new version v59 - beta

[nliaudat]

Hi,
After a lot of work, I have draft a new version of the board.

The major changes are :

Better BEMF :

• Complete new concept of sensing with no more troubles with resistors to GND
  

Remove of AC input :

• That was dangerous
• The cost of HKL-5M was 3.8$ instead of 0.5$ for the new XL1509 module

• With XL1509 module, You can adjust power of motors between 3.3V to 37V (recommended max 12V as not tested)
• Everybody has an old AC/DC 1A charger
• JLCPCB was charging a lot of shipping with the wheight of HKL module
• New DC power input : DC Power Receptacle 2mm 6.4mm + Screw terminal

Motor DC :

• input can be 3.3V to 12V
• a new AMS1117-3.3 powers the ESP32 board

Better PCB :

• Separate 3.3V power of ESP32 board from motors
• Capacitor added to regulate peaks in power
• Via shielding
• Power isolation on bottom side
• Smaller design (126x70mm instead of 126x80). The M4 holes are compatible.
• Lower the price of all components (jlcpcb price soldered)
• use R0402 footprint if possible

ESP32-C3 :

• ESP32-C3 supermini footprint added
• ESP32-C3 costs 2.4$ instead of 3.8$ for nodemcu devkit

OneWire :

• Add 3 onewire XH2.54-3P connectors
• Can get input temperature and output temperature of the heating circuit.

Studies :

• The XL9535 shift register cost the same as 2x SN74HC595, but the esphome code is very new and move to I2C is not compatible with esp-c3 supermini
• The Mini L298N module instead of L9110 soldered is approx the same price (0.7per channel out of 0.52 + resistors)
• Add more channels : if 12, this needs of another opam

V59 :

[Birkemosen]

Hi, I found your repo, and this looks really interesting.

I would like to test it, since i have 2x6 heating circuits that I would like to optimize for using with an air-to-water heat pump, (having as much water as possible flowing in the system, while keeping the forward temperature as low as possible).

Is the schematic for the prerelease version ready to be shared, or are there issues with it ? (Can’t find them under the prerelease sources)

Thanks in advance

[nliaudat]

Hi,
The XL1509 power module has issue. It cannot run the motors. I have to find another one.

[nstadigs]

Is there a problem with the XL1509 module overall or is it your particular copy that's broken?

[nliaudat]

I have 10 pieces of XL1509 with all the same result : the motor do not start.
I mean it's an inductance related issue or a XL1509 internal current limiting protection.

[nliaudat]

The problems are corrected.
I've added a large capacitor and a Schottky diod to prevent esp32 brownout
The XL1509 has enough power but peaks can shutdown esp32
I've bought another 5 pieces of pcb for testing the new version
Please wait till approved.
Regards

[nliaudat]

• The AMS1117-3.3 is pcb ready but not in BOM. It's only needed in case if you want to power > 3.3V motors
• Usb-C slot added with 5.1k resitors to get up to 3A power. It's power source only

[nstadigs]

And you added usb-c! ❤️

[nliaudat]

Some bad news :

The L9110S chip I use for it's low price is not the same as L9110 and many datasheets are wrong.
In fact, the S version as no flyback diodes and can support 2.2~6.5V at 100mA (max 180 mA).

With no incorporated diodes, the proposed BEMF sensing do not work at all.

I will switch the L9110S module to TC118S

[bezigebever]

Great work ! So we have to wait a bit for the new board becomes stable and tested ?

[nliaudat]

I wait on the new motor driver module ordered at jlcpcb to validate the BEMF.
Then the pcb has to be rewritten

[FreezedBrain]

I am also waiting for the result and the new BOM and Gerber files. The ones from version v58_rev_1.52 are not orderable on jlcpcb because parts are missing in the BOM.

Error:
The below parts won't be assembled due to data missing.
WROOM-LEFT1,WROOM-RIGHT,WROOM-LEFT,HLK-PM03,P1,P2,P3,P4,H1,H3,H4,H5,OPAMP-H1,U1 designators don't exist in the BOM file.

[nliaudat]

It will take more time.
I received 10x T118s modules I ordered with the previous schematic.

They are not working at all and overheating.
I search the problem without success

If I put 3.3V on INA or INB, the module get warm and the power on VCC drop to 1.6v
I tried to add 1k resistors to lower INx cause their limit is 20mA = fail.

I have to test others :
But there is no documentation on BEMF for all of them.
In fact, getting BEMF from GND as in L9110S was a luck, but the L9110S module is end of life and less available.

[nliaudat]

feel free to test or adapt yourself.

Here is the easyeda pro project
ReuseBlock_TC118s_2024-10-09.zip

[nliaudat]

I have good news :

I found the problem with T118s module. (shortcut in OA / OB with GND)
The 2nd problem was the diodes D1/D2, the motor need to be grounded in every case. It was a stupid idea.

With the new design, there is no need for opamp as the output in running conditions is 0.7V and 0.8 at stall,

The new diode D4 between BEMF and GND increase accuracy from 0.2v to 0.7V in running state.
The fact of injecting BEMF in GND was disturbing ADC reading.

[nliaudat]

The final board ordered today :

The power is usb-c only cause it's enough.

[marcelveldt]

I'm very interested in this board (either the old or the new revision) - currently it cant be ordered due to some components of the BOM are no longer available.

[bezigebever]

@nliaudat what is the status of the board ? I would really like to order some ;-)

[nliaudat]

All preliminary tests are carried out.
I have a bug with the ADC BEMF measurement when it comes at endstop (0.700V).
This causes the ESP32 to reboot ...
By adding a 1.2k resistor to BEMF, it no longer crashes.
For the moment, I don't understand why and I'm looking for answers before final publication.

Another problem is that TC118s output is only 2.6V on motor as it should be 3.3V

[nliaudat]

After some more tests, one resistor of low value as 10 ohm solves the reboot problem.
I mean that it's linked to the filtering property of the resistor which act as a low pass filter or perhaps an impedance reduction.

Finally, I will add a 180 ohm resistor cause it's suitable and can correct some nodemcu devkits ADC reading.

Here are the ADC values :

• 0.383 V running on pcb only without motor
• 0.610 V opening/closing with no load
• 0.620-0.635 V opening with load
• 0.620-0.635 V closing with load
• 0.650 V endstop

[bezigebever]

@nliaudat So you wil make a new version tot test it again ?
I would love to go for this version without the 230Vac connection

[nliaudat]

Please have a look at new surveys: https://github.com/nliaudat/esp32_8ch_motor_shield/discussions

[nliaudat]

New version 61 rev 4.51 ready :

[THorst92]

@nliaudat Do you know why the cut outs are not working when I want to order the PCB:

[nliaudat]

Are you ordering at jlcpcb ?
Have you done modifications on gerber files ?
Can you try to pass your upload to https://jlcdfm.com/

[THorst92]

I directly ordered from the link above (https://oshwlab.com/nliaudat/floor_heatin_controller_v61)
I also tried to download the Gerber files (Exported from EasyEDA and taken from the release) and upload it again without any modifications.
https://jlcdfm.com/ gives me the same result :(
When I select the 3D-view in EasyEDA the cutouts are displayed correctly.

[nliaudat]

Can you try that ?
This is the production file generated by jlcpbc after validation on my last order :
Gerber_61-451_2024-11-17_Y61.zip

[THorst92]

This is working! Thanks a lot! :)

[nliaudat]

I received the new boards and they works as expected. :)

[WMP]

Do you have 2 to sell to Poland?

[THorst92]

@nliaudat @bezigebever
Do you have one PCB (version 61 rev 4.51) which you could sell me (Germany) so that I do not have to order 5 pieces?

[marcelveldt]

I just ordered 5 pieces (need 2 myself) - I'm in the Netherlands. Contact me if you want one
EDIT: sold

[nliaudat]

Please open a new buy/sell discussion

[nliaudat]

v61 completed

[nliaudat]

For v61, plz update your firmware to latest version as IA/IB motor control is inverted
https://github.com/nliaudat/floor-heating-controller/releases