0 PB1 1 P8075SCTND POT1 1 ST7A103CT 7mm Squared SMD J-Lead-CT -ND POT2 1 3310C-1103-ND 9mm Squared RT ANGLE PLAS P1 - MALE 1 A2096-ND DB9-PCB R1->R6 6 22 Axial 1/4W type ERDS2T R13->R18, R27, R33, R34 9 1K _0603 R19, R31 2 27 _0603 R20 1 22K _0603 R21 1 47K _0603 R22 1 300K _0603 R24 1 20K _0603 R25, R26, R32, R36 4 10K _0603 R28 1 10-1.0W _2512 R29 1 100 _0603 R30 1 270 _0603 R35 1 3K _0603 R37 1 1K _0603 R38, R39 2 150 _0603 R40 2 0.005 resistors in parallel, 0.010 ohms@5W R41 1 4K7 _0603 TP1 1 GND POINT SIL1 T1 1 KT110 SIL2 U1 1 C868TSSOP tssop38 User's Manual 18 SPST V 1.0, 2003-06 Motor Control Development Kit Appendix 2: BOM Table 8 Bill of Material for MCDK Reference Design Designator Quantity Part Type Footprint U2 1 EEPROM 64K 2.7V SOIC8 U3 1 TLE4274GS P-SOT223-4-1 V33 U4 1 LM6132AIM SOIC8 -ND U5 1 TLE6280GP P-DSO36-12 U6 1 MAX3221E User's Manual 19 TSSOP16 V 1.0, 2003-06 Motor Control Development Kit Appendix 3: Schematics 9 Appendix 3: Schematics User's Manual 20 V 1.0, 2003-06 Motor Control Development Kit Appendix 4: Waveforms 10 Appendix 4: Waveforms Phase A POS0 (H0) POS1 (H1) POS2 (H2) CC0 (A+) COUT0 (A-) CC1 (B+) COUT1 (B-) CC2 (C+) COUT2 (C-) Figure 12 User's Manual Waveforms of PWM and Hall Pattern Signals Driving a 3-phase BLDC motor (Measured with a Mixed Signal Oscilloscope). 21 V 1.0, 2003-06 http://www.infineon.com Published by Infineon Technologies AG