PD-97175B DIGITAL SENSORLESS MOTOR DRIVE MODULE IRMCT3UF1 Complete Integrated High Performance Sensorless Speed Control in a Compact, Ruggedized Package • For up to 500VA, 3Phase Brushless DC and PMAC Sinusoidal Motors • Ideal for Pumps, Fans, Compressors in Rugged Environments needing a Small Footprint • Uses IR’s iMOTIONTM Digital Integrated Motor Drive Technology MP-3T Description Feature Summary IR’s HiRel Digital Sensorless Motor Drive Module is a complete digital speed/torque controller ideal for applications demanding efficient operation in a compact and rugged package such as fuel pumps, fans, and compressors. This control is supported by the latest hardware motion control technology from IR, including the Servo Designer TM tools. No software code development is required due to its pre-configured Motion Control Engine. n No Software - Digital Sine FOC Algorithm utilizes IR’s New Hardware based Motion Control Engine n Digital Configuration Interface supports Dynamic Re-Configuration of FOC n Complete Digital Sine-Drive supports both 2 and 3-Phase Center Aligned and Assymetrical SVM Operation > 20KHz PWM Rate n Ideal for Speed/Torque Control of High Performance Motors ( > 25000 RPM ) n Speed/Torque command >10KHz Digital Speed Command Rate/Sampled Analog Command Input n Control Loop Computation Time 11µsec n Output Current up to 20Arms ( 48Vdc Bus ) n Max RS232C Speed 57.6 Kbps n Stand-Alone Operation possible ( without Host Micro ) n Lightweight Plastic Ring-Frame Enclosure n Low Rth Insulated Metal Substrate ( IMS ) with Low Rds(on) MOSFETs and IR’s Advanced HVIC Gate Drivers n Storage Temperature Range -55°C to +125°C n Case Operating Temperature -40°C to +85°C n Thermal Resistance 1.5°C/W The HiRel Motor Drive Module contains IR’s advanced iMOTIONTM Motion Control Chipset with monolythic Gate Driver ICs and state of the art 100V MOSFETs enabling simple and cost effective design of high reliability speed controls. www.irf.com 1 10/20/06 IRMCT3UF1 Electrical Characteristics @Tc = 25°C (Unless Otherwise Specified) Parameter Value INPUT POWER Voltage Power Dissipation OUTPUT POWER Power Phase Current 28Vdc to 48Vdc 12.5Watts 500VA Continuous 15Arms Continuous 20Arms Overload INTERFACE Diagnostic Inteface ( RS232C/422 ) Analog Input DISCRETE I/O Input Output ANALOG FEEDBACK Current Sensing Voltage Sensing Analog to Digital Converter PROTECTION Output Current Trip Level Over-Temperature Trip Level Short Circuit Response Time DC BUS VOLTAGE Maximum DC Bus Voltage Minimum DC Bus Voltage AMBIENT ENVIRONMENT 57.6Kbaud Single Ended 0-2.5V or 2.5-5.0V Input Reference Command ON / OFF, Fault Clear FAULT Leg Shunt - ( low side ) Vbus Voltage Divider 12 bit Resolution 500VA Version - 30A Peak 110°C Min 5.0 µs 48V 20V Case Operating Temperature -40°C to 85°C Storage Temperature POWER MODULE -55°C to125°C Power Stage Rth-JC Maximum Operating TJ (MOSFET) 2 IMS contains 6 Mosfets 1.5°C/W 150°C www.irf.com IRMCT3UF1 Overview The IRMCT3UF1 is a complete Sensorless drive system based on a proprietary digital motion control ASIC. The system is based on a configurable control engine implemented by hardware logics in the ASIC. The system has a simple and low cost structure, made possible by an advanced IR motion power components including the MOSFET module and IR2011 monolithic gate driver IC. These components together with the ASIC simplify hardware implementation. Since all control logic is implemented in hardware state machine as opposed to programmed software, unmatched parallel computation is achieved resulting in higher bandwidth control and higher motor operating frequency (< 25µsec PWM period). Module Block Diagram DC Bus Controller Section EEPROM Power Interface Section Sensorless FOC Algorithm Serial Interface RAMP RS232 C + + - - Host Register Interface e + jθ Space Vector PWM Gate Gate Driv Gate Driv Drive e e Dead time FAULT Configuration Power Substrate Rotor Angle / speed Estimator Registers Monitoring Registers VBus e Discrete Interface jθ 2/ 3 A/D interface Motor Current Measurement A/D Analog Speed Command Power Interfac e Discrete I/O Analog Speed Command Current shunt +15 +5 +3.3 DC Bus Rtn Application Diagram 28V DC Bus Bus Capacitor Transient Protection 16,17 DCDC 1 7 DCDC 2 Linear Reg 24 +5V 26 +3.3V 28V Bus Rtn 28 27 FLT Control Computer FLT Clr Start/Stop Analog 0 Ref +15V Status - Fault 31 Status - OK 30 Power Substrate (IMS) Control Board Gate Drive Gate Drive Gate Power 10,11 14,15 5,6 Drive Drive RS232 8,9 .02 Sensorless Control ASIC Fault Logic Over-Temp 3,4 Over-Load .02 33 VBus 32 A/D 34 18 29 U Phase Current V Phase Current W Phase Current 12,13 .02 Analog 0 Ref PM Motor substrate Speed cmd Analog Speed Command 22,23,25 1,2 28V Bus Rtn www.irf.com 3 IRMCT3UF1 Pin Designation Table Power Side Control Side Pin # Pin Description Pin # Pin Description 1 MOT_RTN 18 2.5V_REF_BUF 2 MOT_RTN 19 CS_LU ( sense ) 3 CS_LW 20 CS_LV ( sense ) 4 CS_LW 21 CS_LW ( sense ) 5 PHASE_W 22 GND 6 PHASE _W 23 GND 7 +15V 24 +5.0V 8 CS_LU 25 GND 9 CS_LU 26 +3.3V 10 PHASE_U 27 RX 11 PHASE _U 28 TX 12 CS_LV 29 SPD_CMD GRN 13 CS_LV 30 14 PHASE_V 31 RED 15 PHASE_V 32 FLT_CLR 16 17 VBUS VBUS 33 34 FAULT START/STOP Pin Descriptions MOT_RTN (Pins 1, 2) - These two pins are connected to the motor bus voltage return path as well as the control power supply grounds. CS_LW, CS_LU and CS_LV (Pins 3 & 4, 8 & 9, 12 & 13) - These pins are the current sense connections for corresponding motor phase. The pins on the power side are the output of the low side MOSFETs and must be connected to the current sense resistor in the external application. Each pin must also be connected to the coresponding current sense connection on the control side (see CS_LU, CS_LV, CS_LW description below). PHASE_W, PHASE_U, PHASE_V (Pins 5 & 6, 10 & 11, 14 &15) - Motor connections for the three phases. VBUS (Pins 16 & 17) - Input voltage for the motor. The nominal value is 28Vdc with a maximum of 48V. 2.5V_REF_BUF (Pin 18) - 2.5V reference buffer provided for speed command referencing. (see SPD_CMD description) 4 CS_LU, CS_LV, CS_LW (Pins 19, 20 & 21) Control side inputs from the current sense resistors. These monitor the voltage waveform at the top of the current sense resistor and use this signal to track the rotation of the motor. An approximate value for the resistor can be found using the Servo Designer software needed to configure the motor controller. The pins must be connected directly to the corresponding pins on the power side and care should be taken to make sure all three traces are approximately equal in length. Use low-inductance shunt resistors and keep leads short. GND (Pins 22, 23 & 25) - Ground connections for the +15V, +5V and +3.3V power supplies. All three should be connected. This can be accomplished at the hybrid interface or by tying all three pins to a common ground plane. +15V, +5.0V, +3.3V (Pins 7, 24 & 26) - Local housekeeping power supplies for the unit. The +15V power supply is used to drive the MOSFETs and should be rated at 100mA. The +5.0V and +3.3V supplies are responsible for the rest of the ICs in www.irf.com IRMCT3UF1 the circuit including logic and the iMotion digital controller. The +5.0V supply should be rated at 100mA and +3.3V supply at 200mA. RX, TX (Pins 27 & 28) - RS-232 interface pins for programming the controller. The interface operates at 57.6kBaud. SPD_CMD (Pin 29) - Speed command for the motor controller. For the IRMCT3UF1, there are two operating ranges for the speed command input: 02.5V and 2.5-5V. In each case, 2.5V is zero speed and the other extreme (0V or 5V) is maximum speed. An external 2.5V reference is provided to help configure a particular speed command interface. FLT_CLR, FAULT (Pins 32 & 33) - Fault indication and Fault Clear function. Use these pins to monitor the Fault status of the controller. When there is no fault (clear condition), the fault pin is low. It goes to 3.3V upon the occurrence of a Fault. The controller can be reset by pulsing the Fault Clear pin high for a minimum of 1µs. This is a Schmitt input and is 5.5V tolerant. START/STOP (Pin 34) - Start and Stop command for the controller. The drive will start on the rising edge of the command and will stop on the falling edge. This is a Schmitt input and is 5.5V tolerant. GRN, RED (Pins 30 & 31) - Outputs for driving Green and Red LEDs. These outputs are provided as a visual interface to determine the status of the drive. The Green LED output indicates a clear condition and the Red LED indicates that a Fault has occurred. Each output is referenced to +3.3V and is capable of driving a maximum current of 30mA. Also, each output has an internal series resistance of 100Ω. Input / Output Characteristics I/O Pin Description Parameter Min. Typ. Max. Units 2.5 2.525 V RED, GREEN Reference Voltage Drive Current 2.475 Pins 30, 31 1.0 - 100 30 - mA Internal Series Resistance No FAULT FAULT 3.3 - 0.2 - V Clear Pulse Clear Pulse Amplitude 1.0 - - - µs 5.5 0 Max Speed 1 - 2.5 0 - Max Speed 2 Voltage 14.25 5.0 15 15.75 Load Current Voltage 4.75 100 5.0 5.25 mA V Load Current 3.135 100 3.3 3.465 mA - mA Pins 32, 33 Pin 29 FAULT SPEED COMMAND Pin 7 +15V Pin 24 +5.0V Pin 26 www.irf.com 3.3V Voltage Load Current - 200 Ω V V 5 IRMCT3UF1 Case Outline and Dimensions - MP-3T 34 6 www.irf.com IRMCT3UF1 Module Screening Test Method Frequency Sampling Internal Visual (Hybrids) MIL-STD-883 TM2017 100% Temperature Cycling Pre-Burn Electrical Test MIL-STD-883 TM1010 (20 Cycles -55°C To 125°C) Test Specification 100% 100% Burn-In-Static-Power Stage Burn-In Active Hybrid MIL-STD-883 TM1015 Condition A (125°C, 160 hrs) MIL-STD-883 TM1015 Condition A (85°C, 160 hrs) 100% 100% Final Electrical Test High Potential Test Test Specification MIL-STD-883 TM1003 Condition E (500 Vdc) 100% 100% Physical and Mechanical External Visual MIL-STD-883 TM2009 100% Part Numbering Nomenclature IR Motor Control Technology Module Control Technology MCT 3 UF 1 A 01 P Screening Level P = Unscreened, 25°C Electrical Test ( Not for Qualification ) H = Refer to Screening Table 3 = Digital Controller Sine Current based Sensorless Customer Specific Identification Package Type Application Specific UF = MP-3T Low Voltage Digital Control Blank = Standard Part Blank = Standard Part A = Custom Part Output Voltage ( Switch Rating ) 1 = 100V IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, USA Tel: (310) 252-7105 IR LEOMINSTER : 205 Crawford St., Leominster, Massachusetts 01453, USA Tel: (978) 534-5776 TAC Fax: (310) 252-7903 Visit us at www.irf.com for sales contact information. Data and specifications subject to change without notice. 10/2006 www.irf.com 7