Standard Products ACT5101-1 Brushless DC Motor Drive High Voltage 3-Phase www.aeroflex.com/Power March 29, 2006 FEATURES ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ 500VDC Rating 50Amp DC Rating Package Size 3.0" x 2.1" x 0.39" 4 Quadrant Control 6 Step Trapezoidal Drive Capability Military Processing Available Isolated Upper and Lower Gate Drivers Temperature Range -55°C TO +125°C Designed for commercial, industrial and aerospace applications Aeroflex-Plainview is a Class H & K MIL-PRF-38534 manufacturer DESCRIPTION The Aeroflex-Plainview ACT5101-1 is a high voltage 3 phase brushless DC motor drive that combines a 500VDC, 50A high power output stage along with a low power digital input and gate drive stages. A digital lock-out feature protects the output stage from accidental cross-conduction thus preventing shoot-through conditions. The ACT5101-1 also includes a floating gate drive design for each upper and lower transistor. On-board gate drive supplies provide a continuous floating voltage for each upper and lower transistor, even during a motor stall. The high power output stage rated at 500VDC, 50A is capable of delivering over 25KW to the load. This is accomplished through the use of high power IGBTs with ultra-fast recovery rectifiers in parallel. The ACT5101-1 utilizes power hybrid technology to provide the highest levels of reliability and lightest weight while requiring the smallest amount of board space. The ACT5101-1 is available with military processing and operates over the -55 to +125°C temperature range. This makes the ACT5101-1 ideal for all military, space, and commercial avionics applications. These include electro-hydrostatic actuators (EHA's) and electro-mechanical actuators (EMA's) for flight surface control, missile fin actuators, thrust vector control, electric brakes, fuel and cooling pumps. Additional applications include environmental conditioning blowers, radar positioning, solar panel positioning, and cryogenic cooler pumps. The ACT5101-1 is therefore especially suitable for use in applications for all military tank upgrades, helicopters, planes and new commercial avionics using 270VDC as the main power. SCD5101-1 Rev M VCC Isolation VCC DC / AC Converter Phase V+ SD Isolation VCC XFMR & Rect Ux Phase OUT VCC 500V Optical Isolation Isolation XFMR & Rect Lx Phase RTN To Other Sections FIGURE 1 – BLOCK DIAGRAM SCD5101-1 Rev M 329/06 Aeroflex Plainview 2 TABLE I – ABSOLUTE MAXIMUM RATINGS PARAMETER SYMBOL RANGE UNITS V+A, V+B, V+C 500 Max 1/ VDC Input Supply Voltage (Pin 12) VCC +18 Max VDC Output Current (Refer to Figure 2) Continuous Pulsed lOF lOFP 50 Max 1/ 90 Max 2/ A A Junction-Case Thermal Resistance (IGBT) each transistor θJCIGBT .45 Max °C/W Junction-Case Thermal Resistance (DIODE) each Diode θJCDIODE .85 Max °C/W TS 250 Max °C Junction Temperature Range TJ -55 to 150 °C Case Operating Temperature TC -55 to 125 °C Case Storage Temperature Range TCS -55 to 150 °C Output Supply Voltage (Pins 3,7,11) Maximum Lead Soldering Temp 3/ Notes: 1/ Tc = +25°C. 2/ Pulse Width < 10ms, Duty Cycle < 10%. Guaranteed, not tested. 3/ Solder 1/8" from case for 5 seconds maximum. TABLE II – NORMAL OPERATING CONDITIONS TC = +25°C unless otherwise specified SYMBOL TEST CONDITIONS MIN Input Supply Current lS Vcc = +15V - 100 115 mA Input Supply Voltage VCC - 14.25 15 15.75 VDC Input Voltage Low VINL - - 4 VDC Input Voltage High VINH 11.0 - - VDC Input Current Low IINH NOTE: Internally pulled up to Vcc = +15V - - 3.75 mA lOF - - - 50 A V+ A,V+ B,V+ C - 15 270 500 VDC VDROPF 3/ lOF = 40A - 2.2 2.5 VDC VDROPF lOF = 6.5A - - 1.85 VDC VDROPR 1/ 3/ lOR = 40A - 1.3 1.6 VDC VDROPR 1/ 3/ lOR = 6.5A - - 1.0 VDC tRR - - - 35 nsec lR25 lR125 V+ = 500V V+ = 480V - - 500 8.0 µA mA PARAMETERS TYP MAX UNIT INPUT STAGE POWER OUTPUT STAGE Output Current Continuous (Refer to Figure 2) 3/ Output Supply Voltage Output Voltage Drop (Each IGBT) NOTE: VDROPF = VPHASE V+ - VPHASE Out or VDROPF = VPHASE Out - VPHASE RTN Instantaneous Forward Voltage (Flyback Diode) NOTE: VDROPR = VPHASE Out - VPHASE V+ or VDROPR = VPHASE RTN - VPHASE Out Reverse Recovery Time (Flyback Diode) Reverse Leakage Current (VIN High) Tc = 25°C 3/ Tc = 125°C 1/ 3/ 4/ 3/ SCD5101-1 Rev M 329/06 Aeroflex Plainview 3 TABLE II – NORMAL OPERATING CONDITIONS (con’t) TC = +25°C unless otherwise specified SYMBOL TEST CONDITIONS MIN VISO - 500 - - V Turn-on propagation delay td (on) - - - 700 nsec Turn-off propagation delay td (off) - - - 2 µsec tSDU - - - 3.5 µsec Turn-on Transition Time tr - - - 250 nsec Turn-off Transition Time tf - - - 250 nsec Turn-on propagation delay td (on) - - - 700 nsec Turn-off propagation delay td (off) - - - 2 µsec tSDL - - - 3.5 µsec Turn-on Transition Time tr - - - 250 nsec Turn-off Transition Time tf - - - 250 nsec Turn-on Energy Eon TC = +125°C - - 0.5 mJ Turn-off Energy Eoff - - 3.0 mJ 500 - - nsec PARAMETERS TYP MAX UNIT ISOLATION CHARACTERISTICS Isolation Voltage SWITCHING CHARACTERISTICS 2/ UPPER DRIVE (See Figure 3 – Timing Diagram): Shut-down propagation delay LOWER DRIVE (See Figure 3 – Timing Diagram): 2/ Shut-down propagation delay SWITCHING ENERGY LOSSES (At IOF = 40A, V = 270V) 3/ DEAD TIME (See Digital Input Stage Description herein) tdt - Notes: 1/ Pulse width ≤ 300usec duty cycle ≤2%. 2/ Tested @ 6.5Amps. 3/ Guaranteed, not tested. 4/ Not to exceed TJ of +150°C. See Mechanical Applications for Case Interface Temperature Description herein. SCD5101-1 Rev M 329/06 Aeroflex Plainview 4 DIGITAL INPUT STAGE The ACT5101-1 offers complete flexibility by allowing the user to turn on/off each of the 6 IGBTs in any order or combination desired which enables the hybrid to be commutated in a 6 step trapezoidal mode. The only unacceptable combination would be to turn on an upper and lower transistor of the same phase. This is not a desirable condition for normal operation and is therefore not allowed. The ACT5101-1 has a digital lockout feature that prevents turn-on of two in-line transistors. Damage to one or both of the transistors would occur if this protection circuitry was not present in the hybrid. As a safety precaution, it is still recommended that a 500nsec dead time be installed between commands at the inputs of the upper and lower transistors of the same phase. This will compensate for any lag in transistor turn-off due to the inductive load. The SD input allows the user to enable/disable the drive stage of the ACT5101-1 on demand. This input can be incorporated into the user's temperature or current monitoring circuitry to shutdown the hybrid if excessive current or case temperatures are sensed. The digital input circuits are of the Schmitt trigger type with hysteresis, thus greatly enhancing the input noise immunity. The inputs are internally pulled up to 15 volts so that an uncommitted input is sensed as "OFF", providing a measure of protection against an accidental input disconnect. GATE DRIVE The ACT5101-1 includes a gate drive supply which provides a floating voltage for each upper and lower transistor. This constant voltage allows the motor to be operated at very low duty cycles or driven into a stall without any loss of upper or lower gate drive. This performance could not be obtained with only a conventional boot strap design. POWER OUTPUT STAGE IGBTs (insulated gate bipolar transistors) are technically similar to bipolars and MOSFETS. An IGBT is a composite of a transistor with an N-channel MOSFET connected to the base of a PNP transistor. Like the MOSFET, it offers high input impedance and requires low input drive current. IGBT conduction losses are low, as with bipolar technology, and IGBT voltage drops are much lower compared with those of MOSFETs. Consequently, the IGBT offers a high current density. With a smaller die size than the MOSFET, it can handle the same current rating. Unlike MOSFETS, IGBTs have no intrinsic body diode. The ACT5101-1 includes 35nsec fast recovery rectifiers in parallel across each of the 6 IGBTs to carry the reverse current when the IGBT is turned off. It is important for the user to observe the Absolute Maximum ratings of the ACT5101-1 so that the voltage and current rating is not exceeded. If over-voltage/over-current protection is desired it must be implemented external to the ACT5101-1. Figure 2 shows the ACT5101-1 output current capability vs. case temperature. Motor Running Total Motor Current IO (A) 120 100 80 Motor Running, PWM = 10KHz 60 Motor Running, PWM = 20KHz 40 20 0 0 20 40 60 80 100 120 140 Case Temperature TC (°C) FIGURE 2A - OUTPUT CURRENT vs CASE TEMPERATURE – MOTOR RUNNING SCD5101-1 Rev M 329/06 Aeroflex Plainview 5 Locked Rotor 80 Phase Current IO (A) 70 60 50 Locked Rotor, PWM = 20KHz 40 Locked Rotor, PWM = 10KHz 30 20 10 0 0 20 40 60 80 100 120 140 Case Temperature TC (°C) FIGURE 2B - OUTPUT CURRENT vs CASE TEMPERATURE – LOCKED ROTOR Locked Rotor, No PWM 100 90 Phase Current IO (A) 80 70 60 Locked Rotor, No PWM (DC) 50 40 30 20 10 0 0 20 40 60 80 100 120 140 Case Temperature TC (°C) FIGURE 2C - OUTPUT CURRENT vs CASE TEMPERATURE – LOCKED ROTOR, NO PWM SCD5101-1 Rev M 329/06 Aeroflex Plainview 6 MECHANICAL The ACT5101-1 construction utilizes only the highest quality materials and manufacturing available to ensure a high reliability, robust power hybrid design. The case is selected for best thermal conductivity, hermeticity, and voltage/current carrying capability. The case is electrically isolated from the circuit and can withstand 1500VAC from pin to case, therefore no insulating pads or washers are required for mounting. In order to remove the heat being generated from the ACT5101-1, it must be bolted down to the motor, a heat sink or the actual system chassis such as a missile structure or aircraft wing rib for example. Thermally conductive grease or a "Sil-pad" is recommended between the hybrid case baseplate and its mounting surface to fill in any surface imperfections and improve the heat transfer from case-to-heat sink. It is important to keep the temperature at this interface no greater than +125°C in order to maintain safe semi-conductor junction temperatures. The leads of the ACT5101-1 can be formed upward, away from the baseplate, so that a PC board can be mounted directly above it. A wiring harness can also be hand-wired and soldered directly to the leads of the ACT5101-1 if this is preferred. TABLE III – INPUT / OUTPUT TRUTH TABLE INPUTS OUTPUTS UA UB UC LA LB LC SD PHASE A PHASE B PHASE C 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 1 1 1 0 0 0 0 0 0 1 1 1 1 1 1 0 0 0 0 0 0 1 1 1 0 0 0 1 1 1 0 0 0 1 1 1 1 0 0 1 0 0 0 0 0 1 1 1 1 1 0 1 1 0 0 1 0 1 1 1 1 1 0 1 0 0 0 0 0 1 0 1 1 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Z L L Z L L L L L H H H H H Z H H Z L Z L H H H H H Z Z L L L L L H Z H H H H L Z L H Z H L Z L H Z H L L L 1 1 0 1 1 0 1 1 0 1 0 1 1 0 1 1 0 1 0 0 0 Z L H Z L H Z L H X X X X X X 1 Z Z Z H=high level, L=low level, X=irrelevant, Z=high impedance (off) SCD5101-1 Rev M 329/06 Aeroflex Plainview 7 Ux INPUTS 50% 50% Lx INPUTS td on td off td off td on 90% PHASE OUTPUTS 50% 10% tr tf tr tf 50% SD tSDU H PHASE OUTPUTS Z tSDL UPPER TRANSISTOR BEING SHUTDOWN LOWER TRANSISTOR BEING SHUTDOWN Z L FIGURE 3 – TIMING DIAGRAM SCD5101-1 Rev M 329/06 Aeroflex Plainview 8 TABLE IV – FUNCTION vs PIN NUMBERS / DESCRIPTION FUNCTION PIN # DESCRIPTION V+ A 11 High Voltage D.C. Bus, Phase A V+ B 7 High Voltage D.C. Bus, Phase B V+ C 3 High Voltage D.C. Bus, Phase C VCC 12 +15VDC input required to power gate drive supply and gate drive circuitry of all three phases. GND 19,22,26 RTN A 8 Return for High Voltage Bus, Phase A. RTN B 5 Return for High Voltage Bus, Phase B RTN C 1 Return for High Voltage Bus, Phase C PHASE A 9 Output to motor winding Phase A PHASE B 6 Output to motor winding Phase B PHASE C 2 Output to motor winding Phase C UA 18 Digital input to Phase A upper transistor LA 17 Digital input to Phase A lower transistor UB 21 Digital input to Phase B upper transistor LB 20 Digital input to Phase B lower transistor UC 25 Digital input to Phase C upper transistor LC 24 Digital input to Phase C lower transistor SD 23 Digital shut-down input to enable / disable all six gate drives N/C 4,10,13-16 Reference for LOGIC supply, +15V supply, and digital inputs. No connection Internally TABLE V – PIN NUMBERS vs FUNCTION PIN # FUNCTION PIN # FUNCTION 1 RTN C 26 GND 2 PHASE C 25 UC 3 V+ C 24 LC 4 N/C 23 SD 5 RTN 4B 22 GND 6 PHASE B 21 UB 7 V+ B 20 LB 8 RTN A 19 GND 9 PHASE A 18 UA 10 N/C 17 LA 11 V+ A 16 N/C 12 VCC 15 N/C 13 N/C 14 N/C SCD5101-1 Rev M 329/06 Aeroflex Plainview 9 POWER PACKAGE OUTLINE Chamfer .035-.065 X 45° 4X .128 -.005,+.002 THRU 26 1 3.000 2.750 See note 3 12X .200 13 14 .300 .120 .125 1.860 .250 1.600 2.100 2.010 26X .048 - .052 .057 ±.020 .003IN/IN .050 .54-.58 .330 .003IN/IN .165 R .110 Notes: 1. Package contains BeO substrate. 2. Dimensions Tolerance: ±.005, unless otherwise noted. 3. Pin Tolerance: non-cumulative SCD5101-1 Rev M 329/06 Aeroflex Plainview 10 ORDERING INFORMATION MODEL NUMBER SCREENING ACT5101-1 Operating Temperature Range -55°C to +125°C. Screened to the individual test methods of MIL-STD-883. Class H DSCC QML Pending. ACT5101-1-7 Commercial Flow, 25°C testing only PLAINVIEW, NEW YORK Toll Free: 800-THE-1553 Fax: 516-694-6715 INTERNATIONAL Tel: 805-778-9229 Fax: 805-778-1980 NORTHEAST Tel: 603-888-3975 Fax: 603-888-4585 SE AND MID-ATLANTIC Tel: 321-951-4164 Fax: 321-951-4254 WEST COAST Tel: 949-362-2260 Fax: 949-362-2266 CENTRAL Tel: 719-594-8017 Fax: 719-594-8468 www.aeroflex.com [email protected] Aeroflex Microelectronic Solutions reserves the right to change at any time without notice the specifications, design, function, or form of its products described herein. All parameters must be validated for each customer's application by engineering. No liability is assumed as a result of use of this product. No patent licenses are implied. Our passion for performance is defined by three attributes represented by these three icons: solution-minded, performance-driven and customer-focused SCD5101-1 Rev M 329/06 11