Mini Drive User Manual
Contents
1. of the power devices inside the IC will produce high heat loss which combined with the switching losses may per April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore Table 2 List of items included in the standard Mini Drive Kit Item Quantity Description 1 Mini drive PCB 1 Motor controller board with heat sink mounted on top side 2 User manual 1 This manual may be downloaded if not availabe with the kit 3 Switch interface 2 For the ON OFF and F R switches 300 mm length 3 wire cable with switch on one side and male connector on the other end 4 Potentiometer 1 10 k 10 turn pot on one end of 3 wire interface cable with male connector at the other end 300 mm length 5 Hall sensor 1 600 mm 5 wire cable with 5 pin interface female connector at one end 6 Mounting nuts 4 Nuts to lock the mounting screws manently damage the control board Table 3 Rating of the drive typical and maximum values Description Min Max Typ Units Supply voltage Vs 8 32 12 24 Vdc Supply current J 10m 2 0 lt 1 A dc Ambient temperature Top 5 45 25 C Speed with 8 pole motor 30k rpm Please ensure that the typical current rating is not crossed and the maximum voltage and temperature ratings are honored at all April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 5 times Load curre2. Three Phase BLDC Motor Driver Mini Drive 100 1E User Manual Vita Technology Pvt Ltd 3 1 Annaiah Road Yelachenahalli off 10th km Kanakapura Road J P Nagar Post Bangalore 560 078 India Web http www vitatechindia com April 2010 rl Contents Contents i List of Figures ii List of Tables iii 1 Introduction 1 2 Identification of Components 2 Vita Technology Bangalore ii 2 1 List of Items Included inthe Kit 3 3 Maximum Limits and Typical Rating 3 4 Controller Dimensions 5 5 Connections 6 5 1 Supply Voltage Connections 7 5 2 Hall Effect Sensor Connections 7 5 3 Motor Phase Connections 7 6 Operation 9 6 1 Tuning the PI Controller Gains 10 6 2 Adjusting the Motor Speed 11 7 Features and Caution 11 8 Warranty 12 Index 14 List of Figures 1 Top view of the board 1 2 Identification of components on the drive 2 3 Controller dimensions x y 5 4 Controller dimensions z 6 5 Mini drive runningafanload 9 April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore iii List of Tables Components of the board Items included inthe kit Drive ratime ok ee ew RO Hall sensor connector color code Motor phase connections Dunk WN o o A A Motor and Hall sensor phasing April 2010 Mini Drive 100 1E User Manual Vita Techno
3. d up to a lower point after which the speed control is lost On the higher side the controller should maintain the same speed all the way up to 32 V dc 7 Features and Caution The drive is protected against reverse voltage polarity via a se ries diode It is also protected against voltage transients by using a parallel zener diode The fault indicator red LED will light up when e The internal temperature of the IC is excessive e An over current situation has occurred When the fault indicator lights up the power switches of the three phase bridge of the controller are automatically disabled If the fault indicator lights up the drive must be switched off immediately and the temperature of the IC checked Important Never change the direction of rotation when the motor is already running in any one direction The following instructions must be followed to prevent permanent drive failure April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 12 due to over current conditions that exist in dynamic direction reversals of the motor 1 Switch off motor by using the ON OFF switch 2 Wait for the rotor or load to completely stop rotating 3 Change the direction with F R switch 4 Switch on the motor now using the ON OFF switch The blue LED indicates operation in one direction it is not lit while operating in the reverse direction The drive is not coated with any protective coating after assem bly Pl
4. ease ensure that no moisture liquid or any conducting fluid or components come in contact with the PCB Periodically please clean the board with low pressure compressed air to re move dirt and dust that may cause faults and perhaps permanent drive failure 8 Warranty No modification of any sort of the PCB is permitted without written authorization from Vita Each unit is completely tested at our factory after assembly of the PCB with a brushless DC motor and data recorded with the serial number The switches and potentiometer that are included in the kit are used during testing No defective components will be shipped out As the drive can be damaged if not used with caution and if used outside the envelope that it has been de signed to operate in and the cause cannot be verified after fail April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 13 ure there is no warranty for the drive implied or supplied In no case will a free replacement PCB be provided Vita reserves the right to change this specification with suitable modi fications at anytime Vita Technology Pvt Ltd Bangalore India All rights reserved No part of this document may be reproduced or copied in printed or electronic form without written permission from Vita April 2010 Mini Drive 100 1E User Manual Index 5 Vdc 7 caution 4 11 CCW 6 coating 12 components 2 connections 6 connector 2 connectors 2 copyrigh
5. ification of Components Fig 2 shows the list of components of the drive Later sec tions describe in detail the method of connecting the motor and various other parts to the controller PCB Ore Rechnology gt WIM D Figure 2 Identification of the components on the board of the drive Please refer to table 1 for the complete listing April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 3 Table 1 List of important components located on the PCB Item number Description 1 Supply voltage connector Note polarity on PCB when connecting 2 ON OFF switch header 3 pin 3 Forward Reverse switch header 3 pin 4 Speed control potentiometer header 3 pin 5 ON OFF LED green 6 Forward Reverse LED blue 7 FAULT LED red 8 Integrator gain control Pot 9 Multiplier gain control Pot 10 Hall effect sensor header 5 pin 11 Motor phase connectors 2 1 List of Items Included in the Kit Table 2 lists the items provided in the kit Please make sure you have all the components before attempting to mate the motor and controller board 3 Maximum Limits and Typical Rating Table 3 shows the maximum and typical values of the drive con troller Please note that the maximum current is only for inter mittent duty and the drive should not be driven for more than a few seconds at the extreme end of the current value The on resistance
6. logy Bangalore 1 1 Introduction Thank you for using our product It is highly recommended that you go through this user manual to understand the safety limits and rating limits so as to not damage the motor or drive The drive may be permanently damaged if used im properly The Mini Drive 100 1E is a robust high quality three phase brushless DC motor drive based on Hall effect sensor feedback and provides six step commutation It has been designed by Vita and is a result of our expertise in BLDC motors and con trols It is a low power unit with integrated mosfets in the con troller IC and is capable of supplying more than 1 A at a max imum voltage of 32 V The controller has the ability to switch off and turn on the motor change the direction of rotation en able set point speed reference for closed loop speed control and provide diagnostic warning under fault conditions Figure 1 The top view of the board Both sides of the board are populated with components The drive is specially designed for small motors that consume less than 25 W continuously and up to 40 W for a few seconds of intermittent duty The maximum input voltage is 32 V dc April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 2 It is suitable for small brushless DC motors that drive pumps fans and other such applications Customized versions of the drive with additional controls can be provided by Vita if required 2 Ident
7. ly into the ON OFF female connector on the PCB This becomes the ON switch 3 Attach the male of the second switch assembly into the F R female connector on the PCB This becomes the di rection control switch 4 Attach the male connector of the potentiometer assem bly into the female marked Speed on the board Make sure that the potentiometer is turned fully CCW when looking at the shaft ensuring zero speed command CW Clockwise CCW Counter Clockwise April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 7 The above instructions take care of switching the drive on and off changing directions and adjustable speed control 5 1 Supply Voltage Connections Connect two wires with appropriate color coding and cross sec tional area these two wires are not supplied as part of the kit to the supply voltage connector Make sure that the polarity of the positive and return lines match with the drive 5 2 Hall Effect Sensor Connections Table 4 shows the color code for the Hall sensor connector with the 600 mm cable assembly Please ensure that the colors and description in the table is followed when soldering the wire ends to the Hall sensors The control board contains the required pull up resistors The Hall sensor spacing should be 120 elec trical degrees This controller cannot work with 60 electrical degree spaced Hall sensors The controller has been verified us ing bi polar Hall sensors with inter
8. motor is operated after the power supply connection has been made and the supply voltage is turned on Even when the motor is not operating and supply is available the drive is in sleep mode It is turned on when the on off switch is moved to ON position If the motor does not rotate slowly move the speed potentiometer knob CW to increase the speed command The motor will start to rotate and increase its speed When the potentiometer has turned CW fully the motor should be running at its maximum speed with no PWM to control speed If the motor runs and it appears to be not fully controllable it means that the drive motor combination needs tunings Figure 5 The image shows the drive running a small fan load The speed can be controlled by using the potentiometer the switch on the left is to turn on or off the motor the switch on the right is to change the direction of rotation The Hall sensors inside the motor are fed to the controller using the supplied 5 pin cable with the 5 pin male attached to one end item 5 in kit April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 10 6 1 Tuning the PI Controller Gains The drive is tuned at our factory using a small BLDC motor However it may have to be again tuned when the inertia of the rotor load combination changes drastically Closed loop speed control is based on proportional integral feedback 1 Rotate the multiplier gain potentiometer by using a small screwd
9. nal Schmidt trigger Please do not use analog Hall sensors as the controller will not work A dedicated regulator on the PCB supplies 5 V dc to the Hall effect sensors 5 3 Motor Phase Connections Table 5 shows the sequence of connecting the three phases of the motor to the control board For proper operation of the motor controller combination the back emf generated by the phases must be in phase with the Hall effect sensor outputs See table 6 April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 8 Table 4 The color codes for the Hall sensor connector These are marked on the silk screen of the PCB Wire Wire color Designation 1 Blue H 2 Green H gnd 3 Yellow H3 4 Orange H1 5 Brown H2 Table 5 Motor phase connections These are marked on the silk screen of the PCB Wire Connector Motor phase 1 Ol C 2 02 B 3 03 A Table 6 Motor and Hall sensor output phasing The table indi cates that H1 will be positioned such that it is in phase with the back emf generated by phase CB in a wye or delta connected motor Sensor H2 will be in phase with phases BA and sensor H3 with phases AC If this is not implemented the drive will not work dependably Item Hall sensor Motor phases 1 H1 CB 2 H2 BA 3 H3 AC April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 9 6 Operation The
10. nts greater than 1 A can be obtained if there is no chopping Please ensure that the motor rated torque and rated speed can be fully obtained at rated voltage without PWM for current regulation This way the full power spec trum of the IC can be used If the motor used is of a higher volt age and speed rating the duty cycle reduction of the PWM may cause severe overheating of the IC which will result in severe degradation of the available output power The typical input power for continuous operation is 25 W 4 Controller Dimensions The board size is approximately 77 x 57 mm it is about the size of a business or credit card Fig 3 and 4 show the top view and side view of the board F A ie 5 o N K t Figure 3 All dimensions are in mm April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 6 M3 N t i j I I a f i aa LO SPACER f6L M3 X L Figure 4 All dimesnions are in mm Two heat sinks are used one set on the top side and a single one on the bottom side 5 Connections This section describes the steps to connect the switches and po tentiometer to the PCB 1 Mount the 2 switches and the potentiometer on a suitable mounting plate and tighten the locking nuts 2 Attach one of the male connectors of the switch assem b
11. river in the CW direction until you reach the end Refer to Fig 2 2 Now rotate the speed potentiometer fully CW to maxi mum speed 3 Rotate the integrator gain control pot in the CW direction until the motor fully stops after decelerating The pot may have to be rotated slowly when the rotor begins to slow to allow for inertial effects to die out 4 Now slowly rotate the integrator pot in the CCW direc tion until the motor starts and accelerates to full speed Rotate a further half turn The motor drive is tuned now 5 If the motor does not slow down then rotate the integrator potentiometer back fully in the CCW direction Rotate the multiplier pot just 1 turn in the CCW direction and then repeat from step 3 until the motor drive combination is tuned It is recommended that the tuning of the motor be done at low voltages before tuning at higher voltages April 2010 Mini Drive 100 1E User Manual Vita Technology Bangalore 11 6 2 Adjusting the Motor Speed If required the tuning described in the previous section has to be performed After which the speed potentiometer can be rotated back in the CCW direction to reduce the speed When it is ro tated fully in the CCW direction the motor should stop When it is rotated fully in the the CW direction the motor should reach maximum speed At any midway point say 50 speed if the supply voltage is reduced it should be seen that the motor stays at almost the same spee
12. t 13 CW 6 delta 7 dimensions 5 direction of rotation 6 11 dust 12 Hall sensor 7 Hall sensor requirements 7 Hall sensors 7 header 2 identification 2 inertia 10 introduction 1 kit 3 LED 2 limits 3 motor phase 7 motor requirements 5 off 6 on 6 operation 9 phasing 7 pull up resistors 7 PWM 9 rating 3 Schmidt trigger 7 size 5 speed control 11 supply voltage 7 switch 2 three phase brushless motor tuning 9 10 values 3 warning 11 warranty 12 wye 7
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