Order this document by MC33035m MOTOROLA @ Brushless DC Motor Controller The MC33035 is a high performance second generation monolithic brushless DC motor controller containing all of the active functions required to implement afull featured open Ioop, three or four phase motor control system. This device consists of a rotor position decoder for proper commutation sequencing, temperature compensated reference capable of supplying sensor power, frequency programmable sawtooth oscillator, three open collector top drivers, and three high current totem pole bottom drivers ideally suited for driving power MOSFETS. Also included are protective features consisting of undervoltage lockout, cycle-by+ycle current limiting with a selectable time delayed latched shutdown mode, internal thermal shutdown, and a unique fault output that ,,,,M can be interfaced into microprocessor controlled systems. $,' Typical motor control functions include open loop speed, forwar~~~] reverse direction, run enable; and dynamic braking. The MC3$~3&$~ designed to operate with electrical sensor phasings of 60*~ or 120/2400, and can also efficiently control brush DC motors. $:~f;~, `~t' .<.:. \*}, \,;<~R,* ~)i::~ ,,~.,,:, :\~.!$,, 10 to 30 V Operation >,P:l,ii *,.$, {:,* " :,>, . Undervoltage Lockout .,\ ,.,!rl ., 6.25 V Reference Capable of Supplying Sens,@~~ower , ~~ :$+, +ii:\ . Fully Accessible Error Amplifier for Closed~&q~ Sbrvo Applications ,~ .:~ ~,,: +'.. $>.1,,, . Cycle-By-Cycle Current timiting}i(t~:$(~j.," ,,:&, ~,. ~' ...... ~.J,:,: ~,.` . Pinned-Out Current Sense ~feanw .,,},.,,$: ,,$/::i "L~~,.~ . Internal Thermal Shutdo@ t "l,\a ,,,C,.,,,,,i$ . Selectable 60/3000 ~~1$~~40 Sensor Phasings .i:l,.*,`t.>. ~,y<' . Can Efficiently ~~t~ Brush DC Motors with External MOSFET H-Bridge ,a, `$8,FC ,,:,$$' ~:.$ .,:,*t:.,. l:. ..: $.t,}, *.,,.$\\* .J: :.\.<$.Q,. ~,:,, `.,'~"..}... ,,,~?..``.~.,~,;} .:*$., . DW SUFFIX PLASTICPAC~GE CASE 751 E (SO-24L) 24 e 1 PIN CONNECTIONS FwdRev 3 b 22 60~ 1 B] B a E 1D SA 4 21 Sensor SE 5 Inputs lg I 1 I CB Reference Output 8 17 Vcc Current Sense Noninverting Input 16 Gnd Error Amp Noninverting Input Error Amp Inverting Input Bottom Drive outputs 16 Vc OutputEnable 7 I AB 20 BB { Sc 6 Oscillator Select ~ ,5 10 ,1 Current Sensa Inverting Input 14 m ,2 ,3 output Error Amp OUV PWM Input (Top View) @ Motorola, Inc. 1996 Rev 2 MC33035 Representative Schematic Diagram r ---- --__ T 1 T 7 II i JI ------__ i / J Motor output Buffers 18 I I !II I Reference Regulator , ~ `mt b =- I 1+ Speed :p /:Fa,terti RT 13 * This device contains 285 active transistors. 2 MOTOROLA ANALOG [C DEVICE DATA MC33035 MAXIMUM RATINGS Rating Symbol Power Supply Voltage Value Vcc Digital Inputs (Pins 3,4,5,6,22, 23) Unit 40 v Vref v mA Oscillator Input Current (Source or Sink) Iosc 30 Error Amp Input Voltage Range (Pins ll,lZ, Notel) V[R -0.3 to Error Amp Output Current (Source or Sink, Note 2) lout 10 mA Current Sense Input Voltage mange (Pins 9, 15) v Vref vse"~e -0.3 to 5.0 v ~ Output Voltage VcE(Fa"lt) 20 v ~ Output Sink Current l~"k(~) 20 mA 40 v Top Drive Voltage (Pins 1,2, 24) vCE(top) Top Dtive Sink Current (Pins 1,2, 24) ISink(top) Bottom Drive Supply Voltage (Pin 18) Bottom Drive Output Current (Source or Sink, Pins 19,20, 21) Power Dissipation and Thermal Characteristics P Suffix, Dual In Line, Case 724 Maximum Power Dissipation Q TA = 65C v lDRV 100 ,$75 `"~> ,7)*.... *i}, ,,,F~;.\* l\,. `.~,;t: PD `V650 ;;$ ReJA ~ `$? J>..?e 100 .!.:?,*,::* TJ 150 `*:t14> Thermal Resistance, Junction-t&Air Operating Junction Temperature ,$:. T%@ Operating Ambient Temperature Range Storage Temperature Range 4`$:'<$~:$~stg ]1, ..*; ....,`\$<. ,<{t<~,.,>;.>. ~.::i, CHARACTERISTICS m$~, ,,.,... ~.,, r:., ..,;%:. {$!, .\'~\$ir,:,\. ,Km ,il,,:. , $& :$, ,.;S ,.., 86p+:4\&p` `"mw ReJA DW Suffix, Surface Mount, Case 751 E Maximum Power Dissipation Q TA = 85C (V&~~'$~& "c Oc -65 to +150 Oc Symbol ~~ .$%,.*" Regline Reg[Oad (Note 3) Lockout Threshold Min Typ Max 5.9 5.82 6.24 6.5 6.57 - 1.5 30 mV 30 mV Vref Load Regulation (l,$~<$;b to 20 mA) \ Refere~q:,~~e~%oltage \ ERR&\~tiFIER .,,.,.,. mW `cm -40 to +85 Line Regulation (V~@*~@W#O V, I,ef = 1.0 mA) outputsho~Wuj$Current Ocm 20 V, RT = 4.7 k, CT = 10 nF, TA = 25C, unless otherwise noted.) Characteristic...!~:+ `:?},:~$' .\\i..} :1,:: ` " ` `~~. ,*,*`i!,,,` REFERENCE SECTION . . !\ Reference Output Voltage (lr~.~l ;&~~) .~*'\ .),j TA = 25C ,\\,,,,y> ~ TA = -40 to +85C mA 30 pD Thermal Resistance, Junction-tbAir ELECTRICAL 50 Vc Unit v - 16 Isc '40 75 Vth 4.0 4.5 5.0 v 0.4 10 mV mA :\,\b4:( ..*,;, Voltage (TA = -40 to +85C) V[o ~,~~b%@ . t Offset Current WA = -400 to +85C) Ilo 8.0 500 nA 116 -46 -1000 nA ~~WQffSet Bias Current (TA = -40 to +85C) ,+.$,, -"':*.@:`Nfnput *$j:#, .. >.,\\., k.. -+.'..'~ )>,,.:>...t >' Input Common Mode Voltage Range `y; Open Loop Voltage Gain (V. = 3,0 V, RL = 15 k) vlc~ (o v to v,,,) v AvOL 70 80 dB Input Common Mode Rejection Ratio CMRR 55 86 dB Power Supply Rejection Ratio (Vcc = Vc = 10 to 30 V) PSRR 65 105 NOTES 1. The input common mode voltsge or input signal voltege should not be allowed to go negative by more than 0.3 2. The comphance voltage must not exceed fie range of-0.3 to V,sf. 3. Maximum package power dissipation timits must be obsewed. dB V. / MOTOROLA ANALOG IC DEVICE DATA 3 MC33035 ELECTRICAL CHARACTERISTICS (continued) (Vcc = Vc = 20 V, RT = 4.7 k, CT = 10 nF, `TA= 25C, unless othewise Characteristic I Symbol Min Typ VoH VoL 4.6 5.3 0.5 noted.) Max Onit ERROR AMPLIFIER Output Voltage Swing High State (RL = 15 k to Grid) Low State (RL = 15 k to Vref) v 1.0 `~1., $.,., .3?$ ~ OSCILLATOR SECTION Oscillator Frequency Frequency Change with Voltage (Vcc = 10 to 30 V) fosc 22 25 Afosc/AV - 0.01 Sawtooth Peak Voltage Vosc(p) Sawtooth Valley Voltage vosc~) 1.2 VIH VIL 3.0 4.1 23) Sensor Inputs (Pins 4,5, 6) High State Input Current (VIH = 5.0 V) Low State Input Current (V]L = O V) [IH IIL ForwardReverse, 60m Select (Pins 3,22, 23) High State Input Current (VIH = 5.0 V) Low State Input Current (VIL = OV) CURRENT-LIMIT -150 .*$; :$:~' -70 -600 "$i;+., -337 ,,.J ,, *i, \J/~;: ~,,, ~, p':+;-"*%6 ,, ~ IIL ,$ ~!~a ..9300 .!, .\ $~i,,*IS ."1{,s , ,.$flH .,->+:, -60 -60 .,,,~$~, ,?4' :>. ,,, J.t.\ ~,:;:' ~$,:, .,,... +,:,:$, *<$$$ Vth 65 ,,. ~.?,. VlcR ,\J< IIH Output Enable High State Input Current (VIH = 5.0 V) Low State input Current (VIL = O V) COMPARATOR Threshold Voltage Input Common Mode Voltage Range \,#$.:w""' 5.0 +>,::' :c;it~ oh *;$:$, \~:y .* , ...:,.. ":';:* ,~,.. .:,:~, -.i ,.> g%;$,, 0.6 .$,k"!~;~. `: .?1 `its!,? ,..j~. ,,,;+.,,> `- LOGIC INPUTS Input Threshold Voltage (Pins 3,4,5,6,7,22, High State Low State 28 v v PA -20 -150 M -36 -175 -10 -75 -29 -29 -lo -10 101 115 WA 3.0 mV v Input Bias Current OUTPUTS AND POWER SECTIONS . ~i.:.],. ..s, ,. Top Drive Output Sink Saturation (l~ink= 25 @m \ Top Drive Output Off-State Leakage (Vc~~~,~$* TopDrive Output Switching Tme (C~~~{~~L Rise Time Fall Time t$~ \\, .:*.$, `a:, ~~ ,*?7 ,. ":.(\ , ~,t... \$*,?$J . - 0.5 1.5 v - 0.06 100 M 107 26 300 300 (vCc-l ,1) 1.5 2.0 38 30 200 200 = 1.0 k) Bottom Drive Output volts.~+~t$..$ High State (Vcc = 20 ~, V% ~b V, l~ource= 50 mA) LOW state (Vcc =,~$~~w& 30 V, [~i"k = 50 mA) Bottom Drive O$tp$@hing VcE(~at) lD~v([~ak) ns tr tf v VoH VoL (Vcc -2,0) Time (CL= 1000 PF) Rise ~me .!$' .. ,aL `\,,-,,,j$~ Fall ~me+~,,VRi~+' \ saturation (l~i"k = 16 mA) ~~~~~nk . ~~wtil Off-State Leakage (VcE = 20 V) ns t, tf VcE(~at) - 225 500 mV [FLT(l~ak) - 1.0 100 pA 8.2 0.1 8.9 0.2 10 0.3 12 14 3.5 5.0 16 20 6.0 10 `~n@%Voltage Lockout $}t:@'tive Output Enabled (Vcc or Vc Increasing) X3 Hysteresis Power Supply Current Pin17~cc=Vc=20V) Pin17~cc=20 V, Vc=30V) Pin16~cc=Vc=20V) Pin18(Vcc= 20 VrVc=30V) 4 v vth(~") VH mA Icc Ic MOTOROLA ANALOG IC DEVICE DATA MC33035 Figure 1. Oscillator Frequency versus Timing Resistor Figure 2. Oscillator Frequency Change 100 10 0 1.0 10 100 1000 RT,TIMING RESISTOR (W) `*i$ Figure 3. Error Amp Open Loop Gain and Phase versus Frequency 4. Error Amp Output Saturation Voltage versus Load Current 56 I I , Source Saturation, I (Load toGround) I 40 32 z w `"-1 W 16 ~ ~ 8.0 ~ + 3 n ~ 1.6 -- `i-6,0 ~ -16 < -24 m::~]= .&'$ *;,,~ w o a ?!*,,. ./ -1.6 ~ 24 z >W 1 I 1 VCC=20V _ VC=20V r. - OKOP `*-LQ" I Vref 46 i ii -- / 0.8 / ` 1 I1 I 1 I I I `i -- ~ Grid\ -- -- ~ -- 1 1 1 I -- ~ -- ~ = ~ , I ~ Snk Saturation (Load to Vref) o / o 1.0 2.0 3.0 4.0 5.0 10, OUTPUT LOAD CURRENT (mA) Figure 6. Error Amp Larg~Signal Transient Response 5.0 @DIV MOTOROLA ANALOG IC DEVICE DATA 5 MC33035 Figure 7. Reference Output Voltage Change versus Output Source Current s g u a o z z : _4,0 a a 5 -8.0 0 > + 2 -12 + 3 0 w -16 0 z w 5 -20 L w :-24 ~~ o 10 20 30 40 50 Figure 8. Reference Output Voltage 60 Iref,REFERENCE OUTPUT SOURCE CURRENT (mA) -:,.':, s g figure 9. Reference Output Voltage versus Temperature g u z a 5 40 w u a 5 ~ 20 w u ~o & w :-20 w 10. Output Duty Cycle versus PWM Input Voltage A 80 -- / RT = 4.7 k CT=lonF TA = 25C / / ` 60 / 40 N i ` 20 : _40 o z ~ -5 % o 1.0 0 2.0 3.0 4.0 5.0 PWM INPUT VOLTAGE (V) Figure 12. ~ Output Saturation versus Sink Current -0.25 I ~ 1 I I # 50 m so 1.0 2.0 3.0 4,0 5.0 8.07,08.09,010 CURRENT SENSE INPUT VOLTAGE (NORMALIZED TO V,h) 6 l~nk, SINK CURRENT (mA) MOTOROLA ANALOG IC DEVICE DATA MC33035 Figure 13. Top Drive Output Saturation Voltage versus Sink Current Figure 14. Top Drive Output Waveform 1.2 -VCCL20V _vc=20v TA = 25C A 0.8 A 0.4 0/ o 10 30 ]~nk, SINK ;;RRENT 40 (mA) Figure 15. Bottom Drive Output Waveform 100 0 50 ndDIV Figure 18. Power and Bottom Drive Supply Current versus Supply Voltage ~,$&Vol~&~& versus Load Current ,$ ..,...>$ :). * . `.">,.A<\:, Vc . ~ o ~ u 16 14 Source Saturation _ (Load to Ground) Icc / 12 -- -- -- p . 1 8.0 6.0 + ~ ~ 1.0 RT = 4.7 k cT=lonF Hns H, 9,15,23 Rns 7,22 = Open TA 25C I I f 10 i / Gnd Hnk Saturation _ (Load to VC) Gn~ \ > ~o o 20 .40 60 10, OUTPUT LOAD CURRENT (MA) MOTOROLA ANALOG IC DEVICE DATA 80 0 5.0 10 15 20 25 30 Vcc, SUPPLY VOLTAGE (V) 7 MC33035 PIN FUNCTION DESCRIPTION Hn 1,2,24 Description Symbol BT AT These three open collector Top Drive outputs are designed to drive the external upper power switch transistors. CT FwWRev The Forwar~Reverse SA, SB, Sc These three Sensor Inputs control the commutation sequence. Output Enable A logic high at this input causes the motor to run, while a low causes it to @$,. Reference Output This output provides charging current for the oscillator timing capacito#~.~&a reference for the error amplifler. It may also serve to furnish sensor RoMr. .<,. , ..,>..,., .,.i.+' 9 Current Sanse Noninverffng Input A 100 mV si nal, with respect to Rn 15, at this input terminates#~@>@~"itch conduction 1"urmg a given oscillator cycle. This pin normally ~-,~lo the top *,:\ ,,~ ., ,,,.?)3,.0 ~ side of the current sense resistor. ... ,,.. , 10 Oscillator The Oscillator frequency is programmed by the values+@%~r ,. components, RT and CT. `f,.h <:$ 3 4,5,6 7 .8 11 Error Amp Noninveting 12 Error Amp Inverting Input ..!. the timing Input Input This pin is available for compensation in @@ lo8~ applications. 13 Error Amp Ou~WM 14 m 15 Current Sense inverting Input Reference pin for internal l&~$xreshold. bottom side of the current y~fesistor. 16 Gnd This pin supplies a gr'~ #Yo?~e control circuit and should be referenced back to the power source ,~oun %, . 17 Vcc 18 Vc 19,20,21 This open collector output is active low {@&@fie or more of the following conditions: Invatid Sensor Input code:Input at logic O, Current Sense Input Pin 15), Undervoltage Lockout greater than 100 mV (Rn 9 with r~ectw activation, and Thermal Shutd~.@~j ,,,, output . This pin is the ~$s~? minimum V@'w@"W CBI BB, AB 22 60~ 23 Brake This pin is normally connected to the supply of the control IC. The controller is functional over a 10 to 30 V. The high~$:,~~$H) of the Bottom Drive Outputs is set by the voltage appfied to this pi@.~&~ohtroller is operational over a minimum Vc range of 10 to 30 V. .,.!. ..,,,~.:, ,. These thh exter~l Select totem pole Bottom Drive Outputs are designed for direct drive of the bottom power switch transistors. $'`~;~he electrical state of this pin configures the control circuit operation for either 60 ,, `:iy. ~bh state) or 120 (low state) sensor electrical phasing inputs. ,,,,~'~~~ ">A logic low state at ttis input allows the motor to run, while a high state does not ~IF ....,~ ,Ii:.. , ~*' allow motor operation and if operating causes rapid deceleration. J,+:+\J \ !:J,\. ~:, :*h&> INTRODUCTION ~...,.,., s .~., ,,.> The MC33035 is one of a .~er~'s'hf high performance monolithic DC brushless -~$t~ntrollers produced by Motorola. It contains ~1 `~ ~%e functions required to .,.$,*t,!. ,.h>>..<:.~ implement a full-featu~,d, `~en loop, three or four phase motor control syste~A~@@tion, the controller can be made to operate DC brus~~o&rs. Constructed with Bipolar Analog technology, it,:d~ers"~~ high degree of performance and ruggedness.@:@:sJK industrial environments. The MC33035 contains~:~j/$}oFPosition decoder for proper commutation seque~~#*emperature compensated reference capable of w*3 a sensor power, a frequency programmable @$&$ oscillator, a fully accessible error amplifier, a pulse ,&?,*~Qj+@ modulator comparator, three open collector top drive :{,%,s~tputs, and three high current totem pole bottom driver . ,,\. \:~Y)~,3 `!.outputs ideally suited for driving power MOSFETS. \\,".Jf.yy Included in the MC33035 are protective features :$ir' consisting of undervoltage lockout, cycl+by+ycle current limiting with a selectable time delayed latched shutdown mode, internal thermal shutdown, and a unique fault output that can easily be interfaced to a microprocessor controller, Typical motor control functions include open loop speed control, forward or reverse rotation, run enable, and dynamic braking. In addition, the MC33035 has a 60~ select pin which configures the rotor position decoder for either 60 or 120 sensor electrical phasing inputs. 8 Input is used to change the direction of motor rotation. FUNCTIONAL DESCRIPTION A representative internal block diagram is shown in Figure 19 with various applications shown in Figures 36, 38, 39,43,45, and 46. A discussion of the features and function of each of the internal blocks given below is referenced to Figures 19 and 36. Rotor Position Decoder An internal rotor position decoder monitors the three sensor inputs (Pins 4, 5, 6) to provide the proper sequencing of the top and bottom drive outputs. The sensor inputs are designed to interface directly with open collector type Hall Effect switches or opto slotted couplers. Internal pull-up resistors are included to minimize the required number of external components. The inputs are ~L compatible, with their thresholds typically at 2.2 V. The MC33035 series is designed to control three phase motors and operate with four of the most common conventions of sensor phasing. A 60~0 Select (Pin 22) is conveniently provided and affords the MC33035 to configure itself to control motors having either 60, 120,240 or 300 electrical sensor phasing, Mth three sensor inputs there are eight possible input code combinations, six of which are valid rotor positions. The remaining two codes are invalid and are usually caused by an open or shorted sensor line. With six valid input codes, the MOTOROLA ANALOG IC DEVICE DATA MC33035 prevent simultaneous conduction of the the top and bottom decoder can resolve the motor rotor position to within a power switches. in half wave motor dtive applications, the window of 60 electrical degrees. top drive outputs are not required and are normally left The Fomard/Reverse input (Pin 3) is used to change the disconnected, Under these conditions braking will still be direction of motor rotation by reversing the voltage across the accomplished since the NOR gate senses the base voltage stator winding, When the input changes state, from high to to the top drive output transistors. low with a given sensor input code (for example 100), the enabled top and botiom drive outputs with the same alpha Error Amplifier designation are exchanged (AT to AB, BT to BB, CT to CB). In A high performance, fully compensated error am~~[~fj~ith effect, the commutation sequence is reversed and the motor access to both inputs and output (Pins 11, 12, 1~~ $~~~ed changes directional rotation. to facihtate the implementation of closed lo~ @& $ speed Motor otioff control is accomplished by the Output Enable control. The amplifier features a typical Q& w~~~~ gain of (Pin 7). When left disconnected, an internal 25 VA current 80 dB, 0.6 MHz gain bandwidth, and ~w$:~~ut common source enables sequencing of the top and bottom drive mode voltage range that extends fro~~~@WYo Vref. In most outputs. When grounded, the top drive outputs turn off and open loop speed control appli,Wtt*f\he amplifier is the bottom drives are forced low, causing the motor to coast configured as a unity gain fi;~a$e follower with the and the ~ output to activate. noninvefling input connected$\~\~he~~eed set voltage source. Dynamic motor braking allows an additional margin of Additional configurations ~~ ~Hn in Figures 31 through 35. .. ":.:i{.~,, ,*J.:$: safety to be designed into the final product. Braking is Oscillator "..p,~,.,..<.~~. accomplished by placing the Brake Input (Pin 23) in a high The frequency w?~~tik' internal ramp oscillator is state. This causes the top drive outputs to turn off and the programmed by t~:~aes selected for timing components bottom drives to turn on, shorting the motor-generated back RT and CT ~~aci~ar CT is charged from the Reference EMF. The brake input has unconditional priority overall other Output (Pin `8J$%mugh resistor RT and discharged by an inputs. The internal 40 kQ pull-up resistor simplifies internal @'"W~e transistor. The ramp peak and valley interfacing with the system safe~-switch by insuring brake volta~,x$t~pically 4.1 V and 1.5 V respectively. To provide activation if opened or disconnected. The commutation logic a g%> compromise between audible noise and output truth table is shown in Figure 20. A four input NOR gate is ~,~fichik efiiency, an oscillator frequency in the range of used to monitor the brake input and the inputs to the three 2&~ 30 kHz is recommended. Refer to F~gure 1 for top drive output transistors. Its purpose is to disable braking .F:$:,. @mponent selection. until the top drive outputs attain a high state. This helps t~.*i>*,\ !;3,,,,,,+ ,s.,. . .;:,:.,$ .3~~.j}\ , Hgure 19. Repr~tifative Block Diagram t AB ~} BE Bonom Di~e outputs 1 CaJ -101 4 1 I Oscillator & I SinkOnly `5t > pOSitiVO True Wth Hysteresis LO~C iL = -------- ------_ ____ 16 Gnd __,_ Y.-__ J CurrentSenseInput CurrentSense Referance Input 23 BrakeInput 11 -- MOTOROLA ANALOG IC DEVICE DATA = Y MC33035 Figure 20. Three Phaae, Six Step Commutation Truth Table (Note 1) Inputs(Note 2) Outputs(Note 3) Sensor Electrical 60 SA 1 1 SB i SA Sc 10 11 1 0 :10 0 oil 101 1 1 1 n n F/R 1 Enable Brake Sense AT . 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 1 17 1 11 n n ; 1 1 n 1 i o 0 1 1 0 1 6 0 :1: o i: : 0 :1: : Vvv Vvv Vvv Vvv Vvv Vvv Vvv NOTES 1. 2. 3. 4. 5. 6. 7. 6. 9. 10. 11. : : {i 0 0 I B7 . 0 CT AB . Al CB : 00 : 0 1 BB 001 00 10 1 :10 i 010 +In inn 6 0 0 0 .- 0 i.- x 111 111 0 0 x x 11 11 0 i 0 o x x x o x o x x x x 1 1 x x x 1 o o 1 1 0 x x x 11 11 11 x ,,.! ~+,- ?,\. o& w .,,0 "$$$)$ 1 ,i+~.:y ,&.,':+:*$< 1 ,,,.>2:..:;$, , I!$,,p;::l$$' 1 1 1 1 f , 1 i.i<;~n o 0 ` `:,s} Vvv x 000 1 0 ~y~ 1> 1 1 o (Note 11) `., .....+l .,. `.t.!,:~{,;y l..,,,.,.,\ V= Anyone ofsixvahd sensorordrive combinations X= Don'tcare. Thedigi@l inpuk(Wns3,4,5,6,7, Z,23)are all~Lcompatible. Thecurrent ee~@~@$~in9)hasal OOmVthresholdwith respectto Pin 15. A logic Ofor this input is definedas< 85 mV,and a logic 1 is> 115mV. ~$. The fault and top drive outputs are open collectordesignand active in the IOW$$)&Jf' With 60~select (Rn 22) in the high (1) state, configurationis for 60 senw~]ectrical phasinginputs.Witi Pin 22 in low (0) state, configuration .+*%.,8 is for 120sensorelectricalphasinginputs. Valid60 or 120sensorcombinationsfor correspondingvald top antiti~rn dflve outputs. Invahdcensorinputswith brake= O;All top and bottomdrivesoff,,RJow.P Invahdsensorinputswith brake= 1; All top drivesoff, all bottom~ves'~, ~ low. Valid60 or 120sensorinputswith brake= 1; All top drivesoW~@~:@,* driveson, ~ Mgh. bottomdrives on, ~ low. Validsensorinputswith brake= 1 and enable= O;All top dw~~,d~ Vatidsensorinputswith brake= Oand enable= O;All top and~~~ti drivesoff, ~ low. .... All bottomdrivesoff, ~ low. .,::$. ..,. *s:yl ~\\ Pulse Width Modulator *:. The use of pulse width modulation provid~+ a~}energy efficient method of controlling the motor s~:~~~~$kying the average voltage applied to each statom~!pd~~ during the commutation sequence. As CT dischat%~~oscillator sets both latches, allowing conduction ~~%wp and bottom drive outputs. The PWM compara~r N'&S the upper latch, terminating the bottom dtiv~ow conduction when the positive-going ramp of C~$~~c,@es greater than the error amplifier output. The puke @k modulator timing diagram is shown in Figure 21. @@@th modulation for speed control appears only at thd~~~,$m drive outputs. Current Limi%j,: ` Continu~~y~q$eration of a motor that is severely over-lo~~w$esults in overheating and eventual failure. This, &&~&tive condition can best be prevented with the u~$~%~~c~tle-by-cycle current limiting. That is, each &n-qc~e is treated as a separate event. Cycle-by-cycle ..'tcw "+ ,~~~$,fU@'nt limiting is accomplished by monitoring the stator `w$$\;d&rrentbuild-up each time an output switch conducts, and :!$!:$.$:,$. \ ,., "$~, ~%. ` 11?upon sensing an over current condition, immediately turning ~'<:, off the switch and holding it off for the remaining duration of w oscillator rampup period. The stator current is converted to a voltage by inserting a ground-referenced sense resistor Rs (Figure 36) in series with the three bottom switch transistors (Q4, Q5, Q6). The voltage developed across the sense resistor is monitored by the Current Sense Input (Pins 9 and 15), and compared to the internal 100 mV reference. The current sense comparator inputs have an input common mode range of approximately 3.0 V. If the 100 mV current sense threshold is exceeded, the comparator resets the 10 I BottomDrives Current Sc 10 1 o 120" SB 100 00 : 0: OOA Top Drives Phasing (Note 4) lower sense latch and terminates output switch conduction, The value for the current sense resistor is: 0.1 `S=l stator(max) The ~ output activates during an over current condition, The dual-latch PWM configuration ensures that only one single output conduction pulse occurs during any given oscillator cycle, whether terminated by the output of the error amp or the current limit comparator. Figure 21. Pulse Width Modulator Timing Diagram CapacitorCT ErrorAmpOUU PWMlnput Current SenseInput Latch"Se~ Inputs TopDrivellllll outputs I I I I ! I I I I I I I I I 1[1 1 I 1 1 1 1 1 I I I I I 11111111 I I I I 1111111 I I BoffomDrive outputs m Outpui I I 11111111 r [ 1 1 I 1 I I I I I Ill MOTOROLA ANALOG IC DEVICE DATA MC33035 Reference The on-chip 6.25 V regulator (Pin 8) provides charging current for the oscillator timing capacitor, a reference for the error amplifier, and can supply 20 mA of current suitable for directly powering sensors in low voltage applications. in higher voltage applications, it may become necessa~ to transfer the power dissipated by the regulator off the IC. This is easily accomplished with the addition of an external pass transistor as shown in Figure 22. A 6.25 V reference level was chosen to allow implementation of the simpler NPN circuit, where Vref - VBE exceeds the minimum voltage required by Hall Effect sensors over temperature. With proper transistor selection and adequate heatsinking, up to one amp of load current can be obtained. Figure 22. Reference Output Buffers ,7r-- Vi" 18 I I REF *1== MPS UOIA a 1 Control Urcuitw =5.6V 6"25V --- 6.25 V = I= To se~~or power UVLO UVLO m output The open collector ~ Output (Pin 14) was designed to provide diagnostic information in the event of a system malfunction. It has a sink current capability of 16 mA and can directly drive a light emitting diode for visual indi~tion. Additionally, it is easily interfaced with TTUCMO~~l~Jor use in a microprocessor controlled systemtl .,~~~,w Output is active low when one or more o~?,~~~~~$lowing .ts.h ,*!,:.~4 " conditions occuc .>,,.., >8$.::..:J.S `*y{*,.$'~,. Output Enable a~logic [0] Current Sense Input great~~ti*~$$O mV Undervoltage Lockout, acti~},~ of one or more of It$:, ~ the comparators ..+.,`*,. 5) Thermal Shutdow~~~f&um junction temperature being exceeded$v~ "X8 c This unique out~~~ also be used to distinguish between motor *%P or sustained operation in an overloaded c~~jtiotil:~th the addition of an RC network between t~:=.Qutput and the enable input, it is possible to creatqa t~~delayed latched shutdown for overcurrent. The ~~~cggkuit~ shown in Figure 23 makes easy starting ofm@~$systems which have high inertial loads by providing ,&ditio?&l starting torque, while still preserving overcurrent .,W~p;~gction. This task is accomplished by setting the current ~' `~t to a higher than nominal value for a predetermined time. "~~<..,v ` `~~''~buring an excessively long overcurrent condition, capacitor :.'~:y, `.$> *,?:, COLY will charge, causing the enable input to cross its ~~. .,. threshold to a low state. A latch is then formed by the positive ~:$ feedback loop from the ~ Output to the Output Enable. Once set, by the Current Sense Input, it can only be reset by shorting CDLYor cycling the power supplies. *:l:\.:\ J:!<$e me NPNcircuitisreCOMMeflde@$Q~A,~&g Hall oroptosensors, where the ouputvo]tagetemperature co#)~~:~'fShot cfitical. The PNP circuit is slightly more complax, but is also ~~r~c@te over temperature. Neither circuit has *,t..,l\J\ .*:.,:/~ ,.$ current limiting. `.,~>\. J Undervoltage .bockd~' A triple ~&@tage Lockout has been incorporated to prevent d4~&$$~ the IC and the external power switch transi~\$~~&~~er low power supply conditions, it guarantees that:~g~~knd sensors are fully functional, and that there is q@4cMRt bottom drive output voltage, The positive power ,,,,.&PP,@Sto the IC (Vcc) and the bottom drives (VC) are each ~~~~~~fitored by separate comparators that have their ~@N~.thresholds at 9.1 V. This level ensures sufficient gate drive S::+..:.,, `~$~ necessary to attain low RDs(on)when driving standard power s... !:; MOSFET devices. When directly powering the Hall sensors from the reference, improper sensor operation can result if the reference output voltage falls below 4.5 V. A third comparator is used to detect this condition. [f one or more of the comparators detects an undervoltage condition, the ~ Output is activated, the top drives are turned off and the bottom drive outputs are held in a low state. Each of the MOTOROLA ANALOG IC DEVICE DATA comparators contain hysteresis to prevent oscillations when crossing their respective thresholds. 2j 3) 4) Drive Outputs The three top drive outputs (Pins 1, 2, 24) are open collector NPN transistors capable of sinking 50 mA with a minimum breakdown of 30 V. Intetiacing into higher voltage applications is easily accomplished with the circuits shown in Figures 24 and 25. The three totem pole bottom drive outputs (Pins 19, 20, 21) are particularly suited for direct drive of N-Channel MOSFETS or NPN bipolar transistors (Figures 26, 27, 28 and 29). Each output is capable of sourcing and sinking up to 100 mA. Power for the botiom drives is supplied from Vc (Pin 18). This separate supply input allows the designer added flexibility in tailoring the drive voltage, independent of VCC. A zener clamp should be connected to this input when driving power MOSFETS in systems where Vcc is greater than 20 V so as to prevent rupture of the MOSFET gates. The control circuitry ground (Pin 16) and current sense inverting input (Pin 15) must return on separate paths to the central input source ground. Thermal Shutdown Internal thermal shutdown circuitry is provided to protect the IC in the event the maximum junction temperature is exceeded. When activated, typically at 170"C, the [C acts as though the Output Enable was grounded. 11 MC33035 figure 23. Timed Delayed Latched Over Current Shutdown --------- + I 41 ---------- ---- --___ figure 24. High Voltage Interface with NPN Power Transistors _ I ------------1 .. + 51 + 61 I i Pos DEC `"" L- Dwoder w Load Ill 11111 & *o Q4 I tDLY = `DLY CDLY `"( G Transistor Q1 isacommon base stsge used to level shitifrom VCCto the high motor voltage, VM. Tha collector tiode is required ifVcc is present while VM is low. figure 26. Current Waveform Spike Suppression 23 ~ Brake Input The addition of the RCfilterwill efiminate current-timitinstabitity caused bytha leading edge spike on the current waveform. Resistor RS should ba a low inductance type. 12 MOTOROLA ANALOG IC DEVICE DATA MC33035 Figure 27. MOSFET Drive Precautions 23 + T, Brake Input Figure 28. Bipolar Transistor Drive D=1N5819 ,.s.:).\, ;:, ~,,,~. \i,,\, Series gata reeistor Rg will dampen any high frequency oscillationa caused by the MOSFET input capacitance and any series wiring induction in tie gate+ource circuit. Diode D is raquirad if the negative current into the Bottom Drive Outputs exceeds 50 mA. Thetotem*Wu&~an sistor tu@ff'~ti:%e .&t, furnish negativa base current for enhanced tranaddition of capacitor C. VCC=12V h. !vMt80b w 0, + 51 2- ~fi +k ----- J MC1555 ------- &l 18k 1.0/200 v `---.--'"-". " ~lN:_vB"s & `= MUR115 i I vM= 170v . TNs circuit generates VBoO~tfor Figure 25. wro~+rctit~ Ground (Pin 18) and Current Senea Invarting Input (Rn 15) @st Mum on sepsrate paths to the Central Input Source Ground. ,.,::$:$.:$$,l,%,ls' :X $~~@UallY10SSlaSScurrent sensing can be achievad with the implementation of ~Jiw ~~~~~NSEFET power switches. ,:. ~~?lJ.," ~'f$,:::~t $. . MOTOROLAANALOG IC DEVICE DATA 13 MC33035 Hgure 31. Differential Input Speed Controller I ,, figure 32. Controlled AcceleratiotiDeceleration REF . + ~ t 25fl EA + PWM 1: ~& `Hn .> 13 = `A(-) `,,, %-(%VB) .. ?~ `J* .~.i,,},: Resistor RI with capacitor C s~,~~mceleration time constant while R2 controls the deceleration. T~~~* of RI and R2 should be at least tan times greater than the s~~.~<~t,~otentiometer to minimize time constant variations with differ:flt:~,~&@ngs. ...~ji:.,.'*...,$,, >*J, ~ Figure 35. Closed Loop Temperature Control (H)*-(5VB)I pREFJ `Hn 3 = vref RI + R2 ~1 v VB = * ref 5+1 R5 () `6 R3 >> R5 IIR6 ~ . Thiscircuitcancontrol the speed ofacoolingfan propotionaltofhe diffarance between the sensor and set temrzeratures. The control looD is closad as the forcad air cools the NTC the~istor. For controlled hea~ng applications, axchange the posifiona of RI and R2. 14 MOTOROLA ANALOG IC DEVICE DATA MC33035 SYSTEM APPLICATIONS Three Phase Motor Commutation The three phase application shown in Figure 36 is a full-featured open loop motor controller with full wave, six step drive. The upper power switch transistors are Darlingtons while the lower devices are power MOSFETS. Each of these devices contains an internal parasitic catch diode that is used to return the stator inductive energy back to the power supply. The outputs are capable of driving a delta or wye connected stator, and a grounded neutral wye if split supplies are used. At any given rotor position, only one top and one bottom power switch (of different totem poles) is enabled. This configuration switches both ends of the stator winding from supply to ground which causes the current flow to be bidirectional or full wave. A leading edge spike is usually present on the current waveform and can cause a current-limit instability. The spike can be eliminated by adding an RC filter in series with the Current Sense Input. Using a low inductance type resistor for RS will also aid in spike reduction. Care must be taken in the selection of the bottom power switch transistors so that the current during braking does not exceed the device rating. During braking, the peak current generated is limited only by the series resistance of the conducting botiom switch and winding. If the motor is running at maximum speed<,,W~W?oad, the generated back EMF can be as high as @:~-~ly voltage, and at the onset of braking, the pea~j~~w~may approach twice the motor stall current,..,~tg~~~' 37 shows the commutation waveforms over twd$el~~~cal cycles. The first cycle (0 ta 360) depicts motqjoph%on at full speed while the second cycle (360 to~~@\;&ows a reduced speed with about 5070 pUISe width,@ @@,@tion.The current waveforms reflect a constant tor.~@@@qdand are shown synchronous to the commutation frq~ti~ for clarity. ~?$~~ ,.ii:t.:~. .${,,: . Figure 36. Three Phase, Six Step, Full Wa~,@,$~~~OntrOller i K F I L ------ I I I -1OI CT ! I 1, Oscillator I I I I I I I I I I I I I II --_ J Motor s " c ` `--"""-"'-' ` H" I II I Q~ A 1 Gnd 16 23 Brake . MOTOROLA ANALOG IC DEVICE DATA 15 MC33035 * figure 37. Three Phase, Six Step, Full Wave Commutation Waveforms FwWRev = 1 16 MOTOROLA ANALOG IC DEVICE DATA MC33035 Rgure 38 shows a three phase, three step, half wave motor controller. This configuration is ideally suited for automotive and other low voltage applications since there is only one power switch voltage drop in series with a given stator winding. Current flow is unidirectional or half wave because only one end of each winding is switched. Continuous braking with the typical half wave arrangement presents a motor overheating problem since stator current is limited only by the winding resistance. This is due to the lack of upper power switch transistors, as in the full wave circuit, used to disconnect the windings from the supply voltage VM. A unique solution is to provide braking until the motor stops and then turn off the bottom drives, This can be accomplished by using the ~ Output in conjunction with the Output Enable as an over current timer. Components RDLYand CDLYare selected to give the motor sufficient time to stop before latching the Output Enable and the top drive AND gates low. When enabling the motor, the brake switch is closed and t~ PNP transistor (along with resistors RI and RDLY)are us~~bet the latch by discharging CDLY The stator flyb~~~~~age is .\ clamped by a stngle zener and three d[odes.{}l,,<$%~,.~!+ "J**Lt ,.l$:. .> ) ,,$. ``~J$# `Q" ,. ~ :I?i..>., ,4J$? ,,,L~,.:iiy> 4'..?:,,} \.\ ~'$... `.~?i:$: figure 38. Three Phase, Three Step, Half Wave Motor controller ,<~~':fi%l'w' ..,;: ,5. ... ..:. ...\,,t+JMotor 1; I 61 I I I `-l--F- 3 "Fas'er&? I v i ~lo, CT I - Oscillator I I I L I -------- -------- ---- -- __ -- _ __ r Gnd 16 = MOTOROLA ANALOG [C DEVICE DATA ( 23 ! BrWe ( 17 MC33035 Three Phase Closed Loop Controller The MC33035, by itself, is only capable of open loop motor speed control. For closed loop motor speed control, the MC33035 requires an input voltage propotiional to the motor speed, Traditionally, this has been accomplished by means of a tachometer to generate the motor speed feedback voltage. Figure 39 shows an application whereby an MC33039, powered from the 6.25 V reference (Pin 8) of the MC33035, is used to generate the required feedback voltage without the need of a costly tachometer. The same Hall sensor signals used by the MC33035 for rotor position decoding are utilized by the MC33039. Every positive or negative going transition of the Hall sensor signals on any of the sensor lines causes the MC33039 to produce an output pulse of defined amplitude and time duration, as determined by the external resistor RI and capacitor Cl. The output train figure of pulses at Pin 5 of the MC33039 are integrated by the error amplifier of the MC33035 configured as an integrator to produce a DC voltage level which is propotiional to the motor speed. This speed propotiional voltage establishes the PWM reference level at Pin 13 of the MC33035 motor controller and closes the feedback loop. The MQ$3035 outputs drive a TMOS power MOSFET >pha~~xe. High currents can be expected during condition~~+,~~-up, breaking, and change of direction of the motW $:+:~~~ The system shown in Figure 39 is dea~~~jor a motor having 120/240 degrees Hall sensor e}a~$$phasing. The system can easily be modified to ~~"~,~modate 60/300 degree Hall sensor electrical @w&by removing the jumper (J2) at Pin 22 of the M~33'Wk <:.:,~~, .:i.>. *.{*TX} V*++. ~ .:t::'q."'v$~,, ,,::*, ,,.1'.'~, .~.x, -N*,:};i:<~ :. ,:~ 39. Closed Loop Brushless DC Motor Ce' Using The MC33035 and MC3303,%Ii,, `a ,iy:--: ,!\*\~:;. `$:.$,+,* -- .... I I + ... I , I I ,. ,," I !I ~7 ~ "~t~ & F lC ," 14 ) Faster Iinb I 18 13 12 AI: 1.OM I = J1 I I 470 1 I TI I L L-- &lN5a19 17 15 I I I I I ! ---- -. --J -------- Motor 330 1N5355B lav = 2.2k 0!1 TP2 Fault * 100 0.05/1.0 w 1N4148[ii: I T 0.1 33 i" 1 MOTOROLA ANALOG IC DEVICE DATA MC33035 Sensor Phasing Comparison There are four conventions used to establish the relative phasing of the sensor signals in three phase motors. Wth six step drive, an input signal change must occur eve~ 60 electrical degrees; however, the relative signal phasing is dependent upon the mechanical sensor placement. A comparison of the conventions in electrical degrees is shown in Figure 40. From the sensor phasing table in Figure 41, note that the order of input codes for 60 phasing is the reverse of 300. This means the MC33035, when configured for 60 sensor electrical phasing, will operate a moto~ with either 60 or 300 sensor electrical phasing, but resulting in opposite directions of rotation. The same is true for the part when it is configured for 120 sensor electrical phasing; the motor will operate equally, but will result in opposite directions of rotation for 120 for 240 conventions. Figure 40. Sensor Phasing Comparison Rotor Electrical Position (Degrees) 0 60 120180 240300360420480540600 111111111111 [sA~ ]--l z n `A ~ z .~ 1200 `B ~ z ~ [ Sc ~%;"" w SA I I I I I 860720 I j 1 I In this data sheet, the rotor position is always given in electrical degrees since the mechanical position is a function of the number of rotating magnetic poles. The relationship between the electrical and mechanical position is: An increase in the number of magnetic pol~&@&s more electrical revolutions for a given mec~$'wk revolution. General purpose three phase motor:J~&ai$~'kontain a four pole rotor which yields two elec$rJ$~~r$Wlutions for one ~.;' ` mechanical. ~(,.,, -~.<:i ~, :"$,i. ~.~.~,i: Two and Four Phase Motq~:&,rnmtitation The MC33035 is alsq":~~~B& of providing a four step output that can be us@Jp ~We MO or four phase motors. The truth table in Fig~~&&hows that by connecting sensor inputs SB and S&_~er, it is possible to truncate the number of drJ~.oufpMt states from six to four. The output power swit-we connected to BT CT BB, and CB, Figure 4$':~~,@ a four phase, four step, full wave motor contr~a~w~@tion. Power switch transistors Q1 through Q8 are %fllngton type, each with an internal parasitic catch .?~$~e~~t~ four step dflve, only two rotor position sensors ,,,x,~sb%~ed at 90 electrical degrees are required. The , $1' "@mutation waveforms are shown in Figure 44. *.*.+ ":-?4?,`~p> Figure 45 shows a four phase, four step, half wave motor h..., controller. It has the same features as the circuit in Figure 38, except for the deletion of speed control and brating. I I IYL ~,:~ , Commutation Truth Table MC33035(60~ Salect Pin Opsn) Inputs Ssnsor Electrical Spacing* = 900 SB SA Figurq;f~.$~#sor Phasing Table S@S,or~k$tricel Phasing(Degrees) -- 0110 `1111 `s.',~. 01 -~,:j `.,.. .t~, ,+\\,> , 001 ~:, ?. f: ,<*,$,, .$,, 000 1 1111 01 0110 OIIK O11o lB IA 000 011 011 001 001 010 011 MOTOROLA ANALOG !C DEVICE DATA CT BB CB 1 1 1 1 1 0 1 0 0 0 1 1 0 0 0 0 1 1 1 0 1 0 0 0 0 1 0 0 1 1 0 1 1 1 0 1 1 0 ,0 0 0 0 1 1 1 0 0 0 `Wti MC33035 001 010 B~ 0 1 1 Bottom Drives FIR 1 1 0 0 1 10 outputs Top Drives, to Sc. 19 i+ k II Figure U. Four Phase, Four Step, Full Wave Motor Controller .---------------------- -- ,- 41 1+ 51 I 1: Rotor Poeition Decoder 3 FwWRev Q, -- L Enable - ,------ -- i -- I / Al T !1 I I `1 I c1 I -- DL______ !0 Motor ; 9- d Q5 .?.: L------------------ -------------- Gnd ~ 16 -- --------. 1~ 23 MC33035 figure U. Four Phase, Four Step, Full Wave Motor Controller Rotor ElectricalPosition (Degrees) o 90 I I 180 270 360 450 540 630 720 I I I .~.. SA Sensor Inputs 60"~ Select Pin Open SB 1 Code BT Top Drive outputs { CT BB Bottom Drive Outpute \ Conducting Power Switch Transistors CB I Q3tQ5 I Q4t Q6 I I I Motor Drive Current FwdRev = 1 MOTOROLA ANALOG IC DEVICE DATA 21 -------------------------- r+ ------------------. I 41 Rotor Position Decoder 1 FwdRev i+ I r--Ll- CIVdUl~ - I 171 ,,. `M. tI i 18 t I Undervoltaae .3-- 24 &25PA 7! ------ - - . -- --------3 rake ---------- . Motor I MC33035 Brush Motor Control Thouah the MC33035 was desianed to control brushless DC mot;rs, it may also be used ~o control DC brush type motors. Figure 46 shows an application of the MC33035 driving a MOSFET H-bridge affording minimal parts count to operate a brush-type motor. Key to the operation is the input sensor code [100] which produces a to~left (Ql) and a bottom-right (Q3) drive when the controller's forward/reverse pin is at logic [1]; top-right (Q4), bottom-left (Q2) drive is realized when the Foward/Reverse pin is at logic [0]. This code supports the requirements necessa~ for H-bridge dtive accomplishing both direction and speed control. The controller functions in a normal manner with a pulse width modulated frequency of approximately 25 kHz. Motor speed is controlled by adjusting the voltage presented to the noninverting input of the error amplifier establishing the PWM'S slice or reference level. Cycle-by-cycle current limiting of the motor current is accomplished by sensing the voltage (100 mV) across the RS resistor to ground of the H-bridge motor current, The over current sense circuit makes it possible to reverse the direction of the motor, using the normal forwartireverse switch, on the fly and not have to completely-, stop before reversina. LAYOUT CONSIDERATIONS Do not attempt to construct motor control circuits any of the brushless on wirewrap or plug-in prototype High frequency printed circuit layout techniques are imperative to prevent pulse jitter. This is usually caqd by excessive noise pick-up imposed on the current :$~F, or error amp inputs. The printed circuit layout sho$?~%~,h~in a ground plane with low current signal and *,,.@*e and output buffer grounds returning on separa~~$~~~back to the power supply input filter capacitor ,~,$ `$&%mic bypass t, ,\$..i capacitors (O.1 ~F) connected f.y:. *X. ;>,:.\ \h t$<, ~t~, .$! `k! `::,\:. \ ,~$s~' ~Y:;: >$$.! .. 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