1 1 refout 13 e/a - 25+reg in 37 b? 2 hall a 14 gnd 26 lgnd 38 bv+ 3 hall b 15 +current command 27 rtn 39 avs 4 hall c 16 -current command 28 rtn 40 avs 5 60 /120 17 +15 vin 29 cvs 41 a? 6 brake 18 current monitor out 30 cvs 42 a? 7 clock sync 19 -15 vin 31 c? 43 av+ 8 dis 20 -reg in 32 c? 9 gnd 21 l1 33 cv+ 10 n/c 22 -15 vout 34 bvs 11 n/c 23 gnd 35 bvs 12 e/a out 24 +15 vout 36 b? 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. 4707 dey road liverpool, n.y. 13088 (315) 701-6751 m.s.kennedy corp. 4362 30 amp, 75v, 3 phase mosfet brushless motor controller block diagram 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. features: rev. f 6/00 typical applications 3 phase brushless dc motor control servo control fin actuator control gimbal control az-el control pin-out information mil-prf-38534 qualified iso 9001 certified by dscc
guaranteed by design but not tested. typical parameters are representative of actual device performance but are for reference only. industrial grade devices 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 = +25c 2, 5 ta = tc =+125c 3, 6 ta = tc = -55c 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. 1 1 4 5,6 - - - - 1,2,3 1,2,3 1,2,3 4 - - - - 4 5,6 1 2,3 4 5,6 - - - - - - - - - - input current +15 vin -15 vin pwm clock sync input vil vih duty cycle sync frequency regulators +15 vout -15 vout refout -15 vout ripple logic inputs (hall a,b,c,brake,60/120,dis) vil vih analog section current command input range current command input current current monitor voltage swing error amp e/a out swing slew rate gain bandwidth product large signal voltage gain output section voltage drop across bridge (1 upper & 1 lower) voltage drop across bridge (1 upper & 1 lower) leakage current diode vsd trr dead time output pwm'ing current command=0 volts 25ma load 25ma load 15ma load 50ma load 5ma load 5ma load 30 amps 30 amps @ 150c junction all switches off, v+=60v, 150c junction high voltage supply (internal regulators disabled) high voltage supply (using internal r egulators) current command input logic inputs 15vout external load refout external load e/a out external load clock sync input continuous output current peak output current 75v 55v 13.5v -0.2v to refout 25 ma 15 ma 5 ma -0.2v to +15v 30 amps 41 amps 2 rev. f 6/00 electrical specifications absolute maximum ratings thermal resistance (output switches) thermal resistance (regulator) storage temperature range lead temperature range (10 seconds) case operating temperature junction temperature 1.5c/w 9c/w -65c to +150c +300c -55c to +125c +150c r q jc r q jc t st t ld t c t j parameter units msk 4362 test conditions ma ma khz khz volts volts % khz volts volts volts mv volts volts volts ma a/v a/v ma ma v/a v/a volts volts v/sec mhz v/mv volts volts a volts nsec sec min. typ. max. msk 4362(h) min. typ. max. group a subgroup - - 21 18.7 - 12.5 10 clock +0 14.25 -14.25 5.82 - - 3.0 -13.5 - 2.70 2.55 -25 -50 0.300 0.280 -12 -12 6.5 - 175 - - - - - - 68 30 22 22 - - - - - - - - - - - - 3 3 0 0 0.33 0.33 - - 8 6.5 275 - - - - 280 2 85 40 23 25.3 2.5 - 90 clock +3 15.75 -15.75 6.57 250 0.8 - +13.5 1.5 3.30 3.45 25 50 0.367 0.380 +12 +12 - - - 1 1.83 750 2.6 - - - - 20 - - 12.5 10 clock +0 14.25 -14.25 5.82 - - 3.0 -13.5 - 2.55 - -50 - 0.280 - -12 -12 6.5 - 175 - - - - - - 68 30 22 - - - - - - - - - - - - - 3 - 0 - 0.33 - - - 8 6.5 275 - - - - 280 2 85 40 24 - 2.5 - 90 clock +3 15.75 -15.75 6.57 250 0.8 - +13.5 1.5 3.45 - 50 - 0.380 - +12 +12 - - - 1 1.83 750 2.6 - - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7 1 6 1 3 6 2 transconductance offset current current monitor clock free running frequency 1 2 3 4 5 6 7 8 notes: current command=0volts 8 8 1 1
application notes in msk 4362 pin descriptions av+, bv+, cv+ - are the power connections from the hy- brid 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 f of ceramic capacitance and 6200 f of bulk capacitance was used in the test circuit. the voltage range on these pins is from 16 volts up to 75 volts. a?, b? & c?- are the connections to the motor phase wind- ings 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. 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 require- ments of the motor. rtn - is the power return connection from the module to the bus. all ground returns connect to this point from internal to the module in a star fashion. all external ground connections to this point should also be made in a similar fashion. the v+ capacitors should be returned to this pin as close as possible. wire sizing to this pin connection should be made according to the required current. 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. +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 infor- mation. +15 vout- is a regulated +15 volt output available for ex- ternal 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 micro- farad 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 re- quired 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 f capacitor and a 0.1 f capacitor as close to this pin as possible. 3 -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. l1 - is a pin for connecting an external inductor to the dc - dc converter for generating -15 volts. a 47 h inductor capable of running at 250 khz and about 1 amp of dc cur- rent shall be used. connect the inductor between l1 and gnd. -15 vout - is a regulated -15 volt output available for exter- nal uses. up to 25 ma is available at this pin. a 100 micro- farad 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 regu- lator 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 re- quired bypassing of the -15 vout pin is sufficient in this case. for bringing in -15 volts, this pin should be bypassed with a 10 f capacitor and a 0.1 f capacitor as close to this pin as possible. current command (+,-) - are differential inputs for con- trolling 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 com- mutation direction. the maximum operational command volt- age should be 10 volts for 30 amps of motor current. current monitor- is a pin providing a current viewing sig- nal 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. e/a out - is the current loop error amp output connection. it is brought out for allowing various loop compensation cir- cuits to be connected between this and e/a-. e/a- - is the current loop error amp inverting input connec- tion. it is brought out for allowing various loop compensa- tion 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 ap- plied 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. refout- is a 6.25 volt regulated output to be used for pow- ering 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. rev. f 6/00
brake - is a pin for commanding the output bridge into a motor brake mode. when pulled low, nor- mal operation commences. when pulled high, the 3 high side bridge switches turn off and the 3 low side bridge switches turn on, causing rapid decel- eration 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 amp 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 commuta- tion. logic levels for this input are ttl compatible. it is internally pulled high. application notes continued 4 voltage regulator power dissipation - to figure volt- age 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% p diss due to +15v iq,85 ma x 13v = 1.11 w p diss due to -15v iq, (40 ma / 0.5) x 13v = 1.04 w p diss due to +15v ext load, 25 ma x 13v = 325 mw p diss due to -15v ext load, (25 ma / 0.5) x 13v = 650 mw p diss total = 1.11 w + 1.04 w + 325 mw+650 mw=3.13w 3.13 w x 9c/w = 28.1c rise above case temperature maximum case temperature = 150c - 28.1c = 121.9c 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 51.8c above case temperature, limiting maximum case temperature to 98.2c. 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 19.7c above case temperature, allowing a maximum case tem- perature all the way to +125c. rev. f 6/00 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:
hall a hall b hall c hall a hall b hall c a? b? c? a? b? c? 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 5 rev. f 6/00 1 = high level h = source note: because of the true 4 quadrant method of output switching, 0 = low level l = sink the output switches will pwm between the i command positive x = don't care - = open and i command negative states, with the average percentage based on i command being a positive voltage and a negative voltage. with a zero voltage i command , the output switches will modulate with exactly a 50% duty cycle between the i command positive and i command negative states. application notes continued commutation truth table 60 hall sensor phasing 120 i command = pos. i command = neg. brake
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 resonan t 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 f 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 f or 1 f will aid in suppress - ing 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 s upply to test out connections and the low current stability. with a limited current supply, even if the controller locks up, the dis sipa- tion 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. f 6/00 application notes continued
7 rev. f 6/00 MSK4362 test circuit
8 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. mechanical specifications rev. f 6/00 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 MSK4362 h u lead configuration s=straight, u=bent up, d=bent down screening blank=industrial, h=mil-prf-38534 general part number ordering information note: all dimensions are .010 inches unless otherwise labeled.
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