STK544UC62K-E Application Note http://onsemi.com 1. Product synopsis This application handbook is intended to provide practical guidelines for the STK544UC62K-E use. The STK544UC62K-E is hybrid ICs based upon ONs Insulated Metal Substrate Technology (IMST) for 3-phase motor drives which contain the main power circuitry and the supporting control circuitry. The key functions are outlined below: • Highly integrated device containing all High Voltage (HV) control from HV-DC to 3-phase outputs in a single small SIP module. • Output stage uses IGBT/FRD technology and implements Under Voltage Protection (UVP) and Over Current Protection (OCP) with a Fault Detection output flag. Internal Boost diodes are provided for high side gate boost drive. • Option of a combined or individual shunt resistor per phase for OCP. • Externally accessible embedded thermistor for substrate temperature measurement. • All control inputs and status outputs are at low voltage levels directly compatible with microcontrollers. • Single control power supply due to internal bootstrap circuit for high side pre-driver circuit. • Mounting points are available on SIP package A simplified block diagram of a motor control system is shown if Figure 1. Figure 1. Motor Control System Block Diagram Semiconductor Components Industries, LLC, 2013 June, 2013 1/17 Rev.0 STK544UC62K-E Application Note 2. Product description Table1. Give an overview of the available devices, for a detailed description of the package refer to Chapter 6. Device Feature Package Voltage (VCEmax.) Current (Ic) Peak current (Ic) Isolation voltage Shunt resistance STK544UC62K-E triple shunts SIP-23 56*21.8 (SIP1) - Vertical pins 600V 10A 20A 2000V external Vertical type models; STK544UC62K-E are available for pin forming option. Table 1. Device Overview VB3 (1) W,VS3 (2) VB2 (4) V,VS2 (5) VB1 (7) V,VS1 (8) V+ (10) DB DB DB U.V. U.V. U.V. VRU (12) VRV (13) VRW (14) Level Shifter Level Shifter Level Shifter HIN1 (15) HIN2 (16) HIN3 (17) Logic Logic Logic LIN1 (18) LIN2 (19) LIN3 (20) Thermistor T/ITRIP (21) Shut down VDD (22) S Under voltage DETECT VSS (23) Vref Q Timer R Latch time about 9ms Figure 2. STK544UC62K-E equivalent circuits The high side drive is used with a bootstrap circuit to generate the higher voltage needed for gate drive. The Boost diodes are internal to the part and sourced from VDD (15V). There is an internal level shift circuit for the high side drive signals allowing all control signals to be driven directly from VSS levels common with the control circuit such as the microcontroller without requiring external level shift such as opto-isolators. 2/17 STK544UC62K-E Application Note 3. Performance test guidelines The following Chapter gives performance test method shown in Figures 3 to 7. 3.1. Switching time definition and performance test method trr 10% 90% 90% VCE HIN/LIN Io 10% 10% td(ON) td(OFF) tr tf tOFF tON IN Figure 3. Switching time definition Ex) Lower side U phase measurement 7 VD1=15V 10 8 4 VD2=15V 5 8 CS 1 VD3=15V VCC 2 22 VD4=15V Input signal Io 18 12 23 Figure 4. Evaluation circuit (inductive load) H-IC Ho HIN1,2,3 Driver Lo U,V,W Input signal LIN1,2,3 VCC CS Io Input signal Io Figure 5. Switching loss circuit 3/17 STK544UC62K-E Application Note H-IC Ho HIN1,2,3 Driver Lo U,V,W Input signal LIN1,2,3 VCC CS Io Input signal Io Figure 6. R.B.SOA circuit H-IC Ho HIN1,2,3 Driver Lo U,V,W Input signal LIN1,2,3 VCC CS Io Input signal Io Figure 7. S.C.SOA circuit 4/17 STK544UC62K-E Application Note 3.2. Thermistor Characteristics An integrated thermistor is used to sense the internal module temperature its electrical characteristic is outlined below. Parameter Symbol Condition Min. Typ. Max. Unit Resistance R25 Tc=25°C 97.0 100.0 103.0 kΩ Resistance R125 Tc=125°C 2.358 2.522 2.695 kΩ B-Constant(25-50°C) B - 4207.5 4250 4292.5 K Temperature Range - - -40 - +125 °C Table 2. NTC Thermistor value Rt is the value of the integrated NTC thermistor at Tc=25 °C. The resistance value is 100kΩ±3% and the value of the B-Constant (25-50 °C) is 4250K±1%. The temperature depended value is calculated as shown in the formula. R t =R25 × The resulting in the NTC values over temperatures 10000 Case Temperature (Tc) - Thermistor Resistance (Rth) Thermistor Resistance, Rth (kΩ) Minimum Nomal 1000 Maximum 100 10 1 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Case Temperature, Tc (°C) Figure 8. NTC value vs temperature 4. Protective functions and Operation Sequence This chapter describes the protection features • over current protection • under Voltage Lockout (UVLO) protection • cross conduction prevention 5/17 STK544UC62K-E Application Note 4.1. Over current protection In difference to the internal single shunt series modules, the STK544UC62K-E module utilizes an external shunt resistor for the OCP functionality. As shown in Figure 9 the emitters of all three lower side IGBTs brought out to module pins. An external ‘over current protection circuitry’ consisting of the shunt resistor and an RC filter network define the trip level. Figure 9. Over-current protection circuit setting The OCP function is implemented by comparing the voltage on the Itrip input to an internal reference of 4.17V (typ). In case the voltage on this terminal i.e. across the shunt resistor exceeds the trip level an OCP fault is triggered. Note: The current value of the OCP needs to be set by correctly sizing the external shunt resistor to less than 2x of the modules rated current. In case of an OCP event all internal gate drive signal for the IGBTs of all three phases become inactive and the FLT/EN fault signal output is activated (low). An RC filter is used on the Itrip input to prevent an erroneous OCP detection due to normal switching noise and/or recovery diode current. The time constant of that RC filter should be set to a value between 1.5μ to 2μs. In any case the time constant must be shorter than the IGBTs short current safe operating area (SCSOA) according to Figure 10. The resulting OCP level due to the filter time constant is shown in Figure 11. SCSOA time(Gate-pulse) -Tc SCSOA time [us] 10 8 6 4 2 0 0 20 40 60 Tc [℃ ] 80 100 120 Figure 10. IGBT SCSOA 6/17 Collector Current Ic (A) STK544UC62K-E Application Note Over-current protective level Collector Current Waveform Input pulse width tw (usec.) Figure 11. filter time constant For optimal performance all traces around the shunt resistor need to be kept as short as possible Figure 12. shows the sequence of events in case of an OCP event. Figure 12. Over current protection timing chart 4.2. Under Voltage Lockout Protection The UVLO protection is designed to prevent unexpected operating behavior as described in Table 3. Both High-side and Low-side have UV protecting function. However the fault signal output only corresponds to the Low-side UVLO Protection. During the UVLO state the fault output is continuously driven (low). 7/17 STK544UC62K-E Application Note VDD Voltage (typ. Value) Operation behavior < 12.5V As the voltage is lower than the UVLO threshold the control circuit is not fully on. A perfect function cannot be guaranteed. 12.5V - 13.5V IGBTs can work, however conduction and switching losses increase due to low voltage gate signal. 13.5V - 16.5V Recommended conditions. 16.5V-20.0V IGBTs can work. Switching speed is faster and saturation current higher, increasing short-circuit broken risk. > 20.0V Control circuit is destroyed. Absolute max rating is 20V Table 3. Module operation according to control supply voltage The sequence of events in case of a low side UVLO event (IGBTs turned off and active fault output) is shown in Figure 13. Figure 14 shows the same for a high side UVLO (IGBTs turned off and no fault output). Figure 13. Low side UVLO timing chart 8/17 STK544UC62K-E Application Note Figure 14. High side UVLO timing chart 4.3. Cross conduction prevention The STK544UC62K-E module implement a cross conduction prevention logic at the pre-driver to avoid simultaneous drive of the low-side and high-side IGBTs as shown in Figure 15. Figure 15. Cross input conduction prevention In case of both high and low side drive inputs are active (Low) the logic prevents both gates from being driven a corresponding timing diagram can be found in Figure 16 below. 9/17 STK544UC62K-E Application Note Figure 16. Cross conduction prevention timing chart Even so cross conduction on the IGBTs due to incorrect external driving signals is prevented by the circuitry the driving signals (HIN and LIN) need to include a “dead time”. This period where both inputs are inactive between either one becoming active is required due to the internal delays within the IGBTs. Figure 17 shows the delay from the HIN-input via the internal HVG to high side IGBT, the similar path for the low side and the resulting minimum dead time which is equal to the potential shoot through period: Figure 17. Shoot trough period 10/17 STK544UC62K-E Application Note 5. PCB design and mounting guidelines This chapter provides guidelines for an optimized design and PCB layout as well as module mounting recommendations to appropriately handle and assemble the HIC module. 5.1. Application (schematic) design The following figures 18 give an overview of the external circuitry’s functionality when designing with the STK544UC62K-E module. Stability of VDD Noise absorb Prevention of voltage up by the surge voltage Noise absorb +15V Vz< 22V To micro control Prevention of miss operation by the noise HIN1 Stability of VB 100μF /25V +5V 100 LIN2 100 LIN3 VSS T/ITRIP VB3 7 W, VS3 8 VB2 4 V, VS2 5 VB1 1 U, VS1 2 100nF /25V 10μF /25V Vz< 22V 100nF /25V 10μF /25V Vz< 22V 100nF /25V 10μF /25V Vz< 22V 470μF /630V snubber W V 4.3k 100 LIN1 23 3.3k 3.3k 3.3k 3.3k 3.3k 3.3k 100 HIN3 VDD 21 100 100 HIN2 100nF /25V 22 100 15 HIN1 16 HIN2 17 HIN3 18 LIN1 19 LIN2 20 LIN3 V+ DC IN 10 Rshunt VRU 12 VRV 13 VRW 14 U Restraint of surge voltage and vibration voltage DC OUT From small voltage to large voltage To micro control Prevention of miss operation by the noise Amp. Figure 18. STK544UC62K-E application circuit 5.2. Pin by pin design and usage notes This section provides pin by pin PCB layout recommendations and usage notes. For a complete list of module pins refer to the datasheet or Chapter 6. V+ & VRU, VRV, VRW U, V, W VDD, VSS These pins are connected with the main DC power supply. The applied voltage is up to the Vcc level. Overvoltage on these pins could be generated by voltage spikes during switching at the floating inductance of the wiring. To avoid this behavior the wire traces need to be as short as possible to reduce the floating inductance. In addition a snubber capacitor needs to be placed as close as possible to these pins to stabilize the voltage and absorb voltage surges. These terminals are the output pins for connecting the 3-phase motor. They share the same GND potential with each of the high side control power supplies. Therefore they are also used to connect the GND of the bootstrap capacitors. These bootstrap capacitors should be placed as close to the module as possible. These pins connect with the circuitry of the internal protection and pre-drivers for the low -side power elements and also with the control power supply of the logic circuitry. Voltage to input these terminals is monitored by the under voltage protection circuit. The VSS terminal is the reference voltage for the control inputs signals as well as Fault and ISO. VSS is connected with the ‘VRU, VRV, VRW’ terminal internally. The main circuit does typically not draw current from VSS. When the ‘VRU, VRV, VRW’ and ‘VSS’ pins are connected externally care must be taken to select a single connection point as close as possible to the IC. In case of multiple connections to these pins and longer traces being used, the over current protection level may become low. Therefore this should be avoided. 11/17 STK544UC62K-E Application Note VB1, 2, 3 The VBx pins are internally connected to the positive supply of the high-side drivers. The supply needs to be floating and electrically isolated. The boot-strap circuit shown in Figure 19 forms this power supply individually for every phase. Due to integrated boot resistor and diode (RB & DB) only an external boot capacitor (CB) is required. There are two current path to charge CB – depicted as ① and ②. ① when the low side power IGBT is ON ② when motor current is flows in CB The capacitor is discharged while the high-side driver is activated. Thus CB needs to be selected taking the maximum on time of the high side and the switching frequency into account. DB Driver CB RB ① ② Driver VDD Figure 19. Boot strap circuit To set an initial charge on CB a high ohmic resistor can be used between the motor and the ‘VRU, VRV, VRW’ pins – considering the max voltage rating of the device. The voltages on the high side drivers are individually monitored by the under voltage protection circuit. In case an UVP event is detected on a phase its operation is stopped. HIN1, 2, 3 LIN1, 2, 3 Typically a CB value of less or equal 47uF (±20%) is used. In case the CB value needs to be higher an external resistor (of apx. 20Ω or less) should be used in series with the capacitor to avoid high currents which can cause malfunction of the hybrid IC. These pins are the control inputs for the power stages. The inputs on HIN1/HIN2/HIN3 control the high-side transistors of U/V/W, and the inputs on LIN1/LIN2/LIN3 control the low-side transistors of U/V/W respectively. The input are active high and the input thresholds VIH and VIL are 5V compatible to allow direct control with a microcontroller system Simultaneous activation of both low and high side is prevented internally to avoid shoot through at the power stage. However, due to IGBT switching delays the control signals must include a dead-time. The equivalent input stage circuit is shown in Figure 20. VDD 100kΩ IN VSS Figure 20. Internal input circuit For fail safe operation the control inputs are internally tied to VDD via a 100kΩ (typ) resistor. To avoid switching captured by external wiring to influence the module behavior an additional external low-ohmic pull-up resistor with a value of 2.2k to 3.3kΩ should be used. The output might not respond when the width of the input pulse is less than 1µs (both ON and OFF). 12/17 STK544UC62K-E Application Note T/ITRIP An internal thermistor to sense the substrate temperature is connected between “VDD” and the “T/ITRIP” terminal. The substrate temperature is accessible externally by this terminal. Figure 21. Internal input circuit Figure 22. Variation of temperature sense voltage with internal thermistor by using external bias resistance of 4.3kΩ ±1% and VDD=15V This terminal also has the function for shutdown input. When the input voltage to “T/ITRIP exceed threshold, al IGBTs are shut down. And Normal operation resumes 8ms after the condition of over current is removed. Note: with this mimic only the substrate temperature can be monitored. 5.3. Heat sink mounting and torque If a heat sink is used, insufficiently secure or inappropriate mounting can lead to a failure of the heat sink to dissipate heat adequately. This can lead to an inability of the device to provide its inherent performance, a serious reduction in reliability, or even destruction, burst and burn of the device due to over-heating. The following general points should be observed when mounting H-IC on a heat sink: 1. Verify the following points related to the heat sink: - There must be no burrs on aluminum or copper heat sinks. - Screw holes must be countersunk. - There must be no unevenness in the heat sink surface that contacts H-IC. - There must be no contamination on the heat sink surface that contacts H-IC. 13/17 STK544UC62K-E Application Note 2. Highly thermal conductive silicone grease needs to be applied to the whole back (aluminum substrate side) uniformly, and mount H-IC on a heat sink. Upon re-mounting apply silicone grease (100 to 200μm) again uniformly. 3. For an intimate contact between the H-IC and the heat sink, the mounting screws should be tightened gradually and sequentially while a left/right balance in pressure is maintained. Either a bind head screw or a truss head screw is recommended. Please do not use tapping screw. We recommend using a flat washer in order to prevent slack. The standard heat sink mounting condition of an STK544UC62K-E is as follows. Item Pitch Screw Washer Heat sink Torque Grease Recommended Condition 56.0 ± 0.1mm Diameter :M3 Bind machine screw, Truss machine screw, Pan machine screw Plane washer The size is D : 7mm, d : 3.2mm and t : 0.5mm (Figure 23-b.) JIS B 1256 Material : copper or Aluminum Warpage (the surface that contacts H-IC) : -50 to +100μm Screw holes must be countersunk. No contamination on the heat sink surface that contacts H-IC. Final tightening : 0.6 to 0.9Nm Temporary tightening : 20 to 30% of final tightening Silicon grease Thickness : 100 to 200μm Uniformly apply silicon grease to whole back. (Figure 23-c.) Table 4. Heat sink mounting Figure 23-a. Mount H-IC on a heat sink Figure 23-b. Size of washer Figure 23-c. About uniformly application steps to mount an HIC on a heat sink 1st: Temporarily tighten maintaining a left/right balance. 2nd : Finally tighten maintaining a left/right balance. 14/17 STK544UC62K-E Application Note 5.4. Mounting and PCB considerations In designs in which the printed circuit board and the heat sink are mounted to the chassis independently, use a mechanical design which avoids a gap between H-IC and the heat sink, or which avoids stress to the lead frame of H-IC by an assembly that a moving H-IC is forcibly fixed to the heat sink with a screw. Figure 24-a. Fix to heat sink Maintain a separation distance of at least 1.5 mm between the H-IC case and the printed circuit board. In particular, avoid mounting techniques in which the H-IC substrate or case directly contacts the printed circuit board. Do not mount H-IC with a tilted orientation. This can result in stress being applied to the lead frame and H-IC substrate could short out tracks on the printed circuit board. Always mount the H-IC vertically. If stress is given by compulsory correction of a lead frame after the mounting, a lead frame may drop out. Be careful of this point. Figure 24-b. Lead frame after the mounting When designing the PCB layout take care that the bent part portion of the lead frame pins does not short-circuit to VIA holes or tracks on the PCB. Figure 24-c. VIA holes or tracks on the PCB 15/17 STK544UC62K-E Application Note Since the use of sockets to mount H-IC can result in poor contact with H-IC leads, we strongly recommend making direct connections to PCB. H-IC modules are flame retardant. However, under certain conditions, it may burn, and poisonous gas may be generated or it may explode. Therefore, the mounting structure of the H-IC module should also be flame retardant. Mounting on a Printed Circuit Board 1. Align the lead frame with the holes in the printed circuit board and do not use excessive force when inserting the pins into the printed circuit board. To avoid bending the lead frames, do not try to force pins into the printed circuit board unreasonably. 2. Do not insert H-IC into printed circuit board with an incorrect orientation, i.e. be sure to prevent reverse insertion. H-IC may be destroyed, exploded, burned or suffer a reduction in their operating lifetime by this mistake. 3. Do not bend the lead frame. 5.5. Cleaning H-IC has a structure that is unable to withstand cleaning. As a basic policy, do not clean independent H-IC or printed circuit boards on which an H-IC is mounted. 6. Package Outline STK544UC62K-E is SIP23 56*21.8 (SIP1) package. (Single-inline-package) Every second pin is bent forward to form two rows on the PCB see Figure 25. 6.1. Package outline and dimension and laser marking missing pin ;3,6,9,11 note2 note3 ① 4DB00 STK544UC62K note1 23 1 ③ ② note1：Mark for No.1 pin identification. note2：The form of a character in this drawing differs from that of HIC. note3：This indicates the lot code. The form of a character in this drawing differs from that of HIC. Figure 25.STK544UC62K-E package outline 16/17 STK544UC62K-E Application Note 6.2. Pin Out Description Pin Name Description 1 VB3 High Side Floating Supply Voltage 3 2 W, VS3 Output 3, High Side Floating Supply Offset Voltage 3 3 - Without pin 4 VB2 High Side Floating Supply Voltage 2 5 V, VS2 Output 2, High Side Floating Supply Offset Voltage 2 6 - Without pin 7 VB1 High Side Floating Supply Voltage 1 8 U, VS1 Output 1, High Side Floating Supply Offset Voltage 1 9 - Without pin 10 V+ Positive Bus Input Voltage 11 - Without pin Pin Name Description 12 VRU Low Side Emitter Connection – Phase 1 13 VRV Low Side Emitter Connection – Phase 2 14 VRW Low Side Emitter Connection – Phase 3 15 HIN1 Logic Input High Side Gate Driver – Phase 1 16 HIN2 Logic Input High Side Gate Driver – Phase 2 17 HIN3 Logic Input High Side Gate Driver – Phase 3 18 LIN1 Logic Input Low Side Gate Driver – Phase 1 19 LIN2 Logic Input Low Side Gate Driver – Phase 2 20 LIN3 Logic Input Low Side Gate Driver – Phase 3 21 T/ITRIP Temperature Monitor and Shut-down Pin 22 VDD +15V Main Supply 23 VSS Negative Main Supply 17/17