MIL-PRF-38534 AND 38535 CERTIFIED FACILITY M.S.KENNEDY CORP. 30 AMP, 75V, 3 PHASE MOSFET BRUSHLESS MOTOR CONTROLLER 4462 4707 Dey Road Liverpool, N.Y. 13088 (315) 701-6751 FEATURES: 75V Absolute Max, 52V Maximum Motor Voltage 30 Amp Output Switch Capability 100% Duty Cycle High Side Conduction Capable Shoot-Through/Cross Conduction Protection Hall Sensing and Commutation Circuitry on Board "Real" Four Quadrant Torque Control Capability Good Accuracy Around the Null Torque Point Isolated Package Design for High Voltage Isolation Plus Good Thermal Transfer 60°/ 120º Phasing Selectable Plus and Minus 15 Volt Regulated Voltage Outputs are available for Powering Other Circuitry. Non-Hermetic Lower Cost Package DESCRIPTION: The MSK 4462 is a complete 3 Phase MOSFET Bridge Brushless Motor Control System in a low cost convenient isolated non-hermetic package. The hybrid is capable of 30 amps of output current and 52 volts of DC bus voltage. It has the normal features for protecting the bridge. Included is all the bridge drive circuitry, hall sensing circuitry, commutation circuitry and all the current sensing and analog circuitry necessary for closed loop current mode (torque) control. When PWM'ing, the transistors are modulated in locked anti-phase (complementary) mode for the tightest control and the most bandwidth. Provisions for applying different compensation schemes are included. The MSK 4462 has good thermal conductivity of the MOSFET's due to isolated package design that allows direct heat sinking of the hybrid without insulators. BLOCK DIAGRAM PIN-OUT INFORMATION TYPICAL APPLICATIONS 3 Phase Brushless DC Motor Control Servo Control Fin Actuator Control Gimbal Control AZ-EL Control 1 2 3 4 5 6 7 8 9 10 REFOUT HALL A HALL B HALL C 60/120 BRAKE GND DIS E/A OUT E/A- 1 11 12 13 14 15 16 17 18 19 20 +CURRENT COMMAND -CURRENT COMMAND CURRENT MONITOROUT +15 VIN -15 VIN -REG IN L1 -15 VOUT +15 VOUT +REG IN 21 22 23 24 25 26 27 28 29 30 RTN RTN CVS CVS CØ CØ CV+ CV+ BVS BVS 31 32 33 34 35 36 37 38 39 40 BØ BØ BV+ BV+ AVS AVS AØ AØ AV+ AV+ 8548-70 Rev. I 9/12 ABSOLUTE MAXIMUM RATINGS 6 75V High Voltage Supply (internal regulators disabled) 55V High Voltage Supply (using internal regulators) ±13.5V Current Command Input -0.2V to REFOUT Logic Inputs ±25 mA ±15VOUT External Load 15 mA REFOUT External Load 5 mA E/A OUT External Load 30 Amps Continuous Output Current 41 Amps Peak Output Current ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ RθJC Thermal Resistance (Output Switches) 2.0°C/W RθJC Thermal Resistance (Regulator) 13°C/W TST Storage Temperature Range -40°C to +150°C TLD Lead Temperature Range +300°C (10 Seconds) TC Case Operating Temperature -40°C to +85°C TJ Junction Temperature +150°C ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ELECTRICAL SPECIFICATIONS Parameter INPUT CURRENT +15 VIN -15 VIN PWM Clock Frequency REGULATORS +15 VOUT -15 VOUT REFOUT -15 VOUT Ripple LOGIC INPUTS (Hall A,B,C,Brake,60°/120°,DIS) VIL 1 VIH 1 ANALOG SECTION Current Command Input Range 1 Current Command Input Current 1 Test Conditions ERROR AMP E/A OUT Swing 1 Slew Rate 1 Gain Bandwidth Product 1 Large Signal Voltage Gain 1 OUTPUT SECTION 1 Voltage Drop Across Bridge (1 Upper & 1 Lower) 1 Voltage Drop Across Bridge (1 Upper & 1 Lower) 1 Leakage Current 1 3 Diode VSD 1 trr 1 Dead Time 1 Typ. Max. Units - 65 25 90 40 mA mA 20 22 24 KHz 14.25 -14.25 5.82 - - 15.75 -15.75 6.57 250 VOLTS VOLTS VOLTS mV 3.0 - 0.8 - VOLTS VOLTS 2.55 0.250 - 3 0.33 - ±13.5 1.5 3.45 ±100 0.410 ±12 VOLTS mA A/V A/V mA V/A VOLTS 5mA Load 6.5 175 8 6.5 275 ±12 - VOLTS V/μSec MHz V/mV 30 AMPS 30 AMPS @ 150°C Junction All switches off, V+=60V, 150°C Junction - 280 2 1 1.83 750 2.6 - VOLTS VOLTS μA VOLTS nSec μSec Output PWM'ing Current Command=0 Volts 25mA Load 2 25mA Load 2 15mA Load 25mA Load Transconductance 4 Offset Current Current Monitor 4 Current Monitor Voltage Swing 1 MSK 4462 5 Min. Current Command=0Volts 5mA Load NOTES: 1 2 3 4 5 6 Guaranteed by design but not tested. Typical parameters are representative of actual device performance but are for reference only. Maximum power dissipation must be limited according to voltage regulator power dissipation. Module powered by external ±15V supplies. Measurements do not include offset current at 0V current command. Specifications are for TC=25°C unless otherwise specified. Continuous operation at or above maximum ratings may adversely effect the device performance and/or life cycle. 2 8548-70 Rev. I 9/12 APPLICATION NOTES MSK 4462 PIN DESCRIPTIONS AV+, BV+, CV+ - are the power connections from the hybrid to the bus. The pins for each phase are brought out separately and must be connected together to the V+ source externally. The external wiring to these pins should be sized according to the RMS current required by the motor. These pins should be bypassed by a high quality monolithic ceramic capacitor for high frequencies and enough bulk capacitance for keeping the V+ supply from drooping. 78 μF of ceramic capacitance and 6200 μF of bulk capacitance was used in the test circuit. The voltage range on these pins is from 16 volts up to 75 volts. AØ, BØ & CØ- are the connections to the motor phase windings from the bridge output. The wiring to these pins should be sized according to the current required by the motor. There are no short circuit provisions for these outputs. Shorts to V+ or ground from these pins must be avoided or the bridge will be destroyed. AVS, BVS, CVS - are the return pins on the bottom of each half bridge. They are brought out separately and should be connected together externally to allow the current from each half bridge to flow through the sense resistor. The wiring on these pins should be sized according to the current requirements of the motor. RTN - is the power return connection from the module to the bus. All ground returns connect to this point from internal to the module in a star fashion. All external ground connections to this point should also be made in a similar fashion. The V+ capacitors should be returned to this pin as close as possible. Wire sizing to this pin connection should be made according to the required current. GND - is a ground pin that connects to the ground plane for all low powered circuitry inside the hybrid. +REG IN - is the input pin for applying power to the internal +15V regulator. To use the regulator, connect the +REG IN pin to the motor bus (V+). See regulator app. note for more info on input voltage. If the +15V regulator is not needed, no connection should be made to +REG IN and +15 VOUT. +15 volts will have to be supplied from an external source to +15VIN. Absolute maximum voltage on this pin is 55 volts. See voltage regulator portion of app. note for additional information. +15 VOUT - is a regulated +15 volt output available for external uses. Up to 25 mA is available at this pin. A 100 microfarad capacitor should be connected as close to this pin as possible and returned to GND along with a 0.22 microfarad monolithic ceramic capacitor. CAUTION: See Voltage Regulator Power Dissipation. +15 VIN - is the input for applying +15 volts to run the low power section of the hybrid. This pin should be connected to +15 VOUT if running off of the internal regulator. The required bypassing of the +15 VOUT pin is sufficient in this case. For bringing in external +15 volts, this pin should be bypassed with a 10 μF capacitor and a 0.1 μF capacitor as close to this pin as possible. -REG IN - is the input pin for applying power to the internal -15V DC - DC converter. To use the converter, connect the -REG IN pin to +15 VOUT pin. If the -15V converter is not needed, no connection should be made to -REG IN and -15 VOUT. -15 volts will have to be supplied from an external source to -15VIN. Also, L1 can be left open. See voltage regulator portion of app. note for additional information. L1 - is a pin for connecting an external inductor to the DC - DC converter for generating -15 volts. A 47 μH inductor capable of running at 250 KHz and about 1 amp of DC current shall be used. Connect the inductor between L1 and GND. -15 VOUT- is a regulated -15 volt output available for external uses. Up to 25 mA is available at this pin. A 100 microfarad capacitor should be connected as close to this pin as possible and returned to GND along with a 0.22 microfarad monolithic ceramic capacitor. CAUTION: See Voltage Regulator Power Dissipation -15 VIN - is the input for applying -15 volts to run the low power section of the hybrid. This pin should be connected to -15 VOUT if running off of the internal regulator. The required bypassing of the -15 VOUT pin is sufficient in this case. For bringing in -15 volts, this pin should be bypassed with a 10 μF capacitor and a 0.1 μF capacitor as close to this pin as possible. CURRENT COMMAND (+,-) - are differential inputs for controlling the module in current mode. Scaled at ±3 amps per volt of input command, the bipolar input allows both forward and reverse current control capability regardless of motor commutation direction. The maximum operational command voltage should be ±10 volts for ±30 amps of motor current. IN CURRENT MONITOR - is a pin providing a current viewing signal for external monitoring purposes. This is scaled at ±3 amps of motor current per volt output, up to a maximum of ±10 volts, or ±30 amps. As ±30 amps is exceeded, the peaks of the waveform may become clipped as the rails of the amplifiers are reached. This voltage is typically ±12.5 volts, equating to ±37 amps of current peaks. In DIS mode, the CURRENT MONITOR output may rail positive or negative, depending on internal bias currents. When re-enabled, this output will resume expected operation. E/A OUT - is the current loop error amp output connection. It is brought out for allowing various loop compensation circuits to be connected between this and E/A-. E/A- -is the current loop error amp inverting input connection. It is brought out for allowing various loop compensation circuits to be connected between this and E/A OUT. REFOUT - is a 6.25 volt regulated output to be used for powering the hall devices in various motors. Up to 15 mA of output current is available. HALL A, B & C - are the hall input pins from the hall devices in the motor. These pins are internally pulled up to 6.25 volts. The halls can reflect a 120/240 degree commutation scheme or a 60/ 300 degree scheme. 3 8548-70 Rev. I 9/12 APPLICATION NOTES CONTINUED BRAKE - is a pin for commanding the output bridge into a motor BRAKE mode. When pulled low, normal operation commences. When pulled high, the 3 high side bridge switches turn off and the 3 low side bridge switches turn on, causing rapid deceleration of the motor and will cease motor operation until pulled high again. Logic levels for this input are TTL compatible. It is internally pulled high. DIS - is a pin for externally disabling the output bridge. A TTL logic low will enable the bridge and a TTL logic high will disable it. It is internally pulled up by a 100 μAmp pullup. 60/120 - is a pin for selecting the orientation of the commutation scheme of the motor. A high state will produce 60/300 degree commutation, whereas a low state will produce 120/240 degree commutation. Logic levels for this input are TTL compatible. It is internally pulled high. VOLTAGE REGULATOR POWER DISSIPATION - To figure voltage regulator power dissipation and junction temperature, use the following as an example: Given: V+ = 28V, MSK 4462 +15V IQ = 85mA, -15V IQ = 40mA. External Loads: +15V = 25 mA, -15V = 25 mA -15V Converter Efficiency = 50% PDISS due to +15V IQ,85 mA x 13V = 1.11 W PDISS due to -15V IQ, (40 mA / 0.5) x 13V = 1.04 W PDISS due to +15V Ext load, 25 mA x 13V = 325 mW PDISS due to -15V Ext load, (25 mA / 0.5) x 13V = 650 mW PDISS Total = 1.11 W + 1.04 W + 325 mW+650 mW=3.13W 3.13 W x 13°C/W = 41°C RISE above case temperature 150°C - 41°C =109°C Case Temperature can go up to the maximum of 85°C case-see absolute maximum table. ALTERNATE REGULATOR CONNECTION OPTIONS By connecting the regulators in different ways, various capabilities can be obtained. 4 8548-70 Rev. I 9/12 APPLICATION NOTES CONTINUED COMMUTATION TRUTH TABLE 1 0 X = High Level = Low Level = Don't Care H L - = SOURCE = SINK = OPEN NOTE: Because of the true 4 quadrant method of output switching, the output switches will PWM between the ICOMMAND POSITIVE and ICOMMAND NEGATIVE states, with the average percentage based on ICOMMAND being a positive voltage and a negative voltage. With a zero voltage ICOMMAND, the output switches will modulate with exactly a 50% duty cycle between the ICOMMAND POSITIVE and ICOMMAND NEGATIVE states. 5 8548-70 Rev. I 9/12 APPLICATION NOTES CONTINUED BUS VOLTAGE FILTER CAPACITORS The size and placement of the capacitors for the DC bus has a direct bearing on the amount of noise filtered and also on the size and duration of the voltage spikes seen by the bridge. What is being created is a series RLC tuned circuit with a resonant frequency that is seen as a damped ringing every time one of the transistors switches. For the resistance, wire resistance, power supply impedance and capacitor ESR all add up for the equivalent lumped resistance in the circuit. The inductance can be figured at about 30 nH per inch from the power supply. Any voltage spikes are on top of the bus voltage and the back EMF from the motor. All this must be taken into account when designing and laying out the system. If everything has been minimized, there is another solution. A second capacitance between 5 and 10 times the first capacitor and it should either have some ESR or a resistor can be added in series with the second capacitor to help damp the voltage spikes. Be careful of the ripple current in all the capacitors. Excessive ripple current, beyond what the capacitors can handle, will destroy the capacitors. REGULATED VOLTAGE FILTER CAPACITORS It is recommended that about 100 μF of capacitance (tantalum electrolytic) for bypassing the + and -15V regulated outputs be placed as close to the module pins as practical. Adding ceramic bypass capacitors of about 0.1 μF or 1 μF will aid in suppressing noise transients. GENERAL LAYOUT Good PC layout techniques are a must. Ground planes for the analog circuitry must be used and should be tied back to the small pin grounds, pin 7-GND. Power ground planes should be tied to pins 21, 22-RTN. LOW POWER STARTUP When starting up a system utilizing the MSK 4462 for the first time, there are a few things to keep in mind. First, because of the small size of the module, short circuiting the output phases either to ground or the DC bus will destroy the bridge. The current limiting and control only works for current actually flowing through the bridge. The current sense resistor has to see the current in order for the electronics to control it. If possible, for startup use a lower voltage and lower current power supply to test out connections and the low current stability. With a limited current supply, even if the controller locks up, the dissipation will be limited. By observing the E/A OUT pin which is the error amp output, much can be found out about the health and stability of the system. An even waveform with some rounded triangle wave should be observed. As current goes up, the DC component of the waveform should move up or down. At full current (with a regular supply) the waveform should not exceed +8 volts positive peak, or -8 volts negative peak. Some audible noise will be heard which will be the commutation frequency. If the motor squeals, there is instability and power should be removed immediately unless power dissipation isn't excessive due to limited supply current. For compensation calculations, refer to the block diagram for all information to determine the amplifier gain for loop gain calculations. 6 8548-70 Rev. I 9/12 MSK4462 TEST CIRCUIT 7 8548-70 Rev. I 9/12 MECHANICAL SPECIFICATIONS WEIGHT= TBD GRAMS MOUNTING TORQUE= 3-4 INCH POUNDS ESD TRIANGLE INDICATES PIN 1 NOTE: ALL DIMENSIONS ARE ±0.010 INCHES UNLESS OTHERWISE LABELED. CAUTION: THIS IS A NON-HERMETIC DEVICE. DO NOT EXPOSE PLASTIC HOUSING TO LIQUID ORDERING INFORMATION MSK4462 U LEAD CONFIGURATION S=STRAIGHT, U=BENT UP, D=BENT DOWN, G=GULL WING GENERAL PART NUMBER THE ABOVE EXAMPLE IS A HYBRID WITH LEADS BENT UP. M.S. Kennedy Corp. 4707 Dey Road, Liverpool, New York 13088 Tel. (315) 701-6751 FAX (315) 701-6752 www.mskennedy.com The information contained herein is believed to be accurate at the time of printing. MSK reserves the right to make changes to its products or specifications without notice, however, and assumes no liability for the use of its products. 8 8548-70 Rev. I 9/12