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mCP X Brushless Mods Blade Micro CPx Brushless Mods and Conversions


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Old 03-01-2012, 12:27 PM   #1
sskaug
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Default BLHeli for SiLabs ESCs

The BLHeli code has now been converted to run on SiLabs ESCs.

This link describes the Atmel version of the code, which has the same functionality: http://www.helifreak.com/showthread.php?t=357151

The BLHeli code supports:
- Brushless tail. Get rid of that heavy SR120 tail motor.
- Governed main. Get consistent cyclic and collective response in hard maneouvers.
Other features are:
- Parameters programmable from TX
- Optional pitch to tail mix in governed mode.
- Allows build of ultralight main and tail ESCs (<0.4gram).
- Both v1 and v2 3in1 boards are supported.
There are probably also other applications, like for instance MQX brushless ESC?

So, over to the implementation facts. What do you need to do to set up a BLHeli ESC:
- Buy a "Toolstick base adapter that costs 18.63$ (a little more than a programming card for other ESCs).
- Buy one of the supported ESCs.
- Download free flashing SW from SiLabs.
- Connect three wires to the ESC and flash the code.

And the details:
The Toolstick base adapter looks like this:
Click image for larger version

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The pictures also show where to connect the three wires (I have used black, red and white).
And you have to short two pins on the connector (highlighted with a green circle in the pic).
You can buy it here: http://search.digikey.com/us/en/prod...345-ND/1207734
Or here: http://www.silabs.com/products/mcu/Pages/ToolStick.aspx ("TOOLSTICKBA" link)
And probably many other places too....


Then you have to choose your ESC. The ones below are currently supported:
DP 3A: Click image for larger version

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Supermicro 3.5A: Click image for larger version

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XP 3A: Click image for larger version

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XP 7A: Click image for larger version

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ID:	294859 (Remove the cap as shown)
XP 12A: Click image for larger version

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ID:	294861 (Remove the cap as shown)
Turnigy 6A: Click image for larger version

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The above pictures also have black, red and white circles showing where to connect to the toolstick.
All of them have PCB points that are fairly easily accessible with a soldering iron.

Then you need to download and install software for flashing:
Click the "Flash Programming Utility" link on this page: http://www.silabs.com/products/mcu/P...Utilities.aspx

With the Toolstick and the ESC at hand, follow the guidelines in this document: SiLabs code flashing.pdf
Hex files for downloading into the various ESCs, as well as source code and TX programming manual can be found here: https://github.com/bitdump/BLHeli

Alternatively use the excellent BLHeliSetup software (windows only), that lets you flash hex files, change parameter settings and more. You can download it from 4712's blog page: http://helifreak.com/blog.php?b=1859

And that's it. Now just build the ESC into your heli and fly!

Happy modding and flying
Steffen







PS: Although shown many other places, below are pics of wire connection to the "resistor taps" on the back of the v1 and v2 3in1 boards:
v1 board:
v2 board:
Attached Files
File Type: zip BLHeli SiLabs Hex files Rev1.0.zip (47.1 KB, 1642 views)
File Type: zip BLHeli SiLabs Source code Rev1.0.zip (34.7 KB, 1555 views)

Last edited by TowPilot; 05-13-2012 at 11:06 AM.. Reason: Edits Per OP
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Old 03-01-2012, 12:35 PM   #2
sskaug
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Just some additional information:
This spreadsheet shows the governor headspeed versus programmed throttle setting: Governor SiLabs.xls
The SiLabs version of the BLHeli code will support headspeeds in excess of 8000rpm (with 6pole motor and 8t pinion).

And this spreadsheet has a bit of information on the FETs that you will find in various ESCs: MOSFETs SiLabs.xls

Finally just the spreadsheet used for calculation of the low voltage limiter settings for the various ESCs: Voltage cutoff SiLabs.xls
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Old 03-01-2012, 12:47 PM   #3
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Default Ultra lightweight ESCs

If you would like to build ultra lightweight ESCs for your mCP X, you can do like this:
Start off with one of the small ESCs, the DP 3A, the XP 3A or the Supermicro 3.5A (the lightest one).

Then replace the FETs with good FETs, like for instance the DMN2041/DMP2035:
http://search.digikey.com/us/en/prod...ICT-ND/2182586
http://search.digikey.com/us/en/prod...ICT-ND/2181234

For the main you "piggyback" a second set of FETs on top of the first.
Such an ESC with double DMN2041/DMP2035 is better than an XP 7A and only weighs about 0.4g.

Some pics of my beli build:
XP 3A main with double FETs:
DP 3A tail:
Supermicro tail:
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Old 03-01-2012, 02:38 PM   #4
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Great work Steffen! Thanks for your tremendous effort!

I am currently running an XP-12A (with converter) and HP06v2 main motor.
I am using a 120SR tail with Plantraco 65mm prop.

Encouraged by your great documentation, I'd like to install a brushless tail
with the XP-3A. What motor and prop would you recommend? Would a
Oversky HP03T be a good choice?
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Old 03-01-2012, 02:51 PM   #5
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I have been using both the Oversky HP03T "regular" 2.9g, and the "new" HP03T 2.5g with Plantraco together with HP06v2, WOW07 and HP08. And I am happy with both. The 2.9g has 12 magnets, while the 2.5g has 6 magnets, and the 2.9G is more powerful and probably a safer bet.

Anybody else have other experiences on tail motors?

Quote:
Originally Posted by rfto View Post
Great work Steffen! Thanks for your tremendous effort!

I am currently running an XP-12A (with converter) and HP06v2 main motor.
I am using a 120SR tail with Plantraco 65mm prop.

Encouraged by your great documentation, I'd like to install a brushless tail
with the XP-3A. What motor and prop would you recommend? Would a
Oversky HP03T be a good choice?
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Old 08-04-2012, 09:35 AM   #6
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Default Link to Atmel ESC photos, please?

I have searched for a half hour. Please, can someone link me to the Atmel ESC photos that BLheli supports?
thanks,
Dave

Should we add this to the Wiki?
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Old 03-15-2012, 02:07 PM   #7
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Quote:
Originally Posted by sskaug View Post
If you would like to build ultra lightweight ESCs for your mCP X, you can do like this:
Start off with one of the small ESCs, the DP 3A, the XP 3A or the Supermicro 3.5A (the lightest one).

Then replace the FETs with good FETs, like for instance the DMN2041/DMP2035:
http://search.digikey.com/us/en/prod...ICT-ND/2182586
http://search.digikey.com/us/en/prod...ICT-ND/2181234

For the main you "piggyback" a second set of FETs on top of the first.
Such an ESC with double DMN2041/DMP2035 is better than an XP 7A and only weighs about 0.4g.
I have some XP3A and DP3A coming from HobbyKing. I'm going to order the toolstick adaptor from Digi key along with some FETs and have a question. I notice the DMN2041 is rated 6.4A while DMN2035 is rated 3.6A only. I wonder if Vishay's SI2333CDS-T1-E3CT-ND (commonly used to repair burnt tail FETs on 3-in-1 board) would be a better choice since it's rated 7.1A which is closer to DMN2041? The specs seem close enough but would you recommend mixing brands for complementary N/P channel pair?
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Old 03-15-2012, 02:18 PM   #8
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I've ordered the TA915, XP12A and toolstickba. I've been poking around but not finding what brushless tail you guys are running with this setup. Can someone point me in the right direction?
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Last edited by memheli; 03-15-2012 at 02:42 PM.. Reason: wrong motor noted
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Old 03-15-2012, 02:34 PM   #9
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Quote:
Originally Posted by memheli View Post
I've ordered the spin 16,3 motor, XP12A and toolstickba. I've been poking around but not finding what brushless tail you guys are running with this setup. Can someone point me in the right direction?
I think the best so far has been the HP03T 2.9G version.
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Old 03-15-2012, 02:51 PM   #10
sskaug
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Quote:
Originally Posted by DoubleCH View Post
I have some XP3A and DP3A coming from HobbyKing. I'm going to order the toolstick adaptor from Digi key along with some FETs and have a question. I notice the DMN2041 is rated 6.4A while DMN2035 is rated 3.6A only. I wonder if Vishay's SI2333CDS-T1-E3CT-ND (commonly used to repair burnt tail FETs on 3-in-1 board) would be a better choice since it's rated 7.1A which is closer to DMN2041? The specs seem close enough but would you recommend mixing brands for complementary N/P channel pair?

Mixing brands should not be a problem!
However, I am not sure the si2333cds is better.
Device: DMP2035 SI2333CDS
Resistance: 30mohm 36mohm
Rthja: 153K/W 75K/W
Max curr: 3.6A 5.1A
The maximum current is mostly about temperature. And on those spec items there are a lot of footnotes in the datasheet! And the differences between the two is probably a difference in package with lower thermal resistance for the SI2333CDS, but also a lot about how it is specified.
And! Remember that in an ESC, each FET only carries current one third of the time. So a 3.6A spec for a FET means much more than that for the ESC (not three times as much though, since there are square law effects involved).
I would still go for the DMP2035, due to it's lower resistance

Cheers,
-S
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Old 03-15-2012, 03:07 PM   #11
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Agree about IR, package, and continuous current. From my search, both parts show the same 35mOhm so I thought the Vishay has an edge on peak current. Do you think double FET is good enough for peak current for 915 or hp08 with the DMN's? If so, the DMNs are cheaper and I'll go with those.
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Old 03-29-2012, 08:16 AM   #12
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Quote:
Originally Posted by sskaug View Post
If you would like to build ultra lightweight ESCs for your mCP X, you can do like this:
Start off with one of the small ESCs, the DP 3A, the XP 3A or the Supermicro 3.5A (the lightest one).

Then replace the FETs with good FETs, like for instance the DMN2041/DMP2035:
http://search.digikey.com/us/en/prod...ICT-ND/2182586
http://search.digikey.com/us/en/prod...ICT-ND/2181234

For the main you "piggyback" a second set of FETs on top of the first.
Such an ESC with double DMN2041/DMP2035 is better than an XP 7A and only weighs about 0.4g.
Thanks you so much Steffen for your amazing work and making this possible!

I'm interested in replacing FETs but can't seem to find both FETs shown above here in the UK. Are there any equivalent FETs that could be used?

Also sorry if this is a silly question but how do I tell which FETs are N or P channel on the ESC when replacing them?

Also I have a couple XP 3A ESCs that are not working. They respond to programming but no output when throttle is applied. Could this possibly be faulty FETs causing this problem? If so is there a way to test the FETs to tell which ones are faulty?

Thanks again for your help!
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Old 03-29-2012, 09:07 AM   #13
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Hi, perhaps look for:
IRLML6244 = N-Fet
Si2333CDS = P-Fet

HTH
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Old 03-29-2012, 01:53 PM   #14
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Quote:
Originally Posted by 4712 View Post
Hi, perhaps look for:
IRLML6244 = N-Fet
Si2333CDS = P-Fet

HTH
I ordered a flashed XP-3A for my main motor and some DMN204IL-7 mosfets from Digi-Key. After reading this post I am thinking I don't have all the parts I need to piggyback the fets on this controller. Will the fets I have work on all 6 fets on the esc or do I need to get 3 more of a different part numer?
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Old 03-29-2012, 09:32 AM   #15
sskaug
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Quote:
Originally Posted by microheliaddict View Post
Thanks you so much Steffen for your amazing work and making this possible!

I'm interested in replacing FETs but can't seem to find both FETs shown above here in the UK. Are there any equivalent FETs that could be used?

Also sorry if this is a silly question but how do I tell which FETs are N or P channel on the ESC when replacing them?

Also I have a couple XP 3A ESCs that are not working. They respond to programming but no output when throttle is applied. Could this possibly be faulty FETs causing this problem? If so is there a way to test the FETs to tell which ones are faulty?

Thanks again for your help!
If you don't find Achim's proposals below, you can search for SOT23 fets that have low on resistance specified at 2.5V. That is the basic criteria for a 1S ESC. If you are going above 1S, you also need to look for maximum voltage that the fets can handle.

As for the ESC not responding to throttle signal, are you sure you have chosen the correct hex file? Maybe a dumb question, but I have done the error myself The input signal is on different pins on the various ESCs. I do not think faulty fets cause this. If one or more fets are faulty you will generally have a motor that "wiggles" but does not run.

There is also a notice of caution on choosing the right hex file, as some erroneous combinations of hex file and ESC can burn fets.
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Old 03-29-2012, 11:07 AM   #16
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Quote:
Originally Posted by 4712 View Post
Hi, perhaps look for:
IRLML6244 = N-Fet
Si2333CDS = P-Fet

HTH
Thanks 4712 this helps a lot!

Quote:
Originally Posted by sskaug View Post
If you don't find Achim's proposals below, you can search for SOT23 fets that have low on resistance specified at 2.5V. That is the basic criteria for a 1S ESC. If you are going above 1S, you also need to look for maximum voltage that the fets can handle.

As for the ESC not responding to throttle signal, are you sure you have chosen the correct hex file? Maybe a dumb question, but I have done the error myself The input signal is on different pins on the various ESCs. I do not think faulty fets cause this. If one or more fets are faulty you will generally have a motor that "wiggles" but does not run.

There is also a notice of caution on choosing the right hex file, as some erroneous combinations of hex file and ESC can burn fets.
Thanks for the info.. the ESC is not responding to throttle response before even flashing with BLHeli code. Will try flashing as soon as I get my Toolstick and hopefully they will work unless there is a faulty component! Is there a way to test if FETs are faulty with a multimeter? Seems like all the caps and resistors are fine and nothing looks burnt.
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Old 03-29-2012, 09:01 PM   #17
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Quote:
Originally Posted by sskaug View Post
If you don't find Achim's proposals below, you can search for SOT23 fets that have low on resistance specified at 2.5V. That is the basic criteria for a 1S ESC. If you are going above 1S, you also need to look for maximum voltage that the fets can handle.

As for the ESC not responding to throttle signal, are you sure you have chosen the correct hex file? Maybe a dumb question, but I have done the error myself The input signal is on different pins on the various ESCs. I do not think faulty fets cause this. If one or more fets are faulty you will generally have a motor that "wiggles" but does not run.

There is also a notice of caution on choosing the right hex file, as some erroneous combinations of hex file and ESC can burn fets.

So, if I can only find this combination, like:
DMP2035U - P CH
IRLML6244TRPBF - N CH
Is it fine to work?
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Old 04-01-2012, 11:29 PM   #18
Hydros27
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Quote:
Originally Posted by sskaug View Post
If you would like to build ultra lightweight ESCs for your mCP X, you can do like this:
Start off with one of the small ESCs, the DP 3A, the XP 3A or the Supermicro 3.5A (the lightest one).

Then replace the FETs with good FETs, like for instance the DMN2041/DMP2035:
http://search.digikey.com/us/en/prod...ICT-ND/2182586
http://search.digikey.com/us/en/prod...ICT-ND/2181234

For the main you "piggyback" a second set of FETs on top of the first.
Such an ESC with double DMN2041/DMP2035 is better than an XP 7A and only weighs about 0.4g.

Some pics of my beli build:
XP 3A main with double FETs:
DP 3A tail:
Supermicro tail:
I have ordered the fets in this post. Will they work in the 3 in 1 also?
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Old 05-18-2012, 04:21 AM   #19
itsmillertime0
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Quote:
Originally Posted by sskaug View Post
If you would like to build ultra lightweight ESCs for your mCP X, you can do like this:
Start off with one of the small ESCs, the DP 3A, the XP 3A or the Supermicro 3.5A (the lightest one).

Then replace the FETs with good FETs, like for instance the DMN2041/DMP2035:
http://search.digikey.com/us/en/prod...ICT-ND/2182586
http://search.digikey.com/us/en/prod...ICT-ND/2181234

For the main you "piggyback" a second set of FETs on top of the first.
Such an ESC with double DMN2041/DMP2035 is better than an XP 7A and only weighs about 0.4g.

Some pics of my beli build:
XP 3A main with double FETs:
DP 3A tail:
Supermicro tail:
Just to reiterate as I'm apparently a little slow, the supermicro 3.5 can be used as a main and tail esc for a very lightweight setup. But the fets will have to be replaced entirely with the DMN2041/DMP2035 fets for tail usage and then the DMN2041/DMP2035 soldered on top of the original fets for main usage. What then would be the max amperage the main could handle? I found the fets dirt cheap and the 3.5 esc's are $5.something so I think this is the route I'll be taking.
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Old 05-18-2012, 06:51 AM   #20
4712
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Quote:
Originally Posted by itsmillertime0 View Post
...and then the DMN2041/DMP2035 soldered on top of the original fets for main usage.
I would not mix different types of FET. Either double the original ones or double the DMN2041/DMP2035.
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