Active-semi HYDRA-X BLDC User manual

Copyright © 2014 Active-Semi, Inc.
HYDRA-X BLDC Head
Power Application Controllers
TM
PAC5220 Expansion - HYDRA-X BLDC Head User’s Guide
www.active-semi.com

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C 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

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O 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

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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.

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HYDRA-X BLDC H EAD R ESOURCES
Header Descriptions
The following table shows the female header descriptions for the HYDRA-X10 Body module.
Header
Pin
Description
J
1
1-10 Refer to HYDRA-X20 pinout diagram
J
2
1-8 Refer to HYDRA-X20 pinout diagram
J
3
1-20 Refer to HYDRA-X20 pinout diagram
J4
1-10 Refer to HYDRA-X20 pinout diagram
J5
1-6 Refer to HYDRA-X20 pinout diagram
J6
- 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
J7
- VIN Power Input -Spade connector (16V to 48V)
J8
- GND Power Input – Spade Connector
J9
- 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

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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.

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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.

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External and Internal Resources
The following table illustrates the systems resources utilized
Header
Pin
Description
GPIO Resource
J6
2 Hall Sensor U Phase PD2
J6
3 Hall Sensor V Phase PD3
J6
4 Hall Sensor W Phase PD6
J6
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

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HYDRA-X BLDC H EAD H 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

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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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HYDRA-X BLDC H EAD S CHEMATIC
Figure 7:HYDRA-X BLDC Head Schematic Diagram

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A BOUT A CTIVE -S EMI
Founded in 2004 in Silicon Valley and headquartered in Allen, Texas, Active-Semi is a rapidly emerging
leader in the multi-billion dollar power management IC and intelligent digital motor drive IC markets. The
company's portfolio of analog and mixed signal SoCs (systems-on-chips) are scalable core platforms
used in charging, powering and embedded digital control systems for end applications such as industrial,
commercial and consumer equipment. The company offers power application microcontrollers, DC/DC,
AC/DC, PMU and LED drivers that significantly reduce solution size and cost while improving system-
level reliability. Active-Semi's turnkey solutions deliver energy-saving power conversion architectures
that minimize energy usage and compress system development cycle-time by greater than 50 percent.
Active-Semi ships 50 million power ICs per quarter and reached the "one billion units shipped" milestone
in May 2012. The multi-national company focuses on commercializing industry leading power
management IC solution platforms and has developed broad intellectual property with over 150 patents
granted and pending. For more information visit: http://active-semi.com/
LEGAL INFORMATION & DISCLAIMER
Copyright © 2012-2013 Active-Semi, Inc. All rights reserved. All information provided in this document is subject to legal disclaimers.
Active-Semi reserves the right to modify its products, circuitry or product specifications without notice. Active-Semi products are not intended, designed, warranted
or authorized for use as critical components in life-support, life-critical or safety-critical devices, systems, or equipment, nor in applications where failure or
malfunction of any Active-Semi product can reasonably be expected to result in personal injury, death or severe property or environmental damage. Active-Semi
accepts no liability for inclusion and/or use of its products in such equipment or applications. Active-Semi does not assume any liability arising out of the use of any
product, circuit, or any information described in this document. No license, express, implied or otherwise, is granted under any patents, copyrights or other
intellectual property rights of Active-Semi or others. Active-Semi assumes no liability for any infringement of the intellectual property rights or other rights of third
parties which would result from the use of information contained herein. Customers should evaluate each product to make sure that it is suitable for their
applications. Customers are responsible for the design, testing, and operation of their applications and products using Active-Semi products. Customers should
provide appropriate design and operating safeguards to minimize the risks associated with their applications and products. All products are sold subject to Active-
Semi's terms and conditions of sale supplied at the time of order acknowledgment. Exportation of any Active-Semi product may be subject to export control laws.
Active-Semi™, Active-Semi logo, Solutions for Sustainability™, Power Application Controller™, Micro Application Controller™, Multi-Mode Power Manager™,
Configurable Analog Front End™, and Application Specific Power Drivers™ are trademarks of Active-Semi, I. ARM® is a registered trademark and Cortex™ is a
trademark of ARM Limited. All referenced brands and trademarks are the property of their respective owners.

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