International Rectifier Preliminary Data Sheet IRVR101 LIN Controlled Alternator Voltage Regulator Features: • • • • • • • • • • 9600 Baud Rate 10.7 to 16.0V Setpoint Control Programmable Load Response Control Programmable Field Excitation Full Diagnostic Capability Self Excitation Short Circuit Protected EMI and ESD Immunity Field Excitation, Temperature, and Fault Status Feedback < 200uA Standby Current B+ Voltage Sense B+ RECTIFIER ROTOR LIN Control Circuitry Fly back Diode F STATOR Field Driver P Phase Sense VOLTAGE REGULATOR ALTERNATOR Description The IRVR101 is an integral alternator voltage regulator that allows for external control of the setpoint voltage in an automotive charging system where optimized alternator output control is desired. The setpoint control is achieved using the Local Interconnect Network (LIN) serial communications protocol. Slew rate control and filtering of the interface lines provide electromagnetic compatibility. The regulator consists of a control ASIC, discrete low side power MOSFET (field driver), re-circulation diode, and passive components. The discrete circuitry allows for optimal flexibility with respect to the alternator rotor circuit and charging system requirements. The IRVR101 is characterized over the temperature range of –40 oC to 150 oC. Design The IRVR101 is manufactured using thick-film hybrid technology. The hybrid circuit can be customized for your application to optimize performance and reliability. The hybrid circuit can also be assembled in a custom housing with an insert–molded leadframe specifically designed for flame-soldering or heavy wire bonding. Thick-film hybrid technology offers reliable high temperature operation with excellent parametric stability over the entire operating temperature range. Resistor values are trimmed within +/-1% using laser equipment that provides precise calibration of voltage and current sensing circuitry. The control IC is attached to the substrate using flip chip technology in order to optimize space and reliability. Bare die is also used for the low side field driver and re-circulation diode in order to optimize space and heat transfer. www.irf.com Preliminary Data Sheet Custom Thick-film Hybrid Module 1 International Rectifier IRVR101 Introduction The IRVR101 is designed for use in a 12V automotive charging system where optimized battery charging and dynamic alternator control are desired. The Block Diagram illustrates the main components and potential system configuration of the LIN controlled charging system. The regulator is shown separate from the alternator assembly but it is typically integrated into the machine. The interface between the Engine Control Unit (ECU) and the regulator requires one bi-directional line with a transceiver at each end for serial communication. Alternatively, communication may be achieved between the regulator and Body Control Module (BCM) as illustrated in below. The signals to the regulator (received from the ECU or BCM) include the voltage setpoint, load response control ramp, load response control ramp cut-off speed, and the field excitation limit. The voltage setpoint command also allows for disabling of the field driver to achieve a momentary no output condition. Signals from the regulator (transmitted to the ECU or BCM) include the field excitation duty cycle, the field excitation current OR temperature (customer defined), and the fault status. Transmitted fault codes provide unique indication for mechanical, electrical, temperature, communication, and timeout errors. Block Diagram Optional communication path LIN Transceiver LIN Transceiver Additional LIN nodes (up to 15) Battery Voltage Sense LIN CAN Transceiver Lamp Transceiver control CAN Transceiver Body Control Module (BCM) Additional CAN nodes Engine Electronic Control Unit P ower Input LIN Controlled Voltage Regulator ECT AT VSS Sensor data inputs * P hase detection Stator GND www.irf.com Low side field driver Rotor Alternator B+ Voltage Sense Optional sense line Warning indicator Instrument Panel B+ Vehicle electrical loads + - 12V Battery Preliminary Data Sheet Sensor data inputs *: ECT =Engine Coolant Temp; AT = A mbient Te mpe rature; VSS = Vehicle Speed Sensor 2 International Rectifier IRVR101 Interface Design The interface design is based on the LIN communication protocol. Detailed information regarding this communication protocol can be found in the latest revision of the LIN Specification Package. This package can be obtained from the LIN Website located at www.lin-subbus.org. Activation and De-activation The voltage regulator is activated by a wake up signal that consists of the character ‘0x80’. The regulator is also capable of waking up with the presence of any normal bus activity. Once the regulator has been activated, the regulator will wait until a valid message is received prior to turning on the field driver. The regulator will then hold the field duty cycle at 18.75% until a cut-in phase signal is recognized at which time the regulator will soft start ramp to normal regulation. The cut-in phase voltage and frequency must be greater than 2V and 1200 Generator RPM (GRPM) respectively. De-activation requires a bus timeout in combination with a phase signal timeout. Bus timeout occurs 2s after the last valid message is received. Phase signal timeout occurs 500mS after the phase voltage and frequency have fallen below 0.6V AND 600 GRPM, respectively. Self-excitation In the event of a LIN bus fault, the voltage regulator is capable of self-excitation if a phase voltage and frequency of greater than 0.6VAND 1200 Generator RPM is detected. This signal is only possible if the residual magnetism in the alternator rotor core is sufficient enough to generate a magnetic field capable of inducing the voltage signal in the stator windings. If this signal is detected, the regulator will apply an 18.75% duty cycle until the cut-in phase signal is recognized at which time the regulator will soft start ramp to default regulation. The regulator will return to sleep mode at any time when the phase signal has timed out as described above. Voltage Sensing System voltage sensing can be achieved via the dedicated battery sense input or through machine sensing from the rectifier B+ output via the F+ input to the regulator. The battery sense input is optional and can be deleted. If the battery sense option is exercised, an open or short circuit at this input will cause voltage sensing to transfer to the machine voltage sense input (an electrical fault can be indicated if the regulator is configured for this fault option). The machine voltage setpoint can be set to a different value than the battery sense voltage to compensate for system voltage variation between the alternator and the battery. Voltage Regulation Voltage regulation is achieved using fixed frequency pulse width modulation. The base frequency is typically 150 Hz and the proportional control range for regulation is 100mV. This provides for very stable regulation over the entire speed and electrical load range. Load Response Control Load response control is programmable and can be varied from 0.426 seconds to 13.2 seconds in 16 steps. Additionally, the load response control cut-off speed is programmable and can be set to “always active” or varied from 2400 to 8000 Generator RPM. The load response at startup is equal to the programmed value for the load response control. The load response will always be executed on the first ramp to full field after engine start regardless of frequency in order to assist in achieving a smooth engine start. Fault Detection Respective fault codes are transmitted per the “Fault Detection” table. A 500mS delay is enforced prior to the transmission of any fault code. Mechanical faults are based on the frequency detection of the stator phase signal. Electrical faults are based on the voltage detection of the stator phase and system voltage sense inputs. A temperature fault is based on the regulator IC junction temperature. Communication errors are detected after a delay of 2s. Examples of sync communication errors are sync bit, checksum, and bit detect errors. A sync bit error is detected when the sync field does not = ‘0x55’. A checksum error is generated when the sum of the modulo-256 sum over all data bytes and the checksum byte do not equal ‘0xFF’. A bit error is detected when a transmitted bit does not correspond to the appropriate bus state due to another device forcing the bus to a www.irf.com Preliminary Data Sheet 3 different state. Bus timeout errors are detected for any lack of a valid signal within a 2s time frame. www.irf.com Preliminary Data Sheet 4 International Rectifier IRVR101 Absolute Maximum Ratings Absolute Maximum Ratings indicate sustained limits beyond which damage to the device may occur. All voltage parameters are referenced to GROUND pin . T Ambient = 25 °c unless otherwise specified . Condition Power Supply Continuous DC Voltage Transient Voltage (load dump) Reverse Battery (connector/other terminals) Temperature Operating baseplate temperature Storage temperature Field Current Continuous @ -40 oC Continuous @ 25 oC Continuous @ 150 oC Symbol Rating Unit VBATT VMAX VMIN 25 40 -12/-3 V V V TA TSTG -40 to +150 -50 to +170 IFLD-40 IFLD+25 IFLD+150 11 8 5 o C C o A A A Signal Characteristics SIGNAL S C FP TYPE FREQUENCY RANGE NORMAL VOLTAGE RANGE MAXIMUM VOLTAGE QUIESCENT CURRENT DRAIN DC PCM PWM AC N/A 9600 Hz 100-150 Hz 0-2000 Hz 12.5 to 16.0V 0.2 to 15.0V 0.5 to 17.0V -1 to 17V 100V 100V 100V 100V 100uA N/A 100uA N/A Terminal Functions Pin Name LIN B+ Voltage Sense Symbol C B+ Battery Voltage Sense Low Side Field Driver Phase Detection Ground S www.irf.com FP G Description Serial communication input/output Alternator rectifier output. Provides machine voltage sense input and power supply input to regulator. Also used as re-circulation diode cathode connection. Optional input for remote battery voltage sensing Low side of alternator field coil. Connected to the drain of the FET when using a low side drive. Stator phase input to the regulator. Used for self-excitation and fault detection. Ground connection Preliminary Data Sheet 5 International Rectifier IRVR101 Electrical Characteristics Function Default regulation setpoint voltage Setpoint voltage range Default Load Response Control Load Response Control range Default LRC cut-off speed LRC cut-off speed range Field excitation current limit range Field excitation duty cycle limit range Field excitation current feedback Field excitation duty cycle feedback Temperature range feedback Temperature feedback resolution High voltage threshold Battery sense line fault threshold Base switching frequency Field minimum duty cycle Field maximum duty cycle High speed under-voltage warning (> 3000 GRPM) Low speed under-voltage warning (< 3000 GRPM) www.irf.com Symbol VRDEF - Min 13.6 10.7 16.3 5.0 135 10.0 Typ 13.8 3.0 3000 6 16.5 6.0 150 3 100 10.5 16.7 7.0 165 11.00 Unit V V s s GRPM GRPM A % A % o C o C V V Hz % % V 9.0 9.5 10.00 V 0.4 2400 2 0 0 0 -29 VHV VSTh f DCMIN DCMAX Preliminary Data Sheet Max 14.0 16.0 13.2 8000 7.75 100 7.75 100 157 6 International Rectifier IRVR101 Fault Detection Fault Condition Open phase terminal Detection P = 0V, 0 Hz Type Mechanical Broken belt P = 0V, 0 Hz Mechanical Open rotor circuit P = 0V, 0 Hz Mechanical Field driver open circuit P = 0V, 0 Hz Mechanical Shorted rotor circuit P = 0V, 0 Hz Mechanical Field driver short circuit Electrical Open circuit B+ F = “ON” with no gate drive; no recirculation current Overvoltage Electrical Rectifier fault P < 8V, P > 60 Hz Electrical High RPM system under voltage B+ < 10.5V, P > 300Hz Setpoint < 12.2V B+ < 9.5V, P < 300Hz Setpoint < 11.4V B+ > 17.0, Electrical S > 2.2V Electrical (fault indication optional) Comm error Low RPM system under voltage High system voltage Loss of S (optional function) Corrupted communication Loss of/corrupted communication High temperature www.irf.com Sync bit, checksum, or bit error C open/shorted > 2s or Comm error > 2s 160 < Tj < 190 oC Effect Normal or reduced alternator output No alternator output No alternator output No alternator output No alternator output High system voltage Delay 500mS Regulation Mode Attempted normal regulation 500mS Same as “Open phase terminal” 500mS Same as “Open phase terminal” 500mS Same as “Open phase terminal” 0mS Short circuit mode 500mS 0% duty cycle field drive System supplied by battery Low system voltage Battery drain 500mS 500mS B+ regulation at 17V or B+ > S +/-3.0V when using a remote battery sense. Full field 500mS Full field Electrical Battery drain 500mS Full field Electrical Battery drain Battery voltage regulation inaccuracy Rx/Tx request ignored Preexcitation until phase > 2V Potential alternator damage 500mS Attempt to turn off field driver Voltage sensing from B+ Comm and Timeout error Thermal Preliminary Data Sheet 500mS 2s 2s 500mS Maintain regulation based on last good communication 18.75% duty cycle or default regulation (based on stator signal) Attempt to maintain regulation 7 International Rectifier IRVR101 Identifier Requirements (Regulator IC mask option configured as either Regulator 1 or Regulator 2) Write data: Regulator 1 ID for RX-frame - 100101 (ID0-5) ID0=1, ID1=0, ID2=0, ID3=1, ID4=0, ID5=1 Regulator 2 ID for RX-frame - 010101 (ID0-5) ID0=0, ID1=1, ID2=0, ID3=1, ID4=0, ID5=1 Read data: Regulator 1 ID for TX-frame - 100010 (ID0-5) ID0=1, ID1=0, ID2=0, ID3=0, ID4=1, ID5=0 Regulator 2 ID for TX-frame - 110010 (ID0-5) ID0=1, ID1=1, ID2=0, ID3=0, ID4=1, ID5=0 Read data for alternator identification: Regulator 1 ID for TX-frame_2 - 010010 (ID0-5) ID0=0, ID1=1, ID2=0, ID3=0, ID4=1, ID5=0 Regulator 2 ID for TX-frame_2 - 001010 (ID0-5) ID0=0, ID1=0, ID2=1, ID3=0, ID4=1, ID5=0 www.irf.com Preliminary Data Sheet 8 International Rectifier IRVR101 LIN Regulator Communication Protocol – Receive Frame (Write Data) Rx Frame: (Signals sent TO the ACM) A. Voltage Setpoint, 6bit, bit-offset 0 B. Load Resp Ramp, 4bit, bit-offset 8 C. Cut Off Speed, 4bit, bit-offset 12 D. Excitation Limitation, 5bit, bit-offset 16 A B C 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 : : : : : : : : : : : : : : : : : : 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 D 3 3 3 3 3 3 4 4 4 4 4 4 4 : : : : : : : : : : : : : 2 3 4 5 6 7 0 1 2 3 4 5 6 4 : 7 LIN Regulator Communication Protocol – Transmit Frame (Read Data) Tx Frame: (Signals sent FROM the ACM) E. Status bit 1, 1bit, Offset 0 F. Status bit 2, 1bit, Offset 1 G. Status bit 3, 1bit, Offset 2 H. Excitation Duty cycle, 5bit, Offset 3 I. ACM Excitation Current OR Regulator Temperature, 6bit, Offset 8 J. Communication error, 1bit, offset 14 K. Time Out, 1bit, offset 15 E 1 : 0 F 1 : 1 G H I J 1 1 1 1 1 1 2 2 2 2 2 2 2 : : : : : : : : : : : : : 2 3 4 5 6 7 0 1 2 3 4 5 6 K 2 : 7 LIN Regulator Communication Protocol – Transmit Frame (Read Alternator Identification Data) Tx Frame: (Signals sent FROM the ACM) L. Supplier ID, 3bit, Offset 0 M. Alternator ID, 5bit, Offset 3 L M 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 : : : : : : : : : : : : : : : : 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 www.irf.com Preliminary Data Sheet 9 International Rectifier IRVR101 Voltage Setpoint Signal to the Regulator (A) Setpoint Voltage, 10.7-16.0V, 100mV resolution, 6 bits (1:0 – 1:5), 55 values. A setpoint voltage of ”10.6V” shall mean: Field driver off. Default = 13.8 V Voltage setpoint 16.0 : : 16.0 15.9 15.8 15.7 15.6 15.5 15.4 15.3 15.2 15.1 15.0 14.9 14.8 14.7 14.6 14.5 14.4 14.3 14.2 14.1 14.0 13.9 13.8 13.7 13.6 13.5 13.4 www.irf.com Byte 1Bit: 543210 111111 : : 110110 110101 110100 110011 110010 110001 110000 101111 101110 101101 101100 101011 101010 101001 101000 100111 100110 100101 100100 100011 100010 100001 100000 011111 011110 011101 011100 13.3 13.2 13.1 13.0 12.9 12.8 12.7 12.6 12.5 12.4 12.3 12.2 12.1 12.0 11.9 11.8 11.7 11.6 11.5 11.4 11.3 11.2 11.1 11.0 10.9 10.8 10.7 10.6 = field driver off Preliminary Data Sheet 011011 011010 011001 011000 010111 010110 010101 010100 010011 010010 010001 010000 001111 001110 001101 001100 001011 001010 001001 001000 000111 000110 000101 000100 000011 000010 000001 000000 10 International Rectifier IRVR101 Load Response Control Signals to the Regulator (B and C) B. LRC Ramp time, 0.426-13.2s, 4 bits (2:0 – 2:3), 16 values. Time for excitation duty cycle to go from 0-100% during soft start and step up in electrical load. Default 3.0 s. LRC Ramp Time 13.2s 12.35s 11.5s 10.65s 9.8s 8.9s 8.1s 7.25s 6.4s 5.55s 4.69s 3.84s 2.99s 2.13s 1.28s 0.426s Byte 2 Bit: 3210 1111 1110 1101 1100 1011 1010 1001 1000 0111 0110 0101 0100 0011 0010 0001 0000 C. LRC Ramp cut-off speed, 0- 8000 alternator rpm, 4 bits (2:4 – 2:7), 16 Values. Over this speed no ramp function is allowed except for the first ramp after start. Default 3000 rpm. LRC Ramp cut-off speed (alternator RPM) Always active 8000 6860 6000 5330 4800 4360 4000 3690 3430 3200 3000 2820 2670 2530 2400 www.irf.com Byte 2 Bit: 7654 1111 1110 1101 1100 1011 1010 1001 1000 0111 0110 0101 0100 0011 0010 0001 0000 Preliminary Data Sheet 11 International Rectifier IRVR101 Excitation Limitation (current or duty cycle) Signal to the Regulator (D) 2.0 - 7.75 amps, 5 bits (3:0 – 3:4), 32 values (bit select option: 3:5 = 0). Limitation of the excitation current to the rotor. Default; max excitation current (100% duty cycle). PWM Field Current Maximum Excitation 7.75 7.5 7.25 7.0 6.75 6.5 6.25 6.0 5.75 5.5 5.25 5.0 4.75 4.5 4.25 Byte 3 Bit: (5)43210 (0)11111 (0)11110 (0)11101 (0)11100 (0)11011 (0)11010 (0)11001 (0)11000 (0)10111 (0)10110 (0)10101 (0)10100 (0)10011 (0)10010 (0)10001 4.0 3.75 3.5 3.25 3.0 2.75 2.5 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 Full field (0)10000 (0)01111 (0)01110 (0)01101 (0)01100 (0)01011 (0)01010 (0)01001 (0)01000 (0)00111 (0)00110 (0)00101 (0)00100 (0)00011 (0)00010 (0)00001 (0)00000 0-100%, 5 bits (3:0 – 3:4), 32 values (bit select option: 3:5 = 1). Limitation of the excitation duty cycle to the rotor. Default 100% PWM Field Duty Cycle Maximum Excitation 100% 93.75 90.625 87.5 84.375 81.25 78.125 75 71.875 68.75 65.625 62.5 59.375 56.25 53.125 www.irf.com Byte 3 Bit: (5)43210 (1)11111 (1)11110 (1)11101 (1)11100 (1)11011 (1)11010 (1)11001 (1)11000 (1)10111 (1)10110 (1)10101 (1)10100 (1)10011 (1)10010 (1)10001 50 46.875 43.75 40.625 37.5 34.375 31.25 28.125 25 21.875 18.75 15.625 12.5 9.375 6.25 3.125 0 Preliminary Data Sheet (1)10000 (1)01111 (1)01110 (1)01101 (1)01100 (1)01011 (1)01010 (1)01001 (1)01000 (1)00111 (1)00110 (1)00101 (1)00100 (1)00011 (1)00010 (1)00001 (1)00000 12 International Rectifier IRVR101 Status Signals from the Regulator (E, F, and G) 3 bits used to indicate an electrical fault, mechanical fault, or high temperature. E. High Temperature, 1 bit (1:0) F. Mechanical fault, 1 bit (1:1) G. Electrical, 1 bit (1:2) Error indication High Temperature Mechanical Electrical No fault present Byte 1 Bit: 210 001 010 100 000 Excitation Duty Cycle Signal from the Regulator (H) 5 bits (1:3-1:7), 32 values. Information needed for calculation of alternator output current and torque. PWM Field Excitation Duty Cycle 96.875 and 100% 93.75 90.625 87.5 84.375 81.25 78.125 75 71.875 68.75 65.625 62.5 59.375 56.25 53.125 www.irf.com Byte 1 Bit: 76543 11111 11110 11101 11100 11011 11010 11001 11000 10111 10110 10101 10100 10011 10010 10001 50 46.875 43.75 40.625 37.5 34.375 31.25 28.125 25 21.875 18.75 15.625 12.5 9.375 6.25 3.125 0 Preliminary Data Sheet 10000 01111 01110 01101 01100 01011 01010 01001 01000 00111 00110 00101 00100 00011 00010 00001 00000 13 International Rectifier IRVR101 Excitation Current or Temperature Signal from the Regulator (I) Excitation Current. 6 bits (2:0 – 2:5), 64 values. Information needed for calculation of alternator output current and torque. Excitation current will be sent by 6 bits, the least significant bit will always be set to 0. Excitation current >7.750 >7.500 >7.250 >7.000 >6.750 >6.500 >6.250 >6.000 >5.750 >5.500 >5.250 >5.000 >4.750 >4.500 >4.250 Byte 2 (I) Bit: 543210 11111x 11110x 11101x 11100x 11011x 11010x 11001x 11000x 10111x 10110x 10101x 10100x 10011x 10010x 10001x >4.000 >3.750 >3.500 >3.250 >3.000 >2.750 >2.500 >2.250 >2.000 >1.750 >1.500 >1.250 >1.000 >0.750 >0.500 >0.250 >0.000 10000x 01111x 01110x 01101x 01100x 01011x 01010x 01001x 01000x 00111x 00110x 00101x 00100x 00011x 00010x 00001x 00000x Regulator Temperature, 6 bits (2:0 – 2:5), 32 values (pin selectable option). Information needed for calculation of alternator output current and torque. To be used in place of excitation current per customer specific requirements. Temperature will be sent by 6 bits, the least significant bit will always be set to 0. Regulator baseplate temp -29 -23 -17 -11 -5 1 7 13 19 25 31 37 43 49 55 www.irf.com Byte 2 (I) Bit: 543210 111110 111100 111010 111000 110110 110100 110010 110000 101110 101100 101010 101000 100110 100100 100010 61 67 73 79 85 91 97 103 109 115 121 127 133 139 145 151 157 Preliminary Data Sheet 100000 011110 011100 011010 011000 010110 010100 010010 010000 001110 001100 001010 001000 000110 000100 000010 000000 14 International Rectifier IRVR101 Communication Fault Signals from the Regulator (J and K) J. Communciation error, 1bit (2:6). Set when the regulator recognizes a communication error. Reset after one correct read. K. Time Out flag, 1 bit (2:7). Time out after 2s with no valid communication. Default values after time out. Reset after one correct read. Error indication Communication error Time out flag No communication error present Byte 2 (K,J) Bit: 76 01 10 00 Data and specifications subject to change without notice. This product has been designed and qualified for the Automotive market. Qualification Standards can be found on IR’s Web site. International Rectifier IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 USA Tel: (310) 252-7105 TAC Fax: (310) 252-7903 Visit us at www.irf.com for sales contact information. 09/03 www.irf.com Preliminary Data Sheet 15