Sensorless Brushless DC Motor Driver Module in a

SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Sensorless Brushless DC Motor Driver Module in a Power
Flatpack
600V/70A, 1200V/60A
DESCRIPTION:
The SMCS6GXXX-XXX-1 is an, integrated three-phase brushless DC motor controller/driver subsystems
housed in a compact power package. The SMCS6GXXX-XXX-1 is used in two quadrant modes of
operation. Two-quadrant mode is recommended for steady operation because of the reduced switching
losses. The controller is best used as a speed controller for controlling/driving fans, pumps, and motors in
applications which require small size. Many integral control features provide the user much flexibility in
adapting the SMCS6GXXX-XXX-1 to specific system requirements.
The small size of this subsystem is ideal for aerospace, military, industrial, and medical applications.
FEATURES:
• Fully integrated 3-phase brushless DC motor control subsystem includes power stage, non-isolated
driver stage, and controller stage
• Up to 60A average DC bus current with up to 300VDC bus voltage, or 40A with up to 600VDC bus
voltage.
• sensorless commutation
• Internal precision current sense resistor.
• Cycle by cycle current limiting.
• Fixed frequency PWM from zero speed to full speed.
• Closed-loop speed control.
• Direction input for direction reversal of motor
• Tacho output with frequency output proportional to speed
• Soft start input with adjustable starting time.
• Adjustable over-temperature shutdown set-point.
• Under-voltage shutdown for the 15V VCC.
• Case temperature sense output.
• Over-temperature shutdown with auto recovery and soft re-start.
• Duty-cycle is limited to 99% .
• Current limit reference for programmable over-current limit.
• DC bus current sense amplifier with absolute value output.
• Desaturation protection for all six IGBTs.
• Shoot-through protection
• Package size - 3.59" x 1.55" x 0.80"
• Total Weight 5.0 OZ.
APPLICATIONS:
• Fans and Pumps
• Hoists
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1
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
ABSOLUTE MAXIMUM RATINGS (TC=25 oC)
Characteristic
Maximum
Motor DC Bus Supply Voltage
SMCS6G070-060-1
SMCS6G060-120-1
Motor Peak Voltage
SMCS6G070-060-1
SMCS6G060-120-1
Average Output Current
SMCS6G070-060-1
SMCS6G060-120-1
Peak Output Current
SMCS6G070-060-1
SMCS6G060-120-1
Control Supply Voltage VCC
Logic Input Voltage
Reference Source Current
Speed Command Input Voltage
Operating and storage Junction Temperature
IGBT Thermal Resistance RthjC
Diode Thermal Resistance RthjC
Pin-to-Case Voltage Isolation, at room conditions
Lead Soldering Temperature, 10 seconds maximum, 0.125” from case
* Tcase = 25° C
400V
800V
600V
1200V
70 A
60A
80 A
70A
18 V
-0.3 V to +5 V
-30 mA
- 0.3 V to +5 V
-55 oC to +150 oC
0.45 oC/W
0.80 oC/W
1500V DC
300°C
Recommended Operating Conditions (TC=25 oC)
Characteristic
Maximum
Motor DC Bus Supply Voltage
SMCS6G070-060-1
SMCS6G060-120-1
Average Output Current,
TC=80 oC
SMCS6G070-060-1
SMCS6G060-120-1
60 A
40A
Control Supply Voltage VCC
15 V +/-10%
300V
600V
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2
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
PARAMETER SYMBOL CONDITIONS (NOTE 1)
MIN.
TYP.
MAX.
UNITS
400
uA
V
Power Output Section
Collector-Emitter Leakage Current ICES
SMCS6G070-060-1
at VCE=480V
at VCE=960V
SMCS6G060-120-1
Collector-to-Emitter Saturation Voltage VCEsat, at VCC=15V
SMCS6G070-060-1
SMCS6G060-120-1
IC=30A
IC=70A
IC=90A
IC=40A
1.15
1.50
1.70
1.30
1.80
2.00
1.9
2.3
IC=30A
IC=70A
IC=90A
IC=40A
1.18
1.50
1.62
1.8
1.35
1.80
1.95
2.3
V
8.0
10.0
40
11.5
mA
V
4.7
-
5.0
-
5.3
30
V
mA
9
0.45
10
0.5
11
0.55
mV/A
V
3.5
4
2
2.5
1.5
1
3
V
V
V
V
V
4.5
-
-
5.0
0.50
V
V
13
15
17
kHz
Diode Forward Voltage
SMCS6G070-060-1
SMCS6G060-120-1
Control Section
Control Supply Current Icc at Vcc =15V
Turn-On Threshold Vcc(+) Tc over operating range
5V Reference Section
Output Voltage Vref
Output Current Io
Current-Sense Amplifier Section
Amplifier Voltage Gain
Over-current detection voltage
Logic Input Section
Dir in, LA,Ov-Lap, Fm High-Level Input Voltage Threshold
Dir in, LA, Ov-Lap, Fm Low-Level Input Voltage Threshold
Fsc High-Level Input Voltage Threshold
Fsc Low-Level Input Voltage Threshold
Fsc Middle-Level Input Voltage Threshold
Tachometer
Tachometer Output High Level Voh
Tachometer Output Low Level Vol
PWM Section
PWM Frequency Fs
Over-Temperature Shutdown
Over-Temperature Shutdown
Over-Temperature Shutdown Hysteresis
106
111
116
30
o
C
o
C
SPECIFICATION NOTES:
1- All parameters specified for Ta = 25C, Vcc = 15Vdc, and all Phase Outputs unloaded. All negative currents shown are sourced
by (flow from) the pin under test
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3
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Package Drawing Top View
(All dimensions are in inches, tolerance is +/- 0.010”)
Base Plate Flatness 0.010” Concave
Fig. 2: Package Outline
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4
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Package Pin Locations
(All dimensions are in inches; tolerance is +/- 0.005” except otherwise specified)
Fig. 3: Package Outline
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5
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
PIN OUT
PIN
NUMBER
NAME
1
+15V Input
2, 19
Signal Gnd
3
VDD
(+5V Output)
4
Ov-Lap
5
LA
6
Dci
7
Start
DESCRIPTION
The +15V power supply connection for the controller. Under-voltage
lockout keeps all outputs off for Vcc below 9 to 10.5V. The return of
+15V is Pin 2. The input current requirement is 50mA without any
external loads on Pin 3. Recommended input range is 14V min, 15.5V
max.
+15V supply should be an isolated power supply.
Return for +15V supply, and +5V output
Reference ground for all control signals of the device. All bypass
capacitors and compensation components must be connected as
close as possible to Pins 2 and 19. This ground is internally connected
to the +VDC Rtn.
It is preferred not to have external connection between Signal Gnd and
+VDC Rtn at Pins 29 and 30.
+5V Output. . The maximum output current is 30mA. The return of
+5V is Pin 2. This Pin should be bypassed to Gnd with 3-5µF
capacitor. The range of this output is 4.7V to 5.3V.
Overlap Commutation Angle Select
Low: Overlap commutation
High: 120° commutation
This pin has a pull-up resistor of 100K.
The lead angle control input.
The lead angle settings are:
LA (Low) Lead angle 7.5 degrees
LA (High) Lead angle 15 degrees
The pin has a pull-down resistor of 100K.
DC excitation time setting pins
When Vin ≥ 1 V (typ.), the START pin goes low to start DC excitation.
The duration of the DC excitation mode is given by tdc
Tdc = 0.69. R1. C1 sec
After the Dci pin reaches VDD/2, the controller moves from DC
excitation to forced commutation mode.
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6
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
8
Tachometer
Output
Tachometer Output
Variable frequency output proportional to the motor speed. The pulse
duty cycle is 50%. There are 3 pulses every 360 electrical degrees.
The number of pulses per motor revolutions is P*3/2. The
Tachometer output frequency is
ft =
P.n
40
Hz
Where P is the number of poles, n is the motor speed in rpm.
Rotation direction input
High : Reverse rotation (A → C → B)
Low or open : Forward rotation (A → B → C)
The pin has a pull-up resistor of 10K.
9
Dir-in
It is not safe to reverse the direction of rotation when the motor
is running at high speed. First reduce the command input, then
reverse direction when the motor speed is very low.
10
Vin
11
Startup
Ramp
Speed Command Input (Duty Cycle Control Input)
0 ≤ Vin ≤ Vin (L): Output off
Vin (L) ≤ Vin ≤ Vin (H): Set the PWM duty cycle according to the
analog input.
Vin (H) ≤ Vin ≤ VDD: Duty cycle = 100% (63/64)
0.8V < Vin (L) <1.2 V, 1.0V typical
3.8V < Vin (H) <4.2 V, 4.0V typical
This pin has a pull-down resistor of 100K.
Startup Ramp (Soft Start)
Set a startup commutation time and duty cycle ramp-up.
Connect this pin to a capacitor to set the ramp-up time.
The capacitor charge current Isc is
2.6uA < Isc <5.0 uA, 3.8uA typical
This pin is internally connected to C2 of 1uF.
The ramp-up time duration, is given by
tr =
Vin.C 2
sec
3.8
Hz
where C2 is the total capacitance connected to Pin 11, in uF, and Vin
is the speed command voltage applied at Pin 10 in volts.
The ram-up time duration depends on the motor and its load. It
should be optimized experimentally.
12
Fsc
Forced Commutation Frequency Select Input
Low :
Fsc = 2.5 Hz
Middle :
Fsc = 5 Hz
High or open : Fsc = 10 Hz
This pin has a pull-up resistor of 15K.
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7
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
PIN OUT (continued)
This Pin together with Pin 12, set an upper limit of the maximum
commutation frequency.
13
Fm
Fsc = Low
Fm = Low ,
Maximum commutation frequency Fm = 162
Fm = High or Open , Maximum commutation frequency Fm = 325
Fsc = High or Middle
Fm =Low ,
Maximum commutation frequency Fm = 1302
Fm = High or Open , Maximum commutation frequency Fm = 2604
The pin has a pull-up resistor of 15K.
14
NC
Not connected
15
NC
Not connected
16
NC
Not connected
17
Iso
Current Sense Amplifier Output for external monitoring.
This pin is internally connected to the over-current comparator for
cycle-by-cycle current limiting.
It is recommended to have the over-current limit 20-30% higher than
the target peak motor current.
The gain of Iso is internally set to 0.010 V/A.
Over-current Limit Adjustment.
Connect a resistor Rg KOhms between Pins 18 and 19 to decrease
the current amplifier gain and increase peak current limit. The current
amplifier gain attenuation due to Rg will be
18
Ioc-Ref -
Kc =
Rg
2 Rg + 49.9
The output signal gain at Pin 17 will be 0.01*KC V/A.
The internal over-current shutdown threshold is 0.5V
20
Tco-Ref
Over-Temperature Shutdown Reference.
It is internally set to 1.11V using a resistor divider of 50K pull-up to
+5V, 10K pull-down, and 400K feedback.
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8
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
It is an active low, dual function input/output pin. It is internally pulled
high to +15V by 15K Ω. As a low input it shuts down all IGBTs
regardless of the Hin and Lin signals.
SD is internally activated by the over-temperature shutdown, or
desaturation protection
21
SD
SD can be used to shutdown all IGBTs by an external command. An open
collector switch shall be used to pull down SD externally.
SD can be used as a fault condition output. Low output at SD indicates a
latching fault situation.
SD is automatically cleared during more startup.
22
Tco
Analog output of case temperature sensor. The sensor output gain is 0.010
V/oC, with zero DC offset. This sensor can measure only positive oC. The
internal impedance of this output is 4.99KΩ.
The internal block diagram of the temperature sensor is shown in Fig. 12.
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9
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
PIN OUT (continued)
23, 24
Phase A Output
Phase A terminals. Both terminals shall be used.
25, 26
Phase B Output
Phase B terminals. Both terminals shall be used.
27, 28
Phase C Output
Phase C terminals. Both terminals shall be used.
29, 30
+VDC Return
31, 32
+VDC
Case
NC
Motor supply DC bus return. Both terminals shall be used.
DC Bus Positive Input.
Both terminals shall be used. +VDC bus should be bypassed to
+VDC Rtn with adequately voltage-rated low ESR capacitor.
Not connected
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10
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Application Information
Operation
SMCS6GXXX-XXX uses back EMF sensing for rotor position detection. The position detection is
done in synchronization with the PWM signal. Positional variation occurs in connection with the
frequency of the PWM signal.
Fig. 5. illustrates the back EMF detection.
High Side Gate
Drive Signal
Low Side Gate
Drive Signal
Motor Terminal
Voltage
Fig. 4. High side Gate drive, Low Side Gate drive, and Motor Terminal Voltage
PWM Signal
Reference
Voltage
Back EMF
Voltage
Position Detection Signal
Fig. 5. Back EMF and Rotor Position Detection
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11
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Startup operation
When the motor is stationary, there is no back-EMF and the motor position is unknown. On
receiving an analog voltage command input, the rotor is aligned to a known position in DC
excitation mode for a period (tdc), during which the Dci pin voltage decreases to half VDD level.
The time constant for the period is determined by C1 and R1. After that, switching
occurs to forced commutation mode represented by (tf). The duty cycles for DC excitation and
forced commutation modes are determined according to the ramp pin voltage. The ramp
duration is determined by C2.
An external capacitor, in parallel with C1, sets the times that the controller stays in DC excitation
and forced commutation modes. Those times vary depending on the motor type and motor
loading. Thus, they must be adjusted experimentally.
When the number of turn of a motor is more than forced commutation frequency, the motor
switches to sensorless mode. The PWM duty cycle for sensorless mode after the ramp-up time
is determined by the Vin value.
Fig. 6: Controller Startup Timing
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12
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Speed Control Input
An analog voltage applied to the Vin, Pin 10, is converted by the 6-bit AD converter to control
the PWM duty cycle.
0 < Vin < Vin (L), PWM Duty cycle = 0%
Vin (L) < Vin < Vin (H), PWM Duty Cycle according to Fig. 7 (1/64 to 63/64)
Vin (H) < Vin < VDD, PWM Duty cycle = 100% (63/64)
Fig. 7: PWM Duty Cycle vs Input Command
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13
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Fault protection
When a signal indicating the following faults is applied to the internal back EMF sensing, the
output transistors are disabled. After time toff, about one second, the motor is restarted. This
operation is repeated as long as a fault is detected.
• The maximum commutation frequency is exceeded.
• The rotation speed falls below the forced commutation frequency.
Fig. 8: Fault Detection & Re-Start
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14
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Two Quadrant Mode Of Operation Of BDC Motor
Fig. 9 illustrates the four possible quadrants of operation for a BDC motor. Two-quadrant mode
refers to a motor operating in quadrants I and III. With a two-quadrant BDC motor, friction is the
only force to decelerate the load.
Two-quadrant mode, modulates only the high-side devices of the output power stage, as shown in
Fig. 4. The current paths within the output stage during the PWM on and off times are illustrated in
Fig. 10. During the on time, both switches S1 and S4 are on, the current flows through both
switches and the motor winding. During the PWM cycle off time, the upper switch S1 is shut off,
and the motor current circulates through the lower switch S4 and D2. The motor is assumed to be
operated in quadrants I or III. During direction reversal in quadrants II and IV, the motor current
path is as shown in Fig. 11.
Two-quadrant mode of operation is the most efficient mode, because the controller and motor
switching losses are minimized. Also, EMI emission is minimum with two-quadrant mode of
operation.
The limitation of two-quadrant mode of operation is, it is not safe to reverse motor direction at high
speed.
In four-quadrant mode, both upper and lower switches are modulated. Motor current always
decays during off time, eliminating any uncontrolled circulating current. In addition, the current
always flows through the current sense resistor. For servo system applications, refer to
SMCT6MXX-XX, or SMCT6GXX-XX motor controllers.
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15
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Temperature Sensor Output:
4.99KΩ
Pin 22
0.1uF
Fig. 12 Temperature Sensor Internal Block Diagram
For both negative and positive temperature measurement capability, Contact the Factory.
Cycle-by-cycle
Current limiting is provided internally by an over-current comparator.
A current monitoring output is provided at Pin 17.
A user adjustable over-current limit reference input is provided at Pin 18.
The over-current reference adjustment procedure is described in the Pin Description section.
Closed Loop Speed Control
The motor speed is directly proportional to the input analog command at Pin 10. However, speed
regulation is poor in open loop systems. For tight speed regulation, a closed loop speed control
can be implemented as shown in Fig. 13.
A tachometer can be used to provide speed feedback information, and an error amplifier to close
the speed loop.
Motor Terminals Connection
Since the rotor position detection is done through the phases, the phase IDs are irrelevant. Any
motor terminal connection to the controller with the sequence ABC, or BCA, or CAB will results in
the same direction of rotation as long as the controller direction input is not changed. A motor
terminal connection sequence of the opposite as CBA, or BAC, or ACB will result in a reversed
rotation.
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16
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Fig. 13. Closed Loop Speed Control
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17
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Lead angle control
The motor runs with a lead angle of 0° in forced commutation mode at startup. After switching to
natural commutation, the lead angle automatically changes to the value set by the LA pin.
VA
VB
VC
Back
EMF
LA = 0 o
GAH
GAL
GBH
GBL
GCH
GCL
o
LA = 7.5
GAH
GAL
GBH
GBL
GCH
GCL
LA = 15 o
GAH
GAL
GBH
GBL
GCH
GCL
Fig. 14: Lead angle control
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18
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Overlap commutation
When Over-Lap (Pin 4) = high, the controller is configured to allow for 120° commutation. When
Over-Lap (Pin 4)= low, it is configured to allow for overlap commutation. In overlap
commutation, there is an overlap period during which both the outgoing transistor and incoming
transistor are conducting (as shown in the shaded areas). This period varies according to the
lead angle.
VA
VB
VC
Back
EMF
LA = 7.5
o
GAH
GAL
GBH
GBL
GCH
GCL
LA = 15 o
GAH
GAL
GBH
GBL
GCH
GCL
Fig. 15: Overlap commutation
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19
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
DC Bus Filtering
To minimize the circuit parasitic inductance effect on the power stage, the layout of Fig. 14 is
suggested. C1, and C2 are 0.5µF to 1µF ceramic capacitors, connected across the DC bus as
close as possible to the controller. Also, a bulk low ESR capacitor C3 with adequately voltagerating shall be used.
Fig. 16: DC Bus Bypass Capacitors
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20
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
IGBT and Diode Switching Characteristics and Waveforms
(for SMCS6G070-060-1)
1- Test Conditions: VCE=280V, IC= 25A
Test Results: Rise time tr= 66 nsec, Fall time tf= 52 nsec
Current Scale is 20A/div, Voltage Scale is 50V/div, Power Loss Scale is 2000Watt/div
Turn On Switching Loss = 0.47 mJ, Turn Off Switching Loss = 0.8 mJ
Fig. 17: IGBT Switching Performance
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21
SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
2- Test Conditions: VCE=280V, IC= 35A
Test Results: Rise time tr= 102 nsec, Fall time tf= 45 nsec
Current Scale = 20A/div, Voltage Scale = 50V/div, Power Loss Scale = 4000Watt/div
Turn On Switching Loss = 0.7 mJ, Turn Off Switching Loss = 1.4 mJ
VCE
IC
PLoss
Fig. 18: IGBT Switching Performance
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SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
IGBT and Diode Conduction Characteristics:
(for SMCS6G070-060-1)
Tj=25oC
Tj=150oC
Figure 19.
Figure 20.
IGBT Conduction Characteristics
Diode Conduction Characteristics
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SENSITRON
SEMICONDUCTOR
SMCS6G070-060-1
SMCS6G060-120-1
TECHNICAL DATA
DATASHEET 5041, Preliminary
Cleaning Process:
Suggested precaution following cleaning procedure:
If the parts are to be cleaned in an aqueous based cleaning solution, it is recommended that the parts be baked
immediately after cleaning. This is to remove any moisture that may have permeated into the device during the
cleaning process. For aqueous based solutions, the recommended process is to bake for at least 2 hours at 125oC.
Do not use solvents based cleaners.
Soldering Procedure:
Recommended soldering procedure
Signal pins 1 to 22: 210C for 10 seconds max
Power pins 23 to 32: 260C for 10 seconds max. Pre-warm module to 125C to aid in power pins soldering.
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24