DB73HR

DB73HR DB73HR DB73HR SA306 Demonstration Board for the SA306 INTRODUCTION The DB73HR is designed to demonstrate the capabilities of the SA306 3 phase brushless DC (BLDC) motor driver IC. This fully assembled demonstration allows the user to directly control the speed and direction of the motor. An onboard controller decodes HALL Effect sensor inputs for commutation in either direction and provides four quadrant PWM signals to control the power outputs of the SA306. LEDs provide visual feedback for motor control status and fault indications. Provisions on the DB73HR allow the user to bypass the onboard control circuit and directly interface with the SA306 brushless motor driver. The DB73HR demonstrates proper layout techniques for the SA306 high current switching amplifier. The economical construction uses only a two-sided PCB and allows the SA306 to dissipate up to 5W. THERMAL CONSIDERATIONS The SA306 is offered in a surface mount package which can deliver peak power of over 1kW. This presents an obvious and significant thermal challenge. The DB73HR offers a compact design which can deliver 17A peak current. The DB73HR assembly can dissipate approximately 5W in still air at 25ºC ambient temperature. To use the DB73HR in higher power applications, use of a fan is recommended. Although the SA306 is rated for operation from -25 to +85ºC, the other components on the DB73HR are limited to 0 to 70ºC ambient temperature. CIRCUIT OPERATION The DB73HR control circuit receives power via two terminal block Figure connections. The Vs connection supplies power to drive the motor and must be above the under-voltage lockout threshold of the SA306, approximately 8.3V. The control circuit requires 12V for proper operation. A regulator on the DB73HR provides the 5V logic supply for the SA306. There are no special considerations for sequencing the two supplies. Figure 1 shows the user control features of the DB73HR. The PWM duty cycle is controlled with the potentiometer. LED5 will illuminate when the 12V supply is connected. The DB73HR will power up with the SA306 disabled. SW2 will toggle the SA306 on and off with LED2 illuminating to indicate the enable status. Direction of the motor is similarly controlled with SW1 and is indicated by the LED1. The DB73HR monitors the Temperature warning status pin of the SA306. If this pin goes high LED4 illuminates and the enable circuit is forced to a disable status. The temperature LED is not latched and may stay illuminated only briefly while the temperature of the SA306 is above 135ºC. The temperature decrease rapidly via the heatsink once the SA306 is disabled. The SA306 current limit feature is set to limit at approximately 15A to provide a demonstration of the full capabilities of the SA306. LED3 will illuminate if the SA306 cycle-by-cycle current limit circuit engages. The thermal and current limit features are robust, but will not protect the SA306 in all circumstances. The user must consider the worst case thermal and power dissipation conditions. www.apexanalog.com DB73HRU Copyright © Apex Microtechnology, Inc. 2012 (All Rights Reserved) 1 – User Control Features OCT 2012 1 DB73HRU REVB DB73HR Hall Effect inputs to connector J3 are required to commutate the motor correctly. Filtering networks and 5V pull-up are provided for glitch-free operation. The Hall sensor connector, J3, also includes a tachometer output which is based on the commutation signals from the Hall inputs. Power for the Hall sensors is provided by U2 in figure 3, an integrated brushless motor controller IC. The controller decodes the Hall sensor inputs and generates six PWM control signals directly to the SA306. 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 DB73HR control circuit. The 5V regulator, U3, provides 5V to the SA306, the latches and the status LEDs. TACH CB CT BB BT AB AT J4 HALL_A HALL_B HALL_C Figure 2 – Schematic J3 1 2 3 4 5 6 1 2 3 4 5 6 GND +12V +5V C7 1 GND 2 R7 C12 C13 33pF X7R 2200pF C17 GND 2200pF GND 3 1 GND CHI CLOW DIR_IN 11 QUAD SNS_I BRAKE I_OUT COAST OC_REF HALLC PWM_I HALLB PWM_NI HALLA 28 R9 27 26 4.99K 1.0K 5% R2 R5 24 R15 R16 4.99K 1% C11 X7R 2200pF R17 4.99K 1% 22 4.99K 1% 21 20 1.0K R6 470 1.0K 5% GND C9 X7R 2200pF C10 X7R 2200pF GND +12V GND +5V 8 C16 18 GND 3 4 R24 5 TP1 6 R11 1% GND +5REG 0.1uF 2 3 1 4 3 +5REG 4 Q 6 15 +5REG 1.0K 5% 7 TP4 R25 TP3 +5REG R31 24.9K 1% R18 1.0K 5% GND 1 2 SW2 ENABLE 13 10 4 3 GND +5REG LED3 16 17 2.0K 18 R19 1.0K 5% 19 20 +5V R27 10K 1% R30 3.30K 1% U4-B TP6 R13 GND 6.8K 1% 12 12 14 R21 +5V 11 10 5 GND D8 2.0K GND Q CLR PRE 9 13 CLK GND 8 11 LED1 SW1 DIRECTION D R12 U4-A GND R23 4.99K 1% GND 7 TP7 VCC 14 D7 TP5 R29 3.30K 1% C15 TP8 2.0K 21 22 LED4 R26 C18 X7R 1UF 5% U1 2 15 GND +5V 1.0K 1 16 6.8K R22 4.99K 1% C1 X7R 1UF UCC3626PW GND LED5 R32 1 OUT GND +12V 2 IN 0.1uF GND TP2 1 +5REG U3 19 17 5% R3 +5V 4.99K 1% 4.99K 1% 23 +5V 470 R10 1% R14 25 GND NC HS NC NC NC PGNDC NC PGNDC CB PGNDC OUTC CT IC OUTC SC VSB/C IB VSB/C ILIM/DIS1 VSB/C SGND OUTB BT OUTB BB PGNDA/B AB PGNDA/B AT PGNDA/B VDD OUTA IA OUTA DIS2 VSA TEMP VSA NC VSA NC NC NC HS SA306HR 44 43 GND 42 41 40 GND D1 PDS5100 39 38 37 D2 PDS5100 +VS +VS OSTTA054163 36 35 34 D3 PDS5100 33 32 31 C4 C6 1.0uF 1.0uF 150uF GND GND D4 PDS5100 28 27 26 25 24 23 GND GND GND 4 3 OUTC 2 OUTB 1 OUTA TB1 30 29 5 C3 GND D5 PDS5100 +VS D6 PDS5100 C2 1.0uF GND C5 150uF GND D CLK CLR PRE Q Q 9 8 MMBT3904LT1 Q1 MMBT3904LT1 R20 10K 1% D9 Q2 1.0K 5% GND LED2 1 2 3 4 5 6 BLOW SNS_NI 14 0.1uF C_TACH -IN 13 C14 2 20K BHI SYNCH 12 R8 R_TACH CT 8 9 +5V J5 6 10 +12V CW 5 7 X7R AHI TACH_OUT ALOW 4 24.9K 1% GND VDD VREF 3 C8 0.1uF U2 2 3 6 7 GND R4 470 +5V 0.1uF +5V R1 GND GND GND ENHANCING & BYPASSING THE DB73HR CONTROL CIRCUIT Connector J5 allows the user to bypass many of the manual control features of the DB73HR. 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 DB73HR. With these resistors jumped, the direction and enable LEDs will not represent the states of the DB73HR and the push buttons will have no effect on the operation. The Temperature disable feature of the DB73HR 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 SA306. This connector may be used to monitor the signals or to bypass the control IC on the DB73HR. The enable function is not controlled via these pins, although pulling all six input pins low provides the same effect. The Enable push button and the connection via J5 are also effective as previously described. The circuit shown in figure 2 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. 2 DB73HRU DB73HR LAYOUT CONSIDERATIONS A simple two layer construction is sufficient because of the convenient pinout of the SA306 HSOP 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 150μF electrolytic capacitors provide a local, low inductance source to accommodate surge currents up to 17A. Six 100V Schottky diodes conduct the commutation current via low forward voltage paths which reduces the power dissipation in the SA306. These diodes are rated for 5A continuous and are mounted close to the SA306 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 3 shows the top and bottom layouts of the EVAL73. Gerber files for the circuit board are available upon request. Figure 3 – PCB Layout (not to scale) 3.50” 3.00” TOP SIDE DB73HRU BOTTOM SIDE 3 DB73HR BILL OF MATERIALS Designation C1,C18 C13 C2,C3,C4 C5,C6 C7,C8,C14,C15,C16 C9,C10,C11,C12,C17 D1,D2,D3,D4,D5,D6 D7,D8,D9 J3,J4,J5 LED1, LED2, LED3, LED4, LED5 Q1,Q2 R1,R2,R3 R11,R12,R13 R24,R25 R26,R27 R29,R30 R4,R5,R6,R18,R19,R20,R21,R32 R7,R31 R8 R9,R10,R14,R15,R16,R17,R22,R23 SW1,SW2 TB1 U1 U2 U3 U4 4 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 LED, Red XTR, NPN, 40V RES, 470, 5% 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 Term. Blk., 5.08mm Vert. 5 pos, PCB SA306HR-FH UCC3626 LM78L05 74AC74 Heatsink PCB, 3.0" x 3.5" Screw, #4-40 x 1/2” 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 Lite-On LTST-C190CKT MMBT3904LT1 RK73B1JTTDD471J Vishay,CRCW06032K00FKEA Vishay,CRCW06036K80FKEA Vishay,CRCW060310K0FKEA Vishay,CRCW06033K30FKEA RK73B1JTTD102J RK73H1JTTD2492F PVG3A203C01R00 Vishay,CRCW06034K99FKEA Panasonic, EVQ-Q2B01W OSTTA054163 Apex Microtechnology, SA306HR-FH Texas Instruments, UCC3626PW National Semiconductor, LM78L05ACMX/NOPB Texas Instruments, SN74AC74PW Apex Microtechnology, HS36, 2.8ºC/W Apex Microtechnology, EVAL73 18-8 SS Pan Head Phillips 91772A110 Paste INDC121NCSMQ90 83% MTL MSH-325+500 DB73HRU DB73HR DB73HR Quick Start Guide 1. Connect the following: Connection Location Indicator Comment Vs TB1 Ground TB1 Vctrl J5-6 Motor Phase A TB1 Motor Phase B TB1 Motor Phase C TB1 Hall Sensor A J3-1 Hall Sensor B J3-2 Hall Sensor C J3-3 Hall 5V J3-5 Hall ground J3-6 9-60V LED 2 12V Output from PCB 2. Apply 12V to Vctrl. LED5 should light. 3. Apply voltage to Vs based on rated motor voltage, normally 12-48V. 4. Press ENABLE SW2. LED2 will light and motor should start. ORDERING INFORMATION DB73HR Demonstration Board includes one populated EVAL73 rev B PCB and one SA306HR-FH sample NEED TECHNICAL HELP? CONTACT APEX SUPPORT! For all Apex Microtechnology product questions and inquiries, call toll free 800-546-2739 in North America. For inquiries via email, please contact apex.support@apexanalog.com. International customers can also request support by contacting their local Apex Microtechnology Sales Representative. To find the one nearest to you, go to www.apexanalog.com IMPORTANT NOTICE Apex Microtechnology, Inc. has made every effort to insure the accuracy of the content contained in this document. However, the information is subject to change without notice and is provided "AS IS" without warranty of any kind (expressed or implied). Apex Microtechnology reserves the right to make changes without further notice to any specifications or products mentioned herein to improve reliability. This document is the property of Apex Microtechnology and by furnishing this information, Apex Microtechnology grants no license, expressed or implied under any patents, mask work rights, copyrights, trademarks, trade secrets or other intellectual property rights. Apex Microtechnology 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 Apex Microtechnology integrated circuits or other products of Apex Microtechnology. 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. APEX MICROTECHNOLOGY PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR WARRANTED TO BE SUITABLE FOR USE IN PRODUCTS USED FOR LIFE SUPPORT, AUTOMOTIVE SAFETY, SECURITY DEVICES, OR OTHER CRITICAL APPLICATIONS. PRODUCTS IN SUCH APPLICATIONS ARE UNDERSTOOD TO BE FULLY AT THE CUSTOMER OR THE CUSTOMER’S RISK. Apex Microtechnology, Apex and Apex Precision Power are trademarks of Apex Microtechnolgy, Inc. All other corporate names noted herein may be trademarks of their respective holders. DB73HRU www.apexanalog.com Copyright © Apex Microtechnology, Inc. 2012 (All Rights Reserved) OCT 2012 5 DB73HRU REVB