Preliminary PT2434 3-Phase Sensorless BLDC Motor Controller DESCRIPTION FEATURES The PT2434 is a three-phase, sensor-less, brushless DC motor control chip. System operating voltage depends on the VM (motor voltage), from 12V to 400Vdc. On-chip LDO can provide 5V voltage for logic and analog circuits operation. The three-phase sensor-less control is based on trapezoid wave, and additional soft-switching scheme is designed for reducing electrical audible noise in motor phase commutation. To combine with an external high voltage gate driver and six n-channel MOSFETs, PT2434 can operate high voltage motor up to 400V. On the 12V to 36V operation, it is easy to setup with simple level-shift circuit and combined with external PN MOSFETs. The PT2434 offers external parameters setting for optimum adjustment with different motors or applications. The package of PT2434 is SSOP28. Sensor-less control for 3-phase BLDC Current limit function Over temperature protection from external NTC Motor lock protection Reverse function. PWM or DC input for speed control APPLICATIONS Three-phase BLDC motor Three-phase BLDC fan, blower Three-phase BLDC ceiling fan FG OUTPUT FOR ROTATION SPEED RD output for look detection BLOCK DIAGRAM V5V V15V OSC_C +5V LDO OSC1 OSC2 PWM Gen. SGND SGND RD/FG ZCO FWR DCPWM SW0/SW1 SW2/SW3 FLT COMI UH UL VH VL WH WL Sensorless Controller ZCD CT OCP ZCW ZCV ZCU CT RF OTP RSEN Tel: 886-66296288‧Fax: 886-29174598‧ http://www.princeton.com.tw‧2F, No.233-1, Baociao Rd., Sindian Dist., New Taipei City 23145, Taiwan PT2434 APPLICATION CIRCUIT CCT FG 28 RD 27 SW1 DCPWM 26 4 FWR OSC_C U1 25 5 WL FLT 24 6 VL COMI 23 SW3 22 1 CT 2 SW0 3 X1 COSCC CFLT PTC Gate Driver PT2434 7 UL 8 WH ZCW 21 9 VH ZCV 20 10 UH ZCU 19 11 SGND SGND 18 12 V15V RF 17 13 V5V RSEN 16 14 SW2 ZCO 15 From Motor RRF CBYP RNTC V5V RDET +15V PRE 1.2 2 April 2015 PT2434 ORDER INFORMATION Valid Part Number PT2434-X Package Type 28-Pin, SSOP Top Code PT2434-X PIN CONFIGURATION PRE 1.2 3 April 2015 PT2434 PIN DESCRIPTION PRE 1.2 Pin Name I/O/P Description CT O Connect to external capacitor for setting lock and release time 1 SW0 SW1 I I Dead-time parameter setting. Refer to ELECTRIC CHARACTERISTIC, floating for HIGH 2 3 FWR I WL O Forward and reverse rotation setting. LOW for CCW, and HIGH (or floating ) for CW W phase low side signal output VL UL WH VH UH SGND V15V O O O O O P P V phase low side signal output U phase low side signal output W phase high side signal output V phase high side signal output U phase high side signal output Signal ground +15V supply input 6 7 8 9 10 11 12 V5V O 13 SW2 I ZCO O RSEN O RF SGND ZCU ZCV I P I I +5V LDO output PWM type setting. LOW for soft-switching, and HIGH (or floating) for normal trapezoid-wave. ZC comparator output for signal monitoring Connect to external resistors for over temperature sensing Current limit voltage sensing Signal ground U phase zero crossing input V phase zero crossing input ZCW I 21 SW3 I COMI FLT OSC_C DCPWM O I I I RD O FG O W phase zero crossing input Startup alignment strength setting. LOW for normal alignment, and HIGH (or floating) for light alignment Motor virtual neutral voltage Zero crossing filter Connect to external capacitor for startup step setting DC or PWM input for speed control Motor lock indicator, OPEN DRAIN structure, HIGH for abnormal event. Motor rotation speed indicator, OPEN DRAIN structure. Refer to FUNCTION DESCRIPTION 4 Pin No. 4 5 14 15 16 17 18 19 20 22 23 24 25 26 27 28 April 2015 PT2434 FUNCTION DESCRIPTION POWER SUPPLY Due to PT2434 consumes very low current (<5mA) and is embedded a 15V to 5V LDO for logic and analog circuit operation, so it can use a 15V supply directly from a ordinary HV(<400V) motor system. On the 12V to 36V motor application, PT2434 can use a voltage supply through a simple resistor-voltage-divider, or an external 12V regulator, without adding an external 5V regulator. To avoid instability on external power, PT2434 will detect the LDO voltage internally. When the LDO voltage reach 3.5V, a power good signal will pass to logic circuits and the logic circuits will start to operate within 10ms. In motor system, the chip is easily influenced by induced noise, and the bypass capacitors are suggested to be placed to IC power pins. PWM OR DC INPUT FOR SPEED CONTROL The PT2434 offers an external DC or PWM control input to change the motor speed. When using PWM input, the high voltage potential needs to be greater than 3.3V and the low potential to be less than 0.6V. The PWM frequency is recommended between 15KHz to 25KHz, and the PWM voltage low level is smaller than 0.3V, high level is higher than 3.5V. When using a DC input, the DC control ranges should be between 0.6V to 3.3V. PT2434 has no speed control loop and it is suggested to get speed information from FG signal. SENSORLESS CONTROL The PT2434 control scheme is based on sensor-less (no Hall sensor) trapezoidal wave. The benefit of sensor-less is to save Hall sensor which causing inconvenience, such as cost, processing effects and temperature deviations issues. Sensorless control is mainly through measurement of the induced BEMF (back electro-motive force) of motor wires under motor rotation state. When the motor is controlled, UVW coil endpoints voltage (phase voltage) is mixed with control signal and BEMF. It is hardly to find out BEMF from phase voltage. So we need to float motor for a while (an angle) when motor is commutating to obtain BEMF signal. In general, the floating electrical angle is 60 degrees in a pure square wave control, or named as 120 degrees commutation control. And 30 degrees floating angle for trapezoidal wave control is knew as 150 degrees commutation control. The PT2434 senses UVW phase voltages by dividing resistors to lower the phase voltages to around 5V. It will let analog circuit has ability to handle the singles, among the selectors, filters and comparators to generate ZC (zero crossing) signal for commutation. For motors with different operation voltage, speed and mechanical factors, UVW phase divider resistance and filter need to be adjusted. When the system noise is too large or motor’s BEMF signal is too weak, it will impact the control system to collect ZC signal accurately, which may cause control failure. The PT2434 use 150 degrees commutation and soft-switching control function is helpful to reduce audible electro-current noise. START UP The most difficulty of sensor-less control is the startup procedure, because the rotor position is unknown and the BEMF signal is weak, or is even impossible to detect. The startup method of PT2434 is alignment and progressively increasing voltage (or increase the PWM duty) in order to achieve motor excitation and rotation. This behavior of alignment may cause the rotor forward or reverse one time randomly at startup stage. More unclear of ZC signal will cause starting failure. If the motor can not startup at a certain time (CT rise time), the startup procedure is failed and going to locked protection mode. PRE 1.2 5 April 2015 PT2434 To consider with different motors or loads, it needs to use different pace to excite motor at startup for getting a proper and smooth behavior. The PT2434 offered "OSC_C" capacitance adjustment for different starting pace. In general OSC_C capacitance value range from 100pF to 3.9nF. The lighter or faster motor use smaller capacitance value, and vice versa. CURRENT LIMIT The PT2434 current limit function is implemented by sensing the phase-to-phase current with an external resistor to get a RF voltage. When the detected RF voltage is higher than 0.5V, the PWM signal to motor will be turned off. After the RF voltage is lower than 0.5V, the PWM signal is resumed. LOCK PROTECTION PT2434 need detect the periodical ZC signal to operate properly. If it did not detect the expected ZC signal, PT2434 will put itself to lock protection mode. In lock protection mode, PT2434 will wait for a period of time (fall time of CT), then try to re-startup motor again. After 20 times trying, if the motor can not start successfully, PT2434 would go into the dead lock mode. PT2434 no longer re-startup itself at this mode, and we can only cycle the power supply(power-off then power-on) to escape PT2434 from dead lock mode. The lock protection time is determined by the capacitance on CT pin. CT will charge the external capacitor when motor is starting. If the CT voltage had charged to 3V, but motor still does not start successfully, the control program goes to lock protection mode, and CT capacitor start to discharge. If motor start successfully, CT will charge the capacitor to 5V and keep there. We can change the CT capacitance value or shunt resistance with it to get different lock and release time for motors. In lock mode or over temperature protection(OTP) mode, RD pin will stay HIGH. RD pin is open drain structure, and it needs an external pull high resistor to function. OVER TEMPERATURE PROTECTION PT2434 use the external negative temperature coefficient resistor (NTC) as the sources of over temperature protection detector. In pin RSEN, a normal resistor will connect to 5V and a NTC resistor will connect to ground. The NTC resistor may be placed near a heat source, such as a MOSFET. If the temperature rises, the NTC resistance will decrease and RSEN voltage level will be reduced. When RSEN voltage is less than 0.8V, PT2434 will enter over temperature protection(OTP) mode to put pin RD high and system in shutdown mode. After the system is cooling, RSEN voltage rise to higher than 1.2V and the system will start again. In shutdown mode, UH/UL/VH/VL/WH/WL will output as LOW. FG OUTPUT FOR SPEED INFORMATION PT2434 has FG output for motor speed indication. When the rotor is running an electric cycle, the FG output one-pair High and Low signal. So when calculating the rotation speed, it is needed to take into account the pole numbers of the rotor. For example, if rotor is 8 poles (four pairs of NS), the motor run a lap will have 4 FG output. Motor speed is usually present in RPM (Revolutions Per Minute), so the rotation speed of the motor is calculated as: RPM = FG x 120 / POLE, FG is frequency in Hz, “POLE” is pole number of rotor FG pin is open drain structure, and it needs an external pull high resistor to function. FORWARD AND REVERSE SETTING PT2434 can be set as forward or reverse rotation through FR pin. If FR is switched, the motor will stop automatically and rotate with opposite direction. It is also suggested to control the motor speed with monitoring FG signal to optimize the reverse behavior, such as slow down profile or reverse waiting time. PRE 1.2 6 April 2015 PT2434 ABSOLUTE MAXIMUM RATINGS Parameter Supply Voltage Rage I/O Voltage Operating Temperature Range Storage Temperature Range Symbol VDD – TA TSTG Min. 10 -0.3 -40 -40 Max. 18 5 +85 +150 Unit V V °C °C ELECTRICAL CHARACTERISTICS Nominal conditions: VDD = 15.0V, SGND=VSS, TA = +27°C. Parameter Symbol Conditions General Characteristics Supply voltage VDD Current consumption IDD VDD=15V Regulator output voltage VREG Regulator output current IREG Parameters Setting Over temperature protection trigger VOTP RSEN pin voltage Over temperature protection release VREL RSEN pin voltage Over current protection voltage VOCP RF pin Charge current of lock protection ILOCK CT pin Discharge current of lock release IUNLOCK CT pin Lock Threshold VLOCK CT pin Startup oscillator FOSC_1K OSC_C = 1nF Startup oscillator range FOSC_C OSC_C pin ZC filter Capacitor CFLT COMI, FLT pin SW0 = open SW1=open SW0 = low SW1=open Dead time Tdead SW0 = open SW1=low SW0 = low SW1=low Operation Characteristics PWM switching frequency Fsw I/O Interface Logic output high level VOH UVWL, UVWH Logic output low level VOL UVWL, UVWH BEMF sensing input VZC ZCU, ZCV, ZCW SW0, SW1, SW2, SW3, FWR pin SW0, SW1, SW2, SW3, ISOURCE pull high current FWR FG, RD open drain sink voltage VSINK I = 1mA DC/PWM internal pull high resistance RDC DC pin, connect to VREG DC for speed control input level VDC DC input (DC pin) PWM input high level VPWMH PWM input (DC pin) PWM input low level VPWML PWM input (DC pin) PWM input clock FPWM_IN PWM input (DC pin) PRE 1.2 7 Min. Typ. Max. Unit 11 2.6 4.5 15 2.9 5 20 18 3.2 5.5 V mA V mA 0.1 1 0.8 V 1.2 V 0.5 3.4 1.7 3 1 2.8 2.0 1.2 0.4 V μA μA V KHz KHz nF μsec μsec μsec μsec 10 330 20 4.0 0.6 3.5 15 4.5 0 KHz 5.5 0.3 5.5 V V V 6 μA 10 150 mV KΩ V V V KHz 3.3 0.3 25 April 2015 PT2434 APPLICATION EXAMPLE – HV MOTOR (< 400V) 1 2 3 4 UO VO WO 6 7 8 Control Interface JP1 JP2 D 5 1 2 3 4 5 6 7 1 2 3 4 HVIN R31 R32 R19 R33 PWM FG C8 RD ZD2 FG0 C19 15V_IN 15V C18 D ZD1 C17 RD0 R36 15V_IN HVDC PWM0 R34 R35 Motor Connector R20 HVIN GND VR30 C9 Power Supply Drive Stage R27 C C 15V D3 HVDC TEST1 R6 5V 15 R7 C4 16 17 RF0 R8 18 ZCU ZCV B ZCW R9 19 20 21 22 C5 23 24 C6 25 26 PWM0 C7 RD0 FG0 A Control Unit 27 28 ZCO SW2 RSEN V5V RF V15V GND SGND ZCU UH ZCV VH ZCW WH SW3 UL COMI VL FLT WL OSC_C FWR DCPWM SW1 RD SW0 FG CT Designator U1 U2 R1 R2, R3, R4, R5, R6 R7 R8 R9 R10 R11, R12, R13 R14, R15, R16 R17, R18, R19 R20 R21, R23, R25 R22, R24, R26 R27 R31 R32, R33 R34, R35, R36 2 1 VCC 5V 13 VBU 2 HOU C10 C3 12 3 C2 11 VSU 4 10 5 9 6 8 7 7 8 6 9 5 10 SW1 VBU 27 HOU HU VBV HV HOV HW VSV QUH R21 HOU C11 LOU VBV 23 HOV VO QUL LOV LV VBW LW HOW LOW RF0 12 17 2 R2 13 16 1 CT C1 SGND2 VSW VBW 19 HOW R3 R11 RF0 C13 ZCU UO R12 ZCV 18 WO VO R13 ZCW WO C14 PGND LOU LOW LOV 15 PT5617-SOP28 3 4 C15 C16 LOU LOV R17 R18 R14 R15 R16 A Feedback Sensing Gate Driver 5 6 7 8 Designator Part Type Note QUH, QVH, QWH 4N60 - TO252 600V NMOS QUL, QVL, QWL 4N60 - TO252 600V NMOS R1=NC ZD1 Zener Diode 18V 1W ZD1=NC R2=R3=NC ZD2 TVS 400V 400W R7=NC C1 2.2uF 10V 0603 C2 100nF 25V 0805 C3 1uF 10V 0603 C4 330pF 10V 0603 C5 33nF 10V 0603 C6 1nF 10V 0603 C7, C8, C9 100nF 10V 0603 C10 1uF 25V 1206 C11, C12, C13 1uF 25V 1206 C14, C15, C16 1nF 10V 0603 NC C17 4.7uF 50V 1210 C18, C19 47nF 500V 1206 JP1 7 pins connector JP2 4 pins connector To Motor SW1 SW SPST CW/CCW VR30 VR200K SIP3 Speed Control Note: A part of components value is related to motor styles, operating voltage or applications, need to make appropriate adjustments. PRE 1.2 Part Type PT2434-SSOP28 PT5617-SOP28 1M 5% 0603 100K 5% 0603 NTC resistor 0603 47K 5% 0603 100K 5% 0603 100R 5% 0603 560K 5% 0603 10K 5% 0603 3.3R 5% 1206 3.3R 5% 1206 10R 5% 0805 100R 5% 0603 100R 5% 0603 100R 5% 0603 100K 5% 0603 100K 5% 0603 22K 5% 0603 B D1 20 3 R1 QWL R26 21 LU 14 WO QVL R24 C12 22 VO R4 LOW QWH R25 HOW UO R22 24 QVH R23 HOV D2 26 UO 25 SGND 11 28 4 PT2434-SSOP28 1 U2 R10 R5 14 Note 8 April 2015 PT2434 APPLICATION EXAMPLE – 12V/24V/36V MOTOR 2 3 4 UO VO WO 6 1 2 3 4 5 6 7 1 2 3 4 VIN R31 R32 D PWM0 R34 R19 RD0 R36 FG RD C8 R20 VIN VM ZD2 C19 1 VIN Vin C18 3 Vout 12V ZD1 C17 VR30 C9 2 PWM U2 FG0 R35 12V 8 R33 GND Motor Connector 7 PT2434_P/NMOS for 12V-36V BLDC Motor Control Interface JP1 JP2 D 5 GND 1 Power Supply C Drive Stage VM C TEST1 24 C6 26 PWM0 C7 RD0 FG0 A 25 Control Unit 27 28 COMI VL FLT WL OSC_C DCPWM RD FG FWR SW1 SW0 CT 5 4 Designator U1 U2 R1 R2, R3, R4, R5, R6 R7 R8 R9 R10 R11, R12, R13 R14, R15, R16 R17, R18, R19 R19 R20 R21, R23, R25 R22, R24, R26 R27 R31 R32, R33 R34, R35, R36 2 1 2 3 4 1 2 3 4 1 2 3 4 G(P) S(P) G(N) S(N) G(P) S(P) G(N) S(N) D(P) D(N) D(N) QW D(P) D(P) D(N) D(N) UO 6 7 VO 5 6 7 6 HOW LOU Q3 B WH B 8 WH 8 R25 B VH HOV QV D(P) 7 VH Q2 5 8 UH 8 9 RF0 R23 B S(N) 10 UH C2 11 WO LOV SW1 LOW R22 R4 3 R3 2 R2 1 CT C1 PT2434-SSOP28 1 12V D(N) UL 12 7 SW3 VM HOU S(P) WH Q1 G(N) VH ZCW C3 D(N) 23 ZCV R21 5V 13 6 C5 UH LOW G(P) 22 SGND ZCU HOW D(P) R9 21 GND LOV QU D(P) ZCW 20 V15V HOV 5 ZCV B 19 RF V5V R5 14 C 18 ZCU RSEN SW2 LOU E 17 R8 ZCO C RF0 16 E C4 C 15 R7 E 5V HOU R6 R24 RF0 R26 R11 ZCU UO R12 ZCV VO R13 ZCW WO C14 R17 C15 R14 R1 R15 R16 Level Shift 3 Part Type PT2434-SSOP28 PT5617-SOP28 1M 5% 0603 100K 5% 0603 NTC resistor 0603 47K 5% 0603 100K 5% 0603 100R 5% 0603 560K 5% 0603 10K 5% 0603 0.5R 5% 1206 0.5R 5% 1206 10R 5% 0805 1K 5% 0603 1K 5% 0603 100R 5% 0603 100K 5% 0603 100K 5% 0603 22K 5% 0603 4 A Feedback Sensing 5 Note R1=NC R2=R3=NC R7=NC C16 R18 Designator Q1, Q2, Q3 QU, QV, QW ZD1 ZD2 C1 C2 C3 C4 C5 C6 C7, C8, C9 C10 C14, C15, C16 C17 C18, C19 JP1 JP2 SW1 VR30 6 7 Part Type NPN-3904 SOP8_PN Zener Diode 18V 1W TVS 40V 400W 2.2uF 10V 0603 100nF 25V 0805 1uF 10V 0603 330pF 10V 0603 33nF 10V 0603 1nF 10V 0603 100nF 10V 0603 1uF 25V 1206 1nF 10V 0603 4.7uF 25V 1210 4.7uF 50V 1210 7 pins connector 4 pins connector SW SPST VR200K SIP3 8 Note 60V MOS ZD1=NC NC C19=NC To Motor CW/CCW Speed Control Note: A part of components value is related to motor styles, operating voltage or applications, need to make appropriate adjustments. PRE 1.2 9 April 2015 PT2434 PACKAGE INFORMATION 28 Pins, SSOP 150MIL Symbol Min. Nom. Max. A A1 b c D 1.35 0.10 0.20 0.10 9.80 9.90 1.75 0.25 0.30 0.25 10.00 E E1 e L 5.80 3.80 0 6.00 3.90 0.635 BSC. 0.40 - 6.20 4.00 1.27 8 Notes: 1. Refer to JEDEC MO-137AF 2. Unit: mm PRE 1.2 10 April 2015 PT2434 IMPORTANT NOTICE Princeton Technology Corporation (PTC) reserves the right to make corrections, modifications, enhancements, improvements, and other changes to its products and to discontinue any product without notice at any time. PTC cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a PTC product. No circuit patent licenses are implied. Princeton Technology Corp. 2F, 233-1, Baociao Road, Sindian Dist., New Taipei City 23145, Taiwan Tel: 886-2-66296288 Fax: 886-2-29174598 http://www.princeton.com.tw PRE 1.2 11 April 2015