PD-97175B
DIGITAL SENSORLESS MOTOR DRIVE MODULE
Complete Integrated High Performance Sensorless
Speed Control in a Compact, Ruggedized Package
•
For up to 500VA, 3Phase Brushless DC and PMAC
Sinusoidal Motors
•
Ideal for Pumps, Fans, Compressors in
Rugged Environments needing a Small Footprint
•
Uses IR’s
iMOTION
TM
Digital Integrated Motor
Drive Technology
IRMCT3UF1
MP-3T
Description
IR’s HiRel Digital Sensorless Motor Drive Module is a
complete digital speed/torque controller ideal for
applications demanding efficient operation in a compact
and rugged package such as fuel pumps, fans, and
compressors. This control is supported by the latest
hardware motion control technology from IR, including
the Servo Designer
TM
tools. No software code
development is required due to its pre-configured
Motion Control Engine.
The HiRel Motor Drive Module contains IR’s advanced
iMOTION
TM
Motion Control Chipset with monolythic Gate
Driver ICs and state of the art 100V MOSFETs enabling
simple and cost effective design of high reliability
speed controls.
Feature Summary
n
No Software - Digital Sine FOC Algorithm
utilizes IR’s New Hardware based Motion
Control Engine
n
Digital Configuration Interface supports
Dynamic Re-Configuration of FOC
n
Complete Digital Sine-Drive supports both 2 and
3-Phase Center Aligned and Assymetrical SVM
Operation > 20KHz PWM Rate
n
Ideal for Speed/Torque Control of High
Performance Motors ( > 25000 RPM )
n
Speed/Torque command
>10KHz
Digital
Speed Command Rate/Sampled Analog
Command Input
n
Control Loop Computation Time 11µsec
n
Output Current up to 20Arms ( 48Vdc Bus )
n
Max RS232C Speed 57.6 Kbps
n
Stand-Alone Operation possible
( without Host Micro )
n
Lightweight Plastic Ring-Frame Enclosure
n
Low R
th
Insulated Metal Substrate ( IMS )
with Low Rds(on) MOSFETs and IR’s
Advanced HVIC Gate Drivers
n
Storage Temperature Range -55°C to +125°C
n
Case Operating Temperature -40°C to +85°C
n
Thermal Resistance 1.5°C/W
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1
10/20/06
IRMCT3UF1
Electrical Characteristics @Tc = 25°C
(Unless Otherwise Specified)
Parameter
INPUT POWER
Voltage
Power Dissipation
OUTPUT POWER
Power
Phase Current
INTERFACE
Diagnostic Inteface ( RS232C/422 )
Analog Input
DISCRETE I/O
Input
Output
ANALOG FEEDBACK
Current Sensing
Voltage Sensing
Analog to Digital Converter
PROTECTION
Output Current Trip Level
Over-Temperature Trip Level
Short Circuit Response Time
DC BUS VOLTAGE
Maximum DC Bus Voltage
Minimum DC Bus Voltage
AMBIENT ENVIRONMENT
Case Operating Temperature
Storage Temperature
POWER MODULE
Power Stage
R
th-JC
Maximum Operating T
J
(MOSFET)
57.6Kbaud Single Ended
0-2.5V or 2.5-5.0V Input Reference Command
ON / OFF, Fault Clear
FAULT
Leg Shunt - ( low side )
Vbus Voltage Divider
12 bit Resolution
500VA Version - 30A Peak
110°C Min
5.0
µs
48V
20V
-40°C to 85°C
-55°C to125°C
IMS contains 6 Mosfets
1.5°C/W
150°C
28Vdc to 48Vdc
12.5Watts
500VA Continuous
15Arms Continuous
20Arms Overload
Value
2
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IRMCT3UF1
Overview
The IRMCT3UF1 is a complete Sensorless drive system based on a proprietary digital motion control ASIC.
The system is based on a configurable control engine implemented by hardware logics in the ASIC. The
system has a simple and low cost structure, made possible by an advanced IR motion power components
including the MOSFET module and IR2011 monolithic gate driver IC. These components together with the
ASIC simplify hardware implementation. Since all control logic is implemented in hardware state machine
as opposed to programmed software, unmatched parallel computation is achieved resulting in higher
bandwidth control and higher motor operating frequency (< 25µsec PWM period).
Module Block Diagram
DC Bus
EEPROM
Controller Section
Sensorless FOC Algorithm
Power
Interface
Section
Space
Vector
PWM
Serial
Interface
RS232 C
Host
Register
Interface
RAMP
+
-
+
-
+
-
FAULT
e
j
θ
Dead
time
Gate
Gate
Driv
Gate
Driv
Drivee
e
Configuration
Registers
Monitoring
Registers
Rotor Angle /
speed
Estimator
Power
Substrate
VBus
A/D
interface
Discrete
Interface
e
j
θ
2/ 3
A/D
Current
Measurement
Analog
Speed
Command
Motor
Power
Interfac
e
Discrete I/O
Current
shunt
Analog
Speed
Command
+15 +5 +3.3
DC Bus Rtn
Application Diagram
28V DC Bus
DC-
DC 1
7
DC-
DC 2
24
16,17
Bus
Capacitor
Transient
Protection
+15V
+5V
+3.3V
Control Board
Gate
Drive
Gate
Drive
Gate
Drive
Drive
Power
Substrate
(IMS)
10,11
Linear
Reg
26
14,15
28V Bus Rtn
28
27
Power
5,6
8,9
.02
RS232
Status - Fault
Status - OK
31
30
Sensorless
Control
ASIC
Fault
Logic
Over-Temp
3,4
.02
Over-Load
FLT
33
Control
Computer
FLT Clr
32
VBus
U Phase
Current
V Phase
Current
W Phase
Current
substrate
12,13
.02
Start/Stop
34
A/D
PM
Motor
Analog 0 Ref
Analog Speed
Command
18
29
Analog 0 Ref
Speed cmd
22,23,25
1,2
28V Bus Rtn
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3
IRMCT3UF1
Pin Designation Table
Power Side
Pin #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Pin Description
MOT_RTN
MOT_RTN
CS_LW
CS_LW
PHASE_W
PHASE _W
+15V
CS_LU
CS_LU
PHASE_U
PHASE _U
CS_LV
CS_LV
PHASE_V
PHASE_V
VBUS
VBUS
Pin #
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Control Side
Pin Description
2.5V_REF_BUF
CS_LU ( sense )
CS_LV ( sense )
CS_LW ( sense )
GND
GND
+5.0V
GND
+3.3V
RX
TX
SPD_CMD
GRN
RED
FLT_CLR
FAULT
START/STOP
Pin Descriptions
MOT_RTN (Pins 1, 2)
- These two pins are connected
to the motor bus voltage return path as well as the
control power supply grounds.
CS_LW, CS_LU and CS_LV (Pins 3 & 4, 8 & 9,
12 & 13)
- These pins are the current sense
connections for corresponding motor phase. The
pins on the power side are the output of the low
side MOSFETs and must be connected to the
current sense resistor in the external application.
Each pin must also be connected to the
coresponding current sense connection on the
control side (see CS_LU, CS_LV, CS_LW
description below).
PHASE_W, PHASE_U, PHASE_V (Pins 5 & 6,
10 & 11, 14 &15)
- Motor connections for the three
phases.
VBUS (Pins 16 & 17)
- Input voltage for the motor.
The nominal value is 28Vdc with a maximum of 48V.
2.5V_REF_BUF (Pin 18)
- 2.5V reference buffer
provided for speed command referencing.
(see SPD_CMD description)
CS_LU, CS_LV, CS_LW (Pins 19, 20 & 21)
-
Control side inputs from the current sense
resistors. These monitor the voltage waveform at
the top of the current sense resistor and use this
signal to track the rotation of the motor. An
approximate value for the resistor can be found
using the Servo Designer software needed to
configure the motor controller. The pins must be
connected directly to the corresponding pins on the
power side and care should be taken to make sure
all three traces are approximately equal in length.
Use low-inductance shunt resistors and keep leads
short.
GND (Pins 22, 23 & 25)
- Ground connections
for the +15V, +5V and +3.3V power supplies. All
three should be connected. This can be
accomplished at the hybrid interface or by tying all
three pins to a common ground plane.
+15V, +5.0V, +3.3V (Pins 7, 24 & 26)
- Local
housekeeping power supplies for the unit. The
+15V power supply is used to drive the MOSFETs and
should be rated at 100mA. The +5.0V and +3.3V
supplies are responsible for the rest of the ICs in
4
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IRMCT3UF1
the circuit including logic and the iMotion digital
controller. The +5.0V supply should be rated at
100mA and +3.3V supply at 200mA.
RX, TX (Pins 27 & 28)
- RS-232 interface pins for
programming the controller. The interface operates
at 57.6kBaud.
SPD_CMD (Pin 29)
- Speed command for the
motor controller. For the IRMCT3UF1, there are two
operating ranges for the speed command input: 0-
2.5V and 2.5-5V. In each case, 2.5V is zero speed
and the other extreme (0V or 5V) is maximum
speed. An external 2.5V reference is provided to
help configure a particular speed command
interface.
GRN, RED (Pins 30 & 31)
- Outputs for driving
Green and Red LEDs. These outputs are provided
as a visual interface to determine the status of the
drive. The Green LED output indicates a clear
condition and the Red LED indicates that a Fault
has occurred. Each output is referenced to +3.3V
and is capable of driving a maximum current of
30mA. Also, each output has an internal series
resistance of 100Ω.
FLT_CLR, FAULT (Pins 32 & 33)
- Fault indication
and Fault Clear function. Use these pins to monitor
the Fault status of the controller. When there is no
fault (clear condition), the fault pin is low. It goes to
3.3V upon the occurrence of a Fault. The controller
can be reset by pulsing the Fault Clear pin high for
a minimum of 1µs. This is a Schmitt input and is
5.5V tolerant.
START/STOP (Pin 34)
- Start and Stop command for
the controller. The drive will start on the rising edge
of the command and will stop on the falling edge.
This is a Schmitt input and is 5.5V tolerant.
Input / Output Characteristics
I/O
Pins 30, 31
Pin Description
RED, GREEN
Parameter
Reference Voltage
Drive Current
Internal Series Resistance
No FAULT
FAULT
Clear Pulse
Clear Pulse Amplitude
0
Max Speed 1
Max Speed 2
Voltage
Load Current
Voltage
Load Current
Voltage
Load Current
Min.
2.475
1.0
-
-
3.3
1.0
-
-
-
-
14.25
-
4.75
-
3.135
-
Typ.
2.5
-
100
-
-
-
-
2.5
0
5.0
15
100
5.0
100
3.3
200
Max.
2.525
30
-
0.2
-
-
5.5
-
-
-
15.75
-
5.25
-
3.465
-
Units
V
mA
Ω
V
µs
Pins 32, 33
FAULT
Pin 29
SPEED COMMAND
V
Pin 7
Pin 24
Pin 26
+15V
+5.0V
3.3V
mA
V
mA
V
mA
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