Application Note

Electric Bike BLDC Hub Motor

Control Using the Z8FMC16100
MCU
AN026004-0413

Abstract
This application note describes a controller for a 200 W, 24 V Brushless DC (BLDC)
motor used to power an e-bike (i.e., electric bicycle). The design uses Zilog’s
Z8FMC16100 MCU and associated circuitry to implement motoring control, regenerative
braking, and fault protection.

Note: The source code file associated with this application note, AN0260-SC01.zip, is available
for download on zilog.com. This source code has been tested with version 5.0.0 of ZDS II
for Z8 Encore! XP MCUs. Subsequent releases of ZDS II may require you to modify the
code supplied with this application note.

Features
The main features of this high-torque motor control application include:
• Hall sensor commutation
• Motor speed measurement
• Potentiometer-adjustable motor speed
• Open-loop or closed-loop speed control for precise speed regulation
• Protection logic for over-voltage, over-current, and thermal protection.

Discussion
The Z8FMC16100 MCU features a flexible Pulse Width Modulation (PWM) module with
three complementary pairs or six independent PWM outputs supporting dead-band opera-
tion and fault protection trip input. These features provide multiphase control capability
for a variety of motor types and ensure safe operation of the motor by providing pulse-by-
pulse or latched fast shutdown of the PWM pins during fault condition.
The Z8FMC16100 MCU features up to eight single-ended channels of 10-bit analog-to-
digital conversion (ADC), with a sample and hold circuit. It also features one operational
amplifier for current sampling and one comparator for over-current limiting or shutdown.
A high-speed ADC enables voltage and current sensing, while dual-edge interrupts and a
16-bit timer provide a Hall-effect sensor interface.
A full-duplex 9-bit UART provides serial, asynchronous communication and supports an
option for the Local Interconnect Network (LIN) serial communications protocol. The

AN026004-0413 Page 1 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

LIN bus is a cost-efficient single Master, multiple Slave organization that supports speed
up to 20 kbps.
The Z8FMC16100 MCU has a rich set of peripherals and other features such as: additional
16-bit timer with capture/compare/PWM capability, SPI, and I2C Master/ Slave for serial
communication, and an internal precision oscillator.
The single-pin debugger and programming interface simplifies code development and
allows easy in-circuit programming.
A block diagram of the Z8FMC16100 MCU is shown in Figure 1.

12-Bit PWM 16-Bit Timer

Operational
Module for Capture/
Amplifier
Motor Control Compare/PWM

Up to 16 KB 8-Channel
Flash 10-Bit ADC
20 MHz
512 B SRAM
eZ8 CPU VBO/POR
2
I C, SPI, and and Reset
UART with LIN Control

Internal
Watchdog Single-Pin
Precision
Timer Debugger
Oscillator

Comparator Interrupt Controller

17 General Purpose I/O Pins

Figure 1. Z8FMC16100 MCU Block Diagram

Braking and Regenerative Charging

In this e-bike application, the Z8FMC16100 MCU’s PWM registers are configured to
operate in a complementary PWM mode when applied to an inverter bridge that consists
of six MOSFETs. This complementary PWM mode allows for greater control of the e-
bike’s braking and regenerative charging process. The BLDC motor will effectively run in
either a motoring mode or a generative mode.
Generative Mode is achieved when the the applied operating voltage is less than the
BEMF voltage produced by the rotating motor. Motoring Mode is achieved when the
applied voltage is equal to or greater than the BEMF voltage produced by the rotating
motor. Varying the applied operating voltage can be accomplished by changing the duty
cycle for each phase in the inverter bridge.
For quicker braking, the lower MOSFET devices of the inverter bridge are turned on while
the upper MOSFETs are turned off, thereby quickly producing a negative current (i.e., a
negative torque) to stop the motor. To gain a regenerative charge, the upper MOSFETs are

AN026004-0413 Page 2 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

turned on to allow current flow back to the battery, while the lower MOSFETs are turned
off.

Hardware Architecture
In a Brushed DC motor, commutation is controlled by brush position. In a BLDC motor,
however, commutation is controlled by the supporting circuitry. The rotor's position must
therefore be fed back to the supporting circuitry to enable proper commutation.
Two different techniques can be used to determine rotor position:
Hall Sensor-Based Commutation. In the Hall sensor technique, three Hall sensors are
placed inside the motor, spaced 120 degrees apart. Each Hall sensor provides either a High
or Low output based on the polarity of magnetic pole close to it. Rotor position is deter-
mined by analyzing the outputs of all three Hall sensors. Based on the output from hall
sensors, the voltages to the motor's three phases are switched.
The advantage of Hall sensor-based commutation is that the control algorithm is simple
and easy to understand. Hall sensor-based commutation can also be used to run the motor
at very low speeds. The disadvantages are that its implementation requires both separate
Hall sensors inside the motor housing and additional hardware for sensor interface.
Sensorless Commutation. In the sensorless commutation technique, the back-EMF
induced in the idle phase is used to determine the moment of commutation. When the
induced idle-phase back-EMF equals one-half of the DC bus voltage, commutation is
complete.
The advantage of sensorless commutation is that it makes the hardware design simpler. No
sensors or associated interface circuitry are required. The disadvantages are that it requires
a relatively complex control algorithm and, when the magnitude of induced back-EMF is
low, it does not support low motor speeds.
When a BLDC motor application requires high torque, when the motor is running at low
speed, or when the motor is moving from a standstill, the Hall sensor commutation tech-
nique is an appropriate choice. A motor used in an electric bicycle application, for exam-
ple, requires high initial torque and is a perfect application for Hall sensor commutation.
Furthermore, two voltage application techniques can be applied, based on the configura-
tion of the supply-to-motor windings:
Sinusoidal. Sinusoidal voltage is continuously applied to the three phases. Sinusoidal
voltage provides a smooth motor rotation and fewer ripples.
Trapezoidal. DC voltage is applied to two phases at a time, and the third phase remains
idle. Trapezoidal voltage is less complex to implement. The idle phase is generating the
BEMF from the rotating magnet that passes the unenergized idle phase and provides the
BEMF zero-crossing data.

How Hall Sensor Commutation Works

To better understand how Hall sensor commutation works, let's look at how it's imple-
mented with a two-pole motor. Six different commutation states are required to turn the
rotor one revolution. The motor’s commutation states are shown in Figure 2.

AN026004-0413 Page 3 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Figure 2. Hall Sensor Commutation States for a 2-Pole Motor

AN026004-0413 Page 4 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Table 1 indicates the relationship between the Hall sensor output and phase switching opera-
tions shown in Figure 2.

Table 1. Relationship Between Hall Sensor Output and Phase Switching

State Hall A Hall B Hall C Phase B Phase C Phase A

1 0 1 1 0 +VDC –VDC
2 0 0 1 +VDC 0 –VDC
3 1 0 1 +VDC –VDC 0
4 0 1 0 0 –VDC +VDC
5 1 1 0 –VDC 0 +VDC
6 1 0 0 –VDC +VDC 0

Table 2 lists the rating of the motor used to develop this application.

Table 2. Motor Rating for Electric Bike BLDC Motor Control Application

Type of Motor Linix BLDC

Power Rating 30 W
Speed 3200 RPM
Number of poles 6
Voltage 24 V

Additionally, the application uses a 3-amp High Rupturing Capacity (HRC) fuse.

AN026004-0413 Page 5 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Using the Z8FMC16100 MCU in an Electric Bike BLDC Motor

Controller
Figure 3 offers a visual overview of the electric bike BLDC motor controller. For more
details about hardware connections, see Appendix A. Schematics on page 12.

:&-# 6$#
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07-,
0H !
0ROTECTION 07-(  0HASE 0H "
,OGIC 07- 07-, -/3&%4
0H #
"RIDGE
07-(
07-,

(EAT3INK4EMP

0) $#"US6OLT 6REF
!$# $#"US#URRENT
3PEED#OMMAND

#OMMUTATION
(ALL3ENSOR !
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0ORT " (ALL3ENSOR " 3IGNAL
(ALL3ENSOR # #ONDITIONING

3PEED
4IMER 
#ALC

Figure 3. Electric Bike BLDC Motor Controller Block Diagram

Hardware Architecture
The design involves running the BLDC motor in a closed loop or an open loop, with speed
as set by a potentiometer. As shown in the architecture diagram, the design generates
PWM voltage via the Z8FMC16100 MCU’s PWM module to run the BLDC motor.
After the motor is running, the states of the three Hall sensors change based on the rotor
position. Voltage to each of the three motor phases is switched based on the state of the
sensors (commutation). Hall sensor interrupts capture timer ticks every sixty degrees to

AN026004-0413 Page 6 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

measure the rotor speed of the motor. Other peripheral functions can be used to protect the
system in case of overload, undervoltage, and overtemperature.
The hardware is described in the following sections.

Three-Phase Bridge MOSFET

The three-phase bridge MOSFET consists of six MOSFETs connected in bridge fashion
used to drive the three phases of the BLDC motor. The DC bus is maintained at 24 V,
which is same as voltage rating of BLDC motor. A separate Hi-Lo gate driver is used for
each high- and low-side MOSFET phase pair, making the hardware design simpler and
robust. The high-side MOSFET is driven by charging the bootstrap capacitor.
The DC bus voltage is monitored by reducing it to suitable value using a potential divider.
The DC bus current is monitored by putting a shunt in the DC return path. An NTC-type
temperature sensor is mounted on MOSFET heat sink, providing analog voltage output
proportional to temperature.

PWM Module
The Z8FMC16100 MCU contains a six-channel, 12-bit PWM module configured in this
application to run in Complementary Mode. The switching frequency is set to 20 KHz.
The output on the PWM outputs is controlled according to the inputs from the Hall sen-
sors.
The inputs from the Hall sensors determine the sequence in which the three-phase bridge
MOSFET is switched. The Duty cycle of the PWM is directly proportional to the acceler-
ator potentiometer input. The change in the duty cycle controls the current through the
motor winding, thereby controlling motor torque.

Commutation Logic
The Hall sensors are connected to ports PB0, PB1 and PB2 on the Z8FMC16100 MCU.
An interrupt is generated when the input state on any pin changes. An interrupt service
routine checks the state of all three pins and accordingly switches the voltage for the three
phases of the motor.
Trapezoidal commutation is used for this application to make implementation simple. In
this process of commutation, any two phases are connected across the DC bus by switch-
ing the top MOSFET of one phase and bottom MOSFET of another phase ON. The third
phase is left un-energized (both top and bottom MOSFET of that phase are switched
OFF).

Speed Measurement
The Hall sensor outputs are connected to to ports PB0, PB1 and PB2. One out of three Hall
sensors is used to capture the Timer0 ticks, which represent the actual Hall period for
closed loop calculations.

AN026004-0413 Page 7 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Closed Loop Speed Control

Closed-loop speed control is implemented using a PI loop, which works by reducing the
error between the speed set by the potentiometer and actual motor speed. The output of
this PI loop changes the duty cycle of the PWM module, thereby changing the average
voltage to the motor, and ultimately changing the power input. The PI loop adjusts the
speed at the same rate as the Hall frequency from one of three Hall sensors. In this applica-
tion, Open Loop operation is selected in the software by default because any rider of the e-
bike will control the speed of the bike.

Protection Logic
The ADC module periodically checks DC bus voltage, DC bus current, and heat sink tem-
perature. If these values go beyond the set limits, the motor is shut down. These checks are
timed by Timer0 interrupt.

Over-Current Hardware Protection

The Z8FMC16100 MCU has a built-in comparator that is used to shut down the PWM for
over-current protection. When the current exceeds the set threshold, a PWM Comparator
Fault is generated to turn OFF the PWM Module.

Software Implementation
During implementation of the software, the following actions are performed:
Initialization. Hardware modules are initialized for the following functions:
• Switch from internal to external oscillator for system operation
• Enable alternate function on respective pins for ADC, Comparator, UART, PA6 as
GPIO configured to drive LED
• Configure Timer0 to run in Continuous Mode to capture the Hall period timing
• Configure the comparator to shut down the PWM module when an overcurrent results
• Enable the Op Amp to measure the DC bus current flowing to the motor
• Configure the ADC to read analog values such as DC bus voltage, current, temperature,
and acceleration potentiometer (only one channel at a time)
• Configure the PWM module for the individual mode of operation with a 20 kHz switch-
ing frequency, control output depending on the values in the PWMOUT Register, and
drive the PWMOUT as defaulted to a low off state at Power-On Reset and at any Reset
• Configure the Reset/Fault0 pin functions as a Fault0 function
• Write-protect Flash memory
• Enable Open Loop operation (shown in the main.h file)
• Hardware control of the application, with the UART disabled

AN026004-0413 Page 8 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Interrupt. The Port B interrupt controls commutation. The Hall sensor output is read on
pins PB0:2, the software performs its filtering operation, and the switching sequence of
the MOSFET is determined. The PWM timer interrupt is used to time periodically occur-
ring tasks and for the background loop to read analog values from different channels and
average these values, update the LED indicator status, and update the read parameters on
the UART.
For a visual representation of the application, see Appendix B. Flowcharts on page 17.

Testing/Demonstrating the Application

This section presents a list of the equipment used and procedures observed to test this e-
bike application.

Equipment Used
Testing for this application was conducted using the following equipment:
• Z8FMC16100 Series Motor Control Development Kit
• Tektronix digital oscilloscope
• Fluke multimeter
• 30 W BLDC motor
• 24 V 7 Ah battery
• Tektronix power supply

System Configuration
The system requirements on your PC are as follows:
• Windows 7 OS
• ZDS II version 5.0.0 installed
• Optically isolated USB smart cable for program download and debugging

Procedure
Observe the following steps to test the BLDC motor:
1. On the Zilog MC MDS Board, configure the following jumpers:
a. Shunt the 1–2 positions on J4, J5, and J6
b. Shunt J2 and J3
2. Set the R7 potentiometer on MC MDS Board (99C0987; contained in the
Z8FMC16100 Series Motor Control Development Kit) to the middle position to start
the motor.
3. Connect the following wires from the motor to the 3-Phase Motor Control Application
Board (contained in the Z8FMC16100 Series Motor Control Development Kit but not
shown in the schematic).

AN026004-0413 Page 9 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

a. Connect the heavy-gauge blue wire to Motor Phase A (P1)

b. Connect the heavy-gauge green wire to Motor Phase B (P2)
c. Connect the heavy-gauge white wire to Motor Phase C (P3)
4. Connect the following wires from the motor to the MC MDS Board (contained in the
Z8FMC16100 Series Motor Control Development Kit but not shown in the sche-
matic).
a. Connect the Hall Sensor-C light gauge blue wire to PB2 at J1 pin 6 with additional
added 680 pF ceramic capacitor to GND.
b. Connect the Hall Sensor-B light gauge green wire to PB1 at J1 pin 4 with addi-
tional added 680 pF ceramic capacitor to GND.
c. Connect the Hall Sensor-A light gauge white wire to PB0 at J1 pin 2 with addi-
tional added 680 pF ceramic capacitor to GND.
d. Connect the light gauge black wire (Sensor Power Ground) to GND at TP1.
e. Connect the light gauge red wire (Sensor Power VCC) to VCC (3.3V) at TP2.

5. Connect the oscilloscope across the motor terminals.

6. Connect the motor control board to the 24 V power supply.
7. Build the code on ZDS II v5.0.0 and download the code through USB smart cable.
8. Measure the performance of motor at different loads, for each speed setting of the
potentiometer.
9. Record the readings and carry out the process for each step in the test sequence.

Test Results
Laboratory performance test of BLDC motor is as follows:
1. Minimum motor speed: 800 RPM
2. Maximum motor speed: 3200 RPM
3. Power consumption: 6 W at 3200 RPM (no load)
4. Regenerative Current at 200 RPM: 350 mA

Future Implementation
The application discussed in this document covers the motoring and regenerative braking
features for a BLDC hub motor used in an electric bike. Further improvements can be
made to the design by adding the following features:
• Controlled charging of SLA batteries by plugging to the AC Mains adaptor
• Implementing ‘Torque-boost’ functionality (through a push-switch), which will give a
boost to motor performance

AN026004-0413 Page 10 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

• Utilizing LIN/UART communication to create a dashboard display of measured

parameters (speed, Battery voltage, Current, and Fault conditions)

References
The following supporting documents are available free for download from the Zilog web-
site.
• eZ8 CPU User Manual (UM0128)
• Z8FMC16100 Series Product Specification (PS0246)
• PID Motor Control with the Z8PE003 Application Note (AN0030)
• Z8 Encore!-Based SLA Battery Charger Application Note (AN0223)
• Sensorless Brushless DC Motor Control with Z8 Encore! MC Microcontrollers
(AN0226)
• Z8 Encore! XP-Based BLDC Fan Control Application Note (AN0228)

AN026004-0413 Page 11 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Appendix A. Schematics
Figures 4 through 8 show schematic representations of each of the application’s key blocks.

3 PHASE POWER STAGE

P4 F1
+VDC +BUS
+BUS

5A FUSE

Q1 Q3
GATE_AH GATE_BH Q5
GATE_CH
IRFZ48 IRFZ48
IRFZ48

P1 P2 P3
PHASE_A PHASE_B
PHASE_B PHASE_C

R6 A C1 B C2 C C3
150k
+ C4 + C5 0.1uF 50V 0.1uF 50V 0.1uF 50V

3300uF 50V 3300uF 50V Q2 Q4 Q6

GATE_AL GATE_BL GATE_CL

IRFZ48 IRFZ48 IRFZ48

V+
R2 10.0k CS+

R5 R1
10.00k 0.100 OHM

P5 R3 10.0k CS-
GND

HEATSINK TEMP SENSOR

TH
TH

R4
NTC 10k
Title
3 PHASE MOTOR CONTROL APPLICATION BOARD

Size Document Number Rev

A B
96C0960-001
Figure 4. Electric Bike BLDC Motor Controller Application Schematic, #1 of 5

AN026004-0413 Page 12 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

GATE DRIVE
D1 BAV19
BEMF DIVIDERS +12V
C6 C7 C8 C9

PHASE_A PHASE_B PHASE_C

10uF 0.1uF 0.1uF 10uF
U1
1 VCC VB 8
R8 R10 R12
150k 150k 150k AH 2 7 R13 22.1 GATE_AH
HIN HO
AL 3 6 PHASE_A
LIN VS
4 5 R14 22.1 GATE_AL
VC COM LO
VA VB

IR2101

R7 R9 R11
10.00k 10.00k 10.00k +12V D2 BAV19

C10 C11 C12 C13

10uF 0.1uF 0.1uF 10uF

U2
1 VCC VB 8

BH 2 7 R15 22.1 GATE_BH

HIN HO
BL 3 6 PHASE_B
LIN VS
4 5 R16 22.1 GATE_BL
COM LO

VCC_33V IR2101

D3 BAV19
12V SUPPLY +12V
C14 C15 C16 C17
L1
D4 BAV19 +12V 10uF 0.1uF 0.1uF 10uF
U3
10uH 1 8
VCC VB
CH 2 7 R17 22.1 GATE_CH
C18 C19 HIN HO
C20 CL 3 6 PHASE_C
U4 R20 LIN VS
10uF 1 86.6k 10uF 4 5 R18 22.1 GATE_CL
SW 68pF COM LO
5 VIN
3 IR2101
FB
4 EN
2 R19
GND 10.0k Title
TPS61041 3 PHASE MOTOR CONTROL APPLICATION BOARD

Size Document Number Rev

A B
96C0960-001
Date: Wednesday June 08 2005 Sheet 2 of 3

Figure 5. Electric Bike BLDC Motor Controller Application Schematic, #2 of 5

AN026004-0413 Page 13 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

UNUSED POWER INTERFACE

JP1 JP2

1 2 VA 1 2 VB
VC
3 4 3 4 CS+
5 6 CS- 5 6
7 8 V+ 7 8 TH
9 10 VCC_33V 9 10
11 12 11 12
13 14 CH 13 14 CL
15 16 15 16
17 18 BH 17 18 AH
19 20 19 20 AL
21 22 BL 21 22
23 24 23 24
25 26 25 26
27 28 27 28
29 30 29 30
31 32 31 32
33 34 33 34
35 36 35 36
37 38 37 38
39 40 39 40
41 42 41 42
43 44 43 44
45 46 45 46
47 48 47 48
49 50 49 50
51 52 51 52
53 54 53 54
55 56 VCC_33V 55 56
57 58 57 58
59 60 VCC_33V 59 60

HEADER 30x2/SM HEADER 30x2/SM

Figure 6. Electric Bike BLDC Motor Controller Application Schematic, #3 of 5

AN026004-0413 Page 14 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

VCC_33V
R1
connector 2
100 D1 JP2
2 1
ANA0_M 1 2 ANA1_M
ANA2_M 3 4 PA1_OP_CN
RED -RESET PA0_OPINN PB3_ANA3_OPOUT
5 6

-RESET

PA2_CINP
DBG ANA4 ANA5

PA7_COUT
7 8
VCC_33V 9 10 GND

DBG
PC0_T0OUT
ANA6 11 12 ANA7

PWM2H
PWM2H PWM2L

PWM1L

PWM2L
13 14
PA2_CINP 15 16 VREF
PWM1H 17 18 PWM0H
GND 19 20 PWM0L
U1 PWM1L 21 22
Z8FMC16110_32 PC0_T0OUT

16
15
14
13
12
11
10
23 24

9
25 26 NC
C1 27 28

PC0/T0OUT

PA7/FAULT1/T0OUT/COUT
PA2/CINP
PWM1L

PWM2L

DBG
RESET/FAULT0
PWM2H
NC NC
R2 R3 NC 29 30 GND
R4 C2 7.5K 12.4K 0.1uF 31 32 NC
NC
PA6_CTS 33 34 PA7_COUT
10K 100pF PA4_RXD 35 36 PA5_TXD
NC 37 38 NC
GND 39 40 NC
C16 C17 NC 41 42 NC
PWM1H 17 8 PA1_OP_CN 43 44
PWM1H PA1/OPINP/CINN NC NC
0.01 0.01 PWM0L 18 7 PA0_OPINN PA3_TXDE 45 46
PWM0H PWM0L PA0/OPINN R5 10K GND
19 PWM0H VREF 6 47 48
GND 20 5 AGND NC 49 50
XOUT GND AGND AVCC -DIS_232
21 XOUT AVDD 4 NC 51 52 -DIS_IRDA
XIN 22 3 ANA0 R6 -RESET 53 54 NC
XIN PB0/ANA0/T0IN0

3
VCC_33V 23 2 ANA1 0 VCC_33V 55 56 GND
PA3_TXDE VDD PB1/ANA1/T0IN1 ANA2 C26 R7 5K
24 PA3/TXDE/SCL PB2/ANA2/T0IN2 1 NC 57 58 NC
PB3/ANA3/OPOUT PA6_CTS VCC_33V 59 60 NC
Y1 VCC_33V C20 10uF ANA6
2
PB4/ANA4/CINN

1 3
PA6/CTS/SDA

1 3 C19 C18 0.01 SPEE D 1K R24 C3

C4 HEADER 30x2/SM
PB7/ANA7
PB6/ANA6
PB5/ANA5
PA4/RXD
PA5/TXD
2

C5 0.01 0.01 1000pF

1
22pF
22pF 20MHz GND
2

25
26
27
28
29
30
31
32

Connection between AG ND and GND JP1

should be done as close as possible
PB3_ANA3_OPOUT

1 2
to the pin 5, AGND. 3 4
Connection between AVCC and VCC_33V 5 6
R8
PA4_RXD

PA6_CTS
PA5_TXD

100 D2 7 8
ANA7
ANA6

ANA4

2 1
should be done as close as possible GND 9 10 VCC_33V
to the pin 4, AVCC. 11 12
LED YEL 13 14
R9 49.9K GND VCC_33V
PA4_RXD 15 16
PA5_TXD 17 18
PA6_CTS 19 20
C6 12pF
21 22
23 24
25 26 GND
J4 27 28
R10
ANA5

100 D3 HEADER 3 29 30
R23 10K
2 1 31 32
VREF 33 34
LED GRN VCC_33V 35 36
37 38 VCC_33V
39 40
LOCAL/ MDS
1
2
3

41 42
VCC_33V R11 10K 43 44
C21 ANA2 ANA2_M R12 10K 45 46
J5 R13 10K 47 48
100pF HEADER 3 49 50 GND
51 52
R14 R15 C22 53 54
10K 10K GND 55 56
100pF 57 58
ANA1_M 59 60
1
2
3

PC0_T0OUT -RESET
ANA1
HEADER 30x2/SM
10
J6
2
4
6
8
HEADER 3
J1
ANA0_M
HEADER 5X2 Z8FMC16 AND MDS CONNECTORS
S1 S2
DIRECT ION C23 C24 C25
SW SPDT SW SPDT
1
2
3

1
3
5
7
9

RUN/ST OP 0.1uF 0.1uF 0.1uF

ANA0

Figure 7. Electric Bike BLDC Motor Controller Application Schematic, #4 of 5

AN026004-0413 Page 15 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

VCC_33V

P1
C7

19
2
3 C8 U2 0.1uF
1 VCC_5V 0.1uF 2 3
CONSOLE

VCC
C1+ V+ GND
PWR JACK + C9 P2
4 C1-
C10 1
0.1uF 100/10 5 C11 6
C2+ 0.1uF TXD0 2
C12 6 7 CTS0 7
0.1uF C2- V- RXD0
U3 3
SPX2815AU-3.3 8
3 2 VCC_33V PA5_TXD 13 17 4
VI VO VCC_33V PA5_TXD T1IN T1OUT
9

GND
GND 12 8 5
R16 T2IN T2OUT
+ C13 R17 0
change p inout C14 680 DB9 Female
1
PA6_CTS 15 R1OUT R1IN 16
100/10
0.1uF PA4_RXD 10 9 USER
PA4_RXD R2OUT R2IN

2
D4
1
LED 3.3 O K EN
14

GND
NC
20 SHDN NC 11

18
GND SP3222EBCA
VCC_33V
GND

R18
10K
U4A

14
74LVC04/SO

U4B -DIS_232 1 2
14

74LVC04/SO

7
3 4 J2
1 GND
2
7

DIS RS 232

U4C
14

74LVC04/SO R19 C15

GND 5 6 VCC_33V

68
330nF
R20
U5
7

2R7 5 VCC
R21 U4D 1
10K LEDA

14
U4E
PA5_TXD
14

74LVC04/SO 2 TXD
74LVC04/SO
9 8 IRDA_SD 4
-DIS_IRDA SD
11 10
PA4_RXD 3 RXD
J3

7
1 6 GND

T
7

2
ZHX1810
GND

0
DIS I RDA
U4F GND
VCC_33V
14

74LVC04/SO
13 12 R22
1
2
3
4
5

1
2
3
4
5

10K

DBG POWER AND COMMUN ICATIONS

7

TP1 TP2 INTERF ACE

P3
VCC_33V -RESET
1 2 -RESET
DBG
3 4 DBG
GND
5 6
Header 3x2

Figure 8. Electric Bike BLDC Motor Controller Application Schematic, #5 of 5

AN026004-0413 Page 16 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Appendix B. Flowcharts
Figure 9 presents a simple flow chart of the main, timer interrupt and Port B interrupt rou-
tines for the electric bike BLDC motor controller application.

Start

Main()

Initialize MCU
peripherals

Capture 3 Hall
sensor binary Obtain ADC result
states for set-speed used
for open/closed
loop

Switch into next

commutation state Yes No
Hall interrupt?

Yes No Capture Timer0

Hall states = 3? Timer0 period and reset
rollover? Timer0

No Yes

Hall period =
0xFFFF

Apply PI control Yes Closed loop

value to PWM
selected?
registers

No

Figure 9. Electric Bike BLDC Motor Controller Application Flowchart

AN026004-0413 Page 17 of 18
 Electric Bike BLDC Hub Motor Control Using the Z8FMC16100 MCU
Application Note

Customer Support
To share comments, get your technical questions answered, or report issues you may be
experiencing with our products, please visit Zilog’s Technical Support page at 
http://support.zilog.com.
To learn more about this product, find additional documentation, or to discover other fac-
ets about Zilog product offerings, please visit the Zilog Knowledge Base at http://
zilog.com/kb or consider participating in the Zilog Forum at http://zilog.com/forum.
This publication is subject to replacement by a later edition. To determine whether a later
edition exists, please visit the Zilog website at http://www.zilog.com.

Warning: DO NOT USE THIS PRODUCT IN LIFE SUPPORT SYSTEMS.

LIFE SUPPORT POLICY

ZILOG’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE
SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF
THE PRESIDENT AND GENERAL COUNSEL OF ZILOG CORPORATION.

As used herein
Life support devices or systems are devices which (a) are intended for surgical implant into the body, or (b)
support or sustain life and whose failure to perform when properly used in accordance with instructions for
use provided in the labeling can be reasonably expected to result in a significant injury to the user. A
critical component is any component in a life support device or system whose failure to perform can be
reasonably expected to cause the failure of the life support device or system or to affect its safety or
effectiveness.

Document Disclaimer
©2013 Zilog, Inc. All rights reserved. Information in this publication concerning the devices, applications,
or technology described is intended to suggest possible uses and may be superseded. ZILOG, INC. DOES
NOT ASSUME LIABILITY FOR OR PROVIDE A REPRESENTATION OF ACCURACY OF THE
INFORMATION, DEVICES, OR TECHNOLOGY DESCRIBED IN THIS DOCUMENT. ZILOG ALSO
DOES NOT ASSUME LIABILITY FOR INTELLECTUAL PROPERTY INFRINGEMENT RELATED
IN ANY MANNER TO USE OF INFORMATION, DEVICES, OR TECHNOLOGY DESCRIBED
HEREIN OR OTHERWISE. The information contained within this document has been verified according
to the general principles of electrical and mechanical engineering.
Z8 Encore! MC is a trademark or registered trademark of Zilog, Inc. All other product or service names are
the property of their respective owners.

AN026004-0413 Page 18 of 18