MIL-PRF-38534 AND 38535 CERTIFIED FACILITY M.S.KENNEDY CORP. STARTER / GENERATOR MOTOR CONTROLLER 4413 (315) 701-6751 FEATURES: 28V/160A Brushless DC motor control capability. 28V/90A Synchronous Boost Generator capability. Fully isolated microprocessor control and gate drive circuitry. Rugged open frame PC Board construction with ample area for heat sinking. DESCRIPTION: The MSK 4413 is a dual mode Brushless DC Motor controller providing both motor drive capability and dc power generation capability. It utilizes output phase current sensing as part of a current feedback system for torque control in the motor control mode. In generator mode the bus voltage is sensed and processed then used to set the current control loop. Current control provides reverse torque on the motor, using regeneration/back EMF as a source for boost mode power generation. Motor drive mode is selected by applying the V+ supply to a pin on the J1 connector. Generator mode is selected by applying the V+ supply to a pin on the J1 connector as well. BLOCK DIAGRAM 1
TYPICAL APPLICATIONS UAV engine starter motor/airframe power generator Small electric vehicle motor drive Small wind turbine powered generator HEADER CONNECTION: 1 GROUND 2 START 3 NC 4 GEN 5 GROUND 6 GROUND 7 GROUND 8 +12V 9 GROUND 10 NC 11 NC 12 NC 13 NC 14 NC 15 NC 16 NC 17 NC 18 NC 19 NC 20 GROUND 21 HALL A 22 GROUND 23 HALL C 24 GROUND 25 HALL B 26 GROUND PIN-OUT INFORMATION PCB PADS L1 A PHASE OUT L2 B PHASE OUT L3 C PHASE OUT V+ +28V IN V+RTN +28V GROUND RETURN ABSOLUTE MAXIMUM RATINGS IOUT IPK V+ START Input GEN Input +12V Current Continuous Output Current Peak Output Current 32V 32V 32V 60mA 160A 200A TST TJ Thermal Resistance Storage Temperature Operating Temperature Solder Temperature (10 Seconds) Junction Temperature 1.0C /W -40 C to +85 C -40 C to +85 C +300 C `+150 C ELECTRICAL SPECIFICATIONS 2
APPLICATION NOTES MSK 4413 CONNECTION DESCRIPTIONS POWER CONNECTIOS: V+ BUS - Is the power connection to the bus. The external wiring to this connection should be sized according to the RMS current required by the motor. Additional capacitance will be required by many applications and should be in the form of low ESR film capacitors. V+ RTN - Is the power return connection to the bus. As with the V+ connection the external wiring to this connection should be sized according to the RMS current required by the motor. Any additional bulk capacitance in the form of low ESR film capacitors should be connected as close as possible to this connection. L1 A PHASE OUT, L2 B PHASE OUT, L3 C PHASE OUT - Are the connections to the motor phase windings. The wires connected to these outputs should be sized to the current requirements of the motor. Shorts from these connections to either V+ or V+RTN should be avoided as there is no short circuit protection, thus the MOSFET bridge will be damaged under these circumstances. CONTROL CONNECTIONS, 26 PIN HEADER: 1, 5, 6, 7, 9, 20, 22, 24, 26 GROUND - Are connected to the V+ RTN. 3, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 NC - Are unused and unconnected pins. 2 START - This connection is used to put the MSK 4413 into START MODE and apply power to the connected motor. V+ is applied to this pin to select this mode. This can be accomplished by a manual switch or some type of controlled relay. This connection drives the input LED of an opto-coupler through a current limiting resistor of value 2500 ohms rated for 1/2 watt. If V+ is a nominal 28 volts the current drawn will be around 11 milliamps. OPERATION Start mode provides a motor with up to 9000 watts of power to turn over a piston engine with a preprogrammed torque level. The torque is maintained by a digital current control loop using a PID algorithm. Current is sensed on phase A and B providing the necessary feedback input to the control processor thus adjusting the PWM duty cycle of the power bridge. When initially activated a soft start period occurs ramping the voltage up to the phase outputs until the required torque is reached at which point the torque is maintained. Generator mode operates by using synchronous rectification and boost modulation of the power bridge to supply and maintain the bus at a selected voltage from 24 volts up to 28 volts. An analog error amplifier processes the bus voltage and provides an error signal to the control processor. This analog error signal is converted to a digital error signal by the processor's Analog to Digital Converter (ADC). The ADC output is then applied to the control input of the digital current control loop PID algorithm to determine the correct PWM duty cycle of the power bridge. To protect a connected battery or other bias source from regenerative voltage on the bus a blocking diode is required. The diode should be rated for 300 Amps and 40 volts. Proper managment of heat dissipation from the power bridge will allow sustained operation of both modes. An aluminum plate attached at the bottom of the assembly and in physical contact with the power bridge module gives flexibility in selecting the required heat sink arrangement. It can be removed for drilling and/or milling. Some arrangement of active cooling is necessary when operating at high power levels and extended periods. 4 GEN - This connection is used to put the MSK 4413 into GENERATOR MODE and manage power from the connected motor as it is being spun and place that power onto the bus connection. V+ is applied to this pin to select this mode. As with the START pin this can be done with a manual switch or some type of controlled relay. This connection drives the input LED of an opto-coupler through a current limiting resistor of value 2500 ohms rated for 1/2 watt. If V+ is a nominal 28 volts the current drawn will be around 11 milliamps. 8 +12V - This output is intended to supply the connected motor phase hall sensors. The return connection should be GROUND, pin 9.5 milliamps is the maximum supply current. 21 HALL A, 25 HALL B, 23 HALL C - These are the inputs for the motor phase hall sensors. Each one is connected to the input of an opto-coupler through a 1200 ohm, 1 watt resistor. Source current is around 10 milliamps. 3
TYPICAL APPLICATION 4
MECHANICAL SPECIFICATIONS WEIGHT=900 GRAMS TYPICAL 5
MECHANICAL SPECIFICATIONS CONT'D WEIGHT=900 GRAMS TYPICAL M.S. Kennedy Corp. 4707 Dey Road, Liverpool, New York 13088 Phone (315) 701-6751 FAX (315) 701-6752 www.mskennedy.com The information contained herein is believed to be accurate at the time of printing. MSK reserves the right to make changes to its products or specifications without notice, however, and assumes no liability for the use of its products. Please visit our website for the most recent revision of this datasheet. 6