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tm data device corporation 105 wilbur place bohemia, new york 11716 631-567-5600 fax: 631-567-7358 www.ddc-web.com for more information contact: technical support: 1-800-ddc-5757 ext. 7677 or 7381 features ? self-contained 3-phase motor controller operates as current or voltage controller 1, 3 and 10 amp output current radiation tolerant to 100krads 1.5% linearity 3% current regulating accuracy user-programmable compensation 10 khz - 100 khz pwm frequency complementary four-quadrant operation holding torque through zero current cycle-by-cycle current limit non-radiation tolerance also available (see pwr-82520/21n data sheet) description the pwr-82520r (100vdc) is a high performance radiation tolerant current regulating torque loop controller designed to accurately regu- late the current in the motor windings of 3-phase brushless dc and brush dc motors. the pwr-82520r is a completely self-contained motor controller that converts an analog input command signal into motor current and uses the signals from hall-effect sensors in the motor to commutate the current in the motor windings. the motor current is internally sensed and processed into an analog signal. the current signal is summed together with the command signal to produce an error sig- nal that controls the pulse width modulation (pwm) duty cycle of the output, thus controlling the motor current. the pwr-82520r can be tuned by using an external proportional/integral (pi) regulator net- work in conjunction with the internal error amplifier. applications the pwr-82520r is ideal for space and radiation tolerant applica- tions requiring current regulation and/or holding torque at zero input command. system applications that can use the pwr-82520r are: pumps, actuators, antenna position, environmental control and reac- tion/momentum wheel systems using brushless and brush motors. available in a 1 and 3 amp small dip-style or a 10 amp flat-pack hybrid package, the pwr-82520r is suitable for applications with lim- ited printed circuit board area. ? 2001 data device corporation make sure the next card you purchase has... pwr-82520r radiation tolerant 3-phase dc motor torque controller preliminary
2 data device corporation www.ddc-web.com pwr-82520r figure 1. pwr-82520r block diagram drive a drive b drive current c phase a phase a phase b phase b phase c phase c vbus+ a pwm logic circuitry commutation logic ha hb hc 5.0v 10k 10k 10k vbus? rsense pwm in + + 10.0k 5.0v error amplifier 100 - - + - + + amp command buffer 100 50k 50k 50k 50k hall a command out command in - command in + enable v dd supply gnd v ee pwm out command gnd v cc +5v error amp out error amp in current monitor out r s + hall b hall c case gnd +15v sync in v dr tach out case tach circuit vbus+ c vbus+ b v cc rtn +5v rtn 100 dir out 100 470pf
3 data device corporation www.ddc-web.com pwr-82520r i oc i op i cl i offset r on r c v f a a a ma ? ? ? v a a a ma ? ? ? v 10 20 +100 0.055 0.075 0.08 1.9 3 8 +20 0.18 0.27 0.08 1.8 14.0 4 -100 -20 t = 50sec figure 7, v cmd = 0v +25c +85c +85c i d = 10a i oc i op i cl i offset r on r c v f t = 50sec figure 7, v cmd = 0v +25c +85c +85c i d = 3a i oc i op i cl i offset r on r c v f output (pwr-82520r10) output current continuous output current pulsed current limit current offset output on-resistance output conductor resistance diode forward voltage drop output (pwr-82520r3) output current continuous output current pulsed current limit current offset output on-resistance output conductor resistance diode forward voltage drop table 1. pwr-82520r absolute maximum ratings (tc = +25c unless otherwise specified) parameter symbol value units command input + continuous output current pwr-82520r1 pwr-82520r3 pwr-82520r10 -5v to -15v +5v supply +5v to +15v +15v supply bus voltage pwr-82520r i oc v ee v cc v dd v dr 15.0 1 3 10 -17.5 +5.5 +17.5 +17.5 100.0 vdc a a a vdc vdc vdc vdc table 2. pwr-82520r specifications (unless otherwise specified, vbus=28vdc, v dr =+15v, v cc = +5v, v dd =+5v, v ee =-5v, tc = 25c, ll = 500 h, 100krad) parameter output (pwr-82520r1) output current continuous output current pulsed current limit current offset output on-resistance output conductor resistance diode forward voltage drop t = 50sec figure 7, v cmd = 0v +25c +85c +85c i d = 1a symbol test conditions -20 min typ max units 1.5 1 3 +20 0.60 0.90 0.08 1.5 a a a ma ? ? ? v peak output current (pulsed, t = 50 s) pwr-82520r1 pwr-82520r3 pwr-82520r10 i peak 3.0 8.0 20.0 a a a command input - command input - 15.0 vdc logic inputs enable , sync, ha, hb, hc, error amp, pwm in v ih 7.0 vdc vbus+ vdc vbus- to gnd voltage differential v gnddif 0v to v dd +1.0 vdc command input + tach out / dir out v oh 40 vdc tach out / dir out i ol 20 ma propagation delay td (on) td (off) from 0.8v on enable to 90% of vbus from 2.4v on enable to 10% of vbus 40 20 s s
4 table 2. pwr-82520r specifications (continued) (unless otherwise specified, vbus=28vdc, v dr =+15v, v cc = +5v, v dd =+5v, v ee =-5v, tc = 25c, ll = 500 h, 100krad) parameter symbol test conditions min typ max units switching characteristics (r1) upper drive turn-on rise time turn-off fall time lower drive turn-on rise time turn-off fall time tr tf tr tf rise time = 90% to 10% of vbus fall time = 10% to 90% of vbus i o = 1a 75 30 50 60 ns ns ns ns switching characteristics (r3) upper drive turn-on rise time turn-off fall time lower drive turn-on rise time turn-off fall time tr tf tr tf rise time = 90% to 10% of vbus fall time = 10% to 90% of vbus i o = 3a 150 150 160 130 ns ns ns ns switching characteristics(r10) upper drive turn-on rise time turn-off fall time lower drive turn-on rise time turn-off fall time tr tf tr tf rise time = 90% to 10% of vbus fall time = 10% to 90% of vbus i o = 10a 200 200 200 200 ns ns ns ns thermal (all models) junction temperature case operating temperature case storage temperature tj t c t cs -55 -65 +150 +125 +150 c c c thermal (pwr-82520r3) thermal resistance junction-case case-air j-c c-a 9 10 c/w c/w thermal (pwr-82520r10) thermal resistance junction-case case-air j-c c-a 4 5.5 c/w c/w radiation total dose dose rate seu at let* level latch-up immune 100 0.5 36 36 krad rad/sec mev/mg/cm 2 mev/mg/cm 2 weight r1, r3 r10 1.7 (48) 2.9 (82) oz (g) oz (g) data device corporation www.ddc-web.com pwr-82520r * let = linear energy threshold current monitor amp (all models) current monitor offset output current output resistance rout ioc = 0a -10 -10 +10 +10 1 mvdc ma ? current monitor amp (r3) current monitor gain 1.33 v/a current monitor amp (r10) current monitor gain 0.40 v/a thermal (pwr-82520r1) thermal resistance junction-case case-air j-c c-a 25 10 c/w c/w current monitor amp (r1) current monitor gain 4 v/a
5 data device corporation www.ddc-web.com pwr-82520r pwm in + peak - peak frequency linearity error duty cycle v p + v p - f lin d cycle vcc = 4.5 - 5.5v 2.3 -2.7 10 -2 49 2.5 -2.5 50 2.7 -2.3 110 +2 51 v v khz % % pwm out free run frequency r10 r1, r3 accuracy stability, temperature f pwm f pwm full temp range 47.5 95 50 100 10 0.5 52.5 105 2.0 khz khz khz % hall signals logic 0 logic 1 ha, hb, hc 2.4 0.8 vdc vdc table 2. pwr-82520r specifications (continued) (unless otherwise specified, vbus=28vdc, v dr =+15v, v cc = +5v, v dd =+5v, v ee =-5v, tc = 25c, ll = 500 h, 100krad) parameter symbol test conditions min typ max units current command transconductance ratio pwr-82520r1 pwr-82520r3 pwr-82520r10 non-linearity temperature coefficient of g g figure 7 0.24 0.73 2.40 -1.5 0.25 0.75 2.50 0.035 0.26 0.77 2.60 +1.5 a/v a/v a/v % fsr % fsr/c vbus+ supply nominal operating voltage vnom 18 28 70 vdc sync low high duty cycle sync range as % of free-run frequency sync in 2.4 100 50 0.8 120 vdc vdc % % +15v supply voltage current current r1 r3 r10 enable = high enable = low v dr i dr i dr +13.5 +15.0 100 8 18 40 +16.5 15 25 60 vdc ma ma ma ma +5v supply voltage current v cc i cc +4.5 +5.0 40 +5.5 60 vdc ma +5v to +15v supply voltage current v dd i dd +4.5 35 +16.5 50 vdc ma -5v to -15v supply voltage current v ee i ee -16.5 40 -4.5 50 vdc ma isolation case to ground 500 vdc hipot 10 m ? tach out/ dir out current sink v ol open collector @ 1ma 0.7 1.2 vdc vdc v v/c +4 800 2 -4 v cmd command in+/- differential input input offset input offset drift vdc v/s s to 0.1% +5 3 1.4 -5 v clamp v o = 0.2 - 4.5v command out internal voltage clamp slew rate settling time enable enable enabled disabled 2.4 0.8 vdc vdc
6 introduction the pwr-82520r is a, radiation hardened, 3-phase high per- formance current control (torque loop) hybrid, which provides true four-quadrant control through zero current. its high pulse width modulation (pwm) switching frequency makes it suitable for operation with low inductance motors. the pwr-82520r hybrids can accept either single-ended or differential mode com- mand signals. the current gain can be easily programmed to match the end user system requirements. the addition of an externally wired compensation network provides the user with optimum control of a wide range of loads. the pwr-82520r uses single point current sense technology with an internal non-inductive hybrid sense resistor (r sense ), which yields a highly linear current output over the wide -55c to +125c military temperature range. the output current non-lin- earity is less than 1.5% and the total error due to all the factors such as offset, initial component accuracy etc. is maintained well below 3% of the full scale rated output current. the hall sensor interface for current commutation has built-in decoder logic that ignores illegal codes and ensures that there is no cross conduction. the hall sensor inputs are internally pulled up to +5v and can be driven from open-collector outputs the pwm frequency can be programmed externally by adding a capacitor from pwm out to pwm gnd. multiple pwr- 82520r's can be synchronized in two ways: 1) by using one device as a master and connecting its pwm out pin to the pwm in of all the other slave devices, or 2) by applying a mas- ter sync pulse from an external source to the pwm in pins on all devices to be synchronized. the enable input signal provides quick start and shutdown of the internal pwm. in addition, built-in under voltage fault protec- tion turns off the output in case of improper power supply volt- ages. the hybrid features dual current limiting functions. the input command amplifier output is limited to 5v, limiting the motor current under normal operation. in addition, there is a cycle-by-cycle current limit, which kicks in to protect the hybrid as well as the load (see i cl table 2 for limits). basic operation and advantages the pwr-82520r utilize a complementary four-quadrant drive technique to control current in the load. the complementary drive has the following advantages over the standard drive: 1. holding torque in the motor at zero commanded current 2. linear current control through zero 3. no deadband at zero the complementary drive design produces a 50% pwm duty cycle in response to a zero current command. during a zero cur- rent command the benefit of a complementary 4 quadrant drive over a standard 4 quadrant is shown in the following figures (figures 2a, 2b, 3a, and 3b). pwr-82520r data device corporation www.ddc-web.com
7 data device corporation www.ddc-web.com pwr-82520r v bus phase a upper phase a lower phase b upper phase b lower rsense phase a phase b phase c - + off off on on i figure 2a. complementary 4-quadrant drive drive first half of pwm cycle v bus phase a upper phase a lower phase b upper phase b lower rsense phase a phase b phase c + _ on on off off i during the first half of the pwm cycle, one pair of mosfets (phase a upper & phase b lower) are turned on, to supply cur- rent into the load as shown in figure 2a. v bus phase a upper phase a lower phase b upper phase b lower rsense phase a phase b phase c - + off off on on i v bus phase a upper phase a lower phase b upper phase b lower rsense phase a phase b phase c + _ off off off off i flyback figure 3a. standard 4 quadrant drive first half of pwm cycle figure 3b. standard 4 quadrant drive second half of pwm cycle figure 2b. complementary 4-quadrant drive second half of pwm cycle during the first half of the pwm cycle the standard 4 quadrant drive operation in figure 3a is identical to the complementary 4 quadrant drive shown in figure 2a. during the second half of the pwm cycle, a second pair of tran- sistors are turned on, phase a lower & phase b upper as shown in figure 2b, to provide load current in the opposite direction. current flowing in both directions results in, zero average current in the motor that provides a holding torque. during the second half of the pwm cycle this drive operates in dead time where the motor current continues to flow (i flyback) in the same direction through the power device diodes for stan- dard 4-quadrant drive as shown in figure 3b. this results in an average current flow through the motor in one direction, producing in a net torque in one direction.
8 data device corporation www.ddc-web.com pwr-82520r major advantages the advantage of a complementary 4 quadrant drive over a stan- dard 4-quadrant drive is during a zero current command, zero average current in the motor, that provides positive holding torque to maintain position. the motor current at 50% duty cycle is simply the magnetizing current of the motor winding. using the complimentary 4-quadrant technique allows the motor direction to be defined by the duty cycle. relative to a given switch pair, i.e. phase a upper and phase b lower, a duty cycle greater than 50% will result in a clockwise rotation whereas a duty cycle less than 50% will result in a counter clockwise rotation. therefore, with the use of average current mode control, direction can be controlled without the use of a direction bit and the current can be controlled through zero in a very precise and linear fashion. the pw-82520r contains all the circuitry required to close an average current mode control loop around a complimentary 4- quadrant drive. the pwr-82520r use of average current mode control simplifies the control loop by eliminating the need for slope compensation and eliminating the pole created by the motor inductance. slope compensation and the pole created by the motor inductance are two limitations normally associated with implementing standard 4 quadrant current mode controls. functional pin descriptions vbus+a, vbus+b, vbus+c the vbus+ supply is the power source for the motor phases. the normal operating voltage is 28vdc and may vary from +18 to +70vdc with respect to vbus-. the power stage mosfets in the hybrid have an absolute maximum vbus+ supply voltage rating of 100v. the user must supply sufficient external capaci- tance or circuitry to prevent the bus supply from exceeding the maximum recommended voltages at the hybrid power terminals under any conditions. the vbus should be applied at least 50ms after v dd and v ee to allow the internal analog circuitry to stabilize. if this is not possi- ble, the hybrid must be powered up in the "disabled" mode. vbus- this is the high current ground return for vbus+. this point must be closely connected to supply gnd for proper operation of the current loop. v cc (+5v supply) and v cc rtn these inputs are used to power the digital circuitry of the hybrid. v dr (+15v supply) this input is used to power the gate driver circuitry for the output mosfets. there is no power consumption from v dr when the hybrid is disabled. v dd (+5v to +15v supply), and v ee (-5v to -15v supply) these inputs can vary from ?v to ?5v as long as they are symmetrical. v dd and v ee are used to power the small signal analog circuitry of the hybrid. please note that using ?v supply will reduce the quiescent power consumption by approximately 60% when compared to ?5v operation. supply gnd supply gnd is the return for the v dr ,v ee , v dd supplies. the phase current sensing technique of the pwr-82520r requires that vbus- and supply gnd (see figures 6 and 7) be con- nected together externally (see vbus- supply). case gnd this pin is internally connected to the hybrid case. in some appli- cations the user may want to tie this to ground for emi consid- erations. hall a, b, c signals these are logic signals from the motor hall-effect sensors. they use a phasing convention referred to as 120 degree spacing; that is, the output of ha is in phase with motor back emf voltage vab, hb is in phase vbc, and hc is in phase with vca. logic ? 1 ? (or high ) is defined by an input greater than 2.4vdc or an open circuit to the controller; logic ? 0 ? (or low) is defined as any hall voltage input less than 0.8vdc. internal to the pwr-82520r are 10k pull-up resistors tied to +5vdc on each hall input. hall-effect sensor phasing vs. motor back emf for cw rotation (120 commutations) 300 0 60 120 180 240 300 360 /0 60 v ab v bc v ca back emf of motor rotating cw cw ha hb hc hc in phase with v ab in phase with v bc in phase with v ca in phase with v ac (60?) figure 4. hall phasing s hc ha 120 n hb 120 n hc 120 remote position sensor (hall) spacing for 120 degree commutation 60 60 remote position sensor (hall) spacing for 60 degree commutation s ha hb hc figure 5. hall sensor spacing
9 data device corporation www.ddc-web.com pwr-82520r phase a phase a phase b phase c vbus- phase b vbus+ c phase c hall c hall b hall a r4 r3 r2 1k 1k 1k c3 2000pf c4 2000pf c5 2000pf ha hb hc case gnd pwm in pwm out +5v to +15v supply gnd -5v to -15v command gnd command in - command in + error amp out command out error amp input current monitor out enable c6 c7 10k 10k r1 r5 + + + gnd +28v motor bldc pwr-82520r v dd gnd v ee command signal enable - - - optional current monitor out cext + + v dr v cc +5v supply +15v supply +15v vbus+ b vbus+ a sync in sync in { c1 { { { { { { figure 6. voltage control hook-up phase a vbus- phase b vbus+ b phase c hall c hall b hall a case gnd pwm in pwm out +5v supply supply gnd +15v supply command gnd command in - command in + error amp out command out error amp input current monitor out enable c6 c7 10k, 0.5% 10k r2a 10k, 0.5% r2b 1meg r7 c1 4700pf r1 + + + pwr-82520r v dd gnd v ee command signal enable - - - optional cext + + v dr v cc +5v to +15v -5v to -15v vbus+ c vbus+ a phase a phase b phase c r4 r3 r2 1k 1k 1k c3 2000pf c4 2000pf c5 2000pf ha hb hc gnd +28v motor bldc +15v tach dir 100 100 10k 10k tach out dir out { { { { { { { c1 figure 7. torque (current) control hook-up
10 data device corporation www.ddc-web.com pwr-82520r the pwr-82520r will alternately operate with hall phasing of 60 electrical spacing. if 60 commutation is used, then the out- put of hc must be inverted as shown in figures 4 and 5. figure 4 illustrates the hall sensor outputs along with the cor- responding back emf voltage they are in phase with. hall input signal conditioning when the motor is located more than two feet away from the pwr-82520r controller in a noisy electrical environment the hall inputs require filtering from noise. it is recommended to use a 1k ? resistor in series with the hall signal and a 2000 pf capacitor from the hall input pin to the hall supply ground pin as shown in figures 6 and 7. phase a, b, c these are the power drive outputs to the motor and switch between vbus+ input and vbus- input or become high imped- ance (see table 3). enable the enab le input is an active low (l) logic signal that enables or disables the internal pwm. in the disable mode (h), the pwm is shut down and the outputs, phase a, phase b and phase c, are in an "off" state and no voltage is applied to the motor. tach out the tach out provides a tachometer signal that is a square wave clock with a frequency relative to motor speed that is derived from the three hall inputs ha, hb, hc. the tachometer circuitry combines these three signals into a single pulse train as a 50%-duty-cycle pulse. there are three pulses that occur every 360 electrical degree. the number of pulses per motor revolu- tion is formulated below: dir out the dir out indicates the direction the motor is rotating, clock- wise (cw) for a hi (open collector), or counterclockwise (ccw), indicated as a logic low (ground). current monitor out this is a bipolar analog output voltage representative of motor current. the current monitor out will have the same scal- ing as the command in inputs. sync in this input, as shown in figure 9, is used to synchronize the pwm switching frequency with an external clocking device. the pwm switching frequency can be pulled to up-to 20% faster than its free running frequency. pwm in pwm comparator inputs used to control the pwm pulse width. pwm out or an external triangular waveform is connected to this pin. pwm frequency the pwm frequency from the pwr-82520r1/r3 (pwr-82520r10) pwm out pin will free-run at a frequency of 100khz 5khz (50khz 2.5khz). the pwm frequency is user adjustable from 100khz (50khz) down to 10khz through the addition of an external capacitor. the pwm triangular waveform generated internally is brought out to the pwm out pin. this output, or an external triangular waveform generated by the user, may be connected to pwm in on the hybrid. pwm out this is the output of the internally generated pwm triangular waveform. it is normally connected to pwm in. the frequency of this output may be lowered by connecting an npo capacitor (cext) between pwm out and command gnd. the pwm fre- quency is determined by the following formulas: pwr-82520r1, r3: pwr-82520r10: 33.0e-6 16.5e-6 330pf + c ext pf 330pf + c ext pf sync period 0v 5v 50% duty cycle figure 9. sync input signal external pi regulator 10.0 k r1 4700 pf c1 1 meg error amp input command out current monitor out r2a 10.0 k r2b 10.0 k - + o error amp out 470 pf r7 100 figure 8. standard pi current loop warning: never apply power to the hybrid without connect- ing either pwm out or an external triangular waveform to pwm in! failure to do so may result in one or more outputs latching on. tf x 60 pr pr = x 3 (e.g., 6 pulses/revolution for a 4 pole motor) p 2 rpm = p = number of motor poles pr = number of pulses per revolution tf = tach output frequency cycles/second the motor rpm is: where:
11 data device corporation www.ddc-web.com pwr-82520r the duty cycle range of the output voltage is limited to approxi- mately 5-95% in both current and voltage modes. command gnd command gnd is used when the command buffer is used sin- gle-ended and the command in- or command in+ are tied to command gnd. transconductance ratio and offset when the pwr-82520r is used in the current mode, the com- mand inputs (command in+ and command in-) are designed such that 4vdc on either input, with the other input connected to ground will result in full-scale current ioc flow into the load. the dc current transfer ratio accuracy is 5% of the rated current including offset and initial component accuracy. the initial output dc current offset with both command in+ and command in- tied to the ground will be as shown in table 2 (ioffset) when measured using a load of 0.5mh and 1.0w at ambient room temperature with standard current loop compensation (see fig- ure 7). the winding phase current error shall be within the cumulative limits of the transconductance ratio error and the off- set error. rs + rs + is the high side of the sense resistor used for test purpos- es only. accuracy is not guaranteed. output current output current derating as a function of the hybrid case temper- ature is provided in figures 11 and 12. the hybrid contains internal pulse by pulse current limit circuitry to limit the output current during fault conditions. (see table 2) current limit accuracy is +10/-15%. warning! the pwr-82520r does not have short circuit protection. the pwr-82520r must see a minimum of 100h inductive load or enough line-to-line resistance to limit the continuous output current to less than i oc at all times. operation into a short or a condition that requires excessive output current will damage the hybrid. error amp in, error amp out these are the input and output pins for the error amplifier and are used for compensation. compensation the pi regulator in the pwr-82520r can be tuned to a specific load for optimum performance. figure 8 shows the standard current loop configuration and tuning components. by adjusting r1, r2 and c1, the amplifier can be tuned. the value of r1, c1 will vary, depending on the loop bandwidth requirement. command in+, command in- , command ground, command out these are the connection pins for the command amplifier. the command amplifier has a differential input that operates from a 4vdc full-scale analog current command. the command ampli- fier output signal is internally limited to approximately 5vdc to prevent the amplifier from saturating. the input impedance of the command amplifier is 50k ? . the pwr-82520r can be used either as a current or voltage mode controller. when used as a torque controller (current mode), the input command signal is processed through the com- mand buffer, which is internally limited to 5vdc. the output of the buffer (command out) is summed with the current monitor output into the error amplifier. external compensation is used on the error amplifier, so the response time can be adjusted to meet the application. when used in the voltage mode, the voltage command signal is applied to the command amplifier, to control the voltage applied to the motor. the command amplifier output is coupled into the error amplifier. the error amplifier directly varies the pwm duty cycle to control the voltage applied to the motor phase. the nominal pwm frequency in the voltage mode is 50% with zero volts applied to the command input. the pwm duty cycle is var- ied by the voltage applied to the command input according to the transfer function, 12% per volt applied to the command input. table 3. commutation truth table inputs outputs enable dir** ha hb hc phase b phase c phase a l cw 1 0 0 l z h l cw 1 1 0 z l h l cw 0 1 0 h l z l cw 0 1 1 h z l l cw 0 0 1 z h l l cw 1 0 1 l h z l ccw 1 0 1 h l z l ccw 0 0 1 z l h l ccw 0 1 1 l z h l ccw 0 1 0 l h z l ccw 1 1 0 z h l l ccw 1 0 0 h z l h - - - - z z z 1=logic voltage >2.4vdc, 0=logic voltage < 0.8vdc ** dir is based on the convention shown in figure 4. actual motor set up might be different. table 4. hall inputs for h-bridge controller inputs outputs enable command in ha hb hc ph b ph c ph a l positive 1 1 0 z l h l negative 1 1 0 z h l h - 1 1 0 z z z
12 data device corporation www.ddc-web.com pwr-82520r -50 -25 0 25 50 75 100 125 0 0.2 0.4 0.6 0.8 1.0 1.2 pwr-82520r1 amps case temperature ( ? c) -50 -25 0 25 50 75 100 125 0.5 1.0 1.5 2.0 2.5 3.0 pwr-82520r3 amps case temperature ( ? c) 3.5 -50 -25 0 25 50 75 100 125 0 2 4 6 8 10 12 pwr-82520r10 amps case temperature ( ? c) figure 11. output current for continuous commutation (electrical > 600rpm, vbus+ = 28v, pwm = 50khz) thermal operation it is recommended that the pwr-82520r be mounted to a heat sink. this heat sink shall have the capacity to dissipate heat gen- erated by the hybrid at all levels of current output, up to the peak limit, while maintaining the case temperature limit as per figure 11. radiation total dose the hybrid shall operate, as specified in table 2, when subject- ed to a total dose radiation environment of 100krad (si) at a dose rate of 0.5 rad/sec. single event upset the hybrid shall be single event upset (seu) immune and still meet the requirements of table 2 for a linear energy transfer (let) level of 36 mev/mg/cm 2 . latch-up the hybrid is latch-up immune and meets the requirement of table 2 for a let (linear energy threshold) level of 36 mev/mg/cm 2 . figure 10. brush motor hook-up phase a phase a phase c vbus- phase b vbus+ b phase c hall c hall b hall a c1 gnd +28v + +5v +5v vbus+ c vbus+ a { { { { { { { note: 100krad (si) total dose of radiation is usually two to three times the operational level of commercial and military satel- lites. this is a large cost saving for the end users since lot acceptance tests (lat) are usually not required. brush motor operation the pwr-82520r can also be used as a brush motor controller for current or voltage control in an h-bridge configuration. the pwr-82520r would be connected as shown in figure 10. all other connections are as shown in either figures 6 or 7 depending on voltage or current mode operation. the hall inputs are wired per table 4. a positive input command will result in positive current to the motor out of phase a. optional features external sensing resistor the external sensing point available for the end users to install an external resistor (non-inductive). the resistance of the resis- tor is scaled to the applicable current range. please contact fac- tory for this option.
13 data device corporation www.ddc-web.com pwr-82520r i ob t on i oa vbus i o t s2 t s1 figure 12. output characteristics pwr-82520x power dissipation there are two major contributors to power dissipation in the motor driv- er: conduction losses, and switching losses. an example calculation is shown below: vbus = +28 v (bus voltage) i oa = 3 a, i ob = 7 a (see figure 12) fo = 50 khz (switching frequency) ton = 36 s, t = 40 s (90% duty cycle) (see figure 12) ron = 0.055 ? (on-resistance, see table 2) rc = 0.133 ? (conductor resistance, see table 2) ts1 = 125 ns, ts2 = 200 ns (see figure 12) 1. transistor conduction losses (p t ) p t = (imotor rms) 2 x (ron) p t = (4.87) 2 x (0.055) p t = 1.30 watts ( i ob i oa + (i ob - i oa ) 2 )( ton t ) 3 i motor rms = ( 7 * 3 + (7 - 3) 2 )( 36 ) 3 i motor rms = 40 2. switching losses (p s ) ps = [ vbus ( i oa (ts1) + i ob (ts2) ) fo] / 2 ps = [ 28 v ( 3 a (125 ns) + 7 a (200 ns) ) 50 khz] / 2 ps = 1.24 watts transistor power dissipation ( p q ) pq = p t + p s pq = 1.30 + 1.24 = 2.54 watts output conductor dissipation p c = (imotor rms) 2 x (rc) p c = (4.87) 2 x (0.133) p c = 3.15 watts transistor power dissipation for continuous commutation pqc = pq (0.33) pqc = (2.54) x (0.33) pqc = 0.84 watts total hybrid power dissipation p total = (pq + pc) x 2 p total = (2.54 + 3.15) x 2 p total = 11.38 watts
14 data device corporation www.ddc-web.com pwr-82520r phase b function pin function 1 vbus+ a 41 tach out 2 vbus+ a 40 dir out 3 phase a 39 hall c 4 phase a 38 hall b 5 vbus+ b 37 hall a 6 vbus+ b 36 enable 7 phase b 35 v cc 8 34 v cc rtn 9 vbus- 33 v dr 10 vbus- 32 sync in 11 r s + 31 v dd 12 r s + 30 supply gnd 13 vbus+ c 29 v ee 14 vbus+ c 28 n/c 15 phase c 27 n/c 16 phase c 26 current monitor out 25 error amp in 24 error amp out 23 command out 22 command in - 21 command in + 20 command gnd 19 pwm out 18 pwm in 17 case gnd * n/c pins have internal connections for factory test purposes. table 5a. pin functions pwr-82520 r1 and r3 pin command out function pin function 1 case gnd 27 vbus+ a 2 n/c 28 vbus+ a 3 pwm in 29 phase a 4 pwm out 30 phase a 5 command gnd 31 vbus+ b 6 command in+ 32 7 command in- 33 phase b 8 34 phase b 9 error amp out 35 vbus- 10 error amp in 36 vbus- 11 current monitor out 37 rs+ 12 n/c 38 rs+ 13 n/c 39 vbus+ c 14 v ee 40 vbus+ c 15 supply gnd 41 phase c 16 v dd 42 phase c 17 sync in 43 n/c 18 v dr 19 vcc rtn 20 vcc 21 enable 22 hall a 23 hall b 24 hall c 25 dir out * n/c pins have internal connections for factory test purposes. table 5b. pin functions pwr-82520 r10 pin 26 tach out vbus+ b
15 data device corporation www.ddc-web.com pwr-82520r 1.400 0.005 (35.58 0.127) 1.150 0.005 (29.21 0.254) pin no.1 contrasting color bead 0.100 0.005 typ (2.54 0.127) 24 eq. sp. @ 0.100 = 2.400 0.010 (@ 2.54 = 60.96 0.254) 2.600 0.005 (66.04 0.127) 0.150 0.005 typ (3.81 0.127) 15 eq. sp. @ 0.150 = 2.250 0.010 (@ 3.81 = 57.15 0.254) 0.250 max (6.35) 0.250 0.010 (6.35 0.254) 0.030 0.002 dia typ (0.762 0.002) 0.018 0.002 dia typ (0.457 0.051) bottom view side view notes: 1. dimensions in inches (mm). tol = 0.005 (0.127) 2. lead identification numbers are for reference only. 41 1 17 16 figure 13. mechanical outline (r1, & r3)
16 data device corporation www.ddc-web.com pwr-82520r 3.110 (78.994) (max) 25 eq. sp. @ 0.100 = 2.500 (2.540 = 63.500) (tol. noncum) 0.300 (7.620) 26 0.25 (6.35) 1.60 (40.64) 27 0.150 (3.810) (typ) 43 1 16 eq. sp.@ 0.150 = 2.400 (3.810 = 60.960) (tol. noncum) pin numbers for reference only 1.860 (47.244) 2.110 (53.594) (max) 0.05 (1.27) x 45 ? chamfer (denotes pin 1) 0.12 (3.05) 0.040 0.002 dia (1.016 0.051) (17 plcs) 0.050 (1.270) 0.500 (12.70) (min) (typ) 0.020, 0.002 dia (0.508, .051) (26 plcs) 0.140 (3.556) 0.255 (6.477) (max) 0.100 (2.54) (typ) 0.25 (6.35) (typ) 0.147, +0.002, -0.005 dia (3.734, +0.051, -0.127) (4 holes) 2.850 (72.390) 0.125 0.010 (3.175 0.254) 0.350 (8.890) top view side view notes: 1. dimensions in inches (mm). tol = 0.005 (0.127) 2. lead identification numbers are for reference only. figure 14. mechanical outline (r10)
17 data device corporation www.ddc-web.com pwr-82520r ordering information pwr-82520rx- x x 0 reliability grade: 0 = standard ddc processing, no burn-in (see table below.) 1 = mil-prf-38534 compliant 2 = b* 3 = mil-prf-38534 compliant with pind testing 4 = mil-prf-38534 compliant with solder dip 5 = mil-prf-38534 compliant with pind testing and solder dip 6 = b* with pind testing 7 = b* with solder dip 8 = b* with pind testing and solder dip 9 = standard ddc processing with solder dip, no burn-in (see table below.) temperature range: 1 = -55 c to +125 c 2 = -40 c to +85 c 3 = 0 c to +70 c 4 = -55 c to +125 c with variables test data 5 = -40 c to +85 c with variables test data 8 = 0 c to +70 c with variables test data rating: 1 - 1a 3 - 3a 10 - 10a consult factory for class k processing. *standard ddc processing with burn-in and full temperature test see table below. mil-std-883 test method(s) condition(s) inspection seal temperature cycle constant acceleration burn-in standard ddc processing 2009, 2010, 2017, and 2032 1014 a and c 1010 c 2001 a 1015, table 1
18 data device corporation www.ddc-web.com pwr-82520r notes:
19 data device corporation www.ddc-web.com pwr-82520r notes:
20 pre 02-03/01-250 printed in the u.s.a. the information 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. 7677 or 7381 headquarters - tel: (631) 567-5600 ext. 7677 or 7381, fax: (631) 567-7358 west coast - tel: (714) 895-9777, fax: (714) 895-4988 southeast - tel: (703) 450-7900, fax: (703) 450-6610 united kingdom - tel: +44-(0)1635-811140, fax: +44-(0)1635-32264 ireland - tel: +353-21-341065, fax: +353-21-341568 france - tel: +33-(0)1-41-16-3424, fax: +33-(0)1-41-16-3425 germany - tel: +49-(0)8141-349-087, fax: +49-(0)8141-349-089 japan - tel: +81-(0)3-3814-7688, fax: +81-(0)3-3814-7689 world wide web - http://www.ddc-web.com data device corporation registered to iso 9001 file no. a5976 r e g i s t e r e d f i r m ? u

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