A4960 Automotive, Sensorless BLDC Controller Not for New Design This part is in production but has been determined to be NOT FOR NEW DESIGN. This classification indicates that the product is obsolete and notice has been given. Sale of this device is currently restricted to existing customer applications. The device should not be purchased for new design applications because of obsolescence in the near future. Samples are no longer available. Date of status change: A4960KJPTR-T January 29, 2014 Recommended Substitutions: For existing customer transition, and for new customers or new applications, refer to A4960KJPTR-A-T. NOTE: For detailed information on purchasing options, contact your local Allegro field applications engineer or sales representative. Allegro MicroSystems, LLC reserves the right to make, from time to time, revisions to the anticipated product life cycle plan for a product to accommodate changes in production capabilities, alternative product availabilities, or market demand. The information included herein is believed to be accurate and reliable. However, Allegro MicroSystems, LLC assumes no responsibility for its use; nor for any infringements of patents or other rights of third parties which may result from its use. A4960 Automotive, Sensorless BLDC Controller Features and Benefits Description •3-phase BLDC sensorless start-up and commutation •Gate drive for N-channel MOSFETs •Integrated PWM current limit •7 to 50 V supply voltage operating range •Compatible with 3.3 V and 5 V logic •Cross-conduction protection with adjustable dead time •Charge pump for low supply voltage operation •Extensive diagnostics output •Low current sleep mode The A4960 is a three-phase, sensorless, brushless DC (BLDC) motor controller for use with external N-channel power MOSFETs and is specifically designed for automotive applications. The motor is driven using block commutation (trapezoidal drive) where phase commutation is determined, without the need for independent position sensors, by monitoring the motor back-EMF. A programmable motor start-up scheme allows the A4960 to be adjusted for a wide range of motor and load combinations. Applications: An external bootstrap capacitor is used to provide the above battery supply voltage required for N-channel MOSFETs. An automatic internal bootstrap charge management scheme ensures that the bootstrap capacitor is always sufficiently charged for safe operation of the power MOSFETs. The power MOSFETs are protected from shoot-through by integrated crossover control and adjustable dead time. •Hydraulic pump •Fuel pump •Urea pump •Blower fan Package: 32-pin LQFP with exposed thermal pad (suffix JP) Integrated diagnostics provide indication of undervoltage, overtemperature, and power bridge faults and can be configured to protect the power MOSFETs under most short circuit conditions. Detailed diagnostics are available as a serial data word. The A4960 is supplied in a 32-pin LQFP with exposed pad for enhanced thermal dissipation (suffix JP). This package is lead (Pb) free, with 100% matte-tin leadframe plating (suffix –T). Not to scale Typical Application VBAT VBAT A8450 Regulator SPI PWM Microcontroller TACHO RESET FAULT A4960-DS, Rev. 1 A4960 3-Phase BLDC Motor A4960 Selection Guide Part Number Automotive, Sensorless BLDC Controller Packing* A4960KJPTR-T 1500 pieces per 13-in. reel *Contact Allegro™ for additional packing options Absolute Maximum Ratings1,2 Rating Unit Load Supply Voltage Characteristic Symbol VBB Notes –0.3 to 50 V Logic Supply Voltage VDD –0.3 to 6 V Terminal VREG VREG –0.3 to 16 V Terminal CP1 VCP1 –0.3 to 16 V Terminal CP2 VCP2 VCP1 – 0.3 to VREG + 0.3 V Logic Inputs Terminals STRN, SCK, SDI, PWM –0.3 to 6 V VI Terminal RESETN – can be pulled to VBB with >22 kΩ –0.3 to 6 V Terminals SDO, TACHO –0.3 to VDD + 0.3 V –0.3 to VDD + 0.3 V Logic Outputs VO Terminal DIAG VDIAG Terminal VBRG VBRG –5 to 55 V Terminals CA, CB, CC VCx –0.3 to VREG + 50 V Terminals GHA, GHB, GHC VGHx VCX – 16 to VCX + 0.3 V VSx VCX – 16 to VCX + 0.3 V Terminals GLA, GLB, GLC VGLx VREG – 16 to 18 V Terminal LSS VLSS VREG – 16 to 18 V Terminal REF VREF –0.3 to 6.5 V Terminals CSP, CSM VCSx –0.3 to 1 V –40 to 150 °C 150 °C 175 °C –55 to 150 °C Terminals SA, SB, SC Terminal AGND Connect directly to GND Ambient Operating Temperature Range TA Maximum Continuous Junction Temperature TJ(max) Transient Junction Temperature TJt Storage Temperature Range Tstg Temperature Range K; limited by power dissipation Over temperature event not exceeding 10 s, lifetime duration not exceeding 10 hours, guaranteed by design characterization. 1With respect to GND. Ratings apply when no other circuit operating constraints are present. 2Small “x” in pin names and symbols indicates a variable sequence character. Thermal Characteristics may require derating at maximum conditions, see application information Characteristic Symbol Package Thermal Resistance, Junction to Ambient RθJA Package Thermal Resistance, Junction to Pad RθJP Value Unit On 4-layer PCB based on JEDEC standard Test Conditions* 23 ºC/W On 2-layer PCB with 3 in.2 copper each side 44 ºC/W 2 ºC/W *Additional thermal information available on the Allegro website Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 2 A4960 Automotive, Sensorless BLDC Controller Table of Contents Specifications 2 4 5 6 10 10 12 Functional Description 12 12 13 13 14 14 14 14 15 15 16 16 16 16 17 17 17 17 Pin-out Diagram and Terminal List Functional Block Diagram Electrical Characteristics Table Timing Diagrams Operation Timing Diagrams Functional Description Input and Output Terminal Functions Motor Drive System Rotor position sensing using motor BEMF Commutation Blank Time BEMF Window BEMF Hysteresis Start-up Motor control Phase advance Power Supplies Gate Drives Gate drive voltage regulation Bootstrap charge management Low-side gate drive High-side gate drive Dead Time Sleep Mode and RESETN Current Limit Current sense amplifier Fixed off-time Blank time Diagnostics DIAG pin Serial interface fault output Fault response action Fault Mask register Chip-level diagnostics Chip Fault States: Temperature Thresholds Chip Fault State : VREG Undervoltage Chip Fault State: VDD Undervoltage Bootstrap Undervoltage Fault State MOSFET fault detection MOSFET fault blank time Short fault operation MOSFET Fault State: Short to Supply MOSFET Fault State: Short to Ground MOSFET Fault State: Shorted Winding Serial Interface Description Configuration and control registers Diagnostic register Applications Information Control Timing Diagrams Input/Output Structures Package Outline Drawing 18 18 18 19 19 19 19 20 20 20 20 21 21 21 21 22 22 22 22 22 23 24 25 31 31 32 33 Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 3 A4960 Automotive, Sensorless BLDC Controller VBB AGND GND CP1 CP2 VERG CA SA 32 31 30 29 28 27 26 25 Pin-out Diagram VBRG 1 24 GHA RESETN 2 23 GLA 22 CB 21 SB REF 3 VDD 4 DIAG 5 20 GHB PWM 6 19 GLB TACHO 7 18 GHC SDO 8 17 CC 16 SC 13 CSP GLC 12 CSM 15 11 STRN 14 10 SDI LSS 9 SCK PAD Terminal List Table Name Number AGND 31 Reference ground Function Name Number LSS 14 Low-side source CA 26 CB 22 Bootstrap capacitor, Phase A PAD – Exposed thermal pad Bootstrap capacitor, Phase B PWM 6 PWM Input CC 17 Bootstrap capacitor, Phase C CP1 29 Pump capacitor Function REF 3 Reference voltage input RESETN 2 Standby mode control CP2 28 Pump capacitor SA 25 Motor connection, Phase A CSM 12 Sense amplifier negative input SB 21 Motor connection, Phase B Motor connection, Phase C CSP 13 Sense amplifier positive input SC 16 DIAG 5 Programmable diagnostic output SCK 9 Serial clock input GHA 24 High-side gate drive, Phase A SDI 10 Serial data input GHB 20 High-side gate drive, Phase B SDO 8 Serial data output GHC 18 High-side gate drive, Phase C STRN 11 Serial Strobe (chip select) input GLA 23 Low-side gate drive, Phase A TACHO 7 Speed output GLB 19 Low-side gate drive, Phase B VBB 32 Main power supply GLC 15 Low-side gate drive, Phase C VBRG 1 High-side drain voltage sense GND 30 Power ground VDD 4 Logic supply VREG 27 Regulated voltage, above supply Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 4 A4960 Automotive, Sensorless BLDC Controller Functional Block Diagram Battery + CP VDD STRN SCK SDI SDO REF Serial Interface Start Registers Ref DAC Start Sequencer CP1 CP2 VBB Charge Pump Regulator Config Registers VREG VBRG Phase A shown (Repeated for B and C) PWM CA CBOOTA Bootstrap Monitor High-Side Drive TACHO VDS Monitor RESETN Run Control Motor State Sequencer Bridge Control Gate Drive Control VREG Diagnostics and Protection Comm Timer Blank Time Dead Time GHA RGATE SA VDS Monitor Low-Side Drive DIAG VBAT CREG Blank Time Phase C GLA RGATE Phase B LSS CSP Zero X Detect CSM VRI AGND GND Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 5 A4960 Automotive, Sensorless BLDC Controller ELECTRICAL CHARACTERISTICS Valid at TJ = –40°C to 150°C, VDD = 5 V, VBB = 7 to 28 V; unless otherwise specified Characteristics Symbol Test Conditions Min. Typ. Max. Unit 6 – 50 V 5.5 – 50 V Supply and Reference Operating, outputs active VBB Functional Operating Range1 VBB Quiescent Current VDD Logic Supply VDD Quiescent Current VBB Operating, outputs disabled No unsafe states 0 – 50 V IBBQ RESETN = high; GHx, GLx = low, VBB = 12 V – 10 14 mA IBBS RESETN = low, sleep mode, VBB = 12 V µA VDD IDDQ RESETN = high, outputs low IDDS RESETN = low VREG Bootstrap Diode Resistance Bootstrap Diode Current Limit System Clock Period 10 – 5.5 V – 6 16 mA – – 15 µA 13 13.8 V 7.5 V < VBB ≤ 9 V, IREG = 0 to 6 mA 12.4 13 13.8 V 6 V < VBB ≤ 7.5 V, IREG = 0 to 5 mA 2×VBB – 2.5 – – V 9 10 – V 5.5 V < VBB ≤ 6 V, IREG < 4 mA Bootstrap Diode Forward Voltage – 12.4 VBB > 9 V, IREG = 0 to 8 mA VREG Output Voltage – 3.0 ID = 10 mA 0.4 0.7 1.0 V ID = 100 mA 1.5 2.2 2.8 V rD(100mA) = (VfBOOT(150mA) – VfBOOT(50mA)) / 100 (mA) 6.5 15.0 22.5 Ω IDBOOT 250 500 750 mA tOSC 42.5 50 57.5 ns VfBOOT rD Gate Output Drive Turn-On Time tr CLOAD = 500 pF, 20% to 80% – 35 – ns Turn-Off Time tf CLOAD = 500 pF, 80% to 20% – 20 – ns TJ = 25°C, IGHx = –150 mA 9 13 17 Ω TJ = 150°C, IGHx = –150 mA 16 21 27 Ω TJ = 25°C, IGLx = 150 mA 1.8 3.0 5.0 Ω TJ = 150°C, IGLx = 150 mA 2.8 4.5 7.0 Ω VC – 0.2 – – V –10 µA < IGH < 10 µA – – VSx + 0.3 V –10 µA < IGL < 10 µA VREG – 0.2 – – V Pull-Up On-Resistance2 RDS(on)UP Pull-Down On-Resistance RDS(on)DN GHx Output Voltage High VGHH Bootstrap capacitor fully charged GHx Output Voltage Low VGHL GLx Output Voltage High VGLH GLx Output Voltage Low VGLL –10 µA < IGL < 10 µA – – VLSS + 0.3 V GHx Passive Pull-Down RGHPD VGSH = 1 V – 350 – kΩ GLx Passive Pull-Down RGLPD VGSL = 1 V – 350 – kΩ 200 250 300 ns Turn-Off Propagation Delay tP(off) Input change to unloaded gate output change, see figure 3 Turn-On Propagation Delay tP(on) Input change to unloaded gate output change, see figure 3 200 250 300 ns Dead Time (Turn-Off to Turn-On delay) tDEAD Default power–up state, see figure 3 0.85 1.0 1.15 µs Continued on the next page… Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 6 A4960 Automotive, Sensorless BLDC Controller ELECTRICAL CHARACTERISTICS (continued) Valid at TJ = –40°C to 150°C, VDD = 5 V, VBB = 7 to 28 V; unless otherwise specified Characteristics Symbol Test Conditions Min. Typ. Max. Unit 0 – 200 mV 0.8 – 2.0 V 1.84 2 2.16 V –3 0 3 µA – VREF – V Current Limiting Differential Input Voltage VID Reference Input Voltage VREF Reference Clamp Voltage VREFC Reference Input Current2 Internal Reference Voltage Current Trip Point Error3 Fixed Off-Time Blank Time VID = VCSP – VCSM REF tied to VDD IREF VRI EITRIP Default power–up state VREF = 2 V –5% – +5% %FS tOFF Default power–up state 30.3 35.6 40.9 µs tBL Default power–up state 2.72 3.2 3.68 µs Logic Inputs and Outputs Input Low Voltage VIL Input High Voltage VIH Terminals PWM, SDI, SCK, STRN – – 0.3VDD V Terminal RESETN – – 0.25VDD V 0.7VDD – – V Terminals PWM, SDI, SCK, STRN 150 550 – mV Terminal RESETN 150 370 – mV Terminals PWM, SDI, SCK 30 50 70 kΩ Terminal RESETN 45 80 110 kΩ Input Hysteresis VIhys Input Pull-Down Resistor RPD Input Pull-Up Resistor RPU Terminal STRN 30 50 70 kΩ Output Low Voltage VOL IOL = 1 mA – 0.2 0.4 V VOH IOL = –1 mA VDD – 0.4 VDD – 0.2 – V –1 – 1 µA Output High Voltage2 Output Leakage (SDO)2 IO 0 V < VO < VDD, STRN = 1 Logic Inputs and Outputs – Dynamic Parameters RESETN Pulse Width tRES 0.2 – 4.5 µs RESETN Shutdown Width tRSD 10 – – µs Input Pulse Filter Time (PWM) tPIN – 35 – ns PWM Brake Time tBRK 500 – – µs Clock High Time tSCKH A in figure 1 50 – – ns Clock Low Time tSCKL B in figure 1 50 – – ns Strobe Lead Time tSTLD C in figure 1 30 – – ns Strobe Lag Time tSTLG D in figure 1 30 – – ns Strobe High Time tSTRH E in figure 1 300 – – ns Data Out Enable Time tSDOE F in figure 1 – – 40 ns Data Out Disable Time tSDOD G in figure 1 – – 30 ns Data Out Valid Time from Clock Falling tSDOV H in figure 1 – – 40 ns Data Out Hold Time from Clock Falling tSDOH I in figure 1 5 – – ns Continued on the next page… Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 7 A4960 Automotive, Sensorless BLDC Controller ELECTRICAL CHARACTERISTICS (continued) Valid at TJ = –40°C to 150°C, VDD = 5 V, VBB = 7 to 28 V; unless otherwise specified Characteristics Symbol Test Conditions Min. Typ. Max. Unit – – ns Logic I/O – Dynamic Parameters (continued) Data In Set-up Time to Clock Rising tSDIS J in figure 1 15 Data In Hold Time from Clock Rising tSDIH K in figure 1 10 – – ns tEN RESETN rising to undervoltage faults cleared – – 2 ms VHQ Default power–up level: IDS = 0 33.7 37.5 41.3 %VREF Hold Torque Duty Cycle DHQ Default power–up level: IDS = 1 33.7 37.5 41.3 % Hold Time tHOLD Default power–up level 28.9 34.0 39.1 ms Start Commutation Time tCOMS Default power–up level 34 40 46 ms End Commutation Time tCOME Default power–up level 2.72 3.20 3.68 ms Wake Up from Sleep Mode Motor Start-up Parameters Hold Torque Internal Reference Ramp Torque Internal Reference VRQ Default power–up level: IDS = 0 50.6 56.25 61.9 %VREF Ramp Torque Duty Cycle DRQ Default power–up level: IDS = 1 50.6 56.25 61.9 % ΔtCOM RR[3:0] = 1001 1.7 2.0 2.3 ms θADV Denominated in electrical degrees, PA[3:0] = 1000 12 15 18 deg Ramp Rate (Change in commutation time) Motor Run Parameters Phase Advance BEMF Hysteresis – High VBHYSH – 240 – mV BEMF Hysteresis – Low VBHYSL – 60 – mV BEMF Window Time tBW Default power–up level 5.4 6.4 7.4 µs Commutation Blank Time tCB Default power–up level 42.5 50 57.5 µs VREG rising 7.5 8 8.5 V VREGUVOFF VREG falling 6.6 7.1 7.6 V 58 – 71 %VREG – 13 – %VREG 2.45 2.7 2.85 V 50 100 150 mV Protection VREG Undervoltage Threshold Bootstrap Undervoltage Bootstrap Undervoltage Hysteresis VREGUVON VBOOTUV VBOOT falling, VCx – VSx VBOOTUVHys VDD Undervoltage Threshold VDDUV VDD Undervoltage Hysteresis VDDUVHys VDD falling Drain-Source Threshold Voltage VDSTH Default power–up level VBRG Input Voltage VBRG When VDS monitor is active VBRG Input Current IVBRG VDSTH = default, VBB = 12 V, 0 V < VBRG < VBB High side on, VDSTH ≥ 1 V Short-to-Ground Threshold Offset4 Short-to-Battery Threshold Offset5 VSTGO VSTBO 720 800 880 mV VBB – 1 VBB VBB + 1 V – – 250 µA – ±100 – mV High side on, VDSTH < 1 V –150 ±50 +150 mV Low side on, VDSTH ≥ 1 V – ±100 – mV –150 ±50 +150 mV Low side on, VDSTH < 1 V Continued on the next page… Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 8 A4960 Automotive, Sensorless BLDC Controller ELECTRICAL CHARACTERISTICS (continued) Valid at TJ = –40°C to 150°C, VDD = 5 V, VBB = 7 to 28 V; unless otherwise specified Characteristics Symbol Test Conditions Min. Typ. Max. Unit – – – Protection (continued) DIAG Output Clock Division Ratio ND DGx = 01 400 DIAG Output VDS Threshold Error EVTHD DGx = 10 –10 – 10 mV Temperature increasing 125 135 145 ºC Temperature Warning Threshold TJW Temperature Warning Hysteresis TJWHys – 15 – ºC Overtemperature Threshold TJF Temperature increasing 155 170 – ºC Overtemperature Hysteresis TJFHys Recovery = TJF – TJHys – 15 – ºC 1Function is correct but parameters are not guaranteed above or below the general limits (7 to 28 V). 2For input and output current specifications, negative current is defined as coming out of (sourcing) the specified device terminal. 3Current Trip Point Error is the difference between the actual current trip point and the target current trip point, referred to maximum full scale (100%) current: EITRIP = 100 × (ITRIP(Actual) – ITRIP(Target)) / IFullScale (%) . 4As V Sx decreases, a fault occurs if VBAT – VSx > VSTG . STG threshold, VSTG = VDTSTH + VSTGOFF . 5As V Sx increases, a fault occurs if VSx – VLSS > VSTB . STB threshold, VSTB = VDTSTH + VSTBOFF . Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 9 A4960 Automotive, Sensorless BLDC Controller Operation Timing Diagrams STRN C A B D E SCK J SDI K D15 X F SDO D14 X X D0 X X I G D15’ Z D14’ D0’ Z H X=don’t care, Z=high impedance (tri-state) Figure 1. Serial Interface Timing (letters A through K are referenced in the Electrical Characteristics table, Logic Inputs and Outputs – Dynamic Parameters section) PWM tP(off) tDEAD PWM tBRK GHx Run PWM Off Brake GLx tDEAD tP(off) Figure 2. Gate Drive Output Timing – PWM Input Figure 3. PWM Brake Timing PWM tP(off) GHx tDEAD HS VDS Monitor Action tBL Disabled Active Disabled tP(off) GLx tDEAD LS VDS Monitor Action Active tBL Active Disabled Figure 4. VDS Fault Blanking Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 10 A4960 Automotive, Sensorless BLDC Controller Phase TACHO Phase Internal or External PWM tBW tCB tCB TACHO Figure 5. Commutation Blank Time Phase Voltage BEMF ignored tBW BEMF monitored BEMF ignored BEMF monitored Figure 6. BEMF Window Phase Phase TACHO TACHO VBHYSL Normal Zero-Crossing with low hysteresis with high hysteresis with high hysteresis VBHYSH with low hysteresis Normal Zero-Crossing High hysteresis TACHO when Low hysteresis No hysteresis Figure 7. BEMF Hysteresis – Falling Phase Voltage VBHYSH VBHYSL High hysteresis TACHO when Low hysteresis No hysteresis Figure 8. BEMF Hysteresis – Rising Phase Voltage Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 11 A4960 Automotive, Sensorless BLDC Controller Functional Description The A4960 is a three-phase, sensorless, brushless DC (BLDC) motor controller for use with external N-channel power MOSFETs and is specifically designed for automotive applications. The motor is driven using block commutation (trapezoidal drive), where phase commutation is determined by a proprietary, motor back-EMF (BEMF) sensing technique. The motor BEMF is sensed to determine the rotor position without any requirement for independent position sensors. Motor current is provided by six external N-channel power MOSFETs arranged as a three-phase bridge. The A4960 provides six high current gate drives, three high-side and three low-side, capable of driving a wide range of MOSFETs. It includes all the necessary circuits to ensure that the gate-source voltage of both high-side and low-side MOSFETs are above 10 V at motor supply voltages down to 7 V. An integrated start-up scheme can be configured with programmable parameters through a serial interface allowing the A4960 to be adjusted for a wide range of motor and load combinations. The serial interface also provides the ability to program various gate drive and diagnostic parameters. Integrated diagnostics provide indication of undervoltage, overtemperature, and power bridge faults. They can be configured to protect the power MOSFETs under most short circuit conditions. Detailed diagnostic information is available through the serial interface. to provide the transient charging current. REF Voltage reference input to internal reference DAC. Connect to VDD to use the internal 2 V reference. GND Analog reference, digital and power ground. Connect to supply ground. VBRG Sense input to the top of the external MOSFET bridge. Allows accurate measurement of the voltage at the drain of the high-side MOSFETs. CA, CB, CC High-side connections for the bootstrap capacitors and positive supply for high-side gate drivers. GHA, GHB, GHC High-side, gate-drive outputs for external N-channel MOSFETs. SA, SB, SC Motor phase connections. These terminals sense the voltages switched across the load. They are also connected to the negative side of the bootstrap capacitors and are the negative supply connections for the floating high-side drivers. GLA, GLB, GLC Low-side, gate-drive outputs for external N-channel MOSFETs. LSS Low-side return path for discharge of the capacitance on the MOSFET gates, connected to the common sources of the lowside external MOSFETs through a low impedance track. Specific functions are described more fully in following sections. CSP, CSM Current sense amplifier inputs. Connect directly to each end of the sense resistor using separate PCB traces. Input and Output Terminal Functions PWM PWM input to control high-side switching. When pulsed VBB Main power supply for internal regulators and charge pump. The main power supply should be connected to VBB through a reverse voltage protection circuit and should be decoupled with ceramic capacitors connected close to the supply and ground terminals. VDD Logic supply. Compatible with 3.3 V and 5 V logic. This should be decoupled to ground with a 100 nF capacitor. CP1, CP2 Pump capacitor connections for charge pump. Connect a 220 nF ceramic capacitor between CP1 and CP2. VREG Regulated voltage, nominally 13 V, used to supply the low side gate drivers and to charge the bootstrap capacitors. A sufficiently large storage capacitor must be connected to this terminal low, this turns off any active high-side drivers and turns on the complementary low-side drivers. When held low for longer than the PWM brake time, this turns off all high-side drivers and turns on all low-side drivers, when RUN (bit 0 in the Run register) is set to 1. RESETN Resets faults when pulsed low. Forces low-power shutdown (sleep mode) when held low for more than the reset shutdown width, tRSD . Can be pulled to VBB with 22 kΩ resistor. SDI Serial data input. 16-bit serial word input, MSB first. SDO Serial data output. High impedance when STRN is high. Outputs FF (bit 15 of the Diagnostic register), the Fault flag, as soon as STRN goes low. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 12 A4960 Automotive, Sensorless BLDC Controller SCK Serial clock. Data is latched in from SDI on the rising edge of SCK. There must be 16 rising edges per write and SCK must be held high when STRN changes. STRN Serial data strobe and serial access enable. When STRN is high any activity on SCK or SDI is ignored, and SDO is high impedance allowing multiple SDI slaves to have common SDI, SCK, and SDO connections. DIAG Diagnostic output. Programmable output to provide four alternative functions: Fault output flag (default), Sensorless Operation Indicator, internal timer, and VDS threshold. TACHO Motor speed output. Provides a pulse signal with a frequency proportional to the motor speed. TACHO remains low until the first BEMF zero-crossing is detected. Motor Drive System The motor drive system consists of three half bridge gate drive outputs, each driving one leg of an external 3-phase MOSFET power bridge. The state of the gate drive outputs is determined by a state sequencer with six possible states. These states are shown in table 1 and change in a set sequence depending on the required direction of rotation. For the A4960, forward is defined as the state sequence shown in table 1, DIR (Run bit 1) set to 0, incrementing in steps of one from 1 to 6, then repeating from 1. Reverse (DIR set to 1) is decrementing in steps of one from 6 to 1, then repeating from 6. The effect of these states on the motor phase voltage is illustrated in figure 11. The point at which the state of the gate outputs changes is defined as the commutation point and must occur each time the magnetic poles of the rotor reach a specific point in relation to the poles of the stator. This point is determined by a complete self contained BEMF sensing scheme with an adaptive commutation timer. Rotor position sensing using motor BEMF Determining the rotor position using BEMF sensing relies on the accurate comparison of the voltage on the undriven (tri-state) motor phase (indicated by Z in table 1) to the voltage at the centertap of the motor, approximated using a reference voltage at half the supply voltage. The BEMF zero crossing, the point where the tri-stated motor winding voltage crosses the reference voltage, is used as a positional reference. When the motor is running at a constant speed, this zero crossing occurs approximately halfway through one commutation cycle. Adaptive commutation circuitry and programmable timers then determine the optimal commutation points. Zero crossings are indicated by the output at the TACHO terminal, which goes high at each valid zero crossing and low at the next commutation point, as shown in figure 9. In each state, the BEMF detector looks for the first correct polarity (low-to-high State 1 2 3 4 5 6 1 2 3 4 5 6 SA SB SC TACHO Figure 9. Motor phase state sequence, DIR = 0 Table 1. Control and Phase Sequence Table Control Bits RUN BRK 1 0 DIR = 1 DIR = 0 State 1 Motor Phase Gate Drive Outputs SA SB SC GHA GLA GHB GLB GHC GLC HI Z LO HI LO LO LO LO HI 1 0 2 Z HI LO LO LO HI LO LO HI 1 0 3 LO HI Z LO HI HI LO LO LO 1 0 4 LO Z HI LO HI LO LO HI LO 1 0 5 Z LO HI LO LO LO HI HI LO Mode Run 1 0 6 HI LO Z HI LO LO HI LO LO 0 x x x x Z Z Z LO LO LO LO LO LO Coast 1 1 x x x LO LO LO LO HI LO HI LO HI Brake x: don’t care; HI: high-side MOSFET active; LO: low-side MOSFET active; Z: high impedance, both MOSFETs off Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 13 A4960 Automotive, Sensorless BLDC Controller or high-to-low) zero crossing and latches it until the next state change. This latching action, combined with precise comparator hysteresis, provides a robust sensing system. There are three variables that effect the BEMF sensing, these are: •Commutation Blank Time, tCB •BEMF Hysteresis, VBHYS •BEMF Window, tBW Commutation Blank Time The BEMF detectors are inhibited for tCB following a commutation event. This prevents any commutation transients and winding demagnetization periods from disturbing the BEMF sensing system. The commutation blank time is shown in figure 5 and is selected by CB[1:0] (Config0 bits 11:10 ). BEMF Window The BEMF window is the length of time after any PWM change, low-to-high or high-to-low, during which the phase voltage and the output of the BEMF comparator is ignored, as shown in figure 6. It is selected using BW[2:0] (Run bits 9:7). The BEMF window is effectively the BEMF comparator blank time. If the PWM-on time is less than the BEMF window, then the phase voltage is ignored for the whole PWM-on time. If the PWM-off time is less than the BEMF window, then the phase voltage is ignored for the whole PWM-off time. BEMF Hysteresis The BEMF hysteresis is the amount by which the BEMF voltage, measured on the undriven phase, must exceed the normal zerocrossing value before zero crossing is detected and TACHO goes high. This is illustrated in figures 7 and 8. If the BEMF is falling, then the zero crossing will be detected when the BEMF voltage is lower than the normal zero-crossing value minus the BEMF hysteresis (figure 7). If the BEMF is rising, then the zero crossing will be detected when the BEMF voltage is higher than the normal zero-crossing value plus BEMF hysteresis (figure 8). The BEMF hysteresis is selected using BH[1:0] (Run bits 11:10). It can be set to zero, low (typically 60 mV), high (typically 240 mV) or Auto. Auto sets the hysteresis to the high level during start-up and reduces it to the low level during running. This provides added security during start-up in achieving a stable BEMF detection but permits the motor to run slower or at a lower voltage when BEMF detection is achieved. Start-up In order to correctly detect the zero crossing, the changing motor BEMF on any phase must be detectable when that phase is not being driven. When the motor is running at a relatively constant speed, this is ensured by the adaptive commutation scheme used. However, during start-up, particularly when the motor load has a high friction component, the motor must be accelerated from rest in such a way that the BEMF zero crossing can be detected. Initially, as the motor is started, there is no rotor position information from the BEMF sensor circuits and the motor must be driven in an open loop 3-phase stepper mode. Unlike a true stepper motor, which is designed for open loop operation, most 3-phase BLDC motors are unstable when driven in this way and will overshoot the intended step point by a large margin. To overcome this limitation the motor must be accelerated such that the motor movement and the phase step sequence can synchronize to allow correct BEMF zero crossing detection. The initial start speed, the acceleration rate, and the accelerating torque must be adjusted for each combination of motor and mechanical load. These parameters can be programmed in the A4960 through the serial interface. Configuration registers Config4 and Config5 provide the following programmable parameters: • Config4 bits SC[3:0] – set the start of ramp speed • Config4 bits EC[3:0] – set the end of ramp speed • Config5 bits RR[3:0] – set the ramp rate • Config5 bits RQ[3:0] – set the acceleration torque To ensure that the motor start-up and sensorless BEMF capture is consistent, the start sequencer always forces the motor to a known start position. The time during which the motor is forced into the start position can be programmed through the serial interface using the four hold time bits, HT[3:0] (Config3 bits 3:0). The torque applied during this hold time is programmed using the four hold torque bits, HQ[3:0], (Config3 bits 7:4). These two variables allow a stable start condition to be achieved for different motor and attached mechanical loads. As soon as a valid BEMF zero crossing is detected during the start sequence, the A4960 will transition to full BEMF commutation and the start sequencer will be reset. The TACHO output Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 14 A4960 Automotive, Sensorless BLDC Controller will remain low until the first BEMF zero crossing is detected. TACHO will then go high at each BEMF zero crossing and will go low at each commutation point. Sensorless operation is also indicated by a zero in LOS (Diagnostic bit 9), and by a high level when the Sensorless Operation Indicator option is selected on the DIAG pin output. If sensorless operation cannot be achieved by the end of the acceleration ramp, then the sequencer will reset and retry if RSC (Run bit 3) is set to 1. This will continue until stopped by pulling PWM or RESETN low, or by control via the serial interface. If RSC is set to 0, then the retry will not take place, and the outputs will remain off and the LOS bit will be set. Motor control The running state, direction, and speed of the motor are controlled by a combination of commands through the serial interface and by signals on specific terminals (see Applications Information section). The serial interface provides three control bits: RUN, DIR, and BRK (Run bits 2:0). When RUN is set to 1, the A4960 is allowed to run the motor or to commence the start-up sequence. When RUN is set to 0 all gate drive outputs go low, no commutation takes place, and the motor is allowed to coast. Setting RUN to 0 overrides all other control inputs. The DIR bit determines the direction of rotation. Forward is defined as the state sequence shown in table 1, DIR (Run bit 1) set to 0, incrementing in steps of one from 1 to 6, then repeating from 1. Reverse (DIR set to 1) is decrementing in steps of one from 6 to 1, then repeating from 6. The BRK bit can be set to apply an electrodynamic brake which will decelerate a rotating motor. It also can provide some holding torque for a stationary motor. When RUN and BRK are both set to 1, all low-side MOSFETs will be turned on and all high-side MOSFETs turned off, effectively applying a short between the motor windings. This allows the reverse voltage generated by the rotation of the motor (motor BEMF) to set up a current in the motor phase windings that will produce a braking torque. This braking torque will always oppose the direction of rotation of the motor. The strength of the braking or holding torque will depend on the motor parameters. No commutation takes place during braking and no current control is available. Care must be taken to ensure that the braking current does not exceed the capability of the low-side MOSFETs. When RUN is set to 1, automatically LOS (Diagnostic bit 9) is set to 1 and the Sensorless Operation Indicator option on the DIAG pin output, if selected, is set low until sensorless operation is achieved. When RUN is set to 0, or BRK is set to 1, the LOS bit and the Sensorless Operation Indicator are inactive (LOS set to 0 and DIAG set high). When the motor is running, the motor speed can be varied by applying a variable duty cycle input to the PWM terminal. The motor speed will be proportional to the duty cycle of this signal but will also vary with the mechanical load and the supply voltage. Precise speed control requires an external control loop which can use the PWM input to vary the motor speed within the overall closed loop speed controller. The motor speed can be determined by monitoring the TACHO output. When the A4960 is running with sensorless commutation, the TACHO output provides a square wave output with a frequency proportional to the motor speed. The PWM input can be driven from 3.3 V or 5 V logic, and has hysteresis and a filter to improve noise performance. When pulsed low, any active high-side drivers will be turned off and the complementary low-side drivers will be turned on. This provides high-side chopped, slow-decay PWM with synchronous rectification. Holding the PWM input low for longer than the PWM brake time, tBRK , will force a brake condition in the same way as the BRK bit in the Run register. The brake will only be active when RUN is set to 1. Except for the PWM brake function, the PWM input will be ignored during start-up, until sensorless commutation is achieved. It also will also be ignored when BRK is set to 1. Phase advance In some motor control systems, improved motor performance can be achieved by starting to energize the phase windings in advance of the timing defined by the rotor position. This ensures that the phase windings have reached the required current level at the point where the resulting forward torque on the rotor will be most Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 15 A4960 Automotive, Sensorless BLDC Controller effective. It also ensures that the current in the phase windings will start to decay in time to ensure that the torque produced by the decaying phase current will not cause any rotor drag. If correctly set up, phase advance can result in greater motor efficiency. In motors that use Hall sensors or rotary decoders this can be achieved by a mechanical offset in the sensor position. However this is only valid for one direction of rotation. The A4960 overcomes this mechanical limitation by providing a programmable electronic method of setting the phase advance in either direction of rotation. The PA[3:0] (Config5 bits 11:8 ) setting provides phase advance in electrical commutation angle from 0° to 28° in steps of 1.9°. This is equivalent to a phase advance up to almost half of the commutation period on any one phase. The phase advance is automatically always in relation to the motor direction. There is no need to change the value with a direction change. Power Supplies Two power supply voltages are required, one for the logic interface and control, and another one for the analog and output drive sections. The logic supply, connected to VDD, is a 5 V nominal supply, but the TTL threshold logic inputs allow the inputs to be driven from a 3.3 V or 5 V logic interface. The normal operating voltage range of the A4960, where the electrical parameters are fully defined, is 7 to 28 V. However, it is designed to function correctly up to 50 V during load dump conditions, and will maintain full operation down to 6 V. Below 7 V and above 28 V some parameters may exceed the limits specified for the normal supply voltage range. The A4960 will function correctly with a VBB supply down to 5.5 V. However, full sensorless start-up and commutation may not be possible. This provides a very rugged solution for use in the harsh automotive environment. The main power supply should be connected to VBB through a reverse voltage protection circuit. Both supplies should be decoupled with ceramic capacitors connected close to the supply and ground terminals. Gate Drives The A4960 is designed to drive external, low on-resistance, power N-channel MOSFETs. It supplies the large transient currents necessary to quickly charge and discharge the external MOSFET gate capacitance in order to reduce dissipation in the MOSFET during switching. The charge current for the high-side drives is provided by the bootstrap capacitors connected between the Cx and Sx terminals, one for each phase. The charge and discharge rate can be controlled using an external resistor in series with the connection to the gate of the MOSFET. Gate drive voltage regulation The gate drives are powered by an internal regulator which limits the supply to the drives and therefore the maximum gate voltage. When the VBB supply is greater than approximately 16 V, the regulator is a simple linear regulator. Below 16 V, the regulated supply is maintained by a charge pump boost converter, which requires a pump capacitor connected between the CP1 and CP2 pins. This capacitor must have a minimum value of 220 nF, and is typically 470 nF. The regulated voltage, nominally 13 V, is available on the VREG pin. A sufficiently large storage capacitor must be connected to this pin to provide the transient charging current to the low-side drives and the bootstrap capacitors. Bootstrap charge management The A4960 monitors the individual bootstrap capacitor charge voltages to ensure sufficient high-side drive. Before a high-side drive can be turned on, the bootstrap capacitor voltage must be higher than the turn-on voltage limit. If this is not the case, then the A4960 will attempt to charge the bootstrap capacitor by activating the complementary low-side drive. Under normal circumstances this will charge the capacitor above the turn-on voltage in a few microseconds and the high-side drive will then be enabled. The bootstrap voltage monitor remains active while the high-side drive is active, and if the voltage drops below the turn-off voltage, a charge cycle is initiated also. The bootstrap charge management circuit may actively charge the bootstrap capacitor regularly when the PWM duty cycle is very high, particularly when the PWM off-time is too short to permit the bootstrap capacitor to become sufficiently charged. If, for any reason, the bootstrap capacitor cannot be sufficiently charged a bootstrap fault will occur. See the Diagnostics section for further details. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 16 A4960 Automotive, Sensorless BLDC Controller Low-side gate drive The low-side gate drive outputs GLA, GLB, and GLC are referenced to the LSS terminal. These outputs are designed to drive external N-channel power MOSFETs. External resistors between each gate drive output and the gate connection to the respective MOSFET (as close as possible to the MOSFET) can be used to control the slew rate seen at the gate, thereby providing some control of the di/dt and dv/dt of the voltage at the SA, SB, and SC terminals. When GLx is set high, the upper half of the driver is turned on and the drain sources current to the gate of the respective low-side MOSFET in the external power bridge, turning on the MOSFET. When GLx is set low, the lower half of the driver is turned on and the drain sinks current from the external MOSFET gate circuit to the LSS terminal, turning off the MOSFET. LSS is the low-side return path for discharge of the capacitance on the MOSFET gates. It should be connected to the common sources of the low-side external MOSFETs through a low-impedance circuit board trace. across the load. They are also connected to the negative side of the bootstrap capacitors and are the negative supply connections for the floating high-side drives. The discharge current from the high-side MOSFET gate capacitance flows through these connections which should have low impedance circuit board traces to the MOSFET bridge. These terminals also provide the phase voltage feedback to used to determine the rotor position. Dead Time To prevent cross conduction (shoot through) in any phase of the power MOSFET bridge, it is necessary to have a dead-time delay between a high- or low-side turn-off and the next complementary turn-on event. The potential for cross conduction occurs when any complementary high-side and low-side pair of MOSFETs are switched at the same time, for example, at the PWM switchpoints. In the A4960, the dead time for all three phases is set by the contents of DT[5:0] (Config0 bits 5:0 ). These six bits contain a positive integer that determines the dead time by division from the system clock. High-side gate drive The high-side gate drive outputs GHA, GHB and GHC are referenced to the SA, SB, and SC pins respectively. These outputs are designed to drive external N-channel power MOSFETs. External resistors between each gate drive output and the gate connection to the respective MOSFET (as close as possible to the MOSFET) can be used to control the slew rate seen at the gate, thereby controlling the di/dt and dv/dt of the voltage at the SA, SB, and SC terminals. When GHx is set high, the upper half of the driver is turned on and the drain sources current to the gate of the respective high-side MOSFET in the external motor-driving bridge, turning on the MOSFET. When GHx is set low, the lower half of the driver is turned on and the drain sinks current from the external MOSFET gate circuit to the respective Sx terminal, turning off the MOSFET. The accuracy of tDEAD is determined by the accuracy of the system clock, as defined in the Electrical Characteristics table, tOSC . A DT[5:0] value of 000000, 000001, or 000010 (0, 1, or 2 in decimal) sets the minimum programmable tDEAD of 100 ns. The CA, CB, and CC pins are the positive supplies for the floating high-side gate drives. The bootstrap capacitors are connected between the Cx and Sx terminals of the same phase. The bootstrap capacitors are charged to approximately VREG when the associated output Sx terminal is low. When the Sx output swings high, the charge on the bootstrap capacitor causes the voltage at the corresponding Cx terminal to rise with the output to provide the boosted gate voltage needed for the high-side MOSFETs. Sleep Mode and RESETN RESETN is an active-low input which allows the A4960 to enter sleep mode, in which the current consumption from the VBB and VDD supplies is reduced to its minimum level. When RESETN is held low for longer than the reset pulse time, tRES , the internal pump regulator and all internal circuitry is disabled and the A4960 enters sleep mode. In sleep mode the latched faults and corresponding fault flags are cleared. The SA, SB, and SC terminals are connected directly to the motor phase connections. These terminals sense the voltages switched When coming out of sleep mode, the protection logic ensures that the gate drive outputs are off until the charge pump reaches The dead time is defined as: tDEAD = n × 50 ns (1) where n is a positive integer defined by DT[5:0] and tDEAD has a minimum programmable value of 100 ns. For example, when DT[5:0] contains 011000 (24 in decimal), then tDEAD = 1.2 µs (typical). Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 17 A4960 Automotive, Sensorless BLDC Controller its correct operating condition. The charge pump will stabilize in approximately 3 ms under typical conditions. To allow the A4960 to start-up without requiring external logic input, the RESETN terminal can be pulled to VBB with an external pull-up resistor. The resistor value should be between 20 and 33 kΩ. RESETN can also be used to clear any fault conditions without entering sleep mode by taking it low for the reset pulse time, tRES . Latched short fault conditions, which disable the outputs, will be cleared as will the serial fault register. Current Limit An integrated fixed off-time PWM current control circuit is provided to limit the motor current during periods when the torque demand exceeds the normal operating range. It is also available at start-up to set the hold torque and the ramp torque if IDS (Config3 bit 8) is set to 0. The fixed off-time is programmable through the serial interface and the current limit is set by an external sense resistor and a programmable reference voltage derived from the voltage at the REF input. During normal running, the internal current control can be used in conjunction with any external PWM control on the PWM input by ensuring that the programmable off-time of the internal control circuit is longer than the maximum off-time of the external PWM signal. During the start-up sequence, the PWM input is ignored, unless it is held low in the brake condition. If IDS is set to 0, the current limit circuit provides full control over the hold torque and acceleration torque. Current sense amplifier A differential sense amplifier with a gain of 10 is provided to allow the use of low-value sense resistors or a current shunt as the current sensing element. The output of the sense amplifier is compared to an internally generated reference voltage, VRI , the value of which is programmed through the serial interface as a ratio of the voltage, VREF , at the reference input terminal, REF. When the REF terminal is connected to VDD, VREF is then limited to the reference clamp voltage, VREFC . VRI = [(n + 1) × 6.25%] × VREF For example, when VR[3:0] contains 1100 (12 in decimal), then VRI = 81.25%VREF . VRI is generated by a digital-to-analog converter (DAC) with VREF as the reference input to the DAC. VRI will therefore scale directly with VREF . With the PWM input high, or during start-up when PWM is ignored, when the outputs of the MOSFETs are turned on, current increases in the motor winding until it reaches a value given by approximately: ITRIP ≈ VRI AV × RSENSE where (3) VRI is defined as above, AV is the gain of the sense amplifier, typically 10, and RSENSE is the value of the sense resistor. At the trip point, the sense comparator switches off any active high-side MOSFETs and switches on the complementary lowside MOSFETs. This makes the bridge switch from a drive configuration, where the current is forced to increase, into a recirculation configuration, where the motor inductance causes the current to recirculate for a fixed duration defined as the off-time. During this off-time the current will decay at a rate defined by the motor inductance and the impedance of the MOSFET bridge. This is classic slow decay PWM current control. Fixed off-time The duration of the fixed off-time is set by the contents of PT[4:0] (Config2 bits 4:0). These five bits contain a positive integer that determines the off-time derived by division from the system clock. The off-time is defined as: tOFF = 10 µs + (n × 1.6 µs) (4) where n is a positive integer defined by PT[4:0]. VRI can have a value between 6.25%VREF and 100%VREF defined as: where n is a positive integer defined by VR[3:0] (Config1 bits 9:6). (2) For example, when PT[4:0] contains 11010 (26 in decimal), then tOFF = 51.6 µs typically. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 18 A4960 Automotive, Sensorless BLDC Controller The accuracy of tOFF is determined by the accuracy of the system clock, tOSC , as defined in the Electrical Characteristics table. A value of 00000 in PT[4:0] sets the minimum off-time of 10 µs. Blank time When the bridge is switched into the drive configuration, a current spike occurs due to the reverse-recovery currents of the clamp diodes and switching transients related to distributed capacitance in the load. To prevent this current spike from being detected as a current limit trip, the current-control comparator output is blanked for a short period of time when the source driver is turned on. The length of the blanking time is set by the contents of BT[3:0] (Config0 bits 9:6). These four bits contain a positive integer that determines the blank time derived by division from the system clock. The blank time is defined as: tBL = n × 400 ns (5) where n is a positive integer defined by BT[3:0]. For example, when BT[3:0] contains 1011 (11 in decimal), then tBL = 4.4 µs typically. The accuracy of tBL is determined by the accuracy of the system clock, tOSC , as defined in the Electrical Characteristics table. The blank time is also used with the MOSFET drain-source monitors, which are used to determine MOSFET short faults. The blank time is used in these circuits, as shown in figure 4, to mask the effect of any voltage or current transients caused by any PWM switching action. The user must ensure that blank time is long enough to mask any current transient seen by the internal sense amplifier and mask any voltage transients seen by the drain-source monitors. Diagnostics Several diagnostic features are integrated into the A4960 to provide indication of fault conditions. In addition to system-wide faults such as undervoltage and overtemperature, the A4960 integrates individual drain-source monitors for each external MOSFET, to provide short circuit detection. The fault status is available from two sources, the DIAG output terminal and the serial interface. DIAG pin The DIAG terminal is a diagnostic output that can be programmed through the serial interface DG[1:0](Run bits 5:4) to provide any one of four alternative dedicated diagnostic signals: •the general fault output flag •the Sensorless Operation Indicator •the programmed VDS threshold voltage •a clock signal derived from the internal chip clock After a power-on reset the DIAG output defaults to the fault output flag. The general logic-level fault output flag outputs a low on the DIAG pin to indicate a fault is present. This fault output flag remains low while an unlatched fault is present or if one of the latched faults has been detected and the outputs are disabled. (Note there also is a common Fault flag, described in the Serial fault output section.) The Sensorless Operation Indicator is a logic level signal that is set high when the A4960 has achieved sensorless commutation. The Sensorless Operation Indicator is set low before sensorless operation is achieved at start-up, or if sensorless operation is lost while the motor should be operating. This indicator is held high even when the motor is stopped, by setting RUN (Run bit 0) to 0 or BRK (Run bit 2) to 1. The VDS threshold output provides access to the internal threshold voltage to allow more precise calibration of the MOSFET fault monitor threshold if required. The clock output provides a logic-level square wave output to allow more precise calibration of the timing settings if required. Serial interface fault output The serial interface allows detailed diagnostic information to be read from the Diagnostic register at any time. The first bit (bit 15) of the Diagnostic register contains the common Fault flag, FF, which is set high when any of the fault bits in the Diagnostic register have been set. This allows fault conditions to be detected using the serial interface by simply taking STRN low. As soon as STRN goes low the fist bit in the Diagnostic register can be read to determine if a fault has been detected at any time since the last Diagnostic register reset. In all cases the fault bits in the Diagnostic register are latched and only cleared after a Diagnostic register reset (see Diagnostic Register section on serial access). Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 19 A4960 Automotive, Sensorless BLDC Controller Note that FF does not provide the same function as the general fault output flag output on the DIAG pin (described above). The fault output on the DIAG pin provides an indication that certain types of faults are present and in some cases that the outputs have been disabled. FF provides an indication that certain types of faults have occurred since the last Diagnostic register reset and the respective fault bit has been set. Fault response action For certain fault conditions, the response of the A4960 is determined by the state of the Enable Stop on Fault bit, ESF (Run bit 6), as shown in table 2. When a short fault or overtemperature condition is detected, if ESF is set to 1 the A4960 disables all the gate drive outputs and coasts the motor. For short faults, this disabled state will be latched until RESETN goes low, a serial interface read is completed, or a power-on reset occurs. For undervoltage fault conditions, the outputs will always be disabled, regardless of the ESF bit setting. When ESF is set to 0, although the general fault output flag (DIAG pin) is still activated (low), the A4960 will not disrupt normal operation under most conditions, and will therefore not protect the motor or the drive circuit from damage. It is imperative that the application master control circuit or other external circuit takes any necessary action when a fault occurs, to prevent damage to components. Fault Mask register Certain individual diagnostics can be disabled by setting the corresponding bit in the Mask register. If a bit is set to 1 in the Mask Table 2: Fault Response Actions Fault Description Disable Outputs ESF = 0 No fault ESF = 1 Fault Latched No No n.a. VDD Undervoltage Yes* Yes* No VREG Undervoltage Yes* Yes* No Bootstrap Undervoltage Yes* Yes* Yes No No No No Temperature Warning Overtemperature No Yes* Short to Ground No Yes* Short to Supply No Yes* Shorted Load No Yes* * All gate drives low, all MOSFETs off Only when ESF = 1 register, then the corresponding diagnostic will be completely disabled. No fault states for the disabled diagnostic will be generated and neither the general fault output flag (DIAG pin) nor bits in the Diagnostic register will be set. The VDD Undervoltage and VREG Undervoltage faults cannot be masked. VDD undervoltage detection cannot be disabled because the diagnostics and the output control depend on VDD to operate correctly. VREG undervoltage detection cannot be disabled because it is safe to turn on the gate drive outputs only when VREG is at a sufficiently high voltage. Note: Care must be taken when diagnostics are disabled to avoid potentially damaging conditions. Chip-level diagnostics Parameters critical for safe operation of the A4960 and the external MOSFETs are monitored. These include: maximum chip temperature, minimum logic supply voltage, and the various minimum voltages required to drive the external MOSFETs (VREG and each of the bootstrap voltages). Note that the main supply voltage, VBB , is not monitored for minimum voltage. This is because the critical minimum voltages are generated by the charge pumps internal to the A4960. When a fault is present, the general fault output flag (DIAG pin) will be active (low). Chip Fault States: Temperature Thresholds Two temperature threshold actions are provided: a high temperature warning and an overtemperature shutdown. • If the chip temperature rises above the Temperature Warning Threshold, TJW , the general fault output flag (DIAG pin) goes low and the High Temperature Warning bit, TW (Diagnostic bit 11) and the common Fault flag bit, FF (bit 15), are set to 1. No other action is taken by the A4960. When the temperature drops below TJW by more than the hysteresis value, TJWHys , the general fault output flag (DIAG pin) goes high, but TW and FF remain set in the Diagnostic register until a register reset. • If the chip temperature rises above the Overtemperature Threshold, TJF , the general fault output flag (DIAG pin) goes low and the overtemperature bit, TS (Diagnostic bit 10) and the common Fault flag bit, FF (bit 15), are set to 1. When ESF (Run bit 6) is set to 1, if an overtemperature is detected, all gate drive outputs will be disabled automatically. If an overtemperature condition occurs when ESF is set to 0, then no circuitry will be disabled and action must be taken by the user to limit the power dissipa- Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 20 A4960 Automotive, Sensorless BLDC Controller tion in some way, so as to prevent overtemperature damage to the chip and unpredictable device operation. When the temperature drops below TJF by more than the hysteresis value, TJFHys , the general fault output flag (DIAG pin) goes high, but the overtemperature bit, TS, and FF remain set in the Diagnostic register until cleared. Chip Fault State : VREG Undervoltage The internal charge-pump regulator supplies the low-side gate driver and the bootstrap charge current. Before enabling any of the outputs, it is critical to ensure that the regulated voltage, VREG , at the VREG terminal is sufficiently high. If VREG goes below the VREG Undervoltage Threshold, VREGUVOFF , the general fault output flag (DIAG pin) goes low and the VREG undervoltage bit, VR (Diagnostic bit 13) and the common Fault flag bit, FF (bit 15), are set to 1. All gate drive outputs go low, the motor drive is disabled, and the motor coasts. When VREG rises above VREGUVON, the gate drive outputs are reenabled and the general fault output flag (DIAG pin) goes high. The fault bit, VR, and FF remain set in the Diagnostic register until cleared. The VREG undervoltage monitor circuit is active during powerup. The general fault output flag (DIAG pin) is low and all gate drives will be low until VREG is greater than approximately 8 V. Note that this is sufficient to turn on standard-threshold, external power MOSFETs at a battery voltage as low as 5.5 V, but the on-resistance of the MOSFET may be higher than its specified maximum. Chip Fault State: VDD Undervoltage The logic supply voltage, VDD , at the VDD terminal is monitored to ensure correct logical operation. If VDD drops below the VDD Undervoltage Threshold, VDDUV , then the logical function of the A4960 cannot be guaranteed and the outputs will be immediately disabled. The A4960 will enter a power-down state and all internal activity, other than the VDD voltage monitor, will be suspended. When VDD rises above the rising undervoltage threshold, VDDUV + VDDUVHys , the A4960 will perform a power-on reset. All serial control registers will be reset to their power-on state, all fault conditions and fault-specific bits in the Diagnostic register will be reset, and the general fault output flag (DIAG pin) will go high. The FF bit and the POR bit (Diagnostic bits 15 and 14) will be set to 1 to indicate that a power-on reset has taken place. The same power-on reset sequence occurs for initial power-on, and also for a VDD “brown-out,” where VDD drops below VDDUV only momentarily. Bootstrap Undervoltage Fault State In addition to a monitor on VREG , the A4960 also monitors the individual bootstrap capacitor charge voltages to ensure sufficient high-side drive. Before a high-side drive can be turned on, the bootstrap capacitor voltage must be higher than the turn-on voltage limit, VBOOTUV + VBOOTUVHys . If this is not the case, then the A4960 will attempt to charge the bootstrap capacitor by activating the complementary low-side drive. Under normal circumstances this will charge the capacitor above the turn-on voltage in a few microseconds and the high-side drive will then be enabled. The bootstrap voltage monitor remains active while the highside drive is active, and if the voltage drops below the turn-off voltage, VBOOTUV , a charge cycle is also initiated. In either case, if there is a fault that prevents the bootstrap capacitor charging, then the charge cycle will time out, the general fault output flag (DIAG pin) will go low, and the outputs will be disabled. The appropriate bit (VA, VB, or VC, according to the phase) in the Diagnostic register will be set to allow the faulty bootstrap capacitor to be determined by reading the serial data word from the Diagnostic register. The bootstrap undervoltage fault state will be latched until RESETN is set low, a serial interface read is completed, or a power-on reset occurs due to a VDD undervoltage on the logic supply. MOSFET fault detection Faults on external MOSFETs are determined by measuring the drain-source voltage of the MOSFET and comparing it to the Drain-Source Threshold Voltage, VDSTH , defined by VT[5:0] (Config1 bits 5:0). These bits provide the input to a 6-bit DAC with a least significant bit value of typically 25 mV. The output of the DAC produces VDSTH , defined as approximately: VDSTH ≈ n × 25 mV (6) where n is a positive integer defined by VT[5:0]. For example, when VT[5:0] contains 101000 (40 in decimal), then VDSTH = 1 V typically. The accuracy of VDSTH is defined in the Electrical Characteristics table. The low-side drain-source voltage for any MOSFET is measured between the LSS terminal and the appropriate Sx terminal. Using the LSS terminal rather than the ground connection avoids adding any low-side current sense voltage to the real low-side drain-source voltage. The high-side drain-source voltage for any MOSFET is measured between the VBRG terminal and the appropriate Sx terminal. Using the VBRG terminal rather than the Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 21 A4960 Automotive, Sensorless BLDC Controller bridge supply avoids adding any high-side current sense voltage to the real high-side drain-source voltage. The VBRG terminal is a low-current sense input to the top of the external MOSFET bridge. It should be connected directly to the common connection point for the drains of the power bridge MOSFETs at the positive supply connection point. The input current to the VBRG terminal is proportional to the drain-source threshold voltage, VDSTH , and is approximately: IVBRG = 72 × VVBRG + 52 (7) where IVBRG is the current into the VBRG terminal in µA and VDSTH is the Drain-Source Threshold Voltage, described above. Note that the VBRG terminal can withstand a negative voltage as great as –5 V. This allows the terminal to remain connected directly to the top of the power bridge during negative transients where the body diodes of the power MOSFETs are used to clamp the negative transient. The same applies to the more extreme case where the MOSFET body diodes are used to clamp a reverse battery connection. MOSFET fault blank time To avoid false MOSFET fault detection during switching transients the VDS-to-VDSTH comparison is delayed, following a MOSFET turn-on, by the internal blank timer. This is the same blank time as used for current sensing phase voltage monitoring. The length of the blanking time is set by the contents of BT[3:0] (Config0 bits 9:6 ). These four bits contain a positive integer that determines the blank time derived by division from the system clock. The blank time is defined as in equation 5: tBL = n × 400 ns where n is a positive integer defined by BT[3:0]. For example, when BT[3:0] contains 1001 (9 in decimal), then tBL = 3.6 µs typically. The accuracy of tBL is determined by the accuracy of the system clock, tOSC , as defined in the Electrical Characteristics table. Short fault operation Power MOSFETs take a finite time to reach the rated on-resistance, so the measured drain-source voltages may show a fault as the phase switches. To overcome this and avoid false short fault detection, the voltages are not sampled until a blank time elapses after the external MOSFET is turned on. If the drain-source voltage remains above the threshold after the blank time, then a short fault will be detected. If ESF (Run bit 6) is set to 1 this fault will be latched and the MOSFET disabled until there is an A4960 Diagnostic register reset. If a short circuit fault occurs when ESF is set to 0, then the external MOSFETs are not disabled by the A4960. To limit any damage to the external MOSFETs or the motor, the A4960 should either be fully disabled by the RESETN input or all MOSFETs switched off by setting RUN (bit 0 in the Run register) to 0, through a serial interface write. Alternatively, setting the ESF bit to 1will allow the A4960 to disable the MOSFETs as soon as a fault is detected. MOSFET Fault State: Short to Supply A short from any of the motor phase connections to the battery or VBB connection is detected by monitoring the voltage across the low-side MOSFETs in each phase using the respective Sx terminal and the LSS terminal. This drain-source voltage is then compared to the Drain-Source Threshold Voltage, VDSTH , after a blank time. While the drain source voltage exceeds VDSTH , the general fault output flag (DIAG pin) will be low and, when ESF is set to 1, it will be latched low and the outputs will be disabled. MOSFET Fault State: Short to Ground A short from any of the motor phase connections to ground is detected by monitoring the voltage across the high-side MOSFETs in each phase using the respective Sx terminal and the voltage at VBRG. This drain-source voltage is then compared to the Drain-Source Threshold Voltage, VDSTH , after a blank time. While the drain source voltage exceeds VDSTH the general fault output flag on the DIAG pin will be low and, when ESF is set to 1, it will be latched low and the outputs will be disabled. Note: The distinction between short to ground and short to supply can only be made by examining the serial Diagnostic register. The general fault output flag (DIAG pin) simply indicates the presence of a probable short circuit. MOSFET Fault State: Shorted Winding The short to ground and short to supply detection circuits will also detect a short across a motor phase winding. In most cases a shorted winding will be indicated by a high-side and low-side fault latched at the same time in the Diagnostic register. In some cases the relative impedances may only permit one of the shorts to be detected. In any case when a short of any type is detected the general fault output flag (DIAG pin) will go low and, when ESF is set to 1, it will be latched low and the outputs will be disabled. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 22 A4960 Automotive, Sensorless BLDC Controller Serial Interface Description SCK, and SDO connections. Each slave then requires an independent STRN connection. A three wire synchronous serial interface, compatible with SPI, is used to control the features of the A4960. A fourth wire can be used to provide diagnostic feedback and read back of register contents. When 16 data bits have been clocked into the shift register, STRN must be taken high to latch the data into the selected register. When this occurs, the internal control circuits act on the new data and the Diagnostic register is reset. The A4960 can be started only by using the serial interface to set the RUN bit (Run bit 0) to 1. Application specific settings are configured by setting the appropriate register bits through the serial interface. If there are more than 16 rising edges on SCK, or if STRN goes high and there are fewer than 16 rising edges on SCK, the write will be cancelled without writing data to the registers. In addition the Diagnostic register will not be reset and the FF bit (Diagnotic bit 15) will be set to 1 to indicate a data transfer error. The serial interface timing requirements are specified in the Electrical Characteristics table, and illustrated in figure 1. Data is received on the SDI terminal and clocked through a shift register on the rising edge of the clock signal input on the SCK terminal. STRN is normally held high, and is brought low only to initiate a serial transfer. No data is clocked through the shift register when STRN is high, allowing multiple slave units to use common SDI, Diagnostic information or the contents of the configuration and control registers is output on the SDO terminal, MSB first, while STRN is low. The output stream changes to the next bit on each falling edge of SCK. The first bit, which is always the FF bit, is output as soon as STRN goes low. Table 3. Serial Registers Definition Config 0 (Blank,Dead) Config 1 (VREF,VDSTH) Config 2 (PWM) 15 14 13 12 0 0 0 WR 0 0 0 1 1 0 11 10 9 8 7 6 5 4 3 2 1 0 CB1 CB0 BT3 BT2 BT1 BT0 DT5 DT4 DT3 DT2 DT1 DT0 0 0 1 0 0 0 0 1 0 1 0 0 VR3 VR2 VR1 VR0 VT5 VT4 VT3 VT2 VT1 VT0 0 0 1 1 1 1 1 0 0 0 0 0 PT4 PT3 PT2 PT1 PT0 WR WR 0 Config 3 (Hold) Config 4 (Start Com) Config 5 (Ramp) Mask Run Diagnostic 0 1 1 1 1 1 0 0 1 1 1 0 1 0 1 FF POR VR 1 1 0 0 0 WR 0 0 0 0 1 0 0 0 0 IDS HQ3 HQ2 HQ1 HQ0 HT3 HT3 HT1 HT0 0 1 0 1 0 1 0 0 0 0 0 0 EC3 EC2 EC1 EC0 SC3 SC2 SC1 SC0 0 0 0 0 1 1 1 1 0 1 0 0 PA3 PA2 PA1 PA0 RQ3 RQ2 RQ1 RQ0 RR3 RR2 RR1 RR0 0 0 0 0 1 0 0 0 0 0 0 0 TW TS LOS VA VB VC AH AL BH BL CH CL 0 0 0 0 0 0 0 0 0 0 0 0 BH1 BH0 BW2 BW1 BW0 ESF DG1 DG0 RSC BRK DIR RUN 0 0 1 0 0 0 0 0 0 0 0 0 TW TS LOS VA VB VC AH AL BH BL CH CL 0 0 0 0 0 0 0 0 0 0 0 0 WR WR WR WR 0 *Power-on reset value shown below each input register bit. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 23 A4960 Automotive, Sensorless BLDC Controller Each of the 8 configuration and control registers has a write bit, WR (bit 12), as the first bit after the register address (bits 15:13). This bit must be set to 1 to write the subsequent bits into the selected register. If WR is set to 0 then the remaining data bits (bits 11:0) are ignored. The state of the WR bit also determines the data output on SDO. By setting the WR bit to 1, writing to any register will allow the Diagnostic register to be read at the SDO output. If WR is set to 0, then the output is the contents of the register addressed by the first three input bits. In all cases the first three bits output on SDO will always be the FF, POR, and VR bits from the Diagnostic register. Configuration and control registers The serial data word is 16 bits, input MSB first, with the first three bits defined as the register address. This provides eight writable registers: •Six registers are used for configuration: one for blank time and dead time programming, one for current and voltage limits, one for PWM set-up parameters, and three for start-up parameters. •The seventh register is the fault Mask register, which provides the ability to disable individual diagnostics. •The eighth register is the Run register, containing motor control inputs. Config0 Configuration register 0 contains basic timing settings: •CB[1:0], 2 bits to select the commutation blank time, tCB •BT[3:0], a 4-bit integer to set the blank time, tBL , in 400 ns increments •DT[5:0], a 6-bit integer to set the dead time, tDEAD , in 50 ns increments Config1 Configuration Register 1 contains basic voltage settings: •VR[3:0], a 4-bit integer to set the current limit reference voltage, VRI , as a ratio of the voltage at the REF terminal, VREF •VT[5:0], a 6-bit integer to set the Drain-Source Threshold Voltage, VDSTH , in 25 mV increments Config2 Configuration Register 2 contains PWM settings: PT[4:0], a 5-bit integer to set the off-time for the PWM current control used to limit the motor current during start-up and normal running Config3 Configuration Register 3 contains start-up hold settings: •IDS, to select between current control and duty cycle control to set the initial holding torque. •HQ[3:0], a 4-bit integer to set the holding torque for the initial start position. The holding torque is set by an internally generated PWM duty cycle or by internal PWM current control. ▫ If IDS is set to zero then HQ[3:0] selects the hold current in increments of 6.25%. ▫ If IDS is set to one then HQ[3:0] selects the duty cycle in increments of 6.25%. • HT[3:0], a 4-bit integer to set the hold time of the initial start position in increments of 8 ms from 2 ms. Config4 Configuration Register 4 contains start-up timing set- tings: • EC[3:0], a 4-bit integer to set the end commutation time in increments of 200 µs. • SC[3:0], a 4-bit integer to set the start commutation time in increments of 8 ms. Config5 Configuration Register 5 contains start-up ramp settings: • PA[3:0], a 4-bit integer to set the phase advance in increments of 1.875° (electrical degrees) • RQ[3:0], a 4-bit integer to set the torque during ramp-up. The ramp torque is set by an internally generated PWM duty cycle or by internal PWM current control. ▫ If ISD is set to zero then RQ[3:0] selects the hold current in increments of 6.25%. ▫ If ISD is set to one then RQ[3:0] selects the duty cycle in increments of 6.25%. • RR[3:0], a 4-bit integer to set the acceleration rate during the forced commutation ramp up. Sets the reduction in commutation time, in 200 µs steps, at each commutation change. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 24 A4960 Automotive, Sensorless BLDC Controller Mask This register contains a fault masking bit for each fault bit in the Diagnostic register. If a bit is set to one in the Mask register then the corresponding diagnostic will be completely disabled. No fault states for the disabled diagnostic will be generated and no fault flags or diagnostic bits will be set. Run This register contains various bits to set running conditions: •BH[1:0], 2 bits to select the BEMF hysteresis. •BW[2:0], 3 bits to select the BEMF window. •ESF, the Enable Stop on Fault bit; defines the action taken when a short is detected. See Diagnostics section for details of fault actions. •DG[1:0], 2 bits to select the output routed to the DIAG terminal. The default output is the general fault output flag, which is a low true (active low) signal that is active anytime a fault is present or a fault state has been latched. The second option sets the DIAG output high whenever the A4960 is running with sensorless commutation. The other two outputs provide an external controller with the facility to read back the drain-source threshold voltage, or to measure the system clock frequency for calibration. •RSC, the Restart control bit. ▫ When set to 1 allows restart after loss of BEMF synchronization if RUN is 1 and BRK is 0. ▫ When set to 0 the motor will coast to a stop when bemf synchronization is lost. •BRK, brake control. •DIR, direction control. •RUN, enables the A4960 to start and run the motor. Diagnostic register There is one diagnostic register in addition to the eight writable registers. Each time a register is written, the Diagnostic register can be read, MSB first, on the serial output terminal, SDO (see serial timing diagram, figure 1). The Diagnostic register contains fault flags for each fault condition and a general fault flag. Whenever a fault occurs, the corresponding flag bit in the Diagnostic register will be set and latched. The fault flags in the Diagnostic register are reset only on the completion of a serial interface access, or when the RESETN input is low for the Reset Pulse Width, tRES. Resetting the Diagnostic register only affects latched faults that are no longer present. For any static faults that are still present, for example overtemperature, the fault flag will remain set after the register reset. At power-up or after a power-on reset, the FF bit and the POR bit are set and all other bits are reset. This indicates to the external controller that a power-on reset has taken place and all registers have been reset. Note that a power-on reset only occurs when the VDD supply rises above its undervoltage threshold. Power-on reset is not affected by the state of the VBB supply or VREG. The first bit in the register is the diagnostic register flag, FF. This is high if any bits in the diagnostic register are set or if a serial write error has occurred. When STRN goes low to start a serial write SDO comes out of its high impedance state and outputs the serial register fault flag. This allows the main controller to poll the A4960 through the serial interface to determine if a fault has been detected. If no faults have been detected then the serial transfer may be terminated without generating a serial read fault by ensuring that SCK remains high while STRN is low. When STRN goes high the transfer will be terminated and SDO will go into its high impedance state. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 25 A4960 Automotive, Sensorless BLDC Controller Serial Register Reference Config 0 Config 1 15 14 13 12 0 0 0 WR 0 0 1 11 10 9 8 7 6 5 4 3 2 1 0 CB1 CB0 BT3 BT2 BT1 BT0 DT5 DT4 DT3 DT2 DT1 DT0 0 0 1 0 0 0 0 1 0 1 0 0 VR3 VR2 VR1 VR0 VT5 VT4 VT3 VT2 VT1 VT0 1 1 1 1 1 0 0 0 0 0 WR *Power on reset value shown below each input register bit. Configuration Register 0 CB[1:0] Commutation blank time CB1 0 0 1 1 CB0 0 1 0 1 Blank Time 50µs 100µs 400µs 1ms Configuration Register 1 Default D The accuracy of tCB is determined by the system clock frequency as defined in the electrical characteristics table. BT[3:0] Blank time t BL = n × 400 ns where n is a positive integer defined by BT[3:0] e.g. for the power-on-reset condition BT[3:0] = [1 0 0 0] then tBL=3.2µs The range of tBL is 0 to 6µs. The accuracy of tBL is determined by the system clock frequency as defined in the electrical characteristics table. DT[5:0] Dead time t DEAD = n × 50 ns where n is a positive integer defined by DT[5:0] e.g. for the power-on-reset condition DT[5:0] = [0 1 0 1 0 0] then tDEAD=1µs VR[3:0] Current sense reference ratio for normal running conditions. Typically: V RI = (n +1) × 6 . 25 %V REF where n is a positive integer defined by VR[3:0] e.g. for the power-on-reset condition VR[3:0] = [1 1 1 1] then VRI=VREF If the REF terminal is connected to VDD then VREF is clamped to VREFC. The range of VRI is 6.25% VREF to 100%VREF. VT[5:0] VDS Threshold. Typically: V DSTH = n × 25 mV where n is a positive integer defined by VT[5:0] e.g. for the power-on-reset condition VT[5:0] = [1 0 0 0 0 0] then VDSTH=800mV The range of VDSTH is 0 to 1.575V. The range of is 100ns to 3.15µs. Selecting a value of 0, 1 or 2 will set the dead time to 100ns. The accuracy of tDEAD is determined by the system clock frequency as defined in the electrical characteristics table. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 26 A4960 Automotive, Sensorless BLDC Controller Serial Register Reference Config 2 (PWM) Config 3 (Hold) 15 14 13 12 0 1 0 WR 0 1 1 11 10 WR *Power on reset value shown below each input register bit. Configuration Register 2 Fixed off time t OFF = 10 µs +( n × 1 .6 µs ) where n is a positive integer defined by PT[4:0] e.g. for the power-on-reset condition PT[4:0] = [1 0 0 0 0] then tOFF=35.6µs The range of tOFF is 10µs to 59.6µs. The accuracy of tOFF is determined by the system clock frequency as defined in the electrical characteristics table. PT[4:0] 9 8 7 6 5 4 3 2 1 0 PT4 PT3 PT2 PT1 PT0 1 0 0 0 0 IDS HQ3 HQ2 HQ1 HQ0 HT3 HT3 HT1 HT0 0 0 1 0 1 0 1 0 0 Configuration Register 3 IDS Start-up Torque control method IDS 0 1 HQ[3:0] Start-up Torque control Current limited Duty cycle limited Default D Current sense reference ratio or duty cycle ratio for hold torque during initial start sequence. If IDS is 0 then HQ[3:0] sets the hold current. If IDS is 1 then HQ[3:0] sets the hold duty cycle. Typically: V RH = ( n + 1)× 6 . 25 %V REF ...... when IDS=0 D H = (n + 1 )× 6 . 25 % ............... when IDS=1 where n is a positive integer defined by HQ[3:0] e.g. for the power-on-reset condition HQ[3:0] = [0 1 0 1] then VRH=37.5%VREF ...................... when IDS=0 DH=37.5% ............................... when IDS=1 The range of VRH is 6.25% VREF to 100%VREF. The range of DH is 6.25% to 100%. The accuracy of VRH and DH is defined in the electrical characteristics table. HT[3:0] Hold Time. t HOLD = 2 ms + (n × 8 ms) where n is a positive integer defined by HT[3:0] e.g. for the power-on-reset condition HT[3:0] = [0 1 0 0] then tHOLD=34ms The range of tHOLD is 2ms to 122ms. The accuracy of tHOLD is determined by the system clock frequency as defined in the electrical characteristics table. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 27 A4960 Automotive, Sensorless BLDC Controller Serial Register Reference Config 4 (Start Com) Config 5 (Ramp) 15 14 13 12 1 0 0 WR 1 0 1 WR 11 10 7 6 5 4 3 2 1 0 EC3 EC2 EC1 EC0 SC3 SC2 SC1 SC0 1 1 1 1 0 1 0 0 PA2 PA1 PA0 RQ3 RQ2 RQ1 RQ0 RR3 RR2 RR1 RR0 0 0 0 0 1 0 0 0 0 0 0 0 Configuration Register 4 EC[3:0] End Commutation time t COME = ( n + 1 )× 0 .2 ms where n is a positive integer defined by EC[3:0] e.g. for the power-on-reset condition EC[3:0] = [1 1 1 1] then tCOME=3.2ms The range of tCOME is 0.2ms to 3.2ms. The accuracy of tCOME is determined by the system clock frequency as defined in the electrical characteristics table. Start commutation time t COMS = ( n + 1) × 8 ms where n is a positive integer defined by SC[3:0] e.g. for the power-on-reset condition SC[3:0] = [0 1 0 0] then tCOMS=40ms The range of is 8ms to 128ms. The accuracy of tCOMS is determined by the system clock frequency as defined in the electrical characteristics table. SC[3:0] Configuration Register 5 Phase Advance. Typically: θ ADV = n × 1 .875 ° ( electrical ) 8 PA3 *Power on reset value shown below each input register bit. PA[3:0] 9 where n is a positive integer defined by PA[3:0] e.g. for the following condition PA[3:0] = [1 0 0 0] then θADV=15° The range of θADV is 0 to 28.125° (electrical) The accuracy of θADV is defined in the electrical characteristics table. RQ[3:0] Current sense reference ratio or duty cycle ratio for torque during forced commutation ramp-up. If IDS is 0 then RQ[3:0] sets the ramp current. If IDS is 1 then RQ[3:0] sets the ramp duty cycle. Typically: V RR = ( n + 1)× 6 . 25 % V REF ........ when IDS=0 D R = ( n +1 )× 6 .25 % ................. when IDS=1 where n is a positive integer defined by RQ[3:0] e.g. for the power-on-reset condition RQ[3:0] = [1 0 0 0] then VRH=56.25%VREF .................... when IDS=0 DH=56.25% ............................. when IDS=1 The range of VRR is 6.25% VREF to 100%VREF. The range of DR is 6.25% to 100%. The accuracy of VRR and DR is defined in the electrical characteristics table. RR[3:0] Ramp rate. Decrease in commutation time at each commutation change. Typically at each commutation change: t COM ( next ) = t COM – (n + 1)× 0.2ms where tCOM(next) is the next commutation time in ms, tCOM is the present commutation time in ms, and n is a positive integer defined by RR[3:0] e.g. for the condition RR[3:0] = [0 1 1 1] the commutation time will be reduced by 1.6ms at each commutation change. The range of RR is 0 to 15. The range of the commutation change is 0.2ms to 3.2ms. The accuracy of RR is determined by the system clock frequency as defined in the electrical characteristics table. Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 28 A4960 Automotive, Sensorless BLDC Controller Serial Register Reference Run 15 14 13 12 1 1 1 WR 11 10 9 8 7 6 5 4 3 2 1 0 BH1 BH0 BW2 BW1 BW0 ESF DG1 DG0 RSC BRK DIR RUN 0 0 1 0 0 0 0 0 0 0 0 0 *Power on reset value shown below each input register bit. Run Register BH[1:0] BH1 0 0 1 1 BW[2:0] BW2 0 0 0 0 1 1 1 1 ESF BEMF Hysteresis. BH0 0 1 0 1 Hysteresis Auto High Start/Low Run None High Low BEMF Window. BW1 0 0 1 1 0 0 1 1 BW0 0 1 0 1 0 1 0 1 Window 0.4µs 0.8µs 1.6µs 3.2µs 6.4µs 12.8µs 25.6µs 51.2µs Default D BRK Default DIR D RUN Enable Stop on Fail ESF 1 0 DG[1:0] DG1 0 0 1 1 Recirculation Stop on fail. Report fault. No stop on fail, Report fault. RSC Restart control RSC 0 1 Restart No restart Allow restart after loss of sync Default D Brake BRK 0 1 DIR 0 1 Recirculation Brake off – normal operation Brake on – slow decay recirculation Direction of Rotation Direction Forward (Table 1 states 1to 6) Reverse (Table 1 states 6 to 1) Default D Default D Run enable RUN 0 1 Recirculation Disable outputs, coast motor Start and run motor Default D Default D Selects signal routed to DIAG output. DG0 0 1 0 1 Signal on DIAG pin Fault– low true LOS – low true VDSTH Clock Default D Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 29 A4960 Automotive, Sensorless BLDC Controller Serial Register Reference Mask Diagnostic 15 14 13 12 1 1 0 WR FF POR VR 1 1 0 0 11 10 9 8 7 6 5 4 3 2 1 0 TW TS LOS VA VB VC AH AL BH BL CH CL 0 0 0 0 0 0 0 0 0 0 0 0 TW TS LOS VA VB VC AH AL BH BL CH CL 0 0 0 0 0 0 0 0 0 0 0 0 *Power on reset value shown below each input register bit. Diagnostic Register FF General Fault flag POR Power-on-reset VR Undervoltage TW High temperature warning TS Over temperature shutdown LOS bemf synchronization lost VA Fault on bootcap A VB Fault on bootcap B VC Fault on bootcap C AH VDS fault detected on Phase A high-side AL VDS fault detected on Phase A low-side BH VDS fault detected on Phase B high-side BL VDS fault detected on Phase B low-side CH VDS fault detected on Phase C high-side CL VDS fault detected on Phase C low-side Mask Register TW TS LOS VA VB VC AH AL BH BL CH CL xx 0 1 Temperature warning Thermal shutdown Loss of bemf synchronization Bootcap A fault Bootcap B fault Bootcap B fault Phase A high-side VDS Phase A low-side VDS Phase B high-side VDS Phase B low-side VDS Phase C high-side VDS Phase C low-side VDS Fault mask Fault detection permitted Fault detection disabled Default D xx 0 1 Fault No fault detected Fault detected Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 30 A4960 Automotive, Sensorless BLDC Controller Applications Information Control Timing Diagrams RUN BRK Motor State Coast Hold Ramp Run Coast Brake tHOLD TACHO DIAG LOS Figure 9. Control example: Start from coast, coast, then brake to stop PWM PWM duty cycle used to vary speed PWM duty cycle ignored RUN tBRK BRK Motor State Coast Brake Hold Ramp Run pwm off Brake tHOLD TACHO DIAG LOS Figure 10. Control example: Start from brake, PWM brake to stop PWM duty cycle ignored PWM RUN tBRK Motor State Coast TACHO PWM duty cycle used to vary speed tBRK Brake Hold Ramp Run Coast Brake tHOLD DIAG LOS Figure 11. Control example: Start from PWM, coast, then PWM brake to stop Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 31 A4960 Automotive, Sensorless BLDC Controller Input/Output Structures (a) Gate Drive Outputs (b) Supplies Cx VBRG 18V 18V VBB GHx 18V 7.5V 14V CP1 Sx VDD CP2 VREG 18V 18V GLx 18V 18V 18V 18V 18V 14V 14V VREG 6V 18V LSS (c) PWM, SDI, and SCK Inputs (e) RESETN Inputs (d) STR Inputs VDD VDD VDD VDD 50 kΩ 2 kΩ PWM SDI SCK 2 kΩ 2 kΩ STR RESET 50 kΩ 6V 80 kΩ 6V 6V (f) Sense Inputs 6V (g) REF Inputs 7.5V (h) Logic Outputs VDD VREG 18V CSP CSM 7.5V 5 kΩ 25 Ω 80 kΩ REF SDO TACHO DIAG 6V 6V 6V 6V Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 32 A4960 Automotive, Sensorless BLDC Controller Package JP, 32-Pin LQFP With Exposed Thermal Pad 9.00 ±0.20 7.00 ±0.20 0.45 1.80 7º 3.5° ±3.5 0º 0.80 0.20 0.09 B 9.00 ±0.20 7.00 ±0.20 5.00 5.00±0.04 32 1.00 REF A 1 0.60 ±0.15 32 2 0.25 BSC 5.00±0.04 1 2 SEATING PLANE GUAGE PLANE 5.00 8.70 Branded Face 32X SEATING PLANE 0.10 C +0.08 0.37 –0.07 8.70 0.80 BSC C 1.60 MAX 1.40 ±0.05 0.15 0.05 C PCB Layout Reference View For Reference Only; not for tooling use (reference MS-026 BBAHD) Dimensions in millimeters Dimensions exclusive of mold flash, gate burrs, and dambar protrusions Exact case and lead configuration at supplier discretion within limits shown A Terminal #1 mark area B Exposed thermal pad (bottom surface); exact dimensions may vary with device C Reference land pattern layout (reference IPC7351 QFP80P900X900X160-32BM); adjust as necessary to meet application process requirements and PCB layout tolerances; when mounting on a multilayer PCB, thermal vias at the exposed thermal pad land can improve thermal dissipation (reference EIA/JEDEC Standard JESD51-5) Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 33 A4960 Automotive, Sensorless BLDC Controller Revision Table Revision Number Revision Date – October 6, 2011 1 September 9, 2015 Description Initial Release Corrected Figure 10 (page 31) DIAG and LOS signals Copyright ©2011-2015, Allegro MicroSystems, LLC Allegro MicroSystems, LLC reserves the right to make, from time to time, such departures from the detail specifications as may be required to permit improvements in the performance, reliability, or manufacturability of its products. Before placing an order, the user is cautioned to verify that the information being relied upon is current. Allegro’s products are not to be used in life support devices or systems, if a failure of an Allegro product can reasonably be expected to cause the failure of that life support device or system, or to affect the safety or effectiveness of that device or system. The information included herein is believed to be accurate and reliable. However, Allegro MicroSystems, LLC assumes no responsibility for its use; nor for any infringement of patents or other rights of third parties which may result from its use. For the latest version of this document, visit our website: www.allegromicro.com Allegro MicroSystems, LLC 115 Northeast Cutoff Worcester, Massachusetts 01615-0036 U.S.A. 1.508.853.5000; www.allegromicro.com 34