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ISO 9001 CERTIFIED BY DSCC

M.S.KENNEDY CORP.

4707 Dey Road Liverpool, N.Y. 13088

10 AMP, 55V, 3 PHASE

MOSFET BRUSHLESS

MOTOR CONTROLLER

4460

(315) 701-6751

FEATURES:

55 Volt Motor Supply Voltage

10 Amp Output Switch Capability

100% Duty Cycle High Side Conduction Capable

Shoot-Through/Cross Conduction Protection

Hall Sensing and Commutation Circuitry on Board

Internal ±15 Volt Regulators

"Real" Four Quadrant Torque Control Capability

Good Accuracy Around the Null Torque Point

Isolated Package for High Voltage Isolation Plus Good Thermal Transfer

DESCRIPTION:

The MSK 4460 is a complete 3 Phase MOSFET Bridge Brushless Motor Control System in an electrically isolated

low cost package. The hybrid is capable of 10 amps of output current and 55 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 4460 has good thermal

conductivity of the MOSFET's due to isolated substrate/package design that allows direct heat sinking of the hybrid

without insulators.

EQUIVALENT SCHEMATIC

TYPICAL APPLICATIONS

3 Phase Brushless DC Motor Control

Servo Control

Fin Actuator Control

Gimbal Control

AZ-EL Control

PIN-OUT INFORMATION

+15V

-15V

DIS

HALL C

HALL B

HALL A

E/A-

SIG GND

V+

MOTOR DRIVE C

MOTOR DRIVE B

MOTOR DRIVE A

V+ RTN

+CURRENT COMMAND

-CURRENT COMMAND

CURRENT MONITOR

E/A OUT

Rev. E 11/04

ABSOLUTE MAXIMUM RATINGS

○

ELECTRICAL SPECIFICATIONS

MSK 4460

Parameter

PWM

Clock Frequency

REGULATORS

+15 VOUT

-15 VOUT

-15 VOUT Ripple

HALL INPUTS

VIL

VIH

ANALOG SECTION

Current Command Input Range

Current Command Input Current

Transconductance

Offset Current

Current Monitor

Current Monitor Voltage Swing

ERROR AMP

E/A OUTPUT Swing

Slew Rate

Unity Gain Bandwidth

Large Signal Voltage Gain

Current Command=0 Volts

@ ±1 Amp Output

5mA Load

20mA Load

Test Conditions

Min.

14.25

-15.75

3.0

-13.5

1.8

-50

0.45

-12

3.0

Typ.

0.5

1.8

400

0.8

1.6

Max.

15.75

-14.25

250

0.8

+13.5

1.5

2.2

0.55

+12

1.92

750

1.6

0.8

3.1

Units

KHz

VOLTS

A/V

V/A

VOLTS

V/µSec

MHz

V/mV

VOLTS

µA

VOLTS

nSec

µSec

VOLTS

OUTPUT SECTION

Voltage Drop Across Bridge (1 Upper & 1 Lower)

Leakage Current

Diode VSD

trr

Dead Time

DISABLE

10 AMPS

10 AMPS @ 150°c Junction

All switches off, V+=44V, 150°C Junction

Input Current

NOTES:

Guaranteed by design but not tested. Typical parameters are representative of actual device performance but are for reference only.

V+=28V, T

CASE

=25°C unless otherwise specified.

Maximum power dissipation must be limited according to voltage regulator power dissipation.

Measurements do not include offset current at 0V current command.

Rev. E 11/04

○

V+

+15V

-15V

OUT

High Voltage Supply

V+ Quiescent Current

Current Command Input

Output Current

Continuous Output Current

Peak Output Current

55V

0.16A

±13.5V

20mA

10A

16A

11.1°C/W

Thermal Resistance (Regulator)

Thermal Resistance

9.5°C/W

(Output Switches)

-55°C to +125°C

Storage Temperature Range

Lead Temperature Range

+300°C

(10 Seconds)

Case Operating Temperature

-40°C to +85°C

MSK4460

+150°C

Junction Temperature

APPLICATION NOTES

MSK 4460 PIN DESCRIPTIONS

V+ -

is the power connection from the hybrid to the bus. The

external wiring to the pin should be sized according to the

RMS current required by the motor. The pin should be by-

passed by a high quality monolithic ceramic capacitor for high

frequencies and enough bulk capacitance for keeping the V+

supply from drooping. 78 µF of ceramic capacitance and

1700 µF of bulk capacitance was used in the test circuit.

The voltage range on the pin is from 16 volts up to 55 volts.

CURRENT COMMAND (+,-) -

are differential inputs for con-

trolling the module in current mode. Scaled at ±2 amps per

volt of input command, the bipolar input allows both forward

and reverse current control capability regardless of motor

commutation direction. The maximum operational command

voltage should be ±5 volts for ±10 amps of motor current.

MOTOR DRIVE A,B,C -

are the connections to the motor

phase windings from the bridge output. The wiring to these

pins should be sized according to the required current by the

motor. There are no short circuit provisions for these out-

puts. Shorts to V+ or V+ RTN from these pins must be

avoided or the bridge will be destroyed.

CURRENT MONITOR-

is a pin providing a current viewing sig-

nal for external monitoring purposes. This is scaled at ±2

amps of motor current per volt output, up to a maximum of

±5 volts, or ±10 amps. As ±10 amps is exceeded, the

peaks of the waveform may become clipped as the rails of

the amplifiers are reached. This voltage is typically ±8 volts,

equating to ±16 amps of current peaks.

V+ RTN -

is the power return connection from the module to

the bus. All ground returns connect to this point from inter-

nal to the module in a star fashion. All external ground con-

nections to this point should also be made in a similar fash-

ion. 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.

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.

SIG GND -

is a ground pin that connects to the ground plane

for all low powered circuitry inside the hybrid.

HALL A, B & C -

are the hall input pins from the hall devices

in the motor. These pins are internally pulled up to 15 volts.

The halls reflect a 120/240 degree commutation scheme.

+15 V -

is a regulated +15 volt output available for external

uses. Up to 20 mA is available at this pin. A 10 microfarad

capacitor should be connected as close to this pin as pos-

sible and returned to SIG GND along with a 0.22 microfarad

monolithic ceramic capacitor.

CAUTION: See Voltage Regu-

lator Power Dissipation.

DISABLE -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 low by a 5K ohm resistor.

L1 -

is a pin for connecting an external inductor to the DC -

DC converter for generating -15 volts. A 47 µH switching

inductor capable of running at 250 KHz and about 1 amp of

DC current shall be used. Connect the inductor between L1

and SIG GND.

VOLTAGE REGULATOR POWER DISSIPATION -

To figure volt-

age regulator power dissipation and junction temperature, use

the following as an example:

-15 V -

is a regulated -15 volt output available for external

uses. Up to 20 mA is available at this pin. A 10 microfarad

capacitor should be connected as close to this pin as pos-

sible and returned to SIG GND along with a 0.22 microfarad

monolithic ceramic capacitor.

CAUTION: See Voltage Regu-

lator Power Dissipation

Given:

V+ = 28V, MSK 4460 +15V IQ = 80mA, -15V IQ = 40mA.

External Loads: +15V = 20 mA, -15V = 20 mA

-15V Converter Efficiency = 50%

DISS

due to +15V IQ,80 mA x 13V = 1.04 W

DISS

due to -15V IQ, (40 mA / 0.5) x 13V = 1.04 W

DISS

due to +15V Ext load, 20 mA x 13V = 260 mW

DISS

due to -15V Ext load, (20 mA / 0.5) x 13V = 620mW

DISS

Total = 1.04W + 1.04 W + 260 mW + 520mW = 2.86W

3.12W x 11.1°C/W = 32°C RISE above case temperature

Maximum Case Temperature = 150°C - 32°C = 118°C

Rev. E 11/04

APPLICATION NOTES CONTINUED

COMMUTATION TRUTH TABLE

HALL SENSOR PHASING

120°

HALL

COMMAND

= POS.

COMMAND

= NEG.

AØ

BØ

CØ

AØ

BØ

CØ

= High Level

= Low Level

= Don't Care

= SOURCE

= SINK

= OPEN

NOTE:

Because of the true 4 quadrant method of output switching,

the output switches will PWM between the I

COMMAND

POSITIVE

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

COMMAND

POSITIVE and I

COMMAND

NEGATIVE states.

Rev. E 11/04

APPLICATION NOTES CONTINUED

BUS VOLTAGE FILTER CAPACITORS

The size and placement of the capacitors for the DC bus has a direct bearing on the amount of noise filtered and also on the size

and duration of the voltage spikes seen by the bridge. What is being created is a series RLC tuned circuit with a resonant

frequency that is seen as a damped ringing every time one of the transistors switches. For the resistance, wire resistance, power

supply impedance and capacitor ESR all add up for the equivalent lumped resistance in the circuit. The inductance can be figured

at about 30 nH per inch from the power supply. Any voltage spikes are on top of the bus voltage and the back EMF from the

motor. All this must be taken into account when designing and laying out the system. If everything has been minimized, there is

another solution. A second capacitance between 5 and 10 times the first capacitor and it should either have some ESR or a

resistor can be added in series with the second capacitor to help damp the voltage spikes.

Be careful of the ripple current in all the capacitors. Excessive ripple current, beyond what the capacitors can handle, will destroy

the capacitors.

REGULATED VOLTAGE FILTER CAPACITORS

It is recommended that about 10 µF of capacitance (tantalum electrolytic) for bypassing the + and -15V regulated outputs be

placed as close to the module pins as practical. Adding ceramic bypass capacitors of about 0.1 µF to 1 µF will aid in suppressing

noise transients.

GENERAL LAYOUT

Good PC layout techniques are a must. Ground plane for the analog circuitry must be used and should be tied back to the SIG

GND. Ground plane for the power circuitry should be tied back to the V+ RTN pin, pin 16. Pin 16 should be connected to pin 10

external to the hybrid by a single thick trace. This will connect the two ground planes together.

LOW POWER STARTUP

When starting up a system utilizing the MSK 4460 for the first time, there are a few things to keep in mind. First, because of the

small size of the module, short circuiting the output phases either to ground or the DC bus will destroy the bridge. The current

limiting and control only works for current actually flowing through the bridge. The current sense resistor has to see the current

in order for the electronics to control it. If possible, for startup use a lower voltage and lower current power supply to test out

connections and the low current stability. With a limited current supply, even if the controller locks up, the dissipation will be

limited. By observing the E/A OUT pin which is the error amp output, much can be found out about the health and stability of the

system. An even waveform with some rounded triangle wave should be observed. As current goes up, the DC component of the

waveform should move up or down. At full current (with a regular supply) the waveform should not exceed +8 volts positive

peak, or -8 volts negative peak. Some audible noise will be heard which will be the commutation frequency. If the motor squeals,

there is instability and power should be removed immediately unless power dissipation isn't excessive due to limited supply

current. For compensation calculations, refer to the block diagram for all information to determine the amplifier gain for loop gain

calculations.

Rev. E 11/04