3PMPSRM

Three-Phase Micro Power Stage
Reference Manual
Devices Supported:
MCF5235
MCF5234
MCF5233
MCF5232
MEMC3PMBLDCRM
Rev. 0.1
11/2004
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MEMC3PMBLDCRM
Rev. 0.1
11/2004
Contents
Paragraph
Number
Title
Page
Number
Chapter 1
Introduction and Setup
1.1
1.2
1.3
About this Manual ...............................................................................................................1

Warnings ..............................................................................................................................3
Setup Guide..........................................................................................................................3
Chapter 2
Operational Description
2.1
2.2
Electrical Characteristics .....................................................................................................2

Pittman Motor Characteristics .............................................................................................2
Chapter 3
Pin Descriptions
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
Signal Descriptions ..............................................................................................................2

EVM Motor Board Power Connectors J2 and J3 ............................................................3
The 3-ph. Micro Power Stage 40-Pin Ribbon J1 Connector ...........................................3
The 3-ph. Micro Power Stage J4 Connector....................................................................4
Motor Power Connector...................................................................................................5
Motor Hall Sensor Connector ..........................................................................................5
Chapter 4
Schematics and Parts List
4.1
4.2
Schematics ...........................................................................................................................1
Parts List ..............................................................................................................................7
Chapter 5
Design Considerations
5.1
5.2
5.3
3-Phase Driver .....................................................................................................................1

Bus Voltage and Current Feedback .....................................................................................2
Back EMF Signals ...............................................................................................................3
Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

iii
Contents
Paragraph
Number
Title
Page
Number

iv
Figures
Figure
Number
1-1
1-2
1-3
1-1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-1
1-2
1-3
Title
Page
Number
System Configurations.............................................................................................................. 1-2

3-Ph. Micro Power Stage .......................................................................................................... 1-2
3-ph. Micro Power Stage Setup ................................................................................................ 1-4
40-Pin Input Connector J1 ........................................................................................................ 1-2
3-ph. Micro Power Stage Power Connection............................................................................ 1-1
3-ph. Micro Power Stage 3.3V Analog Voltage Generation .................................................... 1-2
UNI-3 Connector ...................................................................................................................... 1-2
Motor Connector....................................................................................................................... 1-3
Phase Predrivers........................................................................................................................ 1-4
Power Modules ......................................................................................................................... 1-5
Bus Current Feedback............................................................................................................... 1-5
Back EMF Signals .................................................................................................................... 1-6
Dc Bus Voltage Sensing ........................................................................................................... 1-6
Brushless dc Motor Connections Schematic View.............................................................. 1-7
Phase A Output ......................................................................................................................... 1-1
Bus Feedback ............................................................................................................................ 1-3
Phase C Back EMF Feedback................................................................................................... 1-3

Figures
Figure
Number
Title
Page
Number

vi
Tables
Table
Number
1-1
1-2
1-1
1-2
1-3
1-1
Title
Page
Number
Electrical Characteristics .......................................................................................................... 1-2

Pittman Motor Characteristics .................................................................................................. 1-2
The J1 Connector Signal Descriptions...................................................................................... 1-3
The J4 Connector Signal Descriptions...................................................................................... 1-5
Motor Hall Sensor Connector ................................................................................................... 1-5
Parts List ................................................................................................................................... 1-7

vii
Tables
Table
Number
Title
Page
Number

viii
Chapter 1
Introduction and Setup
Motorolas Three-phase Micro Power Stage is a 12-volt, 3-amp power stage that is an integral part of
Motorolas embedded motion control series of development tools. It is supplied in a kit, along with a small
brushless dc motor with Hall sensors and a 40-pin ribbon cable. In combination with one of the embedded
motion control series control or evaluation boards, it provides a ready-made software development
platform for small brushless dc motors among others. The enclosed motor is capable of being controlled
with Hall sensors or with sensorless techniques. An illustration of the systems configurations is shown in
Figure 1-1. Figure 1-2 is an illustration of the board.
1.1
About this Manual
Key items can be found in the following locations in this manual:

Setup instructions are found in Section 1.4, Setup Guide.
Schematics are found in Section 4.1, Schematics.
Pin assignments are shown in Figure 3-1, and a pin-by-pin description is contained in Section 3.1,
Signal Descriptions.
For those interested in the reference design aspects of the boards circuitry, a description is
provided in Chapter 5, Design Considerations.
Controller
Board
MMDS08
Controller
Board
Workstation
Workstation
3-PH. Micro
Power Stage
3-PH. Micro
Power Stage
Motor
Optional Feedback
Motor
Optional Feedback
a) MC68HC08 Microcontroller
b) M523xEVB, MPC555, 56800/E Hybrid Controller,

S12Exx Microcontroller
Figure 1-1. System Configurations
Three-Phase Micro Power Stage Reference Manual, Rev. 2

1-1
Figure 1-2. Three-Phase Micro Power Stage
1.2
Terms and Acronyms
BEMF
BLDC
Hall sensor
PWM
UNI-3
1.3
Back electro-motive force (EMF)

Brushless dc
Sensor whose output changes based on changes in magnetic flux. Used to measure
motor position.
Pulse width modulation
User-to-Network Interface
Warnings
The Three-Phase Micro Power Stage includes power components that can reach temperatures hot enough
to cause burns. To facilitate safe operation, 12-volt input power should come from a dc laboratory power
supply that is current limited to no more than 4 amps.
The user should be aware of the following:
Before moving scope probes, making connections, etc., it is generally advisable to power down the
12 Vdc supply.
Operation in lab setups that have grounded tables and/or chairs should be avoided.
Wearing safety glasses, avoiding ties and jewelry, using shields, and operation by personnel trained
in power electronics lab techniques are also advisable.
1.4
Setup Guide
Setup and connections for the Three-Phase Micro Power Stage are straightforward. The Three-Phase
Micro Power Stage connects to a Motorola embedded motion control series control board via a 40-pin
ribbon cable. The motors power leads plug into output connector J4, and its Hall sensors plug into the
control boards Hall sensor/encoder input connector. Figure 1-3 depicts a completed setup.

1-2
Setup Guide
Follow these steps to set up the board:

1. Plug one end of the 40-pin ribbon cable that is supplied with Motorola embedded motion control
series control boards into input connector J1, located at the edge of the board. The other end of this
cable goes to the control boards 40-pin output connector.
2. Plug the free end of the cable connected to input connector J1 into the control boards 40-pin
connector.
3. Connect a 12 Vdc power supply to the power jack J2 labeled POWER. Then either connect
outgoing cable from the Three-Phase Micro Power Stage labeled +12Vdc to the controller
board jack or use separete power supply to power the controller board. Those connectors are
located in a corner of the Three-Phase Micro Power Stage.
4. If protection features are desired, set the control boards overcurrent detection comparator to
2.25 V. This value limits dc bus current to 3 amps.
5. Apply power to the Three-Phase Micro Power Stage. The green power-on LED is lit when power
is present. Note that the Three-Phase Micro Power Stage doesnt power the control board, so the
control board must be powered by means of this board outgoing +12 Vdc cable and/or an external
12 Vdc power supply to run a complete system.
Motor
40-Pin
Ribbon Cable
J4
J1
Control Board
3-ph. Micro
Power Stage
12-Volt
Motor Supply
Figure 1-3. Three-Phase Micro Power Stage Setup

1-3
THIS PAGE INTENTIONALLY LEFT BLANK

1-4
Chapter 2
Operational Description
Motorolas embedded motion control series Three-Phase Micro Power Stage is a 12-volt, 3-amp,
surface-mount power stage that is shipped with a Pittman (Size 23) brushless dc (BLDC) motor. In
combination with one of the embedded motion control series control boards, it provides a software
development platform that allows algorithms to be written and tested without the need to design and build
a power stage. It supports algorithms that use Hall sensors and back EMF (electromotive force) signals for
sensorless control.
The Three-Phase Micro Power Stage does not have any overcurrent protection that is independent of the
control board, so some care in its setup and use is required if a lower impedance motor is used. With the
motor that is supplied in the kit, the power output stage will withstand a full-stall condition without the
need for overcurrent protection. Current measuring circuitry is set up for 8.25 amps full scale. In a 25C
ambient operation at up to 3A continuous RMS output current is within the boards thermal limits.
Input connections are made via 40-pin ribbon cable connector J1. Pin assignments for the input connector
are shown in Figure 3-1. Power connections to the motor are made on output connector J4. Phase A, B,
and C are labeled on the board. Power requirements are met with a single external 12 V, 4 A power supply.
Two connectors, labeled J2 and J3, are provided for the 12 Vdc power supply. While the former is used for
12 Vdc input, the latter is used for 12 Vdc output for powering the controller board. Both are located in a
corner of the board.
A summary of the information needed to use the Three-Phase Micro Power Stage follows. For design
information, see Chapter 4, Schematics and Parts List.
2.1
Electrical Characteristics
The electrical characteristics in Table 2-1 apply to operation at 25C and a 12-Vdc power supply voltage.
Table 2-1. Electrical Characteristics
Characteristic
Symbol
Min
Typ
Max
Units
Power Supply Voltage
Vdc
10
12
16
Quiescent Current
ICC
18
mA
Min Logic 1 Input Voltage
VIH
2.4
Max Logic 0 Input Voltage
VIL
0.8
Input Resistance
RIn
10
Analog Output Range
VOut
3.3
Bus Current Sense Voltage
ISense
200
mV/A
Bus Voltage Sense Voltage
VBus
202
mV/V
Power MOSFET On Resistance (Top Switch)
RDS(On)
60
70
Power MOSFET On Resistance (Bottom Switch)
RDS(On)
170
200
ID
IDM
15
Continous Output Current

Pulsed Output Current

2-1
Table 2-1. Electrical Characteristics (continued)

Characteristic
Total Power Dissipation
Deadtime
2.2
Symbol
Min
Typ
Max
Units
Pdiss
toff
400
ns
Pittman Motor Characteristics
The motor characteristics in Table 2-2 apply to operation at 25C.

Table 2-2. Pittman (Size 23) BLDC Motor Characteristics
Characteristic
Reference Windind Voltage
Symbol
Min
Typ
Max
Units
Vt
9.6
12000
RPM
0.007
Nm/A
1.082
oz-in/A
Speed @ Vt
Torque Constant
Kt
Voltage Constant
Ke
0.8
V/kRPM
Terminal Resistance
Rt
0.13
0.18
Winding Inductance
2.9
mH
Continuous Current
Ics
9.96
No Load Current @ Vt
Ips
1.20
Number of Poles
Jm
10
80
14
176
Temperature Rating

2-2
Chapter 3
Pin Descriptions
Inputs and outputs are located on four connectors:
Four connectors that are located on the Three-Phase Micro Power Stage board (UNI-3, Motor
power, Power input, Power output).
Two connectors are associated with the motor (Power, Hall sensors).
Pin descriptions for each of these connectors and the test points are identified in the following information.
Pin assignments for the UNI-3 connectors are shown in Figure 3-1. Signal descriptions are provided in
Table 3-1 through Table 3-3.

3-1
J1
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BEMF_sense_C
BEMF_sense_B
BEMF_sense_A
Shielding
PWM_AT
PWM_AB
PWM_BT
PWM_BB
PWM_CT
PWM_CB
GND
GNDA
V_sense_DCB
Shielding
I_sense_DCB
V_sense_DCB
GNDA
GNDA
Shielding
BEMF_sense_B
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
Shielding
Shielding
Shielding
Shielding
Shielding
GND
GNDA
I_sense_DCB
Shielding
BEMF_sense_A
BEMF_sense_C
Physical View
GND
GND
PWM_CB
Shielding
PWM_CT
Shielding
PWM_BB
Shielding
PWM_BT
Shielding
PWM_AB
Shielding
PWM_AT
CON/40
Schematic View
Figure 3-1. 40-Pin Input Connector J1
3.1
Signal Descriptions
Pin descriptions are identified in this subsection.

3-2
Signal Descriptions
3.1.1
EVM Motor Board Power Connectors J2 and J3
Two connectors, labeled J2 and J3, are provided for the 12-volt power supply. While the former is used for
power supply input, the latter is used for power supply output for the controller board powering. J2 and J3
are located in a corner of the board. The J2 connector is a 2.1-mm power jack for plug-in type 12 V power
supply connections. The J3 connector is used as 12 V output which will power the controller board. Power
is supplied to the J2 one. The power supply should be able to deliver at least 3 amps.
3.1.2
The Three-Phase Micro Power Stage 40-Pin Ribbon J1 Connector
Signal inputs are grouped together on a 40-pin ribbon cable connector J1, located at the edge of the board.
Pin assignments are shown in Figure 3-1. Pin descriptions are listed in Table 3-1.
Table 3-1. The J1 Connector Signal Descriptions (Sheet 1 of 2)
Pin
No.
Signal Name
Description
PWM_AT
The gate drive signal for the top half-bridge of phase A. A logic high at input connector J1
turns on the phase A top switch.
Shielding
Connected to a shield wire in the ribbon cable, and ground on the board.
PWM_AB
The gate drive signal for the bottom half-bridge of phase A. A logic high at input connector
J1 turns on the phase A bottom switch.
Shielding
PWM_BT
The gate drive signal for the top half-bridge of phase B. A logic high at input connector J1
turns on the phase B top switch.
Shielding
PWM_BB
The gate drive signal for the bottom half-bridge of phase B. A logic high at input connector
J1 turns on the phase B bottom switch.
Shielding
PWM_CT
The gate drive signal for the top half-bridge of phase C. A logic high at input connector J1
turns on the phase C top switch.
10
Shielding
11
PWM_CB
The gate drive signal for the bottom half-bridge of phase C. A logic high at input connector
J1 turns on the phase C bottom switch.
12
GND
Digital power supply ground
13
GND
Digital power supply ground, redundant connection
14
No connection
15
No connection
16
No connection
17
GNDA
Analog power supply ground
18
GNDA
Analog power supply ground, redundant connection
19
No connection
20
No connection

3-3
Table 3-1. The J1 Connector Signal Descriptions (Sheet 2 of 2)

Pin
No.
Signal Name
Description
21
V_sense_DCB
Analog sense signal that measures dc bus voltage. It is scaled at 0.206 V per volt of dc bus
voltage.
22
I_sense_DCB
Analog sense signal that measures dc bus current. It is scaled at 0.412 V per amp of dc
bus current.
23
No connection
24
No connection
25
No connection
26
No connection
27
No connection
28
Shielding
29
No connection
30
No connection
31
No connection
32
No connection
33
No connection
34
No connection
35
No connection
36
No connection
37
Shielding
38
BEMF_sense_A
Analog sense signal that measures phase A back EMF. It is scaled at 0.206 V per volt of dc
bus voltage.
39
BEMF_sense_B
Analog sense signal that measures phase B back EMF. It is scaled at 0.206 V per volt of dc
bus voltage.
40
BEMF_sense_C
Analog sense signal that measures phase C back EMF. It is scaled at 0.206 V per volt of
dc bus voltage.
3.1.3
The Three Phase Micro Power Stage J4 Connector
Power outputs to the motor are located on connector J4, labeled Motor. Pin assignments are described
in Table 3-2.

3-4
Signal Descriptions
Table 3-2. The J4 Connector Signal Descriptions

Pin
No.
Signal Name
Phase_A
Supplies power to motor phase A. The motor wire color is brown.
Phase_B
Supplies power to motor phase B. The motor wire color is red.
Phase_C
Supplies power to motor phase C. The motor wire color is orange.
3.1.4
Description
Motor Power Connector
Motor power connections are grouped into a connector that plugs into the Three Phase Micro Power
Stages motor connector, J4. Pin assignments are identical to the Three Phase Micro Power Stage J4 output
connector.
3.1.5
Motor Hall Sensor Connector
Hall sensor connections are made with a connector that plugs into the control boards Hall sensor/encoder
connector. Pin assignments are described in Table 3-3.
Table 3-3. Motor Hall Sensor Connector
Pin
No.
Signal Name
+5V
Supplies power from the control board to the Hall sensors. The wire color is violet.
GND
The Hall sensor ground. The wire color is black.
Hall A
Open collector output from Hall sensor A. The wire color is gray.
Hall B
Open collector output from Hall sensor B. The wire color is blue.
Hall C
Open collector output from Hall sensor C. The wire color is white.
Description

3-5

3-6
Chapter 4
Schematics and Parts List
A set of schematics for the Three-Phase Micro Power Stage appears in Figure 4-1 through Figure 4-10.
Power connectors are shown in Figure 4-1. Figure 4-2 represents 3.3 V generation for analog sensing.
Figure 4-3 shows UNI-3 connector and Figure 4-4 shows three-phase motor connector. The phase
pre-drivers are shown in Figure 4-5, power modules appears in Figure 4-6. Bus current feedback is shown
in Figure 4-7. Back EMF signals appear in Figure 4-8. The brushless dc motor is shown in Figure 4-10.
Unless otherwise specified, resistor values are in ohms, resistors are specified as 1/8 watt 5%, and
interrupted lines coded with the same letters are electrically connected.
4.1
Schematics
The schematics for the evaluation motor board appear below and on the following pages.
+12V
D8
MBRA340T3
+12V
-V
1
+V -V
+V
J2
Power IN +12V
GND
DCB_Neg
GND
+V 1
2
-V
3
-V
DCB_Pos
R34
2.4k
Power OUT +12V
-V
+12V
Green LED
D7
Power +12V
J3
GND
Figure 4-1. Three-Phase Micro Power Stage Power Connection
Figure 4-2. Three-Phase Micro Power Stage 3.3 V Analog Voltage Generation

4-1
J1
BEMF_sense_A
BEMF_sense_B
BEMF_sense_C
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GNDA
I_sense_DCB
V_sense_DCB
GNDA
PWM_CB
PWM_CT
PWM_BB
PWM_BT
PWM_AB
PWM_AT
BEMF_sense_C
BEMF_sense_B
BEMF_sense_A
Sheilding
Zero_cross_C
Zero_cross_B
Zero_cross_A
Serial_Con
Brake_control
Sheilding
Temp_sense
I_sense_C
I_sense_B
I_sense_A
I_sense_DCB
V_sense_DCB_3.3
+12V
PWM_CB
Sheilding
PWM_CT
Sheilding
PWM_BB
Sheilding
PWM_BT
Sheilding
PWM_AB
Sheilding
PWM_AT
CON/40
GND
Figure 4-3. UNI-3 Connector

3-ph. Motor
Phase_A
Phase_B
Phase_C
1
2
3
J4
Figure 4-4. Three-Phase Motor Connector

4-2
Schematics
R29
10k
U4
MAX628CSA
6
DCB_Pos
VDD
PWM_AT
C13
C14
100nF/25V
PWM_AB
10uF/16V
2 INA
OUTA
4 INB
OUTB
Gate_AT
Gate_AB
GND
R32
10k
DCB_Neg
Phase A Predriver
R33
10k
U6
MAX628CSA
6
DCB_Pos
VDD
PWM_BT
C15
C16
100nF/25V
PWM_BB
10uF/16V
2 INA
OUTA
4 INB
OUTB
Gate_BT
Gate_BB
R35
GND
10k
DCB_Neg
Phase B Predriver
R36
10k
U7
MAX628CSA
6
DCB_Pos
VDD
PWM_CT
C17
10uF/16V
C18
100nF/25V
PWM_CB
2 INA
OUTA
4 INB
OUTB
Gate_CT
Gate_CB
R37
10k
GND
DCB_Neg
Phase C Predriver
Figure 4-5. Phase Predrivers

4-3
DCB_Neg
C1
330uF/35V
C3
330uF/35V
C2
330uF/35V
C4
100nF/25V
2
0.051-1%
R13
330
D4
MBRM140T3
R7
R2
100
4
GNDA
R18
390
330
330
D5
MBRM140T3
R9
R4
100
R19
100k-1%
R10
100
R25
33k-1%
R21
100k-1%
+3.3V_A
R14
U1A
GNDA
Gate_CB
Phase_B
Gate_CT
GNDA
330
@ +/- Imax
330
D6
MBRM140T3
R11
MC33502/SO-8
U1B
R5
100
4
R12
100
Driver for Phase C
MBRM140T3
D3
R6
I_sense_DCB
1.65V +/- 1.65V
MMDF2C03HD/SO-8
Q2-1
Q2-2
MMDF2C03HD/SO-8
MC33502/SO-8
C6
100nF/6.3V
GNDA
100k-1%
Figure 4-7. Bus Current Feedback
GNDA
1.65V ref
20k-1%
20k-1%
Driver for Phase B
MBRM140T3
D2
R3
Figure 4-6. Power Modules
R16
R20
Gate_BB
Phase_A
Gate_BT
MMDF2C03HD/SO-8
U2
LM285M/SO-8
C8
100nF/6.3V
@ +/- Imax
I_sense_DCB1
I_sense_DCB2
100
Q1-1
Q1-2
MMDF2C03HD/SO-8
Vref = 1.24 (1 + R25 / R21)
+3.3V_A
I_sense_DCB2
I_sense_DCB1
R8
Driver for Phase A
MBRM140T3
D1
delta = +/-330 mV
Gate_AB
Gate_AT
330
5
7
3
6
8
1
R1
8
4
4
8
5
7
3
6
8
1
6
8
3
5
7
DCB_Pos
Phase_C
MMDF2C03HD/SO-8
Q3-1
Q3-2
MMDF2C03HD/SO-8
Schematics
Phase_A
Phase_B
max. 16.3V
Phase_C
max. 16.3V
max. 16.3V
R22
13k-1%
R23
13k-1%
R24
13k-1%
3.30V @ 16.3V
3.30V @ 16.3V
3.30V @ 16.3V
BEMF_sense_A
BEMF_sense_B
BEMF_sense_C
R26
3.3k-1%
R27
3.3k-1%
DCB_Neg
R28
3.3k-1%
DCB_Neg
BEMF Sensing Phase A
DCB_Neg
BEMF Sensing Phase B
BEMF Sensing Phase C
Figure 4-8. Back EMF Signals

DCB_Pos
R15
13k-1%
3.30V @ 16.3V
V_sense_DCB
R17
3.3k-1%
DCB_Neg
Figure 4-9. Dc Bus Voltage Sensing

4-5
Motorola
Embedded Motion Control
Series
Evaluation Module
Motorola
Embedded Motion Control
Series
3-ph. Micro Power Stage
+
+ 12 Vdc
+ 12 Vdc
+ 12 Vdc
J3
40-Pin
Ribbon Cable
J2
J1
J4
Phase_C
Phase_B
Phase_A
Orange
Red
Brushless
Motor
Brown
Hall/Encoder
Connector
1
HALL C (White)
HALL B (Blue)
HALL A (Gray)
GND (Black)
+5V (Violet)
Figure 4-10. Brushless dc Motor Connections Schematic View
4.2
Parts List
The Three-Phase Micro Power Stages parts content is described in the following parts list.
Table 4-1. Parts List
Qty.
Reference
Part Value
330 F/35 V
Description
Multicomp
Mfg. Part No.
C1, C2, C3
C4, C9, C14, C16, C18 100 nF/25 V
Ceramic capacitor, 0805, AVX

100 nF
08055G104ZAT1A
C6, C8, C11
100 nF/6.3 V
Ceramic capacitor, 0805, AVX

100 nF
08055G104ZAT1A
C10, C12, C13, C15,

C17
10 F/16 V
SMD Aluminiun
Electrolytic Capacitor, 4
mm, 10 F/16 V
Panasonic
EEVFC1C100R
D1, D2, D3, D4, D5, D6 MBRM140T3
Shottky Rectifiers 40 V,
1A
ON
Semiconductor
MBRM140T3
D7
LED_QT_PLCC2_CA
EZK
KA3528LSGT
LED Green
Electrolytic Capacitor
10mm, 330 F/35 V
Mfg.
921-373

4-6
Parts List
Table 4-1. Parts List (continued)

Qty.
Reference
Part Value
Description
Mfg.
Mfg. Part No.
D8
MBRA340T3
Voltage Antireverse Avoid ON

Semiconductor
MBRA340T3
J1
CON/40
Header 40 pins
breakaway connector
Fischer Elektronik ASLG40G
J2
Power Jack
Power Jack type

connector 2.5 mm
CUI Stack
PJ-002A
J3
Header with Lock
2 Way Header with Lock
Molex
22-29-2021
J4
Header with Lock
3 Way Header with Lock
Molex
39-26-3030 (mating with

Molex 26-11-2033)
Q1, Q2, Q3
MMDF2C03HD
P+N MOSFET transistor, ON

30 V, 6 A
Semiconductor
MMDF2C03HD
R1, R3, R6, R7, R9,

R11
330
Resistor 330 , 5%, 0805 Multicomp
MC 0.1W 0805 5% 330R
R2, R4, R5, R8, R10,

R12
100
MC 0.1W 0805 5% 100R
R13
0.040-1%
Shunt Resistor
Vishay
LVR-3 0.040 1%
R14, R19, R21
100k-1%
Resistor 100 k, 1%,

0805
Multicomp
MC 0.1W 0805 1% 100K
R15, R22, R23, R24
13k-1%
Resistor 13 k, 1%, 0805 Multicomp
MC 0.1W 0805 1% 13K
R16, R18
20k-1%
MC 0.1W 0805 1% 20K
R17, R26, R27, R28
3.3k-1%
Resistor 3.3 k, 1%, 0805 Multicomp
MC 0.1W 0805 1% 3K3
R20
390
MC 0.1W 0805 5% 390R
R25
33k-1%
MC 0.1W 0805 1% 33K
R29, R32, R33, R35,

R36, R37
10k
MC 0.1W 0805 5% 10K
R30
390-1%
MC 0.1W 0805 1% 390R
R31
240-1%
MC 0.1W 0805 1% 240R
R34
2.4k-1%
Resistor 2.4 k, 1%, 0805 Multicomp
MC 0.1W 0805 5% 2K4
U1
MC33502/SO-8
Operational Amplifier
ON
Semiconductor
MC33502/SO-8
U2
LM285M/SO-8
Adujstable Voltage
Reference
National
Semiconductor
LM285M
U4, U6, U7
MAX628CSA
MOSFET pre-driver
Maxim
MAX4428CSA
U5
LM317LD
Linear Voltage Regulator
ON
Semiconductor
LM317LD

4-7

4-8
Chapter 5
Design Considerations
From a systems point of view, the Three-Phase Micro Power Stage kit fits into an architecture that is
designed for code development. In addition to the hardware that is needed to run a motor, a variety of
feedback signals that facilitate control algorithm development are provided.
The Three-Phase Micro Power Stages power output stage is a complementary MOS field effect transistor
(MOSFET) 3-phase bridge that is capable of supplying and sensing 4 amps of continuous current.
Feedback signals include bus voltage, bus current, and back EMF (electromotive force). Descriptions of
each of these blocks are contained in Section 5.1, 3-Phase Driver, Section 5.2, Bus Voltage and Current
Feedback, and Section 5.3, Back EMF Signals.
5.1
3-Phase Driver
The output stage is configured as a 3-phase driver with complementary MOSFET output transistors. It is
simplified considerably by dual integrated gate drivers that each have one inverting and one non-inverting
driver. A simplified schematic that shows one phase is illustrated in Figure 5-1.
R1
MAX628CSA
100
D1
VDD
PWM_AT
2 INA
OUTA
PWM_AB
4 INB
OUTB
MMDF2C03HD/SO-8
Q1-2
MBRM140T3
U8
R2
10k
R38
330
DCB_Pos
GND
2
R7
330
R8
100
10k
Q1-1
D4
R39
MBRM140T3
Phase_A
MMDF2C03HD/SO-8
DCB_Neg
Figure 5-1. Phase A Output
At the input, weak pulldown resistors, R38 and R39, set a logic low in the absence of a signal. Open input
pulldown is important, since it is desirable to keep the power transistors off in case of either a broken
connection or absence of power on the control board. Gate drive is supplied by a Maxim MAX628CSA,
which has a minimum logic 1 input voltage of 2.4 volts and maximum logic 0 input voltage of 0.8 volts.
The Three-Phase Micro Power Stage will, therefore, accept inputs for either 3.3 or 5 volt logic.
Under-voltage lockout is not included in the gate drive. If this feature is desired, the control boards
under-voltage detection comparator can be set for 1.24 volts.
One of the more important design decisions in a motor drive is selection of gate drive impedance for the
output transistors. In Figure 5-1, resistors R1, R2, and diode D1 determine gate drive impedance for the
lower half-bridge transistor. A similar network is used on the upper half-bridge. These networks set
turn-on gate drive impedance at approximately 430 and turn-off gate drive impedance at approximately
100 . These values produce transition times of approximately 60 ns.
Transition times of this length represent a carefully weighed compromise between power dissipation and
noise generation. Generally speaking, transition times longer than 250 ns tend to get power hungry at
5-1
non-audible PWM rates; and transition times under 50 ns create di/dts so large that proper operation is
difficult to achieve. The Three-Phase Micro Power Stage is designed with switching times at the lower end
of this range to minimize power dissipation.
5.2
Bus Voltage and Current Feedback
Feedback signals proportional to bus voltage and bus current are provided by the circuitry shown in
Figure 5-2. Bus voltage is scaled down by a voltage divider consisting of R15 and R17. The values are
chosen such that a 16-volt maximum bus voltage corresponds to a 3.3 volt maximum analog-to-digital
(A/D) input. Bus current is sampled by resistor R13 in Figure 4-6 and amplified by the circuit in
Figure 5-2. This circuit provides a voltage output suitable for sampling with A/D inputs. An MC33502 is
used for the differential amplifier. The gain is given by:
A = R14 / R16
The output voltage is shifted up by 1.65 V, to accommodate both positive and negative current swings. A
209 mV voltage drop across the shunt resistor corresponds to a measured current range of 8.25 amps.
Note that the Three-Phase Micro Power Stage measures, but does not limit, current. Current limiting is
performed on the control board, where a 2.25 volt setting for the overcurrent detection comparator
produces a 3.0 amp current limit.
R14
I_sense_DCB2
R18
2
3
12.7k-1%
R16
I_sense_DCB1
12.7k-1%
100k-1%
I_sense_DCB
U1A
MC33502/SO-8
R19
100k-1%
DCB_Pos
R20
C8
100nF/6.3V
R15
12.7k-1%
390
R21
100k-1%
+3.3V_A
GNDA
U2
LM285M/SO-8
GNDA
V_sense_DCB
R25
33.2k-1%
R17
3.3k-1%
DCB_Neg
Figure 5-2. Bus Feedback
5.3
Back EMF Signals
Back EMF and zero crossing signals are included to support sensorless algorithms for brushless DC
motors. Referring to Figure 5-3, which shows circuitry for phase C, the raw phase voltage is scaled down
by a voltage divider consisting of R24 and R28. One output from this divider produces back EMF sense
voltage BEMF_sense_C. Resistor values are chosen such that a 16 volt maximum phase voltage
corresponds to a 3.3 volt maximum A/D input.

5-2
Back EMF Signals
Phase_C
R24
12.7k-1%
BEMF_sense_C
R28
3.3k-1%
DCB_Neg
Figure 5-3. Phase C Back EMF Feedback

5-3

5-4

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Three-Phase Micro Power Stage

How to Reach Us:

Information in this document is provided solely to enable system and

Freescale and the Freescale logo are trademarks of Freescale

About this Manual ...............................................................................................................1

Electrical Characteristics .....................................................................................................2

Signal Descriptions ..............................................................................................................2

3-Phase Driver .....................................................................................................................1

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

System Configurations.............................................................................................................. 1-2

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

Electrical Characteristics .......................................................................................................... 1-2

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

Three-Phase Micro Power Stage Reference Manual, Rev. 0.1

About this Manual

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

b) M523xEVB, MPC555, 56800/E Hybrid Controller,

Figure 1-1. System Configurations

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Figure 1-2. Three-Phase Micro Power Stage

Terms and Acronyms

Back electro-motive force (EMF)

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Follow these steps to set up the board:

Figure 1-3. Three-Phase Micro Power Stage Setup

Three-Phase Micro Power Stage Reference Manual, Rev. 2

THIS PAGE INTENTIONALLY LEFT BLANK

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Power Supply Voltage

Min Logic 1 Input Voltage

Max Logic 0 Input Voltage

Analog Output Range

Bus Current Sense Voltage

Bus Voltage Sense Voltage

Power MOSFET On Resistance (Top Switch)

Power MOSFET On Resistance (Bottom Switch)

Continous Output Current

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Table 2-1. Electrical Characteristics (continued)

Pittman Motor Characteristics

The motor characteristics in Table 2-2 apply to operation at 25C.

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Figure 3-1. 40-Pin Input Connector J1

Pin descriptions are identified in this subsection.

Three-Phase Micro Power Stage Reference Manual, Rev. 2

EVM Motor Board Power Connectors J2 and J3

The Three-Phase Micro Power Stage 40-Pin Ribbon J1 Connector

Digital power supply ground

Digital power supply ground, redundant connection

Analog power supply ground

Analog power supply ground, redundant connection

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Table 3-1. The J1 Connector Signal Descriptions (Sheet 2 of 2)

The Three Phase Micro Power Stage J4 Connector

Three-Phase Micro Power Stage Reference Manual, Rev. 2

Table 3-2. The J4 Connector Signal Descriptions

Supplies power to motor phase A. The motor wire color is brown.

Supplies power to motor phase B. The motor wire color is red.

Supplies power to motor phase C. The motor wire color is orange.

Motor Power Connector

Motor Hall Sensor Connector