PWR-82332 SMART POWER 3-PHASE MOTOR DRIVE FOR SPACE APPLICATIONS FEATURES DESCRIPTION APPLICATIONS The PWR-82332 is a Smart Power 3-phase Motor Drive hybrid. The PWR-82332 uses a MOSFET output stage with 400 VDC rating, and can deliver 19A continuous current to the load. Individual fast recovery diodes are internally connected across each of the six output transistors to clamp inductive flyback. High and low-side input logic signals are XOR’d in each phase to prevent simultaneous turn on of inline transistors, thus eliminating a shoot thru condition. The internal logic controls the high and low-side gate drives for each phase and operates from 5 V logic levels. The internal power supply provides a constant voltage source to the floating high-side gate drives. This provides constant output performance for switching frequencies from dc to 50 kHz. Packaged in a small case, this hybrid is an excellent choice for high performance, high-reliability motor drives for servo-amps and speed controls. Among the many applications are robotic arms; electromechanical valve assemblies; actuator systems; antenna and solar panel positioning; fan and blower motors for environmental conditioning; Reaction wheels; compressor motors for cryogenic coolers. The PWR-82332 hybrid is ideal for harsh military/space environments where shock, vibration, and temperature extremes are evident. The PWR82332 operates over the -55°C to +125°C temperature range and is available with K-Level processing. · Small Size (3.0" x 2.3" x 0.40") · 400 VDC Rating · 19 A Continuous Current Capability · Class K Processing · SEU Immune for LET Level of 36 MeV/mg/cm2 · Can Withstand 10 KRad (Si) Total Dose Radiation · Space Station Qualified Drawing #SSQ22691 · High-Efficiency MOSFET Drive Stage · Direct Drive for Commutation Logic · 6 Step Trapezoidal or Sinusoidal Drive · Four Quadrant Operation Vb POWER SUPPLY/BIAS GENERATION VZ VCC A VLPI VUA VO A VLA DRIVE A GND VUB VLB VSS A DIGITAL CONTROL AND PROTECTION CIRCUITRY VCC B VO B DRIVE B GND VSS B VCC C VUC VLC GND VO C DRIVE C VSS C VSd FIGURE 1. PWR-82332 BLOCK DIAGRAM © 1993, 1999 Data Device Corporation TABLE 1. ABSOLUTE MAXIMUM RATINGS (SEE NOTE 1) (TC = +25°C UNLESS OTHERWISE SPECIFIED) SYMBOL VALUE UNITS Supply Voltage (see note 2) PARAMETER Vcc 400 VDC Bias Voltage Vb 50 VDC Logic Power-In Voltage Input Logic Voltage Output Current Continuous Pulsed (fo = 50kHz, duty cycle = 5%, Vcc = 120V VLPI 5.5 VDC VU, VL, Vsd 6.0 VDC IO IOP 19 25 A A Operating Frequency fo 50 kHz Case Operating Temperature Tc -55 to +125 °C Storage Temperature Range Tcs -65 to +150 °C ±3V VDC or peak 500 VDC GND-Vss Differential Voltage Dielectric Withstanding Voltage (all pins to package) DMV TABLE 2. PWR-82332 SPECIFICATIONS (TC = +25°C UNLESS OTHERWISE SPECIFIED) PARAMETER SYMBOL OUTPUT Output Current Continuous Supply Voltage Output On-Resistance (each FET; see FIGURE 13) Instant Forward Voltage (Flyback diode; see FIGURE 12) Reverse Recovery Time (Flyback diode) Reverse Leakage Current at Tc = +25°C Reverse Leakage Current at Tc = +125°C Io Vcc Ron VF trr IR IR IF = 15A (see note 1) IF = 15A (see note 1) IF = 1A, IR = 1A Vcc = 400V, VU = VL = Logic 0 Vcc = 400V, VU = VL = Logic 0 BIAS SUPPLY Input Bias Supply (Tc = -55°C to +125°C) Quiescent Bias Current (see note 2) Bias Current (Tc = -55°C to +125°C;see FIGURES 9, 10, 11) Inrush Current (Tc = -55°C to +125°C) Logic Power Input Current Vb Ibq Ib Iir ILPI Vb = 28V Vb = 28V, fo = 30kHz Vb = 28V VLPI = 5.0V INPUT SIGNALS High-Level Input Voltage Low-Level Input Voltage VIH VIL SWITCHING CHARACTERISTICS (see FIGURE 2) Upper drive: Turn-on Propagation Delay Turn-off Propagation Delay Shut-down Propagation Delay (see FIGURE 5) Turn-on Rise Time Turn-off Fall Time Lower drive: Turn-on Propagation Delay Turn-off Propagation Delay Shut-down Propagation Delay (see FIGURE 5) Turn-on Rise Time Turn-off Fall Time td (on) td (off) tsd tr tf TEST CONDITIONS MIN 120 14 tpw THERMAL Maximum Thermal Resistance Maximum Lead Soldering Temperature Junction Temperature Range Case Operating Temperature Case Storage Temperature θ j-c Ts Tj Tco Tcs MAX UNITS 19 400 0.25 1.6 50 280 7 A V Ohm V nsec µA mA 50 100 1.4 7 V mA mA A mA 0.9 V V 690 1375 800 300 300 nsec nsec nsec nsec nsec 675 1050 700 300 300 nsec nsec nsec nsec nsec 40 3.15 Io = 15A Peak Vcc = 120V td (on) td (off) tsd tr tf MINIMUM PULSE WIDTH TYP 175 see note 3 each transistor WEIGHT NOTES: 1. Pulse width ≤ 300µs, duty cycle ≤ 2%. 2. VU, VL = Logic ‘0’ on pins 17, 18, 20, 21, 24 and 25. 3. Solder 1/8" from case for 5 seconds maximum. 2 -55 -55 -55 nsec 0.85 250 150 125 150 °C/W °C °C °C °C 6.125 (175) oz (g) INTRODUCTION This provides a continuous high-side gate drive even during a motor stall. The high and low-side gate drivers control the Nchannel MOSFET output stage. The MOSFETs used in the PWR-82332 allow output switching up to 50 kHz. A flyback diode parallels each output transistor and controls the regenerative energy produced by the motor. These fast recovery diodes have faster reverse switching times than the intrinsic body diode of the MOSFETS used in the PWR-82332. Care should be taken to adequately heatsink these motor drives to maintain a case temperature under 125°C. Junction temperatures should not exceed 150°C. The PWR-82332 does not have an internal short-circuit or overcurrent protection. For protection of the output transistors, these features must be added external to the hybrid. The 3-Phase PWR-82332 is a 19A motor drive rated at 400V. The PWR-82332 uses a MOSFET output stage for high speed, high current, and high-efficiency operation. This motor drive is ideal for use in high-performance motion control systems, servo amplifiers, and motor speed control designs. Furthermore, multiaxis systems requiring multiple drive stages can-benefit from the small size of this power drive. The PWR-82332 can be driven directly from commutation logic, DSP, or a custom ASIC that supplies digital signals to control the upper and lower transistors of each phase. This highly integrated drive stage has digital inputs that control the high and low side of each phase. Digital protection of each phase eliminates an in-line firing condition, by preventing simultaneous turn-on of both the upper and lower transistors in a given phase. The PWR-82332 has a ground referenced low-side gate drive. An internal dc-dc converter supplies a floating output to each of the 3 high side drives. INPUTS: (VUA, VUB, VUC) INPUTS: (VLA, VLB, VLC) 50% 50% tr OUTPUTS: (VOA, VOB, VOC) tf tr OUTPUTS: (VOA, VOB, VOC) tf 90% 50% 10% 90% 50% 10% t d (ON) t d (ON) t d (OFF) t d (OFF) FIGURE 2. INPUT/OUTPUT TIMING RELATIONSHIPS +5V BIAS VOLTAGES +15V ≤ V ≤ +50Vdc OPEN +120Vdc The PWR-82332 motor drive hybrid requires a single input bias supply for operation. The hybrid generates three independent, floating supplies internally, which eliminates the need for external bias voltages for each phase. 0.01µF In order for the internal power supply to generate these voltages, the input bias voltages (Vb) must be from 15 to 50 Vdc. 0.01µF 16 VLPI 13 12 VB VZ 3 7 11 VCC PWR-82332 Any voltage available in the system in the 15 to 50 Vdc range can be directly connected to the Vb pin of the hybrid. (See FIGURE 3). A 0.01 µF decoupling capacitor must be connected between Vb (pin 12) and GND and VLPI (pin 16) to GND. FIGURE 3. CONNECTION TO BUS VOLTAGE, INPUT BIAS VOLTAGE AND LOGIC POWER INPUT VOLTAGE 3 DIGITALLY CONTROLLED INPUTS not respond to signals on the VL or VU inputs while the Vsd has a logic ‘1’ applied. See FIGURE 5. When the user or the sense circuitry ( as in FIGURE 6) returns the Vsd input to a logic ‘0’, the output transistors will respond to the corresponding digital input. This feature can be used with the external current limit or temperature sense circuitry to disable the drive if a fault condition occurs (see FIGURE 6). The PWR-82332 digital inputs can be driven with any type of 5 V logic, such as TTL or CMOS logic. PIN 16 is the logic power input (VLPI) for the digital circuitry inside the hybrid. An external 5 V power supply must be connected between this pin and GND. A 0.01 µF ceramic capacitor must be placed between this pin and GND as close to the hybrid as possible see (FIGURE 3). The commutation/control circuitry can be as simple as discrete logic with PWM, or as sophisticated as a microprocessor or custom ASIC, depending on the system requirements. The Block diagram in FIGURE 4 shows a typical interface of the PWR82332 with a motor and commutation logic in a Servo-Amp System. INTERNAL PROTECTION CIRCUITRY The hybrid contains digital protection circuitry, which prevents inline transistors from conducting simultaneously. This, in effect, would short circuit the power supply and would damage the output stage of the hybrid. The circuitry allows only proper input signal patterns to cause output conduction. TABLE 3. shows these timing relationships. If an improper input requested that the upper and lower transistors of the same phase conduct together, the output would be a high impedance until removal of the illegal code from the input of the PWR-82332. A dead time is not required for the signals at the VU and VL pins. SHUT-DOWN INPUT (Vsd) Pin 23 (Vsd) provides a digital shut-down input, which allows the user to completely turn off both the upper and lower output transistors in all 3 phases. Application of a logic ‘1’ to the Vsd input will disable the Digital/Control Protection circuitry thereby turning off all output transistors. The circuitry remains disabled and will VCC POWER SUPPLY/BIAS GENERATION CC A OA CC B Ω OB SS B CC C OC SS C CRITICAL GROUND PATH To prevent damage to the internal drive circuitry, the differential voltage between GND (pins 19,22,26) and Vss (pins 1, 5, 8) must not exceed ± 3V max, dc or peak FIGURE 4. PWR-82332 TYPICAL INTERFACE WITH A MOTOR 4 HALL EFFECT DEVICE + SS A MOTOR 1 V UA V LA 1 0 1 0 1 0 V LB 1 0 V LC 1 0 V UB V UC 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 0 V Sd 1 0 V OA H Z L V OB H Z L V OC H Z L V Sd t en 1 0 t sd H V OA Z L FIGURE 5. SHUT-DOWN (Vsd) TIMING RELATIONSHIP 5V INPUT COMMANDS 18 17 21 20 25 24 COMMUTATION LOGIC 23 CURRENT SENSE CIRCUITRY 16 15V 12 120V 11 3 7 9 6 PWR82332 VSd 1 Vss 5 MOTOR 2 19,22,26 8 R SENSE FIGURE 6. FUNCTIONAL SHUT-DOWN INPUT USED WITH CURRENT-SENSING CIRCUITRY 5 PWR-82332 POWER DISSIPATION (see FIGURE 7) 2. Switching Losses (PS) There are three major contributors to power dissipation in the motor driver: conduction losses, switching losses, and flyback diode losses. Consider the following operating conditions PS = [VCC (IOA) (ts1) + IOB (ts2))fo] / 2 PS= [120 (10 (600 ns) + 12 (300ns)) 25kHz] / 2 PS = 14.4 Watts VCC= 120 V (Bus Voltage) (see FIGURE 7) IOA = 10 A, IOB = 12 A ton = 30 µs (see FIGURE 7); T = 40 µs ( period ) Ron = 0.51Ω ( on-resistance, Assume worst case,Tj = +150°C) (see Figure 13) 3. Flyback diode Losses (Pd) Pd = If (avg) x Vf (avg) If (avg) = [( IOB + IOA ) / 2] / 2 = [(12 + 10 ) /2] / 2 = 5.5 A Pd = 5.5 A x 0.95 V Pd = 5.23 Watts ts1 = 600 ns; ts2 = 300 ns (see FIGURE 7) fo = 25 kHz (switching frequency) VF is the diode forward voltage, Io = 12 A, TC=+25°C VF (avg)=0.95 V; IF is the diode forward current Transistor Power Dissipation (PT) 1. Conduction Losses (PC) PC = ( Imotor rms )2 x Ron I motor rms = (IOB - IOA) 2 IOB - IOB (IOB - IOA) + 2 3 To calculate the maximum power dissipation of the output transistor / diode pair as a function of the case temperature, use the following equation. (Reference FIGURE 14 to ensure you don’t exceed the maximum allowable power dissipation of each transistor / diode pair.) ton T PT = PC + PS + Pd In this example, PT = 46.42 + 14.4 + 5.23 = 66.05 Watts I motor rms = 2 12 - 12 (12 - 10) + (12 - 10) 3 2 Total Hybrid Power Dissipation (PHybrid) To calculate Total Power Dissipated in the hybrid add the power dissipation of each conducting transistor / diode pair. Typically, only two transistor / diode pairs are conducting at any given time. 30 40 PC = (9.54)2 x (0.51Ω ) = 46.42 Watts PHASE CURRENT LOWER TRANSISTOR CURRENT PHASE OUTPUT VOLTAGE T t on I OB V CC I OA IO t s1 FIGURE 7. OUTPUT CHARACTERISTICS 6 t s2 GROUND CONNECTIONS LAYOUT AND EXTERNAL COMPONENTS For example, a value of RSENSE of 0.025 Ω will give a voltage drop of 0.375 V at 15 A. and allow enough margin for the voltage drop in the ground conductors. Locate RSENSE 1IN. to 2IN. maximum from the hybrid. It is critical that all ground connections be as short, and of lowest impedance, as the system allows. Important Information - The following layout guidelines and required external components are critical to the proper operation of this motor drive. Permanent damage will result to the motor drive if the user does not make the following recommended ground connections that will ensure the proper operation of the hybrid. C1 and C2 are 0.01µF power supply decoupling capacitors. Care must be taken to control the regenerative energy produced by the motor in order to prevent excessive voltage spiking on the VCC line. Accomplish this by placing a Tantalum capacitor or clamping diode between VCC and the high power ground return. The Vb, VLPI and logic ground returns are on pins 19, 22, and 26 (GND). The VSS connections for the output stage are on pins 1, 5, and 8 (VSS). To prevent damage to the internal drive circuitry, the differential voltage between GND (pins 19, 22, 26) and VSS (pins 1, 5, 8) must not exceed ±3 V max, dc or peak. This includes the combined voltage drop of the associated ground paths and the voltage drop across RSENSE (see FIGURES 6 and 8). VCC 13 18 17 19 21 20 11 Vz VUA VCC A VLA VSS A GND VUB VO A VLB VCC B GND VSS B 22 25 24 26 23 VO B VUC TANT 9 7 5 5Ω 1W 6 3 VCC C VLC VSS C GND VSd Vb 12 0.01uF 100 V 8 C1 VO C VLPI 1 2 15 C2 0.01uF 50 V FIGURE 8. PWR-82332 GROUND CONNECTION 7 0.1uF 200 V + 220uF 200 V 74 140 Bias Supply Current, Ib (mamps) Bias Supply Current, Ib (mamps) 160 fo =30 kHz TC=+125°C 120 100 80 60 TC=+25°C & -55°C 40 15 20 25 30 35 40 45 50 Vb = 28 V 70 68 66 64 30kHz 62 60 58 56 54 -60 20 10 72 55 -40 -20 20 40 60 80 100 120 140 Case Temperature, TC (°C) Bias Voltage, Vb (Volts) FIGURE 9. PWR-82332 BIAS SUPPLY CURRENT VS. BIAS VOLTAGE FIGURE 10. PWR-82332 BIAS SUPPLY CURRENT VS. CASE TEMPERATURE @ fo =30kHz 100 1.2 90 Diode Forward Voltage, Vf (Volts) Bias Supply Current, Ib (mamps) 0 Vb = 28 V 80 TC=+125°C 70 TC=+25°C TC=-55°C 60 50 40 10 15 20 25 30 35 40 45 50 TC=+25°C 1.0 0.9 TC=+125°C 0.8 0.7 0.6 0.5 0 30 5 TC=-55°C 1.1 2 4 6 8 10 12 14 16 18 20 Diode Forward Current, If (amps) PWM Switching Frequency, fo (kHz) FIGURE 12. PWR-82332 DIODE FORWARD VOLTAGE VS. DIODE FORWARD CURRENT FIGURE 11. PWR-82332 BIAS SUPPLY CURRENT VS. PWM SWITCHING FREQUENCY 8 FIGURE 13. PWR-82332 ON-STATE RESISTANCE VS. JUNCTION TEMPERATURE FIGURE 14. PWR-82332 POWER DISSIPATION VS. CASE TEMPERATURE 9 The PWR-82332 is offered in three lead-bend styles,(as shown in FIG. 15A, B, C) downward bend, upward bend or straight leads. 2.300 0.120 2.060 0.250 1.800 0.125 (4 PLS) 0.300 (3 PLS) 1 26 10 EQ. SP. @ 0.200 = 2.00 ( TOL. NONCUM.) 12 EQ. SP. @ 0.200 = 2.400 (TOL. NONCUM.) 3.000 ± 0.010 2.750 16 0.200 ( TYP) 13 SEE NOTE 1 0.130 ± 0.010 DIA (4 HOLES) 0.10 R (MAX) (4 PLS) 0.050 DIA (TYP) (24 PLS) 0.040 (MAX) (24 PLS) 0.125 (TYP) 0.395 (MAX) 0.375 (MIN) 0.004 IN/IN 0.080 0.10 R +0.00 -0.06 90 o ±5 o 0.310 (MIN) 0.040 ± 0.002 DIA (TYP) (24 PLS) 0.150 (REF) 0.150 2.600 NOTES: 1. Pin 1 is marked on lid. All other pin numbers are for reference only and do not appear on package. 2. Tolerance, unless otherwise specified: X.XXX = ± 0.005, X.XX = ± 0.01. 3. All dimensions are in inches, unless otherwise specified. FIGURE 15A. CASE OUTLINE X 10 2.300 0.120 2.060 0.125 ( 4 PLS) 0.250 1.800 0.300 (3 PLS) 1 26 10 EQ. SP.@ 0.200 = 2.00 ( TOL. NONCUM.) 12 EQ. SP. @ 0.200 = 2.400 ( TOl. NONCUM.) 3.000 ± 0.010 2.750 16 0.200 (TYP) 13 SEE NOTE 1 DIA 0.128 +0.002 -0.005 0.10 R (TYP) ( 4 PLS) (4 HOLES) 2.300 (REF) 0.035 (REF) 2.230 ± 0.010 0.040 ± 0.002 DIA (TYP) (24 PLS) o 90 ±5 o +0.00 0.10 R – 0.06 0.040 (MAX) (24 PLS) 0.830 (MIN) 0.400 (MAX) 0.375 (MIN) 0.004 IN/IN 0.050 DIA (TYP) (24 PLS) 0.125 (TYP) 0.080 NOTES: 1. Pin 1 is marked on lid. All other pin numbers are for reference only and do not appear on package. 2. Tolerance, unless otherwise specified: X.XXX = ± 0.005, X.XX = ±0.01. 3. All dimensions are in inches unless otherwise specified. 4. Material: Frame: Stainless Steel 304 Base: Glid Copper Lead: OFHC Copper Cover: Stainless Steel 304 FIGURE 15B. CASE OUTLINE Y 11 2.300 2.060 0.120 0.250 1.800 0.125 (4 PLS) 0.300 (3 PLS) 1 3.000 ± 0.010 26 10 EQ. SP.@ 0.200 = 2.00 (TOL. NONCUM.) 12 EQ. SP.@ 0.200 = 2.400 (TOL. NONCUM.) 2.750 16 0.200 (TYP) 13 SEE NOTE 1 +0.002 0.128 -0.005 DIA (4 HOLES) 0.10 R (4 PLS) (TYP) 0.880 (MIN) ( 2 PLS) 0.050 DIA (TYP) ( 24 PLS) 0.400 (MAX) (24 PLS) 0.400 (MAX) 0.375 (MIN) 0.004 IN/IN 0.080 0.040 ± 0.002 DIA (TYP) (24 PLS) NOTES: 1. Pin 1 is marked on lid. All other pin numbers are for reference only and do not appear on package. 2. Tolerance, unless otherwise specified: X.XXX = ±0.005, X.XX = ±0.01 3. All dimensions are in inches, unless otherwise specified. 4. Material: Frame: Stainless Steel 304 Base: Glid Copper Lead: OFHC Copper Cover: Stainless Steel 304 FIGURE 15C.CASE OUTLINE Z 12 0.125 (TYP) MOUNTING The package bolts to part of the chassis or even the motor assembly itself, depending on system requirements. In applications where this isn’t convenient, the hybrid can be mounted to its own heatsink. The heat transfer in a hybrid is from semiconductor junction to the bottom of the hybrid case. The flatness and maximum temperature of this mounting surface are critical to proper performance and reliability, because this is the only method of dissipating the power created in the hybrid. Use a mounting surface flatness of 0.004 inches/inch maximum. This interface can be improved with the use of a thermal compound or pad. The heatsink should be designed to insure that the temperature does not exceed +125°C. TABLE 3. INPUT-OUTPUT TRUTH TABLE INPUTS UPPERS OUTPUTS LOWERS CONTROL VUA VUB VUC VLA VLB VLC Vsd VOA VOB VOC 1 0 0 0 1 0 0 H L Z 1 0 0 0 0 1 0 H Z L 0 1 0 0 0 1 0 Z H L 0 1 0 1 0 0 0 L H Z 0 0 1 1 0 0 0 L Z H 0 0 1 0 1 0 0 Z L H 0 0 1 1 1 0 0 L L H 0 1 0 1 0 1 0 L H L 0 1 1 1 0 0 0 L H H 1 0 0 0 1 1 0 H L L 1 0 1 0 1 0 0 H L H 1 1 0 0 0 1 0 H H L 0 0 0 0 0 0 0 Z Z Z 0 0 0 1 1 1 0 L L L 1 1 1 0 0 0 0 H H H X X X X X X 1 Z Z Z H=Vcc, L=RETURN, X=IRERELEVENT, Z=HIGH IMPEDENCE (OFF) TABLE 4. PIN ASSIGNMENTS PIN FUNCTION PIN FUNCTION 1 VSSC 26 GND 2 VOC 25 VUC 3 VCC 24 VLC 4 N/C 23 Vsd 5 VSSB 22 GND 6 VOB 21 VUB 7 VCC 20 VLB 8 VSSA 19 GND 9 VOA 18 VUA 10 N/C 17 VLA 11 VCC 16 VLPI 12 VB 15 NO PIN 13 VZ 14 NO PIN NOTE: Pins 3, 7 and 11 are internally connected. 13 ORDERING INFORMATION PWR-82332-XX0 Reliability Grade:* 0=Standard DDC Procedures 1=B-Level, Military processing available 2=B-level, Military procedures available but without QCI testing Temperature Range: 1=-55 to +125°C 3= 0 to +70°C * For space flight hardware, please refer to NASA Drawing #SSQ 22691 and consult our factory. 14 NOTES 15 The information provided in this data sheet is believed to be accurate; however, no responsibility is assumed by Data Device Corporation for its use, and no license or rights are granted by implication or otherwise in connection therewith. Specifications are subject to change without notice. 105 Wilbur Place, Bohemia, New York 11716-2482 For Technical Support - 1-800-DDC-5757 ext. 7420 Headquarters - Tel: (631) 567-5600 ext. 7420, Fax: (631) 567-7358 Southeast - Tel: (703) 450-7900, Fax: (703) 450-6610 West Coast - Tel: (714) 895-9777, Fax: (714) 895-4988 Europe - Tel: +44-(0)1635-811140, Fax: +44-(0)1635-32264 Asia/Pacific - Tel: +81-(0)3-3814-7688, Fax: +81-(0)3-3814-7689 World Wide Web - http://www.ddc-web.com ILC DATA DEVICE CORPORATION REGISTERED TO ISO 9001 FILE NO. A5976 H-06/99-500 PRINTED IN THE U.S.A. 16