www.fairchildsemi.com ML4425 Sensorless BLDC Motor Controller Features General Description • • • • The ML4425 PWM motor controller provides all of the functions necessary for starting and controlling the speed of delta or wye wound Brushless DC (BLDC) motors without Hall Effect sensors. Back EMF voltage is sensed from the motor windings to determine the proper commutation phase sequence using a PLL. This patented sensing technique will commutate a wide range of 3-Phase BLDC motors and is insensitive to PWM noise and motor snubbing circuitry. • • • • Stand-alone operation Motor starts and stops with power to IC On-board start sequence: Align ♦ Ramp ♦ Set Speed Patented Back-EMF commutation technique provides jitterless torque for minimum “spin-up” time Onboard speed control loop PLL used for commutation provides noise immunity from PWM spikes, compared to noise sensitive zero crossing technique PWM control for maximum efficiency Direct FET drive for 12V motors; drives high voltage motors with IC buffers The ML4425 limits the motor current using a constant offtime PWM control loop. The velocity loop is controlled with an onboard amplifier. The ML4425 has circuitry to ensure that there is no shoot-through in directly driven external power MOSFETs. The timing of the start-up sequence is determined by the selection of three timing capacitors. This allows optimization for a wide range of motors and loads. Block Diagram 17 VDD VDD CAT 21 CRT 20 750nA 15 16 SPEED CVCO FB CRR 750nA RVCO – – FB A + 1.5V + 1.5V 22 19 VDD FB B 23 FB C 24 500nA BACK EMF SAMPLER VCO/TACH VOLTAGE CONTROLLED OSCILLATOR 13 VCO OUT VCO OUT R A F B + COMMUTATION STATE MACHINE – 8 E 3.9V SPEED SET HA C D 5 HB – SPEED COMP 1.7V – CT ×5 6 20kHz ISENSE 1.7V – VREF + 1.4V ILIMIT 1-SHOT + HC LA LB LC UVLO VDD 16kΩ UV FAULT 1 4kΩ ILIMIT 12 GATING LOGIC & OUTPUT DRIVERS + 2 3 4 9 10 11 18 REFERENCE 8kΩ CIOS 26 VDD BRAKE 25 14 GND 28 RREF 27 VREF 7 REV. 1.0.2 7/2/01 ML4425 PRODUCT SPECIFICATION Pin Configuration ML4425 28-Pin Narrow PDIP (P28N) 28-Pin SOIC (S28) ISENSE 1 28 GND HA 2 27 RREF HB 3 26 CIOS HC 4 25 BRAKE SPEED COMP 5 24 FB C CT 6 23 FB B VREF 7 22 FB A SPEED SET 8 21 CRR LA 9 20 SPEED FB LB 10 19 CRT LC 11 18 UV FAULT ILIMIT 12 17 CAT VCO/TACH 13 16 RVCO VDD 14 15 CVCO TOP VIEW Pin Description 2 Pin 1 Name ISENSE 2 3 4 5 6 HA HB HC SPEED COMP CT 8 9 10 11 12 VREF SPEED SET LA LB LC ILIMIT 13 VCO/TACH 14 15 VDD CVCO Function Motor current sense input. When ISENSE exceeds 0.2 ↔ ILIMIT, the output drivers LA, LB, and LC are shut off for a fixed time determined by CIOS. Active low output driver for the phase A high-side switch. Active low output driver for the phase B high-side switch. Active low output driver for the phase C high-side switch. Speed control loop compensation is set by a series resistor and capacitor from SPEED COMP to GND. A capacitor from CT to GND sets the PWM oscillator frequency. 6.9V reference voltage output. Speed loop input which ranges from 0 (stopped) to VREF (maximum speed). Active high output driver for the phase A low-side switch. Active high output driver for the phase B low-side switch. Active high output driver for the phase C low-side switch. Voltage on this pin sets the ISENSE threshold voltage at 0.2 ↔ ILIMIT, leaving this pin unconnected selects an internally set threshold. This TTL level output corresponds to the signal used to clock the commutation state machine. The output frequency is proportional to the motor speed when the backEMF sensing loop is locked onto the rotor position. 12V power supply input. A capacitor to GND sets the voltage-to-frequency ratio of the VCO. REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION Pin Description ML4425 (continued) Pin 16 17 18 Name RVCO CAT UV FAULT 19 20 CRT SPEED FB 21 CRR 22 FB A 23 FB B 24 FB C 25 BRAKE 26 CIOS 27 RREF 28 GND Function An resistor to GND sets up a current proportional to the input voltage of the VCO. A capacitor to GND sets the time that the controller stays in the align mode. This output goes low when VDD drops below the UVLO threshold, and indicates that all output drivers have been disabled. A capacitor to GND sets the time that the controller stays in the ramp mode. Output of the back-EMF sampling circuit and input to the VCO. An RC network connected to SPEED FB sets the compensation for the PLL loop formed by the back-EMF sampling circuit, the VCO, and the commutation state machine. A capacitor to between CRR and SPEED FB sets the ramp rate (acceleration) of the motor when the controller is in ramp mode. The motor feedback voltage from phase A is monitored through a resistor divider for back-EMF sensing at this pin. The motor feedback voltage from phase B is monitored through a resistor divider for back-EMF sensing at this pin. The motor feedback voltage from phase C is monitored through a resistor divider for back-EMF sensing at this pin. A logic low input activates motor braking by shutting off the high-side output drivers and turning on the low-side output drivers. A capacitor to GND sets the time that the low-side output drivers remain off after ISENSE exceeds its threshold . An 137kΩ resistor to GND sets a current proportional to VREF that is used to set all the internal bias currents except for the VCO. Signal and power ground. Absolute Maximum Ratings Absolute maximum ratings are those values beyond which the device could be permanently damaged. Absolute maximum ratings are stress ratings only and functional device operation is not implied. Parameter Min. VDD Max. Units 14 V Logic Inputs (SPEED FB, BRAKE) GND – 0.3 7 V All Other Inputs and Outputs GND – 0.3 VDD + 0.3 V Output Current (LA, LB, LC, HA, HB, HC) ±50 mA Junction Temperature 150 °C 150 °C Lead Temperature (Soldering 10 sec.) 260 °C Thermal Resistance (θJA) 28-Pin Narrow PDIP 28-Pin SOIC 48 75 °C/W °C/W Storage Temperature Range -65 Operating Conditions Parameter Min. Max. Units Temperature Range ML4425CX ML4425IX 0 –40 70 85 °C °C VDD 10.8 13.2 V REV. 1.0.2 7/2/01 3 ML4425 PRODUCT SPECIFICATION Electrical Characteristics Unless otherwise specified, VDD = 12V ± 10%, RSENSE = 1Ω, CVCO = 10nF, CIOS = 100pF, RREF = 137kΩ, TA = Operating Temperature Range (Notes 1, 2). Symbol Parameter Conditions Min. Typ. Max. Units 6.5 6.9 7.5 V Reference VREF Total Variation Line, Temp PWM Oscillator Total Variation CT = 1nF 28 kHz Ramp Peak 3.9 V Ramp Valley 1.7 V Ramp Charging Current µA Speed Control Loop SPEED SET Input Voltage Range 0 VREF V SPEED FB Input Voltage Range 0 VREF V SPEED COMP Output Current ±5 ±20 µA VSPEED SET = xV, VSPEED FB = yV 144 µ Ω SPEED SET Error Amp Transconductance Start-up CAT Charging Current C Suffix 0.68 0.98 µA I Suffix 0.5 1.1 µA 1.4 1.7 V C Suffix 0.68 0.98 µA I Suffix 0.5 1.1 µA 1.4 1.7 V CAT Threshold Voltage CRT Charging Current CRT Threshold Voltage Voltage Controlled Oscillator Frequency Range RVCO = 5V, SPEED FB = 6V Frequency vs. SPEED FB RVCO = 5V, 0.5V ≤ SPEED FB ≤ 7V 1.5 1.85 2.2 300 kHz Hz/V Current Limit ISENSE Gain V(ILIMIT) ≤ 2.5V One Shot OFF-Time CIOS = 100pF 4.5 5.0 5.5 V/V C Suffix 9 18 µs I Suffix 9 20 µs 0.8 V Logic Inputs (BRAKE) (Note 3) 4 VIH Input High Voltage VIL Input Low Voltage 2 V IIH Input High Current VIH = 2.4V 2.4 mA IIL Input Low Current VIL = 0.4V 2.9 mA REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION ML4425 Electrical Characteristics (continued) Unless otherwise specified, VDD = 12V ± 10%, RSENSE = 1Ω, CVCO = 10nF, CIOS = 100pF, RREF = 137kΩ, TA = Operating Temperature Range (Notes 1, 2). Symbol Parameter Conditions Min. Typ. Max. Units Logic Outputs (VCO/TACH, UV FAULT) (Note 3) VCO/TACH Output High Voltage IOUT = –100µA VCO/TACH Output Low Voltage IOUT = 400µA UV FAULT Output High Voltage IOUT = –10µA UV FAULT Output Low Voltage 2.2 C Suffix 3.4 I Suffix 3.2 V 4.5 IOUT = 400µA 0.6 V 5.4 V 5.6 V 0.6 V 250 mV Back-EMF Sampler SPEED FB Align Mode Voltage 125 SPEED FB Ramp Mode Current SPEED FB Run Mode Current State A, CRT = 5V, VPHB = VDD/3 C Suffix 500 720 nA I Suffix 500 750 nA C Suffix 30 90 µA I Suffix 27 90 µA State A, CRT = 5V, VPHB = VDD/2 –15 15 µA State A, CRT = 5V, VPHB = 2↔VDD/3 C Suffix –90 –30 µA I Suffix –90 –27 µA 0.5 1.2 mA Output Drivers High Side Driver Output Low Current VHX = 2V High Side Driver Output High Voltage IHX = –10µA Low Side Driver Output Low Voltage ILX = 1mA Low Side Driver Output High Voltage V(ISENSE) = 0V VCC – 1.3 V 0.2 0.7 V C Suffix VDD – 2.2 V I Suffix V VDD – 2.9 Phase C Cross-conduction Lockout Threshold VDD – 3.0 V Supply IDD VDD Current UVLO Threshold C Suffix 8.8 I Suffix 8.6 UVLO Hysteresis 32 50 mA 9.5 10.2 V 10.3 V 150 mV Notes: 1. Limits are guaranteed by 100% testing, sampling, or correlation with worst case test conditions. 2. For explanation of states, see Figure 4 and Table 1. 3. The BRAKE and UV FAULT pins each have an internal 4kΩ resistor to the internal reference. REV. 1.0.2 7/2/01 5 ML4425 Functional Description General The ML4425 provides all the circuitry for sensorless speed control of 3-phase Brushless DC (BLDC) motors. Controller functions include start-up circuitry, back-EMF commutation control, Pulse Width Modulation (PWM) speed control, fixed OFF-time current limiting, braking, and undervoltage protection. The start-up circuitry aligns the motor to a known position, then ramps up the motor speed to generate a back-EMF signal. A back-EMF sampling circuit controls commutation timing by forming a Phase Locked Loop (PLL). The commutation control circuitry also outputs a speed feedback (SPEED FB) signal used in the speed control loop. The speed control loop consists of an error amplifier and PWM comparator that produce a PWM duty cycle for speed regulation. Motor current is limited by a fixed OFF-time PWM shutdown comparator that is controlled by an external sense resistor. Commutation control, PWM speed control, and current limiting are combined to produce the output driver signals. Six output drivers are used to provide gating signals to an external 3 phase bridge power stage sized for the BLDC motor voltage and current requirements. Additional functions include a braking function and undervoltage protection circuit to shut down the output drivers in the event of a low voltage condition on VDD of the ML4425. Component Selection Selecting external components for the ML4425 requires calculations based on the motor’s electrical and mechanical parameters. The following is a list of the motor parameters needed for these calculations : • • • • • • • • 6 DC motor supply voltage – VMOTOR (V) Maximum operating current – IMAX (A) Number of magnetic poles – N Back EMF constant – Ke (V-s/Rad) Motor torque constant – Kt (Nm/A) (Kt = Ke in SI units) Maximum speed of operation RPMMAX (RPM) Moment of inertia of the motor and load – J (Kg-m2) Viscous damping factor of the motor and load – ζ PRODUCT SPECIFICATION If one or more of the above values is not known, it is still possible to pick components for the ML4425, but some experimentation may be necessary to determine the optimal values. All quantities are in SI units unless otherwise specified. The following formulas should be considered as a starting point for optimization. All calculations for capacitors and resistors should be used as the first approximation for selecting the closest standard value. Power Supply and Reference The supply voltage (VDD) is nominally 12V ±10%. A 100nF bypass capacitor to ground should be placed as close as possible to VDD. A 6.9V voltage reference output (VREF) is provided to set the speed command and current limit of the ML4425. A 137kΩ from RREF to GND is required to set up a reference current for internal functions. Output Drivers The output drivers LA, LB, LC, HA, HB, and HC provide totem pole output drive signals for a 3 phase bridge power stage. All control functions in the ML4425 translate to outputs at these pins. LA, LB, and LC provide the low-side drive signals for phases A, B, and C of the 3 phase power stage and are 12V active high signals. HA, HB, and HC provide the high-side signals and are 12V active low signals. VMOTOR 12V DC SUPPLY CAPACITOR HA HB HC MOTOR PHASE A LA LB MOTOR PHASE B MOTOR PHASE C LC RSENSE Figure 1. Using RSENSE in a 3-Phase 12V Power Stage REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION ML4425 Current Limiting in the Power Stage The current sense resistor (RSENSE) shown in Figure 1 regulates the maximum current in the power stage and the BLDC motor. Current regulation is accomplished by shutting off the output drivers LA, LB, and LC for a fixed amount of time if the voltage across RSENSE exceeds the current limit threshold. ILIMIT The voltage on the ILIMIT pin sets the current limit threshold. The ML4425 has an internal voltage divider from VREF that sets a default current limit threshold of 2.3V (see Figure 2). An external voltage divider referenced to VREF can be used to override the default ILIMIT setting. The external divider should have at least 10 times the current flow of the internal divider. starting values for this circuit are R = 1kΩ and C = 330pF. This gives a time constant of 330ns, and will filter out spikes of shorter duration. C can be increased to as much as 2.2nF, but should not exceed a time constant of more than a few microseconds. CIOS When ISENSE exceeds 0.2 ↔ ILIMIT, the current limit oneshot is activated, turning off LA, LB, and LC for a fixed amount of time (tOFF). tOFF is set by the amount of capacitance connected to CIOS. CIOS is usually set for a fixed off time equal to or less than the PWM period. For a 25kHz PWM frequency, the PWM period is 40µs; tOFF should be between 20µs and 40µs. The lower limit of tOFF is dictated by the minimum on time of the power stage; a safe approximation is 5µs or less. The equation for finding the CIOS capacitance value is as follows: RSENSE The function of RSENSE is to provide a voltage proportional to the motor current to set the current limit trip point. The default trip voltage across RSENSE is 460mV, set by the internal ILIMIT divider ratio. The current sense resistor should be a low inductance resistor such as a carbon composition. For resistors in the milliohms range, wire-wound resistors tend to have low values of inductance. RSENSE should be sized to handle the power dissipation (IMAX2 ↔ RSENSE). ISENSE Filter The ISENSE RC lowpass filter is placed in series with the current sense signal as shown in Figure 2. The purpose of this filter is to remove the diode reverse recovery shootthrough current. This current causes a voltage spike on the leading edge of the current sense signal which may falsely trigger the current limit. The current sense voltage waveform is shown before and after filtering in Figure 3. The recommended FROM RSENSE t OFF × 50µA C OS = -------------------------------2.4V (1) Commutation Control A 3-phase BLDC motor requires electronic commutation to achieve rotational motion. Electronic commutation requires the switching on and off of the power switches of a 3-phase half bridge. For torque production to be achieved in one direction, the commutation is dictated by the rotor position. Electronic commutation in the ML4425 is achieved by turning on and off, in the proper sequence, one N output from one phase and one P output from another phase. There are six combinations of N and P outputs (six switching states) that constitute a full commutation cycle. These combinations are illustrated in Table 1 and Figure 4, and are labeled states A through F. This sequence is programmed into the commutation state machine. Clocking of the commutation state machine is provided by a voltage controlled oscillator (VCO). PWM ON/OFF ISENSE ×5 – + VREF VREF S Q R Q 16kΩ ILIMIT 2.9V 8kΩ 0V STOP START 460mV 30µA CIOS 0V (a) Figure 2. Current Sense Circuitry REV. 1.0.2 7/2/01 (b) Figure 3. Current Sense Resistor Waveforms (a) Without Filtering, and (b) With Filtering 7 ML4425 PRODUCT SPECIFICATION Outputs LA LB LC HA HB HC Input Sampling R OFF ON OFF ON OFF ON N/A A OFF OFF ON ON OFF OFF FB B State B OFF OFF ON OFF ON OFF FB A C ON OFF OFF OFF ON OFF FB C D ON OFF OFF OFF OFF ON FB B E OFF ON OFF OFF OFF ON FB A F OFF ON OFF ON OFF OFF FB C Table 1. Commutation State Functions A B C D E F A B C D E F HA HIGH SIDE DRIVE OUTPUTS HB HC LA LOW SIDE DRIVE OUTPUTS LB LC Figure 4. Output Commutation Sequence Timing Diagram Cycle 1 – Full Commutation, Cycle 2 – Commutation with 50% PWM Duty Cycle Voltage Controlled Oscillator (VCO) The VCO provides a TTL compatible clock output on the VCO/TACH pin proportional to the VCO input voltage at the SPEED FB pin. The proportion of frequency to voltage (VCO constant, Kv) is set by an 80.6kΩ resistor on RVCO and a capacitor on CVCO as shown in Figure 5. RVCO sets up a current proportional the VCO input voltage at SPEED FB. This current is used to charge and discharge CVCO between the threshold voltages of 2.3V and 4.3V. The resulting triangle wave on CVCO corresponds to the clock on VCO. Kv should be set so that the VCO output frequency corresponds 8 to the maximum commutation frequency or maximum motor speed when the VCO input is equal to or slightly less than VREF. CVCO is calculated using the following equation: C VCO – 6 Hz • Farad 6.5V × 3.101 × 10 -----------------------------V = ----------------------------------------------------------------------------------Hz 0.05 -------------- × N × SPEED MAX RPM (2) The closest standard value that is equal to or less than the calculated CVCO should be used. REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION ML4425 The maximum frequency on the VCO pin is found by: f MAX = 0.05 × N × RPM MAX (3) CVCO The voltage at the VCO/TACH pin is equal to the rotor speed. The voltage at SPEED FB is controlled by the back EMF sampler. RVCO SPEED CVCO FB Back EMF Sampler The input to the voltage controlled oscillator is the back EMF sampler. The back EMF sense pins FB A, FB B, and FB C inputs to the back EMF sampler require a signal from the motor phase leads that is below the VDD of the ML4425. The phase sense input impedance is 8kΩ. This requires a series resistor RES1 from the motor phase lead as shown in Figure 6 based on the following equation: FROM BACK EMF SAMPLER & RAMP GENERATOR RESET (FROM CAT) RVCO VOLTAGE CONTROLLED OSCILLATOR VCO/TACH 4.3V CVCO 2.3V RES1 = 670Ω ⁄ V × ( V MOTOR – 10V ) (4) 5V The back EMF sampler takes the motor phase voltages divided down to signals that are less than VDD (12V nominal) and calculates the neutral point of the motor by the following equation: PH1 + PH2 + PH3 Neutral = ------------------------------------------------3 (5) This allows the ML4425 to compare the back EMF signal to the motor’s neutral point without the need for bringing out an extra wire on a WYE wound motor. For DELTA wound motors there is no physical neutral to bring out, so this reference point must be calculated in any case. MOTOR ΦA MOTOR ΦB MOTOR ΦC VCO/TACH 0V Figure 5. External VCO Component Connections The back EMF sampler measures the motor phase that is not driven (i.e. if LA and HB are on, then phase A is driven low, phase B is driven high, and phase C is sampled). The sampled phase provides a back EMF signal that is compared against the neutral of the motor. The sampler is controlled by the commutation state machine. The sampled back EMF is compared to the neutral through an error amplifier. The output of the error amplifier outputs a charging or discharging current to SPEED FB, which provides the control voltage to the VCO. RES1 FB A RES2 FB B NEUTRAL SIMULATOR RES3 FB C ΦA + ΦB + ΦC 6 4kΩ 4kΩ gm = SIGN CHANGER 4kΩ + – 1 8kΩ TO SPEED FB MULTIPLEXER 4kΩ 4kΩ 4kΩ F/R F/R COMMUTATION STATE MACHINE Figure 6. Back EMF Sampler Detailed Block Diagram REV. 1.0.2 7/2/01 9 ML4425 PRODUCT SPECIFICATION Back EMF Sensing PLL Commutation Control Three blocks form a phase locked loop that locks the commutation clock onto the back EMF signal: the commutation state machine, the voltage controlled oscillator, and the back EMF sampler. The complete phase locked loop is illustrated in Figure 7. The phased locked loop requires a lead lag filter that is set by external components on SPEED FB. The components are selected as follows: CSPEEDFB1 CSPEEDFB2 20 SPEED FB FB A VDD 22 C SPEEDFB1 2 K O1 NS - = 0.25 × ---------- × -----------------------------------------------d 2 M --------2 In 100- × f VCO f VCO d R SPEEDFB = 2 × M × In ---------- × ------------------------------------------------- 100 N S × K O1 × ( 1 – M ) RSPEEDFB FB B 23 (6a) FB C 24 500nA BACK EMF SAMPLER VOLTAGE CONTROLLED OSCILLATOR VCO/TACH 13 (6b R A C SPEEDFB2 = C SPEEDFB1 × ( M – 1 ) (6c) F B E PHASE LOCKED LOOP C D Start-Up Sequence When power is first applied to the ML4425 and the motor is at rest, the back EMF is equal to zero. The motor needs to be rotating for the back EMF sampler to lock onto the rotor position and commutate the motor. The ML4425 uses an open loop start-up technique to bring the rotor from rest up to a speed fast enough to allow back EMF sensing. Start-up is comprised of three modes: align mode, ramp mode, and run mode. Align Mode (RESET) Before the motor can be started, the rotor must be in a known position. When power is first applied to the ML4425, the controller is reset into the align mode. Align mode turns on the output drivers LB, HA, and HC which aligns the motor into a position 30 electrical degrees before the center of the first commutation state. This is shown as state R in the commutation states of Table 1. Align mode must last long enough to allow the motor and its load to settle into this position. The align mode time is set by a capacitor connected to the CAT pin as shown in Figure 8. CAT is charged by a constant 750µA current from GND to 1.5 V until the align comparator trips to end the align mode. A starting point for CAT is calculated as follows: –7 t S × 7.5 × 10 × amp C AT = ------------------------------------------------------1.5V (7) If the align time is not long enough to allow the rotor to settle for reliable starting, then increase CAT until the desired performance is achieved. 10 COMMUTATION STATE MACHINE Figure 7. Back EMF Commutation Phase Locked Loop Ramp Mode At the end of align mode the controller goes into ramp mode. Ramp mode starts commutating through the states A through F as shown in Table 1. This ramps up the commutation frequency, and therefore the motor speed, for a fixed length of time. This allows the motor to reach a sufficient speed for the back EMF sampler to lock commutation onto the motor’s back EMF. The amount of time the ML4425 stays in ramp mode is determined by a capacitor connected to the CRT pin as shown in Figure 8. CRT is charged by a constant 750µA current from GND to 1.5 V until the ramp comparator trips to end the ramp mode. This gives a fixed ramp time. CRT is calculated as follows: –7 2π × J × 5 × 10 × amp × K C RT = ---------------------------------------------------------------------------VI MAX × K t × 3 × N (8) The rate at which the ML4425 ramps up the motor speed is determined by a fixed 500µA current source on the SPEED FB pin. The current sources charges up the PLL filter components causing the VCO frequency to ramp up. During ramp mode, the back EMF sampler is disabled to allow control of the ramping to be set only by the 500µA current source. The ramp based on the SPEED FB filter is generally too fast for the motor to keep up, so a capacitor from CRR to SPEED FB can be added to slow down the ramping rate. The optimal ramp rate is based on the motor and load parameters and is can be adjusted by varying the value of CRR. REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION ML4425 CRR CAT VDD CRT VDD CAT FB B FB C SPEED CVCO FB RVCO – – 1.5V FB A CRR CRT 750nA 750nA TO SPEED FB FILTER + 1.5V + VDD 500nA BACK EMF SAMPLER VCO/TACH VOLTAGE CONTROLLED OSCILLATOR TO RESET INPUT OF COMMUTATION STATE MACHINE Figure 8. ML4425 Start-up Circuitry for Controlling the Align and Ramp Times Run Mode (Back EMF Sensing) At the end of ramp mode the controller goes into run mode. In run mode, the back EMF sensing is enabled and commutation is now under the control of the phase locked loop. Motor speed is now regulated by the speed control loop. FROM SPEED FB TO GATING LOGIC & OUTPUT DRIVERS VREF + PWM Speed Control 10kΩ Speed control is accomplished by setting a speed command at SPEED SET with an input voltage from 0 to 6.9V (VREF). The accuracy of the speed command is determined by the external components RVCO and CVCO. There are a number of methods that can be used to control the speed command of the ML4425. One is to use a 10kΩ potentiometer from VREF to ground with the wiper connected to SPEED SET. If SPEED SET is controlled from a microcontroller, one of its DACs can be used with VREF as its input reference. – 3.9V SPEED SET – SPEED COMP RSC + 1.7V CSC CT CT 20kHz 1.7V PWM ON/OFF FROM ILIMIT ONE-SHOT Figure 9. Speed Control Loop Component Connections The speed command is compared with the sensed speed from SPEED FB through a transconductance error amplifier. The output of the speed error amplifier is SPEED COMP. SPEED COMP is clamped between one diode drop above 3.9V (approximately 4.6V) and one diode drop below 1.7V (approximately 1V) to prevent speed loop “wind-up”. Speed loop compensation components are connected to this pin as shown in Figure 9. The speed loop compensation components are calculated as follows: 26.9 × N × V MOTOR × C VCO C SC = -----------------------------------------------------------------------------------------2 f SB × K e 2.5 + 98.696 × τm × f SB2 10 R SC = --------------------------------------2π × f SB × C SC The voltage on SPEED COMP is compared with a ramp oscillator to create a PWM duty cycle. The PWM ramp oscillator creates a sawtooth function from 1.7V to 3.9V as shown in Figure 9. A negative clamp at one diode drop below 1.7V (approximately 1V) starts the oscillator on power up. The frequency of the ramp oscillator is set by a capacitor to ground CIOS and is selected using the following equation: CT (9a) (9b) I -------------- × 50µA f PWM = ----------------------------------2.4V (10) Where fPWM is the PWM frequency in Hz. The PWM duty cycle from the speed control loop is gated the current limit one shot that controls the LA, LB, and LC output drivers. Where fSB is the speed loop bandwidth in Hz. REV. 1.0.2 7/2/01 11 ML4425 Cross Conduction Comparator When the ML4425 goes from align mode into ramp mode, there is a possibility of cross conduction in phase 3 of the bridge power stage. This cross conduction can happen when HC is on in the align mode shown as state R in Table 1, and the controller transitions to state A in ramp mode where HC is turned off and LC is turned on. Cross conduction can appear due to the differences in turn on and turn off times of the power devices. To solve this problem, the LC output driver is gated off until the HC is equal to VDD – 3V as shown in Figure 10. Braking When the BRAKE pin is pulled below 1.4V, the low side output drivers LA, LB, and LC are turned on and the high side output drivers HA, HB, HC are turned off. Braking causes rapid deceleration of the motor and current limiting is de-activated, and care should be taken when using the BRAKE pin. BRAKE is has an internal 4kΩ pull-up as shown in Figure 10, and can be driven by a switch to ground, an open collector or drain logic signal, or a TTL logic signal. PRODUCT SPECIFICATION The most flexible configuration is to use high side drivers to control N-Channel MOSFETs (or IGBTs) which allows applications from less than 12V up to 600V. Figure 12 shows the interface between the ML4425 and IR2118 high side drivers from International Rectifier. This configuration is capable of driving motors from busses of up to 320V. The BRAKE pin can be pulsed prior to startup with an RC circuit. This charges the bootstrap capacitors (C19, C20, and C21) for the three high side drivers, allowing the reset phase to operate normally. These capacitors must be sized so that they stay sufficiently charged during the align mode. Refer to AN-43 for additional applications information on the ML4425. FROM COMMUTATION STATE MACHINE Design Considerations HB GATING LOGIC & OUTPUT DRIVERS – + 1.4V Undervoltage Lockout Undervoltage lockout is used to protect the 3-phase bridge power stage from a low VDD condition. Undervoltage is triggered at VDD of 9.5V or less and is indicated by a TTL low output on the UV FAULT pin. Undervoltage lockout also turns off all output drivers (LA, LB, LC, HA, HB, and HC). The comparator that triggers undervoltage lockout has 150mV of hystresis. HA FROM SPEED CONTROL LOOP & CURRENT LIMIT 9.5V HC LA LB + LC – 2 3 4 9 10 11 VDD UV FAULT 4kΩ 18 REFERENCE VDD BRAKE 25 14 GND 28 RREF 27 VREF 7 Figure 10. Cross Conduction, Brake, and UVLO Circuits Interfacing to a 3-Phase Bridge Power Stage The ML4425 output drivers are configured to drive a 3 phase bridge power stage. For applications with buss voltages from 12V up to 80V, level shifting circuitry can be used to drive higher voltage P-channel MOSFETS for the high side switches as shown in Figure 11. 12 REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION VBUSS 24V–80V C2 330µF 100V C1 100nF 100V ML4425 R2 10kΩ R3 10kΩ Q4 FQD8P10 12V Q1 TN6718A R4 10kΩ Q5 FQD8P10 Q6 FQD8P10 Q2 TN6718A Q3 TN6718A Q7 IRFR120 Q8 IRFR120 C3 1µF Q9 IRFR120 MOTOR R1 470mΩ 2W R12 2kΩ R14 2kΩ R13 2kΩ R15 1kΩ C5 2.2nF ML4425 ISENSE HA R20 137kΩ GND RREF HB CIOS HC BRAKE SPEED COMP FB C CT FB B VREF FB A SPEED SET CRR RUN C16 330pF S1 R8 (RES1) R9 (RES1) R16 10kΩ C17 1nF C9 100nF C12 R18 10kΩ R21 787Ω R7 100Ω LA SPEED FB LB CRT LC UV FAULT ILIMIT R5 100Ω R6 100Ω 12V C14 1µF R10 (RES1) C8 1µF R17 10kΩ C6 1µF C7 100nF CAT VCO/TACH RVCO VDD CVCO C13 100nF BRAKE C14 C15 470nF C4 R19 80.5kΩ Figure 11. Driving Lower Voltage Motors (12 to 80V) REV. 1.0.2 7/2/01 13 ML4425 PRODUCT SPECIFICATION 12V IR2118 C16 100nF 25V VBUSS 24V–80V C5 330µF 400V VCC VB IN HO COM VS NC NC D1 MUR150 IR2118 C17 100nF 25V C19 2.2µF 25V VCC VB IN HO COM VS NC NC R6 100Ω R7 100Ω R8 100Ω Q1 FQP4P40 Q3 FQP4P40 Q5 FQP4P40 Q2 FQP5N40 Q4 FQP5N40 D2 MUR150 IR2118 C18 100nF 25V C20 2.2µF 25V VCC VB IN HO COM VS NC NC D3 MUR150 C21 2.2µF 25V Q6 FQP5N40 MOTOR R12 470mΩ 2W R1 1kΩ C1 2.2nF BOOTSTRAP PRE-CHARGE CAPACITOR ML4425 ISENSE C4 1nF C3 100nF C15 100nF R20 10kΩ R19 787Ω R9 100Ω D6 (3×1N5819) RREF HB CIOS HC BRAKE SPEED COMP FB C CT FB B VREF FB A RUN C14 330pF S1 R15 (RES1) R11 100Ω 12V C6 1µF R13 (RES1) BRAKE C13* SPEED SETRAMP COMP LA SPEED FB LB CRT LC UV FAULT ILIMIT R10 100Ω D5 HA R14 (RES1) R5 10kΩ D4 R18 137kΩ GND C11 100nF CAT VCO/TACH RVCO VDD CVCO C7 100nF C10 1µF R17 10kΩ C12 1µF C9 470nF C8 10nF R16 80.6kΩ Figure 12. ML4425 High Voltage Motor Drive Application Circuit 14 REV. 1.0.2 7/2/01 PRODUCT SPECIFICATION ML4425 Mechanical Dimensions inches (millimeters) Package: P28N 28-Pin Narrow PDIP 1.355 - 1.365 (34.42 - 34.67) 28 0.280 - 0.296 0.299 - 0.325 (7.11 - 7.52) (7.60 - 8.26) PIN 1 ID 1 0.045 - 0.055 (1.14 - 1.40) 0.100 BSC (2.54 BSC) 0.020 MIN (0.51 MIN) 0.180 MAX (4.57 MAX) SEATING PLANE 0.015 - 0.021 (0.38 - 0.53) 0.125 - 0.135 (3.18 - 3.43) 0º - 15º 0.008 - 0.012 (0.20 - 0.31) Package: S28 28-Pin SOIC 0.699 - 0.713 (17.75 - 18.11) 28 0.291 - 0.301 0.398 - 0.412 (7.39 - 7.65) (10.11 - 10.47) PIN 1 ID 1 0.024 - 0.034 (0.61 - 0.86) (4 PLACES) 0.050 BSC (1.27 BSC) 0.095 - 0.107 (2.41 - 2.72) 0º - 8º 0.090 - 0.094 (2.28 - 2.39) REV. 1.0.2 7/2/01 0.012 - 0.020 (0.30 - 0.51) SEATING PLANE 0.005 - 0.013 (0.13 - 0.33) 0.022 - 0.042 (0.56 - 1.07) 0.009 - 0.013 (0.22 - 0.33) 15 ML4425 PRODUCT SPECIFICATION Ordering Information Part Number Temperature Range Package ML4425CP 0°C to 70°C 28-Pin PDIP (P28N) ML4425CS 0°C to 70°C 28-Pin SOIC (S28) ML4425IP -40°C to 85°C 28-Pin PDIP (P28N) ML4425IS -40°C to 85°C 28-Pin SOIC (S28) DISCLAIMER FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS. LIFE SUPPORT POLICY FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR CORPORATION. As used herein: 1. Life support devices or systems are devices or systems which, (a) are intended for surgical implant into the body, or (b) support or sustain life, and (c) whose failure to perform when properly used in accordance with instructions for use provided in the labeling, can be reasonably expected to result in a significant injury of the user. 2. A critical component in any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness. www.fairchildsemi.com 7/2/01 0.0m 003 Stock#DS300042003 2001 Fairchild Semiconductor Corporation