E523.05 Demonstration Board Hardware Description AN · PDF fileTP_VG output of the LDO for Low-Side Gate bias VIN Input voltage test ... the LIN bus from the demo ... 05 Demonstration

Elmos Semiconductor AG Application Note QM-No.: 25AN0105E.02

E523.05 Demonstration Board Hardware Description AN 0105Jan 24, 2017

1/16

1 What you get1. Demonstration board version 3.3 (with E523.05 motor controller and B6 bridge driver)

2. Software package (version see software description – to get the software description, please contact your Elmos Sales

Representative).

3. USB cable (USB-A ↔ Micro-USB).

4. For LIN communication: USB-to-LIN converter and LIN cable (to order separately)

The E523.05 demonstration board shows the E523.05 BLDC motor control IC in an application for automotive and industrial

electrical drives. The board is ready to use with a wide variety of compliant with the board’s properties motors. The driver stage

consists of three half-bridges capable of 12-28V / 30A max.. The shunt resistors and other components such as electrolytic ca-

pacitors limit the maximum current to 10A continuous. Use sufficient wire gauge for the power line between the board and

the power supply or battery, and for the motor connection.

Note: Before using a battery as a supply, make sure that the supply circuit is fused by a sufficient current class fuse!

Transistors, cables and shunt can become hot during operation!

Be sure, the motor is well fastened before powering the board. The motor immediately starts as soon as the Power Supply is turned on and the

Jumper ENABLE is closed.

1. Three phase BLDC motor with peak current of up to 10A

2. Power supply or battery with 12V to 24V and sufficient current to run the motor

3. Personal computer with USB 2.0 interface, running Windows® 7 or higher

4. GUI based software to control the motor parameters (from the support CD)

Figure 1. Demonstration Board (Version 3.3)

2 What you need

3 Before you start

2/16Elmos Semiconductor AG Application Note QM-No.: 25AN0105E.02


4 Preparation of operation1. Connect the 3 phase Motor to the terminals AK2 „PH1“, „PH2“ and „PH3“

2. Connect the PC via USB-Cable

3. Remove the Jumper “ENABLE”

4. Connect the Power Supply or battery on „POW“+ and „POW-“ Set the Jumper “ENABLE”. Dependent on the firmware, either

the potentiometer position will set the rotational speed, or the parameters for acceleration, desired rotational speed and

more can be set via software by the GUI-based application.

5. Run the motor control software on the computer

Connector X1 JTAG (use for program the flash memory of the E523.05 controller)

Connector X2 Test pins

Connector LIN LIN interface (must be supported by software)

Socket connectors PH1, PH2, PH3 Motor (3 phases U,V,W)

Socket connectors POW+, POW- Power Supply

X1: JTAG 2-wire JTAG connector

X2: GPIO- ports, communication and test signals (top side)

Test points

5 Connectors and signals

pin1 VCC pins 2, 7, 11, 13, 17, 19 openpin3 TMODE pin5 TDApin9 TCK pin15 NRSTpins 4, 6, 8, 10, 12, 14, 16, 18, 20 Ground

X2/01 PB5 X2/07 PC3X2/02 PB6 X2/08 PC4X2/03 PB7 X2/09 PC5X2/04 PC0/TCK X2/10 PC6/IFASTX2/05 PC1/TDA X2/11 PC7X2/06 PC2 X3/12 GND

TP_1 Phase 1 (via Low pass filter)TP_2 Phase 2 (via Low pass filter)TP_3 Phase 3 (via Low pass filter)TP_VG output of the LDO for Low-Side Gate biasVIN Input voltage test pinTP_GND Power GroundTP_VBAT supply voltage after reverse polarity protection



The E523.05 is a fully integrated pre- driver solution for brushless motor applications with an automotive compatible input

voltage range and high temperature capability. Included in the IC are all necessary power supplies, six 400mA gate drivers, one

current sense amplifier, and a 16bit microprocessor with various motor control relevant hardware modules designed to sup-

port EC-motor commutation algorithms such as block and sinusoidal commutation based on Back-EMF or external sensors.

This demonstration board presents the E523.05 in a typical motor control application including a B6 power stage. In addition

the board offers:

� Active reverse polarity protection.

� PWM or LIN interface connection.

� Access to digital IO Pins.

� A programming/debugging interface via 2-Wire JTAG.

� Galvanic isolated USB interface for communication with a personal computer.

� A back EMF divider for back EMF algorithms.

� Three external fast current sense amplifiers, one for total motor current, and two for the phases PH1 and PH2.

� A potentiometer to adjust the initial motor rotation speed (depending on software support)

The three half bridges are able to deliver up to 30A per phase, limited to 10A max by the shunts, the maximum ripple current

through the tank capacitors and the connectors, so the average current of each of the three phases should not exceed 5A. The

board operates in an input voltage range of 12 to 28V, typical 12-16V.

The reverse polarity protection uses T7 as the active element. After powering the board and before activating the B6 bridge,

the body diode of T7 provides the application current. After the start-up is completed, the PWM pulses of the high-side gate

drivers of the half- bridges charge the capacitor C1 to (VBAT+VG) and turn on T7. In case of reverse polarity, the intrinsic diode

of T7 is reverse- biased, and only the leakage current can flow.

The E523.05 comes with pre- configured firmware for evaluation purposes – see software description for details. It is possible to

operate the demoboard in different operating modes (block- or sinusoidal commutation or FOC with Back- EMF- or Hall- sensor-

based rotor position detection), depending on the software. The user can load self developed software via a 2-wire JTAG interface.

The board supports 3 independent current measurement options, one per phases PH1 and PH2, and the total motor current

measuring. Phase current measurement can be used to support e.g. field-oriented control, and the total current measurement

is used to detect and prevent motor overload by default.

6 Board description

IFAST/ISLOW ISLOW: sets the output of the internal current sense amplifier to the port PB5 of the on-chip µC.

IFAST: (default) sets the output of the external current sense amplifier to PB5.

IFAST U/IFAST V enables the current measuring of the Phases U resp. V

T enables test mode for the internal uC. For test mode only, open in normal operation

ENABLE enables the µC (software dependent). Only effective when software-supported.

WD_RES sets a periodic Watchdog RESET to the on-chip µC. For test mode only, removed in normal operation.

INT_EN enables Interrupt handling (must be supported by software)

3.3V/5V selects the operating voltage of the external current sense amplifiers. Default = 3.3V

BUS enables supply the LIN bus from the demo board (VBAT). Default = open

POTI_EN enables speed control by the onboard potentiometer.

7 Jumper settings



8 Additional options

Figure 2. Resistors R79, R80 and R81 to remove for back- EMF control

There are different possibilities to control the BLDC motor rotation speed or rotor position detection – either using the back-

EMF, or using position sensors, e.g. hall sensors. To support both of the position detection methods, there are hall- sensor sig-

nal amplifiers on board as well as three fast, wide- bandwith operational amplifiers. For advanced BLDC motor control algo-

rithms, e.g. field- oriented control (FOC) or to use the external fast current measurement, the three operational amplifiers are

to use. The inputs of these op-amps are connected to the shunts in the source paths of phase 1, phase 2 and the core path, so

it is possible to measure two phase current values, and the core current. If only the core current is used to measure or limit the

current consumption, and the motor control is to be set to back-EMF algorithm, it is necessary to disconnect the output of the

from the outputs of the hall- sensor amplifiers. By default, the three resistors R79, R80 and R81 (0 ohms) are removed. To use

hall- sensor-based control and regulation modes, the resistors are to place onto the board (see fig. 2), and the back-EMF- resis-

tor divider has to be entered into the calculation of the ADC input voltage range of 2.5V max for full scale.

Since the E523.05 is a BLDC motor controller with a built-in 16 bit microcontroller, the operating mode and parameters for the

chosen motor must be programmed into the uC core of the E523.05. The software must be tailored to the motor in order to

choose the commutation mode, motor speed, motor start mode, over current shutdown etc. Since the software is too complex

to be described in this document, a separate application note „Software description“ is available, containing the basic theory of

BLDC and PMSM motor control, programming steps and operating regimes of the board and the connected motor. If needed,

order this application note via the sales representative.

To program the microcontroller, the on-board JTAG interface will be used. For this, the board can be powered with a low-cur-

rent power source of 140mA with no motor connected.

After programming, the communication between an USB- connected PC and the board can be used to check system status

and to change parameters (depending on the implementation of functions) in a GUI session using the on-board USB – UART

converter circuit. Note that the USB ↔ serial communication is possible only after setting up a virtual COM port via the driver

emulation in Windows ® PC’s. For other operating systems, refer to the operating system manual.

9 Software implementation and status information



10 Schematics

Figure 3. Overview



Figure 4. Power part



Figure 5. Controller part (patch 1)



Figure 6. Current measurement part (2 phases and core, patch 1)

22K / 1%

22K / 1%

56K

56K

56K

R30 2K2

R70 2K2

R75 2K2

R77 2K2

R72 2K2

R32 2K2

22K / 1%



Figure 7. LIN and USB serial Interfaces



Figure 8. Hall Sensor circuit and BEMF measurement part



11 Layout

Figure 9. Top view

Figure 10. Assembly top view (patch 1)



Figure 11. Bottom view

Figure 12. Assembly bottom view (patch 1)



Quantity Pos.-No. Value Order-No. Suppier Remark Manufacturer

1 C1 CAP CER 47nF / 50V 810-CGA3E2X7R1H473K Mouser SMT 0603 TDK

4 C2, C6, C7, C15

CAP CER 100nF/50V 445-1314-2-ND Digikey SMT 0603 TDK

1 C3 CAP POL 47uF 20% 35V 493-7033-1-ND Digikey SMT 8x10 Nichicon

1 C4 CAP CER 22UF 16V 1276-3146-1-ND Digikey SMT 1206 Samsung

8

C5, C17, C18, C19, C20, C21, C44, C45

CAP CER 470nF/ 50V 810-CGA3E3X7R1H474KB Mouser SMT 0603 TDK

2 C8, C9 CAP CER 22UF 16V 1276-3395-1-ND Digikey SMT 1210 Samsung

3 C10, C11, C12

CAP CER 330nF/50V 1276-3160-1-ND Digikey SMT 1206 Samsung

1 C13 CAP CER 10nF/50V 445-5662-1-ND Digikey SMT 0603 TDK

5C14, C29, C31, C37, C39

CAP CER 10nF/50V 490-6058-1-ND Digikey SMT 0805 Murata

1 C16 CAP CER 22nF/50V 445-5663-1-ND Digikey SMT 0603 TDK

2 C22, C23 CAP CER 68pF/50V

81-GCM-1885C1H680J16D Mouser SMT 0603 TDK

3 C24, C25, C26

CAP CER 1nF/50V 399-1136-1-ND Digikey SMT 0805 Kemet

C27 NA SMT 1210

2 C28, C36 CAP CER 4.7uF/100V 81-GRJ32DC72A475KE1L Mouser SMT 1210 Murata

4 C30, C32, C38, C40

CAP CER 1.0uF/50V 810-CGA6L2X7R1H105K Mouser SMT 1210 TDK

6C33, C34, C35, C41, C42, C43

CAP CER 4.7nF/100V 581-12061C472K4T2A Mouser SMT 1206 AVX

C46, C48, C49, C50, C51

CAP CER 1.0uF/50V 581-08055C105K4T2A Mouser SMT 0805 AVX

1 C47 CAP CER 2.2uF/50V 810-CGA6M3X7R1H225K Mouser SMT 1210 TDK

4 C52, C53, C54, C55

CAP POL1000uF/35V 1189-1871-ND Digikey TH 5 X 13 Rubycon

1 CON2 2x10 732-2096-ND Digikey box header 100mil Wuerth Electronics

1 CON3 1x14 571-1-826629-4 Mouser Pin header 14 pos., 100mil TE connectivity

1 CON4 mini_USB ED90341CT-ND Digikey Mini USB connector FCI

1 CON5 CON_STL-1550WH3 STL1550WH3 Schukat LIN connector 3pins PTR

Messtechnik

3CON6, CON7, CON8

brown BIL30 BR Reichelt M6 Hirschmann SKS

1 CON9 red BIL30 RT Reichelt M6 Hirschmann SKS

1 CON10 black BIL30 SW Reichelt M6 Hirschmann SKS

1 CON13 1x05 571-5-146285-5 Mouser TH 5X1, 100mil TE connec-tivity

1 D1 5.6V 200mW Zener 863-MM5Z5V6T1G Mouser SOD-523 ON SEMICON-

DUCTOR

4 D2, D3, D7, D8 LED Green 859-LTST-C150GKT Mouser ChipLED, 1206, 20mA LiteOn

12 Bill of Material (patch 1)



Quantity Pos.-No. Value Order-No. Suppier Remark Manufacturer

13

D4, D5, D6, D9, D11, D12, D13, D14, D15, D16, D17, D18, D19

MUH1PB-M3/89A 625-MUH1PB-M3 Mouser SMT MicroSMP Vishay

1 D10 PESD1LIN, 115 568-4033-1-ND Digikey TVS Diode 15V, SOD-323 NXP

1 D20 15V 200mW Zener 863-MM5Z15VT1G Mouser SOD-523 ON SEMICON-

DUCTOR1 IC1 523.05A QFN48 E523.05A Elmos QFN48L7 Elmos

3 IC2, IC5, IC6 LT6220CS5 LT6220CS5#TRMPBFCT-

ND Digikey SMT SOT323-5 Linear Tech

1 IC3 FT232RL 768-1007-2-ND Digikey SSOP FTDI

1 IC4 ADUM1301A ADUM1301ARWZ-RLCT-ND Digikey SOIC-16 Analog De-

vices

3 IC7, IC8, IC9 SN74LVC1G34 595-SN74LVC1G34DBVR Mouser SOT-23-5 Texas Instru-

ments1 IC10 AP2204K-5.0 AP2204K-5.0TRG1 Mouser SOT-23-5 Diodes Inc1 J1 T 929400E-01-02-ND Digikey 100mil 3M1 J2 Enable 929400E-01-02-ND Digikey 100mil 3M1 J3 WD_RES 929400E-01-02-ND Digikey 100mil 3M1 J4 INT_EN 929400E-01-02-ND Digikey 100mil 3M1 J5 IFAST_U 929400E-01-03-ND Digikey 100mil 3M1 J6 IFAST_V 929400E-01-03-ND Digikey 100mil 3M

4 J7, TP1, TP2, TP3 1x02 929400E-01-02-ND Digikey 100mil 3M

2 J8, J9 1x03 929400E-01-03-ND Digikey 100mil 3M1 J10 CON1X02_M 929400E-01-02-ND Digikey 100mil 3M1 L1 0R 667-ERJ-6GEY0R00V Mouser SMT 0805 Panasonic1 L2 8.2uH XAL1510-822 Coilcraft SMT 1510 X 10 Coilcraft

6R31, R71, R76, R79, R80, R81

0R 667-ERJ-3GEY0R00V Mouser SMT 0603 Panasonic

3 R42, R67, R68 0R01 71-WSR5R0100DEA Mouser SMT 4527 Vishay

2 R34, R35 1,0k 71-CRCW0603-1.0K-E3 Mouser SMT 0603 Vishay

3 R14, R17, R23 1,8k 71-CRCW0603-1.8K-E3 Mouser SMT 0603 Vishay

7

R41, R52, R53, R54, R64, R65, R66

100k 71-CRCW0603-100K-E3 Mouser SMT 0603 Vishay

10

R15, R18, R19, R20, R49, R50, R51, R61, R62, R63

100R 71-CRCW0603-100-E3 Mouser SMT 0603 Vishay

1 R1 10K PTV09A-4015U-B103-ND Digikey TH Bourns

7

R21, R24, R27, R28, R82, R83, R84

10K 71-CRCW0603-10K-E3 Mouser SMT 0603 Vishay

3 R3, R85, R86 10R 660-SG73P1JTTD10R0F Mouser SMT 0603 KOA Speer

1 R11 10R 71-CRCW0805-10-E3 Mouser SMT 0805 Vishay

3 R38, R39, R40 150K 71-CRCW0805-150K-E3 Mouser SMT 0805 Vishay

1 R10 1R 667-ERJ-T06J1R0V Mouser SMT 0805 Panasonic

8

R4, R5, R30, R32, R70, R72, R75, R77

2,2k 71-CRCW0603-2.2K-E3 Mouser SMT 0603 Vishay



Quantity Pos.-No. Value Order-No. Suppier Remark Manufacturer2 R36, R37 220R 71-CRCW0603-200-E3 Mouser SMT 0603 Vishay

7

R7, R13, R16, R22, R33, R73, R78

22K 71-CRCW0603-22K-E3 Mouser SMT 0603 Vishay

6R44, R45, R47, R55, R57, R59

22R 71-CRCW0603-22-E3 Mouser SMT 0603 Vishay

1 R25 3,3k 71-CRCW0603-3.3K-E3 Mouser SMT 0603 Vishay1 R6 4.7K 71-CRCW0603-4.7K-E3 Mouser SMT 0603 Vishay

6R43, R46, R48, R56, R58, R60

4.7R 71-CRCW12064R70FKEA Mouser SMT 1206 Vishay

1 R87 47K 71-CRCW0603-47K-E3 Mouser SMT 0603 Vishay1 R12 560R 71-CRCW0805-560-E3 Mouser SMT 0805 Vishay

3 R8, R29, R69, R74 56k 71-CRCW0603-56K-E3 Mouser SMT 0603 Vishay

1 R26 6.8K 71-CRCW0603-6.8K-E3 Mouser SMT 0603 Vishay1 R2 68K 667-ERJ-3GEYJ683V Mouser SMT 0603 Panasonic1 R9 8.2K 667-ERA-S15J822V Mouser SMT 0805 Panasonic1 T8 BC846 863-BC846ALT3G Mouser SOT23 On Semi

7T1, T2, T3, T4, T5, T6, T7

IRF-S4610TRLPBF 942-IRFS4610TRLPBF Mouser TO-263-3 Int. Rectifier

4 H1, H2, H3, H4 nut M3 MU-6KT-DIN934-161-

SW5,5 Schukat M3 div.

4 H1, H2, H3, H4

PA Distance bolt KDA6M3X10 Schukat M3x10 div.



Elmos Semiconductor AG – Headquarters

Heinrich-Hertz-Str. 1 | 44227 Dortmund | Germany

Phone + 49 (0) 231 - 75 49 - 100 | Fax + 49 (0) 231 - 75 49 - 159

[email protected] | www.elmos.com

Note Elmos Semiconductor AG (below Elmos) reserves the right to make changes to the product contained in this publication without notice. Elmos assumes no responsibility for the use of any circuits de-scribed herein, conveys no licence under any patent or other right, and makes no representation that the circuits are free of patent infringement. While the information in this publication has been checked, no responsibility, however, is assumed for inaccuracies. Elmos does not recommend the use of any of its products in life support applications where the failure or malfunction of the product can reasonably be expected to cause failure of a life-support system or to significantly affect its safety or effectiveness. Products are not authorized for use in such applications.

Copyright © 2017 Elmos Reproduction, in part or whole, without the prior written consent of Elmos, is prohibited.

Elmos Semiconductor AG provide the E523.05 Demonstration Board simply and solely for IC evaluation purposes in laboratory.

The Kit or any part of the Kit must not be used for other purposes or within non laboratory environments. Especially the use or

the integration in production systems, appliances or other installations is prohibited.

The pcb s are delivered to customer are for the temporary purpose of testing, evaluation and development of the Elmos IC s only.

Elmos will not assume any liability for additional applications of the pcb.

Elmos Semiconductor AG shall not be liable for any damages arising out of defects resulting from (1) delivered hardware or soft-

ware, (2) non observance of instructions contained in this document, or (3) misuse, abuse, use under abnormal conditions or

alteration by anyone other than Elmos Semiconductor AG. To the extend permitted by law Elmos Semiconductor AG hereby ex-

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E523.05 Demonstration Board Hardware Description AN · PDF fileTP_VG output of the LDO for Low-Side Gate bias VIN Input voltage test ... the LIN bus from the demo ... 05 Demonstration