PWR-82520X 3-PHASE DC MOTOR TORQUE CONTROLLER FEATURES • Self-Contained 3-Phase Motor DESCRIPTION Controller The PWR-82520X is a high performance current regulating torque loop controller. It is designed to accurately regulate the current in the motor windings of 3-phase brushless DC and brush DC motors. PWR-82520X can be tuned by using an external Proportional/Integral (PI) regulator network in conjunction with the internal error amplifier. The PWR-82520X is a completely self-contained motor controller that converts an analog input command signal into motor current and uses the signals from Hall-effect sensors in the motor to commutate the current in the motor windings. The motor current is internally sensed and processed into an analog signal. The current signal is summed together with the command signal to produce an error signal that controls the pulse width modulation (PWM) duty cycle of the output, thus controlling the motor current. The Packaged in either a small DIP-style or flat-pack hybrid package, the PWR-82520X is ideal for applications with limited printed circuit board area. • Operates as Current or Voltage Controller • 1, 3 and 10 Amp Output Current APPLICATIONS • 1.5% Linearity • 3% Current Regulating Accuracy • User-Programmable Compensation • 10 KHz - 100 KHz PWM Frequency PWR-82520X is ideal for applications requiring current regulation and/or holding torque at zero input command. System applications that can use the PWR-82520X are: pumps, actuators, antenna position, environmental control and reaction/momentum wheel systems using brushless and brush motors. • Complementary Four-Quadrant Operation • Holding Torque through Zero Current • Cycle-by-Cycle Current Limit • Optional Radiation Tolerance to 100Krads 5.0V 10K 10K 10K HA HALL A HALL C COMMAND IN + COMMUTATION LOGIC HC TACH CIRCUIT DIR OUT COMMAND OUT COMMAND IN - TACH OUT HB HALL B 50K 50K - 100 VBUS+ A 50K + DRIVE A COMMAND BUFFER 50K PHASE A PHASE A COMMAND GND SYNC IN VDR +15V VCC +5V VCC RTN VBUS+ B PWM LOGIC CIRCUITRY +5V RTN VDD + SUPPLY GND + DRIVE B PHASE B VBUS+ C VEE CASE GND PHASE B CASE 5.0V DRIVE C 10.0K PHASE C PHASE C ENABLE PWM IN PWM OUT ERROR AMP OUT RS+ ERROR AMP IN + CURRENT MONITOR OUT 100 ERROR AMPLIFIER CURRENT AMP + FIGURE 1. PWR-82520X BLOCK DIAGRAM © 2000 Data Device Corporation Rsense VBUS– TABLE 1. PWR-82520X ABSOLUTE MAXIMUM RATINGS (Tc = +25°C unless otherwise specified) PARAMETER BUS VOLTAGE +15V SUPPLY +5V TO +15V +5V SUPPLY -5V TO -15V VBUS- TO GND Voltage Differential CONTINUOUS OUTPUT CURRENT PWR-82520X1 PWR-82520X3 PWR-82520X10 COMMAND INPUT + COMMAND INPUT - SYMBOL VALUE UNITS VBUS+ VDR VDD VCC 100.0 +16.5 +16.5 +5.5 Vdc Vdc Vdc Vdc VEE -16.5 Vdc VGNDDIF VDD +1.0 Vdc IOC 1.5 4.0 14 ±5.0 ±5.0 A A A Vdc Vdc 7.0 Vdc Command input + Command input ENABLE, SYNC, HA, HB,HC LOGIC INPUTS TABLE 2. PWR-82520X SPECIFICATIONS (Unless otherwise specified, VBUS = 28Vdc, VDR = +15V, VCC = +5V, VDD=+5V, VEE=-5V, Tc = 25°C, LL = 500 µH) PARAMETER OUTPUT (PWR-82520X1) Output Current Continuous Output Current Pulsed Current Limit Current Offset* Output On-Resistance Output Conductor Resistance Diode Forward Voltage Drop OUTPUT (PWR-82520X3) Output Current Continuous Output Current Pulsed Current Limit Current Offset* Output On-Resistance Output Conductor Resistance Diode Forward Voltage Drop OUTPUT (PWR-82520X10) Output Current Continuous Output Current Pulsed Current Limit Current Offset* Output On-Resistance Output Conductor Resistance Diode Forward Voltage Drop COMMAND IN+/Differential Input COMMAND OUT Internal Voltage Clamp SYMBOL TEST CONDITIONS IOC IOP ICL t = 50µsec MIN TYP MAX 1 3 1.5 VCMD = 0V +25°C +85°C +85°C ID = 1A IOFFSET RON RC VF +20 0.60 0.90 0.06 1.5 -20 3 IOC IOP ICL +20 0.18 0.27 0.06 1.8 20 15.4 +100 0.055 0.075 0.060 1.9 A A A mA Ω Ω Ω V 4 VCMD = 0V +25°C +85°C +85°C ID = 1A IOFFSET RON RC VF -20 10 IOC IOP ICL t = 50µsec VCMD = 0V +25°C +85°C +85°C ID = 10A IOFFSET RON RC VF 12.0 -100 14.0 0 A A A mA Ω Ω Ω V A A A mA Ω Ω Ω V 8 t = 50µsec UNITS VCMD -4 +4 Vdc VCLAMP -5 +5 Vdc 2 TABLE 2. PWR-82520X SPECIFICATIONS (CONT) (Unless otherwise specified, VBUS = 28Vdc, VDR = +15V, VCC = +5V, VDD=+5V, VEE=-5V, Tc = 25°C, LL = 500 µH) PARAMETER CUR. MONITOR AMP (X1) Current Monitor Gain Current Monitor Offset Output Current Output Resistance CUR. MONITOR AMP (X3) Current Monitor Gain Current Monitor Offset Output Current Output Resistance CUR. MONITOR AMP (X10) Current Monitor Gain Current Monitor Offset Output Current Output Resistance CURRENT COMMAND* Transconductance Ratio PWR-82520X1 PWR-82520X3 PWR-82520X10 Non-Linearity VBUS+ SUPPLY Nominal Operating Voltage +15V SUPPLY Voltage Current Current +5V SUPPLY Voltage Current +5V TO +15V SUPPLY Voltage Current -5V TO -15V SUPPLY Voltage Current SYNC Low High Duty Cycle SYNC range as % of free-run freq. PWM IN +Peak -Peak Frequency Linearity Duty Cycle PWM OUT Free Run Frequency HALL SIGNALS Logic 0 Logic 1 ENABLE Enabled Disabled TACH OUT/ DIR OUT Current draw ISOLATION Case to Ground SYMBOL TEST CONDITIONS MIN IoC = 0A -10 -10 IoC = 0A -10 -10 IoC = 0A -10 -10 TYP MAX UNITS +10 +10 1 V/A mVdc mA Ω +10 +10 1 V/A mVdc mA Ω +10 +10 1 V/A mVdc mA Ω 4 ROUT 1.33 ROUT 0.40 ROUT G 0.24 0.73 2.40 -1.5 0.25 0.75 2.50 0.26 0.77 2.60 +1.5 A/V A/V A/V % FSR 18 28 70 Vdc +13.5 +15.0 11 0 +16.5 15 Vdc mA mA VCC ICC +4.5 +5.0 13 +5.5 18 Vdc mA VDD IDD +4.5 49 +16.5 65 Vdc mA VEE IEE -16.5 49 -4.5 65 Vdc mA 0.8 120 Vdc Vdc % % V V KHz % % VNOM VDR IDR IDR ENABLE = low ENABLE = high 2.4 50 0 VP+ VPf LIN D CYCLE 4.8 -5.2 10 -2 49 5.0 -5.0 50 5.2 -4.8 110 +2 51 95 100 105 KHz 0.8 Vdc Vdc 0.8 Vdc Vdc 20 mA HA, HB, HC 2.4 ENABLE 2.4 IOL 500 Vdc HIPOT 3 10 MΩ TABLE 2. PWR-82520X SPECIFICATIONS (CONT) (Unless otherwise specified, VBUS = 28Vdc, VDR = +15V, VCC = +5V, VDD=+5V, VEE=-5V, Tc = 25°C, LL = 500 µH) PARAMETER PROPAGATION DELAY SYMBOL Td (on) Td (off) SWITCHING CHARACTERISTICS (X1) Upper Drive Turn-on Rise Time Turn-off Fall Time Lower Drive Turn-on Rise Time Turn-off Fall Time SWITCHING CHARACTERISTICS (X3) Upper Drive Turn-on Rise Time Turn-off Fall Time Lower Drive Turn-on Rise Time Turn-off Fall Time SWITCHING CHARACTERISTICS (X10) Upper Drive Turn-on Rise Time Turn-off Fall Time Lower Drive Turn-on Rise Time Turn-off Fall Time THERMAL (PWR-82520X1) Thermal Resistance Junction-Case Case-Air Junction Temperature Case Operating Temperature Case Storage Temperature THERMAL (PWR-82520X3) Thermal Resistance Junction-Case Case-Air Junction Temperature Case Operating Temperature Case Storage Temperature THERMAL (PWR-82520X10) Thermal Resistance Junction-Case Case-Air Junction Temperature Case Operating Temperature Case Storage Temperature RADIATION (PWR-82520R Series Only) Total dose Dose Rate SEU at LET level of Latch-up Immune tr tf tr tf tr tf tr tf tr tf tr tf TEST CONDITIONS MIN From 0.8V on ENABLE to 90% of VBUS From 2.4V on ENABLE to 10% of VBUS Rise Time = 10% to 90% of VBUS Fall Time = 90% to 10% of VBUS IO= 1A Rise Time = 10% to 90% of VBUS Fall Time = 90% to 10% of VBUS IO= 3A Rise Time = 10% to 90% of VBUS Fall Time = 90% to 10% of VBUS IO= 10A θj-c θc-a Tj TC TCS TYP 20 µs 75 30 ns ns 50 60 ns ns 150 150 ns ns 160 130 ns ns 200 200 ns ns 200 200 ns ns -55 θj-c θc-a Tj TC TCS -55 25 10 +150 +125 +150 °C/W °C/W °C °C °C 9 10 +150 +125 +150 °C/W °C/W °C °C °C 4 5.5 +150 +125 +150 °C/W °C/W °C °C °C 100 0.5 36 36 WEIGHT X1 X3 X10 1.7 (48) 1.7 (48) 2.9 (82) * When used in configuration shown in FIGURE 13. 4 UNITS µs -55 θj-c θc-a Tj Tc Tcs MAX 40 Krad Rad/Sec MeV/mg/cm2 MeV/mg/cm2 oz (g) oz (g) oz (g) INTRODUCTION The PWR-82520X is a 3-phase high performance current control (torque loop) hybrid, which can provide true four-quadrant control through zero current. Its high Pulse Width Modulation (PWM) switching frequency makes it suitable for operation with low inductance motors. The PWR-82520X hybrid can accept singleended or differential mode command signals. The current gain can be easily programmed to match the end user system requirements. With the compensation network externally wired, the hybrid can provide optimum control of a wide range of loads. of transistors are turned on, Phase A lower & Phase B upper as shown in FIGURE 2B, for the flyback current and to provide load current in the opposite direction. This is normally the dead time for standard four-quadrant drive as shown in FIGURE 3B. The result is current flowing in both directions in the motor for each PWM cycle. The advantage this has over standard four-quadrant drive is that at 50% duty cycle, The PWR-82520X uses single point current sense technology with a non-inductive hybrid sense resistor, which yields a highly linear current output over the wide military temperature range (see FIGURE 8). The output current non-linearity is better than 1.5% and the total error due to all the factors such as offset, initial component accuracy, etc., is maintained well below 3% of the full-scale rated output current. VBUS ON PHASE A UPPER The Hall sensor interface for current commutation has built-in decoder logic that separates illegal codes and ensures that there is no cross conduction. The Hall sensor inputs are internally pulled up to +5V and they can be driven from open-collector outputs. PHASE B OFF UPPER I PHASE B PHASE A - + PHASE C OFF PHASE A LOWER The PWM frequency can be programmed externally by adding a capacitor from PWM OUT to PWM GND. In addition, multiple PWR-82520X's can be synchronized by using one device as a master and connecting its PWM OUT pin to the PWM IN of all the other slave devices in a system or by applying a SYNC pulse. PHASE B ON LOWER Rsense The ENABLE input signal provides quick start and shutdown of the internal PWM. In addition, built-in under voltage fault protection turns off the output in case of improper power supply voltages. FIGURE 2A. COMPLEMENTARY FOUR-QUADRANT DRIVE FIRST HALF OF PWM CYCLE The hybrid features dual current limiting functions. The input command amplifier output is limited to ±5V, limiting the motor current under normal operation. In addition, there is a cycle-bycycle current limit which kicks in to protect the hybrid as well as the load (see TABLE 2 for limits). VBUS BASIC OPERATION OFF PHASE A UPPER The PW-82520X utilizes a complimentary four-quadrant drive technique to control current in the load. The complimentary drive has the following advantages over the standard drive: PHASE A ON The complementary drive design uses a 50% PWM duty cycle for a zero command signal. For a zero input command, a pair of MOSFETs are turned on in the drive, Phase A upper & Phase B lower as shown in FIGURE 2A, to supply current into the load for the first half of the PWM cycle. This is the same mode of operation for the standard four-quadrant drive as shown in FIGURE 3A/B. During the second half of the PWM cycle, a second pair PHASE A LOWER ON PHASE B + _ 1. Holding torque in the motor at zero commanded current 2. Linear current control through zero 3. No deadband at zero 4. Reduced power dissipation in the output MOSFETs PHASE B UPPER I PHASE C PHASE B OFF LOWER Rsense FIGURE 2B. COMPLEMENTARY FOUR-QUADRANT DRIVE SECOND HALF OF PWM CYCLE 5 which corresponds to zero average current in the motor, holding torque is provided. The motor current at 50% duty cycle is simply the magnetizing current of the motor winding. cycle greater than 50% will result in a clockwise rotation whereas a duty cycle less than 50% will result in a counter clockwise rotation. Therefore, with the use of average current mode control, direction can be controlled without the use of a direction bit and the current can be controlled through zero in a very precise and linear fashion. Using the complimentary four-quadrant technique allows the motor direction to be defined by the duty cycle. Relative to a given switch pair, i.e., Phase A upper and Phase B lower, a duty The PW-82520X contains all the circuitry required to close an average current mode control loop around a complimentary 4quadrant drive. The PWR-82520X use of average current mode control simplifies the control loop by eliminating the need for slope compensation and eliminating the pole created by the motor inductance. These two effects are normally associated with 50% duty cycle limitations when implementing standard peak current mode control. VBUS ON PHASE A UPPER COMMAND IN+, COMMAND IN- PHASE B PHASE A - + OFF FUNCTIONAL AND PIN DESCRIPTIONS PHASE B OFF UPPER I PHASE C PHASE A LOWER The command amplifier has a differential input that operates from a ±4Vdc full-scale analog current command. The command signal is internally limited to approximately ±5Vdc to prevent the amplifier from saturation. The input impedance of the command amplifier is 10KΩ. PHASE B ON LOWER The (PWR-82520X) can be used either as a current or voltage mode controller. When used as a torque controller (current mode), the input command signal is processed through the command buffer, which is internally limited to ±5Vdc. The output of the buffer (command out) is summed with the current monitor output into the error amplifier. External compensation is used on the error amp, so the response time can be adjusted to meet the application. Rsense FIGURE 3A. STANDARD FOUR-QUADRANT DRIVE FIRST HALF OF PWM CYCLE VBUS OFF PHASE A UPPER When used in the voltage mode, the voltage command uses the same differential input terminals to control the voltage applied to the motor. The error amp directly varies the PWM duty cycle of the voltage applied to the motor phase. The transfer function in the voltage mode is 4.7%V/±5% variation of the PWM duty cycle vs. input command. The duty cycle range of the output voltage is limited to approximately 5-95% in both current and voltage modes. PHASE B OFF UPPER PHASE A PHASE B + _ TRANSCONDUCTANCE RATIO AND OFFSET When the PWR-82520X is used in the current mode, the command inputs (COMMAND IN+ and COMMAND IN-) are designed such that ±4Vdc on either input, with the other input connected to Ground will result in ± full-scale current into the load. The dc current transfer ratio accuracy is ±5% of the rated current including offset and initial component accuracy. The initial output dc current offset with both COMMAND IN+ and COMMAND IN- tied to the Ground will be as shown in TABLE 2 when measured using a load of 0.5mH and 1.0W at ambient room temperature with standard current loop compensation. The winding phase current error shall be within the cumulative limits of the transconductance ratio error and the offset error. I Flyback OFF PHASE A LOWER PHASE C PHASE B OFF LOWER Rsense FIGURE 3B. STANDARD FOUR-QUADRANT DRIVE SECOND HALF OF PWM CYCLE 6 HALL A, B, C SIGNALS The PWR-82520X will operate with Hall phasing of 60° or 120° electrical spacing. If 60° commutation is used, then the output of HC must be inverted as shown in FIGURES 4 and 5. In FIGURE 4 the Hall sensor outputs are shown with the corresponding back emf voltage they are in phase with. Hall A, B and C (HA, HB, HC) are logic signals from the motor Hall-effect sensors. They use a phasing convention referred to as 120 degree spacing; that is, the output of HA is in phase with motor back EMF voltage VAB, HB is in phase VBC, and HC is in phase with VCA. Logic “1” (or HIGH) is defined by an input greater than 2.4Vdc or an open circuit to the controller; Logic “0”(or LOW) is defined as any Hall voltage input less than 0.8Vdc. Internal to the PWR-82520X are 10K pull-up resistors tied to +5Vdc on each Hall input. Hall Input Signal Conditioning: When the motor is located more than two feet away from the PWR-82520X controller the Hall inputs require noise filtering. It is recommended to use a 1KΩ resistor in series with the Hall signal and a 2000 pF capacitor from the Hall input pin to the Hall supply ground pin as shown in FIGURES 12 and 13. HALL-EFFECT SENSOR PHASING vs. MOTOR BACK EMF FOR CW ROTATION (120° Commutations) 300° 0° VAB 60° 120° VBC 180° 240° VCA 300° 360°/0° CURRENT MONITOR OUT 60° This is a bipolar analog output voltage representative of motor current. The CURRENT MONITOR OUT will have the same scaling as the COMMAND IN input. BACK EMF OF MOTOR ROTATING CW CW COMPENSATION The PI regulator in the PWR-82520X can be tuned to a specific load for optimum performance. FIGURE 6 shows the standard current loop configuration and tuning components. By adjusting R1, R2 and C1, the amplifier can be tuned. The value of R1, C1 will vary, depending on the loop bandwidth requirement. In Phase with VAB HA In Phase with VBC HB HC In Phase with VCA ENABLE In Phase with VAC (60˚) HC The Enable input enables or disables the internal PWM. In the disable mode, the PWM is shut down and the outputs, Phase A, Phase B and Phase C, are in an "off" state and no voltage is applied to the motor. FIGURE 4. HALL PHASING HA 120° 120° S EXTERNAL PI REGULATOR N 10.0 K HC 4700 pF HB R1 REMOTE POSITION SENSOR (HALL) SPACING FOR 120 DEGREE COMMUTATION R7 ERROR AMP INPUT 60° HA S N 120° R2B 10.0 K 470 pf ERROR AMP OUT - R2A 10.0 K O + HC COMMAND OUT CURRENT MONITOR OUT 60° HC C1 1 MEG HB REMOTE POSITION SENSOR (HALL) SPACING FOR 60 DEGREE COMMUTATION FIGURE 5. HALL SENSOR SPACING FIGURE 6. STANDARD PI CURRENT LOOP 7 VBUS+A, VBUS+B, VBUS+C VDR (+15V SUPPLY) The VBUS+ supply is the power source for the motor phases. For a 100V-rated device, the normal operating voltage is 28Vdc and may vary from +18 to +70Vdc with respect to VBUS-. The power stage MOSFETS in the hybrid have an absolute maximum VBUS+ supply voltage rating of 100V. The user must supply sufficient external capacitance or circuitry to prevent the bus supply from exceeding the maximum recommended voltages at the hybrid power terminals under any conditions. This input is used to power the gate driver circuitry for the output MOSFETs. There is no power consumption from VDR when the hybrid is disabled. VCC (+5V SUPPLY) AND VCC RTN These inputs are used to power the digital circuitry of the hybrid. VDD (+5V TO +15V SUPPLY), VEE (-5V TO -15V SUPPLY) The VBUS should be applied at least 50ms after VDD and VEE to allow the internal analog circuitry to stabilize. If this is not possible, the hybrid must be powered up in the "disabled" mode. These inputs can vary from ±5V to ±15V as long as they are symmetrical. VDD and VEE are used to power the small signal analog circuitry of the hybrid. Please note that using ±5V supply will reduce approximately 60% of the quiescent power consumption when compared to ±15V operation. VBUSThis is the high current ground return for VBUS+. This point must be closely connected to SUPPLY GND for proper operation of the current loop. PWM FREQUENCY The PWM frequency from the PWM OUT pin will free-run at a frequency of 100KHz ± 5KHz. The PWM frequency is user adjustable from 100KHz down to 10KHz through the addition of an external capacitor. The PWM triangle wave generated internally is brought out to the PWM OUT pin. This output, or an external triangle waveform generated by the user, may be connected to PWM IN on the hybrid. GROUNDS SUPPLY GND: SUPPLY GND is the return for the VDR, VEE, VDD supplies. The phase current sensing technique of the PWR82520X requires that VBUS- and SUPPLY GND be connected together externally (see VBUS- supply). COMMAND GND: COMMAND GND is used when the command buffer is used single-ended and the COMMAND IN- or COMMAND IN+ is tied to COMMAND GND. WARNING! The PWR-82520X does not have short circuit protection. Operation into a short or a condition that requires excessive output current will damage the hybrid. CASE GND: This pin is internally connected to the hybrid case. In some applications the user may want to tie this to Ground for EMI considerations. TABLE 3. COMMUTATION TRUTH TABLE INPUTS OUTPUTS PHASE PHASE PHASE ENABLE DIR** HA HB HC A B C SYNC IN The sync pulse, as shown in FIGURE 7, can be used to synchronize the switching frequency up to 20% faster than the free running frequency of all the slave devices. L L L L L L L L L L L L H SYNC PERIOD 5V CW CW CW CW CW CW CCW CCW CCW CCW CCW CCW - 1 1 0 0 0 1 1 0 0 0 1 1 - 0 1 1 1 0 0 0 0 1 1 1 0 - 0 0 0 1 1 1 1 1 1 0 0 0 - H H Z L L Z Z H H Z L L Z L Z H H Z L H Z L L Z H Z 0V 50% DUTY CYCLE NOTES: 1=Logic Voltage >2.4Vdc, 0=Logic voltage < 0.8Vdc ** DIR is based on the convention shown in FIGURE 4. Actual motor set up might be different. FIGURE 7. SYNC INPUT SIGNAL 8 Z L L Z H H L L Z H H Z Z Current (% Rated Amps) 100 TABLE 4. HALL INPUTS FOR H-BRIDGE CONTROLLER INPUTS OUTPUTS COMMAND ENABLE HA HB HC PH A PH B PH C IN 50 Accuracy = ±5% (of rated output) 0 L Positive 1 1 0 H Z L L Negative 1 1 0 L Z H H - 1 1 0 Z Z Z -50 -100 -4 -3 -2 -1 0 1 2 3 4 Input Command (Volts), Inductive Load FIGURE 8. ACCURACY CURVE PWR-82520X1 PWM OUT 1.2 This is the output of the internally generated PWM triangle waveform. It is normally connected to PWM IN. The frequency of this output may be lowered by connecting an NPO capacitor (Cext) between PWM OUT and COMMAND GND. The PWM frequency is determined by the following formula: 1.0 Amps 0.8 0.6 0.4 0.2 16.5E-6 330pF + CEXTpF 0 -50 -25 0 PHASE A, B, C 25 50 75 Case Temperature (˚C) 100 125 100 125 100 125 PWR-82520X3 3.5 These are the power drive outputs to the motor and switch between VBUS+ Input and VBUS- Input or become high impedance - see TABLE 3. Amps 3.0 OUTPUT CURRENT 2.5 2.0 1.5 Output current derating as a function of the hybrid case temperature is provided in FIGURE 9. The hybrid contains internal pulse by pulse current limit circuitry to limit the output current during fault conditions. (See TABLE 2) Current Limit accuracy is +10/-15%. 1.0 0.5 -50 -25 0 25 50 75 Case Temperature (˚C) PWR-82520X10 WARNING: Never apply power to the hybrid without con- 12 necting either PWM OUT or an external triangular wave to PWM IN! Failure to do so may result in one or more outputs latching on. 10 Amps 8 6 TACH OUT 4 The TACH OUT provides a tachometer signal relative to motor speed which is derived from the three Hall inputs HA, HB, and HC. The tach circuitry combines these three signals into a single pulse train as a 50%-duty-cycle pulse. There are three puls- 2 0 -50 -25 0 25 50 75 Case Temperature (˚C) FIGURE 9. OUTPUT CURRENT FOR CONTINUOUS COMMUTATION (ELECTRICAL > 600RPM, VBUS+ = 28V, PWM = 100KHZ) 9 RADIATION (PWR-82520R SERIES ONLY) Total Dose: The hybrid shall operate, as specified in TABLE 2, when subjected to a total dose radiation environment of 100KRad (Si) at a dose rate of 0.5 Rad/sec. es that occur every 360 electrical degree. The number of pulses per motor revolution is formulated below: Pr = P x 3 (e.g., 6 pulses/revolution for a 4 pole motor) 2 Single Event Upset: The hybrid shall be Single Event Upset (SEU) immune and still meet the requirements of TABLE 2 for a Linear Energy Transfer (LET) level of 36 MeV/mg/cm2. The motor RPM is: RPM = 60 T x Pr Latch-up: The hybrid shall be latch-up immune and still meet the requirement of TABLE 2 for a LET level of 36 MeV/mg/cm2. where, P = number of motor pole Pr = number of pulses per revolution T = pulse period in seconds NOTE: 100KRad (Si) total dose of radiation is usually two to three times the operational level of commercial and military satellites. This results in a large cost savings for the end user since Lot Acceptance Tests (LAT) are usually not required. DIR OUT The DIR OUT indicates the direction the motor is rotating, clockwise (CW) or counterclockwise (CCW). OPTIONAL FEATURES External Sensing Resistor: The external sensing points are available for the end users to install an external resistor (noninductive). The resistance of the resistor is scaled to the applicable current range. Please contact factory for this option. BRUSH MOTOR OPERATION The PWR-82520X can also be used as a brush motor controller for current or voltage control in an H-Bridge configuration. The PWR-82520X would be connected as shown in FIGURE 11. All other connections are as shown in either FIGURE 12 or 13 depending on voltage or current mode operation. The Hall inputs are wired per TABLE 4. A positive input command will result in positive current to the motor out of Phase A. Flat Package: PWR-82520X1 & -X3 are also offered in a flat package configuration as shown in Figure 15. Please contact factory for price and delivery. Class S Processing: PWR-82520XX substrate is set up to be screened to military class S level (hybrid class K). Please contact factory for price and delivery. THERMAL OPERATION It is recommended the PWR-82520X be mounted to a heat sink. This heat sink shall have the capacity to dissipate heat generated by the hybrid at all levels of current output, up to the peak limit, while maintaining the case temperature limit as per FIGURE 9. PSpice modeling: The PSpice mathematical modeling of the PWR-82520XX is also available to support end users in their initial design analysis. Please contact factory for application support. 10 VBUS+ A +28V VBUS+ B VBUS+ C +C1 PHASE A PHASE A t on VBUS PHASE B I OB IOA PHASE C PHASE C VBUS- GND IO t s2 t s1 HALL A +5V HALL B +5V HALL C FIGURE 11. BRUSH MOTOR HOOK-UP FIGURE 10. OUTPUT CHARACTERISTICS PWR-82520X Power Dissipation (see FIGURE 10) 2. Switching Losses (Ps) There are two major contributors to power dissipation in the motor driver: conduction losses, and switching losses. Ps = [ VBUS ( Ioa (ts1) + Iob (ts2) ) fo] / 2 Ps = [ 28 V ( 3 A (125 ns) + 7 A (200 ns) ) 50 KHz] / 2 An example calculation is shown below: Ps = 1.24 Watts VBUS = +28 V (Bus Voltage) TRANSISTOR POWER DISSIPATION ( Pq ) Ioa = 3 A, Iob = 7 A (see FIGURE 10) Pq = Pt + Ps ton = 36 µs, T = 40 µs (90% duty cycle) (see FIGURE 10) Pq = 1.30 + 1.24 = 2.54 Watts Ron = 0.055 W (on-resistance, see TABLE 2) OUTPUT CONDUCTOR DISSIPATION Rc = 0.133 W (conductor resistance, see TABLE 2) Pc = (Imotor rms)2 x (Rc) ts1 = 125 ns, ts2 = 200 ns (see FIGURE 10) Pc = (4.87)2 x (0.133) fo = 50 KHz (switching frequency) Pc = 3.15 Watts 1. Transistor Conduction Losses (PT) TRANSISTOR POWER DISSIPATION FOR CONTINUOUS COMMUTATION Pt = (Imotor rms)2 x (Ron) Pqc = Pq (0.33) Pt = (4.87)2 x (0.055) Pqc = (2.54) x (0.33) Pt = 1.30 Watts Pqc = 0.84 Watts Imotor rms = Imotor rms = TOTAL HYBRID POWER DISSIPATION (IOBIOA + (IOB - IOA)2)( ton ) 3 (7 * 3 + (7 - 3)2)( 3 T 36 40 Ptotal = (Pq + Pc) x 2 Ptotal = (2.54 + 3.15) x 2 ) Ptotal = 11.38 Watts 11 OPTIONAL CASE GND PWM IN VBUS+ A +28V PWM OUT PWR-82520X Cext VDR +15V SUPPLY VCC +5V SUPPLY +15V VBUS+ B VBUS+ C VDD PHASE A PHASE A C6 + +5V to +15V GND C7 + PHASE B SUPPLY GND PHASE B -5V to -15V PHASE C PHASE C COMMAND GND VEE VBUS- COMMAND IN COMMAND SIGNAL - - R4 + + COMMAND IN + GND HA HALL A R3 1K ERROR AMP OUT HALL B COMMAND OUT HALL C R1 R5 - HC 1K + ERROR AMP INPUT CURRENT MONITOR OUT HB R2 1K 10K MOTOR BLDC C4 2000pF 10K CURRENT MONITOR OUT C3 2000pF C5 2000pF ENABLE ENABLE FIGURE 12. VOLTAGE CONTROL HOOK-UP OPTIONAL CASE GND PWM IN Cext VBUS+ A PWM OUT +28V PWR-82520X VDR +15V SUPPLY VCC +5V SUPPLY VBUS+ C VDD + C6 PHASE A +5V to +15V GND PHASE A SUPPLY GND + C7 VEE PHASE B COMMAND GND PHASE C COMMAND IN + R2A C1 R1 4700pF 10K PHASE B -5V to -15V COMMAND IN COMMAND SIGNAL PHASE C - - + + GND R4 MOTOR BLDC HA HALL A COMMAND OUT 10K 1K - R3 HB HALL B + R2B R2 1K HALL C CURRENT MONITOR OUT R7 1MEG VBUS- ERROR AMP OUT ERROR AMP INPUT ENABLE +15V VBUS+ B 10K 1K ENABLE C4 2000pF C3 2000pF C5 2000pF FIGURE 13. TORQUE (CURRENT) CONTROL HOOK-UP 12 HC PIN ASSIGNMENTS TABLE 5B. PIN ASSIGNMENTS X10 TABLE 5A. PIN ASSIGNMENTS X1 & X3 PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 VBUS+ C 41 TACH OUT 1 CASE GND 27 VBUS+ C 2 VBUS+ C 40 DIR OUT 2 N/C 28 VBUS+ C 3 PHASE C 39 HALL A 3 PWM IN 29 PHASE C 4 PHASE C 38 HALL B 4 PWM OUT 30 PHASE C 5 VBUS+ B 37 HALL C 5 COMMAND GND 31 VBUS+ B 6 VBUS+ B 36 ENABLE 6 COMMAND IN + 32 VBUS+ B 7 PHASE B 35 VCC 7 COMMAND IN - 33 PHASE B 8 PHASE B 34 VCC RTN 8 COMMAND OUT 34 PHASE B 9 VBUS- 33 VDR 9 ERROR AMP OUT 35 VBUS- 10 VBUS- 32 SYNC IN 10 ERROR AMP IN 36 VBUS- 11 RS+ 31 VDD 11 CURRENT MONITOR OUT 37 RS+ 12 RS+ 30 SUPPLY GND 12 N/C 38 RS+ 13 VBUS+ A 29 VEE 13 N/C 39 VBUS+ A 14 VBUS+ A 28 N/C 14 VEE 40 VBUS+ A 15 PHASE A 27 N/C 15 SUPPLY GND 41 PHASE A 26 CURRENT MONITOR OUT 16 VDD 42 PHASE A 25 ERROR AMP IN 17 SYNC IN 43 N/C 24 ERROR AMP OUT 18 VDR 23 COMMAND OUT 19 VCC RTN 22 COMMAND IN - 20 VCC 21 COMMAND IN + 21 ENABLE 20 COMMAND GND 22 HALL C 19 PWM OUT 23 HALL B 18 PWM IN 24 HALL A 17 CASE GND 25 DIR OUT 26 TACH OUT 16 PHASE A * N/C pins have internal connections for factory test purposes. * N/C pins have internal connections for factory test purposes. 13 29.21 FIGURE 14. MECHANICAL OUTLINE (X1, X3) 0.055 R (TYP) (1.397) 1.400 (35.56) 0.175 (4.45) 0.100 (2.54) 41 1 .235 (MAX (5.97) 2.600 (66.04) 15 EQ. SP. @ 0.150 = 2.250 (@ 3.81 = 57.15) (TOL. NONCUM) 24 EQ. SP. @ 0.100 = 2.400 (@2.54 = 60.96) (TOL. NONCUM) 0.150 (TYP) (3.81) SIDE VIEW ±.002 .125 (TYP) (3.18) 0.075 R (TYP) (1.91) 0.100 (TYP) (2.54) 16 17 TOP VIEW .400 (MIN) (10.16) .400 (MIN) (10.16) FIGURE 15. OPTIONAL FLAT PACKAGE OUTLINE (X1, X3) 14 0.015 (TYP) (41 PLACES) (.381±.002 ) .05 X 45˚ CHAMFER (DENOTES PIN 1) 2.110 (MAX) .12 +.002 -.005 .147 DIA (4 HOLES) 1.860 1 43 .100 (TYP) .150(TYP) 2.850 3.110 (MAX) 16 EQ. SP.@ .150 = 2.400 (TOL. NONCUM 25 EQ. SP. @ .100 = 2.500 (TOL. NONCUM 27 26 .350 .300 .25(TYP) TOP VIEW PIN NUMBERS FOR REFERENCE ONLY 1.60 .25 .125 ±.002 .020 DIA (26 PLCS) .500 (MIN) (TYP) SIDE VIEW .255 (MAX) ±.002 .040 DIA (17 PLCS) .140 .050 NOTES: 1. DIMENSIONS IN INCHES (MM). TOL = ±0.005 (±0.127) 2. LEAD IDENTIFICATION NUMBERS ARE FOR REFERENCE ONLY. FIGURE 16. MECHANICAL OUTLINE (X10) 15 ±.010 ORDERING INFORMATION PWR-82520XX- XX0 Reliability Grade: 0 = Standard DDC Procedures. 1 = Military processing available. 2 = Military processing available but without QCI Testing. Temperature Range: 1 = - 55 to +125°C 3 = 0 to +70°C Rating: 1 - 1A 3 - 3A 10 - 10A Radiation Tolerance N = Non radiation tolerant R = 100Krad radiation tolerance Consult factory for class K processing. The information in this data sheet is believed to be accurate; however, no responsibility is assumed by Data Device Corporation for its use, and no license or rights are granted by implication or otherwise in connection therewith. Specifications are subject to change without notice. 105 Wilbur Place, Bohemia, New York 11716-2482 For Technical Support - 1-800-DDC-5757 ext. 7420 Headquarters - Tel: (631) 567-5600 ext. 7420, Fax: (631) 567-7358 West Coast - Tel: (714) 895-9777, Fax: (714) 895-4988 Southeast - Tel: (703) 450-7900, Fax: (703) 450-6610 United Kingdom - Tel: +44-(0)1635-811140, Fax: +44-(0)1635-32264 Ireland - Tel: +353-21-341065, Fax: +353-21-341568 France - Tel: +33-(0)1-41-16-3424, Fax: +33-(0)1-41-16-3425 Germany - Tel: +49-(0)8141-349-087, Fax: +49-(0)8141-349-089 Sweden - Tel: +46-(0)8-54490044, Fax +46-(0)8-7550570 Japan - Tel: +81-(0)3-3814-7688, Fax: +81-(0)3-3814-7689 World Wide Web - http://www.ddc-web.com RM ® I FI REG U ST ERED DATA DEVICE CORPORATION REGISTERED TO ISO 9001 FILE NO. A5976 A-08/00-250 PRINTED IN THE U.S.A. 16