Data Pack J

Issued March 1990 009-142

Data Sheet

Phase control IC TDA2086A

RS stock numbers 650-784

The TDA2086A is a bipolar IC designed for use in closed or open loop ac phase control circuits with resistive or inductive loads. Closed loop systems can employ either voltage or tachogenerator frequency feedback for maximum versatility. Ideal for motor speed control in power drills, machines etc.

Absolute maximum ratings

Triac gate voltage pin 2_________________________4V Repetitive peak input current pin 4 ____________80mA Non repetitive peak input current pin 4 (tp<250s) ____________________200mA Peak input current pin 5 positive half cycle _______2mA Repetitive peak input current pin 5 negative half cycle ________________________80mA Non repetitive peak input current pin 5 negative half cycle(tp<250s) _____________ 200mA Peak input current (ISYNC) pin 6________________1mA Peak input current (VSYNC) pin 7 _______________1mA Inhibit input voltage pin 8_____________________VregV 5V regulator current pin 11__________________10mA Control amp input voltage pin 13 ______________VregV Tacho input current pin 15 __________________20mA Operating ambient temperature _______0C to + 85C Storage temperature ______________55C to + 125C

Features q Powered direct from ac mains or dc line q 5V supply available for ancillary circuitry q Low supply current consumption q Average or peak load current limiting q Ramp generator to provide controlled acceleration q Negative triac firing pulse q Warning LED drive circuit q Actual speed derived from tachogenerator frequency or analogue feedback q Well defined control voltage/phase angle q Inhibit input for use with thermistor temperature sensors.

TOP VIEW

Figure 1 Block diagram

009-142 Electrical characteristics measured with respect to pin 3. Ta = 25C

Parameter Operating current Shunt voltage regulator Regulating voltage Voltage monitor enable level Series regulator Regulating voltage (Vreg) Temperature coefficient External load Regulation Ramp generator Capacitor charging current Capacitor discharging current Capacitor discharge current Capacitor to actual speed voltage clamp Speed programme circuit Input voltage range Input bias current Zero power demand voltage Frequency to analogue converter Tacho input voltage Hysteresis Bias current Conversion factor Conversion gain Error amplifier Input voltage range Input bias current Input offset voltage Trans conductance Output current drive Firing pulse timing Voltage SYNC trip level Current SYNC trip level Phase control voltage swing Firing pulse width Pulse repetition time Firing pulse output Drive current Leakage current Load current limiting Offset voltage Current gain Voltage for load current limit Voltage for load current inhibit Pin No. 4 4 Notes 1 2 Min. Typ. 3.1 14.75 Max. 4.1 13.5 9 4.65 1 10 +75 35 Units mA V V V mV/C mV A A mA V V A mV mV mV A mV/rpm

16 11 5.35

11

5V

4 9 5 6

75 25 30 25 10

0.8 10 Vreg 0.5 -100 15 15 15 15 to 14 4 to 13 9 and 13 9 and 13 10,13 and 12 10,13 and 12 12 7 6 12 13 13 2 2 5 5 and 8 8 8 7 100 30 -75

+0.8 0 1 50

40 0.5 1

60 10

Vreg 9 5 80 20 35 35 Vreg 10 11 12 13 100

100 50 50 50 100 125

0 0.5 +15 120 35 65 65 0

V A mV A/V A A A V s s mA A mV V V

150 10 20 0.525

14 15 16

0.475

0.5 1 1.5

Notes: 1. Pin 4 voltage = 13.0V including triac gate drive traffic. 2. 0C to + 85C. 3. 1mA external load. 4. For 0-5mA external load change. 5. Load current limit in operation. 6. Load current inhibit in operation: 5V on ramp capacitor. 7. Peak value. 8. Typical application: C pin 14 = 10nF, R pin 13 = 150k. 8 pole tacho 10,000rpm max. 9. V9-V13 to give I12 = 0 10. C pin 16 = 47nF, 11. C pin 16 = 47nF, R pin 1 = 200k 12. Pin 2 = -3V 13. Pin 2 = 0V 14. Pin 5 = 100A 15. 0.2V reg 16. 0.3V reg

009-142 Circuit description

The TDA2086A incorporates a shunt stabiliser which enables it to be powered from the mains, via current limiting components, or from a dc supply. In addition, an on-chip series regulator provides a 5V supply which powers various internal circuits, the speed programming potentiometer and other ancillary components. Up to 5mA is available from this supply for powering additional external circuitry. A supply voltage monitor circuit prevents triac firing pulses from being generated until an adequate supply voltage is established and by discharging the ramp capacitor, ensures a soft start when the supply returns to normal after a short interruption. Motor acceleration is controlled by a ramp generator to a maximum determined by the speed program input. Grounding the speed program input will cause a general reset and inhibit the triac pulses. The ramp generator rise time and therefore the motor acceleration is determined by a fixed internal changing current and an external capacitor. For use in closed loop systems a frequency to analogue (F-A) converter provides a dc voltage proportional to motor speed, sensed at the tacho input. The conversion is made by transferring a pulse of charge from the F-A converter capacitor to an RC filter on the F-A output pin. Hysteresis on the tacho input prevents noise from giving a false indication of motor speed. The error amplifier has differential inputs that compare the ramp generator voltage with the actual speed voltage from the F-A converter. A clamp circuit across the amplifier inputs prevents the differential input voltages exceeding about 0.5V. The output from this amplifier is a bidirectional current of limited amplitude which is integrated to limit the maximum rate of charge of triac firing pulse angle. For use in open loop systems the amplifier is connected as a voltage follower and acts as a buffer between the ramp generator and pulse timing circuit. Triac firing pulse synchronisation is achieved by delaying the pulse with reference to the zero crossing voltage points of the mains cycle as determined by the zero voltage detection circuit. With inductive loads, the load current will phase lag the mains voltage, and under these conditions the triac firing pulse must be delayed until the load current from the previous half cycle has ceased. The current synchronisation circuit satisfies this requirement by preventing firing pulses until a voltage drop appears across the triac. If the triac fails to latch, repeated firing pulses will be supplied. The firing pulse width and the spacing of repeated pulses are controlled by a single capacitor. An average load current limit which works on positive mains half cycles only is used to protect the triac and motor under stall conditions. External resistors determine the trip point which operates at two levels: the first under moderate overload conditions, discharges the soft start capacitor with a constant current until a safe load current is reached whilst the second initiates a general reset and rapid discharge of the soft start capacitor. A warning LED may be connected in series with the 15V supply to give an indication of an overload condition or the programming of zero speed/power. The diode is extinguished by shunting the supply current to 15V duringve mains half cycles by internal circuitry on the load current monitor pin.

Features description
Low supply current consumption Due to the low current consumption of the device the power dissipation in the mains dropper resistor may be as low as one watt on a 220V ac supply (0.5 W on 100V) By incorporating both a shunt and a series voltage regulator in the IC design, a high ripple voltage can be accommodated on the supply smoothing capacitor. The combination of the above two features results in reduced size and a minimum count of components used in the power supply circuitry. Powered direct from ac mains or dc line This device incorporates a shunt regulator (15V) such that it may be powered from an ac or dc supply via current limiting components or the device may be powered direct from a 12V supply. 5V supply available for ancillary circuitry A 5V series regulator is incorporated to provide a smooth supply for the internal analogue control functions. This supply may be used externally to power ancillary circuitry such as timing circuits and other logic control circuits etc, as well as driving potentiometers for the analogue control inputs. Due to this supply technique, greater symmetry between positive and negative half cycle firing phase angle will result. Low supply inhibit circuit Timing functions and triac gate drive pulses are inhibited until there is sufficient supply voltage across the device to guarantee complete gate drive pulses. This ensures that bulk conduction is established in the triac and correct linear operation of the control system is maintained. Negative triac gate firing pulses Since the device works with the positive supply as common, the triac gate pulses are negative going. this is an advantage when selecting a suitable triac since most triac manufacturers prefer this drive polarity. The device is designed to give a triac pulse that is greater than 50mA for a period of 50 microseconds with standard pulse timing components (47nF, pin 16). Repeated triac gate pulses are given if the triac fails to latch or becomes unlatched due to motor brush bounce. Well-defined control voltage/phase angle (open loop) An internal 5 V stabiliser circuit is used as the charging voltage for the pulse timing ramp capacitor and as the reference voltage for the speed input potentiometer. This ensures that maximum phase angle can be obtained by adjusting the resistor or capacitor on the pulse timing circuit, without affecting the maximum setting. Average or peak load current limiting The load current is normally sensed in the positive mains cycle by means of a low impedance resistor in series with the triac and the load. The voltage drop across this resistor is converted back into a low current source by a second resistor and fed into the load current sensing input (pin 5) of the IC. In high load current applications where the power dissipated in a series sensing resistor would be unacceptable, a current transformer may be utilised. The current fed into the sensing input (pin 5) is mirrored by the ic and fed to the inhibit input (pin 8). Peak current limiting can be provided at this point by insert-

009-142
ing a resistor between pin 8 and common (pin 3), whereas average current limiting requires the addition of an integrating capacitor. When average current limiting is used the double action of the inhibit circuit is utilised. This has two trip points such that when the first trip point (1V) is reached the power to the load will be gradually reduced by decreasing the voltage on the ramp capacitor, (the discharge rate being equal but opposite to the soft start), hence reducing the power and providing a constant current drive (producing constant torque) to the motor. When the second trip point (1.5V) is reached a general reset of all timing functions occurs at a fast rate, hence if a gross overload was suddenly applied to the motor, a rapid reduction in power supplied would result. Since it is not possible to turn the triac off during a cycle, the triac and motor should be chosen to be capable of withstanding one complete mains cycle under the worst overload condition. Peak load current limiting tends to produce a fold back action (of motor speed and torque) at large conduction phase angle. This is due to the peak current initially increasing when the phase conduction angle is reduced at constant load torque. Ramp generator to provide controlled acceleration The ramp generator is a follower integrator design which can be used to control the acceleration rate up to the programmed speed. This can also be used to control the rate of phase angle increase in open loop control systems. The ramp is defined by an internal current source (25 microamps) and the capacitor connected to pin 9. Warning LED drive circuit The LED drive circuit is designed to drive an LED in series with the device such that the overall consumption is minimised by utilising the IC drive current to power the LED. Due to the multiplexing technique on pin 5, some additional current will be required when the circuit is used to provide both load current limit and LED drive (this will normally be about 0.5 amps). The LED will illuminate under one of the following two conditions: 1. The program speed (or phase in open loop systems) is set for zero. 2. The running speed is less than that programmed. Hence, indication will be given when the system is powered up but zero power determined, or when the machine cannot maintain the set operating speed due to the load current circuit operating. The LED will also be illuminated while the soft start function is in operation ie. The LED will turn off only when the set speed has been reached. Actual speed derived from tacho generator frequency or analogue feedback Tacho frequency or analogue feedback may be used with this device. When frequency feedback is used, the frequency to analogue (F-A) conversion circuit is used. This circuit is extremely linear and tracks the regulated (5V) supply. Frequency feedback has the advantage of not being dependent on mechanical clearance, magnetic strength, etc , and since conversion rate is defined by two external components, accurate speed programming can be obtained without the need for calibration. Tacho input drive The TDA2086A requires less than 10A (pk) to drive the tacho input (pin 15) and has bidirectional clamping. This makes it possible to connect a tacho pick up coil directly to the device hence minimising component count. A motor may fail to start up if a signal is picked up by a sensitive tacho due to vibration in the rotor caused by elastic sticktion when power is initially applied. This can be easily overcome by incorporating a filtering capacitor across the tacho input. Tacho fail safe operation The TDA2086A will command maximum power when an open circuit tacho is detected. This may be a safer situation in the case of hand operated tools. Inhibit input for use with thermistor temperature sensors A thermistor may be connected to pin 8, the load current integration pin. This is to ensure that the circuit shuts down if the maximum load temperature is exceeded. the input may also be used as an interface 5V control logic.

System design
Throughout this section, component references are those shown on the Reference System Circuit Diagram, Figure 3.

Open loop operation

The simplest method of motor speed control using electronics is an open loop system. In an open loop system, the phase angle of the triac firing pulse is determined by the program input voltage on pin 10. The TDA2086A is particularly useful in open loop applications due to the well-defined control voltage/phase angle relationship. In this mode, changes in motor loading will cause corresponding variations in motor speed but regulation will be a considerable improvement over that achieved when motor speed regulation is obtained by a conventional series dropper resistor.

Closed loop control

A block diagram of a basic closed loop speed control system is shown in Figure 2. In this case, a voltage proportional to motor speed is compared by the amplifier with the speed program voltage and any difference will cause an appropriate change in firing pulse angle and hence motor speed. In this way automatic compensation for changing motor loads can be made. In addition to the basic speed control functions mentioned above, additional circuitry is provided to allow control of motor acceleration and reduction of firing pulse phase angle in case of motor overload. Figure 2 Basic closed loop control system

009-142 Feedback voltage

An analogue feedback voltage of 0V to 5V, obtained by rectifying and smoothing the output from a tacho generator, may be applied to pin 13. If analogue feedback is used, the frequency to analogue converter circuitry must be made inoperative by connecting pin 15 to ground and leaving pin 14 open circuit. In most motor control applications digital feedback is recommended as this method has the advantage of inherent stability against tacho ageing and temperature drift whilst requiring no speed calibration. When digital feedback is used, it is possible to produce a system which fails in the case of an open circuit tacho connection to full speed. This makes the device safer in the case of say a portable hand tool where an intermittent tacho connection could cause the machine to suddenly start up whilst being examined. The method of tacho input to pin 15 is by direct connection with possibly a small capacitor to ground to reject noise is sufficient, as signal amplitude is unimportant, provided the minimum value is greater than about 350mV peak which is necessary to overcome hysteresis plus input offset voltage. An open circuit tacho will allow the tacho input to be pulled negative by the bias current until a general reset is initiated at a trip level of about 5.5V. In order to prevent a reset condition during normal operation it is necessary to limit the tacho signal to a value significantly less than the trip level, this being achieved by the capacitor C10 and resistor R6, which are chosen to give a substantially constant input voltage at all speeds. Frequency to analogue converter The frequency to analogue converter is used with digital feedback to convert the frequency of the tacho input to an analogue voltage suitable for application to the control amplifier. During negative half cycles at the tacho input, C4 is charged by an internally generated current of nominally 100A until 5.5V is reached, at which point the capacitor is rapidly discharged. Each time C4 is charged a pulse of current equal to and designed to track with that at pin 14 is integrated at pin 13 by C6, producing a dc voltage proportional to motor speed. By choosing a suitable conversion factor for the frequency to analogue converter it is possible to design a system to run at any given speed within the 0V to 5V control voltage range at pin 10. Example: A motor fitted with an 8 pole tacho is required to run at 5000 rev/min with a control voltage at pin 10 of 2.5V. Calculate the values of C4 and R3 required. Since at steady speed the control voltage at pin 10 and the F-A output voltage at pin 13 must balance, C4 and R3 must be chosen to give 2.5V at pin 13 at a motor speed of 5000rev/min. The analogue feedback voltage (Vf) generated by the converter circuit is given by ...1 Vf=Kft 10-3 Volts where K is the conversion factor given by C4 R3 K= mV/Hz ...2 200

Figure 3 Reference system circuit diagram

009-142
and ft is the tacho frequency given by ft = SN Hz 120 using 1 and 3 above K = 2.5V 0.333 = 7.5V/Hz

The control amplifier

...3 In closed loop applications, the control amplifier is used to compare the analogue feedback voltage (Vf) at pin 13 with the speed reference voltage on pin 10 and to produce a phase control voltage Vp on pin 12. The amplifier has a transconductance gain of 100A/V with a limited bidirectional output drive capability of 25A. Proportional control therefore occurs for differential input errors between 250mV. The gain and phase compensation for closed loop control systems are determined by C1, C2 and R2 on pin 12. These components are best chosen empirically to achieve a compromise in terms of speed overshoot and response time in the actual system. For open loop control, the control amplifier may be used as a buffer by connecting pin 12 to pin 13 and disabling the F-A converter by grounding pin 15. Use may still be made of the ramp generator to control the maximum rate of phase angle increase. If required the maximum phase angle can be controlled by a clamp voltage applied to pin 12 but care must be taken to ensure a sharp turn-on knee.

choosing R3 = 150k in the range 100k to 470k and using above C4 = 7.5 200 = 10nF 150k Provided close tolerance components are used for C4 and R3, most systems should not need calibration, but if required R3 can be replaced by a series resistor/potentiometer combination to give precise speed adjustment. The value of capacitor C6 on pin 13 is a compromise between F-A converter response time and ripple voltage at the control amplifier input. In most systems a value of 1F will be sufficient. Under some conditions noise introduced into the tacho coil by vibration of the stationary motor armature when power is first applied, or by electromagnetic induction can produce sufficient feedback to prevent motor start up, the phase control system using the tacho noise as evidence that the motor is running. This condition is most likely with the TDA2086A where the tacho is connected directly to pin 15 without a capacitor to ground. A cure can usually be found by connecting a capacitor to ground or in difficult cases a series resistor as well.

Zero voltage detector

The zero voltage detector resets the pulse timing circuit ramp generator at the zero points of each mains cycle. The mains voltage is applied via a high value current limiting resistor R11 to pin 7 and a reset pulse is generated whenever the input current is between 50A. The circuit is designed to give symmetrical switching about the zero voltage points ensuring symmetrical triac firing in positive and negative mains half cycles. The value of R11 should be chosen to limit the peak current in pin 7 to less than 1mA.

Ramp generator
The ramp generator limits the rate of change of speed reference voltage (Vs) applied to the control amplifier and therefore controls the rate of acceleration of the motor. The ramp rate Vr is set by an internally generated 30A current source Ir and the capacitor C5 on pin 9, the rate being given by -6 ...4 Vr = Ir 10 V/s C10 Using the previous example where the control voltage is increased from zero to 2.5V and C5 = 10F the ramp rate (Vr) will be 30 10-6 = 3.0V/s 10 10-6 and the acceleration time = 2.5V = 0.83 seconds 3.0V/s The final ramp voltage on pin 9 is 2Vbe below the control voltage on pin 10.

Current sync circuit

The current sync circuit operates in conjunction with the pulse timing circuit by supplying an enable signal dependent on the conduction state of the triac. The enable signal is generated if the voltage across the triac is sufficient to produce an input current to pin 6 via R9 greater than 50A. Peak current to pin 6 should be limited to below 1mA.

Pulse timing circuit

The function of the pulse timing circuit is to control the delay and duration of the triac firing pulse. A ramp voltage is produced on the pulse timing capacitor C3 on pin 16 which is charged by a constant current determined by R1 on pin 1. The ramp is reset by the voltage sync circuit at each mains zero crossing. A triac firing pulse is produced when the ramp voltage reaches a level determined by the control amplifier output on pin 6. Full power may be supplied to inductive loads since, when maximum conduction is demanded, the triac pulse is delayed until the lagging load current from the previous half cycle has reduced to zero. At this point the triac will cease to conduct and the supply voltage will appear across it, which when detected by the current sync output, initiates the next triac pulse.

Speed program voltage

The speed program voltage (V10) on pin 10 has a working range from the zero power demand level at 75mV and Vreg. Levels above 75mV on pin 10 will cause the ramp capacitor to remain discharged and the triac drive pulse will be inhibited. The LED on pin 5 will also remain lit. In most applications pin 10 voltage will be derived from a potentiometer connected between Vreg and ground.

009-142
At high motor speeds brush bounce may become severe, causing interruptions in motor supply current and unlatching of the triac. Under these conditions the current sync circuit will initiate a retriggering pulse to the triac. The ramp waveform is generated by rapidly charging C3 on pin 16 to a Vbe more negative than Vreg at the mains zero voltage crossing. After the zero voltage point, C3 is discharged in a linear fashion by a current (ld) defined externally on pin 1 by RI. When the voltage on C3 reaches a value determined by the control amplifier on pin 12 a triac gate pulse is initiated. The dynamic working range of the ramp generator is approximately equal to Vreg. The triac pulse duration is determined by recharging C3 to nominally 50mV above the original trip voltage. If retriggering occurs the delay will be determined by the time taken for the current 1d to discharge C3 back to the original trip voltage. Triac pulse timing equations Ramp discharge current 1d = (Vreg Vbe) R1 When switching on an inductive load the initial current will increase from zero at a rate dependent on the voltage across and the inductance of the load (the minimum voltage being determined by the load current detector). To help with latching, additional triac load current for a short duration can be provided if required by means of a series RC network in parallel with the triac. C9 and R8 provide this function as well as offering some protection from dv/dt triggering of the triac due to noise spikes on the mains.

Load current limiting

The purpose of motor current limitation is more to protect the triac than the motor itself. Since the stall current is generally much higher than that required for maximum working torque, a limitation can be set at a lower value thus guaranteeing safe operation of the triac under all load conditions. The load current is normally sensed in the positive mains half cycle by means of low value resistor R5 in series with the triac and load. This voltage drop is converted back into a low current source by R7 in series with pin 5 and is mirrored internally with a ratio of 2:1 into pin 8. Peak current limiting can be provided at this point by inserting a resistor between pin 8 and common whereas average current limiting requires the addition of an integrating capacitor. When average current limiting is used the double action of the inhibit circuits on pin 8 is utilised. this has two trip points at 1V (load current limit) and 1.5V (load current inhibit). When the first trip point (1V) is reached the power to the load will be gradually reduced by decreasing the voltage on the ramp capacitor, (the discharge rate being equal but opposite to the soft start), hence reducing the power and providing a constant current drive (producing constant torque) to the motor. When the second trip point (1.5V) is reached a general reset of all timing functions occurs at a fast rate, hence if a gross overload was suddenly applied to the motor, a rapid reduction in power supplied would result. Since it is not possible to turn the triac off during a cycle, the triac and motor should be chosen to be capable of withstanding one complete mains cycle under the worst overload condition. The value of R5 can be calculated from For load current limit 1 ...8 R7 R4 Average load current x 0.25 For load current inhibit 1.5 ...9 R7 R4 Average load current x 0.25 The value of R4 can vary between 100k and 470k, the lower value being preferred in order to reduce offset voltages produced by pin 8 bias current. When the LED drive capability of pin 5 is used the overload current level will be increased by about 20%. In high current applications where the power dissipated in a series sensing resistor would be unacceptable, a current transformer may be used as shown in Figure 4.

106A

...5

Dynamic ramp voltage on pin 16 1d 10-6 V Vrp = 2 fm C3

...6

For full phase control the calculated value of Vrp must be less than Vreg. In most applications standard values can be used for C3 and R1. These are: For 50 Hz supply C3 = 47nf 10% R1 = 200k 5% For 60 Hz supply C3 = 47nF 10% R1 = 160k 5% With the above components the triac pulse width will be approximately 70s and the retriggering time 100s.

Triac gate drive

The triac gate pulse is negative going, this being preferred by triac manufacturers and in most cases it will be found that the triggering current requirement is less for negative pulses. Internal current limiting is provided, the current being largely independent of the triac gate voltage although a series resistor can be used to reduce overall power consumption if required. When a series resistor is used the approximate gate drive current may be calculated from Itg = V4 - 1 - Vtg 103mA ...7 Rg provided the series resistor is sufficient to reduce the gate current below the internally limited value.

Triac latching
As mentioned before, it is necessary to trigger the triac when conditions are right for a latching current to be established within the period of the gate pulse. 7

009-142
Figure 4 Current transformer application Due to SCR latching associated with the LED drive circuit it is not possible to use the LED feature with or without load current limiting if the circuit is powered from dc supplies. Figure 5 Over-temperature shut-down

With a 1000:1 current transformer the average overload current can be calculated from For load current limit 4 1000 R13 R14 R12 10 For load current inhibit 4 1.5 1000 R13 R14 R12 ..11 Suitable values for R12 and R13 are 100k and 5.6k. Peak load current limiting tends to produce a foldback action (of motor speed and torque) at large conduction phase angles. This is due to the peak current initially increasing when the phase conduction angle is reduced at constant load torque. If peak current limiting is adequate, capacitor C7 can be removed and the peak overload current calculated from R7 1.5 R5 R4 0.5 ...12

ac supply circuits
The TDA2086A circuit has been designed for very low power consumption, this parameter being particularly important when operating from mains voltages via a dropper resistor. When calculating the value of dropper resistor required additional currents such as those required by the control potentiometer on pin 10 or any other ancillary circuitry powered from the 5V or 15V supplies must be added to the supply current. The circuit design whereby all critical control circuitry is powered from a 5V series stabilised supply ensures that the circuit is insensitive to ripple on the -15V line, thus enabling a single dropper resistor and capacitor to be used as shown in Figure 6. Component values can be calculated from Figure 6 Mains supply circuits

Inhibit circuit
As previously stated the inhibit circuit has two trip levels normally used in load current limiting but if required a general reset can be initiated by the application of a voltage between 1.5 and Vreg to pin 8. This feature allows on/off control by external control circuitry or the fitting of a PTC thermistor to sense motor winding temperature as shown in Figure 6. At normal temperatures pin 8 is held close to the 0V rail as the thermistor resistance is low, but as the thermistor critical temperature is approached, the resistance increases rapidly until the pin 8 voltage falls below 1.5V when the power to the load is removed.

LED drive circuit

The LED drive circuit is designed to drive an LED in series with the device such that the ic supply current is used to drive the LED thereby minimising overall power consumption. In order to turn the LED off an internal circuit with a voltage drop lower than the LED plus its associated silicon diode is used to shunt current from the LED. Due to the multiplexing technique used on pin 5 whereby IC supply current is provided during negative half cycles and load current monitoring during positive half cycles some additional current, usually amounting to about 0.5mA will be required when the LED drive facility is used.

009-142
C8= Is Vcr fm 103F 10 W ...13 ...14 ...15 Figure 8 Operation from unstabilised dc

2 R10= /nVac Vcc Is(mA) 2 Pdr= (2Vac Vcc) 4R10

The low current requirement of the TDA2086A reduces the power dissipation in the mains dropper resistor to below 2W, but in some cases even this level of power can be undesirable. By using a reactive feed arrangement the power loss in the dropper resistor is eliminated, but due to the phase shift introduced by the reactive feed capacitor, the multiplexing of current overload and LED drive on pin 5 will not function. Figure 7a shows a reactive feed using the LED drive feature, and Figure 7b reactive feed with current overload. The value of Cx can be calculated from Is(mA) ...16 Cx= 103F fm(22VacVcc) Resistor Rx is included to limit current due to noise Figure 7 Reactive feed circuits

Symbols used in text

Symbol fm ft 1d 1r 1s Itg K N Rg S Vac Vbe Vcc Vcr Vf Vp Vr Vreg Vrp Vs Vss Vtg V10 Function Mains frequency Tacho frequency Pulse ramp discharge current Ramp current Supply current Triac gate drive current Tacho conversion factor Number of tacho poles Series triac gate resistor Motor speed ac supply voltage (RMS) Transistor base emitter voltage Negative rail voltage pin 4 Supply ripple voltage Analogue feedback voltage Phase control voltage Ramp rate 5V series stabiliser voltage (pin 11) Dynamic ramp voltage Internal speed reference voltage Internal speed reference voltage Triac gate voltage Speed program voltage on pin 10 Units Hz Hz A A mA mA mV/Hz Ohms rpm V V V V V V V/s V V V V V V

Operation from dc supplies

Operation from stabilised or unstabilised dc supplies is possible provided a signal in phase with the mains is available to drive the voltage sync input on pin 7. If a stabilised supply is used, the voltage must always be set between the maximum shunt stabiliser voltage on pin 4 and the minimum voltage monitor enable level. Supplies outside these limits will prevent circuit operation or cause damage to the chip through excessive power dissipation. When operation from an unstabilised dc supply is required, the circuit shown in Figure 7 should be used, R1 value being calculated from Vss Vcc 103 ...17 Is(mA) To ensure a relatively constant current through R1 the unstabilised dc supply should be considerably higher than the shunt stabiliser voltage. N.B. Worst case conditions should be used in the above equations.

Applications information Universal motor applications

Figure 9 shows a typical universal motor closed loop speed control circuit suitable for use in domestic appliances such as food mixers or in electric drills. The circuit is basically that in the reference system diagram with the addition of component values which, with an 8 pole tacho give a speed range from zero to 15,000rev/min.

Open loop control

Where an existing tapped resistor speed control is being updated or where speed regulation is relatively unimportant, an open loop control system may be adequate and provide a lower cost solution. A basic open loop system is shown in Figure 10, but if required, the LED and current overload circuits shown in Figure 9 may be added.

009-142 Current feedback

Another method of speed control possible with the universal motor is to use the increased motor current produced by loading to automatically increase the conduction angle of the control triac thus maintaining motor speed. A circuit designed to achieve this type of control using the TDA2086A is shown in Figure 11. In this case, the normal average load current limiting voltage appearing at pin 8 is connected directly to the program input pin 10, providing a feedback signal of correct polarity. Since load current limiting starts when pin 8 voltage reaches 1V, the full range of phase control must be achieved within this limit. The dynamic working range of the error amplifier is 5V and to satisfy the 1V maximum limit on pin 8, the error amplifier is connected to have a gain of 5.7 using the resistors R5 and R4 between pins 12 and 13. Potentiometer VR1 provides the speed control signal but again the dynamic range must be limited to less than 1V, the resistors R1 and R2 giving a suitable reduction. The potentiometer VR2 is used to set the feedback level but in most cases a fixed resistor will suffice when a suitable level has been determined. When considering this system of speed control it is most important to remember that the regulation is not as good as a true closed loop system and that the low speed range is limited.

Current foldback
In some applications it is desirable to reduce the current overload point as the motor's speed is reduced, preventing the possibility of the motor overheating due to reduced fan cooling. Figures 13 and 14 show two possible methods of achieving foldback operation, together with graphs indicating the degree of overload current reduction for various component values. Both circuits give similar results with the exception that the version shown in Figure 14 produces a fixed current overload point at settings close to maximum phase angle. This constant overload point will extend over about 15% of the control range.

Systems interfacing
The 5V stabilised supply available from the TDA2086A allows standard CMOS logic elements to be powered directly thus enabling easy interface to a logic control system. Figure 15 shows a method of providing 16 speeds controlled by a 4 bit binary input from an isolated digital system. Digital information is transmitted via opto isolators to a single CMOS circuit powered from the TDA2068A, any 4 bit binary counter or latch being suitable. A simple D-A converter using a CA3046 transistor array produces a 16 step analogue output suitable for direct connection to the TDA2068A control input. Where only on/off control is required, this can be accomplished by connecting pin 8 to 5V by using a transistor or relay contacts as shown in Figure 16a if the current limit on pin 5 is being used or by direct connection of a CMOS gate as in Figure 16b if current limiting is not employed. This method of control discharges the ramp capacitor at switch off, allowing controlled acceleration when power is again demanded.

Optical feedback
Most applications utilise a feedback signal derived from a tacho generator but there is no reason why other systems cannot be used. Figure 12 shows how a slotted optical coupler can be interfaced with few additional components. The feedback signal is produced by interrupting the light from the LED using a perforated disc attached to the motor shaft. By connecting the LED in series with the ic, sufficient current for operation is available without increasing dissipation in the mains dropper resistor. The capacitor and resistor associated with the LED are required to provide a smooth dc supply. Figure 9 Universal motor application

Note: A small capacitor may be required across the tacho coil to filter tacho noise at start-up.

10

009-142 Control of temperature

Although the TDA2086A is primarily designed for speed control of electric motors, other types of load such as heating elements or lighting may also be controlled. Figure 17 shows a circuit for temperature Figure 10 Open loop application, 240V control where the voltage on pin 13 set by a fixed resistor and NTC thermistor is compared with the reference voltage on pin 10. The value of Rt should be chosen to give equal voltages at pins 10 and 13 when the thermistor is at the required temperature.

Figure 11 Current feedback application

Figure 12 Optical feedback application

11

009-142
Figure 13 Current limit foldback, method 1

Figure 14 Current limit foldback, method 2

MOTOR SPEED X 1000 RPM

Figure 15 Interface to digital system

12

009-142
Figure 16 On/Off control

Figure 17 Temperature control application

Motor reversing
When the TDA2068A is used in electric drills it is sometimes a requirement to reverse the direction of rotation. Unless some kind of interlock between the reversing switch and the on/off control is fitted, it is possible to damage the motor by operating the reversing switch whilst the motor is still running. To overcome this problem, it is necessary to remove power from the motor automatically when the reversing switch is operated. It is not possible to give a precise method of achieving this as the best method depends on the design of the drill and the number of spare contacts available on the reversing switch. However in general the requirement is to rapidly discharge the soft start capacitor allowing the motor to come to rest and then to accelerate gently in the new direction. Two methods of discharging the soft start capacitor are recommended. 1. Momentarily take pin 10 to within 50mV of the 0V rail (pin 3). 2. Momentarily take pin 8 more negative than the load current inhibit voltage with respect to pin 3. This is typically 1.5V.

13

009-142
Start up delay Problems may arise due to the finite time delay between the application of power to the tool and the motor starting to run. The problem is usually seen in closed loop applications and seems to affect some motors more than others. There is no wholly satisfactory solution to this problem which is basically caused by the fact that many universal motors do not begin to turn until the applied voltage is as much as 30% of their full working voltage. At switch-on, the soft start and compensation circuit capacitors are all discharged; these capacitors must reach such a charge that the output of the error amp is about 1.5V before the motor will begin to rotate - this is the source of the time delay. Obviously, motors with large mechanical time constants (low 3dB frequency on their Bode Plot) will require heavy compensation and thus will be slow to start. The problem can be alleviated by using an alternative compensation circuit. This circuit applies negative feedback around the error amplifier to generate the roll-off at HF, rather than slew-limiting the output as does the present circuit. The component values shown are typical for a large (700W) electric drill. With this circuit it was found that a satisfactory soft start was obtained without having to have a large capacitor on pin 9. The additional advantage of this technique is that no electrolytic capacitors are needed, apart from the main smoothing capacitor.

Figure 18 Alternative compensation circuit

The information provided in RS data sheets is believed to be accurate and reliable; however, RS Components Ltd. assumes no responsibility for inaccuracies or omissions, or for the use of this information, and all use of such information shall be entirely at the users own risk. No responsibility is assumed by RS Components Ltd. for any infringements of patents or other rights of third parties which may result from its use. Specifications shown in RS Components Ltd. data sheets is subject to change without notice.

RS Components Ltd. PO Box 99, Corby, Northants, NN17 9RS

An Electrocomponents Company

Telephone: 01536 201234 RS Components Ltd. 1995