DB63R DB63R P r o d u c t IInnnnoovvaa t i o n FFr roomm Demonstration Board for the SA57-IHZ INTRODUCTION The DB63R is designed to demonstrate the capabilities of the SA57 DC brush motor driver IC. This fully assembled demonstration allows the user to directly control the speed and direction of the motor. An onboard circuit controls the direction and provides four quadrant PWM signals to control the power outputs of the SA57. LEDs provide feedback for motor control status and fault indications. Provisions on the DB63R allow the user to bypass the onboard control circuit and directly interface with the SA57 motor driver. The DB63R demonstrates proper layout techniques for the SA57 high current switching amplifier. The economical construction uses only a two-sided PCB and allows the SA57 to deliver peak currents of over 1kW. THERMAL CONSIDERATIONS: The SA57 is available in a surface mount package which can deliver peak power of over 1kW. This presents an obvious and significant thermal challenge. The DB63R offers a compact design which can deliver 17A peak current by using a patent pending mounting technique. Mounting the SA57 in an inverted fashion as shown in Figure 1 reduces the profile height of the assembly and provides a direct interface between the thermal tab of the PowerQuad package (package outline drawing HQ) and the small HS33 heatsink. The DB63R assembly can dissipate 7-9W in still air at 25C ambient temperature, depending on the orientation of the heatsink fins. To use the DB63R in higher power applications, use a fan or mount a heatsink with larger thermal mass. Although the SA57 is rated for operation from -25 to +85C, the other components on the DB63R are limited to 0 to 70C ambient temperature. CIRCUIT OPERATION Figure 1 - Mounting Technique The DB63R control circuit receives power via two terminal Patent Pending block connections. The Vs connection supplies power to drive the motor and must be above the under-voltage lockout threshold of the SA57, approximately 8.3V. The control circuit requires 12V for proper operation a regulator on the DB63R provides the 5V logic supply for the SA57. There are no special considerations for sequencing the two supplies. DB63RU http://www.cirrus.com Copyright (c) Cirrus Logic, Inc. 2009 (All Rights Reserved) FEB 2009 APEX - DB63RUREVA DB63R P r o d u c t I n n o v a t i o nF r o m Figure 2 - User Control Features Figure 2 shows the user control features of the DB63R. The PWM duty cycle is controlled with the potentiometer (1 in figure 2). The power LED (2) will illuminate when 7 11 the 12V supply is connected. The DB63R will power up with the SA57 disabled. The enable button (3) will toggle 3 the SA57 on and off with the LED (4) illuminating to indi2 cate the enable status. Direction of the motor is similarly 1 controlled with the button (5) and is indicated by the LED (6). The DB63R monitors the Temperature warning status pin 4 8 of the SA57. If this pin goes high an LED (7) illuminates and the enable circuit is forced to a disable status. The 6 temperature LED is not latched and may stay illuminated only briefly while the temperature of the SA57 is above 135C. The temperature decrease rapidly via the heatsink 5 once the SA57 is disabled. The SA57 current limit feature is set to limit at approximately 15A to provide a demonstration of the full capabili10 ties of the SA57. An LED (8) will illuminate if the SA57 cycle-by-cycle current limit circuit engages. The thermal and current limit features are robust, but will not protect the SA57 in all circumstances. The user must consider the worst case thermal and power dissipation conditions. Push-button switches 1 and 2 trigger latches (U4) for direction and enable control, respectively. Diodes D7 & D8 and resistors R24, 25, 29 & 30 provide a means of bypassing the DB63R control circuit. The 5V regulator, U3, provides 5V to the SA57, the latches and the status LEDs. DB63RU P r o d u c t I n n o v a t i o nF r o m DB63R Figure 3 - Schematic ENHANCING & BYPASSING THE DB63R CONTROL CIRCUIT: Connector J5 allows the user to bypass many of the manual control features of the DB63R. A signal generator can control the duty cycle with a 2.5 to 7.5V signal, overriding the control potentiometer. A rising 5V edge on pin 3 or 4 of connector J5 will toggle the Direction or Enable latches, respectively. By jumping resistors R24 & R25, the latches are bypassed completely and the logic signals on pins 3 & 4 will directly control the direction and enable functions of the DB63R. With these resistors jumped, the direction and enable LEDs will not represent the states of the DB63R and the pushbuttons will have no effect on the operation. The Temperature disable feature of the DB63R will also not function, although the LED will continue to provide over-temperature status. Connector J4 is connected directly to the PWM input pins of the SA57. This connector may be used to monitor the signals or to bypass the control IC on the DB63R. The enable function is not controlled via these pins, although pulling all four input pins low provides the same effect. The Enable pushbutton and the connection via J5 are also effective as previously described. The circuit shown in figure 3 in the dashed box is a simple circuit that allows the user to monitor and control the enable or direction status remotely. Either feature can be toggled on the falling edge of the signal at the node labeled TOGGLE. LAYOUT CONSIDERATIONS A simple two layer construction is sufficient because of the convenient pinout of the SA57 PowerQuad package. Input signals are routed into one side of the package and high power output signals are routed from the other side in 2 ounce copper. This eliminates the need to route control signals near motor connections where noise may corrupt the signals. Filling top and bottom layers with copper reduces inductive coupling from the high current outputs. 1nF capacitors with excellent high frequency characteristics bypass the Vs motor supplies on each phase. Two 150F electrolytic capacitors provide a local, low inductance source to accommodate surge currents up to 17A. DB63RU DB63R P r o d u c t I n n o v a t i o nF r o m Six 100V Schottky diodes conduct the commutation current via low forward voltage paths which reduces the power dissipation in the SA57. These diodes are rated for 5A continuous and are mounted close to the SA57 to reduce inductance in the commutating current loop. For applications with continuous currents less than 5A, the Schottky diodes may not be necessary if the higher forward voltage internal body diodes and the associated power dissipation are manageable during commutation cycles. Figure 4 shows the top and bottom layouts of the DB63R. Gerber files for the circuit board are available upon request. Figure 4 - PCB Layout (not to scale) TOP SIDE 3.888" 1.860" BOTTOM SIDE DB63RU DB63R P r o d u c t I n n o v a t i o nF r o m BILL OF MATERIALS Designation C1,C18 C13 C2,C3 C5,C6 C7,C8,C14,C15,C16 C12,C17 D1,D2,D3,D5,D6 D7,D8,D9 J4 J5 LED1-5 Q1,Q2 R11,R12,R13 R24,R25 R26,R27 R29,R30 R18,R19,R20,R21,R32 R7,R31 R8 R9,R10,R16,R17,R22,R23 SW1,SW2 TB1,TB2 Thermal Grease U1 U2 U3 U4 Description CAP, 1.0uF, 16V CAP, 33pF, 50V CAP, 1.0nF,100V CAP, 150uF, 100V CAP, 0.1uF,16V CAP, 2.2nF,50V Diode, 5A Schottky IN4148 Conn, 6 pin .100 ctrs Conn, 4 pin .100 ctrs LED, Red XTR, NPN RES 2.0K, 1% RES, 6.8K RES, 10K RES, 3.3K RES, 1.0K, 5% RES, 24.9K,1/10W, 1% POT, 20K RES, 4.99K Pushbutton, SPST-NO Terminal Block, 3 pin, 5mm Heatsink compound SA57-IHZ UCC3626 LM78L05 74AC74 Heatsink PCB, 1.75" x 3.75" Screw, #4-40 x 1/4" Solder P/N Kemet, C0805C105K4RAC Kemet, C0603C330J5GACTU Kemet,C0805C102J1GACTU Panasonic, EEVFK2A151M GRM188F51C104ZA01D GRM188R71H222KA01D Diodes Inc., DS5100 Vishay, 1N4148WS-V-GS08 Samtec, TSM-106-01-T-SV Samtec, TSM-104-01-T-SV Lite-On, LTST-C190CKT MMBT3904 Vishay,CRCW06032K00FKEA Vishay,CRCW06036K80FKEA Vishay,CRCW060310K0FKEA Vishay,CRCW06033K30FKEA RK73B1JTTD102J RK73H1JTTD2492F muRata, PVG3A203C01 CRCW06034K99FKEA Panasonic, EVQ-Q2B01W On Shore Tech, OSTTA034163 N/A Cirrus Logic, SA57-IHZ Texas Instruments, UCC3626PW National Semiconductor, LM78L05ACMX/NOPB Texas Instruments, SN74AC74PW Cirrus Logic, HS33 Cirrus Logic,EVAL69R N/A Tin/Silver 96/4 DB63R Quick Start Guide 1. Connect the following: Connection Location Vs TB2-3 Ground TB2-2 Vctrl TB2-1 Motor Phase A TB1-1 Motor Phase B TB1-2 Indicator Comment 9-60V LED 2 12V 2. Apply 12V to Vctrl. LED 2 should light. 3. Apply voltage to Vs based on rated motor voltage, normally 12-48V. 4. Press ENABLE switch 3. LED 4 will light and motor should start. ORDERING INFORMATION DB63R Demonstration Board includes one populated EVAL69R PCB and one SA57-IHZ sample. DB63RU DB63R P r o d u c t I n n o v a t i o nF r o m Contacting Cirrus Logic Support For all Apex Precision Power product questions and inquiries, call toll free 800-546-2739 in North America. For inquiries via email, please contact tucson.support@cirrus.com. International customers can also request support by contacting their local Cirrus Logic Sales Representative. To find the one nearest to you, go to www.cirrus.com IMPORTANT NOTICE Cirrus Logic, Inc. and its subsidiaries ("Cirrus") believe that the information contained in this document is accurate and reliable. However, the information is subject to change without notice and is provided "AS IS" without warranty of any kind (express or implied). Customers are advised to obtain the latest version of relevant information to verify, before placing orders, that information being relied on is current and complete. All products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgment, including those pertaining to warranty, indemnification, and limitation of liability. No responsibility is assumed by Cirrus for the use of this information, including use of this information as the basis for manufacture or sale of any items, or for infringement of patents or other rights of third parties. This document is the property of Cirrus and by furnishing this information, Cirrus grants no license, express or implied under any patents, mask work rights, copyrights, trademarks, trade secrets or other intellectual property rights. Cirrus owns the copyrights associated with the information contained herein and gives consent for copies to be made of the information only for use within your organization with respect to Cirrus integrated circuits or other products of Cirrus. This consent does not extend to other copying such as copying for general distribution, advertising or promotional purposes, or for creating any work for resale. CERTAIN APPLICATIONS USING SEMICONDUCTOR PRODUCTS MAY INVOLVE POTENTIAL RISKS OF DEATH, PERSONAL INJURY, OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE ("CRITICAL APPLICATIONS"). CIRRUS PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED TO BE SUITABLE FOR USE IN PRODUCTS SURGICALLY IMPLANTED INTO THE BODY, AUTOMOTIVE SAFETY OR SECURITY DEVICES, LIFE SUPPORT PRODUCTS OR OTHER CRITICAL APPLICATIONS. INCLUSION OF CIRRUS PRODUCTS IN SUCH APPLICATIONS IS UNDERSTOOD TO BE FULLY AT THE CUSTOMER'S RISK AND CIRRUS DISCLAIMS AND MAKES NO WARRANTY, EXPRESS, STATUTORY OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE, WITH REGARD TO ANY CIRRUS PRODUCT THAT IS USED IN SUCH A MANNER. IF THE CUSTOMER OR CUSTOMER'S CUSTOMER USES OR PERMITS THE USE OF CIRRUS PRODUCTS IN CRITICAL APPLICATIONS, CUSTOMER AGREES, BY SUCH USE, TO FULLY INDEMNIFY CIRRUS, ITS OFFICERS, DIRECTORS, EMPLOYEES, DISTRIBUTORS AND OTHER AGENTS FROM ANY AND ALL LIABILITY, INCLUDING ATTORNEYS' FEES AND COSTS, THAT MAY RESULT FROM OR ARISE IN CONNECTION WITH THESE USES. Cirrus Logic, Cirrus, and the Cirrus Logic logo designs, Apex and Apex Precision Power are trademarks of Cirrus Logic, Inc. All other brand and product names in this document may be trademarks or service marks of their respective owners. DB63RU