Application Note 1829
Author: Richard Garcia
HIP4086 3-phase BLDC Motor Drive Demonstration
Board, User’s Guide
Introduction
The HIP4086DEMO1Z is a general purpose 3-phase BLDC
motor drive with a microprocessor based controller. Hall effect
shaft position sensors are used to control the switching
sequence of the three 1/2 bridge outputs. The bridge voltage
can vary between 12V and 60V and the maximum summed
bridge current is 20A (with sufficient air flow). This motor drive
can be used as a design reference for multiple applications
including e-bikes, battery powered tools, electric power
steering, wheel chairs, or any other application, where a BLDC
motor is utilized. Because this demonstration board is
primarily intended to highlight the application of the HIP4086
3-phase MOSFET driver with no specific application targeted,
the control features are limited to simple functions, such as
start/stop, reverse rotation, and braking. Open loop speed
control is implemented. More advanced control features, such
as torque control, speed regulation and regenerative braking
are not implemented because these methods require close
integration with the characteristics of the load dynamics.
Important Note
Because Hall sensor switching logic sequences for BLDC
motors are not all the same, this demo board supports most, if
not all, variations of sequence logic. Please refer to the
sequence charts in “Selecting the Correct Switching
Sequence” on page 9 to verify that your desired sequence is
implemented. If you require a different sequence for your
specific motor application or if you need help identifying the
correct switching sequence for your specific motor, please
contact Intersil prior to ordering this demo board for possible
support for a new switching sequence.
analog signal proportional to the motor current is available on
board as a design reference.
The microcontroller firmware is also provided as a reference
but the only support offered by Intersil will be for bug
corrections and for adding more switching sequences. Please
refer to Microchip for details on the use of the PIC18F2431.
Physical Layout
The HIP4086DEMO1Z board is 102mm by 81mm. The tallest
component is a 470µF capacitor. The total height is 24mm
with standoffs or 18.5mm without standoffs. The Hall effect
shaft position sensor inputs are miniature terminal blocks and
the high current outputs are larger terminal blocks that are
rated for 20A.
Four push-buttons are used for reset, brake, reverse, and
start/stop functions. An on-board potentiometer is used to
adjust the duty cycle of the applied motor voltage or an
optional external potentiometer can be connected to a signal
terminal block located adjacent to the Hall terminal blocks.
The switching sequence selection dip switch is used for various
purposes but the most important function is to select the
desired switching sequence. Please refer to the “Setup and
Operating Instructions” on page 3 for more information.
For those customers who would like to modify the firmware of
the PIC18F2431 microcontroller, an RJ25 connector is
provided for easy connection with Microchip firmware
development tools (not provided or supported by Intersil).
Specifications
Motor topology 3-phase BLDC motor with Hall
sensors
Operating voltage range 15VDC to 60VDC
Maximum bridge current 20A (with sufficient air flow)
Hall sensor bias voltage 5V
PWM switching frequency 20kHz
Scope
This application note covers the design details of the
HIP4086DEMO1Z with a focus on the design implementation
of the HIP4086 driver using recommended support circuits.
Also covered, is the design method of the bipolar current
sensing feature. Presently, current sensing on this demo board
is used only for pulse-by-pulse current limiting. However, an
March 14, 2013
AN1829.0
1
FIGURE 1. HIP4086DEMO1Z INPUTS AND OUTPUTS
CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures.
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Intersil (and design) is a trademark owned by Intersil Corporation or one of its subsidiaries.
All other trademarks mentioned are the property of their respective owners.
|Copyright Intersil Americas LLC 2013. All Rights Reserved
Block Diagram
FIGURE 2. HIP4086DEMO1Z BLOCK DIAGRAM
HIP4086DEMO1Z
ISL8560
+5V
BUCK
REGULATOR
HIP4086
3-PHASE
MOSFET
DRIVER
ISL6719
LINEAR +12V
REGULATOR
CONTROLLER
LEDS
DIP
SWITCHES
PUSH
BUTTONS
15V TO 60V
3-PHASE
BRIDGE
BLDC
MOTOR
ISL28246
CURRENT
LIMIT
AND
MONITOR
HALL
INPUTS
4
3
6
6
2
3
Application Note 1829
The HIP4086DEMO1Z is composed of six major circuits
illustrating the use of several Intersil products.
Bias Supplies
The ISL8560 is a buck regulator with integrated power FETs that
provides +5V bias for the microcontroller, dip switches, push
buttons, LEDs, and the current monitor/limit circuits. The
ISL6719 is a linear regulator that provides 12V bias for the
HIP4086 3-phase MOSFET driver. Please refer to the ISL8560
datasheet for application information.
datasheet or the ISL6719
HIP4086
The HIP4086, the featured Intersil part, drives 3 bridge pairs of
F540NS power FETS with a PWM frequency of 20KHz. Associated
with the HIP4086 are the necessary support circuits such as the
boot capacitors and boot diodes. Recommended negative
voltage clamping diodes on the xHS pins are also provided.
MicroController
The Hall sensor inputs are decoded by the microcontroller to
provide the appropriate switching sequence signals to the
HIP4086 to drive the six F540NS bridge FETs that are connected
to a 3-phase BLDC motor. In addition to decoding the Hall
sensors, the microcontroller also multiplexes the dip switches
(for switching sequence options), the push buttons (for various
control functions of the motor), and the LED status lights.
The on-board potentiometer (or an optional external pot) is
monitored by the microcontroller to provide a duty cycle to the
motor that is proportional to the tap voltage of the potentiometer
2
and varies between 0% and 100% duty cycle. This proportional
duty cycle is open loop and is independent of the bridge voltage.
Consequently, any motor voltage between 15V and 60V can be
used with this demo board.
The microcontroller firmware is provided as a reference but the
only support offered by Intersil will be for bug corrections and for
adding more switching sequences. All firmware revisions for this
demo board can be found on the Intersil website. The firmware
revision of your demo board can be determined by referring to
the “Test Mode Setup” on page 24.
Current Sensing/Current Limit
Two ISL28246 low offset, dual op-amps are used for current
monitoring and current limiting. One op-amp is configured as a
differential amplifier for Kelvin connections across the current
sensing resistor. The diff-amp is also biased so that zero bridge
current results with an output voltage that is 1/2 of the +5V bias.
Consequently, positive bridge currents results with a current
monitor signal that is greater than 2.5V (up to ~5V). Negative
bridge currents (that occur with regenerative braking) is less than
2.5V (down to a minimum of ~0V). This ‘”bipolar” analog signal
can be monitored by the microcontroller for purposes, such as
torque control and/or regenerative braking.
The output of the analog differential amplifier is also connected
to two op amps configured as outside window comparators for
pulse-by-pulse current limits for either positive or negative bridge
currents. The OR’ed comparator outputs are sent to the
microcontroller for processing.
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March 14, 2013
Application Note 1829
ISL6719
(+12v)
FIGURE 3. MAJOR CIRCUIT LOCATIONS
3-phase Bridge
The 3-phase bridge is composed of six F540NS power MOSFETS
(100V, 33A). Each FET is driven by one of the six driver outputs of
the HIP4086. Dead time is provided by the controller (optionally,
dead time can be provided by the HIP4086).
Related Literature
• FN4220 HIP4086, 80V, 500mA, 3-Phase MOSFET Driver
• FN6555
• FN9244
• FN6321
Input-Output (RRIO) Op Amps
ISL6719, 100V Linear Bias Supply
ISL8560, DC/DC Power Switching Regulator
ISL28246, 5MHz, Single and Dual Rail-to-Rail
Setup and Operating Instructions
Required and Recommended Lab Equipment
Lab supply (or battery), 15V minimum to 60V absolute
maximum. The current rating of the lab supply must have
sufficient capacity for the motor being tested. If a battery is the
power source, it is highly recommended that an appropriate fuse
be used listed as follows:
•Bench fan
•Test motor
• Multichannel oscilloscope, 100 MHz
•Multimeter
• Temperature probe (optional)
CAUTION: If the HIP4086DEMO1Z is used for an extended period
at high power levels, it may be necessary that a fan be used to
keep the temperature of the bridge FETs to less than +85°C (as
measured on the heat sink plane).
1. Connect the 3-phase motor leads to the MA, MB, and MC
terminal blocks. For high current applications, it is
recommended that both terminals of each block be used. It is
3
also recommended that during initial setup the motor
mechanically loaded.
2. Connect the HALL sensor leads of the motor to the HA, HB,
and HC terminals. The +5V bias and ground leads must all be
connected.
3. Rotate the R13 potentiometer to the left (CCW) until it clicks.
This will set the starting voltage on the motor to a minimum.
4. Setup the dip switch for the correct switching sequence (see
the switching sequence tables at the end of this application
note).
5. With a lab supply turned off but previously set to the desired
bridge voltage, connect the lab supply (or battery) to the
+BATT a nd -B ATT terminal bloc k .
6. Ensure that the motor is securely mounted prior to proceeding
with the following steps. Also, do not exceed the maximum
rated RPM of your motor.
7. Turn on the lab supply. Observe that the four LEDS turn on and
off, one after another. This initial flash of the LEDs indicates
that power has been applied. After the initial flash, all LEDs
will be off. Operation of the motor is now possible. Note that
the dip switch options are read at initial turn-on and changing
the settings after power is applied will have no effect. As an
not be
AN1829.0
March 14, 2013
Application Note 1829
led0led2led3 led1
At initial turn on , leds will turn on and
off one at a time sta rtin g with le d0
led0led2led3 led1
While the motor is rotating, the RUN LED is blinking
RUNREVERSEBRAKE
ILIMIT
led0led2led3 led1
RUNREVERSEBRAKEILIMIT
led0led2led3 led1
RUNREVERSEBRAKE
ILIMIT
led0led2led3 led1
RUNREVERSEBRAKE
ILIMIT
blinking
led0led2led3 led1
RUNREVERSEBRAKE
ILIMIT
led0led2 led1
RUNREVERSEBRAKE
ILIMIT
led3
alternative to cycling power, the reset push button can be
pressed to re-read the dip switch settings.
8. Press the Start/Stop push button once. The RUN LED (led0)
will blink, indicating that the motor has been started. The
motor at this point may not be rotating because minimal
voltage is being applied to the motor.
9. Slowly increase the voltage on the motor by rotating the
potentiometer, R13, to the right (CW). At some point the
motor will start to rotate slowly. The actual starting voltage is
dependent on the specific motor being used.
10. If the motor is vibrating back and forth instead of rotating, it
is possible that the Hall sensors or the motor leads were not
connected correctly. If the correct switching sequence has
been selected, all that should be necessary to correct this
misbehavior is to swap two of the motors lead (or to swap two
of the Hall sensor leads).
11. Continue to rotate the pot until the motor is running at a
moderate speed of roughly 25%. Do not run the motor with
maximum voltage until the setup check-out is completed.
12. Press again the START/STOP push button. The motor will free
wheel to a stop and the blinking led0 will turn off.
13. Press again the START/STOP button. The motor will
accelerate to the previous run speed (assuming that the
potentiometer was not rotated). The blinking led0 will also
turn on.
14. While the motor is running, press the REVERSE button. The
RUN LED (led0) will turn off and the REVERSE LED (led1) will
turn on without blinking. After a short pause while the motor
is freewheeling to a stop, the motor will restart rotating in the
opposite direction. The RUN LED will be blinking and the
REVERSE LED will continue to be on.
15. Press again the REVERSE button. As before, the motor will
stop. But this time the REVERSE LED will turn off. After a
pause, the motor will restart but this time rotating in the
forward direction.
16. While the motor is running, the motor can be hard braked by
pressing the BRAKE push button. The BRAKE LED (LED2) will
be on without blinking. When the motor is restarted, the
BRAKE LED will turn off.
CAUTION: The braking method implemented turns on all of the
low-side bridge FETs simultaneously. This will force the motor to
a very rapid stop. If the motor is loaded, or if the motor is not
designed for a rapid stop, mechanical damage to the motor or
the load can result. If you are not sure about using this braking
method, only apply the brake when the motor speed is relatively
slow.
17. If while operating, the motors turns off, and the iLIMIT LED
(led3) is blinking, the current limit shut-down has been
activated after 255 consecutive pulse-by-pulse current limits.
This may happen if the motor speed is accelerated too
quickly, or if there is a fault with the motor or connections, or
if the motor is stalled.
4
It is now safe to proceed with testing at higher power levels
speeds.
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March 14, 2013
Application Note 1829
BLDC
MOTOR
AHO
ALO BHO
BLO
CHO
CLO
000 100 110 111 011 000 100 110 111 011001 001
HALL SENSOR LOGIC
HC
HB
HA
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
MB
MA
MC
1 2 3 4 5 6 1 2 3 4 5 6
0° 60° 120° 180° 240°
Bridge State Logic: P = PWM, L = Low, Z = off
0° 60° 120° 180° 240° 0°
SEQUENCE STEP NUMBERS
Z
L
P
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
MB
MA
MC
Bridge State Logic: P = PWM, L = Low, Z = off
IDEALIZED MOTOR VOLTAGE WAVEFORMS
MC
MB
MA
+Vbat
-Vbat
~ ½ Vbat
20kHz PWM freq.
Motor rotation period
per pole
Theory of Operation
The HIP4086DEMO1Z demonstration board is a general purpose
3-phase BLDC motor controller. Three half bridge power circuits
drive the motor as shown in Figure 4.
Three 6 step bridge state logic diagrams, illustrated in Figure 5,
are used to drive the motor. The bridge state logic diagrams
represents the logic status of the each half bridge but the actual
voltage applied to the motor appears much differently. Figure 6
illustrates the bridge status logic vs the actual voltage waveforms
applied to each motor lead.
The HIP4086 has 6 driver outputs, AHO, ALO, BHO, BLO, CHO,
and CLO, to control the six bridge FETs individually. If the gate
drives for both FETs of one half bridge are low, current will not
flow in the corresponding motor lead (high impedance or Hi-Z). If
the gate drive for the low FET is high and the gate drive for the
high FET is low, then the phase node of that half bridge, and the
corresponding motor lead, is connected to ground (Low). If the
low and high gate drives are complementary driven, the phase
node can be pulse width modulated (PWM) to control the
average voltage on that motor lead.
The motor rotation period and the amplitude of the bridge
voltage waveforms are modified by the microcontroller to control
the speed of the motor. Pulse width modulation is used to modify
the amplitude of the voltage waveforms and the motor rotation
period is established by the shaft position hall sensors that signal
the controller to change the switching sequence. Typical hall
sensor logic is illustrated in Figure 5. Each hall logic diagram, HA,
HB, and HC, correspond respectively to the bridge state logic
diagrams, MA, MB, and MC. For example, the transition of the
hall sensor logic, from step 1 to 2, results with the drive
waveform transition of ZLP to PLZ where P, L, and Z define the
state of each half bridge.
FIGURE 5. HALL SENSOR LOGIC vs BRIDGE STATE LOGIC
FIGURE 4. BASIC BLDC MOTOR POWER TOPOLOGY
5
FIGURE 6. BRIDGE STATE LOGIC vs MOTOR VOLTAGE
March 14, 2013
AN1829.0
Application Note 1829
FIGURE 7. SEQUENCE STEPS 1 TO 3
N
N
S
S
N
S
N
S
N
S
N
S
N
S
N
S
S
S
N
N
2
P
Z
L
3
P
L
Z
N
S
N
S
N
S
N
S
N
S
N
S
N
S
N
S
HC
HB
HA
MB
MA
MC
1
2 3
HC
HB
HA
MB
MA
MC
HC
HB
HA
MB
MA
MC
L
L
L
P
P
P
Z
Z
Z
Z
ZPP L
L
1
Z L
NEUTRAL
P
Z
P
L
NEUTRAL NEUTRAL
NEUTRALNEUTRALNEUTRAL
NEUTRAL
NEUTRAL NEUTRAL
NEUTRAL NEUTRAL NEUTRAL
FIGURE 8. SEQUENCE STEPS 4 TO 6
S
N
S
N
S
N
S
N
S
N
S
N
4
Z
L
P
5
L
Z
P
6
L
P
Z
S
S
N
N
N
N
S
S
S
N
S
N
N
S
N
S
N
S
N
S
N
S
N
S
64 5
HC
HB
HA
MB
MA
MC
HC
HB
HA
MB
MA
MC
HC
HB
HA
MB
MA
MC
L Z
P
LL
PP Z
Z
Z
Z
Z
P
PP
L
L
L
NEUTRAL NEUTRAL NEUTRAL
NEUTRALNEUTRALNEUTRAL
NEUTRAL NEUTRAL NEUTRAL
NEUTRAL NEUTRAL
NEUTRAL
Switching Sequence Phase Currents
The following motor winding diagrams illustrate how currents
flow in a 3-phase BLDC motor during each switching period of the
6 step voltage waveform. These diagrams are for a very simple
motor with only 6 stator poles. Most 3-phase motors have more
stator poles (multiples of 6) to reduce torque modulation
(cogging) but the principles of operation are the same.
Each phase winding is color coded and black arrows indicate the
direction of positive current in that winding for each step. As
described in Figure 7, the half bridge state of each motor lead,
MA, MB, or MC, is labeled with P, L, or Z. Observe that the active
coils are highlighted. The inactive coils (those with no current) are
white.
The dark gray structures are the permanent magnets that are
mounted on the light gray rotor. The bold black arrow is the flux
vector of the permanent magnets. The bold dark blue arrow is
the magnetic flux vector generated by the active coils for each
waveform step. The switching step occurs when these two
vectors are perpendicular for maximum torque. Notice how the
flux vectors are rotating counter clockwise, 60° for each step.
This tutorial for BLDC motors is very fundamental. For more
information about a specific motor, please contact the motor
manufacturer.
6
AN1829.0
March 14, 2013
Application Note 1829
AHO
CLO
BLO
ALO
CHO
BHO
CLI
BLI
ALI
CHI
BHI
AHI
CHS
AHS
BHS
CHB
AHB
BHB
VDD
RDEL
HIP4086/A
VSS
MOTOR
VDD V
BAT
CURRENT
SENSE
RFSH
D1
R1
Q1
Q2
C1
C2
VSS
xHS
xLO
xHO
INDUCTIVE
MOTOR LOAD
+
-
+
-
DEAD-TIME
PHASE NODE
(xHS)
LO GATE DRIVE
HI GATE DRIVE
LO FET CURRENT
HI FET CURRENT
di/dt
~-1.5V
0V
NEG. TRANSIENT
(-Ldi/dt)
HIP4086 Circuit Description
In the following discussion, xHI, xLI, xHO, xLO, and xHS is a short
hand notation where the x can be replaced with A, B, or C. An “x”
pin implies that the reference is applicable to the corresponding
A, B, or C pins of the driver.
The simplified schematic of Figure 9 illustrates the three power
stages of the motor driver. Each phase is identical in component
selection. For specific component values and complete circuit
details, please refer to the Bill of Materials (BOM) on page 12
and PCB Layout schematics beginning on page 18.
FIGURE 9. SIMPLIFIED 3-PHASE BRIDGE
Series connected gate resistors on each bridge FET are used to
reduce the switching speed to help minimize EMI radiating from
the power leads to the motor. The user can change these values
if desired, keeping in mind that if the gate resistors are made
larger, the turn off delays of the FETs will also increase, which
may require additional dead time.
All of the xHS pins have recommended external snubber circuits
and negative voltage clamps to ensure that safe operating
conditions are always maintained over-temperature and loading
conditions.
For example, D1 in Figure 9, functions as a negative voltage
clamp on the AHS pin. Frequently, circuit designers overlook the
negative transients on the xHS pins that occur when the high-side
bridge FET turns off. This rapid di/dt transition of the current
from Q1 to Q2 develops a negative voltage transient as a result
of the parasitic inductance in the low-side FET power current path
(see Figure 10).
R1 on the AHS pin is necessary to limit the current in D1 during
the dead time because without this resistor, D1 is essentially in
parallel with the body diode of Q1. During the dead-time, the
commutating negative current in the body diode results with
approximately a -1.5V conduction voltage (with large amplitude
motor currents). Because the conduction voltage of D1 (~0.6V) is
less than the body diode, R1 limits the current that would flow in
7
FIGURE 10. NEGATIVE TRANSIENT ON xHS
D1 during the dead-time to safe levels. Note that when the
low-side bridge FET is turned on, the negative voltage across the
FET is greatly reduced because the conduction voltage of the FET
channel is typically much less than the conduction voltage of the
body diode. This results with a negative conduction voltage much
less than 0.6V and consequently, significant current flows in D1
only during the dead-time.
C1 in parallel with D1 in Figure 9 is used to reduce the dv/dt on
the xHS pin and also filters high frequency oscillations that occur
on xHS because of parasitic inductance and capacitance on the
this node. Clean transitions on xHS ensures fail safe operation of
the HIP4086 driver.
As an alternative to these capacitors on the xHS pins, the gate
resistors of the bridge FETs can be made larger to lessen the
switching speed but at the expense of more switching losses in
the bridge FETs.
The HIP4086 has a refresh pulse feature that is used to ensure
that the boot caps are biased prior to driving on the high-side
drivers. The refresh pulse occurs only once when bias is applied
to the driver. The refresh feature of the HIP4086 is not really
needed when a programmable controller is used but because
this feature cannot be turned off, C32 is used to ensure noise will
not be a problem with this pin, which is not only an output pin but
also an input.
In this design, the built-in dead time feature of the HIP4086 is
not used (because the microcontroller has a programmable dead
time function set to 1µs. A hardware option on the board does
allow the dead-time function of the HIP4086 to be used if
desired. It can be used to further increase the 1µs programmed
dead-time if desired.
AN1829.0
March 14, 2013
Application Note 1829
U2
R17 R21
R18 R22
R14
R12
R15
R3
5V
ISL28246FUZ
32.4k
FILTER CAPACITORS
ARE NOT SHOWN.
R23 R24
FROM
BRIDGE
0.0150.015
I
MOTOR
+
-
ΩΩ
32.4k
Ω
32.4k
Ω
32.4k
Ω
511
Ω
511
Ω
511
Ω
511
Ω
U2
R17+R21
R18+R22
R12||R14
R15||R3
2.5V
THEV
ISL28246FUZ
Note that re s is to rs la b e le d R x||Ry
represent a parallel equivalent resistor
of Rx and Ry. Rx+Ry represents the
series combination of Rx and Ry.
R23||R24
FROM
BRIDGE
0.0075
I
MOTOR
+
-
1022Ω
Ω
1022
Ω
16.2k
Ω
16.2k
Ω
(EQ. 1)
Vout
CS
=
[(R12||R14)) / (R17+R21)] x I
M
x (R23||R24)+ R3 / (R3+R15) x 5V
(EQ. 2)
VoutCS = [(16.2kΩ))/(1022)] x Im x (0.0075) + 32.4kΩ/(64.8kΩ) x 5V
or
Vout
CS
= 0.119 x IM+2.5V
U3
R4
R1
R12A
ISL28246FUZ
+
-
R38
5V
U3
R11
R39
R12B
ISL28246FUZ
+
-
R11B
5V
I
MOTOR
TO
MICROCONTROLLER
10k
Ω
10k
Ω
10kΩ
10kΩ
249
Ω
1M
Ω
1M
Ω
249
Ω
Please refer to the HIP4086 datasheet for additional application
information.
Current Monitor and Current Limit
There are two current control features in the HIP4086DEMO1Z. A
linear current monitor op amp, U2, amplifies the voltage across
R23 and R24. This op amp is configured as a true differential
amplifier to allow Kelvin connections across the current sensing
resistors (see Figure 11). R15 and R3, each 32.4kΩ, have a
Thevinen equivalent value that is the parallel value of R15 and
R3 (or 1/2 of 32.4kΩ). The Thevinen equivalent voltage also is
1/2 of the bias voltage of 5V. Consequently, the output of the
differential amplifier is offset by +2.5V (see Figure 12).
The output voltage of the differential amplifier is:
where I
is the bridge current (motor current), R12||R14 =
M
R15||R3, and (R17+R21) = (R18+R22) (as required for the
differential amp topology).
Using the defaults values of the HIP4086DEMO1Z:
For 20A, Vout
The I
motor
= 4.878V. For -20A, VoutCS= 0.122V.
CS
signal is monitored by two comparators (see
Figure 13). The output of the upper U3 comparator is biased to
go low when the motor current > 20A. Conversely, the output of
the lower comparator is biased to go low when the motor current
is ≤ 20A.
FIGURE 11. DIFFERENTIAL CURRENT MONITOR AMPLIFIER
FIGURE 12. THEVINEN EQUIVALENT DIFFERENTIAL AMPLIFIER
The current monitor output, I
microcontroller, can be used to control the torque of the motor or
to limit the battery recharging current during regenerative
braking. Because of the offset voltage on the current monitor
output, signals above 2.5VDC represents positive motor current
and signals less that 2.5VDC represent negative motor current.
(Note that this hardware feature is provided for customer use but
is not implemented in the microcontroller firmware.)
MOTOR
, digitized by the
8
FIGURE 13. PULSE-BY-PULSE CURRENT LIMIT COMPARATORS
The OR’ed outputs of these two comparators is monitored by the
microcontroller. Pulse-by-pulse current limiting is provided on
each negative transition. After 256 consecutive pulse limits, all
the bridge FETs are permanently turned off and the current limit
alarm LED (led3) is turned on.
There are two different methods to change the pulse-by-pulse
current limit. The easiest method is to change the value of the
current sensing resistors R23 and R24. For example, removing
R24 halves the pulse by pulse current limit to ± 10A while not
affecting the full scale I
output signal.
motor
Equation 3 calculates the value of the current sensing resistors to
set the pulse-by-pulse current limit at the desired level without
changing the full scale output voltage swing of the I
signal.
MOTOR
AN1829.0
March 14, 2013
Application Note 1829
R23||R24 = 4.878V - 2.5V x 1.022kΩ / (16.2kΩ x Im)
(EQ. 3)
R1 = 5V x R38 / (0.119 x Im +2.5V) - R38
(EQ. 4)
R11B = R39 x (0.119 x Im +2.5V) / (2.5 - 0.119 x Im)
(EQ. 5)
This equation assumes that the only change made to the
HIP4086DEMO1Z is modifying the values of the current sensing
resistors R23 and R24.
For example: for I
LIMIT
= ±5A,
R23||R24 = 4.878V - 2.5V x 1.022kΩ / (16.2kΩ x 5A)
R23||R24 = 0.030Ω
An alternative method for changing the pulse-by-pulse current
limit is to modify the threshold bias voltages on the comparators.
This option is only recommended if appropriate small value
resistors for current sensing are not readily available for lab
evaluation of the HIP4086DEMO1Z. Note that the full scale
output swing of the current diff amp will not be realized with this
method.
The threshold bias resistors for the positive current limit are R1
and R38. R39 and R11B are for the negative current limit. The
required threshold is determined by Equation 2 for the desired I
m
value. For example, the VoutCS value for pulse-by-pulse current
limit at 5A is:
Vout
= 0.119 x 5A +2.5V = 3.095V
CS
Equation 4 sets the positive current limit bias voltage.
For pulse-by-pulse positive current limit = 5A and R38 = 10kΩ,
R1 = 6.155kΩ.
Equation 5 sets the negative current limit bias voltage.
For pulse-by-pulse positive current limit = -5A and R39 = 10kΩ,
R11B = 6.155kΩ.
In the previous examples both the positive and negative current
limit value are equal in absolute values. It is acceptable to have
different limits for the positive and negative values.
Selecting the Correct Switching Sequence
In the discussion describing the operation of a BLDC motor, a
specific hall logic pattern was used in Figure 5. Unfortunately, not
all BLDC motors use this logic pattern. In all cases, the three hall
signals are phase shifted by 60° but the logic polarity can be
different. Also, because the 0° start position is not standardized,
two rotation cycles are illustrated so that any start position can
be identified.
The following charts define all possible combinations of hall
logic. It is necessary that the hall sensor logic that matches your
motor is selected by correctly setting the dip switch prior to
applying power to the HIP4086DEMO1Z. Known specific motor
part numbers are labeled in green boxes (see Figure 14).
.
9
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Application Note 1829
FIGURE 14. HALL LOGIC OPTIONS, FIRST CHART
Hall senso r log ic
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
Bridge Logic: P=PWM, L=Low, Z=off
MB
MA
MC
HC
HB
HA
101 001 011 010 110 101 001 011 010 110100 100
HC
HB
HA
110 010 000 001 101 110 010 000 001 101111 111
HC
HB
HA
111 011 001 000 100 111 011 001 000 100110 110
0010
0001
0000
HC
HB
HA
100 000 010 011 111 100 000 010 011 111101 101
0011
Ametek
119056
000 100 110 111 011 000 100 110 111 011001 001
Hall senso r log ic
HC
HB
HA
HC
HB
HA
010 110 100 101 001 010 110 100 101 001011 011
HC
HB
HA
011 111 101 100 000 011 111 101 100 000010 010
0111
0101
0100
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
Bridge Logic: P=PWM, L=Low, Z=off
MB
MA
MC
001 101 111 110 010 001 101 111 110 010000 000
HC
HB
HA
0110
B&D
Dip switch positions hall sensor logic options are defined by the blue boxes:
0011
4 3 2 1
dip switch position numbers
300
o
240
o
180
o
120
o
60
o
240
o
180
o
120
o
60
o
0
o
300
o
300
o
240
o
180
o
120
o
60
o
240
o
180
o
120
o
60
o
0
o
300
o
10
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March 14, 2013
Application Note 1829
FIGURE 15. HALL LOGIC OPTIONS, SECOND CHART
001 011 111 110 100 001 011 111 110 100000 000
000 010 110 111 101 000 010 110 111 101001 001
010 000 100 101 111 010 000 100 101 111011 011
011 001 101 100 110 011 001 101 100 110010 010
LZP LPZ ZPL PZL PLZ ZLP LZP LPZ ZPL PZL PLZ ZLP
Bridge Logic: P=PWM, L = Lo w , Z= off
Bodine
3304
HC
HB
HA
HC
HB
HA
HC
HB
HA
0101
0100
MB
MA
MC
HC
HB
HA
0110
LZP LPZ ZPL PZL PLZ ZLP LZP LPZ ZPL PZL PLZ ZLP
Bridge Logic: P=PWM , L= Lo w , Z =o ff
100 110 010 011 001 100 110 010 011 001101 101
111 101 001 000 010 111 101 001 000 010110 110
110 100 000 001 011 110 100 000 001 011111 111
101 111 011 010 000 101 111 011 010 000100 100
MB
MA
MC
HC
HB
HA
HC
HB
HA
HC
HB
HA
0010
0001
0000
HC
HB
HA
Hall sensor logic Hall sensor logic
Dip switch positions hall sensor logic options are defined by the blue boxes:
0011
4 3 2 1
dip switch position numbers
300
o
240
o
180
o
120
o
60
o
240
o
180
o
120
o
60
o
0
o
300
o
300
o
240
o
180
o
120
o
60
o
240
o
180
o
120
o
60
o
0
o
300
o
0011 0111
Selecting the Correct Switching Sequence
Notice that the dip switch settings for these Hall sensor logic
charts (Figure 15) are the same as Figure 14. This is not an error.
11
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Application Note 1829
12
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Bill of Materials, Rev A
PART NUMBER REF DES QTY VALUE
TOL.
(%) VOLTAGE POWER
PACK AGE
TYPE JEDEC TYPE MANUFACTURER DESCRIPTION
10TPE330M C8, C9 2 330µF 10 10V SMD CAP_7343 SANYO-POSCAP TPE SERIES LOW ESR PRODUCTS CAP
1725656 TB3 1 2MNT CON_TERM_MPT_2POSPHOENIX-
CONTACT
100 Mil Micro-Pitch Terminal Block
1725669 TB1,TB2 2 3MNT CON_TERM_MPT_3POSPHOENIX-
CONTACT
100 Mil Micro-Pitch Terminal Block
1729018 TB4-TB7 4 2 CON_TERM_MKDSN
_2POS
PHOENIXCONTACT
200 Mil PCB Connector Terminal Block
1N4148W-7-F D2, D4, D8, D12-D15 7 SOD SOD123 DIODES Fast Switching Diode (RoHS
COMPLIANT)
3299W-1-103-LF R13 1 10kΩ 10 1/2W RADIAL RES_POT_3299W BOURNS TRIMMER POTENTIOMETER (RoHS
COMPLIANT)
555165-1 J2 1 6M2 CON_JACK_555165-1TYCO Phone Jack Connector
597-3111-402 LED0-LED3 4 SMD DIA_LED1206 Dialight Surface Mount Red LED
B280 D1 1 SMD2 DIO_SMB DIODES 2A 80V SCHOTTKY BARRIER RECTIFIER
B3S-1002 BRAKE, RESET,
REVERSE, START/STOP
4 SMD SW_B3S-1002 OMRON Momentary Pushbutton Tactile SMT
Switch
BAT54A D3 1 COMMON-
ANODE
SOT23 DIODES 30V SCHOTTKY DIODE
C0805C106K8PACTU C7, C10 2 10µF 10 10V 805 CAP_0805 KEMET MULTILAYER CAP
C1608X7R1C105K C16, C33, C47 3 1µF 10 16V 603 CAP_0603 TDK MULTILAYER CAP
C1608X7R1H104K C15 1 0.1µF 10 50V 603 CAP_0603 TDK MULTILAYER CAP
C3225X7R2A105M C5 1 1µF 20 100V 1210 CAP_1 210 TDK Ceramic Chip Cap
CSTCE10M5G55 Y1 1 SMD CSTCE12M MURATA 10MHz CERALOCK Resonator
DR125-220-R L1 1 22.0µH 20 4.71A SMD IND_DR125 COOPER-
BUSSMANN
High Power Density Shielded Inductor
EEVFK1K471M C27 1 470µF 20 80V SMD CAPAE_708X650 PANASONIC Aluminum Elect SMD Cap
ES1B D5-D7, D9-D11 6 DO214 DO214_AC FAIRCHILD 1A 150V Fast Rectifier Diode
GRM21BR71C475KA73L C42, C45, C46, C50 4 4.7µF 10 16V 805 CAP_0805 MURATA CERAMIC CAP
H1045-00101-25V10 C4 1 100PF 10 25V 603 CAP_0603 GENERIC MULTILAYER CAP
H1045-00101-50V10 C23, C25 2 100PF 10 50V 603 CAP_0603 GENERIC MULTILAYER CAP
H1045-00103-50V10 C14, C30, C41 3 0.01µF 10 50V 603 CAP_0603 GENERIC Multilayer Cap
Application Note 1829
13
AN1829.0
March 14, 2013
H1045-00104-25V10 C38, C40 2 0.1µF 10 25V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00221-50V10 C17 1 220pF 10 50V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00224-16V10 C35-C37 3 0.22µF 10 16V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00391-50V10 C24 1 390pF 10 50V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00471-100V10 C26 1 470pF 10 100V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00471-50V10 C32 1 470pF 10 50V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00472-50V10 C3, C49 2 4700pF 10 50V 603 CAP_0603 GENERIC Multilayer Cap
H1045-00473-25V10 C6 1 0.047µF 10 25V 603 CAP_0603 GENERIC Multilayer Cap
H1045-OPEN C51 1 OPEN 5 OPEN 603 CAP_0603 GENERIC Multilayer Cap
H1046-00104-100V10 C1, C2, C11 3 0.1µF 10 100V 805 CAP_0805 GENERIC Multilayer Cap
H1065-00105-100V10 C29, C31, C34, C48 4 1µF 10 100V 1206 CAP_1206 GENERIC Multilayer Cap
H2505-DNP-DNP-1 R5, R34, R52, R61, R62 5 DNP 1 DNP 603 RES_0603 GENERIC Metal Film Chip Resistor (Do Not
Populate)
H2505-DNP-DNP-R1 RJ2, RJ3 2 DNP 0.10 DNP 603 RES_0603 GENERIC Metal Film Chip Resistor (Do Not
Populate)
H2511-00330-1/16W5 R19, R26, R27 ,R36,
R37, R40
6 33 5 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-00R00-1/16W RJ1 1 0 0 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-00R00-1/16W1 R42, RJ4, RJ10, RJ11 4 0 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-01000-1/16W1 R46 1 100 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-01001-1/16W1 R47-R49, R51, R58-R60 7 1kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-01002-1/16W1 R16, R25, R28-R33,
R35, R38 ,R39,
R43-R45, R4, R11
16 10kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-01004-1/16W1 R12A, R12B 2 1MΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-02490-1/16W1 R1, R11B 2 249Ω 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-01622-1/16W1 R10 1 16.2kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-02001-1/16W1 R20 1 2kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-02002-1/16W1 R7, R53-R55 4 20kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-03013-1/16W1 R6 1 301kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-03242-1/16W1 R3, R12, R14, R15 4 32.4kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
Bill of Materials, Rev A (Continued)
PART NUMBER REF DES QTY VALUE
TOL.
(%) VOLTAGE POWER
PACK AGE
TYPE JEDEC TYPE MANUFACTURER DESCRIPTION
Application Note 1829
14
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March 14, 2013
H2511-04700-1/16W1 R41 1 470Ω 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-05110-1/16W1 R17, R18, R21, R22 4 511Ω 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-05112-1/16W1 R9 1 51.1kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-05621-1/16W1 R8 1 5.62kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2511-07151-1/16W1 R50 1 7.15kΩ 1 1/16W 603 RES_0603 GENERIC Thick Film Chip Resistor
H2513-001R2-1/8W1 R2, R56, R57 3 1.2Ω 1 1/8W 1206 RES_1206 GENERIC Thick Film Chip Resistor
HIP4086ABZ U5 1 SOIC SOIC24_300_50 INTERSIL Three Phasre Driver 80v 0.5A
IRFS4710 Q1-Q6 6 D2PAK D2PAK IR N-Channel 100V 75A HEXFET Power
MOSFET
ISL28246FUZ U2, U3 2 MSOP MSOP8_118_256 LINEAR DUAL RAIL TO RAIL OUTPUT AMPLIFIER
(Pb-Free)
ISL6719ARZ U6 1 DFN DFN9_118X118_19
7_EP
INTERSIL 100V Linear Regulator
ISL8560IRZ U1 1 20QFN QFN20_236X236_3
15_EP
INTERSIL 2A DC/DC POWER SWITCHING
REGULATOR
PIC18F2431S0 U4 1 SOIC SOIC28_300_50V2 Microchip Flash Microcontroller
SD04H0SK SW1 1 SMT SD04H0SK C&K SD Series Low Profile DIP Switch 4 Pos
SPST
WSH2818R0150FE R23, R24 2 0.015Ω 1 5W 2818 RES_WSH2818 VISHAY SURFACE MOUNT POWER METAL STRIP
RESISTOR
TOTAL 157
Bill of Materials, Rev A (Continued)
PART NUMBER REF DES QTY VALUE
TOL.
(%) VOLTAGE POWER
PACK AGE
TYPE JEDEC TYPE MANUFACTURER DESCRIPTION
Application Note 1829
15
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March 14, 2013
HIP4086DEMO1Z Board Schematics
FIGURE 16. BIAS SUPPLIES
470PF
V_12V
V_48V
100V
100V
1UF
0603
51.1K
100V
50V
22.0UH
DR125-220-R
ISL8560IRZ
301K
0.1UF
0.01UF
0
0
16.2K
220PF
100V
7.15K
100PF
50V
ISL6719ARZ
1K
1UF
B280
10UF
10UF
V_5V
330UF
330UF
0
DNP
0.1UF
0.1UF
1UF
20K
390PF
100PF
50V
5.62K
1UF
0.1UF
50V
50V
16V
OPEN
21
21
21
12
EP
AUXIN
COMPB
ENABLE
COMPA VSW_FB
VSW
ENABLE_N
GND VPWR
OUT
IN
OUT
1720 19 18 16
R42
C24
EP
VCC5
EN
BOOT
LX
REF
PGOOD
PGND
SS
LX
LX
C8
C9
C16
R50R51
C26
C5
C17
C48
C47
D1
C10
C7
C25 R8
R10 R9
R52 C51
C15
C11
C1
C2
VIN
VINRTCT
SYNC
SGNDFBCOMP
VIN
LX
VIN
8210
10
9
8
7
6
54
3
1
21
15
14
13
12
11
976
5
4
3
2
1
RJ10
RJ11
C23
R6
C14
R7
U1
U6
L1
Application Note 1829
16
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March 14, 2013
FIGURE 17. CONTROLLER
HIP4086DEMO1Z Board Schematics (Continued)
HALL SWITCHES
HALL BIAS
A
POTENTIOMETER
SPEED
(OPTIONAL)
CONTROL
EXTERNAL
B
C
+5V
GND
CONTROLLER
PROGRAMING
PORT
V_5V
10K
470
IMOT
1K
555165-1
SD04H0SK
1K
10K
10K
10K
4.7UF
10K
0.047UF
1K
1K
10K
100PF
0
10K
RB6
RB7
/FLTA
RB6
PIC18F2431S0
V_5V
4.7UF
CSTCE10M5G55
0.01UF
50V
10K
10K
V_5V
V_5V
MCLR
RB7
10MHZ
10K
10K
10K
10K
4.7UF
1K
2K
4.7UF
PWM0
PWM1
PWM2
PWM3
PWM5
PWM4
MCLR
2
1
1
13
12
2
12
12
12
12
12
21
2
21
876
54
3
2
1
4
3 2
1
21
4
3 2
1
4
3 2 2
1
3
1
4
OUT
IN
OUT
OUT
OUT
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
3
3
1
2
2
3
1
2
1
2
1
6
5
1
2
3
4
C30
TB2
TB3
R28
RJ1
TB1
R60
R30
R29
Y1
J2
RC2
RC1
RC0
OSC2
OSC1
AVDD
RA4
RA3
RA2
RA1
RC6
VDD
VSS
RB0
RB1
RB5
RC7
RB3
RB4
RB2
AVSS
RC3
RA0
MCLR
RC4
RC5
RB7
RB6
C6
R32
SW1
R48
R35
C4
LED3
R44
R43
R33
R13
R25
D2
D4
D14
D15
D13
D12
D8
LED1
LED0
R45
R59
R58
R49
LED2
C46
C42
RESET
C45
R31
214
3
567
8
28
27
26
25
24
23
22
21
20
19
18
17
16
1514
13
12
11
10
9
8
7
6
5
4
3
2
1
R41
R20
START/STOP
BRAKE
C50
REVERSE
R16
U4
Application Note 1829
17
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March 14, 2013
FIGURE 18. BRIDGE AND CURRENT SENSE
HIP4086DEMO1Z Board Schematics (Continued)
FOR NO DEAD TIME DELAYS:
RJ4= 0 OHM, R5 = OPEN.
FOR DEAD TIME DELAYS:
RJ4= OPEN, R5=10K...100K.
TO DISABLE BRIDGE
DRIVER WHILE TROUBLESHOOTING CODE:
RJ3 = O OHM
PWM2
PWM0
PWM3
PWM5
ALO
V_12V
10K
100
CLO
CLO
1000PF
MB
ISL28246FUZ
0.1UF
V_5V
HIP4086ABZ
AHO
0.22UF
IRFS4710
1UF
IRFS4710
33
BHO
511
32.4K
DNP
DNP
0.1UF
ISL28246FUZ
ISL28246FUZ
0.01UF
ISL28246FUZ
4700PF
0.015
511
32.4K
IMOT
IRFS4710
0.015
1000PF
DNP
0
DNP
1000PF
0.22UF
0.22UF
IRFS4710
IRFS4710
IRFS4710
CHO
20K
4.7
249249
1M
1M
10K
10K
511
511
4700PF
32.4K
20K
MC
MA
10K
MC
PWM4
4.7
BLO
4.7
BLO
CHO
MA
1UF
MB
1UF
470UF
20K
33
33
AHO
ALO
33
33
33
32.4K
V_48V
BHO
1UF
470PF
DNP
1K
50V
DNP
/FLTA
V_5V
PWM1
1
2
1
2
1
2
1
1
1
1
1
1 2
2
2 3 32 3 32 3232
1
12 12 12
12
12
1
1
2
2
OUT
V+
V-
OUT
V-
V+
IN
IN
OUT
IN
IN
IN
IN
IN
OUT
IN
IN
OUT
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
2
4
5
4
3
2
1
3
7
6
8
1
3
7
6
5
8
1
2
1
2
U2
R14
R18
RJ3
TB5
R22
R21R17
R12
R15
D3
U3
U3
TB7
TB4
TB6
VDD
VSS
ALO
BLO
RFSH
CLI
BHO
BHB
/AHI
/CHI
UVLO
RDEL
CLO
AHS
AHO
AHB
CHS
CHO
CHB
DIS
BHS
ALI
BLI
/BHI
21
R54
C36
C52
D10
RJ4
R38
C37
C34
D9
C55
C40
R61
R39
C38
C49
R24
R23
RJ2
R1R11B
R34
C53
R3
R62
R5
C27
C41
C3
D11
R55 R53
C35
C31 C29
7
20
16
15
18
17
2
1
14
19
12
9
6
8
10
11
13
223
23
24
214
5
R4
R46
Q3
R12B
R12A
Q6
C33
U2
R2
R56
Q4
R11
R57
Q5
Q2
Q1
D6 D7D5
R47
R40
R27
U5
R37
C32
R26
R36
R19
PCB Layout
R43
R44
D12
D13
C45
R41
R32
R33
TB2
TB3
TB1
RESET
L1
C7
C8
C9
R34
R47
R45
R35
RJ2
D15
SW1
R25
C4
D14
C46
R29
R30
HC
Y1
R60
HA
HB
GND
5V
5V
TAP
GND
R42
C10
C25
RJ3
C32
R5
RJ4
U5
U4
C30
R20
R28
C42
R16
R31
D1
C51
R52
C1
C2
R9
R10
R50
R51
C5
R8
C36
D6
R58
RJ1
R13
J2
BRAKE
RJ11
C11
C16
U1
C14
C15
U6
C17
RJ10
R40
D9
C35
C37
D7
C33
R48
R27
D10
R59
R49
C50
R17
R11
LED2
LED3
U3
LED0
LED1
R39
D8
REVERSE
C26
R7
C24
R6
C48
C23
R37
D5
R2
R19
R26
D11
R57
R36
R56
C3
C49
R21
R14
R46
R12B
R12
C40
R12A
D3
C41
R11B
R61
D4
R55
BLDC MOTOR DRIVE
R53
R15
R18
R22
C38
U2
R54
R3
R1
R4
R62
R38
C31
D2
START/STOP
C34
R24
R23
C29
C27
Q6
Q5
Q2
Q1
Q4
Q3
TB6
MC
MC
MA
TB4
MA
MB
TB5
MB
BATT
+
TB7
-BATT
HIP4086DEMO1ZA
Pb
C6
Application Note 1829
18
FIGURE 19. PCB SILKSCREEN, REV A
AN1829.0
March 14, 2013
PCB Layout (Continued)
R43
R44
D12
D13
C45
R41
R32
R33
TB2
TB3
TB1
RESET
L1
C7
C8
C9
R34
R47
R45
R35
RJ2
D15
SW1
R25
C4
D14
C46
R29
R30
HC
Y1
R60
HA
HB
GND
5V
5V
TAP
GND
R42
C10
C25
RJ3
C32
R5
RJ4
U5
U4
C30
R20
R28
C42
R16
R31
D1
C51
R52
C1
C2
R9
R10
R50
R51
C5
R8
C36
D6
R58
RJ1
R13
J2
BRAKE
RJ11
C11
C16
U1
C14
C15
U6
C17
RJ10
R40
D9
C35
C37
D7
C33
R48
R27
D10
R59
R49
C50
R17
R11
LED2
LED3
U3
LED0
LED1
R39
D8
REVERSE
C26
R7
C24
R6
C48
C23
R37
D5
R2
R19
R26
D11
R57
R36
R56
C3
C49
R21
R14
R46
R12B
R12
C40
R12A
D3
C41
R11B
R61
D4
R55
BLDC MOTOR DRIVE
R53
R15
R18
R22
C38
U2
R54
R3
R1
R4
R62
R38
C31
D2
START/STOP
C34
R24
R23
C29
C27
Q6
Q5
Q2
Q1
Q4
Q3
TB6
MC
MC
MA
TB4
MA
MB
TB5
MB
BATT
+
TB7
-BATT
HIP4086DEMO1ZA
Pb
C6
Application Note 1829
19
FIGURE 20. SILKSCREEN WITH PADS, REV A
AN1829.0
March 14, 2013
PCB Layout (Continued)
Application Note 1829
20
FIGURE 21. TOP LAYER, REV A
AN1829.0
March 14, 2013
PCB Layout (Continued)
Application Note 1829
21
FIGURE 22. LAYER 2, REV A
AN1829.0
March 14, 2013
PCB Layout (Continued)
Application Note 1829
22
FIGURE 23. LAYER 3, REV A
AN1829.0
March 14, 2013
PCB Layout (Continued)
Application Note 1829
23
FIGURE 24. BOTTOM LAYER, REV A
AN1829.0
March 14, 2013
Application Note 1829
led0led 1led2led3 Code version 1
led0led 1led2led3 Code version 2
led0led 1led2led3 Code version 3
led0led 1led2led3
Code version 4
led0led 1led2led3 Code version 5
led0led 1led2led3 Code version 6
led0led 1led2led3 C ode version 15
led0led 1led2led3
Code version 7
led0led 1led2led3 C ode version 8
led0led 1led2led3 C ode version 9
Note that the LEDs are binary encoded.
led3 led2 le d1
led0
FIGURE 25. CODE VERSION NUMBERS
led1led2
invalid test mode
configuration
current monitor
test failure
red arrows indicate a flashing LED
led3 led2 led1 led0
led3 led0
successful test
Mode completion
led1led2led3 led0
blue arrows indicate the movement of the flashing LED
led1led2led3 led0
valid test mode
startup, no flashing
FIGURE 26. EXAMPLES OF LED TEST STATUS
MA
MB
MC
FIGURE 27. WAVEFORMS ON MA, MB, and MC WITH HA GROUNDED
Test Mode
To validate the correct performance of the HIP4086 demo board,
a built-in test procedure can be used to verify that the board is
fully functional. A 50V, 200mA lab supply and an oscilloscope
are necessary to perform this test. No motor is required and
should not be connected. Each individual test section must be
valid before proceeding to the next step. Stop testing at any
failure.
Test Mode Setup
1. Connect a ~75mm (3 inch) wire to the GND terminal close to
the HA, HB, HC terminal block.
2. Setup a scope with the vertical scale = 20V/div and the time
base = 10µs/div. Three probes are recommended but not
absolutely necessary.
3. Adjust the lab supply to 50VDC and 200mA current limit.
4. With the lab supply turn off, connect to the +BATT and -BATT
terminal inputs of the HIP4086DEMO1Z board.
5. Set dip switch positions 1 through 4 to on.
6. While pressing simultaneously the BRAKE and REVERSE push
buttons, turn on the lab supply.
7. If led0 and led3 are flashing or if no LEDs are on, the test
mode was not initiated correctly, the board is faulty or the
microcontroller is not programmed. To confirm, restart the
test mode s etup. If one o r mo re LEDS are on without flashing,
the test mode is now active. At this point the binary
combination of the on LEDs indicates the version number of
the firmware (see Figure 25). Figure 26 shows other examples
of faulty setup or failed test results.
Push-button Test
1. Press the START/STOP button. All four LEDs should turn on.
2. Press again the START/STOP button. Led0 should turn off.
3. Press the REVERSE button. Led1 should turn off.
4. Press the BRAKE button. Led2 should turn off.
5. Press again the BRAKE button. Led3 should turn off. At this
point all four LEDs are off and correct operation of the push
buttons is confirmed.
Hall Inputs and Bridge Tests
MA OUTPUT TEST
1. Using the 75mm wire, short the HA terminal input to ground.
LED0 should turn on.
2. While the HA input is grounded, observe the following
waveforms in Figure 27, on the MA, MB, and MC terminals.
24
AN1829.0
March 14, 2013
Application Note 1829
MA
MB
MC
FIGURE 28. WAVEFORMS ON MA, MB, and MC WITH HA GROUNDED
MA
MB
MC
FIGURE 29. WAVEFORMS ON MA, MB, and MC WITH HB GROUNDED
MA
MB
MC
FIGURE 30. WAVEFORMS ON MA, MB, and MC WITH HC GROUNDED
3. Figure 28 illustrates incorrect waveforms. There should not be
any switching on MB and MC while MA is low. (At the very edge
of MA falling, there may be a small amount of induced
switching noise)
4. While the HA input is grounded, observe that the lab supply
current is < 45mA.
MB OUTPUT TEST
1. Using the 75mm wire, short the HB terminal input to ground.
Led1 should turn on.
2. While the HB input is grounded, observe the following
waveforms on the MA, MB, and MC terminals.
MB OUTPUT TEST
1. Using the 75mm wire, short the HC terminal input to ground.
Led2 should turn on. After a short pause, led3 will also turn on.
At this point, all four LEDs are on.
2. While the HC input is grounded, observe the following
waveforms on the MA, MB, and MC terminals.
As the example in Figure 27 shows, there should be no switching
disturbances on MB and MA.
3. While the HC input is grounded, observe that the lab supply
current is < 45mA.
Dip Switch Test
1. Move each dip switch, one at a time starting with position 1,
to the off position.
2. Observe that led0, led1, led2, and led3 turn off one at a time
in synchronous with the dip switches being turned off.
Potentiometer Test
1. After a short pause, all LEDs will turn on if the potentiometer
is turned fully to the right (CW). If the LEDs are not on, rotate
the potentiometer to the right until all LEDs turn or when the
potentiometer starts to click. If all LEDs do not turn on, the
board is faulty.
2. After all the LEDs turn on, rotate the potentiometer to the left
(CCW). Observe that led3, led2, led1, and led0 turn off
sequentially as the potentiometer is rotated towards the
minimum voltage setting.
Current Monitor Test
As the example in Figure 27 shows, there should be no switching
disturbances on MC and MA.
3. While the HB input is grounded, observed that the lab supply
current is <45mA.
Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is
cautioned to verify that the Application Note or Technical Brief is current before proceeding.
For information regarding Intersil Corporation and its products, see www.intersil.com
25
1. This final test is performed automatically after the
potentiometer test. No inputs from the test operator is
necessary. If successful, all four LEDs are sequentially
flashing one at a time. If not successful, all four LEDS flash
simultaneously.
2. The end.
March 14, 2013
AN1829.0
Mouser Electronics
Authorized Distributor
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HIP4086DEMO1Z
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