Active-semi HYDRA-X BLDC Bedienungsanleitung

HYDRA-X BLDC Head

Power Application Controllers

PAC5220 Expansion - HYDRA-X BLDC Head User’s Guide

www.active-semi.com

- 2 - Rev 1.0 June 2014

ONTENTS

Contents ...............................................................................................................................................................2

Overview ..............................................................................................................................................................3

HYDRA-X BLDC Head Resources ......................................................................................................................5

Header Descriptions .........................................................................................................................................5

HYDRA-X20 Pinout and Signal Connectivity ...................................................................................................6

Power Input ......................................................................................................................................................7

External and Internal Resources ......................................................................................................................8

HYDRA-X BLDC Head Hardware ........................................................................................................................9

External Potentiometer (J14)............................................................................................................................9

External Thermistor (J15) .................................................................................................................................9

S1 and S2 Push Buttons ............................................................................................................................... 10

RC PWM Remote Control Input (J13) ........................................................................................................... 10

HYDRA-X BLDC Head Schematic.................................................................................................................... 11

About Active-Semi............................................................................................................................................. 12

- 3 - Rev 1.0 June 2014

VERVIEW

Active-Semi’s HYDRA-X BLDC Head is an expansion board for the Hydra-X20 Body board, providing a

complete motor solution. Although developed to control tri-phase Brushless DC (BLDC) motors, the module

can be utilized to drive other motor topologies including, but not limited to, brushed DC motors.

The HYDRA-X BLDC Head has been designed to accommodate a robust power stage made of six power

MOSFETs rated at 60V and a maximum of 192A. The module contains all of the passive components

required to properly polarize and protect the switch elements.

This module was designed taking into consideration two BLDC control methodologies: Hall Sensor BLDC and

BEMF Detection sensorless. A connector is provided to connect hall sensor signals. In parallel to these

connections, the board provides phase output voltage dividers required to implement BEMF sensorless

algorithms. All that is required from the user is to download the pertinent firmware into the Hydra-X20 Body

board, and establish the respective motor connections.

Other resources made available to prospective developers are a potentiometer which could be used to control

motor speed, two push buttons, and a series of connectors which could be used to add external switches. A

placeholder for a thermistor was designed into the system allowing developers to add their own version of a

thermal protection directly interfaced at the FET block.

Active-Semi’s HYDRA-X BLDC Head kit consists of the following:

•HYDRA-X BLDC Head module

•HYDRA-X BLDC Head User’s Guide

•Schematics, BOM and Layout Drawings

- 4 - Rev 1.0 June 2014

Figure 1: HYDRA-X BLDC Head Block Diagram

Solution Benefits:

•Ideal for most medium voltage and high current motor driving applications

•Six powerful FET switches allow for high current motor driving.

•Motor can be controlled remotely through an RC radio or an UART based serial communications

channel such as a BlueTooth module (Bluetooth module not included).

•Can be programmed to drive BLDC motors in sensored or sensorless implementations.

•Schematics, BOM, Layout drawings available

The following sections provide information about the hardware features of Active-Semi’s HYDRA-X BLDC

Head turnkey solution.

- 5 - Rev 1.0 June 2014

HYDRA-X

BLDC

EAD

ESOURCES

Header Descriptions

The following table shows the female header descriptions for the HYDRA-X10 Body module.

Header

Description

1-10 Refer to HYDRA-X20 pinout diagram

1-8 Refer to HYDRA-X20 pinout diagram

1-20 Refer to HYDRA-X20 pinout diagram

1-10 Refer to HYDRA-X20 pinout diagram

1-6 Refer to HYDRA-X20 pinout diagram

- Hall Sensor Inputs

1 Hall Sensor VCC (5V)

2 Hall Sensor U Phase

3 Hall Sensor V Phase

4 Hall Sensor W Phase

5 Optional Hall Sensor Input (FG)

6 Hall Sensor GND

- VIN Power Input -Spade connector (16V to 48V)

- GND Power Input – Spade Connector

- U Phase Output – Spade Connector

J10

- V Phase Output – Spade Connector

J11

- W Phase Output – Spade Connector

J12

- Extern UART connector.

1 UART VCC (5V)

2 UART RX

3 UART TX

4 UART GND

J13

- External RC PWM connector.

1 RC PWM Signal Digital Input (PD4)

2 RC PWM VCC (5V)

3 RC PWM GND

J14

- External Potentiometer Input

1 External Potentiometer VCC (Voltage Divided VCC = 5V)

2 External Potentiometer Analog Input (PC4)

3 External Potentiometer GND

J15

- Optional Thermistor connector

1 Thermistor Analog Input (AIO2)

2 Thermistor GND

J16

External Push Button

1 External Push Button Digital Input (PE5)

2 Extern Push Button GND

- 6 - Rev 1.0 June 2014

HYDRA-X20 BLDC System Pinout and Signal Connectivity

The following diagram shows the male header pinout for the HYDRA-X BLDC Head module, as seen from

above:

Figure 2 HYDRA-X BLDC Head Pinout

The HYDRA-X BLDC Head module interfaces with the HYDRA-X20 Body module.

Figure 3 HYDRA-X20 Body Pinout

More information on the HYDRA-X20 Body module, and its respective User’s Guide, can be downloaded from

the HYDRA-X website at www.active-semi.com/hydra.

- 7 - Rev 1.0 June 2014

Power Input

Power to the Hydra-X BLDC Head module should be applied to the J7/J8 Spade connectors. Power to the

module should not exceed 48V.

Powering the HYDRA-X BLDC Head through the J7/J8 connectors will power the HYDRA-X20 Body board.

Power to the body board is applied through the J4 VIN and GND terminal.

NOTE: Applying power to the HYDRA-X BLDC system through the HYDRA-X20 J7 connector is not

recommended. Since this is a high current application, and the header connectors are not rated to handle

such high currents, it is crucial that current is supplied through the spade connectors into the headers and not

vice versa.

The HYDRA-X BLDC Head is not protected against voltage reversal. Voltage polarity must be observed

before applying power to the module. Failing to follow correct voltage polarity connections will adversely affect

HYDRA-X BLDC Head power FETs.

- 8 - Rev 1.0 June 2014

External and Internal Resources

The following table illustrates the systems resources utilized

Header

Description

GPIO Resource

2 Hall Sensor U Phase PD2

3 Hall Sensor V Phase PD3

4 Hall Sensor W Phase PD6

5 Optional Hall Sensor Input (FG) PD7

J12

2 UART RX PE2

J12

3 UART TX PE1

J13

1 RC PWM Signal Digital Input PD4

J14

2 External Potentiometer Analog Input PC4

J15

1 Thermistor Analog Input AIO2

J16

1 External Push Button Digital Input PE5

Internal

- VIN Analog Input PC3

Internal

- R11 Potentiometer Analog Input PC2

Internal

- S1 Push Button Digital Input PE4

Internal

- S2 Push Button Digital Input PE5

Internal

- PHASE U Output (Voltage Divided) AIO7

Internal

- PHASE V Output (Voltage Divided) AIO8

Internal

- PHASE W Output (Voltage Divided) AIO9

Internal

- SENSE Resistor + Terminal AIO1

Internal

- PHASE U Low Side FET Gate Drive DRL0

Internal

- PHASE U High Side FET Gate Drive DRH3

Internal

- PHASE U Boot Strap DRB3

Internal

- PHASE U High Side Source DRS3

Internal

- PHASE V Low Side FET Gate Drive DRL1

Internal

- PHASE V High Side FET Gate Drive DRH4

Internal

- PHASE V Boot Strap DRB4

Internal

- PHASE V High Side Source DRS4

Internal

- PHASE W Low Side FET Gate Drive DRL2

Internal

- PHASE W High Side FET Gate Drive DRH5

Internal

- PHASE W Boot Strap DRB5

Internal

- PHASE W High Side Source DRS5

- 9 - Rev 1.0 June 2014

HYDRA-X

BLDC

EAD

ARDWARE

External Potentiometer (J14)

For applications wanting to utilize an external potentiometer, the 3 pin header connector gives access to

analog input PC4. The potentiometer resource is pulled up via a 5.1K resistor. In the event the external

potentiometer requires a different pull up resistance, resistor R19 can be modified accordingly with a 0603

package of suitable resistive value.

Figure 3 External Potentiometer Circuitry

External Thermistor (J15)

In order to protect power FETs from being adversely affected by extremely high temperatures, a thermistor

input is provided. Thermistor temperature can be sampled through analog input AIO2.

By default, the thermistor’s pull up resistor is a Non Populate component. User can select appropriate pull up

resistor (0603 package) and populate at the R18 footprint location.

Figure 4 External Thermistor Circuitry

- 10 - Rev 1.0 June 2014

S1 and S2 Push Buttons

Two push buttons (S1 and S2) are made available for users requiring to add further control functionality to the

motor drive system. Push button S1 is assigned to resource PE4 whereas push button S2 is assigned to

resource PE5.

Alternatively, a non populated two pin connector (J16) is made available in order to allow for an external

switch to be added at a later time, if required.

Figure 5 External Thermistor Circuitry

RC PWM Remote Control Input (J13)

Users wanting to control a motor by employing an off the shelf Remote Control (RC) radio, can take

advantage of the 3 pin header connector J13. This pin provides 5V power to the receiver module and accepts

the typical 1.0 to 2.0 ms PWM signal. Firmware decoding the RC PWM signal is part of our sample code

made available at the HYDRA-X Blog.

RC PWM control signal can be sampled via the PD4 resource.

Figure 6 RC PWM Interface Circuitry

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