ISO 9001 CERTIFIED BY DSCC
M.S.KENNEDY CORP.
30 AMP, 75V, 3 PHASE
MOSFET BRUSHLESS
MOTOR CONTROLLER
4362
4707 Dey Road Liverpool, N.Y. 13088
(315) 701-6751
FEATURES:
MIL-PRF-38534 CERTIFIED
75 Volt Motor Supply 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.
DESCRIPTION:
The MSK 4362 is a complete 3 Phase MOSFET Bridge Brushless Motor Control System in a convenient isolated
hermetic package. The hybrid is capable of 30 amps of output current and 75 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 mode for the tightest control and the most
bandwidth. Provisions for applying different compensation schemes are included. The MSK 4362 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
TYPICAL APPLICATIONS
3 Phase Brushless DC Motor Control
Servo Control
Fin Actuator Control
Gimbal Control
AZ-EL Control
PIN-OUT INFORMATION
1
2
3
4
5
6
7
8
9
10
11
12
REFOUT
HALL A
HALL B
HALL C
60 /120
BRAKE
CLOCK SYNC
DIS
GND
N/C
N/C
E/A OUT
1
13
14
15
16
17
18
19
20
21
22
23
24
E/A GND
+Current Command
-Current Command
+15 VIN
Current Monitor Out
-15 VIN
-REG IN
L1
-15 VOUT
GND
+15 VOUT
25+REG IN
26 LGND
27 RTN
28 RTN
29 CVS
30 CVS
31 CØ
32 CØ
33 CV+
34 BVS
35 BVS
36 BØ
37
38
39
40
41
42
43
BØ
BV+
AVS
AVS
AØ
AØ
AV+
Rev. G 2/05
ABSOLUTE MAXIMUM RATINGS
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
-0.2V to +15V
Clock SYNC Input
30 Amps
Continuous Output Current
41 Amps
Peak Output Current
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RθJC
RθJC
TST
TLD
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TC
TJ
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Thermal Resistance (Output Switches)
Thermal Resistance (Regulator)
Storage Temperature Range
Lead Temperature Range
(10 Seconds)
Case Operating Temperature
MSK4362
MSK4362H/E
Junction Temperature
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1.5°C/W
9°C/W
-65°C to +150°C
+300°C
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-40°C to +125°C
-55°C to +125°C
+150°C
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ELECTRICAL SPECIFICATIONS
Parameter
Group A
Subgroup
Test Conditions
INPUT CURRENT
+15 VIN
Output PWM'ing
-15 VIN
PWM
Current Command=0 Volts
Clock Free Running Frequency
CLOCK SYNC INPUT
VIL 1
VIH 1
Duty Cycle 1
SYNC Frequency 1
REGULATORS
+15 VOUT
-15 VOUT
25mA Load
25mA Load
REFOUT
-15 VOUT Ripple
15mA Load
50mA Load
6
6
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
Transconductance 8
Current Command=0Volts
Offset Current
Current Monitor 8
Current Monitor Voltage Swing
ERROR AMP
E/A OUT Swing 1
1
5mA Load
5mA Load
Slew Rate 1
Gain Bandwidth Product 1
Large Signal Voltage Gain 1
OUTPUT SECTION 1
Voltage Drop Across Bridge (1 Upper & 1 Lower)
1
30 AMPS
Voltage Drop Across Bridge (1 Upper & 1 Lower) 1 30 AMPS @ 150°c Junction
Leakage Current 1 7
All switches off, V+=60V, 150°C Junction
Diode VSD 1
trr 1
Dead Time 1
MSK 4362H/E 3
Min.
Typ.
Max.
Min.
MSK 4362 2
Typ.
Max.
Units
1
1
-
68
30
85
40
-
68
30
85
40
mA
mA
4
5,6
21
18.7
22
22
23
25.3
20
-
22
-
24
-
KHz
KHz
-
12.5
10
Clock +0
-
1,2,3
1,2,3
1,2,3
4
14.25
-14.25
5.82
-
-
15.75
-15.75
6.57
250
-
3.0
-
4
5,6
1
2,3
4
5,6
-
-13.5
2.70
2.55
-25
-50
0.300
0.280
-12
-
2.5
12.5
10
90
Clock +3 Clock +0
-
2.5
VOLTS
VOLTS
90
%
Clock +3 KHz
14.25
-14.25
5.82
-
-
15.75 VOLTS
-15.75 VOLTS
6.57 VOLTS
250
mV
0.8
-
3.0
-
3
3
0
0
0.33
0.33
-
+13.5
1.5
3.30
3.45
25
50
0.367
0.380
+12
-13.5
2.55
-50
0.280
-12
3
0
0.33
-
-
-12
6.5
175
8
6.5
275
+12
-
-12
6.5
175
8
6.5
275
+12
-
VOLTS
V/µSec
MHz
V/mV
-
-
280
2
1
1.83
750
2.6
-
-
280
2
1
1.83
750
2.6
-
VOLTS
VOLTS
µA
VOLTS
nSec
µSec
0.8
-
VOLTS
VOLTS
+13.5 VOLTS
1.5
mA
3.45
A/V
A/V
50
mA
mA
0.380
V/A
V/A
+12 VOLTS
NOTES:
1
2
3
4
5
6
7
8
9
Guaranteed by design but not tested. Typical parameters are representative of actual device performance but are for reference only.
Industrial grade devices and "E" suffix shall be tested to subgroups 1 and 4 unless otherwise specified.
Military grade devices ("H" Suffix) shall be 100% tested to Subgroups 1, 2, 3 and 4.
Subgroups 5 and 6 testing available upon request.
Subgroup 1, 4 TA = TC = +25°C
2, 5 TA = TC =+125°C
3, 6 TA = TC =
-55°C
Maximum power dissipation must be limited according to voltage regulator power dissipation.
Hybrid powered by external ±15V supplies.
Measurements do not include offset current at 0V current command.
Continuous operation at or above absolute maximum ratings may adversly effect the device performance and/or life cycle.
2
Rev. G 2/05
APPLICATION NOTES
-REF 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.
MSK 4362 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.
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
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 required current by the motor. There
are no short circuit provisions for these outputs. Shorts to
V+ or gound from these pins must be avoided or the bridge
will be destroyed.
-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.
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.
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.
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.
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
LGND - is an isolated ground connection to the RTN pin of
the hybrid that is connected internally. For any circuitry that
needs to be connected to the RTN pin without the influence
of current flow through RTN should be connected at this
point.
GND - is a ground pin that connects to the ground plane for
all low powered circuitry inside the hybrid.
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-.
+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.
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.
CLOCK SYNC- is an input for synchronizing to an external
clock. The sync circuit will trigger on the edges of the applied clock and effectively shorten the period of the internal
oscillator on each cycle. The frequency can be increased
from a free running 22 KHz to 25 KHz maximum. The clock
applied shall be 15 volts amplitude with at least a 10% duty
cycle.
+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.
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
Rev. G 2/05
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 4362 +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 9°C/W = 28.1°C RISE above case temperature
Maximum Case Temperature = 150°C - 28.1°C = 121.9°C
To lower power dissipation in the regulator, a dropping resistor
can be added in series from V+ to the +REG IN pin. Using the
above example, if V+ = 39V and there is no dropping resistor,
total power dissipation rises to about 5.76 watts. Temperature
rise is now 51.8°C above case temperature, limiting maximum
case temperature to 98.2°C. By adding a dropping resistor to
lower the +REG IN pin voltage to 24.1V, the regulator power
dissipation is lowered to 2.19 watts. Temperature rise is now
19.7°C above case temperature, allowing a maximum case temperature all the way to +125°C.
ALTERNATE REGULATOR CONNECTION OPTIONS
By connecting the regulators in different ways, various capabilities can be obtained.
1.
Higher than 55 volt operation For operation at higher than 55 volt motor bus voltages, there are three options available:
4
Rev. G 2/05
APPLICATION NOTES CONTINUED
COMMUTATION TRUTH TABLE
HALL SENSOR PHASING
120°
ICOMMAND = POS.
60°
ICOMMAND = NEG.
BRAKE
HALL
A
HAL
B
HAL
C
HAL
A
HAL
B
HAL
C
AØ
BØ
CØ
AØ
BØ
CØ
1
0
0
1
0
0
H
-
L
L
-
H
0
1
1
0
1
1
0
-
H
L
-
L
H
0
0
1
0
1
1
1
L
H
-
H
L
-
0
0
1
1
0
1
1
L
-
H
H
-
L
0
0
0
1
0
0
1
-
L
H
-
H
L
0
1
0
1
0
0
0
H
L
-
L
H
-
0
1
1
1
1
0
1
-
-
-
-
-
-
0
0
0
0
0
1
0
-
-
-
-
-
-
0
X
X
X
X
X
X
L
L
L
L
L
L
1
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
Rev. G 2/05
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 9, 14 and 23. Additional ground, pin 26 is an isolated ground that connects internally directly back to the
main DC bus ground pin 27. This can be used as necessary for voltage sensing, etc.
LOW POWER STARTUP
When starting up a system utilizing the MSK 4362 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
Rev. G 2/05
MSK4362 TEST CIRCUIT
7
Rev. G 2/05
MECHANICAL SPECIFICATIONS
WEIGHT = 88 GRAMS TYPCAL
NOTE: ALL DIMENSIONS ARE ±.010 INCHES UNLESS OTHERWISE LABELED.
ESD TRIANGLE INDICATES PIN 1.
ORDERING INFORMATION
MSK4362 H U
LEAD CONFIGURATION
S=STRAIGHT, U=BENT UP, D=BENT DOWN
SCREENING
BLANK=INDUSTRIAL; E=EXTENDED RELIABILITY;
H=MIL-PRF-38534 CLASS H
GENERAL PART NUMBER
THE ABOVE EXAMPLE IS A MILITARY GRADE HYBRID WITH LEADS BENT UP.
M.S. Kennedy Corp.
4707 Dey Road Liverpool, New York 13088
Phone (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.
Please visit our website for the most recent revision of this datasheet.
8
Rev. G 2/05