MIL-PRF-38534 CERTIFIED M.S.KENNEDY CORP. 10 AMP, 55V, 3 PHASE BRUSHLESS MOTOR SPEED CONTROLLER 4410 4707 Dey Road Liverpool, N.Y. 13088 (315) 701-6751 FEATURES: 55 Volt Motor Supply Voltage 10 Amp Output Switch Capability Shoot-Through/Cross Conduction Protection Hall Sensing and Commutation Circuitry on Board User Programable Current Limit Tach Out-Closed Loop Control Non-Hermetic Isolated Package Available With 3 Lead Configurations DESCRIPTION: The MSK 4410 is a complete 3 Phase Brushless Motor Speed Controller in an electrically isolated low cost package. The hybrid is capable of 10 amps of output current and 55 volts of DC bus voltage. Included is all of the bridge drive circuitry, hall sensing circuitry and commutation circuitry. Also included is a user programable current limit circuit and a tachometer circuit for closed loop operation. The MSK 4410 has good thermal conductivity of the output switches due to the isolated substrate/package design that allows direct heat sinking of the hybrid without insulators. EQUIVALENT SCHEMATIC PIN-OUT INFORMATION TYPICAL APPLICATIONS Fan/Blower Speed Control Azimuth/Elevation Antenna Control Optical Tracking Control Robot Velocity Control 1 2 3 4 5 6 7 8 9 10 1 +15V INPUT -15V INPUT TACH OUT REF OUT TACH RC HALL A HALL B HALL C SPEED - COMMAND SPEED + COMMAND 20 19 18 17 16 15 14 13 12 11 V+ CØ BØ AØ GND BRAKE E/A OUT -E/A CURRENT LIMIT ADJUST SIGNAL GND Rev. E 1/11 3 ABSOLUTE MAXIMUM RATINGS V+ VIN VIND IOUT IpK +15VIN -15VIN 4 High Voltage Supply Speed Command (+,-) Hall A,B,C,Brake Continuous Output Current Peak Output Current +15 Volt Input Voltage -15 Volt Input Voltage ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 8.8°C/W OJC Thermal Resistance (@ 125°C) -55°C to +125°C TST Storage Temperature Range +300°C TLD Lead Temperature Range (10 Seconds) TC Case Operating Temperature -40°C to +85°C MSK4410 +150°C TJ Junction Temperature +55V ±15VIN +V REF 10A 15A +16V -16V ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ELECTRICAL SPECIFICATIONS Parameter PWM Clock Frequency POWER SUPPLY REQUIREMENTS +15 Volt Input Current -15 Volt Input Current HALL INPUTS VIL 2 VIH 2 ANALOG SECTION Speed Command Input Range Speed Command Input Range Speed Command Input Current 2 REFERENCE OUTPUT VOLTAGE Reference Voltage ERROR AMP Input Offset Voltage 2 Input Offset Current 2 Input Bias Current 2 Input Common Mode Voltage Range 2 Open-Loop Voltage Gain 2 Input Common Mode Rejection Ratio 2 Power Supply Rejection Ratio 2 OUTPUT SECTION Voltage Drop Across Bridge (1 Upper & 1 Lower) 2 Voltage Drop Across Bridge (1 Upper & 1 Lower) 2 Leakage Current 2 Diode VSD 2 trr 2 Dead Time 2 TACH OUT Output Voltage High State Output Voltage Low State Output Pulse Width CURRENT LIMIT Current Limit 1 Amp Test Conditions 1 MSK 4410 Units Min. Typ. Max. 20 25 30 KHz - 37 8 60 18 mA mA 3.0 - 0.8 - VOLTS VOLTS E/A DC Gain=1, Positive Command E/A DC Gain=1, Negative Command VIN=5V 1.2 -1.2 - - 4.5 -4.5 1.5 VOLTS VOLTS mA @ 1mA 5.82 6.24 6.57 VOLTS VO=3V, RL=15K 0 70 55 65 0.4 8.0 -46 80 86 105 10 500 -1000 VREF - mV nA nA V db db db 10 AMPS 10 AMPS @ 150°C Junction All switches off, V+=44V, 150°C Junction - 0.8 1.6 86 2 1.92 750 1.6 - VOLTS VOLTS μA VOLTS nSec μSec I Source = 5mA I Sink = 10mA R/C=20K/0.01uF 3.60 150 3.95 0.25 200 4.20 0.50 250 V V μSec Current Limit Adjust Pin=Open 0.3 1 1.70 Amps NOTES: 1 2 3 4 ±15V INPUT=±15V, V+=28V, BRAKE=GND unless otherwise specified. Guaranteed by design but not tested. Typical parameters are representative of actual device performance but are for reference only. Continuous operation at or above absolute maximum ratings may adversely effect the device perfomance and/or life cycle. 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 Rev. E 1/11 APPLICATION NOTES MSK 4410 PIN DESCRIPTIONS V+ - is the power connection from the hybrid to the bus. The external wiring to the pin should be sized according to the RMS current required by the motor. This pin should be bypassed by a high quality monolithic ceramic capacitor for high frequencies and enough bulk capacitance to keep the V+ power supply from drooping. 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 reflect a 120/240 degree commutation scheme. TACH RC - is used to set the tach out pulse width. This is done by connecting a resistor from this pin to the REF OUT pin and a capacitor from the pin to the signal ground. Selection of these components is based on the desired maximum motor speed. (See TACH RC component selection) AØ OUT, BØ OUT, CØ OUT-are the connections to the motor phase windings from the bridge output. The wiring to these pins should be sized according to the motor current requirements. There are no internal short circuit protection provisions for these output pins in the hybrid. Shorts to V+ or ground from these pins must be avoided or the bridge will be destroyed. TACH OUT - is connected to the -E/A pin through a resistor when using the speed controller in a closed loop configuration.. GND- is the power return connection from the hybrid to the bus. All ground returns internal to the hybrid connect to this point in a star configuration. All external ground connections to this point should 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. -E/A - is the error amp inverting input connection. It is brought out to allow various loop compensation circuits to be connected between this and E/A out. E/A OUT - this is the loop error amp output connection. It is brought out for allowing various loop compensation circuits to be connected between this and -E/A. SIG GND - is the ground pin that connects to the ground plane for all low power circuitry inside the device. REF OUT - is a 6.25 volt regulated output that can be used to power the hall devices in various motors. Up to 15 milliamps of current is available. +15 V INPUT - is the pin for applying +15 volts to run the low power control circuitry inside the hybbrid. This pin should be bypassed to the signal ground pin using a high quality 10μF tantalum capacitor and a 0.1μF ceramic capacitor as close to these pins as possible. CURRENT LIMIT ADJUST - is used to adjust the output current limit. The pin, if left open will limit the output current to about 1 amp. The pin, taken to ground will limit the current to about 15 amps. A resistor from the pin to ground will yield current limits in between. (See Current Limit Adjust) -15 V INPUT - is the pin for applying -15 volts to run the low power control circuitry inside the hybrid. This pin should be bypassed to the signal ground pin using a high quality 10μF tantalum capacitor and a 0.1μF ceramic capacitor as close to these pins as possible. SPEED COMMAND (+,-) - are differential inputs for controlling the motor speed. With a positive voltage command the motor will operate in the forward direction and with a negative command the motor will operate in the reverse direction. The maximum operational command voltage should be ±5 volts. BRAKE - is the pin for commanding the output bridge into a motor brake mode. When this pin is taken low, normal operation of the hybrid proceeds. When this pin is taken high, the three high side switches in the bridge turn off and the three lowside switches turn fully on. This will cause rapid deceleration of the motor and will cease motor operation until taken low again. The pin left open is internally pulled high. 3 Rev. E 1/11 APPLICATION NOTES CONTINUED COMMUTATION TRUTH TABLE HALL SENSOR PHASING SPEED COMMAND = POS. SPEED COMMAND = NEG. 120° 1 0 X = High Level = Low Level = Don't Care HALL A HALL B HALL C AØ BØ CØ AØ BØ CØ 1 0 0 H - L L - H 1 1 0 - H L - L H 0 1 0 L H - H L - 0 1 1 L - H H - L 0 0 1 - L H - H L 1 0 1 H L - L H - 1 1 1 - - - - - - 0 0 0 - - - - - - X X X L L L L L L H L - = SOURCE = SINK = OPEN 4 Rev. E 1/11 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. INPUT VOLTAGE FILTER CAPACITORS It is recommended that about 10 μF of capacitance (tantalum electrolytic) for bypassing the + and -15V power supplies be placed as close to the module pins as practical. Adding ceramic bypass capacitors of about 0.1 μF to 1 μF will aid in suppressing noise transients. GENERAL LAYOUT Good PC layout techniques are a must. Ground plane for the analog circuitry must be used and should be tied back to the SIG GND. Ground plane for the power circuitry should be tied back to the GND pin, pin 16. Pin 16 should be connected to pin 11 external to the hybrid by a single thick trace. This will connect the two ground planes together. LOW POWER STARTUP When starting up a system utilizing the MSK 4410 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. The ±15 volt power should be applied prior to applying the V+ voltage. 5 Rev. E 1/11 APPLICATION NOTES CONTINUED TACH RC COMPONENT SELECTION For a given maximum motor speed, the tach output has a maximum pulse width. For example, if a maximum motor speed of 3000 RPM were desired and the permanet magnet on the rotor of the motor being used has two pairs of poles, each mechanical revolution would cause each hall effect sensor to deliver two pulses. The three sensors would generate six pulses. The MSK4410 tachometer would generate 12 pulses, one for each rising and falling edge of the sensor pulses. If a maximum motor speed in the example were desired, this would be 50 revolutions per second. The tachometer will be producing 600 pulses per second or have a frequency of 600Hz. Therefore, the maximum puse width would have to be less than 1.66 milliseconds. Figure one can be used to select component values to achieve the desired pulse width. FIGURE 1 CURRENT LIMIT ADJUST With the current limit adjust pin (pin 12) left open, the current will be limited to 1 amp ±0.7 amps. If a current limit of more than 1 amp but less than 15 amps is desired, a resistor between the pin and ground can be used to set a different limit. Figure two can assist in the selection of the resistor value for this purpose. FIGURE 2 6 Rev. E 1/11 MSK4410 TYPICAL APPLICATION CIRCUIT 7 Rev. E 1/11 MECHANICAL SPECIFICATIONS MOUNTING TORQUE: 3-4 INCH POUNDS WEIGHT=31.5 GRAMS TYPICAL ESD Triangle Indicates Pin 1. NOTE: ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE LABELED. CAUTION: THIS IS A NON-HERMETIC DEVICE. DO NOT EXPOSE PLASTIC HOUSING TO LIQUID ORDERING INFORMATION Part Number Screening Level MSK4410S Industrial Straight MSK4410D Industrial Down MSK4410U Industrial Up MSK4410G Industrial Gull Wing Lead Configuration M.S. Kennedy Corp. 4707 Dey Road Liverpool, New York 13088 Phone (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. 8 Rev. E 1/11