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| MLX90804 Speed regulator for universal motors Features and Benefits * * * * * * * * * * * * * * Low cost - minimal external components In PDIL8, PSOP8 or Chip-on-board 50/60Hz operation Robust digital design: Offering stable triac control Eliminating variations due to changes in analogue parameters No aging and temperature influences True PI speed regulator No external calibration or adjustment required Low power consumption Suited for driving resistive and inductive loads Pulse input to measure the motor speed with a low cost coil or a hall sensor Motor current sensing for power limitation Adaptable to specific motor and application requirements by mask programming Applications Universal motor control applications that require true speed regulation, such as used in blenders, mixers, kitchen appliances, drills, etc Ordering Information Part No. Temperature Suffix Package version Temperature Range MLX90804 S A -x 0C to 85C Automotive The customer specific version code (defining the options) is indicated with 1 character at the end of the ordering number. Functional Diagram 90804 VDD VSS Oscillator PLL Triac T R G drive Voltage regulator VDD1 Gate sensing Description The MLX90804 is a power control IC for controlling the speed of AC motors by means of a triac. The speed setting is done by applying a ratiometric voltage at pin SET (usually by means of a potentiometer). This speed setting is compared with the pulse rate at the SPD input. The input is compatible with inductive and magnetic detectors. The calculation of the required phase angle is done with a PI regulator, which is fully digital. A soft start function is implemented to eliminate high current peaks at startup. Also available are an overload and overspeed protection. The build in Frequency Locked Loop compensates for variations in the mains frequency giving a stable frequency independent trigger control. Several parameters can be adjusted by mask programming: minimum and maximum speed, soft start delay, gain settings of the PI regulator, ... SYN Zero crossing detector Control logic SPD SET ADC MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 1 Page 22/Aug/98 Rev 1.0 Page 1 30/Jun/00 MLX90804 Speed regulator for universal motors Overload shutoff feature General Description Speed Regulator The speed is regulated by a PI regulator with programmable parameters Kp and Ki. Speed Measurement The speed is measured either by a coil or by a hall sensor with digital output. The type of sensor can be defined by mask option. The sensor must be located close to a cylindrical magnet. The number of pole pairs can be programmed. 625 ms after starting the motor (i.e. selecting a speed setting different from 0 rpm) the following function will be enabled: if the speed of the motor gets lower then a programmable value SLIM for longer then 320 ms, the motor speed is permanently set to 0 rpm. As a consequence the first possible timeout to recognize a blocked motor after start will be approximately 1 sec. This state can only be left by disconnecting the power from the electronic circuit. Overspeed shutoff feature If the speed of the motor gets higher than a programmable value SLIMA for longer then 320ms, the selected speed is permanently set to 0 rpm. This state can only be left by disconnecting the power from the electronics. Speed Setting The speed is selected by applying a voltage at pin SET. The voltage at this pin is fed into an ADC (referenced to VDD) and is converted to a 4 bit value. This value is the address of a ROM table in which the different speeds are programmed. This means that 16 different speeds can be selected. The relation between voltage at input SET and the corresponding speed does not need to be linear. It can be freely chosen. Soft Start A soft start procedure is activated at start up and is implemented to guarantee a smooth startup of the motor under all conditions. At very low speed the speed can not yet be measured and therefore several actions are taken so that the PI regulator can smoothly take over once the speed has increased sufficiently. The soft start function is configurable with the option mask. Just after applying power to the electronics there is a delay time until the motor starts movement. The maximum allowable delay time is 300 ms. Speed Set Ramping At any time when the speed setting is changed to a new speed, the change is internally generated with a ramp function to optimize the transient behavior of the PI regulator. This ramp function is configurable with the option mask. Main Switch It is possible to program one or more speed settings with a zero speed. This will stop the motor. However for security reasons it might be considered to combine this setting with a switch to disconnect motor and/or electronics from the mains. MLX90804 Speed regulator for universal motors Page 2 Rev 1.0 30/Jun/00 MLX90804 Speed regulator for universal motors MLX90804 Electrical Specifications DC Operating Parameters TA = 0oC to 85oC Parameter Ambient temperature Symbol Tamb Test Conditions Min 0 Typ Max Units 85 C Maximum chip temperature Tch Thermal resistance Maximum allowed source supply current Rth IDD4m PDIP8 package Drivers off, all the current flows in the chip 110 150 C C/W 10 mA Power supply The 90804 supply pin (VDD1) must be connected by external series resistors and a rectifier diode to the AC line. An internal zener function limits the voltage at VDD1 to approximately 16V. For proper operation a decoupling capacitor must be connected between VDD1 and VSS. Parameter Symbol Test Conditions IDD1 = 5mA Min 14 4.6 Typ 16 5.0 0.7 Max Units 18 5.4 V V mA V Voltage applied at the sup- VDD1 ply pin Internal 5V supply Current consumption For external circuitry VDD IDD1 VEXT VDD1 = 14V IEXT = 8mA 4.5 5 Power on Reset This block ensures a correct start of the digital part. The reset signal (DPORB) goes up for VDD>Vdporh and down for VDD Symbol Vdporh Vdporl Vdphyst Test Conditions Min Typ 2.5 2.0 0.5 Max Units V V V Analog Power-On Reset This block tracks the voltage applied at VDD1. The triac firing is permitted if VDD1 > Vaporh and is stopped when VDD1 Symbol Vaporh Vaporl Vaphyst Test Conditions Min Typ 13 10 Max Units V V 4 V 2 3 MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 3 Page 22/Aug/98 Rev 1.0 Page 3 30/Jun/00 MLX90804 Speed regulator for universal motors Zero crossing detector This detector contains two comparators with hysteresis. The first comparator has reference at VDD1. The reference of the second one is VDD1-1V. Both outputs ZC1 and ZC2 are HIGH during positive half wave of the mains and LOW during negative half wave of the mains. Parameter High level threshold 1 Low level threshold 1 High level threshold 2 Low level threshold 2 Symbol Vzc1h Vzc1l Vzc2h Vzc2l Test Conditions Referenced to VDD1 Referenced to VDD1 Referenced to VDD1 Referenced to VDD1 Min Typ 0.5 -0.5 -1.5 -2.5 Max Units V V V V Speed measurement The chip has an input SPD to measure the motor speed. It is possible to connect a low cost inductor (between SPD and VSS) or a hall sensor with digital output. . The type of sensor can be defined by mask option. In case of the use of a coil the input levels are defined in the table below. In case of the use of a hall sensor, the levels are cmos compatible. Parameter High comparator level Low comparator level Symbol SPDHI SPDLO Test Conditions Min Typ 80 -80 Max Units mV mV Note: When used with a coil, the input voltage is on chip limited to approximately -280mV. However the current injected or pulled out of this pin should not increase above 1 mA. When used with a hall sensor, the SPD input does not have an internal pull up resistor. Ignition driver This driver operates as a current generator to fire the triac. Parameter Triac gate current Symbol ITRG Test Conditions VDD1 > Vaporh Min 30 Typ 60 Max Units 90 mA ADC This is a 4-bit ADC. Parameter Resolution Reference voltage Symbol Test Conditions Min Typ 4 Max Units bits Vref VDD MLX90804 Speed regulator for universal motors Page 4 Rev 1.0 30/Jun/00 MLX90804 Speed regulator for universal motors Application Example - coil sensor VDD1 90804 VSS SET VDD TRG SPD SYN M Application Example - hall sensor VDD1 90804 VSS SET VDD TRG SPD SYN Hall M MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 5 Page 22/Aug/98 Rev 1.0 Page 5 30/Jun/00 MLX90804 Speed regulator for universal motors An example can be found in the table: this is an application where the SET input voltage is defined with a rotating knob which has only 6 positions. Switch position 1 corresponds to a very low speed (1700 rpm) and covers position 0 to 3 of the AD converter. Switch position 2, corresponding to ADC position 4 and 5 has zero speed. For switch position 3 to 6 the speed setting is increasing. Digital features Ignition detector This block tracks if the triac is ON after each firing pulse. It senses the voltage at the gate of the triac. If the triac is OFF 10us after a firing pulse, a new pulse will be generated. There is an option (active mask) allowing to eliminate the ignition detector circuit. Two firing pulses are generated every half period to fire the triac, instead. Multiplier of input frequency from sensor A frequency multiplier is designed in order to guarantee accurate measuring of the low frequency at the SPD input. The multiplier has measured the period of Fspd =>N = Tspd*Fm; where Tspd =1/Fspd; Fm=Fosc/MULT. The value N determines the division coefficient of a down counter (divider), which clock input is Fosc. The output frequency from this counter has value Fout = Fosc/N = Fosc/(Tspd*(Fosc/MULT)) = Fspd*MULT. The output frequency is Fspd multiplied by coefficient MULT. The coefficient MULT is programmable from 1 to 256. Debounce of ADC To assure a stable operation, the result from potentiometer reading is debounced before passing through. Set of speeds (ROM table) The analog voltage at pin SET is converted to a digital value. This digital value is addressing a value in the ROM table. This value defines the required speed and has a resolution of 10 bits. The definition of the speed settings is totally free: it SWITCH position 1 POT settings 0 1 2 3 SPEED [rpm] 1700 1700 1700 1700 0 0 2000 2000 3500 3500 7200 7200 12200 12200 12200 12200 Frequency meter The frequency meter is implemented as a simple counter .This counter is cleared at the beginning of every mains period (20ms) .During the mains period the output frequency from the frequency multiplier (Fout = Fref*Mult) is applied at the clock input of this counter. At the end of the mains period the value of the counter is stored in a latch. This stored value is proportional to Fspd and equals Tmains*Fspd*MULT. The frequency can be measured during a full or during half a period of the mains. If option FP = 1 the frequency is measured over a full mains period. If option FP = 0 the frequency is measured for a half mains period. 2 4 5 3 6 7 4 8 9 Soft start The soft start is initiated after a proper power on reset sequence. The startup sequence can be influenced by several options. The initial phase angle applied to the triac is defined as (MIN[9:0] - LD[9:0]), where MIN[9:0] is the minimum allowed firing angle, and LD[9:0] is the value initially stored in the integrator. The phase angle remains unchanged for a duration defined by the startup time SFT[1:0]. After that time the PI regulator is enabled with a Kp factor defined by PX[3:1]. As long as the measured speed is smaller then the start speed (defined by SPE[1:0]), the error signal at the input of the PI 5 10 11 6 12 13 14 15 does not need to be linear, nor continuously, and different ROM adresses can have the same speed. MLX90804 Speed regulator for universal motors Page 6 Rev 1.0 30/Jun/00 MLX90804 Speed regulator for universal motors FREF FOSC/MULT input frequency multiplier MULT FREF N FOSC/MULT DIV [MULT] CE UPCOUNTER CONTROL FOSC LATCH N = (FOSC/MULT)/FREF FOUT DIV [N] MULT FOUT = FOSC/N = FREF*MULT PX3 0 0 0 0 1 1 1 1 SFT1 0 0 1 1 PX2 0 0 1 1 0 0 1 1 SFT0 0 1 0 1 PX1 0 1 0 1 0 1 0 1 Kp 8 4 2 1 1 -> 4 2 -> 4 1 -> 2 4 -> 8 Duration in half periods 0 7 15 31 the start speed, which is defined by SPE[1:0]. At the same moment the SETP integrator (see PI regulator) is enabled and preloaded with the value of the measured speed. PI regulator The PI regulator calculates the ignition point that corresponds to a selected speed. The signal SETP is driven from the sets of speeds in the ROM table. The signal REAL is driven from the frequency meter and corresponds to the real speed. The error signal ERR at sample time n is the difference between the measured speed and the desired speed for this sample time. The error is multiplied by the proportional coefficient to form the proportional part ERRP. The same error is multiplied by the integral coefficient and summed with the previous errors. The accumulated integral error ERRI is then added to the proportional to form the final product ERRPI. This product is subtracted from the fixed MIN_ANGLE to form the triac ignition point (the new estimated firing angle) The coefficients are mask programmable: Kp is defined by PX[3:1] and Ki is defined by SSE[1:0]. For smooth operation and to avoid overshoots, the setpoint (desired speed) is ramped from its present value to the a desired value: regulator is kept at zero. If PX[3] = 0, the Kp factor is fixed all the time. If PX[3] = 1, the Kp factor changes at the moment the measured speed gets higher than MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 7 Page 22/Aug/98 Rev 1.0 Page 7 30/Jun/00 MLX90804 Speed regulator for universal motors ERRP SUB REAL x1 u1 xn SUM ERR Kp x 1 u xn 1 ERRPI x1 xn SUB u1 IGN MIN_ANGLE ERRI SUM x1 u1 IP SETP COMP Ki xn Preload Counter A D Q1 Q4 Load Carry out ENB P P>Q DELAY Q P=Q START U/D Reset VZC EQU SSE1 0 0 1 1 SSE2 0 1 0 1 Ki 1/ 8 1/ 16 1/ 32 1/ 64 but the FLL uses the AC line frequency as his reference. Overload shutoff feature 625 ms after starting the motor (i.e. selecting a speed setting different from 0 rpm) the following function will be enabled: if the speed of the motor gets lower then a programmable value SLIM for longer then 320 ms, the motor speed is permanently set to 0 rpm. As a consequence the first possible timeout to recognize a blocked motor after start will be approximately 1 sec. This state can only be left by disconnecting the power from the electronic circuit. Speed Set Ramping The SETP integrator is built around a 8 bit counter and guarantees a smooth transition when changing the speed setting. There is a comparator between SETP and IP. If SETP changes then the comparator enables the IP-counter until IP gets equal to SETP. The clock, which defines the rate of change, can be defined for up and down counting independently, and equals Fclkip= 102.3KHz/(128*(UPR[4:0]+1)) in case of counting up. Since the value for the desired speed is 10 bit wide, and the counter only 8, the setpoint ramp speed from the table is effectively multiplied by 4. Overspeed shutoff feature If the speed of the motor gets higher then a programmable value SLIMA for longer than 320ms, the selected speed is permanently set to 0 rpm. This state can only be left by disconnecting the power from the electronics. FLL A frequency locked loop circuit is implemented to obtain a master frequency (approximately 100KHz ) from a free running on-chip oscillator. Both FLL and frequency multiplier have the same functional blocks, MLX90804 Speed regulator for universal motors Firing The PI regulator gives an ignition angle IGN. The resolution is 10 us. The firing circuit compares the ignition point with a maximum and minimum allowed angle MIN and MAX. MAX corresponds to Page 8 Rev 1.0 30/Jun/00 MLX90804 Speed regulator for universal motors the maximum angle with the triac on (fired). This happens when the triac is fired with minimum delay from the zero cross. MIN corresponds to the minimum time the triac is fired. This happens when the triac is fired with maximum delay from the zero cross. If the IGN < MAX ,then IGN = MAX, thus firing with max angle. If MAX < IGN, then firing is done with IGN angle. The IGN value is compared with the value of a down counter, which is clocked by DCLK = 100kHz and is cleared at the beginning of every half period of the AC line. When this counter value gets equal to IGN a firing circuit produces an ignition pulse GATE with a duration selected with option DUTS[1:0]. After each firing pulse the ignition detector is activated. This will check whether the triac is fired correctly and thus no additional firing pulses are required. If there is no current flowing in the triac additional pulses will be generated. MIN IGN MAX MAINS MAINS*2 GATE DUTS1 0 0 1 1 DUTS0 0 1 0 1 Duration in us 320 80 40 20 Options The following table lists all mask options of the 90804 chip: Pinout Standard package is 8-pin dual inline package. (Known as DIP-8, PDIP-8, DIL-8 and PDIL-8) Name MULT[7:0] FPB SFT[1:0] PX[3:1] SSE[1:0] SPE[1:0] LD[9:0] DWR[4:0] UPR[4:0] DUTS[1:0] MULT9 MIN[9:0] MAX[9:0] SLIM[9:0] SLIMA[4:0] Description multiplication coefficient of Fspd Gate of frequency meter startup time Proportional coefficient Kp Integral coefficient Ki Start speed Preload of Integrator SETP integrator down SETP integrator up duration of firing pulse Enable retriggering min allowed firing angle max allowed firing angle minimum speed limitation maximum speed limitation Pin 1 2 3 4 5 6 7 8 Name SET SPD TEST SYN TRG VSS VDD1 VDD Type Input Input Input Input Output Supply Supply Output Description Speed setting input Speed measurement Test pin Zero cross input Triac driver output Ground Supply, high level Reference voltage MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 9 Page 22/Aug/98 Rev 1.0 Page 9 30/Jun/00 MLX90804 Speed regulator for universal motors Applications Information Following additional information is available for the MLX90804: Application note: a basic phase angle speed controller This document describes in detail how to make an application with the MLX90804 The MLX90804 Demo Board This document describes the features and possibilities of the MLX90804 demoboard, and how it can be ordered. Manual for definition of the options This document is a guide to the definition of all options and shows with an example how a set of options can be defined to fit your application. MLXSPI programming users guide This is the users guide to the MLXSPI programmer, which can be used to program all options into the MLX90804 and MLX90805 kitparts. It describes boh hardware and software of the MLXSPI programmer. Disclaimer ESD Precautions Electronic semiconductor products are sensitive to Electro Static Discharge (ESD). Always observe Electro Static Discharge control procedures whenever handling semiconductor products. Melexis reserves the right to periodically make modifications to product specifications. The information included herein is believed to be accurate and reliable. However, Melexis assumes no responsibility for its use; nor for any infringements of patents or other rights of third parties which may result from its use. MLX90804 Speed regulator for universal motors Page 10 Rev 1.0 30/Jun/00 MLX90804 Speed regulator for universal motors MLX90804 Physical Characteristics 0.20 0.38 6.10 7.11 7.62 10.92 B S C Max 1.1 5 1.7 7 2.54 BSC A 5.33 MAX 2.93 0.39 4.06 Min 0.35 0.55 Notes: 1-All measurements in mm 2-Body dimensions do not include mold flash or protrusion - not to exceed 0.15mm Dimension 8 Leads Min Max 9.02 10.16 14 Leads 18.67 19.68 16 Leads 18.67 19.68 18 Leads 22.35 23.67 20 Leads 24.89 26.92 24 Leads 31.24 32.51 A For the latest version of this document, Go to our website at: France Melexis France Tour Arago, 5 rue Bellini, 92806 Puteaux-La-Defense, France. Phone: +33 1 47 78 11 34 Fax: +33 1 47 78 06 35 E-mail: sales_france@melexis.com www.melexis.com Or for additional information contact Melexis Direct: USA Melexis Inc. 41 Locke Road, Concord, NH 03301 Phone: +1 603 223 2362 E-mail: sales_usa@melexis.com Fax: +1 603 223 9614 Italy Dimacred IRL Via Papa Giovanni XXIII no. 25, 20046 Biassono, Italy Phone: +39 039 249 4856 Fax: +39 039 491773 E-mail: sales_italy@melexis.com Japan United Kingdom Silicon Concepts PCB Lynchborough Road, Hampshire GU30 7SB, United Kingdom Phone: +44 1428 751 617 Fax: +44 1428 751 603 E-mail: sales_uk@melexis.com Satori Electric Co., LTD 1-14-10 Shiba, Minato-Ku, Tokyo, Japan Phone: +81 3 3452 7171 Fax: +81 3 3769 2197 E-mail: sales_japan@melexis.com Germany Am Seestern 8, 40547 Dusseldorf, Germany Phone: +49 211 5360212 Fax: +49 211 5360250 E-mail: sales_de@melexis.com Taiwan Beechwood Int'l Taiwan Co. Room 8, 17F, No. 189, Taipei, Taiwan Phone: +886 2 2739 3322 E-mail: sales_taiwan@melexis.com Fax: +886 2 2739 3090 MLX902xx Name of Sensor MLX90804 Speed regulator for universal motors Rev Y.X 11 Page 22/Aug/98 Rev 1.0 Page 11 30/Jun/00 MLX90804 Speed regulator for universal motors MLX90804 Speed regulator for universal motors Page 12 Rev 1.0 30/Jun/00 |
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