Standard Products
ACT5101-1 Brushless DC Motor Drive
High Voltage 3-Phase
www.aeroflex.com/Power
March 29, 2006
FEATURES
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500V
DC
Rating
50Amp DC Rating
Package Size 3.0" x 2.1" x 0.39"
4 Quadrant Control
6 Step Trapezoidal Drive Capability
Military Processing Available
Isolated Upper and Lower Gate Drivers
Temperature Range -55°C TO +125°C
Designed for commercial, industrial and aerospace applications
Aeroflex-Plainview is a Class H & K MIL-PRF-38534 manufacturer
DESCRIPTION
The Aeroflex-Plainview ACT5101-1 is a high voltage 3 phase brushless DC motor drive that combines a 500V
DC
,
50A high power output stage along with a low power digital input and gate drive stages. A digital lock-out feature
protects the output stage from accidental cross-conduction thus preventing shoot-through conditions. The
ACT5101-1 also includes a floating gate drive design for each upper and lower transistor. On-board gate drive
supplies provide a continuous floating voltage for each upper and lower transistor, even during a motor stall.
The high power output stage rated at 500V
DC
, 50A is capable of delivering over 25KW to the load. This is
accomplished through the use of high power IGBTs with ultra-fast recovery rectifiers in parallel.
The ACT5101-1 utilizes power hybrid technology to provide the highest levels of reliability and lightest weight
while requiring the smallest amount of board space. The ACT5101-1 is available with military processing and
operates over the -55 to +125°C temperature range.
This makes the ACT5101-1 ideal for all military, space, and commercial avionics applications. These include
electro-hydrostatic actuators (EHA's) and electro-mechanical actuators (EMA's) for flight surface control, missile
fin actuators, thrust vector control, electric brakes, fuel and cooling pumps. Additional applications include
environmental conditioning blowers, radar positioning, solar panel positioning, and cryogenic cooler pumps. The
ACT5101-1 is therefore especially suitable for use in applications for all military tank upgrades, helicopters, planes
and new commercial avionics using 270V
DC
as the main power.
SCD5101-1 Rev M
V
CC
Isolation
V
CC
DC / AC
Converter
SD
Isolation
Phase V+
V
CC
XFMR
&
Rect
Ux
Phase OUT
500V
Optical
Isolation
Isolation
V
CC
XFMR
&
Rect
Lx
Phase RTN
To Other Sections
FIGURE 1 – BLOCK DIAGRAM
SCD5101-1 Rev M 329/06
Aeroflex Plainview
2
TABLE I – ABSOLUTE MAXIMUM RATINGS
PARAMETER
Output Supply Voltage (Pins 3,7,11)
Input Supply Voltage (Pin 12)
Output Current (Refer to Figure 2)
Continuous
Pulsed
Junction-Case Thermal Resistance (IGBT) each transistor
Junction-Case Thermal Resistance (DIODE) each Diode
Maximum Lead Soldering Temp
Junction Temperature Range
Case Operating Temperature
Case Storage Temperature Range
Notes:
1/ Tc = +25°C.
2/ Pulse Width < 10ms, Duty Cycle < 10%. Guaranteed, not tested.
3/ Solder 1/8" from case for 5 seconds maximum.
SYMBOL
V+A, V+B, V+C
V
CC
l
OF
l
OFP
RANGE
500 Max 1/
+18 Max
50 Max 1/
90 Max 2/
.45 Max
.85 Max
250 Max
-55 to 150
-55 to 125
-55 to 150
UNITS
V
DC
V
DC
A
A
°C/W
°C/W
°C
°C
°C
°C
θ
JCIGBT
θ
JCDIODE
T
S
T
J
T
C
T
CS
3/
TABLE II – NORMAL OPERATING CONDITIONS
T
C
= +25°C unless otherwise specified
PARAMETERS
INPUT STAGE
Input Supply Current
Input Supply Voltage
Input Voltage Low
Input Voltage High
Input Current Low
POWER OUTPUT STAGE
Output Current Continuous (Refer to Figure 2) 3/
Output Supply Voltage
Output Voltage Drop (Each IGBT)
NOTE: V
DROPF =
V
PHASE
V
+
- V
PHASE
Out
or
V
DROP
F
= V
PHASE
Out - V
PHASE
RTN
Instantaneous Forward Voltage (Flyback Diode)
NOTE: V
DROP
R
= V
PHASE
Out - V
PHASE
V
+
or
V
DROP
R
= V
PHASE
RTN - V
PHASE
Out
Reverse Recovery Time (Flyback Diode)
Reverse Leakage Current (V
IN
High)
Tc = 25°C 3/
Tc = 125°C 1/ 3/ 4/
SCD5101-1 Rev M 329/06
SYMBOL
TEST
CONDITIONS
MIN
TYP MAX
UNIT
l
S
V
CC
V
INL
V
INH
I
INH
Vcc = +15V
-
NOTE:
Internally pulled
up to
Vcc = +15V
-
14.25
-
11.0
-
100
15
-
-
-
115
15.75
4
-
3.75
mA
V
DC
V
DC
V
DC
mA
l
OF
V+ A,V+ B,V+ C
V
DROP
F
3/
V
DROP
F
V
DROP
R
1/ 3/
V
DROP
R
1/ 3/
t
RR
l
R25
l
R125
-
-
l
OF
= 40A
l
OF
= 6.5A
l
OR
= 40A
l
OR
= 6.5A
-
V+ = 500V
V+ = 480V
-
15
-
-
-
-
-
-
-
-
270
2.2
-
1.3
-
-
-
-
50
500
2.5
1.85
1.6
1.0
35
500
8.0
A
V
DC
V
DC
V
DC
V
DC
V
DC
nsec
µA
mA
3/
Aeroflex Plainview
3
TABLE II – NORMAL OPERATING CONDITIONS
(con’t)
T
C
= +25°C unless otherwise specified
PARAMETERS
ISOLATION CHARACTERISTICS
Isolation Voltage
SWITCHING CHARACTERISTICS 2/
UPPER DRIVE
(See Figure 3 – Timing Diagram):
Turn-on propagation delay
Turn-off propagation delay
Shut-down propagation delay
Turn-on Transition Time
Turn-off Transition Time
LOWER DRIVE
(See Figure 3 – Timing Diagram):
Turn-on propagation delay
Turn-off propagation delay
Shut-down propagation delay
Turn-on Transition Time
Turn-off Transition Time
SWITCHING ENERGY LOSSES
(At I
OF
= 40A, V = 270V)
3/
Turn-on Energy
Turn-off Energy
DEAD TIME
(See Digital Input Stage Description herein)
E
on
E
off
t
dt
-
T
C
= +125
°
C
-
-
500
-
-
-
0.5
3.0
-
mJ
mJ
nsec
2/
t
d
(on)
t
d
(off)
t
SDL
t
r
t
f
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
700
2
3.5
250
250
nsec
µsec
µsec
nsec
nsec
t
d
(on)
t
d
(off)
t
SDU
t
r
t
f
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
700
2
3.5
250
250
nsec
µsec
µsec
nsec
nsec
V
ISO
-
500
-
-
V
SYMBOL
TEST
CONDITIONS
MIN
TYP MAX
UNIT
Notes:
1/ Pulse width
≤
300usec duty cycle
≤2%.
2/ Tested @ 6.5Amps.
3/ Guaranteed, not tested.
4/ Not to exceed T
J
of +150°C. See Mechanical Applications for Case Interface Temperature Description herein.
SCD5101-1 Rev M 329/06
Aeroflex Plainview
4
DIGITAL INPUT STAGE
The ACT5101-1 offers complete flexibility by allowing the user to turn on/off each of the 6 IGBTs in any order or
combination desired which enables the hybrid to be commutated in a 6 step trapezoidal mode. The only unacceptable
combination would be to turn on an upper and lower transistor of the same phase. This is not a desirable condition for
normal operation and is therefore not allowed. The ACT5101-1 has a digital lockout feature that prevents turn-on of
two in-line transistors. Damage to one or both of the transistors would occur if this protection circuitry was not present
in the hybrid. As a safety precaution, it is still recommended that a 500nsec dead time be installed between commands
at the inputs of the upper and lower transistors of the same phase. This will compensate for any lag in transistor turn-off
due to the inductive load.
The SD input allows the user to enable/disable the drive stage of the ACT5101-1 on demand. This input can be
incorporated into the user's temperature or current monitoring circuitry to shutdown the hybrid if excessive current or
case temperatures are sensed.
The digital input circuits are of the Schmitt trigger type with hysteresis, thus greatly enhancing the input noise
immunity. The inputs are internally pulled up to 15 volts so that an uncommitted input is sensed as "OFF", providing a
measure of protection against an accidental input disconnect.
GATE DRIVE
The ACT5101-1 includes a gate drive supply which provides a floating voltage for each upper and lower transistor.
This constant voltage allows the motor to be operated at very low duty cycles or driven into a stall without any loss of
upper or lower gate drive. This performance could not be obtained with only a conventional boot strap design.
POWER OUTPUT STAGE
IGBTs (insulated gate bipolar transistors) are technically similar to bipolars and MOSFETS. An IGBT is a composite
of a transistor with an N-channel MOSFET connected to the base of a PNP transistor. Like the MOSFET, it offers high
input impedance and requires low input drive current. IGBT conduction losses are low, as with bipolar technology, and
IGBT voltage drops are much lower compared with those of MOSFETs. Consequently, the IGBT offers a high current
density. With a smaller die size than the MOSFET, it can handle the same current rating. Unlike MOSFETS, IGBTs
have no intrinsic body diode. The ACT5101-1 includes 35nsec fast recovery rectifiers in parallel across each of the 6
IGBTs to carry the reverse current when the IGBT is turned off.
It is important for the user to observe the Absolute Maximum ratings of the ACT5101-1 so that the voltage and current
rating is not exceeded. If over-voltage/over-current protection is desired it must be implemented external to the
ACT5101-1. Figure 2 shows the ACT5101-1 output current capability vs. case temperature.
Motor Running
120
Total Motor Current I
O
(A)
100
80
60
40
20
0
0
20
40
60
80
100
120
140
Case Temperature T
C
(°C)
Motor Running,
PWM = 10KHz
Motor Running,
PWM = 20KHz
FIGURE 2A - OUTPUT CURRENT vs CASE TEMPERATURE – MOTOR RUNNING
SCD5101-1 Rev M 329/06
Aeroflex Plainview
5
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