USERS MANUAL HIP2103-4DEMO1Z AN1899 Rev 0.00 HIP2103/HIP2104, 3-phase, Full, or Half Bridge Motor Drive January 8, 2014 implementation of the HIP2103 and HIP2104 drivers including Introduction recommended support circuits. The HIP2103-4DEMO1Z is a general purpose motor drive with Also covered is the design method of the bipolar current a microprocessor controller. Three motor drive topologies are sensing feature. Presently, current sensing on this demo board supported: 3-phase for BLDC motors, and full and half bridge is used only for pulse-by-pulse current limiting but an analog for conventional brushed DC motors. Hall effect rotor position signal proportional to the motor current is available on board sensors are used to control the switching sequence of the as a design reference. BLDC topology (not required for the brushed DC motors). The microcontroller firmware is also provided as a reference The operating bridge voltage can vary between 13V and 50V but the only support offered by Intersil will be for bug and the maximum motor current is 20A (with sufficient air corrections and for adding more switching sequences. Please flow). This motor drive can be used as a design reference for refer to Microchip for details on the use of the PIC18F2431. multiple applications including e-bikes, battery powered tools, electric power steering, wheel chairs, or any other application where a brushed or brushless DC motors are utilized. Because Physical Layout this demonstration board is primarily intended to highlight the The HIP2103-4DEMO1Z board is 90mm by 82.5mm. The application of the HIP2103 and HIP2104 3-phase MOSFET tallest component is a 470F capacitor. The total height is drivers with no specific motor targeted, the control features 32mm with standoffs. The Hall effect rotor position sensor are limited to simple functions such as start/stop, reverse inputs are miniature terminal blocks. The phase terminal rotation, and braking. Open loop speed control is blocks are high current outputs rated for 20A. 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 motor load dynamics. Important 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 at the end of this application note 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. OFF Specifications ON 3-phase BLDC motor with Hall sensors Full bridge for brushed DC motors Motor topologies (bidirectional) FIGURE 1. HIP2103-4DEMO1Z INPUTS AND OUTPUTS Half bridge for brushed DC motors (unidirectional) The controller section is a daughter card which contains push Operating voltage range 13 - 50VDC buttons for reset, brake, reverse, and start/stop functions. Also Maximum continuous on the controller card are dip switches for configuration, LEDs 20A (with sufficient air flow) bridge current for status, and a programming port. As an option, a customer designed controller daughter card can be substituted for the Hall sensor bias voltage 3.3V, 15mA Intersil supplied controller. PWM switching frequency ~20kHz The speed control section includes an on-board potentiometer for speed control or an optional external potentiometer can be Scope connected to the signal terminal block. This application note covers the design details of the The current sense section includes current amplifiers, HIP2103-4DEMO1Z with a focus on the design comparators, and current sense resistors. AN1899 Rev 0.00 Page 1 of 24 January 8, 2014HIP2103-4DEMO1Z The Hall inputs section is the terminal connections from the bridge pair of SiR662DP-T1-GE3 power FETS operating with a BLDC motor for the hall sensors and the 3.3V bias for the PWM frequency of 20kHz. Associated with the HIP2103s and sensors. HIP2104 are the necessary support circuits such as the decoupling and boot capacitors. The phase A, B, and C sections include the HIP2103/4 drivers, bridge FETs, and power terminal connections for the motor. Controller For those customers who would like to modify the firmware of The microcontroller is located on a daughter card to provide the the PIC18F2431 microcontroller, an RJ11 connector is provided customer with the option to incorporate their own controller for easy connection with Microchip firmware development tools design. The features on the controller daughter card are (not provided or supported by Intersil). configuration dip switches, status LEDs, a programming port, and 4 push-buttons. Block Diagram The Hall sensor inputs are decoded by the microcontroller to The HIP2103-4DEMO1Z is composed of seven major circuit provide the appropriate switching sequence signals to the 3 function illustrating the use of several Intersil products. The HIP2103/4s to drive the six bridge FETs that drive a 3-phase following descriptions reference Figure 2. BLDC motor. The SW5 dip switch is used to select the appropriate switching sequence for the BLDC motor. Bias Supplies With appropriate setting to the SW6 dip switch, the motor driver Two bias supplies are required and are provided by one HIP2104 can be configured with a full bridge topology for bidirectional driver with internal linear regulators. The VCC output (3.3V) of the control of a conventional brushed DC motor. A half bridge option HIP2104 provides the bias to the controller, Hall sensors, and is also provided to drive a brushed DC motor without bidirectional LEDs. The VDD output (12V) of the HIP2104 provides its own bias control. See Table 1 for more details on configuring SW6. for its driver portion and also to the other two HIP2103s (which In addition to decoding the Hall sensors, the microcontroller do not have internal regulators). reads the push buttons to invoke the various operating functions HIP2103 and HIP2104 Drivers of the motor, and controls the status LEDs. The one HIP2104 and the two HIP2103s are the featured Intersil The microcontroller firmware is provided for reference but the parts. Each drivers outputs (HO and LO) are connected to a half only support offered by Intersil will be for bug corrections and for VDEN VDen 13-50V SWITCH Bias supplies VBAT VCen are internal to HIP2104 the HIP2104 2 3.3V Vcc Vdd 2 12V DAUGHTER CARD DIP 3-PHASE BLDC 8 2 3 HIP2103 SWITCHES BRIDGE MOTOR 2 PUSH 4 BUTTONS 2 CONTROLLER 4 LEDs HIP2103 6 2 PROGRAM 2 ISL28246 PORT CURRENT LIMIT 2 AND 3 MONITOR 2 3 SPEED CONTROL Hall Bias HALL INPUTS HIP2103-4DEMO1Z REV. A FIGURE 2. HIP2103-4DEMO1Z BLOCK DIAGRAM AN1899 Rev 0.00 Page 2 of 24 January 8, 2014