Texas Instruments DRV830x Rev D. User manual

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DRV830x Rev D. Hardware Quick Start Guide
Version 1.0.5 Motor Solutions
Fig 1: DRV830x EVM with controlCARD
Abstract
The Low Voltage, High Current Motor Drive EVM (DRV8301, Figure 1), provides a great way to
learn and experiment with digital control of sub 60 volt three-phase motors to increase efficiency
of operation. The board is available in two configurations, the DRV8301 or the DRV8302. This
document goes over the typical kit contents and hardware details, and explains the functions and
locations of jumpers and connectors present on the board. This document supersedes all the
documents available for the kit.

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Version: 1.0.5
Revision History:
1.0.5 April 23, 2014 Fixed page 18-20 comments regarding ADC
and IQ CURRENT, VOLTAGE, and pole settings
1.04 January 29, 2014 Changed page 8 regarding GPIO to Enable Pin
connection with TMDSCNCD28027F
1.03 July 11, 2013 Updated for TMDSCNCD28027F support. See
specific instructions on Page 8.
Added section on Optimizing Sense Circuitry
1.0.2 March 21, 2013 Added Revision History
1.0.1 February 26,
2013 First release

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WARNING
This EVM is meant to be operated in a lab environment only and is not
considered by TI to be a finished end-product fit for general consumer use
This EVM must be used only by qualified engineers and technicians familiar
with risks associated with handling high voltage electrical and
mechanical components, systems and subsystems.
This equipment operates at voltages and currents that can result in electrical shock, fire
hazard and/or personal injury if not properly handled or applied. Equipment must be used
with necessary caution and appropriate safeguards employed to avoid personal injury or
property damage.
It is the user’s responsibility to confirm that the voltages and isolation requirements are
identified and understood, prior to energizing the board and or simulation. When
energized, the EVM or components connected to the EVM should not be touched.

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Table of Contents
Getting Familiar with the Kit .......................................................................................................... 5
Kit Contents ..............................................................................................................................................................................5
Board Features:........................................................................................................................................................................5
Warning: about low switching frequencies on the DRV830x ....................................................................................................5
Hardware Overview ........................................................................................................................ 6
Macro Blocks ............................................................................................................................................................................6
Powering the Board......................................................................................................................... 8
Hardware Resource Mapping.......................................................................................................... 9
Resource Allocation..................................................................................................................................................................9
Jumpers and Connectors........................................................................................................................................................11
Optimizing Sense Circuitry........................................................................................................... 16
Overview.................................................................................................................................................................................16
Shunt Current Feedback.........................................................................................................................................................17
Phase Voltage Feedback........................................................................................................................................................18
Phase Voltage Filter Feedback...............................................................................................................................................20
SCHEMATIC DISCLAIMER AND WARNINGS ...................................................................... 22

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Getting Familiar with the Kit
Kit Contents
The DRV830x EVM is usually available packaged as a full solution kit:
•MCU controlCARD
•DRV830x EVM board with slot for the controlCARD
•USB Cable
•USB/DVD with CCStudio IDE, GUI, documentation, and link to project software
distribution
•Some versions ship with a tabletop 24V 2.5A power supply and 24V Motor with built-in
Hall Sensors and Encoder
The DRV830x EVM board can accept many of the TI MCU controlCARDs, but we recommend
using the versions that ship with the kits that include the JTAG emulator, USB to serial, and
isolation on the controlCARD. It is recommended to always check for any updates to the GUI
executable and MCU program.
Board Features:
The board has the following features
•Three-Phase Power Stage, DRV830x capable of driving 3-phase brushless DC motors
and Permanent Magnet Synchronous Motors.
o60V DC max input voltage
o60A peak output current per phase
oUp to 200khz driver switching frequency
oIntegrated 1A buck converter to provide logic and analog power
oDual integrated current sense amplifiers
•Isolated CAN and SPI communication (will only work if MCU supports and SW is
enabled)
•JTAG connector for external emulators
•Quadrature Encoder Interface and Hall Sensor Interface available for speed and position
measurement (only if MCU supports and SW is enabled)
•High precision low-side current sensing using integrated current sense amplifiers in the
DRV830x (2-ch) or optional external 3-ch (Starting with DRV8301 RevD)
•Over current protection on the inverter stage by DRV830x
•Hardware Developer’s Package that includes schematics and bill of materials
•Closed-loop digital control with feedback using the MCU’s on-chip PWM and ADC
peripherals
Warning: about low switching frequencies on the DRV830x
When the DRV830x runs at a low switching frequency (e.g. less than 20 kHz with 100 nF
bootstrap capacitor), the bootstrap capacitor voltage might not be able to maintain a proper

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voltage level for the high-side gate driver. A bootstrap capacitor under voltage protection circuit
(BST_UVP) will start under this circumstance to prevent the potential failure of the high-side
MOSFET. In this circumstance, both the FAULT and OTW pins should pull low and the device
should self-protect itself. The motor’s inductance and the inverter’s bootstrap capacitance will
allow the DRV830x to run efficiently until approximately 10 kHz (with margin). Setting the PWM
switching frequency below 10 kHz may cause issues on the inverter output and is not
recommended. Please reference the datasheet.
Hardware Overview
The example projects made available with the kit may be done with a supplied 24V power supply,
but many of the examples will work with an externally supplied laboratory power supply of a
different voltage or current limit. The DRV830x EVM has all the power and control blocks that
constitute a typical motor drive system for a three-phase system: Communications + Control +
Feedback + Feedforward + Drive
Macro Blocks
The motor control board is separated into functional groups that enable a complete motor drive
system, these are referred to as macro blocks. Following is a list of the macro blocks present on
the board and their functions:
•controlCARD socket – Socket for a controlCARD (preferably using built-in emulation).
•DC Bus Connection
o“PVDD/GND” Terminals – Connect an external 8-60V DC lab supply here
making sure to observe correct polarity..
•DRV830x – This module includes either the DRV8301 or DRV8302 Three Phase Pre-
Driver as well as all of the necessary external passive components.
•Current Sense – Low-side shunt current sensing on each half-bridge.
•Quadrature Encoder Connections – Connections are available for an optional shaft
encoder to interface to the MCU’s QEP peripheral.
•Hall Effect Sensor Connections – Connections are available for optional Hall Effect
Sensors.
Fig 2, illustrates the position of these macro blocks on the board. The use of a macro block
approach, for different power stages enables easy debug and testing of one stage at a time. All
the PWM’s and ADC signals which are the actuation and sense signals have designated test
points on the board, which makes it easy for an application developer to try out new algorithms
and strategies.

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Fig2: DRV830x-EVM Board Macros

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Powering the Board
The board is separated into two power domains*, the low voltage Controller Power domain that
powers the controller and the logic circuit present on the board, and the medium voltage power
delivery line that is used to carry the medium voltage and current like the DC power for the
Inverter also referred to as DC Bus.
1) Controller Power comprises of the 5V and 3.3V that the board uses to power the controller
and the logic and sensing circuit present on the board. This power is regulated from the DC bus
by the DRV830x integrated buck converter.
2) DC Bus Power is the medium voltage line – up to 60V - that provides the voltage to the
inverter stage to generate 3 phases to control the motor
Note: Do not apply power to board before you have verified these settings!
The kit ships with the control card inserted and the jumper and switch settings pre done
for connecting with the GUI. However the user must ensure that these settings are valid
on the board.
1. Make sure nothing is connected to the board, and no power is being supplied to
the board.
2. Insert the controlCARD into the connector if not already populated.
Special Notes Regarding controlCARD Use
•Make sure switches are set properly on the controlCARD according to the
appropriate qsg_hw_cncd280xxx.pdf
•Special notes for using controlCARDs with this motor drive board
oWhen using TMDSCNCD28027F
Connect pin 2 of J12 (GPIO-29) to pin 6 of J5 (EN_GATE).
Note, for all MotorWare versions up to _11 this was pin1 of
J11. Changed in _12 due to pin conflict.
3. Make sure the following jumpers & connector settings are valid i.e.
a. JP2 is installed
4. Connect your PC to the kit
a. controlCARDs with on-card XDS100 USB-JTAG:
i. connect USB cable from computer to USB connector on control
card
b. controlCARDs without on-card USB-JTAG
i. connect USB cable from computer to external emulator, and
emulator to 14-pin JTAG header (J21)
5. Connect the motor you want to spin to the “MOTOR” terminal block as shown
below. The order is not important unless a rotor sensor is used. If ground is
available with your motor it should also be used.

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6. Connect an 8-60V DC power supply to the PVDD and GND terminals.
Fig3: DRV830x-HC-EVM Motor Connections
Hardware Resource Mapping
Resource Allocation
J1
Pin no. GPIO Signal Name Function
(DRV8301/DRV8302)
23 GPIO-00 PWM_AH DRV830x Phase AH PWM input
73 GPIO-01 PWM_AL DRV830x Phase AL PWM input
24 GPIO-02 PWM_BL DRV830x Phase BH PWM input
74 GPIO-03 PWM_BL DRV830x Phase BL PWM input
25 GPIO-04 PWM_CH DRV830x Phase CH PWM input
75 GPIO-05 PWM_CL DRV830x Phase CL PWM input
26 GPIO-06 DAC_PWM4 PWM DAC
76 GPIO-07 STOP Push button input
28 GPIO-08 DAC_PWM3 PWM DAC
78 GPIO-09 START Push button input
29 GPIO-10 DAC_PWM1 PWM DAC
79 GPIO-11 DAC_PWM2 PWM DAC
33 GPIO-12 LED-1 User LED

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83 GPIO-13 OCTWn Over-temperature warning
84 GPIO-14 FAULTn Over-current fault
34 GPIO-15 LED-2 User LED
38 GPIO-16 SPI-SIMO Isolated SPI Interface
88 GPIO-17 SPI-SOMI Isolated SPI Interface
39 GPIO-18 SPI-CLK Isolated SPI Interface
89 GPIO-19 SPI-STE Isolated SPI Interface
40 GPIO-20 QEPA Encoder A
90 GPIO-21 QEPB Encoder B
41 GPIO-22 STATUS User LED
91 GPIO-23 QEPI Encoder Index
35 GPIO-24 SDI SPI Data In/M_DC
85 GPIO-25 SDO SPI Data Out/GAIN
36 GPIO-26 SCLK SPI ClockDC_ADJ
86 GPIO-27 /SCS /SCS/M_PWM
44 GPIO-30 CAN-RX Isolated CAN Interface
94 GPIO-31 CAN-TX Isolated CAN Interface
30 GPIO-40 CAP1 Hall Input 1
80 GPIO-41 CAP2 Hall Input 2
31 GPIO-42 CAP3 Hall Input 3
81 GPIO-43 DC-CAL Short DC current sense amplifier
inputs to ground, calibrate offset
59 ADC-A1 IA-FB Current sense phase A
61 ADC-A2 I-TOTAL DC Bus current sense
63 ADC-A3 IC-FB Current sense phase C
67 ADC-A5 IC-FB Current sense phase C

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71 ADC-A7 ADC-Vhb2 Phase Voltage sense B
7 ADC-B0 TSI Tach/Pot input
9 ADC-B1 IB-FB Current sense phase B
11 ADC-B2 VDCBUS DC Bus voltage sense
13 ADC-B3 IA-FB Current sense phase A
15 ADC-B4 ADC-Vhb3 Phase Voltage sense C
17 ADC-B5 IB-FB Current sense phase B
21 ADC-B7 ADC-Vhb1 Phase Voltage sense A
Table 1: Signal mapping to the controlCARD DIMM slot
Jumpers and Connectors
The Tables below show the various connections available on the board.
Connector Reference # of Pins Name
J2 2 HEADER2x1
J4 5 HEADER5x1
J5 40 HEADER20x2
J6 5 HEADER5x1
J7 3 HEADER3x1
J8 5 HEADER5x1
J10 5 HEADER5x1
J11 4 TERM BLOCK HEADER 4x1
J12 2 HEADER2x1
J13 2 HEADER2x1
J20 10 HEADER5x2
J21 14 HEADER7x2

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J23 2 HEADER2x1
J24 2 HEADER2x1
J25 2 TERM BLOCK HEADER 2X1
J26 2 TERM BLOCK HEADER 2X2
Table 2: List of Connectors

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J2 (User Power Access) J8 (User SPI) J13 (User Power Access) J21 (External JTAG)
Pin # Signal Pin # Signal Pin # Signal Pin # Signal
1 VCC_5V 1 iSD-O 1 VCC_3.3V 1 TMS
2 GND 2 iCLK-O 2 GND 2 TRSTn
3 iSD-I 3 TDI
J4 (Optional Encoder) 4 iGPIO J20 (DRV8301 SPI)) 4 GND
Pin # Signal 5 IGND Pin # Signal 5 VCC_3.3V
1 E1A 1 NC 6 NC
2 E1B J10 (HALL Sensor) 2 GND 7 TDO
3 E1C Pin # Signal 3 NC 8 GND
4 VCC_5V 1 E2A 4 NC 9 TCK
5 GND 2 E2B 5 SDO 10 GND
3 E2C 6 NC 11 TCK
J6 (PWM DAC) 4 VCC_5V 7 SCLK 12 GND
Pin # Signal 5 GND 8 SDI 13 EMU0
1 DAC1 9 /SCS 14 EMU1
2 DAC2 J11 (Motor) 10 GND
3 DAC3 Pin # Signal J25 (Power Input)
4 DAC4 1 Phase A J23 (Push Button) Pin # Signal
5 GND 2 Phase B Pin # Signal 1 PVDD
3 Phase C 1 START 2 PVDD
J7 (CAN) 4 GND 2 GND
Pin # Signal J26 (Power Input)
1 CAN-H J12 (GPIO/SCI) J24 (Push Button) Pin # Signal
2 CAN-L Pin # Signal Pin # Signal 1 GND
3 IGND 1 GPIO-28 1 STOP 2 GND
2 GPIO-29 2 GND

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Tables3-17 Individual Connector Pinouts
J5 (External Controller Access)
Pin # Signal Pin # Signal
1 VCC_5V 2 VCC_5V
3 GND 4 GND
5 STATUS 6 EN_GATE
7 QEPA 8 QEPI
9 FAULTn 10 QEPB
11 CAP3 12 OCTWn
13 DC_CAL 14 CAP1
15 DAC_PWM1 16 CAP2
17 DAC_PWM3 18 DAC_PWM2
19 GND 20 GND
21 DACE_PWM4 22 PWM_CL
23 PWM_AL 24 PWM_BL
25 PWM_AH 26 PWM_CH
27 GND 28 PWM_BH
29 ADC-Vhb1 30 GND
31 ADC-Vhb2 32 ADC-Vhb3
33 IC-FB 34 VDCBUS
35 I_TOTAL 36 IB-FB
37 IA-FB 38 TSI
39 GND 40 GND
Table 18: J5 Pinout

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Test Points Jumpers
Test Point Net Connection Reference Function
TP1 VCC_5V JP2 VCC_5V to controlCARD
TP2 VCC_5V_R5 JP4 CAN termination
TP3 PWRGD
TP4 VCC_3.3V
TP5 REF_1.65V
TP6 PVDD
TP7 GND
TP8 GND
TP9 GND
TP10 GND
TP11 VCC_5V
TP12 SH_A
TP13 SH_B
TP14 SH_C
TP15 S02
TP16 IB-FB
TP17 IA-FB
TP18 U10_1
TP19 IC-FB
TP20 IGND
TP21 S01
TP22 U11_1
TP23 I-TOTAL
Table 20: Testpoints and Jumpers

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Optimizing Sense Circuitry
Overview
Proper resolution of motor signals is critical to the performance of any control system, but especially those
with software observers attempting to replace the precision of an absolute encoder. Because the
DRV83xx are built to work at over 50 Vdc-bus, the resolution of the voltage sensing is not as precise as
you would like for motors < 48V. And in the case of the DRV8301 which measures 41.25A, the current
resolution may also be unacceptable. This section describes how to update both the hardware and
corresponding software to maximize resolution and performance.
Steps to follow
1. Determine MAXIMUM phase current, adjust current gain to 3.3V ADC
2. Set MAX voltage at +30% margin of motor voltage, adjust voltage gain to 3.3V ADC
3. Configure software to hardware changes

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Shunt Current Feedback
 = 1.65 +  

Select resistor values to provide Vout = 3.3V for maximum peak-to-peak phase current
•Ex: For a maximum of 10A, consider a 0.01Ω shunt resistor
oOne possible solution

 = 1.65   =3.3 1.65 10 0.01 = 16.5
 = 16.5  = 16.5 kwith  = 1 k

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oUpdate the current hardware resistors
o = R80, R81, R82
o = R107, R95; R108,R105; R113, R103
o = R92, R94; R101, R104; R99, R102
•Update your software settings in user.h; for this example of +/- 10A peak
//! \brief Defines the maximum current at the input to the AD converter
#USER_ADC_FULL_SCALE_CURRENT_A (20.0)
Insure that your IQ variable is >= 0.5 * the ADC value
#USER_IQ_FULL_SCALE_CURRENT_A (10.0)
Phase Voltage Feedback




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•Ex: for a maximum of 12V, add headroom of 30% to set  to 15.6V
oUpdate the voltage hardware resistors
o = R60; R61; R63
o = R62; R64; R65
oUpdate your software settings in user.h; for this example of 15.6V maximum
//! \brief Defines the maximum voltage at the input to the AD converter
#USER_ADC_FULL_SCALE_VOLTAGE_V (15.6)
In general an IQ value equal to your Voltage bus is effective.
During motor identification – for very small flux motors - you may need to make this value
smaller to lower the minimum flux value that can be identified, which is given by:
USER_IQ_FULL_SCALE_VOLTAGE_V / Effective Estimator Hz / 0.7
After motor identification - for larger flux motors - you may need to increase this value to
insure that the following is true:
USER_IQ_FULL_SCALE_VOLTAGE_V >USER_MOTOR_RATED_FLUX *
Maximum_Frequency_Hz (this is the maximum speed you will ever run the motor,
including deep field weakening).
#USER_IQ_FULL_SCALE_VOLTAGE_V (12.0)
 =

 (4.99 k+)
4.99 k
15.6= 3.3 V (4.99 k+)
4.99 k
 =15.6 V 4.99 k
3.3 V 4.99 k= 18.6 k

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Phase Voltage Filter Feedback
•See 5.2.4 of the User’s Guide
•The voltage filter pole is needed by the FAST estimator to allow an accurate detection of the
voltage feedback. The filter should be low enough to filter out the PWM signals, and at the same
time allow a high speed voltage feedback signal to pass through the filter
•This pole should be designed to fall between
200 Hz <= Pole <= USER_IQ_FULL_SCALE_FREQ_Hz / 4 [hard upper limit]
oHigher poles are more sensitive to capacitor error and drift, so please recognize
the trade-offs in using a higher pole, especially for high frequency motors
•Example
o4 pole pairs; 5 kRPM
Hz = RPM * Poles / 120 = 5000 * 8 / 120 = 333 Hz
Select 400 Hz (> 333 Hz)
oWith our previous  =4.99 kΩ ;  = =18.6 kΩ
o=101 
•Update the hardware capacitors
oC= C67; C68; C69
•Update your software settings in user.h
_ =
 =



_ =400  = 1
2󰇡18.6k4.99 k
18.6k+ 4.99 k󰇢Cv