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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


Freescale Semiconductor

iii

Contents
Paragraph
Number

Title

Page
Number

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


iv

Freescale Semiconductor

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

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


Freescale Semiconductor

Figures
Figure
Number

Title

Page
Number

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


vi

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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

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


Freescale Semiconductor

vii

Tables
Table
Number

Title

Page
Number

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


viii

Freescale Semiconductor

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


Freescale Semiconductor

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.

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


1-2

Freescale Semiconductor

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

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


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1-3

THIS PAGE INTENTIONALLY LEFT BLANK

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


1-4

Freescale Semiconductor

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

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


Freescale Semiconductor

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

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


2-2

Freescale Semiconductor

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.

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


Freescale Semiconductor

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.

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


3-2

Freescale Semiconductor

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

Connected to a shield wire in the ribbon cable, and ground on the board.

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

Connected to a shield wire in the ribbon cable, and ground on the board.

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

Connected to a shield wire in the ribbon cable, and ground on the board.

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

Connected to a shield wire in the ribbon cable, and ground on the board.

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

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


Freescale Semiconductor

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

Connected to a shield wire in the ribbon cable, and ground on the board.

Connected to a shield wire in the ribbon cable, and ground on the board.

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.

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


3-4

Freescale Semiconductor

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

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


Freescale Semiconductor

3-5

THIS PAGE INTENTIONALLY LEFT BLANK

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


3-6

Freescale Semiconductor

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

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


Freescale Semiconductor

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

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


4-2

Freescale Semiconductor

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

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


Freescale Semiconductor

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

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


Freescale Semiconductor

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

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


4-6

Freescale Semiconductor

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

Resistor 100 , 5%, 0805 Multicomp

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%

Resistor 20 k, 1%, 0805 Multicomp

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

Resistor 390 , 5%, 0805 Multicomp

MC 0.1W 0805 5% 390R

R25

33k-1%

Resistor 33 k, 1%, 0805 Multicomp

MC 0.1W 0805 1% 33K

R29, R32, R33, R35,


R36, R37

10k

Resistor 10 k, 5%, 0805 Multicomp

MC 0.1W 0805 5% 10K

R30

390-1%

Resistor 10 k, 1%, 0805 Multicomp

MC 0.1W 0805 1% 390R

R31

240-1%

Resistor 240 , 1%, 0805 Multicomp

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

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


Freescale Semiconductor

4-7

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


4-8

Freescale Semiconductor

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

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.

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


5-2

Freescale Semiconductor

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

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


Freescale Semiconductor

5-3

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


5-4

Freescale Semiconductor