E523.52 Motor Control Demonstration Board AN 0106

E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
Figure 1. Demoboard
1 What you get:
1. Demonstration board for E523.52 (version 3.0)
2. Software package
3. USB cable (A type ↔ Mini USB)
2 What you need in addition
For Evaluation
1. Three phase BLDC motor with peak current of up to 10A. (order sample motors from Elmos sales representative)
2. Power supply or battery with 12V to 72V and sufficient current to run the motor.
3. Personal computer running Windows ® XP or higher with .NET Framework 3.5 (or higher) and LabVIEW runtime 14.2 incl.
LabVIEW runtime driver set installed
For Software Development (contact your elmos sales representative)
1. Three phase BLDC motor with peak current of up to 10A. (order sample motors from Elmos)
2. Power supply or battery with 12V to 60V and sufficient current to run the motor.
3. Personal computer running Windows ® XP or Windows®7 with .NET framework 3.5 or higher and LabVIEW runtime 14.2
incl. LabVIEW runtime driver set installed
4. IAR Embedded Workbench for code development with elmos proprietary EL16 compiler.
5. MAZ JTAG Interface converter (by Eonas) from USB to JTAG-20
3 Before you start
The E523.52 demo board shows the E523.52 BLDC motor control IC in an application for automotive and industrial electrical
drives. The driver stage consists of three half-bridges capable of 72V / 30A. The shunt resistor and other components such as
electrolytic capacitors limit the maximum current to 10A. Use sufficient wire gauge for the power line between the board and
the power supply or battery, and between the phase outputs of the board and the motor.
Note:
Before using a battery as a supply, make sure that the supply circuit is fused by a sufficient current class fuse!
Transistors, cables and shunt can become hot during operation!Button SW1 reset the microcontroller
Elmos Semiconductor AG
Application Note 1/12
QM-No.: 25AN0106E.02
AN 0106
E523.52 Motor Control Demonstration Board
Oct 19, 2015
4 Preparation of operation
1. Connect the 3 phase Motor to the jacks „PH1“, „PH2“ and „PH3“ (usually called „U“, „V“, „W“). Make sure the motor is well
fastened
2. Connect the PC via USB-Cable and make sure the virtual COM port connection is established (for details see chapter 7 and
the document „FTDI_Drivers_Installation_Guide_for_WindowsXP/7/Vista“ on the support CD in this package)
3. Connect the Power Supply or battery on „POW“+ and „POW-“.
4. Run the motor control software on the computer.
The recent delivered software is a GUI- supported application. The software uses a virtual COM Port emulation via USB to start
and stop motor rotation, to set the motor type, speed, commutation type, regulation settings and other parameters, and to
show status information. The board is „ready to use“ with the stored flash memory content (microcode).
5 Connectors and signals
X1 Y JTAG interface
pin1
pin3
pin9
pins 4, 6, 8, 10, 12, 14, 16,
18, 20
VDDA
TMODE
TCK
pins 2, 7, 11, 13, 17, 19
pin5
pin15
open
TDA
NRST
X1/2
X1/4
X1/6
X1/8
X1/10
X1/12
TxD
TCK
PC2
PC4 (IP1)
PC6
open
Ground
X2 Y GPIO- ports, communication and test signals
X1/1
X1/3
X1/5
X1/7
X1/9
X1/11
open
RxD
TDA
open
PC5
PC7
Test points
TP1
TP2
TP3
TP9, TP_GND
TP_VBAT
TP_VPP
TP_VG
Phase 1 (U) via Low pass filter)
Phase 2 (V) via Low pass filter)
Phase 3 (W) via Low pass filter)
Ground
supply voltage after inrush current limiter
14V Flash testpoint – for factory tests only, do not use in applications
Low side Gate voltage (output of the DC-DC converter)
Jumpers and solder joints
JP1 ENABLE SJ1 test mode (solder joint)
enables the internal supply and starts operation of the IC (high- active, VBAT applicable)
1-2 closed (Ground) closed in application (default)
2-3 closed: test mode enabled (during flash the internal memory only)
Elmos Semiconductor AG
Application Note 2/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
6 Board description
The E523.52 is a fully integrated pre- driver solution for brushless motor applications with an automotive and industrial compatible input voltage range and high temperature capability. Included in the IC are all necessary power supplies, six 500mA
gate drivers, one current sense amplifier, and a 16bit microcontroller with various motor control relevant hardware modules
designed to support EC-motor commutation algorithms such as block and sinusoidal commutation based on Back-EMF or external sensors.
This demonstration board presents the E523.52 in a typical motor control application including a B6 power stage. In addition
the board offers:
•
•
•
•
•
•
Inrush current limiter.
Access to GPIO Pins PC2, 4, PC5, PC6, PC7.
A programming / debugging interface via 2-Wire JTAG.
Galvanic isolated USB interface for communication with a personal computer.
A back EMF divider for back EMF algorithms.
A speed regulator potentiometer (software support is required)
6.1 Power part
The three half bridges are able to deliver up to 30A per phase, limited to 10A max. by the shunt, the maximum ripple current
through the tank capacitors and the connectors, so the average current of each of the three phases should not exceed 10A. The
board operates in an input voltage range of 12 to 72V, typical 12 – 48V. The board consists of the Supply parts (reverse polarity
protection, inrush current limiter and tank capacitors), the driver parts (one half bridge with gate resistors, bleed- off circuits
and snubber networks per phase), the shunt for motor current measurement and the connectors for Power Supply, motor and
interfaces. For higher output current, the supply line and the motor wires must be soldered to the PCB directly, and the tank
circuit is to be enhanced by larger capacity Low-ESR capacitors.
The Power MOSFET T7, the rectifier diodes D7 - D9, the RC- filter R14 and C1 and the current limiting resistor R2 form the inrush current limiter. During startup, the supply capacitors C2, C3, C16 and C17 will be charged by the current- limiting resistor
to the input voltage. The current flow through the board’s components is low until the startup sequence in the IC is passed.
After the startup sequence the IC becomes active and delivers gate pulses to the half-bridge MOSFETs, that drive the Gate of
T7 also, and T7 enables the high- current path to the power part and the motor. In case of any failure in the gate control of
the half-bridges, T7 turns off, and the current is limited by R5. This way, most of the parts in the power circuitry are protected
against excessive currents.
6.2 Control part
The controller part consists of the E523.52 itself, the peripheral elements for the gate control outputs, the DC-DC- buck converter for powering the E523.52 and its low-side drivers and the bootstrap elements for the high-side gate drivers.
The supply voltage is regulated to the internal supply for the gate drivers (VG) of approx. 11V by the DC-DC step-down converter using the E523.52 internal switch and regulator elements. The internal supply voltages of 3.3V and 1.8V are generated by onchip LDO regulators, so the peripheral circuitry of the power supply of the E523.52 is robust, simple and uses a few parts only.
For programming the On-chip flash memory with the application software (firmware), a 2-wire JTAG interface can be used.
This interface is designed to support the external flash programmer by MAZ Brandenburg. It is recommended to use this programmer for software implementation.
Elmos Semiconductor AG
Application Note 3/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
7 Software implementation and setup
Since the E523.52 is a BLDC motor controller with a built-in 16 bit microcontroller, the operating mode and parameters for
the chosen motor must be programmed in the µC core of the E523.52. The software must be tailored to the motor in order to
choose the commutation mode, motor speed, motor start mode, over current shutdown etc. For details, see section 6 in this
document.
To program the internal microcontroller part, the board can be powered by a low-current power source of 140mA with no
motor connected. For programming (writing to the flash memory), the solder joint SJ1 must be 2-3 connected or open. After
programming the flash memory, the SJ1 solder joint has to be 1-2 connected (input pin TMODE to Ground (default setting).
After programming, the communication between an USB- connected PC and the demonstration board can be used to check
system status and to change parameters (depending on the implementation of functions) in a terminal session using the onboard USB – UART converter circuit. Note that the USB ↔ serial communication is possible only after setting up a virtual COM
port via the driver emulation in Windows ® PC’s. For other operating systems, refer to the operating system manual.
7.1 Setup of virtual COM port
1. make sure you have got administrator- level rights to the target Windows ® PC
2. run the file setup.exe from the directory drivers on the support CD to install the virtual COM Port driver for the FTDI
USB-to-RS232 interface. To be on the safe side, reboot the PC after the virtual COM port installation.
3. connect the E523.52 demonstration board via USB to the PC
4. check the device manager to determine the COM port of the E523.52 demonstration board (fig. 2). To open the device
manager in Windows ® XP or higher click the „start“- button and choose „run“. In the new window type „devmgmt.msc“
<Enter>. The following window should appear (Windows ® XP, german version):
Figure 2. Serial port device in device manager
5. install LabVIEW runtime and the LabVIEW driver set according to the LabVIEW installation information. It is not necessary to connect the target PC to the Internet during the installation process - the online- update feature should not be
used to ensure that the most compatible version of LabVIEW is used. To install the LabVIEW runtime and drivers, select
the setup tools from the LABVIEW directory on the support CD. After the installation is completed, reboot the PC.
6. copy the content of the folder “gui software” from the support- CD to a local directory on the computer’s harddisk and
run the executable 52305_gui_eonas_15_08_14.exe. Use the selection dropdown box to select the right COM port to
enable communication between the PC and the demoboard. Use the parameter table to select and change the motor
parameters. Since there is a lot of different motor types, it is necessary to tune the motor to achieve optimal regulation
characteristics.
Elmos Semiconductor AG
Application Note 4/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
Figure 3. Software window legend
7.2 Legend of the software window elements
1 communication port:
2 connect
3 update cyclic
4 set mode
5 Current mode
6 Reverse direction
7 Set Speed inc
8 Speed
9 Refresh data
10 VF curve dialogue
11 table only mode
12 tune process
13 driver status dialogue
14 manual operation
15 graphical display
16 table
17 display duration
18 File in and out
to be selected from the dropdown menu for the correct virtual COM port
start and stop of the COM port communication
sends a sequence to get status updates continuously
sends the desired operational mode to the controller when clicked
shows the actual operational mode of the controller
inverses the Set Speed value for reverse rotation.
sets the desired speed after ac/deceleration
current speed of the controller
reads back all available values of the table 16
opens the voltage/frequency table configuration for open loop
closes and disables all GUI elements for simple table control
initializes the tuning process for optimizing control
shows more information about the driver
sets speed and Scale Mult by Sliders
shows status information in a plot
the user interface of parameters that can be set, changed or displayed –
see the parameter table for details
shows the last 10 seconds. To scroll back, click the green button
select a file to write to device or choose read from device to store the table onto the PC
7.3 Parameter setting
The set of parameters that can be used to adjust or change the motor behavior depends on the motor type, desired regulation
type and rotational speed characteristic, and is very complex. Since there is a lot of 3-phase BLDC motors, it is not possible to
recommend a standard set of parameters that will fit all types of motors. For the first trials, a set of parameters for a small
BLDC made by ebmpapast is available. This set of parameters can be loaded for initial successful start. Changes in the parameters can be stored to the integrated motor controller inside the E523.05, and can be loaded from the device to the GUI to get
an overview of possible values of the motor parameters. Every demo board is checked with the ebmpapst motor at Elmos during the tests of the board, and the motor parameters are stored in the E523.05 controller.
Elmos Semiconductor AG
Application Note 5/12
QM-No.: 25AN0106E.02
AN 0106
E523.52 Motor Control Demonstration Board
Oct 19, 2015
Parameter list of the GUI- based software
Parameter
Set Mode
Legend
Sets the operation mode to 0 (idle), 1 (closed
loop), 2 (open loop) or 3 (manual
Current Motor
Motor type
Effect
Changes the motor control mode
Phase Controller KI
Setting the motor type to either blower, pump or
torque motor
User defined target speed after ac/deceleration Sets the target rotational speed
Current ac/decelerated speed reference for the Sets the reference rotational speed for graphical
speed regulator
display
Sets the number of pole pairs (for calculation purNumber of pole pairs (for calculation of rpm
pose only, does not matter when not matching the
from the e-rpm only)
actual motor pole pair count)
Acceleration in open loop mode
Sets the acceleration factor in inc/10ms
Constant applied voltage
Slope factor for BEMF compensation
Added constant voltage to compensate the
motor inertia in case of acceleration
If the current Speed Reference is higher than
Sets the rotational speed where the control mode
Start Control Speed, the controller leaves the
is changed from open loop to closed loop operaopen loop mode and enters closed loop
tion
If the current Speed Reference is lower than
Sets the rotational speed where the control mode
Stop Control Speed, the controller falls back to is chenged from closed loop to open loop operaopen loop
tion
Factor of motor acceleration from current rotational speed to target rotational speed
Factor of motor deceleration from current rotational speed to target rotational speed
Proportional part of the phase controller PI
Sets the gain of the software- based phase PI reguregulator
lator, proportional part
Factor of the integral part of the phase control- Sets the gain of the integral part of the softwareler PI regulator
based phase PI regulator
Phase Controller KI
Shift
Bias of the integral part of the phase controller Not supported
Speed Controller KP
Factor of the proportional part of the speed PI
regulator
Factor of the integral part of the speed controller PI regulator
Set Speed inc
Speed reference
Pole Pairs
Acceleration
UL Func Offset
UL Func Slope
UL Func Boost
Start Control Speed
Stop Control Speed
Acceleration up
Acceleration down
Phase Controller KP
Speed Controller KI
Speed Controller KI
Shift
Maximum Speed
Phase Shift
Phase Reference
Speed
Scale Mult
Scale Shift
Start automatically
Speedset mode
Sets the gain of the software- based PI speed regulator, proportional part
Sets the gain of the software- based PI speed regulator, integral part
Bias of the integral part of the speed controller Not supported
Rotational speed maximum
Sets the user-defined rotational speed limit
the phase of the applied waveform in by the
Phase shift between current and applied volt- Shifts
amount
of
age
(speed controller inc * Phase Shift / 4096)
Setting of the phase reference for the phase
used to create an advance angle between current
shift
and applied voltage.
Step size of Space-vector modulation timescale In manual operational mode only
Space-vector modulation amplitude
In manual operational mode only
Bias of the graphical scaling
Set Mode will be set to closed loop operational
Restart behavior in case of errors
mode, instant start after error detection (e.g.stall)
0: manual per “Set Speed”; 1: analog speed set via
the onboard potentiometer (not supported at the
Control mode of speed settings
time); 2: digital per PWM input at the C0 pin; 3:
digital bus per PWM input at the bus pin
Elmos Semiconductor AG
Application Note 6/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
8 Schematics
Figure 4. Schematic power part
Elmos Semiconductor AG
Application Note 7/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
Figure 5. Controller part
Elmos Semiconductor AG
Application Note 8/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
9 Layout
Figure 6. Top assembly
Figure 7. Bottom assembly
Elmos Semiconductor AG
Application Note 9/12
QM-No.: 25AN0106E.02
AN 0106
E523.52 Motor Control Demonstration Board
Oct 19, 2015
10 Bill of Material
Used Pos.-No.
Value
Order-No.
Supplier
Remark
Manufacturer
1
E523.52
E523.52
ELMOS
QFN48L7
ELMOS
CHIPLED_1206
160-1169-6-ND
Digikey
1206
Lite-On
TP--10_16R_24R
test point
Drill 1mm
TP--12_18R_25R4
test point
Drill 1,2mm
1
1
IC1
USBLED1, USBLED2, VBAT_
LED
TP_VBAT, TP_
VG, TP_VPP
TP_1, TP_2,
TP_3, TP9, TP_
GND
J2
X2
USB-B-MINI-5POLB
X12R
H2961DKR-ND
SL 1x36G 2,54 (broken)
Digikey
Reichelt
1
X1
X20IR
WSL 20G
Reichelt
1
R28
C9, C10, C11,
C12
ROUT
RGD1, RGD2,
RGD3
R14
D1, D2, D3, D4,
D5, D6
C1, C25, C26,
C27
CVDD
RSUP
C5, C13
CSN1, CSN2,
CSN3, CSN4,
CSN5, CSN6
RFN, RFP
RSN1, RSN2,
RSN3, RSN4,
RSN5, RSN6
L2
R22
CIN
RBST
RFP1
REN
RV1, RV2
RVRXD, RVTXD
CEN, C4, C6,
C7, C8
RG
CVCC
RGD4, RGD5,
RGD6, RGD7,
RGD8, RGD9
COUT, COUT1
CUSB1, CUSB2,
CUSB3, CUSB4,
CVG
RPP
RGH1, RGH2,
RGH3, RGL1,
RGL2, RGL3
R2
CINC, CBST1,
CBST2, CBST3
R33, R34, R35
LVG
C2, C3, C16,
C17
IC5
0R01/5W
CSS4527FT10L0CT-ND
1µ/100V
3
2
1
4
1
3
1
6
4
1
1
2
6
1
6
1
1
1
1
1
5
2
2
5
1
1
6
2
5
1
6
1
4
3
1
4
1
Hirose
div
Digikey
Mini USB jack
Pin header 12/2.54
box header 2.54mm male
str 20 pos
4527
445-1429-1-ND
Digikey
1210
TDK
1R0
541-1.00CCT-ND
Digikey
0805
Vishay
910k
RL0603K910-1
Schukat
0603
Vishay
1M0
RL0805M001-1
Schukat
0805
Vishay
TS4148
TS4148-0805
Schukat
0805
Diodes
1nF/100V
175-9288
Farnell
0805
Multicomp
1u/16V
2R2
4.7uF/100V
1276-1026-1-ND
541-2.2ACT-ND
445-5211-1-ND
Digikey
Digikey
Digikey
0805, X7R
0805
1812, X7S
Samsung
Vishay
TDK
4.7n/100V
399-8197-1-ND
Digikey
1206
Kemet
2k0
RMCF0603FT2K00CT-ND
Digikey
0603
Stackpole
4R7
RNCP0603FTD4R70CT-ND
Digikey
0603
Stackpole
8.2uH
8k2
10uF/100V
10R0
10R0
10k0
1k0
200R
XAL1510-882ME
P8.20KCCT-ND
565-2340-1-ND
P10.0CCT-ND
RMCF0603JT10R0CT-ND
RL0603K010-1
RMCF0603FT1K00CT-ND
P200HCT-ND
Coilcraft
Digikey
Digikey
Digikey
Digikey
Schukat
Digikey
Digikey
XAL1510-822
0805
140CLH-0810
0805
0603
0603
0603
0603
Coilcraft
Panasonic
Chemicon
Panasonic
Stackpole
Vishay
Stackpole
Panasonic
10n/100V
490-1652-1-ND
Digikey
0805
Murata
18k0
22uF/6.3V
169-2519
1276-3146-1-ND
Farnell
Digikey
0603
1206
Vishay
Samsung
22R
RMCF0603FT22R0CT-ND
Digikey
0603
Stackpole
22uF/16V
1276-3395-1-ND
Digikey
1210
Samsung
470nF/16V
1276-1062-1-ND
Digikey
0603
Samsung
51k0
P51KGDKR-ND
Digikey
0603
Panasonic
100R
P100HCT-ND
Digikey
0603
Panasonic
100R
RHM100BECT-ND
Digikey
1210
Rohm Semi
100n/100V
445-1418-1-ND
Digikey
0805
TDK
150k
470uH/200mA
RHM150KARCT-ND
LPS6225-474MRB
Digikey
Coilcraft
0805
LPS6225
Rohm Semi
Coilcraft
1000uF/100V
1189-1019-ND
Digikey
Radial 18 x 42, RM 7.5
Rubycon
ADUM1301A
ADUM1301ARWZ-RLCT-ND
Digikey
ADUM1301A
Analog Devices
Elmos Semiconductor AG
Application Note 10/12
div
Stackpole
QM-No.: 25AN0106E.02
AN 0106
E523.52 Motor Control Demonstration Board
Oct 19, 2015
Used Pos.-No.
Value
Order-No.
Supplier
Remark
Manufacturer
1
1
Enable
FT232RL
SL 1x36G 2,54 (broken)
768-1007-1-ND
Reichelt
Digikey
Pin Header 2/2.54
FT232RL
div
FTDI
MUH1PB
625-MUH1PB-N3
Mouser
MUH1PB
Vishay
IRFS4610PBF
IRFS4610PBF
Farnell
IRFS4610PBF
Int. Rectifier
100k
10k lin
RL0603K100-1
PTV09A-4015U-B103-ND
Schukat
Digikey
optional
8 * 10 TH
Vishay
Bourns
7
7
1
1
JP1
IC4
D7, D8, D9,
DBST1, DBST2,
DBST3, DVG
T1, T2, T3, T4,
T5, T6, T7
R9
SPEED
Elmos Semiconductor AG
Application Note 11/12
QM-No.: 25AN0106E.02
E523.52 Motor Control Demonstration Board
AN 0106
Oct 19, 2015
Usage Restrictions
Elmos Semiconductor AG provide the E523.52 Demonstration Board simply and solely for IC evaluation purposes in laboratory.
The Kit or any part of the Kit must not be used for other purposes or within non laboratory environments. Especially the use or
the integration in production systems, appliances or other installations is prohibited.
The pcb´s are delivered to customer are for the temporary purpose of testing, evaluation and development of the Elmos IC´s only.
Elmos will not assume any liability for additional applications of the pcb.
Disclaimer
Elmos Semiconductor AG shall not be liable for any damages arising out of defects resulting from (1) delivered hardware or software, (2) non observance of instructions contained in this document, or (3) misuse, abuse, use under abnormal conditions or
alteration by anyone other than Elmos Semiconductor AG. To the extend permitted by law Elmos Semiconductor AG hereby expressively disclaims and user expressively waives any and all warranties of merchantability and of fitness for a particular purpose,
statutory warranty of non-infringement and any other warranty or product liability that may arise by reason of usage of trade,
custom or course of dealing.
Elmos Semiconductor AG – Headquarters
Heinrich-Hertz-Str. 1 | 44227 Dortmund | Germany
Phone + 49 (0) 231 - 75 49 - 100 | Fax + 49 (0) 231 - 75 49 - 159
[email protected] | www.elmos.com
Note Elmos Semiconductor AG (below Elmos) reserves the right to make changes to the product contained in this publication without notice. Elmos assumes no responsibility for the use of any circuits described herein, conveys no licence under any patent or other right, and makes no representation that the circuits are free of patent infringement. While the information in this publication has been checked,
no responsibility, however, is assumed for inaccuracies. Elmos does not recommend the use of any of its products in life support applications where the failure or malfunction of the product can reasonably be
expected to cause failure of a life-support system or to significantly affect its safety or effectiveness. Products are not authorized for use in such applications.
Copyright © 2015 Elmos Reproduction, in part or whole, without the prior written consent of Elmos, is prohibited.
Elmos Semiconductor AG
Application Note 12/12
QM-No.: 25AN0106E.02