MIL-PRF-38534 CERTIFIED FACILITY M.S.KENNEDY CORP. 10 AMP, 500V, 3 PHASE IGBT BRUSHLESS MOTOR CONTROLLER 4470 4707 Dey Road Liverpool, N.Y. 13088 (315) 701-6751 FEATURES: 500 Volt Motor Supply Voltage 10 Amp Output Switch Capability 100% Duty Cycle High Side Conduction Capable Shoot-Through/Cross Conduction Protection Hall Sensing and Commutation Circuitry on Board "Real" Four Quadrant Torque Control Capability Good Accuracy Around the Null Torque Point Isolated Package Design for High Voltage Isolation Plus Good Thermal Transfer 60°/ 120º Phasing Selectable Non-Hermetic Lower Cost Package DESCRIPTION: The MSK 4470 is a complete 3 Phase IGBT Bridge Brushless Motor Control System in a convenient isolated baseplate package. The hybrid is capable of 10 amps of output current and 500 volts of DC bus voltage. It has the normal features for protecting the bridge. Included is all the bridge drive circuitry, hall sensing circuitry, commutation circuitry and all the current sensing and analog circuitry necessary for closed loop current mode (torque) control. When PWM'ing, the transistors are modulated in locked anti-phase (complementary) mode for the tightest control and the most bandwidth. Provisions for applying different compensation schemes are included. The MSK 4470 has good thermal conductivity of the IGBT's due to isolated package design that allows direct heat sinking of the hybrid without insulators. BLOCK DIAGRAM PIN-OUT INFORMATION TYPICAL APPLICATIONS 3 Phase Brushless DC Motor Control Servo Control Fin Actuator Control Gimbal Control AZ-EL Control 1 2 3 4 5 6 7 8 9 10 11 12 NC REFOUT HALL A HALL B HALL C 60/120 BRAKE CLOCK SYNC DIS GND NC NC 1 13 14 15 16 17 18 19 20 21 22 23 24 E/A OUT E/AGND +Current Command -Current Command +15 VIN Current Monitor -15 VIN NC NC NC GND 25 26 27 28 29 30 31 32 33 34 35 36 NC NC LGND NC NC RTN RTN CVS CVS NC NC CO 37 38 39 40 41 42 43 44 45 46 47 48 PRELIMINARY CO NC CV+ CV+ N/C BVS BVS NC BO BO NC BV+ 49 50 51 52 53 54 55 56 57 58 BV+ NC AVS AVS NC AO AO NC AV+ AV+ Rev. G 2/11 ABSOLUTE MAXIMUM RATINGS High Voltage Supply 4 Current Command Input Logic Inputs REFOUT External Load E/A OUT External Load Clock SYNC Input Continuous Output Current Peak Output Current ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 500V ±13.5V -0.2V to REFOUT 15 mA 5 mA -0.2V to +15V 10 Amps 15 Amps ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 3 ○ ○ ○ ○ ○ ○ ○ ○ ○ RθJC Thermal Resistance (Output Switches) 0.6°C/W TST Storage Temperature Range -40°C to +150°C TLD Lead Temperature Range +300°C (10 Seconds) TC Case Operating Temperature -40°C to +125°C TJ Junction Temperature +150°C ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ELECTRICAL SPECIFICATIONS Test Conditions Parameter INPUT CURRENT +15 VIN -15 VIN PWM Clock Free Running Frequency CLOCK SYNC INPUT VIL 1 VIH 1 Voltage Drop Across Bridge (1 Upper & 1 Lower) Voltage Drop Across Bridge (1 Upper & 1 Lower) Leakage Current 1 Diode VSD 1 trr 1 Dead Time 1 1 Units TBD 40 mA mA 20 22 24 KHz 12.5 10 Clock +0 - 2.5 90 Clock +3 VOLTS VOLTS % KHz 3.0 - 0.8 - VOLTS VOLTS 0.85 0.85 - 1 1 - ±13.5 1.5 1.15 ±50 1.15 ±12 VOLTS mA A/V mA V/A VOLTS 5mA Load 6.5 175 8 6.5 275 ±12 - VOLTS V/μSec MHz V/mV 10 AMPS 10 AMPS @ 150°C Junction - 35 3 5 7.5 5 2.6 - VOLTS VOLTS mA VOLTS nSec μSec 5mA Load 1 Max. TBD 30 Current Command=0 Volts Current Monitor Voltage Swing ERROR AMP E/A OUT Swing 1 Slew Rate 1 Gain Bandwidth Product 1 Large Signal Voltage Gain 1 OUTPUT SECTION 1 Typ. - Output PWM'ing Current Command=0 Volts Duty Cycle 1 SYNC Frequency 1 LOGIC INPUTS (Hall A,B,C,Brake,60°/120°,DIS) VIL 1 VIH 1 ANALOG SECTION Current Command Input Range 1 Current Command Input Current 1 Transconductance 2 Offset Current 2 Current Monitor MSK 4470 Min. All switches off, V+=270V, 150°C Junction NOTES: 1 Guaranteed by design but not tested. Typical parameters are representative of actual device performance but are for reference only. 2 Measurements do not include offset current at 0V current command. 3 Continuous operation at or above absolute maximum ratings may adversly effect the device performance and/or life cycle. 4 When applying power to the device, apply the low voltage followed by the high voltage or alternatively, apply both at the same time. Do not apply high voltage without low voltage present. 2 PRELIMINARY Rev. G 2/11 APPLICATION NOTES MSK 4470 PIN DESCRIPTIONS AV+, BV+, CV+ - are the power connections from the hybrid to the bus. The pins for each phase are brought out separately and must be connected together to the V+ source externally. The external wiring to these pins should be sized according to the RMS current required by the motor. These pins should be bypassed by a high quality monolithic ceramic capacitor for high frequencies and enough bulk capacitance for keeping the V+ supply from drooping. E/A OUT - is the current loop error amp output connection. It is brought out for allowing various loop compensation circuits to be connected between this and E/A-. E/A- -is the current loop error amp inverting input connection. It is brought out for allowing various loop compensation circuits to be connected between this and E/A OUT. CLOCK SYNC- is an input for synchronizing to an external clock. The sync circuit will trigger on the edges of the applied clock and effectively shorten the period of the internal oscillator on each cycle. The frequency can be increased from a free running 22 KHz to 25 KHz maximum. The clock applied shall be 15 volts amplitude with at least a 10% duty cycle. AØ, BØ & CØ- are the connections to the motor phase windings from the bridge output. The wiring to these pins should be sized according to the current required by the motor. There are no short circuit provisions for these outputs. Shorts to V+ or ground from these pins must be avoided or the bridge will be destroyed. AVS, BVS, CVS - are the return pins on the bottom of each half bridge. They are brought out separately and should be connected together externally to allow the current from each half bridge to flow through the sense resistor. The wiring on these pins should be sized according to the current requirements of the motor. REFOUT- is a 6.25 volt regulated output to be used for powering the hall devices in various motors. Up to 15 mA of output current is available. HALL A, B & C - are the hall input pins from the hall devices in the motor. These pins are internally pulled up to 6.25 volts. The halls can reflect a 120/240 degree commutation scheme or a 60/300 degree scheme. RTN - is the power return connection from the module to the bus. All ground returns connect to this point from internal to the module in a star fashion. All external ground connections to this point should also be made in a similar fashion. The V+ capacitors should be returned to this pin as close as possible. Wire sizing to this pin connection should be made according to the required current. BRAKE - is a pin for commanding the output bridge into a motor BRAKE mode. When pulled low, normal operation commences. When pulled high, the 3 high side bridge switches turn off and the 3 low side bridge switches turn on, causing rapid deceleration of the motor and will cease motor operation until pulled high again. Logic levels for this input are TTL compatible. It is internally pulled high. LGND - is an isolated ground connection to the RTN pin of the hybrid that is connected internally. For any circuitry that needs to be connected to the RTN pin without the influence of current flow through RTN should be connected at this point. IN DIS - is a pin for externally disabling the output bridge. A TTL logic low will enable the bridge and a TTL logic high will disable it. It is internally pulled up by a 100 μAmp pullup. GND - is a ground pin that connects to the ground plane for all low powered circuitry inside the hybrid. 60/120- is a pin fpr selecting the orientation of the commutation sheme of the motor. A high state will produce 60/300 degree commutation, whereas a low state will produce 120/ 240 degree commutation. Logic levels for this input are TTL compatible. It is internally pulled high. +15 VIN - is the input for applying +15 volts to run the low power section of the hybrid. This pin should be bypassed with a 10 μF capacitor and a 0.1 μF capacitor as close to this pin as possible. -15 VIN - is the input for applying -15 volts to run the low power section of the hybrid. This pin should be bypassed with a 10 μF capacitor and a 0.1 μF capacitor as close to this pin as possible. CURRENT COMMAND (+,-) - are differential inputs for controlling the module in current mode. Scaled at ±1 amp per volt of input command, the bipolar input allows both forward and reverse current control capability regardless of motor commutation direction. The maximum operational command voltage should be ±10 volts for ±10 amps of motor current. CURRENT MONITOR- is a pin providing a current viewing signal for external monitoring purposes. This is scaled at ±1 amp of motor current per volt output, up to a maximum of ±10 volts, or ±10 amps. As ±10 amps is exceeded, the peaks of the waveform may become clipped as the rails of the amplifiers are reached. This voltage is typically ±12.5 volts, equating to ±12.5 amps of current peaks. In DIS mode, the CURRENT MONITOR output may rail positive or negative, depending on internal bias currents. When re-enabled, this output will resume expected operation. 3 PRELIMINARY Rev. G 2/11 APPLICATION NOTES CONTINUED COMMUTATION TRUTH TABLE 1 0 X = High Level = Low Level = Don't Care H L - = SOURCE = SINK = OPEN NOTE: Because of the true 4 quadrant method of output switching, the output switches will PWM between the ICOMMAND POSITIVE and ICOMMAND NEGATIVE states, with the average percentage based on ICOMMAND being a positive voltage and a negative voltage. With a zero voltage ICOMMAND, the output switches will modulate with exactly a 50% duty cycle between the ICOMMAND POSITIVE and ICOMMAND NEGATIVE states. 4 PRELIMINARY Rev. F 2/11 APPLICATION NOTES CONTINUED BUS VOLTAGE FILTER CAPACITORS The size and placement of the capacitors for the DC bus has a direct bearing on the amount of noise filtered and also on the size and duration of the voltage spikes seen by the bridge. What is being created is a series RLC tuned circuit with a resonant frequency that is seen as a damped ringing every time one of the transistors switches. For the resistance, wire resistance, power supply impedance and capacitor ESR all add up for the equivalent lumped resistance in the circuit. The inductance can be figured at about 30 nH per inch from the power supply. Any voltage spikes are on top of the bus voltage and the back EMF from the motor. All this must be taken into account when designing and laying out the system. If everything has been minimized, there is another solution. A second capacitance between 5 and 10 times the first capacitor and it should either have some ESR or a resistor can be added in series with the second capacitor to help damp the voltage spikes. Be careful of the ripple current in all the capacitors. Excessive ripple current, beyond what the capacitors can handle, will destroy the capacitors. REGULATED VOLTAGE FILTER CAPACITORS It is recommended that about 10 μF of capacitance (tantalum) for bypassing the + and -15V regulated outputs be placed as close to the module pins as practical. Adding ceramic bypass capacitors of about 0.1 μF or 1 μF will aid in suppressing noise transients. GENERAL LAYOUT Good PC layout techniques are a must. Ground planes for the analog circuitry must be used and should be tied back to the small pin grounds 10, 15 and 24. Additional ground, pin 27 is an isolated ground that connects internally directly back to the main DC bus ground pin 30,31. This can be used as necessary for voltage sensing, etc. LOW POWER STARTUP When starting up a system utilizing the MSK 4470 for the first time, there are a few things to keep in mind. First, because of the small size of the module, short circuiting the output phases either to ground or the DC bus will destroy the bridge. The current limiting and control only works for current actually flowing through the bridge. The current sense resistor has to see the current in order for the electronics to control it. If possible, for startup use a lower voltage and lower current power supply to test out connections and the low current stability. With a limited current supply, even if the controller locks up, the dissipation will be limited. By observing the E/A OUT pin which is the error amp output, much can be found out about the health and stability of the system. An even waveform with some rounded triangle wave should be observed. As current goes up, the DC component of the waveform should move up or down. At full current (with a regular supply) the waveform should not exceed +8 volts positive peak, or -8 volts negative peak. Some audible noise will be heard which will be the commutation frequency. If the motor squeals, there is instability and power should be removed immediately unless power dissipation isn't excessive due to limited supply current. For compensation calculations, refer to the block diagram for all information to determine the amplifier gain for loop gain calculations. 5 PRELIMINARY Rev. G 2/11 MSK4470 TEST CIRCUIT 6 PRELIMINARY Rev. G 2/11 MECHANICAL SPECIFICATIONS WEIGHT= 195 GRAMS TYPICAL ESD TRIANGLE INDICATES PIN 1. NOTE: ALL DIMENSIONS ARE ±0.010 INCHES UNLESS OTHERWISE LABELED. CAUTION: THIS IS A NON-HERMETIC DEVICE. DO NOT EXPOSE PLASTIC HOUSING TO LIQUID ORDERING INFORMATION MSK4470 U LEAD CONFIGURATION S=STRAIGHT, U=BENT UP, D=BENT DOWN GENERAL PART NUMBER THE ABOVE EXAMPLE IS A HYBRID WITH LEADS BENT UP. M.S. Kennedy Corp. 4707 Dey Road, Liverpool, New York 13088 Tel. (315) 701-6751 FAX (315) 701-6752 www.mskennedy.com The information contained herein is believed to be accurate at the time of printing. MSK reserves the right to make changes to its products or specifications without notice, however, and assumes no liability for the use of its products. Please visit our website for the most recent revision of this datasheet. Contact MSK for MIL-PRF-38534 qualification status. 7 PRELIMINARY Rev. G 2/11